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XJ LUBRICATION AND MAINTENANCE 0-1

LUBRICATION AND MAINTENANCE


CON T EN T S

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 4
JUMP STARTING, TOWING AND HOISTING . . . . 9

GEN ERAL I N FORM AT I ON

INDEX
page page

GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1


CLASSIFICATION OF LUBRICANTS . . . . . . . . . . . 2 PARTS AND LUBRICANT
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 3 RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 1

GEN ERAL I N FORM AT I ON PARTS AND LUBRICANT RECOMMENDATIONS


Wh en ser vice is r equ ir ed, Ch r ysler Cor por a t ion
INTRODUCTION r ecom m en ds t h a t on ly Mopa r ! br a n d pa r t s, lu br i-
Ser vice a n d m a in t en a n ce pr ocedu r es for com po- ca n t s a n d ch em ica ls be u sed. Mopa r pr ovides t h e
n en t s a n d syst em s list ed in Sch edu le “A” or “B” ca n best en gin eer ed pr odu ct s for ser vicin g Ch r ysler Cor-
be fou n d by u sin g t h e Gr ou p Ta b Loca t or in dex a t por a t ion veh icles.
t h e fr on t of t h is m a n u a l. If it is n ot clea r wh ich
gr ou p con t a in s t h e in for m a t ion n eeded, r efer t o t h e INTERNATIONAL SYMBOLS
in dex a t t h e ba ck of t h is m a n u a l. Ch r ysler Cor por a t ion u ses in t er n a t ion a l sym bols t o
Th er e a r e t wo m a in t en a n ce sch edu les t h a t sh ow iden t ify en gin e com pa r t m en t lu br ica n t a n d flu id
pr oper ser vice ba sed on t h e con dit ion s t h a t t h e veh i- in spect ion a n d fill loca t ion s (F ig. 1).
cle is su bject ed t o.
Sch edu le “A” , list s sch edu led m a in t en a n ce t o be /' A~
per for m ed wh en t h e veh icle is u sed for gen er a l t r a n s- V CHRYSLER CORPORATION
por t a t ion .
Sch edu le “B ” , list s m a in t en a n ce in t er va ls for veh i-
cles t h a t a r e oper a t ed u n der t h e con dit ion s list ed a t ce:,l ENGINE OIL (0) BRAKE FLUID
t h e begin n in g of t h e Ma in t en a n ce Sch edu le sect ion .
Use t h e sch edu le t h a t best descr ibes you r dr ivin g
con dit ion s.

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

Fig. 1 International Symbols


0-2 LUBRICATION AND MAINTENANCE XJ
GEN ERAL I N FORM AT I ON (Cont inue d)

CLASSIFICATION OF LUBRICANTS GEAR LUBRICANTS


On ly lu br ica n t s bea r in g design a t ion s defin ed by SAE r a t in gs a lso a pply t o m u lt iple gr a de gea r
t h e followin g or ga n iza t ion sh ou ld be u sed t o ser vice a lu br ica n t s. In a ddit ion , AP I cla ssifica t ion defin es t h e
Ch r ysler Cor por a t ion veh icle. lu br ica n t s u sa ge.
• Societ y of Au t om ot ive E n gin eer s (SAE )
• Am er ica n P et r oleu m In st it u t e (AP I) (F ig. 2) LUBRICANTS AND GREASES
• Na t ion a l Lu br ica t in g Gr ea se In st it u t e (NLGI) Lu br ica t in g gr ea se is r a t ed for qu a lit y a n d u sa ge
(F ig. 3) by t h e NLGI. All a ppr oved pr odu ct s h a ve t h e NLGI
sym bol (F ig. 3) on t h e la bel. At t h e bot t om NLGI
ENGINE OIL sym bol is t h e u sa ge a n d qu a lit y iden t ifica t ion let t er s.
Wh eel bea r in g lu br ica n t is iden t ified by t h e let t er
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY “G”. Ch a ssis lu br ica n t is iden t ified by t h e la t t er “L”.
An SAE viscosit y gr a de is u sed t o specify t h e vis- Th e let t er followin g t h e u sa ge let t er in dica t es t h e
cosit y of en gin e oil. SAE 30 specifies a sin gle viscos- qu a lit y of t h e lu br ica n t . Th e followin g sym bols in di-
it y en gin e oil. E n gin e oils a lso h a ve m u lt iple ca t e t h e h igh est qu a lit y.
viscosit ies. Th ese a r e specified wit h a du a l SAE vis- NATIONAL LUBRICATING NATIONAL LUBRICATING NATIONAL LUBRICATING
cosit y gr a de wh ich in dica t es t h e cold-t o-h ot t em per a - GREASE INSTITUTE GREASE INSTITUTE GREASE INSTITUTE

t u r e viscosit y r a n ge. NLGI NLGI NLGI


• SAE 30 = sin gle gr a de en gin e oil. AUTOMOTIVE
WHEEL BEARING & CHASSIS
AUTOMOTIVE
WHEEL BEARING & CHASSIS
AUTOMOTIVE
WHEEL BEARING & CHASSIS

• SAE 10W-30 = m u lt iple gr a de en gin e oil. LUBRICANT LUBRICANT LUBRICANT

Ch r ysler Cor por a t ion on ly r ecom m en ds m u lt iple GC LB GC-LB


gr a de en gin e oils.
WHEEL CHASSIS CHASSIS AND
BEARINGS LUBRICATION WHEEL BEARINGS
API QUALITY CLASSIFICATION
9200-7
Th is sym bol (F ig. 2) on t h e fr on t of a n oil con t a in er Fig. 3 NLGI Symbol
m ea n s t h a t t h e oil h a s been cer t ified by t h e Am er i-
ca n P et r oleu m In st it u t e (AP I) t o m eet a ll t h e lu br i-
ca t ion r equ ir em en t s specified by Ch r ysler
Cor por a t ion .
Refer t o Gr ou p 9, E n gin e for ga solin e en gin e oil
specifica t ion .

9400-9

Fig. 2 API Symbol


XJ LUBRICATION AND MAINTENANCE 0-3
GEN ERAL I N FORM AT I ON (Cont inue d)

FLUID CAPACITIES MANUAL TRANSMISSION

FUEL TANK AX5 (4X2) . . . . . . . . . . . . . . . . . . . . . 3.5 L (3.7 qt s.)


AX5 (4X4) . . . . . . . . . . . . . . . . . . . . . 3.3 L (3.5 qt s.)
All . . . . . . . . . . . . . . . . . . . . . . . . . 76.4 L (20.2 ga l.) AX15 (4X2) . . . . . . . . . . . . . . . . . . . 3.15 L (3.3 qt s.)
AX15 (4X4) . . . . . . . . . . . . . . . . . . . 3.15 L (3.3 qt s.)
ENGINE OIL
TRANSFER CASE
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 L (4.0 qt s.)
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L (6.0 qt s.) SE LE C-TRAC 242 . . . . . . . . . . . . . . 1.3 L (2.85 pt s.)
COMMAND-TRAC 231 . . . . . . . . . . . 1.0 L (2.2 pt s.)
COOLING SYSTEM
FRONT AXLE
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (10 qt s.)*
4.0L . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (12 qt s.)** 181–F BI . . . . . . . . . . . . . . . . . . . . 1.48 L (3.13 pt s.)
*In clu des 2.2 L (2.3 qt s) for coola n t r ecover y r eser- REAR AXLE
voir.
**In clu des 0.9 L (1.0 qt ) for coola n t r ecover y r eser- 194–RBI . . . . . . . . . . . . . . . . . . . . 1.66 L (3.5 pt s.*)
voir. 8-1/4 . . . . . . . . . . . . . . . . . . . . . . . 2.08 L (4.4 pt s.**)

AUTOMATIC TRANSMISSION * Wh en equ ipped wit h TRAC-LOK, in clu de 3.5


Dr y fill ca pa cit y* ou n ces of F r ict ion Modifier Addit ive.
** Wh en equ ipped wit h TRAC-LOK, in clu de 4
AW4 . . . . . . . . . . . . . . . . . . . . . . . . 7.8 L (16.5 pt s.) ou n ces of F r ict ion Modifier Addit ive.
30RH . . . . . . . . . . . . . . . . . . . . . . . 4.67 L (9.86pt s.)
POWER STEERING
*Depen din g on t ype a n d size of in t er n a l cooler, P ower st eer in g flu id ca pa cit ies a r e depen den t on
len gt h a n d in side dia m et er of cooler lin es, or u se of en gin e/ch a ssis opt ion s a s well a s st eer in g gea r /cooler
a n a u xilia r y cooler, t h ese figu r es m a y va r y. Refer t o opt ion s. Depen din g on t ype a n d size of in t er n a l
Gr ou p 21, Tr a n sm ission for pr oper flu id fill pr oce- cooler, len gt h a n d in side dia m et er of cooler lin es, or
du r e. u se of a n a u xilia r y cooler, t h ese ca pa cit ies m a y va r y.
Refer t o Sect ion 19 of t h e ser vice m a n u a l for pr oper
fill a n d bleed pr ocedu r es.
0-4 LUBRICATION AND MAINTENANCE XJ

M AI N T EN AN CE SCH EDU LES

INDEX
page

GENERAL INFORMATION
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 4

GEN ERAL I N FORM AT I ON • Rot a t e t h e t ir es a t ea ch oil ch a n ge in t er va l


sh own on Sch edu le “A” (7,500 m iles) or ever y ot h er
MAINTENANCE SCHEDULES in t er va l sh own on Sch edu le “B” (6,000 m iles).
Th er e a r e t wo m a in t en a n ce sch edu les t h a t sh ow • Ch eck coola n t level, h oses, a n d cla m ps.
pr oper ser vice for t h e Ch er okee. • Aft er com plet ion of off-r oa d oper a t ion , t h e
F ir st is Sch edu le “A” . It list s a ll t h e sch edu led u n der side of t h e veh icle sh ou ld be t h or ou gh ly
m a in t en a n ce t o be per for m ed u n der “n or m a l” oper a t - in spect ed. E xa m in e t h r ea ded fa st en er s for loosen ess.
in g con dit ion s.
Secon d is Sch edu le “B ” . It is a sch edu le for veh i- EMISSION CONTROL SYSTEM MAINTENANCE
cles t h a t a r e oper a t ed u n der t h ese con dit ion s: Th e sch edu led em ission m a in t en a n ce list ed in bo ld
• F r equ en t sh or t t r ips dr ivin g less t h a n 5 m iles (8 ty p e on t h e Ma in t en a n ce Sch edu les, m u st be don e a t
km ) t h e m ilea ge specified t o a ssu r e t h e con t in u ed pr oper
• F r equ en t dr ivin g in du st y con dit ion s fu n ct ion in g of t h e em ission con t r ol syst em . Th ese,
• F r equ en t t r a iler t owin g a n d a ll ot h er m a in t en a n ce ser vices in clu ded in t h is
• E xt en sive idlin g m a n u a l, sh ou ld be don e t o pr ovide t h e best veh icle
• Mor e t h a n 50% of dr ivin g is a t su st a in ed h igh per for m a n ce a n d r elia bilit y. Mor e fr equ en t m a in t e-
speeds du r in g h ot wea t h er, a bove 90°F (32°C) n a n ce m a y be n eeded for veh icles in sever e oper a t in g
• Off-r oa d dr ivin g con dit ion s su ch a s du st y a r ea s a n d ver y sh or t t r ip
• Deser t oper a t ion dr ivin g.
Use t h e sch edu le t h a t best descr ibes t h e dr ivin g
con dit ion s. FLUID FILL LOCATIONS AND LUBRICATION
Wh er e t im e a n d m ilea ge a r e list ed, follow t h e POINTS
in t er va l t h a t occu r s fir st . Th e flu id fill/ch eck loca t ion s a n d lu br ica t ion poin t s
a r e loca t ed in ea ch a pplica ble gr ou p.
At Each Stop For Fuel
• Ch eck en gin e oil level, a dd a s r equ ir ed. SCHEDULE “A”
• Ch eck win dsh ield wa sh er solven t a n d a dd if
r equ ir ed. 7,500 Miles (12 000 km) or at 6 months
• Ch a n ge en gin e oil.
Once A Month • Repla ce en gin e oil filt er.
• Ch eck t ir e pr essu r e a n d look for u n u su a l wea r • Lu br ica t e st eer in g lin ka ge (4x4 on ly).
or da m a ge.
• In spect ba t t er y a n d clea n a n d t igh t en t er m in a ls 15,000 Miles (24 000 km) or at 12 months
a s r equ ir ed. Ch eck elect r olyt e level a n d a dd wa t er a s • Ch a n ge en gin e oil.
n eeded. • Repla ce en gin e oil filt er.
• Ch eck flu id levels of coola n t r eser voir, power • Lu br ica t e st eer in g lin ka ge.
st eer in g, br a ke m a st er cylin der, a n d t r a n sm ission • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
a n d a dd a s n eeded.
• Ch eck a ll ligh t s a n d a ll ot h er elect r ica l it em s for 22,500 Miles (36 000 km) or at 18 months
cor r ect oper a t ion . • Ch a n ge en gin e oil.
• Repla ce en gin e oil filt er.
At Each Oil Change • In spect br a ke lin in gs.
• In spect exh a u st syst em . • Lu br ica t e st eer in g lin ka ge (4x4 on ly).
• In spect br a ke h oses.
XJ LUBRICATION AND MAINTENANCE 0-5
GEN ERAL I N FORM AT I ON (Cont inue d)
30,000 Miles (48 000 km) or at 24 months • 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 ) or 24 m on t h s sin ce la st
• Repla ce en gin e oil filt er. ch a n ge.
• Re p la c e a ir c le a n e r e le m e n t. • 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 s p a rk p lu g s . • Dr a in a n d r efill m a n u a l t r a n sm ission flu id.
• 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. 82,500 Miles (133 000 km) or at 66 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. • F lu sh a n d r epla ce en gin e coola n t if it h a s been
30,000 m iles (48 000 km ) or 24 m on t h s sin ce la st
37,500 Miles (60 000 km) or at 30 months ch a n ge.
• Ch a n ge en gin e oil. • Lu br ica t e st eer in g lin ka ge (4x4 on ly).
• Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g lin ka ge (4x4 on ly). 90,000 Miles (144 000 km) or at 72 months
• Dr a in a n d r efill m a n u a l t r a n sm ission flu id. • Ch a n ge en gin e oil.
• Repla ce en gin e oil filt er.
45,000 Miles (72 000 km) or at 36 months • Re p la c e e n g in e a ir c le a n e r e le m e n t.
• 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.
• In spect br a ke lin in gs. • Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id.
• F lu sh a n d r epla ce en gin e coola n t a t 36 m on t h s, • Dr a in a n d r efill t r a n sfer ca se flu id.
r ega r dless of m ilea ge. • 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.

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
page page

SERVICE PROCEDURES JUMP STARTING PROCEDURE . . . . . . . . . . . . . . 9


EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . . 11 TOWING RECOMMENDATIONS . . . . . . . . . . . . . 10
FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . . . 11 TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . . 10
HOISTING RECOMMENDATIONS . . . . . . . . . . . . 11

SERV I CE PROCEDU RES (2) Wh en u sin g a n ot h er veh icle a s a boost er


sou r ce, t u r n off a ll a ccessor ies, pla ce gea r select or in
JUMP STARTING PROCEDURE pa r k or n eu t r a l, set pa r k br a ke a n d oper a t e en gin e a t
1200 r pm .
WARNING: REVIEW ALL SAFETY PRECAUTIONS (3) On disa bled veh icle, pla ce gea r select or in pa r k
AND WARNINGS IN GROUP 8A, BATTERY/START- or n eu t r a l a n d set pa r k br a ke. Tu r n off a ll a ccesso-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT r ies.
JUMP START A FROZEN BATTERY, PERSONAL (4) Con n ect ju m per ca bles t o boost er ba t t er y. RE D
INJURY CAN RESULT. DO NOT JUMP START WHEN cla m p t o posit ive t er m in a l (+). BLACK cla m p t o n eg-
MAINTENANCE FREE BATTERY INDICATOR DOT IS a t ive t er m in a l (-). DO NOT a llow cla m ps a t opposit e
YELLOW OR BRIGHT COLOR. DO NOT JUMP en d of ca bles t o t ou ch , elect r ica l a r c will r esu lt .
START A VEHICLE WHEN THE BATTERY FLUID IS Review a ll wa r n in gs in t h is pr ocedu r e.
BELOW THE TOP OF LEAD PLATES. DO NOT (5) On disa bled veh icle, con n ect RE D ju m per ca ble
ALLOW JUMPER CABLE CLAMPS TO TOUCH cla m p t o posit ive (+) t er m in a l. Con n ect BLACK
EACH OTHER WHEN CONNECTED TO A BOOSTER ju m per ca ble cla m p t o en gin e gr ou n d a s close t o t h e
SOURCE. DO NOT USE OPEN FLAME NEAR BAT- gr ou n d ca ble a t t a ch in g poin t a s possible (F ig. 1).
TERY. REMOVE METALLIC JEWELRY WORN ON POSITIVE NEGATIVE
HANDS OR WRISTS TO AVOID INJURY BY ACCI- CABLE OR GROUND
DENTAL ARCING OF BATTERY CURRENT. WHEN CONNECTION CABLE
CONNECTION
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.

CAUTION: When using another vehicle as a


booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE:


(1) Ra ise h ood on disa bled veh icle a n d visu a lly
in spect en gin e com pa r t m en t for :
• Ba t t er y ca ble cla m p con dit ion , clea n if n ecessa r y.
• F r ozen ba t t er y.
• Yellow or br igh t color t est in dica t or, if equ ipped.
• Low ba t t er y flu id level.
• Gen er a t or dr ive belt con dit ion a n d t en sion . BOOSTER BATTERY J8900-7
• F u el fu m es or lea ka ge, cor r ect if n ecessa r y.
Fig. 1 Jumper Cable Connections—Typical
CAUTION: If the cause of starting problem on dis- CAUTION: Do not crank starter motor on disabled
abled vehicle is severe, damage to booster vehicle vehicle for more than 15 seconds, starter will over-
charging system can result. heat and could fail.
0 - 10 LUBRICATION AND MAINTENANCE XJ
SERV I CE PROCEDU RES (Cont inue d)
(6) Allow ba t t er y in disa bled veh icle t o ch a r ge t o • Do n ot a llow pa ssen ger s t o r ide in a veh icle
a t lea st 12.4 volt s (75% ch a r ge) befor e a t t em pt in g t o bein g t owed.
st a r t en gin e. If en gin e does n ot st a r t wit h in 15 sec- • Alwa ys obser ve st a t e a n d loca l la ws r ega r din g
on ds, st op cr a n kin g en gin e a n d a llow st a r t er t o cool t owin g r egu la t ion s.
(15 m in .), befor e cr a n kin g a ga in . • Do n ot t ow a veh icle in a m a n n er t h a t cou ld
jeopa r dize t h e sa fet y of t h e oper a t or, pedest r ia n s or
DISCONNECT CABLE CLAMPS AS FOLLOWS: ot h er m ot or ist s.
• Discon n ect BLACK ca ble cla m p fr om en gin e • Do n ot a t t a ch t ow ch a in s, T-h ooks, J -h ooks, or a
gr ou n d on disa bled veh icle. t ow slin g t o a bu m per, st eer in g lin ka ge, dr ive sh a ft s
• Wh en u sin g a Boost er veh icle, discon n ect or a n on -r ein for ced fr a m e h ole.
BLACK ca ble cla m p fr om ba t t er y n ega t ive t er m in a l.
Discon n ect RE D ca ble cla m p fr om ba t t er y posit ive GROUND CLEARANCE
t er m in a l.
• Discon n ect RE D ca ble cla m p fr om ba t t er y posi- CAUTION: If vehicle is towed with wheels removed,
t ive t er m in a l on disa bled veh icle. install lug nuts to retain brake drums.

TOWING RECOMMENDATIONS A t owed veh icle sh ou ld be r a ised u n t il lift ed wh eels


A veh icle equ ipped wit h a n SAE a ppr oved Wh eel- a r e a m in im u m 100 m m (4 in ) fr om t h e gr ou n d. Be
lift t owin g device ca n be u sed t o t ow a ll Ch er okee su r e t h er e is a dequ a t e gr ou n d clea r a n ce a t t h e oppo-
veh icles (F ig. 2). Wh en t owin g a 4WD veh icle, u se sit e en d of t h e veh icle, especia lly wh en t owin g over
t ow dollies u n der t h e opposit e en d of t h e veh icle. A r ou gh t er r a in or st eep r ises in t h e r oa d. If n ecessa r y,
veh icle wit h a fla t -bed device ca n a lso be u sed t o r em ove t h e wh eels fr om t h e lift ed en d of t h e veh icle
t r a n spor t a disa bled veh icle. a n d lower t h e veh icle closer t o t h e gr ou n d, t o
in cr ea se t h e gr ou n d clea r a n ce a t t h e opposit e en d of
t h e veh icle. In st a ll lu g n u t s on wh eel a t t a ch in g st u ds
t o r et a in br a ke dr u m s.

FLAT-BED TOWING RAMP ANGLE


If a veh icle wit h fla t -bed t owin g equ ipm en t is u sed,
t h e a ppr oa ch r a m p a n gle sh ou ld n ot exceed 15
degr ees.
WHEEL LIFT
TWO-WHEEL-DRIVE VEHICLE TOWING
TOWING-REAR END LIFTED (SLING-TYPE)
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
FLAT BED
80a7aebb WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
Fig. 2 Tow Vehicles With Approved Equipment MATIC TRANSMISSION) OR A FORWARD DRIVE
NOTE: A vehicle equipped with a SAE approved GEAR (MANUAL TRANSMISSION).
sling type towing device can be used to tow a Cher-
okee with the rear end lifted, provided the Cherokee
CAUTION: Do not use steering column lock to
is not equipped with a factory installed trailer tow
secure steering wheel during towing operation.
package. Damage to the harness connector bracket
may result from sling contact. 2WD XJ veh icles ca n be t owed wit h t h e fr on t
wh eels on t h e su r fa ce for ext en ded dist a n ces a t
speeds n ot exceedin g 48 km /h (30 m ph ). If t h e veh icle
SAFETY PRECAUTIONS is equ ipped wit h a fa ct or y in st a lled t r a iler t ow pa ck-
• Secu r e loose a n d pr ot r u din g pa r t s.
a ge, u se a SAE a ppr oved wh eel lift device.
• Alwa ys u se a sa fet y ch a in syst em t h a t is in de-
(1) At t a ch J -h ooks a r ou n d t h e a xle sh a ft t u be ou t -
pen den t of t h e lift in g a n d t owin g equ ipm en t .
boa r d of t h e sh ock a bsor ber.
• Do n ot a llow t owin g equ ipm en t t o con t a ct t h e
(2) P la ce t h e slin g cr ossba r u n der a n d for wa r d of
disa bled veh icle’s fu el t a n k.
t h e bu m per.
• Do n ot a llow a n yon e u n der t h e disa bled veh icle
(3) At t a ch sa fet y ch a in s a r ou n d t h e fr a m e r a ils.
wh ile it is lift ed by t h e t owin g device.
XJ LUBRICATION AND MAINTENANCE 0 - 11
SERV I CE PROCEDU RES (Cont inue d)
(4) Tu r n t h e ign it ion swit ch t o t h e OF F posit ion t o (6) Secu r e st eer in g wh eel in t h e st r a igh t a h ea d
u n lock t h e st eer in g wh eel. posit ion wit h a cla m p device design ed for t owin g.
(5) Secu r e st eer in g wh eel in t h e st r a igh t a h ea d (7) Sh ift t r a n sfer ca se t o n eu t r a l.
posit ion wit h a cla m p device design ed for t owin g.
(6) Ver ify t h a t st eer in g com pon en t s a r e in good TOWING-REAR END LIFTED (WHEEL LIFT)
con dit ion . (1) Ra ise fr on t of veh icle off gr ou n d a n d in st a ll t ow
(7) Sh ift t h e t r a n sm ission t o NE UTRAL. dollies u n der fr on t wh eels.
(2) At t a ch wh eel lift t o r ea r wh eels.
TOWING-REAR END LIFTED (WHEEL LIFT) (3) P la ce t r a n sm ission in n eu t r a l.
(1) Ra ise fr on t of veh icle off gr ou n d a n d in st a ll t ow (4) Ra ise veh icle t o t owin g h eigh t .
dollies u n der fr on t wh eels. (5) P la ce t r a n sm ission in pa r k (a u t om a t ic t r a n s-
(2) At t a ch wh eel lift t o r ea r wh eels. m ission ) or fir st gea r (m a n u a l t r a n sm ission ).
(3) P la ce t r a n sm ission in n eu t r a l.
(4) Ra ise veh icle t o t owin g h eigh t . TOWING-FRONT END LIFTED
(5) P la ce t r a n sm ission in pa r k (a u t om a t ic t r a n s- To pr even t da m a ge t o fr on t fa scia com pon en t s, u se
m ission ) or fist gea r (m a n u a l t r a n sm ission ). on ly a Wh eel-Lift t ype t owin g device or F la t -Bed
h a u lin g equ ipm en t .
TOWING-FRONT END LIFTED (1) Ra ise t h e r ea r of t h e veh icle off t h e gr ou n d a n d
To pr even t da m a ge t o fr on t fa scia com pon en t s, u se in st a ll t ow dollies u n der r ea r wh eels.
on ly a Wh eel-Lift t ype t owin g device or F la t -Bed (2) At t a ch wh eel lift t o fr on t wh eels.
h a u lin g equ ipm en t . (3) P la ce t r a n sm ission in n eu t r a l.
If u sin g t h e wh eel-lift t owin g m et h od: (4) Ra ise veh icle t o t owin g h eigh t .
(1) Ra ise r ea r of veh icle off gr ou n d a n d in st a ll t ow (5) P la ce t r a n sm ission in pa r k (a u t om a t ic t r a n s-
dollies u n der r ea r wh eels. m ission ) or fir st gea r (m a n u a l t r a n sm ission ).
(2) At t a ch wh eel lift t o fr on t wh eels.
(3) P la ce t r a n sm ission in n eu t r a l. EMERGENCY TOW HOOKS
(4) Ra ise veh icle t o t owin g h eigh t .
(5) P la ce t r a n sm ission in pa r k (a u t om a t ic t r a n s- WARNING: REMAIN AT A SAFE DISTANCE FROM A
m ission ) or fist gea r (m a n u a l t r a n sm ission ). VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
FOUR-WHEEL-DRIVE VEHICLE TOWING AND CAUSE SERIOUS INJURY.
Ch r ysler Cor por a t ion r ecom m en ds t h a t a 4WD
veh icle be t r a n spor t ed on a fla t bed device. A wh eel Som e J eep veh icles a r e equ ipped wit h fr on t a n d
lift or slin g t ype device ca n be u sed pr ovided a ll r ea r em er gen cy t ow h ooks. Th e t ow h ooks sh ou ld be
wh eels a r e lift ed off t h e gr ou n d u sin g t ow dollies. u sed for EMERGEN CY pu r poses on ly.
If t h e veh icle is equ ipped wit h a fa ct or y in st a lled
CAUTION: DO NOT use emergency tow hooks for
t r a iler t ow pa cka ge, u se a SAE a ppr oved wh eel lift
tow truck hook-up or highway towing.
device.

WARNING: WHEN TOWING A DISABLED VEHICLE


AND THE DRIVE WHEELS ARE SECURED IN A
HOISTING RECOMMENDATIONS
Refer t o t h e Own er ’s Ma n u a l for em er gen cy veh icle
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
lift in g pr ocedu r es.
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
FLOOR JACK
Wh en pr oper ly posit ion ed, a floor ja ck ca n be u sed
t o lift a J eep veh icle (F ig. 3) a n d (F ig. 4). Su ppor t t h e
TOWING-REAR END LIFTED (SLING TYPE) veh icle in t h e r a ised posit ion wit h ja ck st a n ds a t t h e
(1) Ra ise fr on t of veh icle off gr ou n d a n d in st a ll t ow fr on t a n d r ea r en ds of t h e fr a m e r a ils.
dollies u n der fr on t wh eels.
(2) At t a ch J -h ooks a r ou n d r ea r a xle sh a ft t u be ou t - CAUTION: Do not attempt to lift a Jeep vehicle with
boa r d of sh ock a bsor ber. a floor jack positioned under:
(3) P la ce slin g cr ossba r u n der a n d for wa r d of
• An a xle t u be.
bu m per.
• A body side sill.
(4) At t a ch sa fet y ch a in s a r ou n d fr a m e r a ils.
• A st eer in g lin ka ge com pon en t .
(5) Tu r n ign it ion swit ch t o OF F posit ion t o u n lock
• A dr ive sh a ft .
st eer in g wh eel.
0 - 12 LUBRICATION AND MAINTENANCE XJ
SERV I CE PROCEDU RES (Cont inue d)

~DRIVE-ON HOIST Illll)TWIN POST CHASSIS HOIST


~ FRAME CONTACT HOIST. FLOOR JACK
J9500-2

Fig. 3 Vehicle Lifting Locations Fig. 4 Correct Vehicle Lifting Locations


• Th e en gin e or t r a n sm ission oil pa n . WARNING: THE HOISTING AND JACK LIFTING
• Th e fu el t a n k. POINTS PROVIDED ARE FOR A COMPLETE VEHI-
• A fr on t su spen sion a r m . CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
NOTE: Use the correct sub-frame rail or frame rail CENTER OF GRAVITY IS ALTERED MAKING SOME
lifting locations only. HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
HOIST DEVICE WHEN THESE CONDITIONS EXIST.
A veh icle ca n be lift ed wit h :
• A sin gle-post , fr a m e-con t a ct h oist .
• A t win -post , ch a ssis h oist .
• A r a m p-t ype, dr ive-on h oist .
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
XJ LUBRICATION AND MAINTENANCE 0-1

LUBRICATION AND MAINTENANCE


CON T EN T S

page page
-
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . 2

GEN ERAL I N FORM AT I ON

INDEX
page page

SPECIFICATIONS FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 1


ENGINE OIL—DIESEL ENGINES . . . . . . . . . . . . . 1

SPECI FI CAT I ON S MANUAL TRANSMISSION


Recom m en ded lu br ica n t for AX15 t r a n sm ission s is
ENGINE OIL—DIESEL ENGINES Mopa r ! 75W–90, AP I Gr a de GL–3 gea r lu br ica n t , or
Use on ly Diesel E n gin e Oil m eet in g st a n da r d MIL- equ iva len t .
2104C or AP I Cla ssifica t ion S G/CD or CCMC P D 2. Cor r ect lu br ica n t level is fr om t h e bot t om edge, t o
n o m or e t h a n 6 m m (1/4 in .) below t h e bot t om edge of
SAE VISCOSITY GRADE t h e fill plu g h ole.
Ap p ro x im a te d ry fill lu bric a n t c a p a c ity is :
CAUTION: Low viscosity oils must have the proper • 3.10 lit er s (3.27 qt s.) for 4–wh eel dr ive a pplica -
API quality or the CCMC G5 designation. t ion s.
• 3.15 lit er s (3.32 qt s.) for 2–wh eel dr ive a pplica -
To a ssu r e of pr oper ly for m u la t ed en gin e oils, it is t ion s.
r ecom m en ded t h a t SAE Gr a de 15W-40 en gin e oils
t h a t m eet Ch r ysler m a t er ia l st a n da r d MS-6395, be TRANSFER CASE
u sed. E u r opea n Gr a de 10W-40 oils a r e a lso a ccept -
a ble. COMMAND-TRAC 231 . . . . . . . . . . . . . . . . . . 1.3 L
Oils of t h e SAE 5W-30 or 10W-30 gr a de n u m ber
a r e pr efer r ed wh en m in im u m t em per a t u r es con sis- FRONT AXLE
t en t ly fa ll below -12°C.
Model 181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 L
FLUID CAPACITIES REAR AXLE
FUEL TANK Model 194 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L*
8-1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 L**
Diesel E n gin e E qu ipped Veh icles . . . . . . . . . . 76.4 L
* Wh en equ ipped wit h TRAC-LOK, in clu de 4
ENGINE OIL ou n ces of F r ict ion Modifier Addit ive.
** Wh en equ ipped wit h TRAC-LOK, in clu de 5
2.5L Diesel E n gin e (in clu des filt er ) . . . . . . . . . 6.5 L ou n ces of F r ict ion Modifier Addit ive.
COOLING SYSTEM

2.5L Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 L


0-2 LUBRICATION AND MAINTENANCE XJ

M AI N T EN AN CE SCH EDU LE

INDEX
page page

GENERAL INFORMATION SCHEDULE—A . . . . . . . . . . . . . . . . . . . . . . . . . . 2


MAINTENANCE SCHEDULE—DIESEL ENGINE . . 2 SCHEDULE—B . . . . . . . . . . . . . . . . . . . . . . . . . . 3

GEN ERAL I N FORM AT I ON • Ch eck a ll flu id levels.


• Ch eck cor r ect t or qu e, in t a ke m a n ifold m ou n t in g
MAINTENANCE SCHEDULE—DIESEL ENGINE n u t s.
Th e followin g a r e en gin e r ela t ed Ma in t en a n ce • Ch eck cor r ect t or qu e, exh a u st m a n ifold m ou n t -
it em s wh ich a r e u n iqu e t o Diesel en gin e-equ ipped in g n u t s.
veh icles. Refer t o t h e 1997 XJ Ser vice Ma n u a l for • Ch eck cor r ect t or qu e, t u r boch a r ger m ou n t in g
ga solin e en gin e a n d n on -en gin e r ela t ed Ma in t en a n ce n u t s.
Sch edu les. • Ch eck cor r ect t or qu e, wa t er m a n ifold bolt s.
Th e ser vice in t er va ls a r e ba sed on odom et er r ea d-
10 000 KM
in gs in kilom et er s. Th er e a r e t wo m a in t en a n ce sch ed-
u les t h a t sh ow pr oper ser vice in t er va ls. Use t h e • Ch a n ge en gin e oil.
sch edu le t h a t best descr ibes t h e con dit ion s t h e veh i- • Ch a n ge en gin e oil filt er.
cle is oper a t ed u n der. S c h e d u le -A list s a ll t h e sch ed-
20 000 KM
u led m a in t en a n ce t o be per for m ed u n der n or m a l
• Ch a n ge en gin e oil.
oper a t in g con dit ion s. S c h e d u le -B is t h e sch edu le for
• Ch a n ge en gin e oil filt er.
veh icles t h a t a r e oper a t ed u n der on e or m or e of t h e
• Repla ce a ir filt er elem en t .
followin g con dit ion s:
• Ch eck dr ive belt t en sion .
• Da y a n d n igh t t em per a t u r es a r e below fr eezin g.
• Ch eck glow plu g oper a t ion .
• St op a n d go dr ivin g.
• Re to rqu e c y lin d e r h e a d bo lts .*
• Lon g per iods of en gin e idlin g.
* E n gin es equ ipped wit h a st eel h ea d ga sket do n ot
• Dr ivin g in du st y con dit ion s.
n eed t h is ser vice pr ocedu r e per for m ed. Refer t o
• Sh or t t r ips of less t h a n 8 kilom et er s (5 m iles).
Gr ou p 9, E n gin es for h ea d ga sket iden t ifica t ion .
• Oper a t ion a t su st a in ed h igh speeds du r in g h ot
wea t h er a bove 32°C (90°F ). 30 000 KM
• Ta xi, police or deliver y ser vice.
• Ch a n ge en gin e oil.
• Tr a iler t owin g.
• Ch a n ge en gin e oil filt er.
AT EACH STOP FOR FUEL OR SCHEDULED 40 000 KM
SERVICE STOP • Ch a n ge en gin e oil.
• Ch eck en gin e oil level. • Ch a n ge en gin e oil filt er.
• Ch eck en gin e coola n t level. • Repla ce a ir filt er elem en t .
• In spect dr ive belt . • Ch eck dr ive belt t en sion .
• Visu a lly in spect in t er cooler for obst r u ct ion . • Ch eck glow plu g oper a t ion .
Clea n a s n ecessa r y. • Repla ce fu el filt er /wa t er sepa r a t or elem en t .**
• Visu a lly in spect r a dia t or for obst r u ct ion . Clea n
a s n ecessa r y. 50 000 KM
• In spect for fu el, oil or coola n t lea ks. • Ch a n ge en gin e oil.
• In spect ba t t er y ca ble con n ect ion a n d excessive • Ch a n ge en gin e oil filt er.
cor r osion .
• In spect for pr esen ce of wa t er in fu el filt er /wa t er
sepa r a t or, dr a in if n ecessa r y.

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

GENERAL INFORMATION EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 2


CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . 1 MUFFLER AND EXHAUST TAILPIPE . . . . . . . . . . 4
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS
DIAGNOSIS AND TESTING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 5
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . 3

GEN ERAL I N FORM AT I ON Th e 4.0L en gin es u se a sea l bet ween t h e en gin e


exh a u st m a n ifold a n d exh a u st pipe t o a ssu r e a t igh t
EXHAUST SYSTEM sea l a n d st r a in fr ee con n ect ion s.
Th e ba sic exh a u st syst em con sist s of a n en gin e Th e exh a u st syst em m u st be pr oper ly a lign ed t o
exh a u st m a n ifold, exh a u st pipe wit h oxygen sen sor, pr even t st r ess, lea ka ge a n d body con t a ct . If t h e sys-
ca t a lyt ic con ver t er wit h oxygen sen sor, m u ffler a n d t em con t a ct s a n y body pa n el, it m a y a m plify objec-
exh a u st t a ilpipe (F ig. 1). t ion a ble n oises or igin a t in g fr om t h e en gin e or body.
Wh en in spect in g a n exh a u st syst em , cr it ica lly
in spect for cr a cked or loose join t s, st r ipped scr ew or
bolt t h r ea ds, cor r osion da m a ge a n d wor n , cr a cked or
br oken h a n ger s. Repla ce a ll com pon en t s t h a t a r e
ba dly cor r oded or da m a ged. DO NOT a t t em pt t o
~6.ll~~*'r',::::;;::~ r,..__ EXHAUST r epa ir.
MANIFOLD Wh en r epla cem en t is r equ ir ed, u se or igin a l equ ip-
m en t pa r t s (or t h eir equ iva len t ). Th is will a ssu r e
pr oper a lign m en t a n d pr ovide a ccept a ble exh a u st
n oise levels.

CATALYTIC C O N ~ CAUTION: Avoid application of rust prevention


compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light over
spray near the edges is permitted. Application of
coating will result in excessive floor pan tempera-
tures and objectionable fumes.

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

DI AGN OSI S AN D T EST I N G

EXHAUST SYSTEM
EX H AU ST SY ST EM DI AGN OSI S CH ART

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE EXHAUST NOISE OR 1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking


LEAKING EXHAUST GASES joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust 3. Replace exhaust pipe.
pipe.
4. Exhaust pipe leaking at manifold 4. Tighten/replace flange attaching
flange. nuts/bolts.
5. Exhaust manifold cracked or 5. Replace exhaust manifold.
broken.
6. Leak between exhaust manifold 6. Tighten exhaust manifold to
and cylinder head. cylinder head bolts.
7. Catalytic converter rusted or 7. Replace catalytic converter assy.
blown out.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.

When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.

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

Fig. 2 Exhaust Pipe Removal—2.5L/4.0L


CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
REAR
ENGINE sensor harness will damage the wiring and/or sen-
MOUNT sor.

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.

MUFFLER AND EXHAUST TAILPIPE


All or igin a l equ ipm en t exh a u st syst em s a r e m a n u -
fa ct u r ed wit h t h e exh a u st t a ilpipe welded t o t h e m u f-
fler. Ser vice r epla cem en t m u ffler s a n d exh a u st
t a ilpipes a r e eit h er cla m ped t oget h er or welded MUFFLER
t oget h er. 80b89899

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

EXHAUST SYSTEM AND TURBOCHARGER


CON T EN T S

page page

GENERAL INFORMATION EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 2


EXHAUST HEAT SHIELDS . . . . . . . . . . . . . . . . . 1 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 10
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1 MUFFLER AND EXHAUST TAILPIPE . . . . . . . . . . 2
REMOVAL AND INSTALLATION SPECIFICATIONS
EXHAUST MANIFOLD AND TURBOCHARGER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 10
(LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
EXHAUST MANIFOLD AND TURBOCHARGER
(RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN ERAL I N FORM AT I ON


EXHAUST SYSTEM
Th e ba sic exh a u st syst em con sist s of a n en gin e
5

EXHAUST HEAT SHIELDS


E xh a u st h ea t sh ields a r e n eeded t o pr ot ect bot h
t h e veh icle a n d t h e en vir on m en t fr om t h e h igh t em -
per a t u r es (F ig. 1).
-
exh a u st m a n ifold, exh a u st pipe, exh a u st h ea t DO NOT a llow t h e en gin e t o oper a t e a t fa st idle for
sh ield(s), m u ffler a n d exh a u st t a ilpipe. ext en ded per iods (over 5 m in u t es). Th is con dit ion
Th e exh a u st syst em u ses a sin gle m u ffler. m a y r esu lt in excessive t em per a t u r es in t h e exh a u st
Th e exh a u st syst em m u st be pr oper ly a lign ed t o syst em a n d on t h e floor pa n .
pr even t st r ess, lea ka ge a n d body con t a ct . If t h e sys-
EXHAUST
t em con t a ct s a n y body pa n el, it m a y a m plify objec- MANIFOLD
t ion a ble n oises or igin a t in g fr om t h e en gin e or body. HEAT
Wh en in spect in g a n exh a u st syst em , cr it ica lly SHIELD
in spect for cr a cked or loose join t s, st r ipped scr ew or
bolt t h r ea ds, cor r osion da m a ge a n d wor n , cr a cked or
br oken h a n ger s. Repla ce a ll com pon en t s t h a t a r e
ba dly cor r oded or da m a ged. DO NOT a t t em pt t o
r epa ir.
Wh en r epla cem en t is r equ ir ed, u se or igin a l equ ip-
m en t pa r t s (or equ iva len t ). Th is will a ssu r e pr oper
a lign m en t a n d pr ovide a ccept a ble exh a u st n oise lev-
els.

CAUTION: Avoid application of rust prevention


80a243e9
compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light over-
Fig. 1 Heat Shields
spray near the edges is permitted. Application of
coating will result in excessive floor pan tempera-
tures and objectionable fumes.
11 - 2 EXHAUST SYSTEM AND TURBOCHARGER XJ

REM OVAL AN D I N STALLAT I ON INSTALLATION


(1) Assem ble exh a u st pipe t o m u ffler, loosely t o
EXHAUST PIPE per m it pr oper a lign m en t of a ll pa r t s.
(2) Con n ect t h e exh a u st pipe t o t h e t u r bo down
WARNING: IF TORCHES ARE USED WHEN WORK- pipe m a n ifold. Tigh t en t h e bolt s t o 22.5 N·m t or qu e.
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW (3) Use a n ew cla m p a n d t igh t en t h e n u t s t o 43
THE FLAME NEAR THE FUEL LINES. N·m t or qu e.
(4) Lower t h e veh icle.
(5) St a r t t h e en gin e a n d in spect for exh a u st lea ks
REMOVAL a n d exh a u st syst em con t a ct wit h t h e body pa n els.
(1) Ra ise a n d su ppor t t h e veh icle. Adju st t h e a lign m en t , if n eeded.
(2) Sa t u r a t e t h e bolt s a n d n u t s a t t u r bo down pipe
t o exh a u st pipe wit h h ea t va lve lu br ica n t . Allow 5 MUFFLER AND EXHAUST TAILPIPE
m in u t es for pen et r a t ion . All or igin a l equ ipm en t exh a u st syst em s a r e m a n u -
(3) Discon n ect bolt s fr om exh a u st pipe t o t u r bo fa ct u r ed wit h t h e exh a u st t a ilpipe welded t o t h e m u f-
down pipe (F ig. 2). fler. Ser vice r epla cem en t m u ffler s a n d exh a u st
t a ilpipes a r e eit h er cla m ped t oget h er or welded
t oget h er.
0
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.

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.

Fig. 3 Front Pipe to Muffler


XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 3
REM OVAL AN D I N STALLAT I ON (Cont inue d)

EXHAUST MANIFOLD AND TURBOCHARGER


(LHD) EXHAUST INLET
PIPE RETAINING
BOLTS
REMOVAL
(1) Discon n ect t h e n ega t ive ba t t er y ca ble.
(2) Discon n ect t h e br ea t h er h ose fr om a ir clea n er
ou t let h ose (F ig. 4).
INNERCOOLER
OUTLET HOSE

80b9a496

Fig. 5 Exhaust System Inlet Pipe Connection

Fig. 4 Engine Compartment


(3) Rem ove t h e a ir filt er cover a n d h ose fr om t u r-
boch a r ger, r em ove t h e a ssem bly (F ig. 4).
(4) Rem ove t h e E GR va cu u m su pply h ose fr om t h e
E GR va lve.
(5) Rem ove t h e in n er cooler in let a n d ou t let h oses
fr om t h e en gin e (F ig. 4).
(6) Rem ove 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.
(7) Rem ove t h e in t a ke m a n ifold elbow a n d E GR
va lve a s a n a ssem bly.
(8) Ra ise t h e veh icle on a h oist .
(9) Dr a in t h e coolin g syst em . Refer t o Gr ou p 7,
Coolin g Syst em for pr ocedu r e.
(10) Rem ove t h e exh a u st syst em su ppor t cla m p
(F ig. 5). Fig. 6 Exhaust Downpipe Heatshield
(11) Discon n ect t h e exh a u st syst em a t t h e (3) bolt
(14) Lower t h e veh icle fr om t h e h oist .
fla n ge (F ig. 5).
(15) Rem ove t h e E GR t u be fr om exh a u st m a n ifold.
CAUTION: Heatshield is very sharp. Wear gloves to (16) Rem ove t h e (2) exh a u st m a n ifold h ea t sh ield
prevent injury. r et a in in g bolt s a n d r em ove t h e h ea t sh ield.
(17) Rem ove t h e h ea t er cor e su pply h oses fr om t h e
(12) Un st r a p t h e exh a u st down pipe h ea t sh ield veh icle.
(F ig. 6). (18) Rem ove t h e oil pr essu r e su pply lin e ba n go
(13) Discon n ect t h e t u r boch a r ger oil r et u r n h ose bolt fr om t h e t u r boch a r ger.
fr om t h e en gin e block (F ig. 7).
11 - 4 EXHAUST SYSTEM AND TURBOCHARGER XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

OIL RETURN LINE WASTE GATE


VACUUM
SUPPLY HOSE

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

INSTALLATION (5) In st a ll t h e exh a u st m a n ifold down pipe. Tor qu e


(1) Tr a n sfer t h e oil r et u r n h ose t o t h e n ew t u r bo- bolt s t o 32 N·m (23 ft . lbs.).
ch a r ger (F ig. 9).
CAUTION: Heatshield is very sharp. Wear gloves to
(2) In st a ll t h e t u r bo on t h e exh a u st m a n ifold (F ig.
prevent injury.
9). Tor qu e t h e n u t s t o 32 N·m (23 ft . lbs.).
(3) In st a ll t h e exh a u st m a n ifold a n d t u r boch a r ger (6) Slide t h e exh a u st down pipe h ea t sh ield down
a ssem bly in t h e veh icle. over pipe. Do n ot a t t em pt t o st r a p h ea t sh ield in posi-
(4) In st a ll t h e (8) exh a u st m a n ifold r et a in in g n u t s. t ion a t t h is t im e, wa it u n t il veh icle is r a ised on h oist .
Tor qu e n u t s t o 32 N·m (23 ft . lbs.).
XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 5
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(7) In st a ll t h e oil pr essu r e su pply lin e on t u r bo-
ch a r ger. Tor qu e ba n go bolt fit t in g t o 27 N·m (20 ft . EXHAUST INLET
lbs.). PIPE RETAINING
(8) In st a ll t h e h ea t er cor e su pply h oses. BOLTS
(9) P osit ion a n d in st a ll t h e exh a u st m a n ifold h ea t -
sh ield. Tor qu e bolt s t o 11 N·m (97 in . lbs.).
(10) Ra ise t h e veh icle on a h oist .
(11) In st a ll t h e t u r boch a r ger oil r et u r n h ose on t h e
en gin e block (F ig. 10).

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

Fig. 10 Turbocharger Oil Return Hose


(12) St r a p t h e exh a u st down pipe h ea t sh ield in it s
or igin a l posit ion .
(13) Con n ect t h e exh a u st syst em a t t h e (3) bolt
fla n ge (F ig. 11). Tor qu e t h e bolt s t o 23 N·m (17 ft .
lbs.).
(14) In st a ll t h e exh a u st syst em su ppor t cla m p
(F ig. 11). Tor qu e n u t s t o 23 N·m (17 ft . lbs.).
(15) Lower t h e veh icle fr om t h e h oist .
(16) In st a ll t h e in t a ke m a n ifold elbow a n d E GR
va lve a s a n a ssem bly. Tor qu e bolt s t o 27 N·m (20 ft .
lbs.).
(17) 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 bolt s t o 27 N·m (20 ft . lbs.).
(18) In st a ll t h e in n er cooler in let a n d ou t let h oses Fig. 12 Engine Compartment
on t h e en gin e (F ig. 12). (24) St a r t t h e en gin e a n d ch eck for lea ks.
(19) 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. EXHAUST MANIFOLD AND TURBOCHARGER
(20) In st a ll t h e a ir filt er cover a n d ou t let h ose on (RHD)
t u r boch a r ger (F ig. 12).
(21) Con n ect t h e br ea t h er h ose on t h e a ir clea n er REMOVAL
ou t let h ose (F ig. 12). (1) Discon n ect t h e n ega t ive ba t t er y ca ble.
(22) F ill t h e coolin g syst em . Refer t o Gr ou p 7, (2) Discon n ect t h e br ea t h er h ose fr om t h e a ir
Coolin g Syst em for pr ocedu r e. clea n er ou t let h ose.
(23) Con n ect t h e n ega t ive ba t t er y ca ble
11 - 6 EXHAUST SYSTEM AND TURBOCHARGER XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rem ove t h e a ir filt er cover a n d t h e h ose fr om
t h e t u r boch a r ger, r em ove t h e a ssem bly.
(4) Ra ise t h e veh icle on a h oist .
(5) Dr a in t h e coolin g syst em . Refer t o Gr ou p 7,
Coolin g Syst em for t h e pr ocedu r e.
(6) Rem ove t h e exh a u st syst em su ppor t cla m p
(F ig. 13).

EXHAUST INLET
PIPE RETAINING
BOLTS

Fig. 14 Exhaust Downpipe Heatshield

EXHAUST SYSTEM
SUPPORT CLAMP

80b9a496

Fig. 13 Exhaust System Inlet Pipe Connection


(7) Discon n ect t h e exh a u st syst em a t t h e (3) bolt
fla n ge (F ig. 13).

CAUTION: Heatshield is very sharp. Wear gloves to


prevent injury. RIGHT:::::::::::::-
ENGINE MOUNT
(8) Un st r a p t h e exh a u st down pipe h ea t sh ield (F ig. THROUGH BOLT
14).
NUT~
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.

(9) 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 down . EXHAUST MANIFOLD
(10) Discon n ect t h e t u r boch a r ger oil r et u r n h ose DOWNPIPE 80b8992e

fr om t h e en gin e block (F ig. 15). Fig. 15 Turbocharger Oil Return Hose


(11) Lower t h e veh icle fr om t h e h oist .
(12) Discon n ect t h e h ea t er cor e coola n t su pply a n d (15) Rem ove t h e (2) bolt s h oldin g t h e E GR t u be t o
t h e br a ke va cu u m su pply h oses fr om t h e r igh t side of t h e E GR va lve.
t h e en gin e. Rem ove t h e st eel lin e su ppor t br a cket (16) Rem ove t h e in t a ke m a n ifold elbow a n d t h e
fr om t h e t op of t h e r ocker cover a n d posit ion t h e E GR va lve a s a n a ssem bly.
a ssem bly ou t of t h e wa y. (17) Rem ove t h e E GR t u be fr om t h e exh a u st m a n -
(13) Rem ove t h e E GR va cu u m su pply h ose fr om ifold.
t h e E GR va lve. (18) Rem ove t h e (2) exh a u st m a n ifold h ea t sh ield
(14) Rem ove t h e in n er cooler in let a n d ou t let h oses r et a in in g bolt s a n d r em ove t h e h ea t sh ield (F ig. 16).
fr om t h e en gin e. (19) Rem ove t h e oil pr essu r e su pply lin e fr om t h e
t u r boch a r ger (F ig. 16).
XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 7
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CLUTCH (24) Discon n ect t h e n eu t r a l sa fet y swit ch elect r ica l
MASTER CYLINDER con n ect or a t t h e clu t ch peda l.
HEATSHIELD (25) Rem ove t h e (2) clu t ch m a st er cylin der r et a in -
in g n u t s fr om t h e bu lkh ea d.
(26) Wor kin g fr om t h e in side of t h e en gin e com -
pa r t m en t , r em ove t h e clu t ch m a st er cylin der fr om
t h e bu lkh ea d a n d posit ion t h e cylin der a n d lin e
a ssem bly ou t of t h e wa y.
(27) Rem ove t h e (5) bolt s fr om t h e exh a u st m a n i-
fold down pipe a n d r em ove t h e pipe.
(28) Rem ove t h e (8) exh a u st m a n ifold r et a in in g
bolt s, it is n ecessa r y t o a ccess t h e bolt beh in d t h e
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.
(29) Rem ove t h e st eer in g sh a ft pin ch bolt a n d slide
t h e sh a ft st r a igh t off of t h e gea r box in pu t sh a ft . P osi-
t ion a side.
(30) Rem ove t h e exh a u st m a n ifold a n d t h e t u r bo-
ch a r ger a ssem bly fr om t h e veh icle.
(31) P la ce t h e t u r bo a ssem bly in a vice t o r em ove
TURBO
OIL PRESSURE
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
SUPPLY LINE sobsee33 n u t s (F ig. 18).

OIL RETURN LINE WASTE GATE


Fig. 16 2.5L Turbo Diesel — Heatshields VACUUM
(20) Rem ove t h e clu t ch m a st er cylin der h ea t sh ield SUPPLY HOSE
(F ig. 16).
(21) Rem ove t h e wa st ega t e a ct u a t or va cu u m su p-
ply h ose fr om t h e a ct u a t or (F ig. 17).
CLUTCH EXHAUST TURBOCHARGER TURBOCHARGER
MASTER DOWNPIPE OIL PRESSURE ASSEMBLY
CYLINDER HEATSHIELD SUPPLY LINE AT (REMOVED
vu TURBO~ FROM

,
VEHICLE) o

Fig. 18 Turbocharger / Exhaust Manifold Assembly

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

Fig. 19 Turbocharger / Exhaust Manifold Assembly


(2) In st a ll t h e exh a u st m a n ifold a n d t u r boch a r ger
a ssem bly in t h e veh icle.
(3) In st a ll t h e (8) exh a u st m a n ifold r et a in in g n u t s,
TURBO
it is n ecessa r y t o a ccess t h e bolt beh in d t h e m a n ifold OIL PRESSURE
ou t let fr om t h e u n der n ea t h of t h e veh icle. Tor qu e SUPPLY LINE sobsee33
n u t s t o 32 N·m (23 ft . lbs.).
(4) In st a ll t h e exh a u st m a n ifold down pipe. Tor qu e Fig. 21 2.5L Turbo Diesel — Heatshields
t h e bolt s t o 32 N·m (23 ft . lbs.). (8) In st a ll t h e E GR t u be on t h e exh a u st m a n ifold.
EXHAUST TURBOCHARGER Lea ve loose a t t h is t im e.
DOWNPIPE OIL PRESSURE (9) Ra ise t h e veh icle on a h oist .
HEATSHIELD SUPPLY LINE AT
vu TURBO~
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.

(10) Slide t h e exh a u st down pipe h ea t sh ield u p


~~~ over t h e pipe a n d st r a p it in it s or igin a l posit ion (F ig.
22).
(11) In st a ll t h e st eer in g sh a ft . Tor qu e t h e pin ch
bolt t o 49 N·m (36 ft . lbs.).
(12) In st a ll t h e t u r boch a r ger oil r et u r n h ose on t h e
en gin e block (F ig. 23).
(13) Con n ect t h e exh a u st syst em a t t h e (3) bolt
fla n ge (F ig. 24). Tor qu e t h e bolt s t o 23 N·m (17 ft .
lbs.).
(14) In st a ll t h e exh a u st syst em su ppor t cla m p
(F ig. 24). Tor qu e n u t s t o 23 N·m (17 ft . lbs.).
TURBOCHARGER (15) Lower t h e veh icle on h oist .
OIL PRESSURE (16) In st a ll t h e clu t ch m a st er cylin der t h r ou gh t h e
SUPPLY LINE AT bu lkh ea d.
ENGINE BLOCK sobse932
(17) Wor kin g fr om t h e in side of t h e veh icle, In st a ll
Fig. 20 R.H.D. Turbo Position & Orientation t h e (2) clu t ch m a st er cylin der r et a in in g n u t s.
(18) Con n ect t h e n eu t r a l sa fet y swit ch a t t h e
clu t ch peda l.
XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 9
REM OVAL AN D I N STALLAT I ON (Cont inue d)

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)

INTAKE MANIFOLD SPECI FI CAT I ON S


REMOVAL TORQUE SPECIFICATIONS
(1) Rem ove exh a u st m a n ifold a n d t u r boch a r ger
a ssem bly. D e s c rip tio n To rqu e
(2) Rem ove wa t er m a n ifold. EGR
(3) Rem ove in t a ke m a n ifold. At t a ch in g Nu t s . . . . . . . . . . . . . . . . . . . . . . . 28 N·m
EGR
CLEANING Tu be Nu t . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 N·m
Clea n t h e in t a ke m a n ifold a n d cylin der h ea d m a t - EGR
in g su r fa ces. D O N OT a llo w fo re ig n m a te ria l to Tu be F la n ge Bolt s . . . . . . . . . . . . . . . . . . . . 26 N·m
e n te r e ith e r th e in ta k e m a n ifo ld o r th e p o rts in Ex h a u s t Ma n ifo ld
th e c y lin d e r h e a d . Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N·m
Ex h a u s t Ma n ifo ld
INSTALLATION
H ea t Sh ield Nu t s . . . . . . . . . . . . . . . . . . . . . 11 N·m
(1) In st a ll t h e n ew in t a ke m a n ifold ga sket .
Ex h a u s t P ip e
(2) P osit ion t h e in t a ke m a n ifold in pla ce a n d fin -
Su ppor t Cla m p Bolt s . . . . . . . . . . . . . . . . . 22.5 N·m
ger t igh t en t h e m ou n t in g n u t s.
Ex h a u s t P ip e
(3) Tigh t en t h e fa st en er s in sequ en ce a n d t o t h e
specified t or qu e 30 N·m . Su ppor t Cla m p Scr ew . . . . . . . . . . . . . . . . 22.5 N·m
(4) P osit ion t h e wa t er m a n ifold in pla ce a n d fin ger In ta k e Ma n ifo ld
t igh t en t h e m ou n t in g n u t s. Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N·m
(5) Tigh t en t h e fa st en er s t o t h e specified t or qu e 12 Mu ffle r-to -Ex h a u s t P ip e
N·m . Cla m p Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . 43 N·m
(6) In st a ll exh a u st m a n ifold a n d t u r boch a r ger Ta il P ip e Cla m p
a ssem bly. H a n ger bolt . . . . . . . . . . . . . . . . . . . . . . . . 22.5 N·m
(7) In st a ll ch a r ge a ir cooler h ose t o in t a ke m a n i- Tu rbo c h a rg e r-to -Ex h a u s t m a n ifo ld
fold. Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m
(8) Con n ect t h e ba t t er y n ega t ive ca ble. Tu rbo c h a rg e r
(9) St a r t en gin e a n d ch eck for lea ks. Oil F eed Lin e . . . . . . . . . . . . . . . . . . . . . . . 27.4 N·m
Tu rbo c h a rg e r D o w n P ip e -to -Ex h a u s t P ip e
Bolt s/Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 N·m
Tu rbo c h a rg e r D o w n P ip e -to -Tu rbo c h a rg e r
Bolt s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m
XJ FRAME AND BUMPERS 13 - 1

FRAME AND BUMPERS


CON T EN T S

page page

BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BU M PERS

INDEX
page page

REMOVAL AND INSTALLATION REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . 3


FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . 1 REAR BUMPER END CAP . . . . . . . . . . . . . . . . . . 2
FRONT BUMPER END CAP . . . . . . . . . . . . . . . . . 1 REAR TOW HOOK . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT TOW HOOK . . . . . . . . . . . . . . . . . . . . . . . 2

REM OVAL AN D I N STALLAT I ON FRONT BUMPER


FRONT BUMPER END CAP REMOVAL
(1) Rem ove bu m per en d ca ps.
REMOVAL (2) If equ ipped, disen ga ge fog la m p wir e h a r n ess
(1) Rem ove t h e r ivet a t t a ch in g t h e en d ca p t o t h e con n ect or s.
a ir deflect or. (3) Discon n ect va cu u m lin e fr om r eser voir (F ig. 3).
(2) Rem ove t h e bolt s a n d n u t s a t t a ch in g t h e en d (4) Rem ove Tor x-h ea d bolt s t h a t a t t a ch bu m per t o
ca p t o t h e bu m per (F ig. 1). m ou n t in g br a cket s (F ig. 1).
(3) P u ll ba ck t h e wh eelh ou se lin er a n d r em ove t h e (5) Rem ove bu m per fr om veh icle.
scr ews a t t a ch in g t h e en d ca p t o t h e fr on t fen der. (6) If n ecessa r y, r em ove bolt s a t t a ch in g bu m per
(4) Lift in g t h e en d ca p fr om t h e bot t om , t ilt m ou n t in g br a cket s t o fr a m e.
sligh t ly u pwa r d a n d slide it ou t wa r d t o disen ga ge t h e
r et a in er t a b fr om t h e bu m per (F ig. 2). INSTALLATION
(5) Sepa r a t e t h e en d ca p fr om t h e bu m per. (1) If r em oved, in st a ll bolt s a t t a ch in g bu m per
m ou n t in g br a cket s t o fr a m e. Tigh t en bolt s t o 55 N·m
INSTALLATION (41 ft . lbs.) t or qu e.
(1) P osit ion t h e en d ca p on t h e bu m per a n d en ga ge (2) P osit ion bu m per on fr on t of veh icle.

-
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

Fig. 1 Front Bumper

80aafb09

Fig. 2 Bumper End Cap


FRONT TOW HOOK
Fig. 3 Vacuum Reservoir
REMOVAL
(1) Rem ove bolt s a t t a ch in g t ow h ook t o t ow h ook (3) In st a ll bolt s a t t a ch in g t ow h ook t o t ow h ook
r ein for cem en t (F ig. 4). r ein for cem en t . Tigh t en bolt s t o 100 N·m (74 ft . lbs.)
(2) Sepa r a t e t ow h ook fr om r ein for cem en t . t or qu e.
(3) If n ecessa r y, r em ove bolt a t t a ch in g t ow h ook
r ein for cem en t t o fr a m e. REAR BUMPER END CAP
INSTALLATION REMOVAL
(1) If r em oved, in st a ll bolt a t t a ch in g t ow h ook (1) Rem ove t h e bolt s a n d n u t s a t t a ch in g t h e
r ein for cem en t t o fr a m e. Tigh t en bolt t o 30 N·m (22 ft . u n der side of t h e en d ca p t o t h e bu m per (F ig. 5).
lbs.) t or qu e. (2) Rem ove t h e scr ew a t t a ch in g t h e fr on t of t h e
(2) P osit ion t ow h ook on r ein for cem en t . en d ca p t o t h e u n der side of t h e qu a r t er pa n el.
XJ FRAME AND BUMPERS 13 - 3
REM OVAL AN D I N STALLAT I ON (Cont inue d)
MOUNTING (4) In st a ll t h e bolt s a n d n u t s a t t a ch in g t h e u n der-
BRACKET side of t h e en d ca p t o t h e bu m per.

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

Fig. 5 Rear Bumper


13 - 4 FRAME AND BUMPERS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

REAR TOW HOOK


REMOVAL
(1) Rem ove 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 (F ig. 6).
(2) Rem ove br a cket a n d t ow h ook fr om fr a m e r a il.

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.

Fig. 6 Rear Tow Hook


XJ FRAME AND BUMPERS 13 - 5

FRAM E

INDEX
page page

REMOVAL AND INSTALLATION TRANSFER CASE SKID PLATE . . . . . . . . . . . . . . 5


FRONT SKID PLATE . . . . . . . . . . . . . . . . . . . . . . 5 SPECIFICATIONS
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . . 5 FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . 6
TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FRAME TORQUE SPECIFICATIONS . . . . . . . . . . 8

REM OVAL AN D I N STALLAT I ON TRANSFER CASE SKID PLATE


FRONT SKID PLATE REMOVAL
(1) Su ppor t skid pla t e.
REMOVAL (2) Rem ove bolt s t h a t a t t a ch skid pla t e t o t r a n s-
(1) Rem ove t h e scr ews t h a t a t t a ch skid pla t e t o m ission su ppor t cr ossm em ber a n d fr a m e sill (F ig. 2).
side sills. (3) Rem ove su ppor t a n d skid pla t e fr om veh icle.
(2) Rem ove t h e n u t s t h a t a t t a ch t h e skid pla t e t o
t h e cr ossm em ber (F ig. 1).
(3) Rem ove t h e skid pla t e fr om t h e veh icle.

J9223-165

Fig. 2 Transfer Case Skid Plate


INSTALLATION
(1) P osit ion a n d su ppor t skid pla t e a t fr a m e sill
a n d t r a n sm ission su ppor t cr ossm em ber.
(2) At t a ch skid pla t e t o fr a m e sill a n d cr ossm em -
ber wit h bolt s. Tigh t en bolt s t o 22 N·m (16 ft . lbs.)
t or qu e.
SCREW NUT SCREW J9123-36
FUEL TANK SKID PLATE
Fig. 1 Front Skid Plate
INSTALLATION REMOVAL
(1) P osit ion t h e skid pla t e a t fr on t cr ossm em ber (1) P osit ion a su ppor t u n der skid pla t e.
a n d side sills. (2) Rem ove bolt s t h a t a t t a ch skid pla t e t o u n der-
(2) In st a ll t h e n u t s t o a t t a ch t h e skid pla t e t o body side r a ils (F ig. 3).
cr ossm em ber. (3) Rem ove su ppor t a n d skid pla t e fr om veh icle.
(3) In st a ll t h e scr ews t o a t t a ch skid pla t e t o side
sills. INSTALLATION
(1) P osit ion a n d su ppor t skid pla t e u n der fu el
t a n k.
13 - 6 FRAME AND BUMPERS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

RIVET H O L E S ~ INSTALLATION

~,P REl~CEMENT

RIVET

FUEL TANK
SKID PLATE
'
Fig. 3 Fuel Tank Skid Plate
80b5cc86

80aa0fe8

(2) In st a ll bolt s t o a t t a ch skid pla t e t o u n der body Fig. 5 Trailer Hitch


r a ils. Tigh t en bolt s t o 74 N·m (55 ft . lbs.) t or qu e.
(1) In st a ll fr a m e r ein for cem en t br a cket s, if
(3) Rem ove su ppor t fr om u n der skid pla t e.
r em oved. Slide t h e br a cket s t h r ou gh t h e veh icle r ea r
sill open in gs a n d a t t a ch t o t h e fr a m e sills wit h blin d
TRAILER HITCH r ivet s.
(2) Usin g a n a dequ a t e lift in g device, posit ion h it ch
REMOVAL a t t h e pr oper loca t ion for in st a lla t ion on veh icle a n d
(1) If n ecessa r y, r em ove t h e t r a iler t ow wir e h a r- su ppor t it .
n ess con n ect or fr om t h e h it ch (F ig. 4). (3) If equ ipped, posit ion fu el t a n k skid pla t e on
(2) Su ppor t t h e h it ch . veh icle fr a m e sills.
(3) Rem ove t h e bolt s t h a t a t t a ch t h e t r a iler h it ch (4) Loosely in st a ll t h e bolt s t o a t t a ch t h e t r a iler
t o t h e fr a m e sills a n d r ein for cem en t br a cket s (F ig. 5). h it ch (a n d t h e skid pla t e) t o fr a m e sills a n d r ein for ce-
(4) If equ ipped, r em ove t h e fu el t a n k skid pla t e. m en t br a cket s.
(5) Tigh t en a ll bolt s/n u t s t o 74 N·m (55 ft . lbs.)
NOTE: The reinforcement brackets are held on the
t or qu e.
frame sills with two blind rivets.
(6) Rem ove t h e lift /su ppor t .
(7) If r em oved, a t t a ch t h e t r a iler wir e h a r n ess con -
n ect or t o t h e h it ch .

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).

Fig. 4 Trailer Hitch Harness Connector


SPECI FI CAT I ON S (Cont inue d)
XJ
i---601.5 _ _.-4
±1.5
• •
o o •O 0 0

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

FRAME AND BUMPERS


±0.75

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)

FRAME TORQUE SPECIFICATIONS


D ES CRIP TION TORQU E
F r on t Skid P la t e Scr ew . . . . . . . . . . . . . . . . 42 N·m
(31 ft . lbs.)
F r on t Skid P la t e Nu t . . . . . . . . . . . . . . . . . . 17 N·m
(125 in . lbs.)
Tr a n sfer Ca se Skid P la t e Bolt . . . . . . . . . . . 22 N·m
(16 ft . lbs.)
F u el Ta n k Skid P la t e Bolt . . . . . . . . . . . . . . 74 N·m
(55 ft . lbs.)
F r on t Bu m per E n d Ca p t o
Mou n t in g Br a cket Nu t . . . . . . . . . . . . . . . . 9 N·m
(7 ft . lbs.)
F r on t Bu m per Mou n t in g
Br a cket t o F r a m e Bolt . . . . . . . . . . . . . . . 55 N·m
(41 ft . lbs.)
F r on t Bu m per t o
Mou n t in g Br a cket Bolt . . . . . . . . . . . . . . . 55 N·m
(41 ft . lbs.)
F r on t Tow H ook Bolt . . . . . . . . . . . . . . . . . 100 N·m
(74 ft . lbs.)
F r on t Tow H ook
Rein for cem en t Bolt . . . . . . . . . . . . . . . . . . 30 N·m
(22 ft . lbs.)
Rea r Bu m per t o
Mt g. Br a cket Nu t . . . . . . . . . . . . . . . . . . 55 N·m
(41 ft . lbs.)
Rea r Bu m per Mt g. Br a cket t o
Rea r Sill Bolt . . . . . . . . . . . . . . . . . . . . . . 55 N·m
(41 ft . lbs.)
Rea r Tow H ook Bolt . . . . . . . . . . . . . . . . . . . 94 N·m
(70 ft . lbs.)
Tr a iler Tow
Rein for cem en t Br kt Bolt . . . . . . . . . . . . . 74 N·m
(55 ft . lbs.)
XJ FRAME AND BUMPERS 13 - 1

FRAME AND BUMPERS


CON T EN T S

page page

FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SWING AWAY SPARE TIRE CARRIER . . . . . . . . . 1

SWI N G AWAY SPARE T I RE CARRI ER

INDEX
page

-
DISASSEMBLY AND ASSEMBLY
SWING AWAY SPARE TIRE CARRIER
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DI SASSEM BLY AN D ASSEM BLY

SWING AWAY SPARE TIRE CARRIER MOUNTING

80aef29c

Fig. 1 Spare Tire Carrier Mounting


13 - 2 FRAME AND BUMPERS XJ

FRAM E

INDEX
page

GENERAL INFORMATION
EMERGENCY TOW EYES . . . . . . . . . . . . . . . . . . 2

GEN ERAL I N FORM AT I ON


EMERGENCY TOW EYES
If you r veh icle is equ ipped wit h em er gen cy t ow
eyes, on e is m ou n t ed in t h e fr on t a n d on e in t h e r ea r.
Th e fr on t t ow eye h a s t wo h oles, t h e fr on t h ole is
for t owin g u se on ly a n d t h e r ea r a n gled h ole is for
sh ippin g u se on ly.

CAUTION: Do not use the angled hole for towing.


You could damage your vehicle.

WARNING: Stand clear of vehicles when pulling


with tow eyes. Tow straps and chains may break,
causing serious injury.

CAUTION: Tow eyes are for emergency use only, to


rescue a vehicle stranded off road. Do not use tow
eyes for tow truck hookup or highway towing. You
could damage your vehicle.
REAR/
TOW EYE 80ad087f

Fig. 1 Emergency Tow Eyes


XJ FUEL SYSTEM 14 - 1

FUEL SYSTEM
CON T EN T S

page page

FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . 1 FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . 23

FU EL DELI V ERY SY ST EM

INDEX
page page

DESCRIPTION AND OPERATION SERVICE PROCEDURES


FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . 3 FUEL SYSTEM PRESSURE RELEASE
FUEL FILTER/FUEL PRESSURE REGULATOR . . . 4 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 4 FUEL TUBES/LINES/HOSES AND CLAMPS . . . . 10
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 5 QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . 11
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL AND INSTALLATION
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . 3 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . 20
FUEL RAIL/FUEL DAMPER—2.5L ENGINE . . . . . . 5 FUEL FILTER/FUEL PRESSURE REGULATOR . . 13
FUEL RAIL—4.0L ENGINE . . . . . . . . . . . . . . . . . . 5 FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 15
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 1 FUEL INJECTOR RAIL—2.5L ENGINE . . . . . . . . 16
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FUEL INJECTOR RAIL—4.0L ENGINE . . . . . . . . 17
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . . 6 FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 18
PCM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 1 FUEL PUMP INLET FILTER . . . . . . . . . . . . . . . . 15
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . 6 FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 14
ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . . . 5 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . 20
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 10 THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . 21
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . 10 SPECIFICATIONS
FUEL PRESSURE LEAK DOWN TEST . . . . . . . . . 7 FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . 22
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . . . . 8 FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . 22
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . . 7 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 22
FUEL PUMP PRESSURE TEST—ALL ENGINES
WITH PRESSURE TEST PORT . . . . . . . . . . . . . 6

DESCRI PT I ON AN D OPERAT I ON FUEL REQUIREMENTS


PCM REPLACEMENT
U S E THE D RB S CAN TOOL TO REP ROGRAM
THE N EW P OWERTRAIN CON TROL MOD U LE
(P CM) WITH THE VEHICLES ORIGIN AL ID EN -
TIF ICATION N U MB ER (VIN ) AN D THE VEHI-
You r en gin e is design ed t o m eet a ll em ission s r eg-
u la t ion s a n d pr ovide excellen t fu el econ om y a n d per-
for m a n ce wh en u sin g h igh qu a lit y u n lea ded ga solin e
h a vin g a n oct a n e r a t in g of 87. Th e u se of pr em iu m
ga solin e is n ot r ecom m en ded. Th e u se of pr em iu m
ga solin e will pr ovide n o ben efit over h igh qu a lit y r eg-
-
CLES ORIGIN AL MILEAGE. IF THIS S TEP IS u la r ga solin e, a n d in som e cir cu m st a n ces m a y r esu lt
N OT D ON E, A D IAGN OS TIC TROU B LE COD E in poor er per for m a n ce.
(D TC) MAY B E S ET. Ligh t spa r k kn ock a t low en gin e speeds is n ot
h a r m fu l t o you r en gin e. H owever, con t in u ed h ea vy
spa r k kn ock a t h igh speeds ca n ca u se da m a ge a n d
im m edia t e ser vice is r equ ir ed. E n gin e da m a ge r esu lt -
14 - 2 FUEL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
in g fr om oper a t ion wit h a h ea vy spa r k kn ock m a y SULFUR IN GASOLINE
n ot be cover ed by t h e n ew veh icle wa r r a n t y. If you live in t h e n or t h ea st Un it ed St a t es, you r
P oor qu a lit y ga solin e ca n ca u se pr oblem s su ch a s veh icle m a y h a ve been design ed t o m eet Ca lifor n ia
h a r d st a r t in g, st a llin g a n d h esit a t ion s. If you exper i- low em ission st a n da r ds wit h clea n -bu r n in g, low-su l-
en ce t h ese sym pt om s, t r y a n ot h er br a n d of ga solin e fu r, Ca lifor n ia ga solin e. Ga solin e sold ou t side of Ca l-
befor e con sider in g ser vice for t h e veh icle. ifor n ia is per m it t ed t o h a ve h igh er su lfu r levels
Th e Am er ica n Au t om obile Ma n u fa ct u r er s Associa - wh ich m a y a ffect t h e per for m a n ce of t h e veh icle’s ca t -
t ion , AAMA, h a s issu ed ga solin e specifica t ion s t o a lyt ic con ver t er. Th is m a y ca u se t h e Ch eck E n gin e or
defin e t h e m in im u m fu el pr oper t ies n ecessa r y t o Ser vice E n gin e Soon ligh t t o illu m in a t e.
deliver en h a n ced per for m a n ce a n d du r a bilit y for you r Illu m in a t ion of eit h er ligh t wh ile oper a t in g on h igh
veh icle. Ch r ysler r ecom m en ds t h e u se of ga solin e su lfu r ga solin e does n ot n ecessa r ily m ea n you r em is-
t h a t m eet t h e AAMA specifica t ion s if t h ey a r e a va il- sion con t r ol syst em is m a lfu n ct ion in g. Ch r ysler r ec-
a ble. om m en ds t h a t you t r y a differ en t br a n d of u n lea ded
ga solin e h a vin g lower su lfu r t o det er m in e if t h e pr ob-
REFORMULATED GASOLINE lem is fu el r ela t ed pr ior t o r et u r n in g you r veh icle t o
Ma n y a r ea s of t h e cou n t r y r equ ir e t h e u se of a n a u t h or ized dea ler for ser vice.
clea n er bu r n in g ga solin e r efer r ed t o a s “r efor m u la t -
ed” ga solin e. Refor m u la t ed ga solin e con t a in oxygen - CAUTION: If the Check Engine or Service Engine
a t es, a n d a r e specifica lly blen ded t o r edu ce veh icle Soon light is flashing, immediate service is
em ission s a n d im pr ove a ir qu a lit y. required; see on-board diagnostics system section.
Ch r ysler st r on gly su ppor t s t h e u se of r efor m u la t ed
ga solin e. P r oper ly blen ded r efor m u la t ed ga solin e will
pr ovide excellen t per for m a n ce a n d du r a bilit y for t h e MATERIALS ADDED TO FUEL
en gin e a n d fu el syst em com pon en t s. All ga solin e sold in t h e Un it ed St a t es a n d Ca n a da
a r e r equ ir ed t o con t a in effect ive det er gen t a ddit ives.
GASOLINE/OXYGENATE BLENDS Use of a ddit ion a l det er gen t s or ot h er a ddit ives is n ot
Som e fu el su pplier s blen d u n lea ded ga solin e wit h n eeded u n der n or m a l con dit ion s.
oxygen a t es su ch a s 10% et h a n ol, MTBE , a n d E TBE .
Oxygen a t es a r e r equ ir ed in som e a r ea s of t h e cou n t r y FUEL SYSTEM CAUTIONS
du r in g t h e win t er m on t h s t o r edu ce ca r bon m on oxide
em ission s. F u els blen ded wit h t h ese oxygen a t es m a y CAUTION: Follow these guidelines to maintain your
be u sed in you r veh icle. vehicle’s performance:

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.

FUEL GAUGE SENDING UNIT


DESCRIPTION
Th e fu el ga u ge sen din g u n it (fu el level sen sor ) is
a t t a ch ed t o t h e side of t h e fu el pu m p m odu le. Th e
sen din g u n it con sist s of a floa t , a n a r m , a n d a va r i- FUEL SUPPLY
a ble r esist or (t r a ck). TUBE

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

An eva por a t ion con t r ol syst em is con n ect ed t o t h e


r ollover va lve(s) t o r edu ce em ission s of fu el va por s Fig. 4 Fuel Injector—Typical
in t o t h e a t m osph er e. Wh en fu el eva por a t es fr om t h e in ject or pu lse widt h ba sed on va r iou s in pu t s it
fu el t a n k, va por s pa ss t h r ou gh ven t h oses or t u bes t o r eceives.
a ch a r coa l ca n ist er wh er e t h ey a r e t em por a r ily h eld. 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
Wh en t h e en gin e is r u n n in g, t h e va por s a r e dr a wn 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
in t o t h e in t a ke m a n ifold. Cer t a in m odels a r e a lso oper a t in g, volt a ge is su pplied by t h e ch a r gin g sys-
equ ipped wit h a self-dia gn osin g syst em u sin g a Lea k t em . Th e P CM det er m in es in ject or pu lse widt h ba sed
Det ect ion P u m p (LDP ). Refer t o E m ission Con t r ol on va r iou s in pu t s.
Syst em for a ddit ion a l in for m a t ion .
FUEL RAIL/FUEL DAMPER—2.5L ENGINE
ROLLOVER VALVE(S) Th e fu el r a il su pplies t h e n ecessa r y fu el t o ea ch
Refer t o Gr ou p 25, E m ission Con t r ol Syst em for in dividu a l fu el in ject or a n d is m ou n t ed t o t h e in t a ke
in for m a t ion . m a n ifold (F ig. 5). On t h e 2.5L en gin e, a fu e l
d a m p e r is loca t ed a t t h e fr on t of t h e fu el r a il (F ig.
FUEL INJECTORS 5). Th e da m per is u sed on ly t o h elp con t r ol fu el pr es-
Th e fu el in ject or s (F ig. 4) a r e elect r ica l solen oids. su r e pu lsa t ion s. Th ese pu lsa t ion s a r e t h e r esu lt of
Th e in ject or con t a in s a pin t le t h a t closes off a n or i- t h e fir in g of t h e fu el in ject or s. It is n o t u s e d a s a
fice a t t h e n ozzle en d. Wh en elect r ic cu r r en t is su p- fu el pr essu r e r egu la t or. Th e fu el pr essu r e r egu la t or is
plied t o t h e in ject or, t h e a r m a t u r e a n d n eedle m ove a n o t m o u n te d t o t h e fu el r a il on a n y en gin e. It is
sh or t dist a n ce a ga in st a spr in g, a llowin g fu el t o flow loca t ed on t h e fu el t a n k m ou n t ed fu el pu m p m odu le.
ou t t h e or ifice. Beca u se t h e fu el is u n der h igh pr es- Refer t o F u el F ilt er /F u el P r essu r e Regu la t or in t h is
su r e, a fin e spr a y is developed in t h e sh a pe of a pen - gr ou p for in for m a t ion .
cil st r ea m . Th e spr a yin g a ct ion a t om izes t h e fu el, Depen din g on veh icle m odel/en gin e, t h e fu el r a il
a ddin g it t o t h e a ir en t er in g t h e com bu st ion ch a m ber. m a y/m a y n ot be equ ipped wit h a fu el pr essu r e t est
An in dividu a l fu el in ject or is u sed for ea ch in divid- por t . Refer t o t h e F u el P u m p P r essu r e Test for a ddi-
u a l cylin der. Th e t op (fu el en t r y) en d of t h e in ject or is t ion a l in for m a t ion .
a t t a ch ed in t o a n open in g on t h e fu el r a il. Th e fu el r a il is n ot r epa ir a ble.
Th e n ozzle (ou t let ) en ds of t h e in ject or s a r e posi-
t ion ed in t o open in gs in t h e in t a ke m a n ifold ju st FUEL RAIL—4.0L ENGINE
a bove t h e in t a ke va lve por t s of t h e cylin der h ea d. Th e fu el r a il su pplies t h e n ecessa r y fu el t o ea ch
Th e en gin e wir in g h a r n ess con n ect or for ea ch fu el in dividu a l fu el in ject or a n d is m ou n t ed t o t h e in t a ke
in ject or is equ ipped wit h a n a t t a ch ed n u m er ica l t a g m a n ifold (F ig. 6). Th e fu el pr essu r e r egu la t or is n ot
(INJ 1, INJ 2 et c.). Th is is u sed t o iden t ify ea ch fu el m ou n t ed t o t h e fu el r a il on a n y 4.0L en gin e. It is
in ject or. loca t ed on t h e fu el t a n k m ou n t ed fu el pu m p m odu le.
Th e in ject or s a r e en er gized in dividu a lly in a Refer t o F u el F ilt er /F u el P r essu r e Regu la t or in t h is
sequ en t ia l or der by t h e power t r a in con t r ol m odu le gr ou p for in for m a t ion .
(P CM). Th e P CM will a dju st in ject or pu lse widt h by Depen din g on veh icle m odel/en gin e, t h e fu el r a il
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 m a y/m a y n ot be equ ipped wit h a fu el pr essu r e t est
on a n d off. In ject or pu lse widt h is t h e per iod of t im e por t . Refer t o t h e F u el P u m p P r essu r e Test for a ddi-
t h a t t h e in ject or is en er gized. Th e P CM will a dju st t ion a l in for m a t ion .
14 - 6 FUEL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

NUMBERED must be pressed (opened) to relieve fuel tank pres-


TAG sure.

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 .

CAUTION: The interior components (o-rings, spac-


ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
80b6f034

Fig. 5 Fuel Rail/Fuel Damper—2.5L Engine


Th e fu el r a il is n ot r epa ir a ble.
DI AGN OSI S AN D T EST I N G
FUEL PUMP PRESSURE TEST—ALL ENGINES
WITH PRESSURE TEST PORT
Use t h is t est in con ju n ct ion wit h t h e F u el P u m p
Ca pa cit y Test , F u el P r essu r e Lea k Down Test a n d
F u el P u m p Am per a ge Test fou n d elsewh er e in t h is
gr ou p.
Ch e c k Va lv e Op e ra tio n : Th e elect r ic fu el pu m p
ou t let con t a in s a on e-wa y ch eck va lve t o pr even t fu el
flow ba ck 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 essu r e (en gin e wa r m ) wh en pu m p is n ot oper-
a t ion a l. It is a lso u sed t o keep t h e fu el su pply lin e
fu ll of ga solin e wh en pu m p is n ot oper a t ion a l. Aft er
t h e veh icle h a s cooled down , fu el pr essu r e m a y dr op
t o 0 psi (cold flu id con t r a ct s), bu t liqu id ga solin e will
r em a in in fu el su pply lin e bet ween t h e ch eck va lve
a n d fu el 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 p s i o n a c o o le d d o w n v e h ic le
Fig. 6 Fuel Rail—4.0L Engine (e n g in e o ff) is a n o rm a l c o n d itio n . Wh en t h e elec-
FUEL TANK FILLER TUBE CAP t r ic fu el pu m p is a ct iva t ed, fu el pr essu r e sh ou ld
Th e loss of a n y fu el or va por ou t of filler n eck is im m e d ia te ly (1–2 secon ds) r ise t o specifica t ion .
pr even t ed by t h e u se of a pr essu r e-va cu u m fu el t a n k All fu el syst em s a r e equ ipped wit h a fu el t a n k
filler t u be ca p. Relief va lves in side t h e ca p will m odu le m ou n t ed, com bin a t ion fu el filt er /fu el pr essu r e
r elea se fu el t a n k pr essu r e a t pr edet er m in ed pr es- r egu la t or. Th e fu el pr essu r e r egu la t or is n ot con -
su r es. F u el t a n k va cu u m will a lso be r elea sed a t pr e- t r olled by en gin e va cu u m .
det er m in ed va lu es. Th is ca p m u st be r epla ced by a
WARNING: THE FUEL SYSTEM IS UNDER CON-
sim ila r u n it if r epla cem en t is n ecessa r y. Th is is in
STANT FUEL PRESSURE EVEN WITH THE ENGINE
or der for t h e syst em t o r em a in effect ive.
OFF. BEFORE DISCONNECTING FUEL LINE AT
CAUTION: Remove fuel tank filler tube cap before FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
servicing any fuel system component. This is done REFER TO THE FUEL SYSTEM PRESSURE
to help relieve tank pressure. If equipped with a RELEASE PROCEDURE.
California emissions package and a Leak Detection
(1) Rem ove pr ot ect ive ca p a t fu el r a il t est por t .
Pump (LDP), the secondary seal below the fill cap
Con n ect t h e 0–414 kP a (0-60 psi) fu el pr essu r e ga u ge
XJ FUEL SYSTEM 14 - 7
DI AGN OSI S AN D T EST I N G (Cont inue d)
(fr om ga u ge set 5069) t o t est por t pr essu r e fit t in g on (6) To a ct iva t e fu el pu m p a n d pr essu r ize syst em ,
fu el r a il (F ig. 7). obt a in DRB sca n t ool a n d a ct u a t e ASD F u el Syst em
Test .
(7) A good fu el pu m p will deliver a t lea st 1/4 lit er
of fu el in 7 secon ds. Do n ot oper a t e fu el pu m p for
lon ger t h a n 7 secon ds wit h fu el lin e discon n ect ed a s
fu el pu m p m odu le r eser voir m a y r u n em pt y.
(a ) If ca pa cit y is lower t h a n specifica t ion , bu t
fu el pu m p ca n be h ea r d oper a t in g t h r ou gh fu el fill
ca p open in g, ch eck for a kin ked/da m a ged fu el su p-
ply lin e som ewh er e bet ween fu el r a il a n d fu el
pu m p m odu le.
(b) If lin e is n ot kin ked/da m a ged, a n d fu el pr es-
su r e is OK, bu t ca pa cit y is low, r epla ce fu el filt er /
fu el pr essu r e r egu la t or. Th e filt er /r egu la t or m a y be
ser viced sepa r a t ely on cer t a in a pplica t ion s. Refer
FUEL RAIL/
t o F u el F ilt er /F u el P r essu r e Regu la t or Rem ova l/In -
80ae8310
st a lla t ion for a ddit ion a l in for m a t ion .
Fig. 7 Fuel Pressure Test Gauge (Typical Gauge (c) If bot h fu el pr essu r e a n d ca pa cit y a r e low,
Installation at Test Port) r epla ce fu el pu m p m odu le a ssem bly. Refer t o F u el
P u m p Modu le Rem ova l/In st a lla t ion .
(2) St a r t a n d wa r m en gin e a n d n ot e pr essu r e
ga u ge r ea din g. F u el pr essu r e sh ou ld be 339 kP a ! 34 FUEL PRESSURE LEAK DOWN TEST
kP a (49.2 psi ! 5 psi) a t idle. Use t h is t est in con ju n ct ion wit h t h e F u el P u m p
(3) If en gin e r u n s, bu t pr essu r e is below 44.2 psi, P r essu r e Test a n d F u el P u m p Ca pa cit y Test .
ch eck for a kin ked fu el su pply lin e som ewh er e Ch e c k Va lv e Op e ra tio n : Th e elect r ic fu el pu m p
bet ween fu el r a il a n d fu el pu m p m odu le. If lin e is n ot ou t let con t a in s a on e-wa y ch eck va lve t o pr even t fu el
kin ked, bu t specifica t ion s for eit h er t h e F u el P u m p flow ba ck 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
Ca pa cit y, F u el P u m p Am per a ge or F u el P r essu r e lin e pr essu r e (en gin e wa r m ) wh en pu m p is n ot oper-
Lea k Down Test s wer e n ot m et , r epla ce fu el pu m p a t ion a l. It is a lso u sed t o keep t h e fu el su pply lin e
m odu le a ssem bly. Refer t o F u el P u m p Modu le fu ll of ga solin e wh en pu m p is n ot oper a t ion a l. Aft er
Rem ova l/In st a lla t ion . t h e veh icle h a s cooled down , fu el pr essu r e m a y dr op
(4) If oper a t in g pr essu r e is a bove 54.2 psi, elect r ic t o 0 psi (cold flu id con t r a ct s), bu t liqu id ga solin e will
fu el pu m p is OK, bu t fu el pr essu r e r egu la t or is defec- r em a in in fu el su pply lin e bet ween t h e ch eck va lve
t ive. Repla ce fu el filt er /fu el pr essu r e r egu la t or. Refer a n d fu el in ject or s. F u e l p re s s u re th a t h a s
t o F u el F ilt er /F u el P r essu r e Regu la t or Rem ova l/In - d ro p p e d to 0 p s i o n a c o o le d d o w n v e h ic le
st a lla t ion for m or e in for m a t ion . (e n g in e o ff) is a n o rm a l c o n d itio n . Wh en t h e elec-
(5) In st a ll pr ot ect ive ca p t o fu el r a il t est por t . t r ic fu el pu m p is a ct iva t ed, fu el pr essu r e sh ou ld
im m e d ia te ly (1–2 secon ds) r ise t o specifica t ion .
FUEL PUMP CAPACITY TEST Abn or m a lly lon g per iods of cr a n kin g t o r est a r t a
B e fo re p e rfo rm in g th is te s t, v e rify fu e l p u m p h o t en gin e t h a t h a s been sh u t down for a sh or t
p re s s u re . Re fe r to F u e l P u m p P re s s u re Te s t. per iod of t im e m a y be ca u sed by:
U s e th is te s t in c o n ju n c tio n w ith th e F u e l P re s - • F u el pr essu r e bleedin g pa st a fu el in ject or (s).
s u re Le a k D o w n Te s t. • F u el pr essu r e bleedin g pa st t h e ch eck va lve in
(1) Relea se fu el syst em pr essu r e. Refer t o F u el t h e fu el pu m p m odu le.
P r essu r e Relea se P r ocedu r e. (1) Discon n ect t h e fu el in let lin e a t fu el r a il. Refer
(2) Discon n ect fu el su pply lin e a t fu el r a il. Refer t o t o F u el Tu bes/Lin es/H oses a n d Cla m ps in t h is sect ion
Qu ick-Con n ect F it t in gs. Som e en gin es m a y r equ ir e of t h e gr ou p for pr ocedu r es. On som e en gin es, a ir
a ir clea n er h ou sin g r em ova l befor e lin e discon n ect ion . clea n er h ou sin g r em ova l m a y be n ecessa r y befor e
(3) Obt a in cor r ect F u el Lin e P r essu r e Test Ada pt er fu el lin e discon n ect ion .
Tool H ose. Tool n u m ber 6539 is u sed for 5/16” fu el (2) Obt a in cor r ect F u el Lin e P r essu r e Test Ada pt er
lin es a n d t ool n u m ber 6631 is u sed for 3/8” fu el lin es. Tool H ose. Tool n u m ber 6539 is u sed for 5/16” fu el
(4) Con n ect cor r ect F u el Lin e P r essu r e Test lin es a n d t ool n u m ber 6631 is u sed for 3/8” fu el lin es.
Ada pt er Tool H ose in t o discon n ect ed fu el su pply lin e. (3) Con n ect cor r ect F u el Lin e P r essu r e Test
In ser t ot h er en d of Ada pt or Tool H ose in t o a gr a du - Ada pt er Tool H ose bet ween discon n ect ed fu el lin e
a t ed con t a in er. a n d fu el r a il (F ig. 8).
(5) Rem ove fu el fill ca p.
14 - 8 FUEL SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
Not e: A qu ick loss of pr essu r e u su a lly in dica t es a
defect ive ch eck va lve in t h e filt er /r egu la t or. A slow
loss of pr essu r e u su a lly in dica t es a defect ive ch eck
va lve in t h e elect r ic fu el pu m p.
Th e elect r ic fu el pu m p is n ot ser viced sepa r a t ely.
Repla ce t h e fu el pu m p m odu le a ssem bly. Th e filt er /
r egu la t or m a y be r epla ced sepa r a t ely on cer t a in
a pplica t ion s. Refer t o F u el F ilt er /F u el P r essu r e Reg-
SPECIAL u la t or Rem ova l/In st a lla t ion for a ddit ion a l in for m a -
TOOL t ion .
FUEL
RAIL._. 6923, 6631,
6541 OR
6539
FUEL PUMP AMPERAGE TEST
Th is a m per a ge (cu r r en t dr a w) t est is t o be don e in
con ju n ct ion wit h t h e F u el P u m p P r essu r e Test , F u el
P u m p Ca pa cit y Test a n d F u el P r essu r e Lea k Down
Test . Befor e per for m in g t h e a m per a ge t est , be su r e
t h e t em per a t u r e of t h e fu el t a n k is a bove 50° F (10°
C).
FUEL LINE Th e DRB Sca n Tool a lon g wit h t h e DRB Low Cu r-
CONNECTION r en t Sh u n t (LCS) a da pt er (F ig. 9) a n d it s t est lea ds
AT RAIL will be u sed t o ch eck fu el pu m p a m per a ge specifica -
t ion s.
Fig. 8 Connecting Adapter Tool—Typical
LOW CURRENT SHUNT ADAPTER
(4) Con n ect t h e 0-414 kP a (0-60 psi) fu el pr essu r e
t est ga u ge (fr om Ga u ge Set 5069) t o t h e t est por t on
t h e a ppr opr ia t e Ada pt or Tool. Th e fittin g s o n bo th
to o ls m u s t be in g o o d c o n d itio n a n d fre e fro m
a n y s m a ll le a k s be fo re p e rfo rm in g th e p ro c e e d -
in g te s t.
(5) St a r t en gin e a n d br in g t o n or m a l oper a t in g
t em per a t u r e.
(6) Obser ve t est ga u ge. Nor m a l oper a t in g pr essu r e
sh ou ld be 339 kP a ! 34 kP a (49.2 psi ! 5 psi).
(7) Sh u t en gin e off.
(8) P r essu r e sh ou ld n ot fa ll below 30 p s i fo r fiv e
m in u te s .
(9) If pr essu r e fa lls below 30 psi, it m u st be det er- PLUG TO
m in ed if a fu el in ject or, t h e ch eck va lve wit h in t h e DRB
fu el pu m p m odu le, or a fu el t u be/lin e is lea kin g.
(10) Aga in , st a r t en gin e a n d br in g t o n or m a l oper-
80add391
a t in g t em per a t u r e.
(11) Sh u t en gin e off. Fig. 9 Low Current Shunt Adapter
(12) Te s tin g fo r fu e l in je c to r o r fu e l ra il le a k -
(1) Be su r e fu el t a n k con t a in s fu el befor e st a r t in g
a g e : Cla m p off t h e r u bber h ose por t ion of Ada pt or
t est . If t a n k is em pt y or n ea r em pt y, a m per a ge r ea d-
Tool bet ween t h e fu el r a il a n d t h e t est por t “T” on
in gs will be in cor r ect .
Ada pt er Tool. If pr essu r e n ow h olds a t or a bove 30
(2) Obt a in LCS a da pt er.
psi, a fu el in ject or or t h e fu el r a il is lea kin g.
(3) P lu g ca ble fr om LCS a da pt er in t o DRB sca n
(13) Te s tin g fo r fu e l p u m p c h e c k v a lv e , filte r/
t ool a t SE T 1 r ecept a cle.
re g u la to r c h e c k v a lv e o r fu e l tu be /lin e le a k a g e :
(4) P lu g DRB in t o veh icle 16–wa y con n ect or (da t a
Cla m p off t h e r u bber h ose por t ion of Ada pt or Tool
lin k con n ect or ).
bet ween t h e veh icle fu el lin e a n d t est por t “T” on
(5) Con n ect (-) a n d (+) t est ca ble lea ds in t o LCS
Ada pt er Tool. If pr essu r e n ow h olds a t or a bove 30
a da pt er r ecept a cles. Use 10 a m p (10A +) r ecept a cle
psi, a lea k m a y be fou n d a t a fu el t u be/lin e. If n o
a n d com m on (-) r ecept a cles.
lea ks a r e fou n d a t fu el t u bes or lin es, on e of t h e
ch eck va lves in eit h er t h e elect r ic fu el pu m p or filt er /
r egu la t or m a y be lea kin g.
XJ FUEL SYSTEM 14 - 9
DI AGN OSI S AN D T EST I N G (Cont inue d)
(6) Ga in a ccess t o MAIN ME NU on DRB scr een . RELAY TERMINALS RELAY CAVITIES
(7) P r ess DVOM bu t t on on DRB.
(8) Usin g left /r igh t a r r ow keys, h igh ligh t CH AN-
NE L 1 fu n ct ion on DRB scr een .
(9) P r ess E NTE R t h r ee t im es.
(10) Usin g u p/down a r r ow keys, h igh ligh t RANGE
on DRB scr een (scr een will defa u lt t o 2 a m p sca le).
(11) P r ess E NTE R t o ch a n ge 2 a m p sca le t o 10
a m p sca le. Th is s te p m u s t be d o n e to p re v e n t
d a m a g e to D RB s c a n to o l o r LCS a d a p te r 85 87 J958A-2
(blo w n fu s e ). TERMINAL LEGEND
(12) Rem ove cover fr om P ower Dist r ibu t ion Cen t er NUMBER IDENTIFICATION
30 COMMON FEED
(P DC). 85 COIL GROUND
(13) Rem ove fu el pu m p r ela y fr om P DC. Refer t o 86 COIL BATTERY
87 NORMALLY OPEN
la bel on P DC cover for r ela y loca t ion . t--8=7A----t--~N~ORMALLY CLOSED

WARNING: BEFORE PROCEEDING TO NEXT STEP, Fig. 10 Type–1 Relay


NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL RELAY CAVITIES
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND FUEL
SYSTEM COMPONENTS ARE CONNECTED. 86
TERMINAL LEGEND
87A 87 85
CAUTION: TO PREVENT POSSIBLE DAMAGE TO NUMBER IDENTIFICATION
THE VEHICLE ELECTRICAL SYSTEM AND LCS
ADAPTER, THE TEST LEADS MUST BE CON-
t.ffJkwn
lccitp
30
85
COMMON FEED
COIL GROUND
86 COIL BATTERY
NECTED INTO RELAY CAVITIES EXACTLY AS
87 NORMALLY OPEN
SHOWN IN FOLLOWING STEPS. 30 86
87A NORMALLY CLOSED
80add392
Depen din g u pon veh icle m odel, yea r or en gin e con -
figu r a t ion , t h r ee differ en t t ypes of r ela ys m a y be Fig. 11 Type–2 Relay
u sed: Type-1, t ype-2 a n d t ype–3.
(14) If equ ipped wit h ty p e –1 re la y (F ig. 10), RELAY CAVITIES
a t t a ch t est lea ds fr om LCS a da pt er in t o P DC r ela y
ca vit ies n u m ber 30 a n d 87. F or loca t ion of t h ese ca v-
it ies, r efer t o n u m ber s st a m ped t o bot t om of r ela y
(F ig. 10).
(15) If equ ipped wit h ty p e –2 re la y (F ig. 11),
a t t a ch t est lea ds fr om LCS a da pt er in t o P DC r ela y
ca vit ies n u m ber 30 a n d 87. F or loca t ion of t h ese ca v- TERMINAL LEGEND
it ies, r efer t o n u m ber s st a m ped t o bot t om of r ela y 4 5 2
NUMBER IDENTIFICATION
(F ig. 11).
(16) If equ ipped wit h ty p e –3 re la y (F ig. 12),
a t t a ch t est lea ds fr om LCS a da pt er in t o P DC r ela y
t.ff Jkwn
lccitp
1
2
COIL BATTERY
COIL GROUND
3 COMMON FEED
ca vit ies n u m ber 3 a n d 5. F or loca t ion of t h ese ca vi- 4 NORMALLY CLOSED
3 1
t ies, r efer t o n u m ber s st a m ped t o bot t om of r ela y 5 NORMALLY OPEN
(F ig. 12). 80add390

(17) Wh en LCS a da pt er t est lea ds a r e a t t a ch ed in t o


Fig. 12 Type–3 Relay
r ela y ca vit ies, fu el pu m p w ill be a c tiv a te d . Det er m in e
fu el pu m p a m per a ge on DRB scr een . Am per a ge F u el P u m p Ca pa cit y a n d F u el P r essu r e Lea k Down
sh ou ld be below 10.0 a m ps. If a m per a ge is below 10.0 t est s wer e m et , t h e fu el pu m p m odu le is OK.
a m ps, a n d specifica t ion s for t h e F u el P u m p P r essu r e,
14 - 10 FUEL SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
(18) If a m per a ge is m or e t h a n 10.0 a m ps, r epla ce CAUTION: Steps 1, 2, 3 and 4 must be performed to
fu el pu m p m odu le a ssem bly. Th e elect r ic fu el pu m p relieve high pressure fuel from within fuel rail. Do
is n ot ser viced sepa r a t ely. not attempt to use following steps to relieve this
(19) Discon n ect t est lea ds fr om r ela y ca vit ies pressure as excessive fuel will be forced into a cyl-
im m edia t ely a ft er t est in g. inder chamber.

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.

CAUTION: The interior components (o-rings, spac-


ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
QUICK-CONNECT
able, do not attempt to repair a damaged fitting or FITTING J9414-25
fuel line. If repair is necessary, replace complete
fuel line assembly. Fig. 14 Disconnecting Single-Tab Type Fitting
(1) P er for m fu el pr essu r e r elea se pr ocedu r e. Refer (a ) To discon n ect qu ick-con n ect fit t in g, squ eeze
t o F u el P r essu r e Relea se P r ocedu r e in t h is gr ou p. pla st ic r et a in er t a bs (F ig. 16) a ga in st sides of
(2) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y. qu ick-con n ect fit t in g wit h you r fin ger s. Tool u se is
(3) Clea n fit t in g of a n y for eign m a t er ia l befor e dis- n ot r equ ir ed for r em ova l a n d m a y da m a ge pla st ic
a ssem bly. r et a in er.
(4) S in g le -Ta b Ty p e F ittin g : Th is t ype of fit t in g (b) P u ll fit t in g fr om fu el syst em com pon en t
is equ ipped wit h a sin gle pu ll t a b (F ig. 13). Th e t a b bein g ser viced.
is r em ova ble. Aft er t a b is r em oved, qu ick-con n ect fit - (c) Th e pla st ic r et a in er will r em a in on com po-
t in g ca n be sepa r a t ed fr om fu el syst em com pon en t . n en t bein g ser viced a ft er fit t in g is discon n ect ed.
(a ) P r ess r elea se t a b on side of fit t in g t o r elea se Th e o-r in gs a n d spa cer will r em a in in qu ick-con -
pu ll t a b (F ig. 14). If re le a s e ta b is n o t p re s s e d n ect fit t in g con n ect or body.
p rio r to re le a s in g p u ll ta b, p u ll ta b w ill be (6) P la s tic Re ta in e r Rin g Ty p e F ittin g : Th is
damaged. t ype of fit t in g ca n be iden t ified by t h e u se of a fu ll-
(b) Wh ile pr essin g r elea se t a b on side of fit t in g, r ou n d pla st ic r et a in er r in g (F ig. 17) u su a lly bla ck in
u se scr ewdr iver t o pr y u p pu ll t a b (F ig. 14). color.
(c) Ra ise pu ll t a b u n t il it sepa r a t es fr om qu ick- (a ) To r elea se fu el syst em com pon en t fr om qu ick-
con n ect fit t in g (F ig. 15). con n ect fit t in g, fir m ly pu sh fit t in g t owa r ds com po-
14 - 12 FUEL SYSTEM XJ
SERV I CE PROCEDU RES (Cont inue d)

FUEL TUBE OR PULL QUICK-CONNECT FUEL TUBE REMOVAL


TAB QUICK CONNECT
FUEL SYSTEM FITTING
COMPONENT FITTING

PUSH

INSTALLATION
FUEL
TUBE
STOP J9414-26

Fig. 15 Removing Pull Tab

PLASTIC
RETAINER J9314-100

Fig. 17 Plastic Retainer Ring Type Fitting

QUICK-CONNECT
TAB($} FITTING
80a35405

Fig. 16 Typical Two-Tab Type Quick-Connect Fitting


n en t bein g ser viced wh ile fir m ly pu sh in g pla st ic LATCH CLIP
r et a in er r in g in t o fit t in g (F ig. 17). Wit h pla st ic r in g
depr essed, pu ll fit t in g fr om com pon en t . Th e p la s - FUEL RAIL
tic re ta in e r rin g m u s t be p re s s e d s qu a re ly 80a92a66

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.

REM OVAL AN D I N STALLAT I ON


FUEL FILTER/FUEL PRESSURE REGULATOR
Th e com bin a t ion F u el F ilt er /F u el P r essu r e Regu la -
t or is loca t ed on t h e fu el pu m p m odu le. Th e fu el
pu m p m odu le is loca t ed on t op of fu el t a n k.
Th e filt er /r egu la t or m a y be r em oved wit h ou t
80b898e5
r em ovin g fu el pu m p m odu le a lt h ou gh fu el t a n k m u st
Fig. 19 Latch Clip—Type 2 be r em oved.

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)

RETAINER FUEL FILTER/FUEL FUEL FILTER/FUEL


CLAMP PRESSURE PRESSURE / ------ ----------~
REGULATOR REGULATOR 1/ ~

_.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.

(1) Dr a in fu el t a n k a n d r em ove t a n k. Refer t o t h e


F u el Ta n k Rem ova l/In st a lla t ion sect ion of t h is gr ou p.
(2) Th or ou gh ly wa sh a n d clea n a r ea a r ou n d pu m p
m odu le t o pr even t con t a m in a n t s fr om en t er in g t a n k.
(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) Th e pla st ic fu el pu m p m odu le lockn u t is
t h r ea ded on t o fu el t a n k (F ig. 24). In st a ll Specia l Tool
Fig. 22 Fuel Filter/Fuel Pressure Regulator Gasket 6856 t o fu el pu m p m odu le lockn u t a n d r em ove lock-
n u t (F ig. 25). Th e fu el pu m p m odu le will spr in g u p
(6) Th e a r r ow (F ig. 21) m olded in t o t op of fu el
wh en lockn u t is r em oved.
pu m p m odu le sh ou ld be poin t ed t owa r ds fr on t of
(5) Rem ove m odu le fr om fu el t a n k.
veh icle (12 o’clock posit ion ).
(7) Rot a t e filt er /r egu la t or u n t il fu el su pply t u be INSTALLATION
(fit t in g) is poin t ed t owa r ds fr on t of veh icle (12 o’clock
posit ion ). CAUTION: Whenever fuel pump module is serviced,
(8) In st a ll n ew r et a in er cla m p (cla m p sn a ps over module gasket must be replaced.
t op of filt er /r egu la t or a n d locks t o fla n ges on pu m p
m odu le). (1) Th or ou gh ly clea n lockn u t t h r ea ds a n d m a t in g
(9) Con n ect fu el lin e a t filt er /r egu la t or. Refer t o fu el t a n k t h r ea ds. Use a soa p/wa t er solu t ion . Do n ot
Qu ick-Con n ect F it t in gs in t h is gr ou p for pr ocedu r es. u se ca r bu r et or clea n er t o clea n t h r ea ds.
(10) In st a ll fu el t a n k. Refer t o F u el Ta n k Rem ova l/ (2) Usin g a n ew ga sket , posit ion ga sket a n d fu el
In st a lla t ion . pu m p m odu le in t o open in g in fu el t a n k.
(3) Apply clea n wa t er t o ga sket a n d lockn u t
t h r ea ds.
XJ FUEL SYSTEM 14 - 15
REM OVAL AN D I N STALLAT I ON (Cont inue d)

- ROLLOVER --- l FUEL PUMP INLET FILTER


VALVE ::j_ Th e fu el pu m p in let filt er (st r a in er ) is loca t ed on
t h e bot t om of fu el pu m p m odu le (F ig. 26). Th e fu el
pu m p m odu le is loca t ed on t op of fu el t a n k.

I
FUEL FIL TERI
FUEL PRESSURE
REGULATOR 80aac284

Fig. 24 Top View of Fuel Tank and Fuel Pump


Module
FUEL PUMP
INLET FILTER

Fig. 26 Fuel Pump Inlet Filter


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) Rem ove fu el pu m p m odu le. Refer t o F u el P u m p
Modu le Rem ova l/In st a lla t ion .
(3) Rem ove filt er by pr yin g fr om bot t om of m odu le
wit h 2 scr ewdr iver s. F ilt er is sn a pped t o m odu le.
(4) Clea n bot t om of pu m p m odu le.

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

Fig. 27 Fuel Gauge Sending Unit Location

80b6f034

Fig. 29 Fuel Rail Mounting—2.5L Engine


T
FUEL PUMP
(6) Discon n ect fu el su pply lin e la t ch clip a n d fu el
lin e a t fu el r a il. Refer t o Qu ick-Con n ect F it t in gs in
MODULE 80a58b60 t h is gr ou p for pr ocedu r es.
(7) Discon n ect t h r ot t le ca ble a t t h r ot t le body. Refer
Fig. 28 Fuel Gauge Sending Unit Release Tab t o Th r ot t le Ca ble Rem ova l/In st a lla t ion in t h is gr ou p
for pr ocedu r es.
INSTALLATION
(8) Discon n ect speed con t r ol ca ble a t t h r ot t le body
(1) P osit ion sen din g u n it t o pu m p m odu le a n d
(if equ ipped). Refer t o Speed Con t r ol Ca ble in Gr ou p
sn a p in t o pla ce.
8H , Speed Con t r ol Syst em for pr ocedu r es.
(2) Con n ect elect r ica l con n ect or t o t er m in a ls.
(9) Discon n ect a u t om a t ic t r a n sm ission ca ble a t
(3) In st a ll fu el pu m p m odu le. Refer t o F u el P u m p
t h r ot t le body (if equ ipped).
Modu le Rem ova l/In st a lla t ion .
(10) Rem ove ca ble r ou t in g br a cket (F ig. 29) a t
(4) In st a ll fu el t a n k. Refer t o F u el Ta n k Rem ova l/
in t a ke m a n ifold.
In st a lla t ion .
(11) Rem ove n u t secu r in g cr a n ksh a ft posit ion sen -
sor pigt a il h a r n ess t o fu el r a il m ou n t in g st u d.
FUEL INJECTOR RAIL—2.5L ENGINE Rem ove cla m p a n d h a r n ess fr om fu el r a il m ou n t in g
st u d.
REMOVAL (12) Clea n dir t /debr is fr om ea ch fu el in ject or a t
in t a ke m a n ifold.
WARNING: THE FUEL SYSTEM IS UNDER CON-
(13) Rem ove fu el r a il m ou n t in g n u t s/bolt s (F ig.
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
29).
THIS PRESSURE MUST BE RELEASED BEFORE
(14) Rem ove fu el r a il by gen t ly r ockin g u n t il a ll
SERVICING FUEL RAIL.
t h e fu el in ject or s a r e ou t of in t a ke m a n ifold.
XJ FUEL SYSTEM 14 - 17
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION
(1) Clea n ea ch in ject or bor e a t in t a ke m a n ifold.
(2) Apply a sm a ll a m ou n t of clea n en gin e oil t o
ea ch in ject or o-r in g. Th is will a id in in st a lla t ion .
(3) P osit ion t ips of a ll fu el in ject or s in t o t h e cor r e-
spon din g in ject or bor e in in t a ke m a n ifold. Sea t in jec-
t or s in t o m a n ifold.
(4) In st a ll a n d t igh t en fu el r a il m ou n t in g bolt s t o
11 !3 N·m (100 !25 in . lbs.) t or qu e.
(5) P osit ion cr a n ksh a ft posit ion sen sor pigt a il wir e
h a r n ess cla m p a n d wir e h a r n ess t o fu el r a il m ou n t -
in g st u d. In st a ll n u t secu r in g h a r n ess t o fu el r a il
m ou n t in g st u d.
(6) Con n ect t a gged in ject or h a r n ess con n ect or s t o
a ppr opr ia t e in ject or.
(7) Con n ect fu el lin e a n d fu el lin e la t ch clip t o fu el
r a il. Refer Qu ick-Con n ect F it t in gs in t h is gr ou p for
pr ocedu r es.
(8) In st a ll pr ot ect ive ca p t o pr essu r e t est por t fit -
t in g (if equ ipped). Fig. 30 Fuel Rail Mounting—4.0L Engine
(9) In st a ll ca ble r ou t in g br a cket t o in t a ke m a n i- (6) Discon n ect fu el su pply lin e la t ch clip a n d fu el
fold. lin e a t fu el r a il. Refer t o Qu ick-Con n ect F it t in gs in
(10) Con n ect t h r ot t le ca ble a t t h r ot t le body. t h is gr ou p for pr ocedu r es.
(11) Con n ect speed con t r ol ca ble a t t h r ot t le body (if (7) Discon n ect t h r ot t le ca ble a t t h r ot t le body. Refer
equ ipped). t o Th r ot t le Ca ble Rem ova l/In st a lla t ion in t h is gr ou p
(12) Con n ect a u t om a t ic t r a n sm ission ca ble a t for pr ocedu r es.
t h r ot t le body (if equ ipped). (8) Discon n ect speed con t r ol ca ble a t t h r ot t le body
(13) In st a ll a ir t u be (or du ct ) a t t op of t h r ot t le (if equ ipped). Refer t o Speed Con t r ol Ca ble in Gr ou p
body. 8H , Speed Con t r ol Syst em for pr ocedu r es.
(14) In st a ll fu el t a n k ca p. (9) Discon n ect a u t om a t ic t r a n sm ission ca ble a t
(15) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y. t h r ot t le body (if equ ipped).
(16) St a r t en gin e a n d ch eck for fu el lea ks. (10) Rem ove ca ble r ou t in g br a cket (F ig. 30) a t
in t a ke m a n ifold.
FUEL INJECTOR RAIL—4.0L ENGINE (11) Rem ove n u t secu r in g cr a n ksh a ft posit ion sen -
sor pigt a il h a r n ess t o fu el r a il m ou n t in g st u d.
REMOVAL Rem ove cla m p a n d h a r n ess fr om fu el r a il m ou n t in g
st u d.
WARNING: THE FUEL SYSTEM IS UNDER CON- (12) Clea n dir t /debr is fr om ea ch fu el in ject or a t
STANT FUEL PRESSURE EVEN WITH ENGINE OFF. in t a ke m a n ifold.
THIS PRESSURE MUST BE RELEASED BEFORE (13) Rem ove fu el r a il m ou n t in g n u t s/bolt s (F ig.
SERVICING FUEL RAIL. 30).
(14) Rem ove fu el r a il by gen t ly r ockin g u n t il a ll
(1) Rem ove fu el t a n k filler t u be ca p.
t h e fu el in ject or s a r e ou t of in t a ke m a n ifold.
(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.
INSTALLATION
(3) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
(1) Clea n ea ch in ject or bor e a t in t a ke m a n ifold.
(4) Rem ove a ir t u be a t t op of t h r ot t le body. Not e:
(2) Apply a sm a ll a m ou n t of clea n en gin e oil t o
Som e en gin e/veh icles m a y r equ ir e r em ova l of a ir
ea ch in ject or o-r in g. Th is will a id in in st a lla t ion .
clea n er du ct s a t t h r ot t le body.
(3) P osit ion t ips of a ll fu el in ject or s in t o t h e cor r e-
(5) Rem ove in ject or h a r n ess elect r ica l con n ect or s
spon din g in ject or bor e in in t a ke m a n ifold. Sea t in jec-
a t ea ch in ject or. E a ch in ject or con n ect or sh ou ld h a ve
t or s in t o m a n ifold.
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-
(4) In st a ll a n d t igh t en fu el r a il m ou n t in g bolt s t o
in g cylin der (F ig. 30). If n ot , iden t ify ea ch con n ect or
11 !3 N·m (100 !25 in . lbs.) t or qu e.
befor e r em ova l.
(5) P osit ion cr a n ksh a ft posit ion sen sor pigt a il wir e
h a r n ess cla m p a n d wir e h a r n ess t o fu el r a il m ou n t -
14 - 18 FUEL SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
in g st u d. In st a ll n u t secu r in g h a r n ess t o fu el r a il
m ou n t in g st u d. PLIERS
(6) Con n ect t a gged in ject or h a r n ess con n ect or s t o
INJECTOR
a ppr opr ia t e in ject or. CLIP
(7) Con n ect fu el lin e a n d fu el lin e la t ch clip t o fu el
r a il. Refer Qu ick-Con n ect F it t in gs in t h is gr ou p for
pr ocedu r es.
(8) In st a ll pr ot ect ive ca p t o pr essu r e t est por t fit -
t in g (if equ ipped).
(9) In st a ll ca ble r ou t in g br a cket t o in t a ke m a n i-
fold.
(10) Con n ect t h r ot t le ca ble a t t h r ot t le body.
(11) Con n ect speed con t r ol ca ble a t t h r ot t le body (if
equ ipped). FUEL
(12) Con n ect a u t om a t ic t r a n sm ission ca ble a t RAIL
t h r ot t le body (if equ ipped).
(13) In st a ll a ir t u be (or du ct ) a t t op of t h r ot t le
body.
(14) In st a ll fu el t a n k ca p.
(15) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y.
(16) St a r t en gin e a n d ch eck for fu el lea ks. J9414-156

FUEL INJECTORS Fig. 32 Injector Retaining Clips—Typical Injector

REMOVAL FUEL TANK


(1) Rem ove fu el r a il. Refer t o F u el In ject or Ra il WARNING: THE FUEL SYSTEM IS UNDER CON-
Rem ova l in t h is sect ion . STANT FUEL PRESSURE EVEN WITH THE ENGINE
(2) Rem ove clip(s) t h a t r et a in fu el in ject or (s) t o OFF. THIS PRESSURE MUST BE RELEASED
fu el r a il (F ig. 31) or (F ig. 32). BEFORE SERVICING FUEL TANK.

Two differ en t pr ocedu r es m a y be u sed t o dr a in fu el


t a n k (lower in g t a n k or u sin g DRB sca n t ool).
Th e qu ickest dr a in in g pr ocedu r e in volves lower in g
t h e fu el t a n k.
As a n a lt er n a t ive pr ocedu r e, t h e elect r ic fu el pu m p
m a y be a ct iva t ed a llowin g t a n k t o be dr a in ed a t fu el
r a il con n ect ion . Refer t o DRB sca n t ool for fu el pu m p
a ct iva t ion pr ocedu r es. Befor e discon n ect in g fu el lin e
a t fu el r a il, r elea se fu el pr essu r e. Refer t o t h e F u el
Syst em P r essu r e Relea se P r ocedu r e in t h is gr ou p for
pr ocedu r es. At t a ch en d of specia l t est h ose t ool n u m -
ber 6541, 6539, 6631 or 6923 a t fu el r a il discon n ec-
INJECTOR J9214-24 t ion (t ool n u m ber will depen d on m odel a n d/or en gin e
a pplica t ion ). P osit ion opposit e en d of t h is h ose t ool t o
Fig. 31 Injector Mounting a n a ppr oved ga solin e dr a in in g st a t ion . Act iva t e fu el
pu m p a n d dr a in t a n k u n t il em pt y.
INSTALLATION If elect r ic fu el pu m p is n ot oper a t in g, t a n k m u st be
(1) In st a ll fu el in ject or (s) in t o fu el r a il a ssem bly lower ed for fu el dr a in in g. Refer t o followin g pr oce-
a n d in st a ll r et a in in g clip(s). du r es.
(2) If sa m e in ject or (s) is bein g r ein st a lled, in st a ll
n ew o-r in g(s). REMOVAL
(3) Apply a sm a ll a m ou n t of clea n en gin e oil t o (1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
ea ch in ject or o-r in g. Th is will a id in in st a lla t ion . (2) Relea se fu el syst em pr essu r e. Refer t o t h e F u el
(4) In st a ll fu el r a il. Refer t o F u el Ra il In st a lla t ion Syst em P r essu r e Relea se P r ocedu r e in t h is gr ou p.
in t h is sect ion . (3) Ra ise a n d su ppor t veh icle.
(5) St a r t en gin e a n d ch eck for fu el lea ks.
XJ FUEL SYSTEM 14 - 19
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) If E qu ipped: Rem ove fu el t a n k skid pla t e. Refer FUEL PUMP LEFT-REAR
t o Gr ou p 23, Body for pr ocedu r es. MODULE CONNECTOR SHOCK ABSORBER

-===------
(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

Fig. 35 Fuel Tank Connections at Front of Fuel Tank

Fig. 33 Fuel Hose Shield


(6) Rem ove fu el t a n k fill h ose a n d ven t h ose
cla m ps a t fu el t a n k filler t u be (F ig. 34). Rem ove bot h
h oses a t fu el filler t u be (F ig. 34).

"' 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.

(9) Discon n ect fu el su pply lin e fr om fu el ext en sion


FUEL VENT rll 'l ~ lin e n ea r fr on t of fu el t a n k (F ig. 35). Refer t o F u el
HOSE I I ~ ~ 80aac286 Tu bes/Lin es/H oses a n d Cla m ps in t h is gr ou p. Also
r efer t o Qu ick-Con n ect F it t in gs for pr ocedu r es.
Fig. 34 Fuel Fill and Vent Hoses
(10) Discon n ect E VAP ca n ist er ven t lin e n ea r fr on t
(7) Rem ove exh a u st t a ilpipe h ea t sh ield m ou n t in g of t a n k (F ig. 35).
bolt s a n d r em ove sh ield. (11) Discon n ect fu el pu m p m odu le elect r ica l con -
n ect or (pigt a il h a r n ess) n ea r fr on t of t a n k (F ig. 35).
CAUTION: To protect fuel tank from exhaust heat, H a r n ess con n ect or is clipped t o body.
this shield must reinstalled after tank installation. (12) Rem ove t wo fu el t a n k st r a p n u t s (F ig. 36).
P osit ion bot h t a n k su ppor t st r a ps a wa y fr om t a n k.
(8) P la ce a h ydr a u lic ja ck t o bot t om of fu el t a n k.
(13) Ca r efu lly lower r igh t side of t a n k wh ile feed-
in g bot h fu el h oses t h r ou gh a ccess h ole in body. F u e l
14 - 20 FUEL SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
FUEL TANK CLAMP INDEX (9) P osit ion fu el h ose sh ield t o body. In st a ll a n d
MARKS t igh t en 4 m ou n t in g bolt s.
FUEL VENT (10) Con n ect fu el pu m p m odu le pigt a il h a r n ess
HOSE
elect r ica l con n ect or n ea r fr on t of t a n k.
(11) Con n ect fu el pu m p m odu le su pply lin e n ea r
fr on t of t a n k. Refer t o Qu ick-Con n ect F it t in gs for
pr ocedu r es.
(12) Con n ect E VAP h ose n ea r fr on t of t a n k.
TANK
INDEX (13) In st a ll exh a u st t a ilpipe h ea t sh ield.
TANGS (14) In st a ll fu el t a n k skid pla t e (if equ ipped).
(15) Lower veh icle a n d con n ect ba t t er y ca ble t o
ba t t er y.

FUEL TANK FILLER TUBE CAP


If r epla cem en t of t h e fu el t a n k filler t u be ca p is
n ecessa r y, it m u st be r epla ced wit h a n iden t ica l ca p
t o be su r e of cor r ect syst em oper a t ion .
FUEL FILL HOSE 80a61227
CAUTION: Remove the fuel tank filler tube cap to
Fig. 37 Fuel Fill/Vent Hose Index Marks relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
Ta n k F u ll An d N o t D ra in e d U s in g D RB S c a n
component or before draining the fuel tank.
To o l: To pr even t fu el loss t h r ou gh h oses, keep left
side of t a n k h igh er t h a n r igh t side wh ile lower in g.
Do n ot a llow h ose open in gs t o dr op lower t h a n t op of ACCELERATOR PEDAL
t a n k.
Th e a cceler a t or peda l is con n ect ed t o t h e t h r ot t le
(14) Con t in u e lower in g t a n k u n t il clea r of veh icle.
body lin ka ge by t h e t h r ot t le ca ble. Th e ca ble is pr o-
P la ce t a n k on floor wit h left side (h ose side) h igh er
t ect ed by a pla st ic sh ea t h in g a n d is con n ect ed t o t h e
t h a n r igh t side.
t h r ot t le body lin ka ge by a ba ll socket . It is con n ect ed
(15) Dr a in t a n k by r em ovin g fu el fill h ose a t t a n k.
t o t h e u pper pa r t of t h e a cceler a t or peda l a r m by a
F u el fill h ose is la r gest of 2 h oses (F ig. 37). In ser t t h e
pla st ic r et a in er (clip) (F ig. 38). Th is r et a in er (clip)
dr a in h ose (fr om a n a ppr oved ga solin e dr a in in g st a -
sn a ps in t o t h e t op of t h e a cceler a t or peda l a r m .
t ion ) in t o h ose open in g. Dr a in t a n k u n t il em pt y.
Ret a in er t a bs (bu ilt in t o t h e ca ble sh ea t h in g) (F ig.
(16) If fu el pu m p m odu le r em ova l is n ecessa r y,
38) fa st en t h e ca ble t o t h e da sh pa n el.
r efer t o F u el P u m p Modu le Rem ova l/In st a lla t ion in
Du a l t h r ot t le r et u r n spr in gs (a t t a ch ed t o t h e t h r ot -
t h is gr ou p for pr ocedu r es.
t le sh a ft ) a r e u sed t o close t h e t h r ot t le.
INSTALLATION CAUTION: Never attempt to remove or alter these
(1) If fu el pu m p m odu le is bein g in st a lled, r efer t o springs.
F u el P u m p Modu le Rem ova l/In st a lla t ion in t h is
gr ou p for pr ocedu r es.
(2) In st a ll fu el fill/ven t h oses t o t a n k fit t in gs. To CAUTION: Be careful not to damage or kink the
pr even t h ose fr om kin kin g, r ot a t e ea ch h ose u n t il cable core wire (within the cable sheathing) while
in dex m a r k on h ose is a lign ed t o in dex t a n g on fu el servicing the accelerator pedal or throttle cable.
t a n k (F ig. 37).
(3) In st a ll h ose cla m ps t o h oses. P osit ion cla m ps
bet ween in dex m a r ks on ea ch h ose (F ig. 37). REMOVAL
(4) P osit ion fu el t a n k t o h ydr a u lic ja ck. (1) F r om in side t h e veh icle, h old u p a cceler a t or
(5) Ra ise t a n k in t o posit ion wh ile gu idin g fu el fill peda l. Rem ove pla st ic ca ble r et a in er (clip) a n d t h r ot -
a n d ven t h oses in t o a n d t h r ou gh a ccess h ole in body. t le ca ble cor e wir e fr om u pper en d of a cceler a t or
(6) Con t in u e r a isin g t a n k u n t il posit ion ed t o body. peda l a r m (F ig. 38). P la st ic ca ble r et a in er (clip) sn a ps
(7) At t a ch t wo fu el t a n k m ou n t in g st r a ps a n d in t o peda l a r m .
m ou n t in g n u t s. Tigh t en n u t s t o 10 N·m (90 in . lbs.) (2) Rem ove a cceler a t or peda l m ou n t in g br a cket
t or qu e. Do n ot over t igh t en n u t s. n u t s. Rem ove a cceler a t or peda l a ssem bly.
(8) In st a ll bot h fu el h oses t o fu el fill t u be. Tigh t en
bot h r et a in in g cla m ps.
XJ FUEL SYSTEM 14 - 21
REM OVAL AN D I N STALLAT I ON (Cont inue d)

J8914-29

Fig. 39 Cable Guide and Squeeze Tabs—Typical


Fig. 38 Accelerator Pedal Mounting—Typical
INSTALLATION
(1) P la ce a cceler a t or peda l a ssem bly over st u ds
pr ot r u din g fr om floor pa n . Tigh t en m ou n t in g n u t s t o
5 N·m (36 in . lbs.) t or qu e.
(2) Slide t h r ot t le ca ble in t o open in g in t op of peda l
a r m . P u sh pla st ic ca ble r et a in er (clip) in t o a cceler a -
t or peda l a r m open in g u n t il it sn a ps in t o pla ce.
(3) 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.

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

SPECI FI CAT I ON S TORQUE CHART


FUEL TANK CAPACITY D ES CRIP TION TORQU E
Acceler a t or P eda l Br a cket Mou n t in g Nu t s . . . 5 N·m
Models Liters U.S. Gallons (36 in . lbs.)
All 76 20 F u el H ose Cla m ps . . . . . . . . . . . . 3 N·m (25 in . lbs.)
Nominal refill capacities are shown. A variation may F u el Ra il Mou n t in g Bolt s . . . . . 11 N·m (100 in . lbs.)
be observed from vehicle to vehicle due to F u el Ta n k Mou n t in g St r a p Nu t s . . . . . . . . . 10 N·m
manufacturing tolerance and refill procedure. (90 in . lbs.)
F u el P u m p Modu le Lockn u t . . . . 74 N·m (55 ft . lbs.)

FUEL SYSTEM PRESSURE


339 kP a ! 34 kP a (49.2 psi ! 5 psi).
XJ FUEL SYSTEM 14 - 23

FU EL I N J ECT I ON SY ST EM

INDEX
page page

DESCRIPTION AND OPERATION MODES OF OPERATION . . . . . . . . . . . . . . . . . . 25


AIR CONDITIONING (A/C) CLUTCH RELAY— OIL PRESSURE SENSOR—PCM INPUT . . . . . . 31
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 33 OXYGEN SENSOR (HO2S)—PCM INPUT . . . . . 30
AIR CONDITIONING (A/C) CONTROLS—PCM POWER GROUND . . . . . . . . . . . . . . . . . . . . . . . 31
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 POWER STEERING PRESSURE SWITCH—
AUTO SHUTDOWN (ASD) RELAY—PCM PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 POWERTRAIN CONTROL MODULE (PCM) . . . . 24
AUTOMATIC SHUTDOWN (ASD) RELAY RADIATOR FAN RELAY—PCM OUTPUT . . . . . . 35
SENSE—PCM INPUT . . . . . . . . . . . . . . . . . . . 28 SENSOR RETURN—PCM INPUT . . . . . . . . . . . . 32
BATTERY TEMPERATURE SENSOR—PCM SPEED CONTROL SOLENOIDS—PCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
BATTERY VOLTAGE—PCM INPUT . . . . . . . . . . . 28 SPEED CONTROL SWITCHES—PCM INPUT . . . 32
BRAKE SWITCH—PCM INPUT . . . . . . . . . . . . . . 28 TACHOMETER—PCM OUTPUT . . . . . . . . . . . . . 35
CAMSHAFT POSITION SENSOR—PCM THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . 35
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 THROTTLE POSITION SENSOR (TPS)—PCM
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS . . . . . 34 INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CRANKSHAFT POSITION SENSOR—PCM TRANSMISSION PARK/NEUTRAL SWITCH—
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DATA LINK CONNECTOR—PCM INPUT AND VEHICLE SPEED AND DISTANCE SENSOR—
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DUTY CYCLE EVAP PURGE SOLENOID DIAGNOSIS AND TESTING
VALVE-PCM OUTPUT . . . . . . . . . . . . . . . . . . . 34 ASD AND FUEL PUMP RELAYS . . . . . . . . . . . . . 39
ENGINE COOLANT TEMPERATURE SENSOR— ENGINE COOLANT TEMPERATURE
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
EXTENDED IDLE SWITCH—PCM INPUT . . . . . . 30 EXTENDED IDLE SWITCH TEST . . . . . . . . . . . . 43
FIVE VOLT SENSOR SUPPLY—PRIMARY . . . . . 28 IDLE AIR CONTROL (IAC) MOTOR . . . . . . . . . . . 42
FIVE VOLT SENSOR SUPPLY—SECONDARY . . 28 INTAKE MANIFOLD AIR TEMPERATURE
FUEL INJECTORS—PCM OUTPUT . . . . . . . . . . 34 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
FUEL LEVEL SENSOR—PCM INPUT . . . . . . . . . 28 MANIFOLD ABSOLUTE PRESSURE (MAP)
FUEL PUMP RELAY-PCM OUTPUT . . . . . . . . . . 35 SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . 40
GENERATOR FIELD DRIVER (-)—PCM OXYGEN (O2S) SENSORS . . . . . . . . . . . . . . . . 41
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 POWER STEERING PRESSURE SWITCH . . . . . 42
GENERATOR FIELD SOURCE (+)—PCM THROTTLE BODY MINIMUM AIR FLOW
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . 44
GENERATOR LAMP—PCM OUTPUT . . . . . . . . . 35 THROTTLE POSITION SENSOR (TPS) . . . . . . . 44
GENERATOR OUTPUT—PCM INPUT . . . . . . . . . 30 VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 43
IDLE AIR CONTROL (IAC) MOTOR—PCM VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . 36
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 REMOVAL AND INSTALLATION
IGNITION CIRCUIT SENSE—PCM INPUT . . . . . 30 AIR CLEANER ELEMENT (FILTER) . . . . . . . . . . 49
IGNITION COIL—PCM OUTPUT . . . . . . . . . . . . . 35 AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . 45
INTAKE MANIFOLD AIR TEMPERATURE DUTY CYCLE EVAP CANISTER PURGE
SENSOR—PCM INPUT . . . . . . . . . . . . . . . . . . 30 SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
LEAK DETECTION PUMP (SWITCH) SENSE— ENGINE COOLANT TEMPERATURE SENSOR . . 50
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . 45
LEAK DETECTION PUMP—PCM OUTPUT . . . . . 35 IDLE AIR CONTROL (IAC) MOTOR . . . . . . . . . . . 47
MALFUNCTION INDICATOR LAMP—ECM/PCM INTAKE MANIFOLD AIR TEMPERATURE
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MANIFOLD ABSOLUTE PRESSURE (MAP) MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR—PCM INPUT . . . . . . . . . . . . . . . . . . 31 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
14 - 24 FUEL SYSTEM XJ

OXYGEN SENSOR . . . . . . . . . . . . . . . . . . . . . . . 48 VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 50


POWER STEERING PRESSURE SWITCH—2.5L SPECIFICATIONS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 51
POWERTRAIN CONTROL MODULE (PCM) . . . . 47 SPECIAL TOOLS
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . 45 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 52
THROTTLE POSITION SENSOR (TPS) . . . . . . . 46

DESCRI PT I ON AN D OPERAT I ON coola n t t em per a t u r e a n d fr om in pu t s it r eceives fr om


t h e a ir con dit ion in g clu t ch swit ch a n d br a ke swit ch .
POWERTRAIN CONTROL MODULE (PCM) Ba sed on in pu t s t h a t it r eceives, t h e P CM a dju st s
Th e P ower t r a in Con t r ol Modu le (P CM) (F ig. 1) ign it ion coil dwell. Th e P CM a lso a dju st s t h e gen er-
oper a t es t h e fu el syst em . Th e P CM wa s for m er ly a t or ch a r ge r a t e t h r ou gh con t r ol of t h e gen er a t or
r efer r ed t o a s t h e SBE C or en gin e con t r oller. Th e field a n d pr ovides speed con t r ol oper a t ion .
P CM is a pr e-pr ogr a m m ed, t r iple m icr opr ocessor dig-
NOTE: PCM Inputs:
it a l com pu t er. It r egu la t es ign it ion t im in g, a ir-fu el
r a t io, em ission con t r ol devices, ch a r gin g syst em , cer- • A/C r equ est (if equ ipped wit h fa ct or y A/C)
t a in t r a n sm ission fea t u r es, speed con t r ol, a ir con di- • A/C select (if equ ipped wit h fa ct or y A/C)
t ion in g com pr essor clu t ch en ga gem en t a n d idle • Au t o sh u t down (ASD) sen se
speed. Th e P CM ca n a da pt it s pr ogr a m m in g t o m eet • Ba t t er y t em per a t u r e
ch a n gin g oper a t in g con dit ion s. • Ba t t er y volt a ge
• Br a ke swit ch
• CCD bu s (+) cir cu it s
• CCD bu s (-) cir cu it s
• Ca m sh a ft posit ion sen sor sign a l
• Cr a n ksh a ft posit ion sen sor
• Da t a lin k con n ect ion for DRB sca n t ool
• E n gin e coola n t t em per a t u r e sen sor
• E xt en ded idle swit ch (4.0L en gin e wit h police
pa cka ge)
• F u el level
• Gen er a t or (ba t t er y volt a ge) ou t pu t
• Ign it ion cir cu it sen se (ign it ion swit ch in on /off/
cr a n k/r u n posit ion )
• In t a ke m a n ifold a ir t em per a t u r e sen sor
• Lea k det ect ion pu m p (swit ch ) sen se (if equ ipped)
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
Fig. 1 PCM Location • Oil pr essu r e
• Oxygen sen sor s
Th e P CM r eceives in pu t sign a ls fr om va r iou s
• P a r k/n eu t r a l swit ch (a u t o. t r a n s. on ly)
swit ch es a n d sen sor s. Ba sed on t h ese in pu t s, t h e
• P ower gr ou n d
P CM r egu la t es va r iou s en gin e a n d veh icle oper a t ion s
• P ower st eer in g pr essu r e swit ch (2.5L en gin e
t h r ou gh differ en t syst em com pon en t s. Th ese com po-
on ly)
n en t s a r e r efer r ed t o a s P ower t r a in Con t r ol Modu le
• Sen sor r et u r n
(P CM) Ou t pu t s. Th e sen sor s a n d swit ch es t h a t pr o-
• Sign a l gr ou n d
vide in pu t s t o t h e P CM a r e con sider ed P ower t r a in
• Speed con t r ol m u lt iplexed sin gle wir e in pu t
Con t r ol Modu le (P CM) In pu t s.
• Th r ot t le posit ion sen sor
Th e P CM a dju st s ign it ion t im in g ba sed u pon
• Veh icle speed sen sor
in pu t s it r eceives fr om sen sor s t h a t r ea ct t o: en gin e
r pm , m a n ifold a bsolu t e pr essu r e, en gin e coola n t t em - NOTE: PCM Outputs:
per a t u r e, t h r ot t le posit ion , t r a n sm ission gea r selec-
t ion (a u t om a t ic t r a n sm ission ), veh icle speed, power • A/C clu t ch r ela y
st eer in g pu m p pr essu r e (2.5L en gin e on ly), a n d t h e • Au t o sh u t down (ASD) r ela y
br a ke swit ch . • CCD bu s (+/-) cir cu it s for : speedom et er, volt m e-
Th e P CM a dju st s idle speed ba sed on in pu t s it t er, fu el ga u ge, oil pr essu r e ga u ge/la m p, en gin e t em p.
r eceives fr om sen sor s t h a t r ea ct t o: t h r ot t le posit ion , ga u ge a n d speed con t r ol wa r n . la m p
veh icle speed, t r a n sm ission gea r select ion , en gin e • Da t a lin k con n ect ion for DRB sca n t ool
XJ FUEL SYSTEM 14 - 25
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
• E GR va lve con t r ol solen oid (if equ ipped) a n d cr u ise m odes, (wit h t h e en gin e a t oper a t in g t em -
• E VAP ca n ist er pu r ge solen oid per a t u r e) a r e Closed Loop m odes.
• F ive volt sen sor su pply (pr im a r y)
• F ive volt sen sor su pply (secon da r y) IGNITION SWITCH (KEY-ON) MODE
• F u el in ject or s Th is is a n Open Loop m ode. Wh en t h e fu el syst em
• F u el pu m p r ela y is a ct iva t ed by t h e ign it ion swit ch , t h e followin g
• Gen er a t or field dr iver (-) a ct ion s occu r :
• Gen er a t or field dr iver (+) • Th e power t r a in con t r ol m odu le (P CM) pr e-posi-
• Idle a ir con t r ol (IAC) m ot or t ion s t h e idle a ir con t r ol (IAC) m ot or.
• Ign it ion coil • Th e P CM det er m in es a t m osph er ic a ir pr essu r e
• Lea k det ect ion pu m p (if equ ipped) fr om t h e MAP sen sor in pu t t o det er m in e ba sic fu el
• Ma lfu n ct ion in dica t or la m p (Ch eck en gin e la m p). st r a t egy.
Dr iven t h r ou gh CCD cir cu it s. • Th e P CM m on it or s t h e en gin e coola n t t em per a -
• Ra dia t or coolin g fa n r ela y t u r e sen sor in pu t . Th e P CM m odifies fu el st r a t egy
• Speed con t r ol va cu u m solen oid ba sed on t h is in pu t .
• Speed con t r ol ven t solen oid • In t a ke m a n ifold a ir t em per a t u r e sen sor in pu t is
• Ta ch om et er (if equ ipped). Dr iven t h r ou gh CCD m on it or ed.
cir cu it s. • Th r ot t le posit ion sen sor (TP S) is m on it or ed.
• Tr a n sm ission con ver t or clu t ch cir cu it • Th e a u t o sh u t down (ASD) r ela y is en er gized by
t h e P CM for a ppr oxim a t ely t h r ee secon ds.
MODES OF OPERATION • Th e fu el pu m p is en er gized t h r ou gh t h e fu el
As in pu t sign a ls t o t h e power t r a in con t r ol m odu le pu m p r ela y by t h e P CM. Th e fu el pu m p will oper a t e
(P CM) ch a n ge, t h e P CM a dju st s it s r espon se t o t h e for a ppr oxim a t ely t h r ee secon ds u n less t h e en gin e is
ou t pu t devices. F or exa m ple, t h e P CM m u st ca lcu la t e oper a t in g or t h e st a r t er m ot or is en ga ged.
differ en t in ject or pu lse widt h a n d ign it ion t im in g for • Th e O2S sen sor h ea t er elem en t is en er gized via
idle t h a n it does for wide open t h r ot t le (WOT). t h e ASD r ela y. Th e O2S sen sor in pu t is n ot u sed by
Th e P CM will oper a t e in t wo differ en t m odes: t h e P CM t o ca libr a t e a ir-fu el r a t io du r in g t h is m ode
Op e n Lo o p a n d Clo s e d Lo o p . of oper a t ion .
Du r in g Open Loop m odes, t h e power t r a in con t r ol
m odu le (P CM) r eceives in pu t sign a ls a n d r espon ds ENGINE START-UP MODE
on ly a ccor din g t o pr eset P CM pr ogr a m m in g. In pu t Th is is a n Open Loop m ode. Th e followin g a ct ion s
fr om t h e oxygen (O2S) sen sor s is n ot m on it or ed du r- occu r wh en t h e st a r t er m ot or is en ga ged.
in g Open Loop m odes. Th e power t r a in con t r ol m odu le (P CM) r eceives
Du r in g Closed Loop m odes, t h e P CM will m on it or in pu t s fr om :
t h e oxygen (O2S) sen sor s in pu t . Th is in pu t in dica t es • Ba t t er y volt a ge
t o t h e P CM wh et h er or n ot t h e ca lcu la t ed in ject or • E n gin e coola n t t em per a t u r e sen sor
pu lse widt h r esu lt s in t h e idea l a ir-fu el r a t io. Th is • Cr a n ksh a ft posit ion sen sor
r a t io is 14.7 pa r t s a ir-t o-1 pa r t fu el. By m on it or in g • In t a ke m a n ifold a ir t em per a t u r e sen sor
t h e exh a u st oxygen con t en t t h r ou gh t h e O2S sen sor, • Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
t h e P CM ca n fin e t u n e t h e in ject or pu lse widt h . Th is • Th r ot t le posit ion sen sor (TP S)
is don e t o a ch ieve opt im u m fu el econ om y com bin ed • Ca m sh a ft posit ion sen sor sign a l
wit h low em ission en gin e per for m a n ce. Th e P CM m on it or s t h e cr a n ksh a ft posit ion sen sor.
Th e fu el in ject ion syst em h a s t h e followin g m odes If t h e P CM does n ot r eceive a cr a n ksh a ft posit ion
of oper a t ion : sen sor sign a l wit h in 3 secon ds of cr a n kin g t h e
• Ign it ion swit ch ON en gin e, it will sh u t down t h e fu el in ject ion syst em .
• E n gin e st a r t -u p (cr a n k) Th e fu el pu m p is a ct iva t ed by t h e P CM t h r ou gh
• E n gin e wa r m -u p t h e fu el pu m p r ela y.
• Idle Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e
• Cr u ise ASD r ela y via t h e P CM. Th e P CM will t h en con t r ol
• Acceler a t ion t h e in ject ion sequ en ce a n d in ject or pu lse widt h by
• Deceler a t ion t u r n in g t h e gr ou n d cir cu it t o ea ch in dividu a l in ject or
• Wide open t h r ot t le (WOT) on a n d off.
• Ign it ion swit ch OF F Th e P CM det er m in es t h e pr oper ign it ion t im in g
Th e ign it ion swit ch On , en gin e st a r t -u p (cr a n k), a ccor din g t o in pu t r eceived fr om t h e cr a n ksh a ft posi-
en gin e wa r m -u p, a cceler a t ion , deceler a t ion a n d wide t ion sen sor.
open t h r ot t le m odes a r e Open Loop m odes. Th e idle
14 - 26 FUEL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
ENGINE WARM-UP MODE • P ower st eer in g pr essu r e swit ch (2.5L en gin e
Th is is a n Open Loop m ode. Du r in g en gin e wa r m - on ly)
u p, t h e power t r a in con t r ol m odu le (P CM) r eceives Ba sed on t h ese in pu t s, t h e followin g occu r s:
in pu t s fr om : • Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e
• Ba t t er y volt a ge ASD r ela y via t h e P CM. Th e P CM will t h en con t r ol
• Cr a n ksh a ft posit ion sen sor in ject ion sequ en ce a n d in ject or pu lse widt h by t u r n -
• E n gin e coola n t t em per a t u r e sen sor in g t h e gr ou n d cir cu it t o ea ch in dividu a l in ject or on
• In t a ke m a n ifold a ir t em per a t u r e sen sor a n d off.
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor • Th e P CM m on it or s t h e O2S sen sor in pu t a n d
• Th r ot t le posit ion sen sor (TP S) a dju st s a ir-fu el r a t io by va r yin g in ject or pu lse widt h .
• Ca m sh a ft posit ion sen sor sign a l (in t h e dist r ibu t or ) It a lso a dju st s en gin e idle speed t h r ou gh t h e idle a ir
• P a r k/n eu t r a l swit ch (gea r in dica t or sign a l—a u t o. con t r ol (IAC) m ot or.
t r a n s. on ly) • Th e P CM a dju st s ign it ion t im in g by in cr ea sin g
• Air con dit ion in g select sign a l (if equ ipped) a n d decr ea sin g spa r k a dva n ce.
• Air con dit ion in g r equ est sign a l (if equ ipped) • Th e P CM oper a t es t h e A/C com pr essor clu t ch
Ba sed on t h ese in pu t s t h e followin g occu r s: t h r ou gh t h e A/C com pr essor clu t ch r ela y. Th is is don e
• Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e if A/C h a s been select ed by t h e veh icle oper a t or a n d
ASD r ela y via t h e P CM. Th e P CM will t h en con t r ol specified pr essu r es a r e m et a t t h e h igh a n d low–pr es-
t h e in ject ion sequ en ce a n d in ject or pu lse widt h by su r e A/C swit ch es. Refer t o Gr ou p 24, H ea t in g a n d
t u r n in g t h e gr ou n d cir cu it t o ea ch in dividu a l in ject or Air Con dit ion in g for a ddit ion a l in for m a t ion .
on a n d off. Th e opt ion a l E xt en ded Idle Swit ch is u sed t o r a ise
• Th e P CM a dju st s en gin e idle speed t h r ou gh t h e a n d h old t h e en gin e idle speed t o a ppr oxim a t ely 1000
idle a ir con t r ol (IAC) m ot or a n d a dju st s ign it ion t im - r pm . Th is is wh en t h e sh ift er is in eit h er t h e P a r k or
in g. Neu t r a l posit ion a n d t h r ot t le peda l is n ot u sed. A
• Th e P CM oper a t es t h e A/C com pr essor clu t ch r ocker-t ype swit ch (ext en ded idle swit ch ) is m ou n t ed
t h r ou gh t h e A/C com pr essor clu t ch r ela y. Th is is don e t o t h e in st r u m en t pa n el. Th is swit ch will su pply a
if A/C h a s been select ed by t h e veh icle oper a t or a n d gr ou n d cir cu it (in pu t ) t o t h e power t r a in con t r ol m od-
specified pr essu r es a r e m et a t t h e h igh a n d low–pr es- u le (P CM). Th e s w itc h is a v a ila ble o n ly w ith 4.0L
su r e A/C swit ch es. Refer t o Gr ou p 24, H ea t in g a n d e n g in e w h e n s u p p lie d w ith o p tio n a l p o lic e
Air Con dit ion in g for a ddit ion a l in for m a t ion . package.
• Wh en en gin e h a s r ea ch ed oper a t in g t em per a - On 2.5L 4–cylin der en gin es, a power st eer in g pr es-
t u r e, t h e P CM will begin m on it or in g O2S sen sor su r e swit ch is u sed t o su pply a n in pu t t o t h e P CM
in pu t . Th e syst em will t h en lea ve t h e wa r m -u p m ode wh en st eer in g pu m p pr essu r e is h igh . Th is will r a ise
a n d go in t o closed loop oper a t ion . en gin e speed. Refer t o P ower St eer in g P r essu r e
Swit ch in t h is gr ou p for a ddit ion a l in for m a t ion . Th e
IDLE MODE 4.0L 6–c y lin d e r e n g in e d o e s n o t u s e th is s w itc h .
Wh en t h e en gin e is a t oper a t in g t em per a t u r e, t h is
is a Closed Loop m ode. At idle speed, t h e power t r a in CRUISE MODE
con t r ol m odu le (P CM) r eceives in pu t s fr om : Wh en t h e en gin e is a t oper a t in g t em per a t u r e, t h is
• Air con dit ion in g select sign a l (if equ ipped) is a Closed Loop m ode. At cr u isin g speed, t h e power-
• Air con dit ion in g r equ est sign a l (if equ ipped) t r a in con t r ol m odu le (P CM) r eceives in pu t s fr om :
• Ba t t er y volt a ge • Air con dit ion in g select sign a l (if equ ipped)
• Cr a n ksh a ft posit ion sen sor • Air con dit ion in g r equ est sign a l (if equ ipped)
• E n gin e coola n t t em per a t u r e sen sor • Ba t t er y volt a ge
• E xt en ded idle swit ch (4.0L en gin e wit h police • E n gin e coola n t t em per a t u r e sen sor
pa cka ge on ly) • Cr a n ksh a ft posit ion sen sor
• In t a ke m a n ifold a ir t em per a t u r e sen sor • In t a ke m a n ifold a ir t em per a t u r e sen sor
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor • Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
• Th r ot t le posit ion sen sor (TP S) • Th r ot t le posit ion sen sor (TP S)
• Ca m sh a ft posit ion sen sor sign a l (in t h e dist r ibu - • Ca m sh a ft posit ion sen sor sign a l (in t h e dist r ibu -
t or ) t or )
• Ba t t er y volt a ge • P a r k/n eu t r a l swit ch (gea r in dica t or sign a l—a u t o.
• P a r k/n eu t r a l swit ch (gea r in dica t or sign a l—a u t o. t r a n s. on ly)
t r a n s. on ly) • Oxygen (O2S) sen sor s
• Oxygen sen sor s Ba sed on t h ese in pu t s, t h e followin g occu r s:
XJ FUEL SYSTEM 14 - 27
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
• Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e WIDE OPEN THROTTLE MODE
ASD r ela y via t h e P CM. Th e P CM will t h en a dju st Th is is a n Open Loop m ode. Du r in g wide open
t h e in ject or pu lse widt h by t u r n in g t h e gr ou n d cir cu it t h r ot t le oper a t ion , t h e power t r a in con t r ol m odu le
t o ea ch in dividu a l in ject or on a n d off. (P CM) r eceives t h e followin g in pu t s.
• Th e P CM m on it or s t h e O2S sen sor in pu t a n d • Ba t t er y volt a ge
a dju st s a ir-fu el r a t io. It a lso a dju st s en gin e idle • Cr a n ksh a ft posit ion sen sor
speed t h r ou gh t h e idle a ir con t r ol (IAC) m ot or. • E n gin e coola n t t em per a t u r e sen sor
• Th e P CM a dju st s ign it ion t im in g by t u r n in g t h e • In t a ke m a n ifold a ir t em per a t u r e sen sor
gr ou n d pa t h t o t h e coil on a n d off. • Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
• Th e P CM oper a t es t h e A/C com pr essor clu t ch • Th r ot t le posit ion sen sor (TP S)
t h r ou gh t h e clu t ch r ela y. Th is h a ppen s if A/C h a s • Ca m sh a ft posit ion sen sor sign a l (in t h e dist r ibu -
been select ed by t h e veh icle oper a t or a n d r equ est ed t or )
by t h e A/C t h er m ost a t . Du r in g wide open t h r ot t le con dit ion s, t h e followin g
occu r s:
ACCELERATION MODE • Volt a ge is a pplied t o t h e fu el in ject or s wit h t h e
Th is is a n Open Loop m ode. Th e power t r a in con t r ol ASD r ela y via t h e P CM. Th e P CM will t h en con t r ol
m odu le (P CM) r ecogn izes a n a br u pt in cr ea se in t h e in ject ion sequ en ce a n d in ject or pu lse widt h by
t h r ot t le posit ion or MAP pr essu r e a s a dem a n d for t u r n in g t h e gr ou n d cir cu it t o ea ch in dividu a l in ject or
in cr ea sed en gin e ou t pu t a n d veh icle a cceler a t ion . Th e on a n d off. Th e P CM ign or es t h e oxygen sen sor in pu t
P CM in cr ea ses in ject or pu lse widt h in r espon se t o sign a l a n d pr ovides a pr edet er m in ed a m ou n t of a ddi-
in cr ea sed t h r ot t le open in g. t ion a l fu el. Th is is don e by a dju st in g in ject or pu lse
widt h .
DECELERATION MODE • Th e P CM a dju st s ign it ion t im in g by t u r n in g t h e
Wh en t h e en gin e is a t oper a t in g t em per a t u r e, t h is gr ou n d pa t h t o t h e coil on a n d off.
is a n Open Loop m ode. Du r in g h a r d deceler a t ion , t h e
power t r a in con t r ol m odu le (P CM) r eceives t h e follow- IGNITION SWITCH OFF MODE
in g in pu t s. Wh en ign it ion swit ch is t u r n ed t o OF F posit ion ,
• Air con dit ion in g select sign a l (if equ ipped) t h e P CM st ops oper a t in g t h e in ject or s, ign it ion coil,
• Air con dit ion in g r equ est sign a l (if equ ipped) ASD r ela y a n d fu el pu m p r ela y.
• Ba t t er y volt a ge
• E n gin e coola n t t em per a t u r e sen sor AIR CONDITIONING (A/C) CONTROLS—PCM
• Cr a n ksh a ft posit ion sen sor
INPUT
• In t a ke m a n ifold a ir t em per a t u r e sen sor
• Ma n ifold a bsolu t e pr essu r e (MAP ) sen sor
OPERATION
• Th r ot t le posit ion sen sor (TP S)
Th e A/C con t r ol syst em in for m a t ion a pplies t o fa c-
• Ca m sh a ft posit ion sen sor sign a l (in t h e dist r ibu -
t or y in st a lled a ir con dit ion in g u n it s.
t or )
A/C S ELECT S IGN AL: Wh en t h e A/C swit ch is in
• P a r k/n eu t r a l swit ch (gea r in dica t or sign a l—a u t o.
t h e ON posit ion , a n in pu t sign a l is sen t t o t h e P ow-
t r a n s. on ly)
er t r a in Con t r ol Modu le (P CM). Th e sign a l in for m s
• Veh icle speed sen sor
t h e P CM t h a t t h e A/C h a s been select ed. Th e P CM
If t h e veh icle is u n der h a r d deceler a t ion wit h t h e
a dju st s idle speed t o a pr e-pr ogr a m m ed r pm t h r ou gh
pr oper r pm a n d closed t h r ot t le con dit ion s, t h e P CM
t h e idle a ir con t r ol (IAC) m ot or t o com pen sa t e for
will ign or e t h e oxygen sen sor in pu t sign a l. Th e P CM
in cr ea sed en gin e loa d.
will en t er a fu el cu t -off st r a t egy in wh ich it will n ot
A/C REQU ES T S IGN AL: On ce A/C h a s been
su pply a gr ou n d t o t h e in ject or s. If a h a r d deceler a -
select ed, t h e P CM r eceives t h e A/C r equ est sign a l
t ion does n ot exist , t h e P CM will det er m in e t h e
fr om t h e clu t ch cyclin g pr essu r e swit ch . Th e in pu t
pr oper in ject or pu lse widt h a n d con t in u e in ject ion .
in dica t es t h a t t h e eva por a t or pr essu r e is in t h e
Ba sed on t h e a bove in pu t s, t h e P CM will a dju st
pr oper r a n ge for A/C a pplica t ion . Th e P CM u ses t h is
en gin e idle speed t h r ou gh t h e idle a ir con t r ol (IAC)
in pu t t o cycle t h e A/C com pr essor clu t ch (t h r ou gh t h e
m ot or.
A/C r ela y). It will a lso det er m in e t h e cor r ect en gin e
Th e P CM a dju st s ign it ion t im in g by t u r n in g t h e
idle speed t h r ou gh t h e idle a ir con t r ol (IAC) m ot or
gr ou n d pa t h t o t h e coil on a n d off.
posit ion .
If t h e A/C low-pr essu r e swit ch or h igh -pr essu r e
swit ch open s (in dica t in g a low or h igh r efr iger a n t
pr essu r e), t h e P CM will n ot r eceive a n A/C r equ est
sign a l. Th e P CM will t h en r em ove t h e gr ou n d fr om
14 - 28 FUEL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
t h e A/C r ela y. Th is will dea ct iva t e t h e A/C com pr es- BATTERY VOLTAGE—PCM INPUT
sor clu t ch .
If t h e swit ch open s, (in dica t in g t h a t eva por a t or is OPERATION
n ot in pr oper pr essu r e r a n ge), t h e P CM will n ot Th e ba t t er y volt a ge in pu t pr ovides power t o t h e
r eceive t h e A/C r equ est sign a l. Th e P CM will t h en P ower t r a in Con t r ol Modu le (P CM). It a lso in for m s
r em ove t h e gr ou n d fr om t h e A/C r ela y, dea ct iva t in g t h e P CM wh a t volt a ge level is su pplied t o t h e ign i-
t h e A/C com pr essor clu t ch . t ion coil a n d fu el in ject or s.
If ba t t er y volt a ge is low, t h e P CM will in cr ea se
AUTOMATIC SHUTDOWN (ASD) RELAY in ject or pu lse widt h (per iod of t im e t h a t t h e in ject or
SENSE—PCM INPUT is en er gized). Th is is don e t o com pen sa t e for t h e
A 12 volt sign a l a t t h is in pu t in dica t es t o t h e P CM r edu ced flow t h r ou gh in ject or ca u sed by t h e lower ed
t h a t t h e ASD h a s been a ct iva t ed. Th e ASD r ela y is volt a ge.
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 in t h e en gin e com pa r t m en t (F ig. 2). BRAKE SWITCH—PCM INPUT
Refer t o la bel on P DC cover for r ela y loca t ion . Th e
r ela y is u sed t o con n ect t h e oxygen sen sor h ea t er ele- OPERATION
m en t s, ign it ion coil a n d fu el in ject or s t o 12 volt + Wh en t h e br a ke ligh t swit ch is a ct iva t ed, t h e P ow-
power su pply. er t r a in Con t r ol Modu le (P CM) r eceives a n in pu t in di-
ca t in g t h a t t h e br a kes a r e bein g a pplied. Aft er
r eceivin g t h is in pu t , t h e P CM m a in t a in s idle speed t o
a sch edu led r pm t h r ou gh con t r ol of t h e Idle Air Con -
t r ol (IAC) m ot or. Th e br a ke swit ch in pu t is a lso u sed
t o disa ble ven t a n d va cu u m solen oid ou t pu t sign a ls
t o t h e speed con t r ol ser vo.

FIVE VOLT SENSOR SUPPLY—PRIMARY


OPERATION
Su pplies t h e r equ ir ed 5 volt power sou r ce t o t h e
cr a n ksh a ft posit ion sen sor, ca m sh a ft posit ion sen sor,
MAP sen sor a n d t h r ot t le posit ion sen sor.

FIVE VOLT SENSOR SUPPLY—SECONDARY


OPERATION
Su pplies t h e r equ ir ed 5 volt sou r ce t o cer t a in sen -
sor s.

FUEL LEVEL SENSOR—PCM INPUT

Fig. 2 Power Distribution Center (PDC) OPERATION


Th e P ower t r a in Con t r ol Modu le (P CM) su pplies
Th is in pu t is u sed on ly t o sen se t h a t t h e ASD r ela y
power t o t h e fu el level sen sor (fu el ga u ge sen din g
is en er gized. If t h e power t r a in con t r ol m odu le (P CM)
u n it ). Th e fu el level sen sor will t h en r et u r n a sign a l
does n ot see 12 volt s a t t h is in pu t wh en t h e ASD
t o t h e P CM t o in dica t e fu el level. Th e pu r pose of t h is
sh ou ld be a ct iva t ed, it will set a dia gn ost ic t r ou ble
fea t u r e is t o pr even t a fa lse set t in g of m isfir e a n d
code (DTC).
fu el syst em m on it or t r ou ble codes. Th is is if t h e fu el
level is less t h a n a ppr oxim a t ely 15 per cen t , or, if
BATTERY TEMPERATURE SENSOR—PCM equ ipped wit h a Lea k Det ect ion P u m p (LDP ), m or e
INPUT t h a n a ppr oxim a t ely 85 per cen t of it s r a t ed ca pa cit y.
Th is in pu t is a lso u sed t o sen d a sign a l t o t h e P CM
OPERATION for fu el ga u ge oper a t ion via t h e CCD or J 1850 bu s
P r ovides a sign a l t o t h e P CM cor r espon din g t o t h e cir cu it s.
ba t t er y t em per a t u r e.
XJ FUEL SYSTEM 14 - 29
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

CAMSHAFT POSITION SENSOR—PCM INPUT


A syn c sign a l is pr ovide by t h e ca m sh a ft posit ion
sen sor loca t ed in t h e dist r ibu t or (F ig. 3). Th e syn c
sign a l fr om t h is sen sor wor ks in con ju n ct ion wit h t h e
cr a n ksh a ft posit ion sen sor t o pr ovide t h e P ower t r a in
Con t r ol Modu le (P CM) wit h in pu t s. Th is is don e t o
est a blish a n d m a in t a in cor r ect in ject or fir in g or der.
Refer t o Ca m sh a ft P osit ion Sen sor in Gr ou p 8D,
Ign it ion Syst em for m or e in for m a t ion .

CAMSHAFT
~ - - POSITION
SENSOR

RUBBER
GROMMET
CRANKSHAFT \
POSITION \
SENSOR 80add429

Fig. 4 Crankshaft Position Sensor—Typical


t a n ce ch a n ges. Th e ch a n ge in r esist a n ce r esu lt s in a
80ae8314
differ en t in pu t volt a ge t o t h e P CM.
Fig. 3 Camshaft Position Sensor—Typical Wh en t h e en gin e is cold, t h e P CM will oper a t e in
Open Loop cycle. It will dem a n d sligh t ly r ich er a ir-
CRANKSHAFT POSITION SENSOR—PCM fu el m ixt u r es a n d h igh er idle speeds. Th is is don e
INPUT u n t il n or m a l oper a t in g t em per a t u r es a r e r ea ch ed.
Th is sen sor is a h a ll effect device t h a t det ect s Refer t o Open Loop/Closed Loop Modes of Oper a -
n ot ch es in t h e flywh eel (m a n u a l t r a n sm ission ) or t ion in t h is sect ion of t h e gr ou p for m or e in for m a t ion .
flexpla t e (a u t om a t ic t r a n sm ission ). ~ ENGINE COOLANT
Th is sen sor is u sed t o in dica t e t o t h e power t r a in TEMPERATURE SENSOR
con t r ol m odu le (P CM) t h a t a spa r k a n d or fu el in jec-
t ion even t is t o be r equ ir ed. Th e ou t pu t fr om t h is
sen sor, in con ju n ct ion wit h t h e ca m sh a ft posit ion sen -
sor sign a l, is u sed t o differ en t ia t e bet ween fu el in jec-
t ion a n d spa r k even t s.
Th e sen sor is bolt ed t o t h e t r a n sm ission bellh ou s-
in g (F ig. 4).
Refer t o Gr ou p 8D, Ign it ion Syst em for m or e
cr a n ksh a ft posit ion sen sor in for m a t ion .
Th e en gin e will n ot oper a t e if t h e P CM does n ot
r eceive a cr a n ksh a ft posit ion sen sor in pu t .

ENGINE COOLANT TEMPERATURE SENSOR—


PCM INPUT
Th e en gin e coola n t t em per a t u r e sen sor is in st a lled
in t h e t h er m ost a t h ou sin g (F ig. 5) a n d pr ot r u des in t o 80a871b7
t h e wa t er ja cket . Th e sen sor pr ovides a n in pu t volt -
a ge t o t h e P ower t r a in Con t r ol Modu le (P CM) r ela t in g Fig. 5 Engine Coolant Temperature Sensor—Typical
coola n t t em per a t u r e. Th e P CM u ses t h is in pu t a lon g
wit h in pu t s fr om ot h er sen sor s t o det er m in e in ject or
pu lse widt h a n d ign it ion t im in g. As coola n t t em per a -
t u r e va r ies, t h e coola n t t em per a t u r e sen sor ’s r esis-
14 - 30 FUEL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

EXTENDED IDLE SWITCH—PCM INPUT UPSTREAM HEATED OXYGEN SENSOR


Th e u pst r ea m O2S sen sor is loca t ed in t h e exh a u st
OPTIONAL POLICE PACKAGE WITH 4.0L ENGINE down pipe (F ig. 6). It pr ovides a n in pu t volt a ge t o t h e
ONLY P CM. Th e in pu t t ells t h e P CM t h e oxygen con t en t of
Th e ext en ded idle swit ch is u sed t o r a ise t h e t h e exh a u st ga s. Th e P CM u ses t h is in for m a t ion t o
en gin e idle speed t o a ppr oxim a t ely 1000 r pm . Th is is fin e t u n e t h e a ir /fu el r a t io by a dju st in g in ject or pu lse
wh en t h e sh ift er is in eit h er t h e P a r k or Neu t r a l widt h .
posit ion . A r ocker-t ype swit ch (ext en ded idle swit ch )
is m ou n t ed t o t h e in st r u m en t pa n el. Th is swit ch will
su pply a gr ou n d cir cu it t o t h e power t r a in con t r ol
m odu le (P CM). Th e s w itc h is a v a ila ble o n ly w ith
4.0L e n g in e w h e n s u p p lie d w ith th e o p tio n a l
p o lic e p a c k a g e .
F or t est in g a n d dia gn osis of t h is swit ch a n d it s cir-
cu it , r efer t o t h e Dia gn osis a n d Test in g sect ion of t h is
gr ou p.

GENERATOR OUTPUT—PCM INPUT DOWNSTREAM


OXYGEN SENSOR
OPERATION
P r ovides a ch a r gin g syst em volt a ge in pu t t o t h e
P ower t r a in Con t r ol Modu le (P CM). It is sen sed a t t h e 80524e39
ba t t er y in pu t t o t h e P CM.
Fig. 6 Heated Oxygen Sensors
OXYGEN SENSOR (HO2S)—PCM INPUT DOWNSTREAM HEATED OXYGEN SENSOR
Two h ea t ed O2S sen sor s a r e u sed. Th e sen sor s pr o-
Th e down st r ea m h ea t ed oxygen sen sor is loca t ed
du ce volt a ges fr om 0 t o 1 volt , depen din g u pon t h e
n ea r t h e ou t let en d of t h e ca t a lyt ic con ver t or (F ig. 6).
oxygen con t en t of t h e exh a u st ga s in t h e exh a u st
Th e down st r ea m h ea t ed oxygen sen sor in pu t is u sed
m a n ifold. Wh en a la r ge a m ou n t of oxygen is pr esen t
t o det ect ca t a lyt ic con ver t or det er ior a t ion . As t h e con -
(ca u sed by a lea n a ir /fu el m ixt u r e), t h e sen sor s pr o-
ver t or det er ior a t es, t h e in pu t fr om t h e down st r ea m
du ces a low volt a ge. Wh en t h er e is a lesser a m ou n t
sen sor begin s t o m a t ch t h e u pst r ea m sen sor in pu t
pr esen t (r ich a ir /fu el m ixt u r e) it pr odu ces a h igh er
except for a sligh t t im e dela y. By com pa r in g t h e
volt a ge. By m on it or in g t h e oxygen con t en t a n d con -
down st r ea m h ea t ed oxygen sen sor in pu t t o t h e in pu t
ver t in g it t o elect r ica l volt a ge, t h e sen sor s a ct a s a
fr om t h e u pst r ea m sen sor, t h e P CM ca lcu la t es ca t a -
r ich -lea n swit ch .
lyt ic con ver t or efficien cy.
Th e oxygen sen sor s a r e equ ipped wit h a h ea t in g
Wh en t h e ca t a lyt ic con ver t er efficien cy dr ops below
elem en t t h a t keeps t h e sen sor s a t pr oper oper a t in g
em ission st a n da r ds, t h e P CM st or es a dia gn ost ic
t em per a t u r e du r in g a ll oper a t in g m odes. Ma in t a in in g
t r ou ble code a n d illu m in a t es t h e Ma lfu n ct ion In dica -
cor r ect sen sor t em per a t u r e a t a ll t im es a llows t h e
t or La m p (MIL). F or m or e in for m a t ion , r efer t o
syst em t o en t er in t o closed loop oper a t ion soon er.
Gr ou p 25, E m ission Con t r ol Syst em s.
Also, it a llows t h e syst em t o r em a in in closed loop
oper a t ion du r in g per iods of ext en ded idle.
In Closed Loop oper a t ion , t h e P CM m on it or s t h e
IGNITION CIRCUIT SENSE—PCM INPUT
O2S sen sor in pu t (a lon g wit h ot h er in pu t s) a n d
a dju st s t h e in ject or pu lse widt h a ccor din gly. Du r in g
OPERATION
Open Loop oper a t ion , t h e P CM ign or es t h e O2S sen - Th e ign it ion cir cu it sen se in pu t t ells t h e P ower-
sor in pu t . Th e P CM a dju st s in ject or pu lse widt h t r a in Con t r ol Modu le (P CM) t h e ign it ion swit ch h a s
ba sed on pr epr ogr a m m ed (fixed) va lu es a n d in pu t s en er gized t h e ign it ion cir cu it .
fr om ot h er sen sor s.
Th e Au t om a t ic Sh u t down (ASD) r ela y su pplies ba t - INTAKE MANIFOLD AIR TEMPERATURE
t er y volt a ge t o bot h t h e u pst r ea m a n d down st r ea m SENSOR—PCM INPUT
h ea t ed oxygen sen sor s. Th e oxygen sen sor s a r e Th e in t a ke m a n ifold a ir t em per a t u r e sen sor is
equ ipped wit h a h ea t in g elem en t . Th e h ea t in g ele- in st a lled in t h e in t a ke m a n ifold wit h t h e sen sor ele-
m en t s r edu ce t h e t im e r equ ir ed for t h e sen sor s t o m en t ext en din g in t o t h e a ir st r ea m (F ig. 7) or (F ig.
r ea ch oper a t in g t em per a t u r e. 8). Th e sen sor pr ovides a n in pu t volt a ge t o t h e P ow-
er t r a in Con t r ol Modu le (P CM) in dica t in g in t a ke m a n -
XJ FUEL SYSTEM 14 - 31
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
ifold a ir t em per a t u r e. Th e in pu t is u sed a lon g wit h MANIFOLD ABSOLUTE PRESSURE (MAP)
in pu t s fr om ot h er sen sor s t o det er m in e in ject or pu lse
SENSOR—PCM INPUT
widt h . As t h e t em per a t u r e of t h e a ir-fu el st r ea m in
Th e MAP sen sor r ea ct s t o a bsolu t e pr essu r e in t h e
t h e m a n ifold va r ies, t h e sen sor r esist a n ce ch a n ges.
in t a ke m a n ifold. It pr ovides a n in pu t volt a ge t o t h e
Th is r esu lt s in a differ en t in pu t volt a ge t o t h e P CM.
P ower t r a in Con t r ol Modu le (P CM). As en gin e loa d
ch a n ges, m a n ifold pr essu r e va r ies. Th e ch a n ge in
IDLE AIR CONTROL IDLE AIR m a n ifold pr essu r e ca u ses MAP sen sor volt a ge t o
PASSAGE INLET CONTROL MODULE ch a n ge. Th e ch a n ge in MAP sen sor volt a ge r esu lt s in
a differ en t in pu t volt a ge t o t h e P CM. Th e in pu t volt -
a ge level su pplies t h e P CM wit h in for m a t ion a bou t
a m bien t ba r om et r ic pr essu r e du r in g en gin e loa d
wh ile t h e en gin e is r u n n in g. Th e P CM u ses t h is
in pu t a lon g wit h in pu t s fr om ot h er sen sor s t o a dju st
a ir-fu el m ixt u r e.
Th e MAP sen sor is m ou n t ed on t h e side of t h e
en gin e t h r ot t le body (F ig. 7). Th e sen sor is con n ect ed
t o t h e t h r ot t le body wit h a r u bber L-sh a ped fit t in g.

© 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.

Fig. 7 Intake Man. Air Temp. Sensor Location—4.0L OPERATION


Engine A sign a l is sen t fr om t h e oil pr essu r e sen sor t o t h e
LEAK DETECTION PUMP (SWITCH) SENSE— P ower t r a in Con t r ol Modu le (P CM) r ela t in g t o en gin e
oil pr essu r e.
"- ELECTRIC!~ ~
CONNECT~~ POWER GROUND

~
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

POWER STEERING PRESSURE SWITCH—PCM


INPUT
A pr essu r e sen sin g swit ch is in clu ded in t h e power
st eer in g syst em (m ou n t ed on t h e h igh -pr essu r e lin e).
INTAKE MANIFOLD Th is swit ch will be u sed on ly on veh icles equ ipped
TEMPERATURE SENSOR
wit h a 2.5L en gin e a n d power st eer in g. Th e swit ch
Fig. 8 Intake Man. Air Temp. Sensor Location—2.5L (F ig. 9) pr ovides a n in pu t t o t h e P ower t r a in Con t r ol
Engine Modu le (P CM). Th is in pu t is pr ovided du r in g per iods
of h igh pu m p loa d a n d low en gin e r pm ; su ch a s du r-
PCM INPUT in g pa r kin g m a n eu ver s. Th e P CM will t h en in cr ea se
P r ovides a n in pu t t o t h e P CM t h a t t h e lea k det ec- t h e idle speed t h r ou gh t h e Idle Air Con t r ol (IAC)
t ion pu m p (LDP ) h a s been a ct iva t ed. Refer t o Gr ou p m ot or. Th is is don e t o pr even t t h e en gin e fr om st a ll-
25, E m ission Con t r ol Syst em for LDP in for m a t ion . in g u n der t h e in cr ea sed loa d.
Wh en st eer in g pu m p pr essu r e exceeds 3275 kP a !
690 kP a (475 psi ! 100 psi), t h e n or m a lly closed
14 - 32 FUEL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
swit ch will open a n d t h e P CM will in cr ea se t h e TRANSMISSION PARK/NEUTRAL SWITCH—
en gin e idle speed. Th is will pr even t t h e en gin e fr om
PCM INPUT
st a llin g.
Th e pa r k/n eu t r a l swit ch is loca t ed on t h e t r a n sm is-
Wh en pu m p pr essu r e dr ops t o a ppr oxim a t ely 1379
sion h ou sin g a n d pr ovides a n in pu t t o t h e P ower t r a in
kP a (200 psi), t h e swit ch cir cu it will r e-close a n d
Con t r ol Modu le (P CM). Th is will in dica t e t h a t t h e
en gin e idle speed will r et u r n t o it s pr eviou s set t in g.
a u t om a t ic t r a n sm ission is in P a r k, Neu t r a l or a dr ive
ELECTRICAL gea r select ion . Th is in pu t is u sed t o det er m in e idle
CONNECTOR speed (va r yin g wit h gea r select ion ), fu el in ject or
pu lse widt h a n d ign it ion t im in g a dva n ce. Refer t o
Gr ou p 21, Tr a n sm ission s, for t est in g, r epla cem en t
a n d a dju st m en t in for m a t ion . It is a lso u sed a s a con -
dit ion for speed con t r ol oper a t ion .

THROTTLE POSITION SENSOR (TPS)—PCM


INPUT
Th e TP S is m ou n t ed on t h e t h r ot t le body (F ig. 7).
Th e TP S is a va r ia ble r esist or t h a t pr ovides t h e P ow-
er t r a in Con t r ol Modu le (P CM) wit h a n in pu t sign a l
(volt a ge) t h a t r epr esen t s t h r ot t le bla de posit ion . Th e
sen sor is con n ect ed t o t h e t h r ot t le bla de sh a ft . As t h e
posit ion of t h e t h r ot t le bla de ch a n ges, t h e r esist a n ce
of t h e TP S ch a n ges.
Th e P CM su pplies a ppr oxim a t ely 5 volt s t o t h e
TP S. Th e TP S ou t pu t volt a ge (in pu t sign a l t o t h e
P CM) r epr esen t s t h e t h r ot t le bla de posit ion . Th e
Fig. 9 Power Steering Pump Pressure Switch—2.5L P CM r eceives a n in pu t sign a l volt a ge fr om t h e TP S.
Engine Th is will va r y in a n a ppr oxim a t e r a n ge of fr om .26
SENSOR RETURN—PCM INPUT volt s a t m in im u m t h r ot t le open in g (idle), t o 4.49 volt s
a t wide open t h r ot t le. Alon g wit h in pu t s fr om ot h er
OPERATION sen sor s, t h e P CM u ses t h e TP S in pu t t o det er m in e
Sen sor Ret u r n pr ovides a low n oise gr ou n d r efer- cu r r en t en gin e oper a t in g con dit ion s. In r espon se t o
en ce for a ll en gin e con t r ol syst em sen sor s. en gin e oper a t in g con dit ion s, t h e P CM will a dju st fu el
in ject or pu lse widt h a n d ign it ion t im in g.
SPEED CONTROL SWITCHES—PCM INPUT
Two sepa r a t e speed con t r ol swit ch m odu les a r e VEHICLE SPEED AND DISTANCE SENSOR—
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 PCM INPUT
side of t h e dr iver ’s a ir ba g m odu le. Wit h in t h e t wo Th e veh icle speed sen sor is loca t ed on t h e speed-
swit ch m odu les, five m o m e n ta ry con t a ct swit ch es, om et er pin ion gea r a da pt er (F ig. 10) or (F ig. 11). Th e
su ppor t in g seven differ en t speed con t r ol fu n ct ion s pin ion gea r a da pt er is loca t ed on t h e ext en sion h ou s-
a r e u sed. Th e ou t pu t s fr om t h ese swit ch es a r e fil- in g of t h e t r a n sm ission (dr iver s side—2WD), or on
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 t h e t r a n sfer ca se (4WD). Th e sen sor in pu t is u sed by
(P CM) det er m in es wh ich ou t pu t h a s been a pplied t h e power t r a in con t r ol m odu le (P CM) t o det er m in e
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 veh icle speed a n d dist a n ce t r a veled.
volt a ge is m ea su r ed by t h e P CM t o det er m in e wh ich Th e speed sen sor gen er a t es 8 pu lses per sen sor
swit ch fu n ct ion h a s been select ed. r evolu t ion . Th ese sign a ls, in con ju n ct ion wit h a
A speed con t r ol in dica t or la m p, loca t ed on t h e closed t h r ot t le sign a l fr om t h e t h r ot t le posit ion sen -
in st r u m en t pa n el clu st er is en er gized by t h e P CM via sor, in dica t e a closed t h r ot t le deceler a t ion t o t h e
t h e CCD Bu s. Th is occu r s wh en speed con t r ol syst em P CM. Wh en t h e veh icle is st opped a t idle, a closed
power h a s been t u r n ed ON, a n d t h e en gin e is r u n - t h r ot t le sign a l is r eceived by t h e P CM (bu t a speed
n in g. sen sor sign a l is n ot r eceived).
Th e t wo swit ch m odu les a r e la beled: ON/OF F, SE T, Un der deceler a t ion con dit ion s, t h e P CM a dju st s
RE SUME /ACCE L, CANCE L a n d COAST. Refer t o t h e idle a ir con t r ol (IAC) m ot or t o m a in t a in a desir ed
Gr ou p 8H , Speed Con t r ol Syst em for m or e in for m a - MAP va lu e. Un der idle con dit ion s, t h e P CM a dju st s
t ion . t h e IAC m ot or t o m a in t a in a desir ed en gin e speed.
XJ FUEL SYSTEM 14 - 33
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

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 ).

VEHICLE AUTO SHUTDOWN (ASD) RELAY—PCM


SPEED OUTPUT
SENSOR
80a35409 DESCRIPTION
Th e ASD r ela y is loca t ed in t h e P ower Dist r ibu t ion
Fig. 11 Vehicle Speed Sensor Location—4WD— Cen t er (P DC).
Typical
AIR CONDITIONING (A/C) CLUTCH RELAY— OPERATION
Th e ASD su pplies ba t t er y volt a ge t o t h e fu el in jec-
PCM OUTPUT t or s a n d ign it ion coil(s). Wit h cer t a in em ission s pa ck-
Th e A/C r ela y is loca t ed in t h e P ower Dist r ibu t ion
a ges it a lso su pplys volt a ge t o t h e oxygen sen sor
Cen t er (P DC). Th e P DC is loca t ed in t h e en gin e com -
h ea t in g elem en t s. Th e gr ou n d cir cu it for t h e coil in
pa r t m en t (F ig. 12). Refer t o la bel on P DC cover for
t h e ASD r ela y is con t r olled by t h e P ower t r a in Con -
r ela y loca t ion .
t r ol Modu le (P CM). Th e P CM oper a t es t h e r ela y by
swit ch in g t h e gr ou n d cir cu it on a n d off.
14 - 34 FUEL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

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

Fig. 14 Fuel Rail and Injectors—4.0L 6–Cyl. Engine


NUMBERED
TAG
80aac28e

Fig. 13 Data Link Connector Location


DUTY CYCLE EVAP PURGE SOLENOID
VALVE-PCM OUTPUT
Refer t o Gr ou p 25, E m ission Con t r ol Syst em for
in for m a t ion .

FUEL INJECTORS—PCM OUTPUT


Six in dividu a l fu el in ject or s a r e u sed wit h t h e 4.0L
6-cylin der en gin e (F ig. 14). F ou r in dividu a l fu el in jec-
t or s a r e u sed wit h t h e 2.5L 4-cylin der en gin e (F ig.
15). Th e fu el in ject or s a r e a t t a ch ed t o t h e fu el r a il.
Th e n ozzle en ds of t h e in ject or s a r e posit ion ed in t o
open in gs in t h e in t a ke m a n ifold ju st a bove t h e in t a ke 80add397
va lve por t s of t h e cylin der h ea d. Th e en gin e wir in g
h a r n ess con n ect or for ea ch fu el in ject or is equ ipped Fig. 15 Fuel Rail and Injectors—2.5L 4–Cyl. Engine
XJ FUEL SYSTEM 14 - 35
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

FUEL PUMP RELAY-PCM OUTPUT posit ion ed wh en t h e ign it ion key is t u r n ed t o t h e On


posit ion .
DESCRIPTION A (fa ct or y a dju st ed) set scr ew is u sed t o m ech a n i-
Th e fu el pu m p r ela y is loca t ed in t h e P ower Dist r i- 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
bu t ion Cen t er (P DC). 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
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
OPERATION con t r olled by t h e P CM.
Th e P CM en er gizes t h e elect r ic fu el pu m p t h r ou gh
t h e fu el pu m p r ela y. Ba t t er y volt a ge is a pplied t o t h e IGNITION COIL—PCM OUTPUT
fu el pu m p r ela y wh en t h e ign it ion key is ON. Th e Syst em volt a ge fr om t h e Au t om a t ic Sh u t down
r ela y is en er gized wh en a gr ou n d sign a l is pr ovided (ASD) r ela y is su pplied t o t h e ign it ion coil posit ive
by t h e P CM. t er m in a l. Th e P ower t r a in Con t r ol Modu le (P CM)
Th e fu el pu m p will oper a t e for a ppr oxim a t ely t h r ee oper a t es t h e ign it ion coil. Ig n itio n tim in g is n o t
secon ds u n less t h e en gin e is oper a t in g or t h e st a r t er a d ju s ta ble . Th e P CM a dju st s ign it ion t im in g t o
m ot or is en ga ged. m eet ch a n gin g en gin e oper a t in g con dit ion s.
Refer t o Gr ou p 8D, Ign it ion Syst em for a ddit ion a l
GENERATOR FIELD SOURCE (+)—PCM in for m a t ion .
OUTPUT
LEAK DETECTION PUMP—PCM OUTPUT
OPERATION Cer t a in en gin es wit h cer t a in em ission s pa cka ges
a r e equ ipped wit h a lea k det ect ion pu m p (LDP ). Th e
Th is ou t pu t fr om t h e P ower t r a in Con t r ol Modu le
LDP is a ct iva t ed t h r ou gh t h is P CM ou t pu t . Refer t o
(P CM) r egu la t es ch a r gin g syst em volt a ge t o t h e gen -
Gr ou p 25, E m ission Con t r ol Syst em for a ddit ion a l
er a t or field sou r ce (+) cir cu it . Th e volt a ge r a n ge is
in for m a t ion .
12.9 t o 15.0 volt s. Models of pr eviou s yea r s h a d u sed
t h e ASD r ela y (dir ect ly) t o a pply t h e 12 volt + power
su pply t o t h e gen er a t or field sou r ce (+) cir cu it . RADIATOR FAN RELAY—PCM OUTPUT
An elect r ic r a dia t or coolin g fa n is u sed wit h cer t a in
GENERATOR FIELD DRIVER (-)—PCM OUTPUT m odels/en gin es. It is con t r olled by t h e power t r a in
con t r ol m odu le (P CM) t h r ou gh t h e r a dia t or fa n r ela y.
OPRATION Th e r ela y is en er gized wh en coola n t t em per a t u r e is
Th is ou t pu t fr om t h e P ower t r a in Con t r ol Modu le a bove 103°C (217°F ). It will t h en de-en er gize wh en
(P CM) r egu la t es ch a r gin g syst em gr ou n d con t r ol t o coola n t t em per a t u r e dr ops t o 98°C (208°F ). Refer t o
t h e gen er a t or field dr iver (-) cir cu it . Gr ou p 7, Coolin g Syst em s for m or e in for m a t ion .
Th e r ela y is loca t ed in t h e power dist r ibu t ion cen -
t er (P DC) (F ig. 12).
GENERATOR LAMP—PCM OUTPUT
If t h e power t r a in con t r ol m odu le (P CM) sen ses a
low ch a r gin g con dit ion in t h e ch a r gin g syst em , it will
MALFUNCTION INDICATOR LAMP—ECM/PCM
illu m in a t e t h e gen er a t or la m p (if equ ipped) on t h e OUTPUT
in st r u m en t pa n el. F or exa m ple, du r in g low idle wit h Refer t o Gr ou p 25, E m ission Con t r ol Syst em for
a ll a ccessor ies t u r n ed on , t h e la m p m a y m om en t a r ily in for m a t ion .
go on . Refer t o Gr ou ps 8A a n d 8C for ch a r gin g sys-
t em in for m a t ion . SPEED CONTROL SOLENOIDS—PCM OUTPUT
Speed con t r ol oper a t ion is r egu la t ed by t h e power-
IDLE AIR CONTROL (IAC) MOTOR—PCM t r a in con t r ol m odu le (P CM). Th e P CM con t r ols t h e
OUTPUT va cu u m t o t h e t h r ot t le a ct u a t or t h r ou gh t h e speed
con t r ol va cu u m a n d ven t solen oids. Refer t o Gr ou p
Th e IAC m ot or is m ou n t ed on t h e t h r ot t le body
8H for Speed Con t r ol In for m a t ion .
(F ig. 7) a n d is con t r olled by t h e P ower t r a in Con t r ol
Modu le (P CM).
Th e t h r ot t le body h a s a n a ir con t r ol pa ssa ge t h a t TACHOMETER—PCM OUTPUT
pr ovides a ir for t h e en gin e a t idle (t h e t h r ot t le pla t e Th e power t r a in con t r ol m odu le (P CM) su pplies
is closed). Th e IAC m ot or pin t le pr ot r u des in t o t h e en gin e r pm va lu es t o t h e in st r u m en t clu st er t a ch om -
a ir con t r ol pa ssa ge a n d r egu la t es a ir flow t h r ou gh it . et er. Refer t o Gr ou p 8E for t a ch om et er in for m a t ion .
Ba sed on va r iou s sen sor in pu t s, t h e P CM a dju st s
en gin e idle speed by m ovin g t h e IAC m ot or pin t le in THROTTLE BODY
a n d ou t of t h e a ir con t r ol pa ssa ge. Th e IAC m ot or is F ilt er ed a ir fr om t h e a ir clea n er en t er s t h e in t a ke
m a n ifold t h r ou gh t h e t h r ot t le body (F ig. 16). F u el
14 - 36 FUEL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
does n ot en t er t h e in t a ke m a n ifold t h r ou gh t h e t h r ot -
t le body. F u el is spr a yed in t o t h e m a n ifold by t h e fu el
in ject or s. Th e t h r ot t le body is m ou n t ed on t h e in t a ke
m a n ifold. It con t a in s a n a ir con t r ol pa ssa ge (F ig. 16)
con t r olled by a n Idle Air Con t r ol (IAC) m ot or. Th e a ir
con t r ol pa ssa ge is u sed t o su pply a ir for idle con di-
t ion s. A t h r ot t le va lve (pla t e) is u sed t o su pply a ir for
a bove idle con dit ion s.

IDLE AIR CONTROL IDLE AIR


PASSAGE INLET CONTROL MODULE

Fig. 17 Powertrain Control Module (PCM)


(3) In spect fu el pu m p r ela y a n d a ir con dit ion in g
com pr essor clu t ch r ela y (if equ ipped). In spect ASD
r ela y con n ect ion s. In spect st a r t er m ot or r ela y con n ec-
t ion s. In spect r ela ys for sign s of ph ysica l da m a ge a n d
I cor r osion . Th e r ela ys a r e loca t ed in P ower Dist r ibu -
© I
t ion Cen t er (P DC) (F ig. 18). Refer t o la bel on P DC
a;zt.2"Z.a~-:..:.---'...,.._...1'i
1' ,( INTAKE MANIFOLD
cover for r ela y loca t ion .
AIR TEMPERATURE
MAP SENSOR SENSOR POWER DISTRIBUTION,___,..,(l;ih,-;...,:;;.~~~
80aac28d
CENTER (PDC)
' I I\~ \\' __)~~:--'-'-'---I ----i;;~.u..
Fig. 16 Throttle Body (4.0L Engine Shown)
Th e Th r ot t le P osit ion Sen sor (TP S), IAC m ot or a n d
Ma n ifold Absolu t e P r essu r e sen sor (MAP ) a r e
a t t a ch ed t o t h e t h r ot t le body. Th e a cceler a t or peda l
ca ble, speed con t r ol ca ble (wh en equ ipped) a n d a u t o-
m a t ic t r a n sm ission con t r ol ca ble (wh en equ ipped) a r e
con n ect ed t o t h e t h r ot t le a r m .
A (fa ct or y a dju st ed) set scr ew is u sed t o m ech a n i-
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
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
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
con t r olled by t h e P CM.

DI AGN OSI S AN D T EST I N G


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. Th is
sh ou ld be don e befor e a t t em pt in g t o dia gn ose or ser- Fig. 18 Power Distribution Center (PDC)
vice t h e fu el in ject ion syst em . A visu a l ch eck will
h elp spot t h ese fa u lt s a n d sa ve u n n ecessa r y t est a n d (4) In spect ign it ion coil con n ect ion s. Ver ify coil sec-
dia gn ost ic t im e. A t h or ou gh visu a l in spect ion will on da r y ca ble is fir m ly con n ect ed t o coil (F ig. 19) or
in clu de t h e followin g ch ecks: (F ig. 20).
(1) Ver ify t h e t h r ee 32–wa y elect r ica l con n ect or s (5) Ver ify dist r ibu t or ca p is cor r ect ly a t t a ch ed t o
a r e fu lly in ser t ed in t o t h e con n ect or of t h e power- dist r ibu t or. Be su r e spa r k plu g ca bles a r e fir m ly con -
t r a in con t r ol m odu le (P CM) (F ig. 17). n ect ed t o dist r ibu t or ca p a n d spa r k plu gs a r e in t h eir
(2) In spect ba t t er y ca ble con n ect ion s. Be su r e t h ey cor r ect fir in g or der. Be su r e coil ca ble is fir m ly con -
a r e clea n a n d t igh t . n ect ed t o dist r ibu t or ca p a n d coil. Be su r e ca m sh a ft
XJ FUEL SYSTEM 14 - 37
DI AGN OSI S AN D T EST I N G (Cont inue d)
(9) In spect fu el t u be qu ick-con n ect fit t in g-t o-fu el
r a il con n ect ion s.
(10) Ver ify h ose con n ect ion s t o a ll por t s of va cu u m
fit t in gs on in t a ke m a n ifold a r e t igh t a n d n ot lea kin g.
(11) In spect a cceler a t or ca ble, t r a n sm ission t h r ot -
t le ca ble (if equ ipped) a n d cr u ise con t r ol ca ble con -
n ect ion s (if equ ipped). Ch eck t h eir con n ect ion s t o
t h r ot t le a r m of t h r ot t le body for a n y bin din g or
r est r ict ion s.
(12) If equ ipped wit h va cu u m br a ke boost er, ver ify
va cu u m boost er h ose is fir m ly con n ect ed t o fit t in g on
in t a ke m a n ifold. Also ch eck con n ect ion t o br a ke va c-
u u m boost er.
(13) In spect a ir clea n er in let a n d a ir clea n er ele-
m en t for dir t or r est r ict ion s.
(14) In spect r a dia t or gr ille a r ea , r a dia t or fin s a n d
a ir con dit ion in g con den ser for r est r ict ion s.
(15) Ver ify in t a ke m a n ifold a ir t em per a t u r e sen sor
wir e con n ect or is fir m ly con n ect ed t o h a r n ess con n ec-
Fig. 19 Ignition Coil—2.5L Engine t or (F ig. 21) or (F ig. 22).

"- 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

Fig. 29 Fuel Tank Connections at Front of Fuel Tank


J9414-60 OPERATION
• Ter m in a l n u m ber 30 is con n ect ed t o ba t t er y volt -
a ge. F or bot h t h e ASD a n d fu el pu m p r ela ys, t er m i-
Fig. 27 Vehicle Speed Sensor—4WD
n a l 30 is con n ect ed t o ba t t er y volt a ge a t a ll t im es.
ASD AND FUEL PUMP RELAYS • Th e P CM gr ou n ds t h e coil side of t h e r ela y
Th e fo llo w in g d e s c rip tio n o f o p e ra tio n a n d t h r ou gh t er m in a l n u m ber 85.
te s ts a p p ly o n ly to th e Au to m a tic S h u td o w n • Ter m in a l n u m ber 86 su pplies volt a ge t o t h e coil
(AS D ) a n d fu e l p u m p re la y s . Th e t er m in a ls on t h e side of t h e r ela y.
bot t om of ea ch r ela y a r e n u m ber ed (F ig. 30) or (F ig. • Wh en t h e P CM de-en er gizes t h e ASD a n d fu el
31). pu m p r ela ys, t er m in a l n u m ber 87A con n ect s t o t er m i-
n a l 30. Th is is t h e Off posit ion . In t h e off posit ion ,
volt a ge is n ot su pplied t o t h e r est of t h e cir cu it . Ter-
m in a l 87A is t h e cen t er t er m in a l on t h e r ela y.
14 - 40 FUEL SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
of t h e ju m per wir e t o t h e gr ou n d side of a 12 volt
power sou r ce.
(6) Con n ect on e en d of a n ot h er ju m per wir e (16
I ll)
ga u ge or sm a ller ) t o t h e power side of t h e 12 volt
-7~~_ i'-_oR_
, coMr co
power sou r ce. D o n o t a tta c h th e o th e r e n d o f th e

-+~ i
ju m p e r w ire to th e re la y a t th is tim e .

WARNING: DO NOT ALLOW OHMMETER TO CON-


TERMINAL LEGEND TACT TERMINALS 85 OR 86 DURING THIS TEST.
87A 87 85
NUMBER IDENTIFICATION
tJ~ 30 COMMON FEED (7) At t a ch t h e ot h er en d of t h e ju m per wir e t o
1··~ 85
86
COIL GROUND
COIL BATTERY
r ela y t er m in a l 86. Th is a ct iva t es t h e r ela y. Th e oh m -
m et er sh ou ld n ow sh ow con t in u it y bet ween r ela y t er-
30 86 87 NORMALLY OPEN
87A NORMALLY CLOSED m in a ls 87 a n d 30. Th e oh m m et er sh ou ld n ot sh ow
con t in u it y bet ween r ela y t er m in a ls 87A a n d 30.
9514-16
(8) Discon n ect ju m per wir es.
Fig. 30 ASD and Fuel Pump Relay Terminals (9) Repla ce t h e r ela y if it did n ot pa ss t h e con t in u -
it y a n d r esist a n ce t est s. If t h e r ela y pa ssed t h e t est s,
RELAY TERMINALS RELAY CAVITIES it oper a t es pr oper ly. Ch eck t h e r em a in der of t h e ASD
a n d fu el pu m p r ela y cir cu it s. Refer t o t h e Wir in g
Dia gr a m s.

MANIFOLD ABSOLUTE PRESSURE (MAP)


SENSOR TEST
To per for m a com plet e t est of MAP sen sor (F ig. 32)
a n d it s cir cu it r y, r efer t o DRB sca n t ool a n d a ppr o-
pr ia t e P ower t r a in Dia gn ost ics P r ocedu r es m a n u a l. To
85 87 J958A-2
t est t h e MAP sen sor on ly, r efer t o t h e followin g:
TERMINAL LEGEND
NUMBER IDENTIFICATION (1) In spect r u bber L-sh a ped fit t in g fr om MAP sen -
30 COMMON FEED sor t o t h r ot t le body (F ig. 33). Repa ir a s n ecessa r y.
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN IDLE AIR CONTROL
1----=87'---A-+---N~ORMALLY CLOSED IDLE AIR
PASSAGE INLET CONTROL MODULE
Fig. 31 ASD and Fuel Pump Relay Terminals
• Wh en t h e P CM en er gizes t h e ASD a n d fu el
pu m p r ela ys, t er m in a l 87 con n ect s t o t er m in a l 30.
Th is is t h e On posit ion . Ter m in a l 87 su pplies volt a ge
t o t h e r est of t h e cir cu it .

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

a n oh m m et er t o ch eck t h e r esist a n ce bet ween t er m i- _n--:.~/..i.-...,..1...-.-'--.,...i....!._'..J_,_r_,,-,,1-"- ,, ,l INTAKE MANIFOLD


n a ls 85 a n d 86. Th e r esist a n ce sh ou ld be bet ween 75 AIR TEMPERATURE
!5 oh m s. MAP SENSOR SENSOR
80aac28d
(3) Con n ect t h e oh m m et er bet ween t er m in a ls 30
a n d 87A. Th e oh m m et er sh ou ld sh ow con t in u it y
Fig. 32 Sensor Location (4.0L Engine Shown)
bet ween t er m in a ls 30 a n d 87A.
(4) Con n ect t h e oh m m et er bet ween t er m in a ls 87 CAUTION: When testing the MAP sensor, be sure
a n d 30. Th e oh m m et er sh ou ld n ot sh ow con t in u it y a t that the harness wires are not damaged by the test
t h is t im e. meter probes.
(5) Con n ect on e en d of a ju m per wir e (16 ga u ge or
sm a ller ) t o r ela y t er m in a l 85. Con n ect t h e ot h er en d (2) Test MAP sen sor ou t pu t volt a ge a t MAP sen sor
con n ect or bet ween t er m in a ls A a n d B (F ig. 34). Wit h
XJ FUEL SYSTEM 14 - 41
DI AGN OSI S AN D T EST I N G (Cont inue d)

OXYGEN (O2S) SENSORS


THROTTLE To per for m a com plet e t est of t h e O2S sen sor s a n d
BODY t h eir cir cu it r y, r efer t o t h e DRB sca n t ool a n d a ppr o-
pr ia t e P ower t r a in Dia gn ost ics P r ocedu r es m a n u a l. To
t est t h e O2S sen sor s on ly, r efer t o t h e followin g:
Th e u pst r ea m O2S sen sor is loca t ed on t h e exh a u st
down pipe (F ig. 35).
Th e down st r ea m O2S sen sor is loca t ed n ea r t h e
ou t let en d of t h e ca t a lyt ic con ver t er (F ig. 35).

80a6l168

Fig. 33 Rubber L-Shaped Fitting—MAP Sensor-to-


Throttle Body DOWNSTREAM
OXYGEN SENSOR
ign it ion swit ch ON a n d en gin e OF F, ou t pu t volt a ge
sh ou ld be 4-t o-5 volt s. Th e volt a ge sh ou ld dr op t o 1.5-
t o-2.1 volt s wit h a h ot , n eu t r a l idle speed con dit ion .
80524e39

Fig. 35 Oxygen Sensor Location


A= GROUND
E a ch O2S h ea t in g elem en t ca n be t est ed wit h a n
B = OUTPUT VOLTAGE SIGNAL
oh m m et er a s follows:
C = 5-VOLT SUPPLY
Discon n ect t h e O2S sen sor con n ect or. Con n ect t h e
MAP oh m m et er t est lea ds a cr oss t h e wh it e wir e t er m in a ls
SENSOR of t h e sen sor con n ect or. Resist a n ce sh ou ld be
bet ween 4.5 !.5 oh m s a n d 7 oh m s. Repla ce t h e sen -
sor if t h e oh m m et er displa ys a n in fin it y (open ) r ea d-
in g.

ENGINE COOLANT TEMPERATURE SENSOR


To per for m a com plet e t est of t h e en gin e coola n t
C B A t em per a t u r e sen sor a n d it s cir cu it r y, r efer t o DRB
8056d9f7 sca n t ool a n d a ppr opr ia t e P ower t r a in Dia gn ost ics
P r ocedu r es m a n u a l. To t est t h e sen sor on ly, r efer t o
Fig. 34 MAP Sensor Connector Terminals—Typical t h e followin g:
(3) Test P ower t r a in Con t r ol Modu le (P CM) ca vit y (1) Discon n ect wir e h a r n ess con n ect or fr om coola n t
A-27 for sa m e volt a ge descr ibed a bove t o ver ify wir e t em per a t u r e sen sor (F ig. 36).
h a r n ess con dit ion . Repa ir a s n ecessa r y. (2) Test t h e r esist a n ce of sen sor wit h a h igh in pu t
(4) Test MAP sen sor su pply volt a ge a t sen sor con - im peda n ce (digit a l) volt -oh m m et er. Refer t o SE NSOR
n ect or bet ween t er m in a ls A a n d C (F ig. 34) wit h ign i- RE SISTANCE (OH MS)—COOLANT TE MP E RA-
t ion ON. Th e volt a ge sh ou ld be a ppr oxim a t ely 5 volt s TURE SE NSOR/INTAKE AIR TE MP E RATURE
(!0.5V). F ive volt s (!0.5V) sh ou ld a lso be a t ca vit y SE NSOR ch a r t . Th e r esist a n ce (a s m ea su r ed a cr oss
A-17 of t h e P CM wir e h a r n ess con n ect or. Repa ir or sen sor t er m in a ls) sh ou ld be wit h in r a n ge sh own in
r epla ce wir e h a r n ess a s n ecessa r y. ch a r t . If n ot , r epla ce sen sor.
(5) Test t h e MAP sen sor gr ou n d cir cu it a t sen sor (3) Test con t in u it y of t h e wir e h a r n ess bet ween t h e
con n ect or t er m in a l—A (F ig. 34) a n d P CM con n ect or P CM wir e h a r n ess con n ect or a n d t h e coola n t sen sor
A-4. Repa ir wir e h a r n ess if n ecessa r y. con n ect or t er m in a ls. Refer t o Gr ou p 8, Wir in g for t er-
Refer t o Gr ou p 8W, Wir in g Dia gr a m s for ca vit y m in a l/ca vit y loca t ion s. Repa ir t h e wir e h a r n ess if a n
loca t ion s. open cir cu it is in dica t ed.
14 - 42 FUEL SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
~ ENGINE COOLANT IDLE AIR CONTROL (IAC) MOTOR
TEMPERATURE SENSOR To per for m a com plet e t est of t h e IAC m ot or a n d
it s cir cu it r y, r efer t o DRB sca n t ool a n d a ppr opr ia t e
P ower t r a in Dia gn ost ics P r ocedu r es m a n u a l.

INTAKE MANIFOLD AIR TEMPERATURE


SENSOR
To per for m a com plet e t est of t h e in t a ke m a n ifold
a ir t em per a t u r e sen sor a n d it s cir cu it r y, r efer t o DRB
t est er a n d a ppr opr ia t e P ower t r a in Dia gn ost ics P r oce-
du r es m a n u a l. To t est t h e sen sor on ly, r efer t o t h e
followin g:
(1) Discon n ect wir e h a r n ess con n ect or fr om in t a ke
m a n ifold a ir t em per a t u r e sen sor (F ig. 37) or (F ig.
38).

IDLE AIR CONTROL IDLE AIR


80a871b7
PASSAGE INLET CONTROL MODULE
Fig. 36 Engine Coolant Temperature Sensor—
Typical
SEN SOR RESI STAN CE (OH M S)—COOLAN T
T EM PERAT U RE SEN SOR/I N TAK E AI R
T EM PERAT U RE SEN SOR

TEMPERATURE RESISTANCE (OHMS)

°CEL. °FAHR. MIN. MAX.

-40 -40 291,490 381,710 © I

-20 -4 85,850 108,390 .z;;~tz:r:z:o::i::CZ. 1


• ,l INTAKE MANIFOLD
-10 14 49,250 61,430 AIR TEMPERATURE
MAP SENSOR SENSOR
0 32 29,330 35,990 80aac28d

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.

THROTTLE BODY MINIMUM AIR FLOW CHECK


PROCEDURE
Th e followin g t est pr ocedu r e h a s been developed t o FIXED
ch eck t h r ot t le body ca libr a t ion s for cor r ect idle con di- ORIFICE
t ion s. Th e pr ocedu r e sh ou ld be u sed t o dia gn ose t h e FITTING
t h r ot t le body for con dit ion s t h a t m a y ca u se idle pr ob-
lem s. Th is p ro c e d u re s h o u ld be u s e d o n ly a fte r
n o rm a l d ia g n o s tic p ro c e d u re s h a v e fa ile d to
p ro d u c e re s u lts th a t in d ic a te a th ro ttle bo d y
re la te d p ro ble m . B e s u re to c h e c k fo r p ro p e r AIR FILTER--.~ , -
COVER
o p e ra tio n o f th e id le a ir c o n tro l m o to r be fo re
p e rfo rm in g th is te s t. 8056d9f4
A specia l fixed or ifice t ool (n u m ber 6714) (F ig. 40)
m u st be u sed for t h e followin g t est . Th is t ool h a s a Fig. 41 Install Orifice Tool 2.5L 4–Cylinder Engine
fixed in t er n a l dia m et er of 0.185”. (5) Con n ect DRB sca n t ool t o 16–wa y da t a lin k
con n ect or. Th is con n ect or is loca t ed a t lower edge of
SPECIAL TOO L 6714
in st r u m en t pa n el n ea r st eer in g colu m n . Refer t o
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 for DRB oper a t ion .
(6) St a r t en gin e a n d a llow t o wa r m u p.
(7) Usin g t h e DRB sca n t ool, scr oll t h r ou gh m en u s
a s follows: select —St a n d Alon e DRB III, select 1999
Dia gn ost ics, select —E n gin e, select —Syst em Test ,
select —Min im u m Air F low.
(8) Th e DRB sca n t ool will cou n t down t o st a bilize
J9414-7 idle r pm a n d displa y m in im u m a ir flow idle r pm . Th e
idle r pm sh ou ld be bet ween 500 a n d 900 rp m . If idle
Fig. 40 6714 Fixed Orifice Tool
speed is ou t side t h ese specifica t ion s, r epla ce t h r ot t le
body. Refer t o Th r ot t le Body Rem ova l/In st a lla t ion .
(9) Discon n ect DRB sca n t ool fr om veh icle.
XJ FUEL SYSTEM 14 - 45
DI AGN OSI S AN D T EST I N G (Cont inue d)

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)

IDLE AIR CONTROL


THROTTLE POSITION SENSOR (TPS)
IDLE AIR Th e TP S is m ou n t ed t o t h e t h r ot t le body (F ig. 44)
PASSAGE INLET CONTROL MODULE
or (F ig. 45).

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

Fig. 44 Throttle Body and Sensor Locations—4.0L


Engine
IDLE AIR
TPS
CONTROL MOTOR \ IAT 80a7aec1
SENSOR
Fig. 46 TPS Mounting Screws

' 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

Fig. 45 Throttle Body and Sensor Locations—2.5L


Engine
(6) Disca r d old t h r ot t le body-t o-in t a ke m a n ifold
ga sket .

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)

IDLE AIR CONTROL (IAC) MOTOR


Th e IAC m ot or is loca t ed on t h e side of t h e t h r ot t le THROTTLE
body (F ig. 44) or (F ig. 45). BODY

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

Fig. 49 MAP Sensor Mounting


(3) In st a ll MAP sen sor m ou n t in g bolt s (scr ews).
Tigh t en scr ews t o 3 N·m (25 in . lbs.) t or qu e.
(4) In st a ll a ir clea n er in t a ke t u be.

DUTY CYCLE EVAP CANISTER PURGE


Fig. 48 Mounting Bolts (Screws)—IAC Motor SOLENOID
INSTALLATION Refer t o Gr ou p 25, E m ission Con t r ol Syst em for
r em ova l/in st a lla t ion pr ocedu r es.
(1) In st a ll IAC m ot or t o t h r ot t le body.
(2) In st a ll a n d t igh t en t wo m ou n t in g bolt s (scr ews)
t o 7 N·m (60 in . lbs.) t or qu e.
POWERTRAIN CONTROL MODULE (PCM)
(3) In st a ll elect r ica l con n ect or. Th e P CM is loca t ed in t h e en gin e com pa r t m en t
(4) In st a ll a ir clea n er t u be t o t h r ot t le body. n ext t o t h e a ir clea n er a ssem bly (F ig. 50).

MANIFOLD ABSOLUTE PRESSURE (MAP)


SENSOR
Th e MAP sen sor is m ou n t ed t o t h e side of t h e
t h r ot t le body (F ig. 44) or (F ig. 45). An L-sh a ped r u b-
ber fit t in g is u sed t o con n ect t h e MAP sen sor t o
t h r ot t le body (F ig. 49).

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)

Fig. 52 Power Steering Pressure Switch


804d8eb2
(2) P la ce a sm a ll con t a in er or sh op t owel ben ea t h
swit ch t o collect a n y excess flu id.
Fig. 51 PCM Mounting (3) Rem ove swit ch . Use ba ck-u p wr en ch on power
(2) Rem ove cover over elect r ica l con n ect or s. Cover st eer in g lin e t o pr even t lin e ben din g.
sn a ps on t o P CM.
(3) Ca r efu lly u n plu g t h e t h r ee 32–wa y con n ect or s INSTALLATION
(F ig. 51) fr om P CM. (1) In st a ll power st eer in g swit ch in t o power st eer-
(4) Rem ove t h r ee P CM m ou n t in g bolt s a n d r em ove in g lin e.
P CM fr om veh icle. (2) Tigh t en t o 14–22 N·m (124–195 in . lbs.) t or qu e.
(3) Con n ect elect r ica l con n ect or t o swit ch .
INSTALLATION (4) Ch eck power st eer in g flu id a n d a dd a s n eces-
(1) In st a ll P CM a n d m ou n t in g bolt s t o veh icle. sa r y.
(2) Tigh t en bolt s t o 4 N·m (35 in . lbs.). (5) St a r t en gin e a n d a ga in ch eck power st eer in g
(3) Ch eck pin con n ect or s in t h e P CM a n d t h e t h r ee flu id. Add flu id if n ecessa r y.
32–wa y con n ect or s for cor r osion or da m a ge. Also, t h e
pin h eigh t s in con n ect or s sh ou ld a ll be sa m e. Repa ir OXYGEN SENSOR
a s n ecessa r y befor e in st a llin g con n ect or s. Th e u pst r ea m O2S sen sor is loca t ed in exh a u st
(4) In st a ll t h r ee 32–wa y con n ect or s. down pipe. Th e down st r ea m sen sor is loca t ed n ea r
(5) In st a ll cover over elect r ica l con n ect or s. Cover ou t let en d of ca t a lyt ic con ver t er. Refer t o (F ig. 53).
sn a ps on t o P CM.
(6) In st a ll ba t t er y ca ble.
(7) Use t h e DRB sca n t ool t o r epr ogr a m n ew P CM
wit h veh icles or igin a l Iden t ifica t ion Nu m ber (VIN)
a n d or igin a l veh icle m ilea ge.

POWER STEERING PRESSURE SWITCH—2.5L


ENGINE
Th is swit ch is n ot u sed wit h 4.0L six-cylin der
en gin es.
Th e power st eer in g pr essu r e swit ch is in st a lled in
DOWNSTREAM
t h e power st eer in g h igh -pr essu r e h ose (F ig. 52). OXYGEN SENSOR
REMOVAL
(1) Discon n ect elect r ica l con n ect or fr om power 80524e39
st eer in g pr essu r e swit ch . Fig. 53 Oxygen Sensor Locations
XJ FUEL SYSTEM 14 - 49
REM OVAL AN D I N STALLAT I ON (Cont inue d)
REMOVAL
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
ELEMENT
SENSOR.
{FILTER)

(1) Ra ise a n d su ppor t veh icle.


(2) Discon n ect wir e con n ect or fr om O2S sen sor.

CAUTION: When disconnecting sensor electrical


connector, do not pull directly on wire going into
sensor.

(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 Fig. 54 Air Cleaner Housing and Element (Filter)


Th r ea ds of n ew oxygen sen sor s a r e fa ct or y coa t ed
wit h a n t i-seize com pou n d t o a id in r em ova l. D O
N OT a d d a n y a d d itio n a l a n ti-s e ize c o m p o u n d to
th re a d s o f a n e w o x y g e n s e n s o r.
(1) In st a ll O2S sen sor. Tigh t en t o 30 N·m (22 ft .
lbs.) t or qu e.
(2) Con n ect O2S sen sor wir e con n ect or.
(3) Lower veh icle.

AIR CLEANER ELEMENT (FILTER)


REMOVAL
(1) Un lock a ir t u be cla m p (F ig. 54) a t a ir clea n er
cover. To u n lock cla m p, a t t a ch a dju st a ble plier s t o
cla m p a n d r ot a t e plier s a s sh own in (F ig. 55). )9314-136
(2) Rem ove a ir t u be a t cover. Fig. 55 Clamp Removal
(3) P r y ba ck t h r ee clips r et a in in g a ir clea n er cover
t o a ir clea n er h ou sin g.
(4) Rem ove h ou sin g cover a n d r em ove a ir clea n er
elem en t . 7LEPLIERS
(5) Clea n in side of h ou sin g befor e r epla cin g ele-
m en t .

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).

Fig. 56 Clamp Installation


14 - 50 FUEL SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

ENGINE COOLANT TEMPERATURE SENSOR IDLE AIR CONTROL IDLE AIR


PASSAGE INLET CONTROL MODULE
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.

Th e coola n t t em per a t u r e sen sor is in st a lled in t h e


t h er m ost a t h ou sin g (F ig. 57).
ENGINE COOLANT
~TEMPERATURE SENSOR

l[J

© I

1, ,l INTAKE MANIFOLD
AIR TEMPERATURE
MAP SENSOR SENSOR
soaac28d

Fig. 58 IAT Sensor Location—4.0L Engine

Fig. 57 Engine Coolant Temperature Sensor—


Typical
REMOVAL
(1) P a r t ia lly dr a in coolin g syst em u n t il coola n t
level is below cylin der h ea d. Obser ve t h e WARN -
IN GS in Gr ou p 7, Coolin g.
(2) Discon n ect coola n t t em per a t u r e sen sor wir e
con n ect or.
(3) Rem ove sen sor fr om t h er m ost a t h ou sin g.
Fig. 59 IAT Sensor Location—2.5L Engine
INSTALLATION
(1) Apply sea la n t t o sen sor t h r ea ds (n ew r epla ce- REMOVAL
m en t sen sor s will h a ve sea la n t a lr ea dy a pplied). (1) Discon n ect elect r ica l con n ect or fr om IAT sen -
(2) In st a ll coola n t t em per a t u r e sen sor in t o t h er m o- sor.
st a t h ou sin g. Tigh t en t o 11 N·m (8 ft . lbs.) t or qu e. (2) Rem ove sen sor fr om in t a ke m a n ifold.
(3) Con n ect wir e con n ect or.
(4) F ill coolin g syst em . Refer t o Gr ou p 7, Coolin g INSTALLATION
Syst em . (1) In st a ll IAT sen sor in t o in t a ke m a n ifold.
Tigh t en sen sor t o 28 N·m (20 ft . lbs.) t or qu e.
INTAKE MANIFOLD AIR TEMPERATURE (2) Con n ect elect r ica l con n ect or t o sen sor.
SENSOR
Th e in t a ke m a n ifold a ir t em per a t u r e (IAT) sen sor VEHICLE SPEED SENSOR
is in st a lled in t o in t a ke m a n ifold plen u m n ea r t h r ot t le Th e veh icle speed sen sor is loca t ed on t h e speed-
body (F ig. 58) or (F ig. 59). om et er pin ion gea r a da pt er (F ig. 60) or (F ig. 61). Th e
pin ion gea r a da pt er is loca t ed on t h e ext en sion h ou s-
in g of t r a n sm ission (dr iver s side).
XJ FUEL SYSTEM 14 - 51
REM OVAL AN D I N STALLAT I ON (Cont inue d)

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

O2S (Oxygen Sensor) Remover/Installer—C-4907

Spanner Wrench, Fuel Pump Module Locknut—6856

Test Kit, Fuel Pressure—5069

Adapters, Fuel Pressure Test—6539 and/or 6631

Test Kit, Fuel Pressure—C-4799-B

Fitting, Air Metering—6714

Fuel Line Removal Tool—6782


XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 1

FUEL SYSTEM—2.5L DIESEL ENGINE


CON T EN T S

page page

FUEL DELIVERY SYSTEM— GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1


2.5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . 2
FUEL INJECTION SYSTEM—
2.5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . 23

GEN ERAL I N FORM AT I ON

-
INDEX
page page

GENERAL INFORMATION FUEL SHUTDOWN SOLENOID . . . . . . . . . . . . . . 1


FUEL REQUIREMENTS—2.5L DIESEL . . . . . . . . . 1

GEN ERAL I N FORM AT I ON peda l. Wh en t h e ign it ion (key) swit ch is OF F, the


solen oid is sh u t off a n d fu el flow is n ot a llowed t o the
FUEL SHUTDOWN SOLENOID fu el in ject ion pu m p. Wh en t h e key is pla ced in the
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 ON or START posit ion s, fu el su pply is a llowed a t the
o p e ra te d by th e MS A. in ject ion pu m p.
Th e fu el sh u t down (sh u t -off) solen oid is u sed t o
elect r ica lly sh u t off t h e diesel fu el su pply t o t h e h igh - FUEL REQUIREMENTS—2.5L DIESEL
pr essu r e fu el in ject ion pu m p. Th e solen oid is P r em iu m qu a lit y diesel fu el wit h a m in im u m Cet -
m ou n t ed t o t h e r ea r of t h e in ject ion pu m p. a n e r a t in g of 50 or h igh er is r equ ir ed.
Th e solen oid con t r ols st a r t in g a n d st oppin g of t h e
en gin e r ega r dless of t h e posit ion of t h e a cceler a t or
14 - 2 FUEL SYSTEM—2.5L DIESEL ENGINE XJ

FU EL DELI V ERY SY ST EM —2 .5 L DI ESEL EN GI N E

INDEX
page page

DESCRIPTION AND OPERATION FUEL SUPPLY RESTRICTIONS . . . . . . . . . . . . . 11


FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . . 6 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 7
FUEL FILTER/WATER SEPARATOR . . . . . . . . . . . 3 HIGH-PRESSURE FUEL LINE LEAK TEST . . . . . 12
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 3 VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . 7
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SERVICE PROCEDURES
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . . 7 AIR BLEED PROCEDURES . . . . . . . . . . . . . . . . 12
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . 4 FUEL INJECTION PUMP TIMING . . . . . . . . . . . . 13
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 4 REMOVAL AND INSTALLATION
FUEL SHUTDOWN SOLENOID . . . . . . . . . . . . . . 3 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . 13
FUEL SYSTEM PRESSURE WARNING . . . . . . . . 2 AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . 13
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . 14
FUEL TANK MODULE . . . . . . . . . . . . . . . . . . . . . 3 FUEL FILTER/WATER SEPARATOR . . . . . . . . . . 14
FUEL TUBES/LINES/HOSES AND CLAMPS— FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LOW-PRESSURE TYPE . . . . . . . . . . . . . . . . . . 5 FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . 15
HIGH-PRESSURE FUEL LINES . . . . . . . . . . . . . . 6 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . 15
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 2 FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 19
QUICK-CONNECT FITTINGS—LOW PRESSURE FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . 15
TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FUEL RESERVOIR MODULE . . . . . . . . . . . . . . . 21
DIAGNOSIS AND TESTING FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AIR IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . 10 HIGH-PRESSURE LINES . . . . . . . . . . . . . . . . . . 22
FUEL HEATER RELAY TEST . . . . . . . . . . . . . . . 10 SPECIFICATIONS
FUEL INJECTION PUMP TEST . . . . . . . . . . . . . . 11 FUEL INJECTOR FIRING SEQUENCE . . . . . . . . 22
FUEL INJECTOR / NEEDLE MOVEMENT FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . 22
SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . 11 FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . 22
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . 10 IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FUEL SHUTDOWN SOLENOID TEST . . . . . . . . . 12

DESCRI PT I ON AN D OPERAT I ON HIGH–PRESSURE FUEL LEAKS. INSPECT FOR


HIGH–PRESSURE FUEL LEAKS WITH A SHEET OF
INTRODUCTION CARDBOARD (Fig. 1). HIGH FUEL INJECTION
Th is F u el Deliver y sect ion will cover com pon en t s PRESSURE CAN CAUSE PERSONAL INJURY IF
n ot con t r olled by t h e P CM. F or com pon en t s con - CONTACT IS MADE WITH THE SKIN.
t r olled by t h e P CM, r efer t o t h e F u el In ject ion Sys-
t em —2.5L Diesel E n gin e sect ion of t h is gr ou p.
Th e fu el h ea t er r ela y, fu el h ea t er a n d fu el ga u ge
FUEL TANK
Th e fu el t a n k a n d t a n k m ou n t in g u sed wit h t h e
a r e n ot oper a t ed by t h e P CM. Th ese com pon en t s a r e
diesel power ed en gin e is t h e sa m e a s u sed wit h ga s-
con t r olled by t h e ign it ion (key) swit ch . All ot h er fu el
olin e power ed m odels, a lt h ou gh t h e fu el t a n k m odu le
syst em elect r ica l com pon en t s n ecessa r y t o oper a t e
is differ en t .
t h e en gin e a r e con t r olled or r egu la t ed by t h e P CM.
Th e fu el t a n k con t a in s t h e fu el t a n k m odu le a n d
t wo r ollover va lves. Two fu el lin es a r e r ou t ed t o t h e
FUEL SYSTEM PRESSURE WARNING
fu el t a n k m odu le. On e lin e is u sed for fu el su pply t o
WARNING: HIGH–PRESSURE FUEL LINES DELIVER t h e fu el filt er /wa t er sepa r a t or. Th e ot h er is u sed t o
DIESEL FUEL UNDER EXTREME PRESSURE FROM r et u r n excess fu el ba ck t o t h e fu el t a n k.
THE INJECTION PUMP TO THE FUEL INJECTORS. Th e fu el t a n k m odu le con t a in s t h e fu el ga u ge elec-
THIS MAY BE AS HIGH AS 45,000 KPA (6526 PSI). t r ica l sen din g u n it . An e le c tric a l fu e l p u m p is n o t
USE EXTREME CAUTION WHEN INSPECTING FOR u s e d w ith th e d ie s e l e n g in e .
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

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)

FUEL INJECTION PUMP fu el in ject or ). Ou t pu t s fr om t h e Acceler a t or P eda l


Th e fu el in ject ion pu m p is a m ech a n ica l dist r ibu - P osit ion sen sor, en gin e speed sen sor (en gin e r pm )
t or –t ype, Bosch VP 36 ser ies (F ig. 3). A gea r on t h e a n d en gin e coola n t t em per a t u r e sen sor a r e a lso u sed.
en d of t h e in ject ion pu m p sh a ft m esh es wit h t h e Th e MSA will t h en com pa r e it s set va lu es t o t h ese
dr ive gea r a t t h e fr on t of en gin e. Th e pu m p is ou t pu t s t o elect r ica lly a dju st t h e a m ou n t of fu el t im -
m ech a n ica lly t im ed t o t h e en gin e. Th e MSA ca n in g (a m ou n t of a dva n ce) wit h in t h e in ject ion pu m p.
m a ke a dju st m en t s t o t h e t im in g of t h e in ject ion Th is is r efer r ed t o a s “Closed Loop” oper a t ion . Th e
pu m p. MSA m on it or s fu el t im in g by com pa r in g it s set va lu e
t o wh en t h e in ject or #1 open s. If t h e va lu e is gr ea t er
t h a n a pr eset va lu e a fa u lt will be set .
Act u a l elect r ic fu el t im in g (a m ou n t of a dva n ce) is
a ccom plish ed by t h e fu el t im in g solen oid m ou n t ed t o
t h e bot t om of t h e in ject ion pu m p (F ig. 3). F u el t im in g
will be a dju st ed by t h e MSA, wh ich con t r ols t h e fu el
t im in g solen oid.
An over flow va lve is a t t a ch ed in t o t h e fu el r et u r n
lin e a t t h e r ea r of t h e fu el in ject ion pu m p (F ig. 3).
Th is va lve ser ves t wo pu r poses. On e is t o en su r e t h a t
a cer t a in a m ou n t of r esidu a l pr essu r e is m a in t a in ed
wit h in t h e pu m p wh en t h e en gin e is swit ch ed off.
Th is will pr even t t h e fu el t im in g m ech a n ism wit h in
t h e in ject ion pu m p fr om r et u r n in g t o it s zer o posi-
t ion . Th e ot h er pu r pose is t o a llow excess fu el t o be
' ~ r et u r n ed t o t h e fu el t a n k t h r ou gh t h e fu el r et u r n
FUEL INJECTION
1
lin e. Th e pr essu r e va lu es wit h in t h is va lve a r e pr eset
,1:PUMP 10-WAY::.
----_-_-_-_-_-__,, (90NNECTOR a n d ca n n ot be a dju st ed.
I 1 80ba77f8 Th e fu el in ject ion pu m p su pplies h igh –pr essu r e
fu el of a ppr oxim a t ely 45,000 kP a (6526 psi) t o ea ch
Fig. 3 Fuel Injection Pump in ject or in pr ecise m et er ed a m ou n t s a t t h e cor r ect
Th e in ject ion pu m p con t a in s t h e fu el sh u t down t im e.
solen oid, fu el t em per a t u r e sen sor, con t r ol sleeve sen - F or m ech a n ica l in ject ion pu m p t im in g, r efer t o
sor, fu el qu a n t it y a ct u a t or a n d t h e fu el t im in g sole- F u el In ject ion P u m p Tim in g in t h e Ser vice P r oce-
n oid (F ig. 3). du r es sect ion of t h is gr ou p.
In t h e elect r on ica lly con t r olled in ject ion pu m p, t h e
pu m p plu n ger wor ks t h e sa m e a s t h e pu m p plu n ger FUEL INJECTORS
in a m ech a n ica lly con t r olled in ject ion pu m p, bu t t h e F u el dr a in t u bes (F ig. 4) a r e u sed t o r ou t e excess
a m ou n t of fu el a n d t h e t im e t h e fu el is in ject ed is fu el ba ck t o t h e over flow va lve a t t h e r ea r of t h e
con t r olled by t h e veh icle’s MSA, in st ea d of by a in ject ion pu m p. Th is excess fu el is t h en r et u r n ed t o
m ech a n ica l gover n or a ssem bly. A solen oid con t r olled t h e fu el t a n k t h r ou gh t h e fu el r et u r n lin e.
by t h e MSA is u sed in pla ce of t h e m ech a n ica l gover- Th e in ject or s a r e con n ect ed t o t h e fu el in ject ion
n or a ssem bly, a n d it m oves a con t r ol sleeve in side t h e pu m p by t h e h igh –pr essu r e fu el lin es. A sepa r a t e
pu m p t h a t r egu la t es t h e a m ou n t of fu el bein g in ject or is u sed for ea ch of t h e fou r cylin der s. An
in ject ed. Th er e is n o m ech a n ica l con n ect ion bet ween in ject or con t a in in g a sen sor (F ig. 5) is u sed on t h e
t h e a cceler a t or peda l a n d t h e elect r on ica lly con t r olled cylin der n u m ber on e in ject or. Th is in ject or is ca lled
in ject ion pu m p. In st ea d, a sen sor con n ect ed t o t h e in st r u m en t ed in ject or #1 or n eedle m ovem en t sen sor.
a cceler a t or peda l sen ds a sign a l t o t h e MSA t h a t r ep- It is u sed t o t ell t h e MSA wh en t h e #1 in ject or ’s
r esen t s t h e a ct u a l posit ion of t h e a cceler a t or peda l. in t er n a l spr in g-loa ded va lve sea t h a s been for ced
Th e MSA u ses t h is in pu t , a lon g wit h in pu t fr om open by pr essu r ized fu el bein g deliver ed t o t h e cylin -
ot h er sen sor s t o m ove t h e con t r ol sleeve t o deliver der, wh ich is a t t h e en d of it s com pr ession st r oke.
t h e a ppr opr ia t e a m ou n t of fu el. Th is syst em is kn own Wh en t h e in st r u m en t ed in ject or ’s va lve sea t is for ce
a s “Dr ive-By-Wir e”. open , it sen ds a sm a ll volt a ge spike pu lse t o t h e
Th e a ct u a l t im e t h a t t h e fu el is deliver ed is ver y MSA. Th is t ells t h e MSA t h a t cylin der #1 is fir in g. It
im por t a n t t o t h e diesel com bu st ion pr ocess. Th e MSA is n ot u sed wit h t h e ot h er t h r ee in ject or s.
m on it or s ou t pu t s fr om t h e en gin e speed sen sor (fly- F u el en t er s t h e in ject or a t t h e fu el in let (t op of
wh eel posit ion in degr ees), a n d t h e fu el in ject or sen - in ject or ) a n d is r ou t ed t o t h e n eedle va lve bor e. Wh en
sor (m ech a n ica l m ovem en t wit h in t h e #1 cylin der fu el pr essu r e r ises t o a ppr oxim a t ely 15,000–15,800
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 5
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
A copper wa sh er (ga sket ) is u sed a t t h e ba se of
ea ch in ject or (F ig. 5) t o pr even t com bu st ion ga ses
FUEL DRAIN TUBES fr om esca pin g.
F u el in ject or fir in g sequ en ce is 1–3–4–2.

FUEL TUBES/LINES/HOSES AND CLAMPS—


LOW-PRESSURE TYPE
Also r efer t o t h e pr oceedin g sect ion on Qu ick–Con -
n ect F it t in gs.
In spect a ll h ose con n ect ion s su ch a s cla m ps, cou -
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
lea ks a r e n ot pr esen t . Th e com pon en t sh ou ld be
r epla ced im m edia t ely if t h er e is a n y eviden ce of deg-
r a da t ion t h a t cou ld r esu lt in fa ilu r e.
Never a t t em pt t o r epa ir a pla st ic fu el lin e/t u be or a
qu ick–con n ect fit t in g. Repla ce com plet e lin e/t u be a s
n ecessa r y.
Avoid con t a ct of a n y fu el t u bes/h oses wit h ot h er
FITTING AT veh icle com pon en t s t h a t cou ld ca u se a br a sion s or
PUMP scu ffin g. Be su r e t h a t t h e fu el lin es/t u bes a r e pr op-
80a0c625 er ly r ou t ed t o pr even t pin ch in g a n d t o a void h ea t
sou r ces.
Fig. 4 Fuel Injectors and Drain Tubes Th e lin es/t u bes/h oses a r e of a specia l con st r u ct ion .
NEEDLE MOVEMENT If it is n ecessa r y t o r epla ce t h ese lin es/t u bes/h oses,
FUEL INJECTOR
SENSOR (NUMBER 1 u se on ly or igin a l equ ipm en t t ype.
CYLINDER ONLY} Th e h ose cla m ps u sed t o secu r e t h e r u bber h oses
a r e of a specia l 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
fu el lea ks.
Wh er e a r u bber h ose is join ed t o a m et a l t u be
(st a ked), do n ot a t t em pt t o r epa ir. Repla ce en t ir e
lin e/t u be a ssem bly.
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 2 N·m (20 in . lbs.) t or qu e.
SENSOR
CONNECTOR QUICK-CONNECT FITTINGS—LOW PRESSURE
TYPE
80ba7975 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
Fig. 5 Fuel Injector Sensor 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
kP a (2175–2291 psi), t h e n eedle va lve spr in g t en sion r in g t ype (F ig. 6). Refer t o Qu ick-Con n ect F it t in gs in
is over com e. Th e n eedle va lve r ises a n d fu el flows t h e Rem ova l/In st a lla t ion sect ion for m or e in for m a -
t h r ou gh t h e spr a y h oles in t h e n ozzle t ip in t o t h e t ion .
com bu st ion ch a m ber. Th e pr essu r e r equ ir ed t o lift
t h e n eedle va lve is t h e in ject or open in g pr essu r e set - CAUTION: The interior components (o-rings, spac-
t in g. Th is is r efer r ed t o a s t h e “pop-off” pr essu r e set - ers) of quick-connect fitting are not serviced sepa-
t in g. rately, but new pull tabs are available for some
F u el pr essu r e in t h e in ject or cir cu it decr ea ses a ft er types. Do not attempt to repair damaged fittings or
in ject ion . Th e in ject or n eedle va lve is im m edia t ely fuel lines/tubes. If repair is necessary, replace the
closed by t h e n eedle va lve spr in g a n d fu el flow in t o complete fuel tube assembly.
t h e com bu st ion ch a m ber is st opped. E xh a u st ga ses
a r e pr even t ed fr om en t er in g t h e in ject or n ozzle by
t h e n eedle va lve.
14 - 6 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

FUEL TUBE REMOVAL in ject ed in t o t h e com bu st ion ch a m ber. Th is fu el


QUICK CONNECT
FITTING
dr a in s in t o t h e fu el dr a in t u bes (F ig. 7) a n d ba ck t o
t h e t ee ba n jo fit t in g, wh ich is con n ect ed t o t h e sa m e
lin e a s t h e over flow va lve, wh ich a llows a va r ia ble
qu a n t it y t o r et u r n t o t h e fu el t a n k. Th e over flow
va lve is ca libr a t ed t o open a t a pr eset pr essu r e.
PUSH E xcess fu el n ot r equ ir ed by t h e pu m p t o m a in t a in t h e
m in im u m pu m p ca vit y pr essu r e is t h en r et u r n ed
t h r ou gh t h e over flow va lve a n d on t o t h e fu el t a n k
t h r ou gh t h e fu el r et u r n lin e.

INSTALLATION
FUEL DRAIN TUBES

FUEL INJECTORS
\•usH-~J
PLASTIC
RETAINER J9314-100

Fig. 6 Plastic Retainer Ring-Type Fitting


HIGH-PRESSURE FUEL LINES
CAUTION: The high–pressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld high–pressure fuel lines or to FITTING AT
repair lines that are damaged. Only use the recom- PUMP
mended lines when replacement of high–pressure 80a0c625
fuel line is necessary.
Fig. 7 Fuel Drain Tubes
H igh –pr essu r e fu el lin es deliver fu el u n der pr es-
su r e of u p t o a ppr oxim a t ely 45,000 kP a (6526 psi) FUEL HEATER
fr om t h e in ject ion pu m p t o t h e fu el in ject or s. Th e Th e fu el h ea t er is u sed t o pr even t diesel fu el fr om
lin es expa n d a n d con t r a ct fr om t h e h igh –pr essu r e wa xin g du r in g cold wea t h er oper a t ion . Th e fu el
fu el pu lses gen er a t ed du r in g t h e in ject ion pr ocess. All h ea t er is loca t ed in t h e bot t om pla st ic bowl of t h e
h igh –pr essu r e fu el lin es a r e of t h e sa m e len gt h a n d fu el filt er /wa t er sepa r a t or (F ig. 8).
in side dia m et er. Cor r ect h igh –pr essu r e fu el lin e Th e elem en t in side t h e h ea t er a ssem bly is m a de of
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 a P osit ive Tem per a t u r e Coefficien t (P TC) m a t er ia l,
oper a t ion . a n d h a s power a pplied t o it by t h e fu el h ea t er r ela y
a n yt im e t h e ign it ion key is in t h e “on ” posit ion . P TC
WARNING: USE EXTREME CAUTION WHEN m a t er ia l h a s a h igh r esist a n ce t o cu r r en t flow wh en
INSPECTING FOR HIGH–PRESSURE FUEL LEAKS. it s t em per a t u r e is h igh , wh ich m ea n s t h a t it will n ot
INSPECT FOR HIGH–PRESSURE FUEL LEAKS WITH gen er a t e h ea t wh en t h e t em per a t u r e is a bove a cer-
A SHEET OF CARDBOARD. HIGH FUEL INJECTION t a in va lu e. Wh en t h e t em per a t u r e is below 7°C (45°
PRESSURE CAN CAUSE PERSONAL INJURY IF F ), t h e r esist a n ce of t h e P TC elem en t is lower ed, a n d
CONTACT IS MADE WITH THE SKIN. a llows cu r r en t t o flow t h r ou gh t h e fu el h ea t er ele-
m en t wa r m in g t h e fu el. Wh en t h e t em per a t u r e is
a bove 29°C (85° F ), t h e P TC elem en t ’s r esist a n ce
FUEL DRAIN TUBES r ises, a n d cu r r en t flow t h r ou gh t h e h ea t er elem en t
Th ese r u bber t u bes a r e low–pr essu r e t ype. st ops.
Som e excess fu el is con t in u a lly ven t ed fr om t h e Volt a ge t o oper a t e t h e fu el h ea t er is su pplied fr om
fu el in ject ion pu m p. Du r in g in ject ion , a sm a ll a m ou n t t h e ign it ion (key) swit ch a n d t h r ou gh t h e fu el h ea t er
of fu el flows pa st t h e in ject or n ozzle a n d is n ot r ela y. Refer t o t h e followin g F u el H ea t er Rela y for
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 7
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

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).

FUEL HEATER RELAY


Volt a ge t o oper a t e t h e fu el h ea t er is su pplied fr om
t h e ign it ion (key) swit ch t h r ou gh t h e fu el h ea t er
r ela y. Th e P CM o r MS A is n o t u s e d to c o n tro l
th is re la y.
Th e fu el h ea t er r ela y is loca t ed in t h e 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 -
MOUNTING
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 BOLT 80a35314
P DC, r efer t o la bel on P DC cover.
Fig. 9 PCM Location—Typical
DI AGN OSI S AN D T EST I N G (4) Ver ify t h a t t h e elect r ica l con n ect ion s for t h e
ASD r ela y a r e clea n a n d fr ee of cor r osion . Th is r ela y
GENERAL INFORMATION is loca t ed in t h e P DC. F or t h e loca t ion of t h e r ela y
Th is sect ion of t h e gr ou p will cover a gen er a l dia g- wit h in t h e P DC, r efer t o la bel on P DC cover.
n osis of diesel en gin e fu el syst em com pon en t s. (5) Ver ify t h a t t h e elect r ica l con n ect ion s for t h e
D ia g n o s tic Tro u ble Co d e s : Refer t o On -Boa r d fu el h ea t er r ela y a r e clea n a n d fr ee of cor r osion . Th is
Dia gn ost ics in Gr ou p 25, E m ission Con t r ol Syst em r ela y is loca t ed in t h e P DC. F or t h e loca t ion of t h e
for a list of Dia gn ost ic Tr ou ble Codes (DTC’s) for cer- r ela y wit h in t h e P DC, r efer t o la bel on P DC cover.
t a in fu el syst em com pon en t s. (6) Be su r e t h e elect r ica l con n ect or s a t t h e en ds of
Th e P CM a n d MSA m u st be t est ed wit h t h e t h e glow plu gs (F ig. 11) a r e t igh t a n d fr ee of cor r o-
DRBIII sca n t ool. Th e DRBIII sh ou ld be t h e fir st sion .
st ep in a n y dia gn osis of en gin e per for m a n ce com - (7) Be su r e t h a t t h e elect r ica l con n ect ion s a t t h e
pla in t s. Refer t o t h e 1997 ZJ /ZG 2.5L Diesel P ower- glow plu g r ela y a r e t igh t a n d n ot cor r oded. Th e glow
t r a in Dia gn ost ic P r ocedu r es m a n u a l for dia gn osis plu g r ela y is loca t ed in t h e en gin e com pa r t m en t on
a n d t est in g of t h e diesel en gin e con t r ol syst em . t h e left –in n er fen der (F ig. 12).
(8) In spect t h e st a r t er m ot or a n d st a r t er solen oid
con n ect ion s for t igh t n ess a n d cor r osion .
14 - 8 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
MOUNTING
BOLT

\\~ACCELERATOR PEDAL
~ POSITION SENSOR LOWER
INSTRUMENT
PANEL
80accfe9 80ad08f8

Fig. 10 MSA Location—Typical Fig. 12 Glow Plug Relay Location


FUEL INJECTION
PUMP ASSEMBLY
~

Fig. 11 Glow Plug Connector


(9) Ver ify t h a t t h e F u el In ject ion P u m p elect r ica l
con n ect or is fir m ly con n ect ed. In spect t h e con n ect or
for cor r osion or da m a ged wir es. Th e solen oid is
m ou n t ed t o t h e r ea r of t h e in ject ion pu m p (F ig. 13). 80ba77fb

(10) Ver ify t h a t t h e fu el h ea t er elect r ica l con n ect or


is fir m ly a t t a ch ed t o t h e filt er bowl a t t h e bot t om of Fig. 13 Fuel Shutdown Solenoid Location
t h e fu el filt er /wa t er sepa r a t or. In spect t h e con n ect or (14) Ver ify t u r boch a r ger wa st ega t e oper a t ion .
for cor r osion or da m a ged wir es. Refer t o Gr ou p 11, E xh a u st Syst em a n d In t a ke Ma n -
(11) Ver ify t h a t t h e elect r ica l pigt a il con n ect or ifold Gr ou p for in for m a t ion .
(sen sor con n ect or ) (F ig. 14) for t h e fu el in ject or sen - (15) Ver ify t h a t t h e h a r n ess con n ect or is fir m ly
sor is fir m ly con n ect ed t o t h e en gin e wir in g h a r n ess. con n ect ed t o t h e en gin e coola n t t em per a t u r e sen sor.
In spect t h e con n ect or for cor r osion or da m a ged wir es. Th e sen sor is loca t ed on t h e side of cylin der h ea d
Th is sen sor is u sed on t h e #1 cylin der in ject or on ly. n ea r t h e r ea r of fu el in ject ion pu m p (F ig. 17).
(12) In spect for exh a u st syst em r est r ict ion s su ch (16) Ch eck for a ir in t h e fu el syst em . Refer t o t h e
a s pin ch ed exh a u st pipes or a colla psed or plu gged Air Bleed P r ocedu r e.
m u ffler. (17) In spect a ll fu el su pply a n d r et u r n lin es for
(13) Ver ify t h a t t h e h a r n ess con n ect or is fir m ly sign s of lea ka ge.
con n ect ed t o t h e veh icle speed sen sor (F ig. 15) or
(F ig. 16).
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 9
DI AGN OSI S AN D T EST I N G (Cont inue d)
NEEDLE MOVEMENT FUEL INJECTOR SENSOR
SENSOR (NUMBER 1 ELECTRICAL
CYLINDER ONLY} CONNECTOR

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)

FUEL INJECTOR TEST


Th e fu el in ject ion n ozzles, loca t ed on t h e en gin e
cylin der h ea d, spr a y fu el u n der h igh pr essu r e in t o
t h e in dividu a l com bu st ion ch a m ber s. P r essu r ized
fu el, deliver ed by t h e fu el in ject ion pu m p, u n sea t s a
spr in g-loa ded n eedle va lve in side t h e in ject or, a n d
t h e fu el is a t om ized a s it esca pes t h r ou gh t h e in ject or
open in g in t o t h e en gin e’s com bu st ion ch a m ber. If t h e
fu el in ject or does n ot oper a t e pr oper ly, t h e en gin e
m a y m isfir e, or ca u se ot h er dr ivea bilit y pr oblem s.
A lea k in t h e in ject ion pu m p–t o–in ject or h igh –pr es-
su r e fu el lin e ca n ca u se m a n y of t h e sa m e sym pt om s
a s a m a lfu n ct ion in g in ject or. In spect for a lea k in t h e
h igh –pr essu r e lin es befor e ch eckin g for a m a lfu n c-
t ion in g fu el in ject or.

WARNING: THE INJECTION PUMP SUPPLIES


HIGH–PRESSURE FUEL OF UP TO APPROXI-
MATELY 45,000 KPA (6526 PSI) TO EACH INDIVID-
UAL INJECTOR THROUGH THE HIGH–PRESSURE
LINES. FUEL UNDER THIS AMOUNT OF PRESSURE
CAN PENETRATE THE SKIN AND CAUSE PER-
Fig. 18 Vaccum Pump at Front of Engine SONAL INJURY. WEAR SAFETY GOGGLES AND
(24) Ver ify t h er e is a good con n ect ion a t t h e Boost ADEQUATE PROTECTIVE CLOTHING. AVOID CON-
P r essu r e Sen sor, wh ich is a pa r t of t h e a ir in t a ke TACT WITH FUEL SPRAY WHEN BLEEDING HIGH–
a ssem bly. PRESSURE FUEL LINES.

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)

FUEL SHUTDOWN SOLENOID TEST SERV I CE PROCEDU RES


Refer t o 1997 ZJ /ZG 2.5L Diesel P ower t r a in Dia g-
n ost ic Ma n u a l for t h e F u el Sh u t down Solen oid t est . AIR BLEED PROCEDURES
HIGH-PRESSURE FUEL LINE LEAK TEST AIR BLEEDING AT FUEL FILTER
H igh –pr essu r e fu el lin e lea ks ca n ca u se st a r t in g A cer t a in a m ou n t of a ir m a y becom e t r a pped in t h e
pr oblem s a n d poor en gin e per for m a n ce. fu el syst em wh en fu el syst em com pon en t s a r e ser-
viced or r epla ced. Bleed t h e syst em a s n eeded a ft er
WARNING: DUE TO EXTREME FUEL PRESSURES OF fu el syst em ser vice a ccor din g t o t h e followin g pr oce-
UP TO 45,000 KPA (6526 PSI), USE EXTREME CAU- du r es.
TION WHEN INSPECTING FOR HIGH–PRESSURE FUEL
LEAKS. DO NOT GET YOUR HAND, OR ANY PART OF WARNING: DO NOT BLEED AIR FROM THE FUEL
YOUR BODY NEAR A SUSPECTED LEAK. INSPECT SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
FOR HIGH–PRESSURE FUEL LEAKS WITH A SHEET TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
OF CARDBOARD. HIGH FUEL INJECTION PRESSURE BLEEDING AIR FROM THE FUEL SYSTEM.
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN. Som e a ir en t er s t h e fu el syst em wh en t h e fu el fil-
t er or in ject ion pu m p su pply lin e is ch a n ged. Th is
St a r t t h e en gin e. Move t h e ca r dboa r d over t h e sm a ll a m ou n t of a ir is ven t ed a u t om a t ica lly fr om t h e
h igh –pr essu r e fu el lin es a n d ch eck for fu el spr a y on t o in ject ion pu m p t h r ou gh t h e fu el dr a in m a n ifold t u bes
t h e ca r dboa r d (F ig. 21). If a h igh –pr essu r e lin e con - if t h e filt er wa s ch a n ged a ccor din g t o in st r u ct ion s.
n ect ion is lea kin g, bleed t h e syst em a n d t igh t en t h e E n su r e t h e bowl of t h e fu el filt er /wa t er sepa r a t or is
con n ect ion . Refer t o t h e Air Bleed P r ocedu r e in t h is fu ll of fu el.
gr ou p for pr ocedu r es. Repla ce da m a ged, r est r ict ed or It m a y be n ecessa r y t o m a n u a lly bleed t h e syst em
lea kin g h igh –pr essu r e fu el lin es wit h t h e cor r ect if:
r epla cem en t lin e. • Th e bowl of t h e fu el filt er /wa t er sepa r a t or is n ot
pa r t ia lly filled befor e in st a lla t ion of a n ew filt er
• Th e in ject ion pu m p is r epla ced
HIGH
PRESSURE • H igh –pr essu r e fu el lin e con n ect ion s a r e loosen ed
LINE or lin es r epla ced
• In it ia l en gin e st a r t –u p or st a r t –u p a ft er a n
ext en ded per iod of n o en gin e oper a t ion
• Ru n n in g fu el t a n k em pt y

FUEL INJECTION PUMP BLEEDING


(1) If t h e fu el in ject ion pu m p h a s been r epla ced,
a ir sh ou ld be bled a t t h e over flow va lve befor e
a t t em pt in g t o st a r t en gin e.
(a ) Loosen t h e over flow va lve (F ig. 22) a t t h e
r ea r of t h e in ject ion pu m p.
(b) P la ce a t owel below t h e va lve.

WARNING: WHEN CRANKING THE ENGINE TO


BLEED AIR FROM THE INJECTION PUMP, THE
ENGINE MAY START. PLACE THE TRANSMISSION
IN NEUTRAL OR PARK AND SET PARKING BRAKE
BEFORE ENGAGING THE STARTER MOTOR.
80ba77f9

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

Fig. 23 Bleeding High–Pressure Fuel Line—Typical


FUEL INJECTION PUMP TIMING
Fig. 22 Overflow Valve Refer t o Rem ova l/In st a lla t ion a n d Adju st in g F u el
P u m p Tim in g in t h is Gr ou p.
(2) Cr a n k t h e en gin e for 30 secon ds a t a t im e t o
a llow a ir t r a pped in t h e in ject ion pu m p t o ven t ou t
t h e fu el in ject or dr a in t u bes. Con t in u e t h is pr ocedu r e REM OVAL AN D I N STALLAT I ON
u n t il t h e en gin e st a r t s. Obser ve t h e pr eviou s WARN-
ING a n d CAUTION. ACCELERATOR PEDAL
(3) Tigh t en over flow va lve.
REMOVAL
HIGH–PRESSURE FUEL LINE BLEEDING (1) Discon n ect elect r ica l con n ect or.
(2) Rem ove a cceler a t or peda l m ou n t in g br a cket
WARNING: THE INJECTION PUMP SUPPLIES HIGH- n u t s. Rem ove a cceler a t or peda l a ssem bly.
–PRESSURE FUEL OF APPROXIMATELY 59,000 KPA
(8,557 PSI) TO EACH INDIVIDUAL INJECTOR INSTALLATION
THROUGH THE HIGH–PRESSURE LINES. FUEL (1) P la ce a cceler a t or peda l a ssem bly over st u ds
UNDER THIS AMOUNT OF PRESSURE CAN PENE- pr ot r u din g fr om floor pa n . Tigh t en m ou n t in g n u t s t o
TRATE THE SKIN AND CAUSE PERSONAL INJURY. 5 N·m (46 in . lbs.) t or qu e.
WEAR SAFETY GOGGLES AND ADEQUATE PRO- (2) Con n ect elect r ica l con n ect or.
TECTIVE CLOTHING AND AVOID CONTACT WITH (3) Befor e st a r t in g t h e en gin e, oper a t e t h e a cceler-
FUEL SPRAY WHEN BLEEDING HIGH–PRESSURE a t or peda l t o ch eck for a n y bin din g.
FUEL LINES.
AIR CLEANER ELEMENT
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL REMOVAL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN (1) Rem ove h ose cla m p a t Ma ss Air F low Sen sor.
BLEEDING AIR FROM THE FUEL SYSTEM. (2) Rem ove h ose fr om Ma ss Air F low Sen sor.
(3) Loosen 2 cla m ps h oldin g a ir clea n er h ou sin g
Bleed a ir fr om on e in ject or a t t im e. h a lves t oget h er.
(1) Loosen t h e h igh –pr essu r e fu el lin e fit t in g a t (4) Rem ove left side of a ir clea n er h ou sin g.
t h e in ject or (F ig. 23). (5) Rem ove elem en t fr om a ir clea n er h ou sin g.
(2) Cr a n k t h e en gin e u n t il a ll a ir h a s been bled
fr om t h e lin e. D o n o t o p e ra te th e s ta rte r m o to r INSTALLATION
fo r lo n g e r th a n 30 s e c o n d s . Wa it 2 m in u te s (1) In st a ll a n ew elem en t in h ou sin g.
be tw e e n c ra n k in g in te rv a ls . (2) P osit ion left side of h ou sin g.
(3) St a r t t h e en gin e a n d bleed on e in ject or a t a (3) Sn a p cla m ps in t o pla ce.
t im e u n t il t h e en gin e r u n s sm oot h ly. (4) In st a ll h oses a n d cla m ps.
14 - 14 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

0
@ 0

Fig. 26 Fuel Filter/Water Separator Location


Th e fu el filt er /wa t er sepa r a t or a ssem bly con t a in 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
va lve (F ig. 26).

DRAINING WATER FROM FILTER BOWL


Fig. 24 Accelerator Pedal Mounting-Typical Moist u r e (wa t er ) collect 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 bowl. Wa t er en t er in g t h e fu el
FUEL DRAIN TUBES in ject ion pu m p ca n ca u se ser iou s da m a ge t o t h e
Th e fu el dr a in t u bes (F ig. 25) a r e low–pr essu r e pu m p. N o te th a t th e bu lb w ill be illu m in a te d fo r
t ype. a p p ro x im a te ly 2 s e c o n d s e a c h tim e th e k e y is
P u ll ea ch t u be fr om t h e in ject or for r em ova l. P u sh in itia lly p la c e d in th e ON p o s itio n . Th is is d o n e
on for in st a lla t ion . Cla m ps a r e n ot r equ ir ed for t h ese fo r a bu lb c h e c k .
t u bes.
WARNING: DO NOT ATTEMPT TO DRAIN WATER
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.

(1) Th e bot t om of t h e filt er /sepa r a t or bowl is


equ ipped wit h a dr a in va lve (F ig. 26). Th e dr a in
va lve is equ ipped wit h a fit t in g. At t a ch a piece of
r u bber h ose t o t h is fit t in g. Th is h ose is t o be u sed a s
a dr a in h ose.
(2) P la ce a dr a in pa n u n der t h e dr a in h ose.
(3) Wit h t h e en gin e n ot r u n n in g, open t h e dr a in
va lve (u n scr ew—dr a in va lve h a s r igh t h a n d t h r ea ds)
80ba77fa fr om t h e filt er /sepa r a t or bowl. To ga in a ccess t o t h is
fit t in g, t h e t wo filt er –t o–m ou n t in g br a cket n u t s (F ig.
Fig. 25 Fuel Injectors and Drain Tubes 26) m a y h a ve t o be loosen ed a few t u r n s.
FUEL FILTER/WATER SEPARATOR (4) H old t h e dr a in open u n t il clea n fu el exit s t h e
Th e fu el filt er /wa t er sepa r a t or is loca t ed in t h e dr a in .
en gin e com pa r t m en t on t h e left side n ea r t h e sh ock (5) Aft er dr a in in g, close dr a in va lve.
t ower. (F ig. 26). (6) Rem ove r u bber dr a in h ose.
(7) Dispose of m ixt u r e in dr a in pa n a ccor din g t o
a pplica ble loca l or feder a l r egu la t ion s.
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 15
REM OVAL AN D I N STALLAT I ON (Cont inue d)
FUEL FILTER REMOVAL
(1) Dr a in a ll fu el a n d/or wa t er fr om fu el filt er /wa -
t er sepa r a t or a ssem bly. Refer t o t h e pr eviou s Dr a in -
in g Wa t er F r om F ilt er Bowl.
(2) Un plu g t h e elect r ica l con n ect or s a t bot t om of
pla st ic bowl.
(3) Rem ove pla st ic bowl fr om bot t om of fu el filt er
(u n scr ews).
(4) Rem ove fu el filt er fr om bot t om of filt er ba se
(u n scr ews).

FUEL FILTER INSTALLATION


(1) Clea n bot t om of fu el filt er ba se.
(2) Apply clea n diesel fu el t o n ew fu el filt er ga sket .
(3) In st a ll a n d t igh t en filt er t o filt er ba se. Th e bev-
eled pa r t of t h e r u bber ga sket sh ou ld be fa cin g u p
t owa r ds t h e filt er ba se.
(4) Clea n t h e in side of bowl wit h a soa p a n d wa t er
m ixt u r e befor e in st a lla t ion . Ca r efu lly clea n a n y r esi-
du e bet ween t h e t wo m et a l pr obes a t t h e t op of t h e
wa t er –in –fu el sen sor. Do n ot u se ch em ica l clea n er s
a s da m a ge t o t h e pla st ic bowl m a y r esu lt .
(5) P ou r diesel fu el in t o t h e pla st ic bowl befor e Fig. 27 Power Distribution Center (PDC) Location
in st a llin g bowl t o bot t om of fu el filt er. Do t h is t o h elp FUEL GAUGE
pr even t a ir fr om en t er in g fu el in ject ion pu m p wh ile FLOAT
a t t em pt in g t o st a r t in g en gin e.
(6) In st a ll filt er bowl t o bot t om of filt er.
(7) In st a ll t h e elect r ica l con n ect or s a t bot t om of
bowl.
(8) Tigh t en t h e filt er –t o–m ou n t in g br a cket n u t s
(F ig. 26) t o 28 N·m (250 in . lbs.) t or qu e.

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 .

FUEL HEATER RELAY


Th e fu el h ea t er r ela y is loca t ed in t h e P DC. F or
t h e loca t ion of t h e r ela y wit h in t h e P DC (F ig. 27), FUEL GAUGE
r efer t o la bel on P DC cover. SENDING UNIT
80ace654

FUEL LEVEL SENSOR Fig. 28 Fuel Level Sensor


Th e fu el level sen sor is loca t ed on t h e side of t h e
fu el pu m p m odu le (F ig. 28). FUEL INJECTION PUMP

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

Fig. 34 Pump Gear Tools


(2) In st a ll a n ew in ject ion pu m p–t o–t im in g gea r
cover ga sket .
ADAPTER (3) Rem ove t h e gea r r em ovin g bolt (dr ive bolt )
TOOL VM1011 80a0c5c7 fr om gea r pu ller. CAU TION : D o n o t re m o v e th e
s p e c ia l g e a r p u lle r o r tim in g c o v e r a d a p te r
Fig. 32 Installing Dial Indicator and Special Adapter to o ls fro m tim in g c o v e r a t th is tim e . Ge a r m is -
Tools a lig n m e n t w ill re s u lt.
dr ivin g in ject ion pu m p r ea r wa r d fr om t im in g gea r (4) P la ce t h e key wa y on t h e pu m p sh a ft t o t h e 11
cover m ou n t in g st u ds. o’clock posit ion a s viewed fr om t h e fr on t of pu m p.
(16) Rem ove pu m p fr om en gin e. D o n o t ro ta te In st a ll t h e pu m p in t o t h e r ea r of t im in g gea r cover
e n g in e w h ile g e a r p u lle r is in s ta lle d . En g in e wh ile a lign in g key wa y on pu m p sh a ft in t o pu m p
d a m a g e w ill o c c u r. gea r.
(5) In st a ll a n d sn u g t h e 3 in ject ion pu m p m ou n t -
INSTALLATION/ADJUSTING PUMP TIMING in g n u t s. Th is is n ot t h e fin a l t igh t en in g sequ en ce.
(1) Clea n t h e m a t in g su r fa ces of in ject ion pu m p (6) Rem ove t h e specia l gea r pu ller a n d a da pt er
a n d t im in g gea r cover. t ools fr om t im in g gea r cover.
14 - 18 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

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

Fig. 36 Injection Pump Mounting Nuts


(7) In st a ll t h e in ject ion pu m p dr ive gea r n u t .
Tigh t en n u t t o 88 N·m (65 ft . lbs.) t or qu e.
(8) Rem ove t h e a ccess plu g a n d plu g wa sh er a t ADAPTER
r ea r of pu m p (F ig. 37). Th r ea d specia l dia l in dica t or TOOL VM1011 80a0c5c7

a da pt er t ool VM.1011 (F ig. 38) in t o t h is open in g.


H a n d t igh t en on ly. Fig. 38 Installing Dial Indicator and Special Adapter
(9) At t a ch specia l dia l in dica t or t ool VM.1013 in t o Tools
t h e a da pt er t ool (F ig. 38). (12) Th e “Top Dea d Cen t er ” (TDC) com pr ession fir-
(10) Usin g a socket a t t a ch ed t o t h e fr on t of t h e in g st r oke ca n be det er m in ed a s follows:
cr a n ksh a ft , r ot a t e t h e en gin e in a cou n t er-clockwise (a ) Rot a t e t h e en gin e clockwise u n t il specia l
dir ect ion u n t il t h e dia l ga ge in dica t or st ops m ovin g a lign m en t t ool VM# 1035 ca n be in ser t ed t h r ou gh
(20–25° befor e TDC). t h e h ole in t h e bot t om of t h e clu t ch h ou sin g, st op-
(11) Set t h e dia l in dica t or t o 0m m . Be su r e t h e t ip pin g t h e flywh eel r ot a t ion . Th is posit ion is TDC or
of t h e dia l in dica t or is t ou ch in g t h e t ip in side t h e 180° a wa y fr om TDC. En g in e m u s t be a t TD C #1
a da pt er t ool. c o m p re s s io n firin g s tro k e .
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 19
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(b) To ver ify t h a t you a r e a t TDC. Rem ove t h e (25) In st a ll en gin e a ccessor y dr ive belt . Refer t o
oil fill ca p fr om t h e r ocker cover a n d t h e a lign m en t Gr ou p 7, Coolin g Syst em for pr ocedu r es.
t ool fr om t h e clu t ch h ou sin g. (26) In st a ll n ega t ive ba t t er y ca ble t o ba t t er y.
(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- (27) St a r t t h e en gin e a n d br in g t o n or m a l oper a t -
wise a n d cou n t er-clockwise wh ile obser vin g t h e in g t em per a t u r e.
r ocker a r m t h r ou gh t h e oil fill ca p h ole. If t h e (28) Ch eck for fu el lea ks.
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 FUEL INJECTORS
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 F ou r fu el in ject or s a r e u sed on ea ch en gin e. Of
ca n be r e-in st a lled in t h e flywh eel. You a r e n ow a t t h ese fou r, t wo differ en t t ypes a r e u sed. Th e fu el
TDC. in ject or u sed on cylin der n u m ber on e is equ ipped
(13) Th e ga u ge r ea din g sh ou ld be a t 0.60 m m . If wit h a fu el in ject or sen sor (F ig. 39). Th e ot h er t h r ee
n ot , t h e pu m p m u st be r ot a t ed for a dju st m en t : fu el in ject or s a r e iden t ica l. D o n o t p la c e th e fu e l
(a ) Loosen t h e t h r ee in ject ion pu m p m ou n t in g in je c to r e qu ip p e d w ith th e fu e l in je c to r s e n s o r
n u t s a t t h e m ou n t in g fla n ges. Th ese fla n ges a r e in to a n y o th e r lo c a tio n e x c e p t th e c y lin d e r
equ ipped wit h slot t ed h oles. Th e slot t ed h oles a r e n u m be r o n e p o s itio n .
u sed t o r ot a t e a n d posit ion t h e in ject ion pu m p for
NEEDLE MOVEMENT FUEL INJECTOR
fu el t im in g. Loosen t h e t h r ee n u t s ju st en ou gh t o
SENSOR (NUMBER 1
r ot a t e t h e pu m p.
(b) Rot a t e t h e pu m p u n t il 0.60 m m is in dica t ed CYLINDER ONLY}
on t h e dia l in dica t or ga u ge. If wh ile r ot a t in g t h e
pu m p t h e 0.60m m specifica t ion is pa ssed do n ot
a t t em pt t o r ot a t e t h e pu m p in t h e opposit e dir ec-
t ion . You m u st r ot a t e t h e pu m p ba ck below t h e
0.60m m specifica t ion a n d st a r t t h e pr ocedu r e over
fr om t h e st a r t of t h e TDC pr ocedu r e. Th is will pr e-
ven t a fa lse r ea din g du e t o gea r ba ckla sh .
(c) Tigh t en t h e t h r ee pu m p m ou n t in g n u t s t o 30
N·m (22 ft . lbs.) t or qu e.
(d) Rech eck t h e dia l in dica t or a ft er t igh t en in g
t h e pu m p m ou n t in g n u t s. Ga u ge sh ou ld st ill be
SENSOR
r ea din g 0.60 m m . CONNECTOR
(14) Rem ove dia l in dica t or a n d a da pt er t ools.
(15) In st a ll a ccess plu g a n d wa sh er t o r ea r of
80ba7975
in ject ion pu m p.
(16) In st a ll plu g a t t im in g gea r cover.
Fig. 39 Fuel Injector Sensor — #1 Cylinder
(17) In st a ll a n d con n ect t h e fou r h igh –pr essu r e
fu el lin es t o t h e fu el in ject ion pu m p. Also con n ect REMOVAL
fu el lin es a t t h e fu el in ject or s. F or pr ocedu r es, r efer (1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
t o H igh –P r essu r e F u el Lin es in t h is gr ou p. (2) Th or ou gh ly clea n t h e a r ea a r ou n d t h e in ject or
(18) In st a ll elect r ica l con n ect or a t en gin e coola n t wit h com pr essed a ir.
t em per a t u r e sen sor. (3) Rem ove t h e fu el dr a in h oses (t u bes) a t ea ch
(19) Con n ect elect r ica l con n ect or a t fu el sh u t down in ject or (F ig. 40) bein g ser viced. E a ch of t h ese h oses
solen oid. is slip–fit t o t h e fit t in g on in ject or.
(20) Con n ect t h e m a in en gin e wir in g h a r n ess t o (4) Rem ove t h e h igh –pr essu r e fu el lin e a t in ject or
t h e glow plu gs. bein g r em oved. Refer t o H igh –P r essu r e F u el Lin es in
(21) Con n ect t h e fu el t im in g solen oid pigt a il h a r- t h is gr ou p for pr ocedu r es.
n ess t o t h e en gin e wir in g h a r n ess. (5) Rem ove t h e in ject or u sin g specia l socket t ool
(22) Con n ect t h e over flow va lve/ba n jo fit t in g (fu el n u m ber VM.1012A. Wh en r em ovin g cylin der n u m ber
r et u r n lin e a ssem bly). Repla ce copper ga sket s befor e on e in ject or, t h r ea d t h e wir in g h a r n ess t h r ou gh t h e
in st a llin g. a ccess h ole on t h e specia l socket (F ig. 41).
(23) Con n ect t h e r u bber fu el r et u r n a n d su pply (6) Rem ove a n d disca r d t h e copper wa sh er (sea l) a t
h oses t o m et a l lin es a t pu m p. Tigh t en h ose cla m ps t o bot t om of in ject or (F ig. 39).
2 N·m (20 in . lbs.) t or qu e.
(24) In st a ll gen er a t or a ssem bly.
14 - 20 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
FUEL LINE HIGH-PRESSURE (3) Dr a in fu el t a n k dr y in t o h oldin g t a n k or a
INJECTOR FITTING FUEL LINE pr oper ly la beled d ie s e l sa fet y con t a in er.
~) (4) Ra ise veh icle on h oist .
(5) Discon n ect bot h t h e fu el fill a n d fu el ven t r u b-
ber h oses a t t h e fu el t a n k.
(6) Discon n ect fu el su pply a n d r et u r n lin es fr om
t h e st eel su pply lin e (F ig. 42).

~ FUEL
DRAIN TUBES 80a0c5d4

Fig. 40 Fuel Injector—Typical


FRONT OF
FUEL TANK
FUEL INJECTOR ) ///JI
80a61226
~

Fig. 42 Fuel Tank Connections at Front of Tank


FUEL TANK CLAMP INDEX
MARKS
FUEL VENT
HOSE
FUEL INJECTOR SENSOR SPECIAL
(NUMBER 1 CYLINDER ONLY) SOCKET 80a0c5d3

Fig. 41 Wiring Harness Through Socket


INSTALLATION TANK
(1) Clea n t h e in ject or t h r ea ds in cylin der h ea d. INDEX
(2) In st a ll n ew copper wa sh er (sea l) t o in ject or. TANGS
(3) In st a ll in ject or t o en gin e. Tigh t en t o 70 N·m
(52 ft . lbs.) t or qu e.
(4) In st a ll h igh –pr essu r e fu el lin es. Refer t o H igh –
P r essu r e F u el Lin es in t h is gr ou p for pr ocedu r es.
(5) In st a ll fu el dr a in h oses (t u bes) t o ea ch in ject or.
Do n ot u se cla m ps a t fu el dr a in h oses.
(6) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y.
(7) Bleed t h e a ir fr om t h e h igh –pr essu r e lin es. FUEL FILL HOSE 80a61227

Refer t o t h e Air Bleed P r ocedu r e sect ion of t h is


gr ou p. Fig. 43 Fuel Fill/Vent Hose Index Marks
Th e fu e l re s e rv o ir m o d u le e le c tric a l c o n n e c -
FUEL TANK to r h a s a re ta in e r th a t lo c k s it in p la c e .
(7) Slide elect r ica l con n ect or lock t o u n lock.
REMOVAL (8) P u sh down on con n ect or r et a in er (F ig. 44) a n d
(1) Discon n ect n ega t ive ca ble fr om ba t t er y. pu ll con n ect or off m odu le.
(2) In ser t fu el siph on h ose in t o fu el filler n eck a n d (9) Use a t r a n sm ission ja ck t o su ppor t fu el t a n k.
pu sh it in t o t h e t a n k. Rem ove bolt s fr om fu el t a n k st r a ps.
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 21
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Dr a in fu el t a n k dr y in t o h oldin g t a n k or a
pr oper ly la beled d ie s e l sa fet y con t a in er.
(3) Ra ise veh icle on h oist .
(4) Use a t r a n sm ission ja ck t o su ppor t t h e fu el
t a n k. Rem ove bolt s fr om fu el t a n k st r a ps. Lower
t a n k sligh t ly.
(5) Clea n a r ea a r ou n d fu el r eser voir m odu le a n d
t a n k t o keep dir t a n d for eign m a t er ia l ou t of t a n k.
(6) Discon n ect fu el lin es fr om fu el m odu le by
depr essin g qu ick con n ect r et a in er s wit h t h u m b a n d
for e fin ger.
(7) Slide m odu le elect r ica l con n ect or lock t o
CONNECTOR u n lock.
LOCK 9514-41 (8) P u sh down on con n ect or r et a in er a n d pu ll con -
n ect or off m odu le.
Fig. 44 Module Connector Retainer and Lock (9) Usin g Specia l Tool 6856, r em ove pla st ic lockn u t
cou n t er clockwise t o r elea se pu m p m odu le (F ig. 45).
(10) Lower t a n k sligh t ly. Ca r efu lly r em ove filler
h ose fr om t a n k.
(11) Lower t h e fu el t a n k. Rem ove cla m p a n d
r em ove fu el filler t u be ven t h ose. Rem ove fu el t a n k
fr om veh icle.

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.

FUEL INJECTOR FIRING SEQUENCE


1–3–4–2

~ FUEL FUEL SYSTEM PRESSURE


DRAIN TUBES 80a0c5d4
P e a k In je c tio n P re s s u re /F u e l In je c tio n P u m p
Op e ra tin g P re s s u re : 40,000–45,000 kP a (5801–
Fig. 46 Fuel Lines at Fuel Injectors
6526 psi).
(4) Discon n ect ea ch h igh –pr essu r e lin e fit t in g a t Op e n in g P re s s u re o f F u e l In je c to r:
ea ch fu el in ject ion pu m p deliver y va lve. 15,000–15,800 kP a (2175–2291 psi).
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 23

FU EL I N J ECT I ON SY ST EM —2 .5 L DI ESEL EN GI N E

INDEX
page page

GENERAL INFORMATION SENSOR RETURN—ECM/PCM INPUT


INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 23 (ANALOG GROUND) . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION AND OPERATION SPEED CONTROL—ECM INPUT . . . . . . . . . . . . 28
AIR CONDITIONING (A/C) CONTROLS— SPEED CONTROL—PCM OUTPUTS . . . . . . . . . 28
ECM INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . 27 TACHOMETER—PCM OUTPUT . . . . . . . . . . . . . 29
AIR CONDITIONING RELAY—ECM OUTPUT . . . 28 TIMING SOLENOID—ECM OUTPUT . . . . . . . . . . 29
ASD RELAY—ECM INPUT . . . . . . . . . . . . . . . . . 28 VEHICLE SPEED SENSOR—ECM INPUT . . . . . 27
BATTERY VOLTAGE—PCM INPUT . . . . . . . . . . . 25 VEHICLE THEFT ALARM . . . . . . . . . . . . . . . . . . 25
BOOST / PRESSURE SENSOR . . . . . . . . . . . . . 25 DIAGNOSIS AND TESTING
BRAKE SWITCH—ECM INPUT . . . . . . . . . . . . . . 27 ASD RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . 30
DATA LINK CONNECTOR—PCM AND ECM BOOST / PRESSURE SENSOR . . . . . . . . . . . . . 33
INPUT AND OUTPUT . . . . . . . . . . . . . . . . . . . 27 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . 34
ELECTRIC VACUUM MODULATOR (EVM)— DIESEL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . 30
ECM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 30 ENGINE COOLANT TEMPERATURE
ENGINE COOLANT GAUGE—PCM OUTPUT . . . 28 SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE COOLANT TEMPERATURE SENSOR— ENGINE SPEED SENSOR TEST . . . . . . . . . . . . 30
ECM/PCM INPUT . . . . . . . . . . . . . . . . . . . . . . 26 GLOW PLUG RELAY TEST . . . . . . . . . . . . . . . . 32
ENGINE OIL PRESSURE GAUGE— GLOW PLUG TEST . . . . . . . . . . . . . . . . . . . . . . 31
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 28 RELAYS—OPERATION/TESTING . . . . . . . . . . . . 32
ENGINE SPEED/CRANK POSITION SENSOR— VEHICLE SPEED SENSOR TEST . . . . . . . . . . . . 34
ECM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 REMOVAL AND INSTALLATION
FIVE VOLT POWER—ECM/PCM OUTPUT . . . . . 28 A/C CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . . 34
FUEL INJECTOR SENSOR—GROUND . . . . . . . . 26 ASD RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
GLOW PLUG LAMP—PCM OUTPUT . . . . . . . . . 28 ENGINE COOLANT TEMPERATURE SENSOR . . 34
GLOW PLUG RELAY—ECM OUTPUT . . . . . . . . 29 ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . 34
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 30 GLOW PLUG RELAY . . . . . . . . . . . . . . . . . . . . . 35
IGNITION CIRCUIT SENSE—MSA/PCM INPUT . 25 GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 34
IGNITION CIRCUIT SENSE—PCM INPUT . . . . . 26 POWERTRAIN CONTROL MODULE (PCM) . . . . 35
NEEDLE MOVEMENT OR INSTRUMENTED VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 36
FIRST INJECTOR—ECM INPUT . . . . . . . . . . . 26 SPECIFICATIONS
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . . 26 GLOW PLUG CURRENT DRAW . . . . . . . . . . . . . 37
POWERTRAIN CONTROL MODULE (PCM) . . . . 24 TORQUE CHART—2.5L DIESEL . . . . . . . . . . . . 37

GEN ERAL I N FORM AT I ON im por t a n t t o kn ow t h a t t h e E CM h a s a fea t u r e


wh er e, if possible, it will ign or e t h e fa iled sen sor, set
INTRODUCTION a code r ela t ed t o t h e sen sor, a n d oper a t e t h e en gin e
Th is sect ion will cover com pon en t s eit h er r egu la t ed in a “Lim p H om e” m ode. Wh en t h e E CM is oper a t in g
or con t r olled by t h e E CM con t r oller a n d t h e P ower- in a “Lim p H om e” m ode, t h e Ch eck E n gin e La m p on
t r a in Con t r ol Modu le (P CM). Th e fu el h ea t er r ela y t h e in st r u m en t pa n el m a y be con st a n t ly illu m in a t ed,
a n d fu el h ea t er a r e n ot oper a t ed by t h e E CM con t r ol- a n d t h e en gin e will m ost likely h a ve a n ot icea ble loss
ler or t h e P CM. Th ese com pon en t s a r e con t r olled by of per for m a n ce. An exa m ple of t h is wou ld be a n
t h e ign it ion (key) swit ch . All ot h er fu el syst em elec- Acceler a t or P eda l P osit ion Sen sor fa ilu r e, a n d in t h a t
t r ica l com pon en t s n ecessa r y t o oper a t e t h e en gin e sit u a t ion , t h e en gin e wou ld r u n a t a con st a n t 1100
a r e con t r olled or r egu la t ed by t h e E CM con t r oller, RP M, r ega r dless of t h e a ct u a l posit ion of t h e peda l.
wh ich in t er fa ces wit h t h e P CM. Refer t o t h e follow- Th is is t h e m ost ext r em e of t h e t h r ee “Lim p H om e”
in g descr ipt ion for m or e in for m a t ion . m odes.
Cer t a in fu el syst em com pon en t fa ilu r es m a y ca u se Wh en t h e Ch eck E n gin e La m p is illu m in a t ed con -
a n o st a r t , or pr even t t h e en gin e fr om r u n n in g. It is st a n t ly wit h t h e key on a n d t h e en gin e r u n n in g, it
u su a lly in dica t es a pr oblem h a s been det ect ed som e-
14 - 24 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
wh er e wit h in t h e fu el syst em . Th e DRBIII sca n t ool POWERTRAIN MOUNTING
is t h e best m et h od for com m u n ica t in g wit h t h e E CM CONTROL BRACKET
a n d P CM t o dia gn ose fa u lt s wit h in t h e syst em . MODULE
{PCM)

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

Fig. 2 PCM Location


a n d swit ch es t h a t pr ovide in pu t s t o t h e E CM a r e
con sider ed ECM In p u ts .
ECM In p u ts a re :
• Air Con dit ion in g Select ion
• Th eft Ala r m
• ASD Rela y
• Con t r ol Sleeve P osit ion Sen sor
• F u el Tem per a t u r e Sen sor
ECM HARNESS • Ma ss Air F low Sen sor
CONNECTOR C2 80b5cbb1 • Acceler a t or P eda l P osit ion Sen sor
• E n gin e Coola n t Tem per a t u r e Sen sor
Fig. 1 ECM Controller Location • Low Idle P osit ion Swit ch
Th e E CM Con t r oller is a pr e–pr ogr a m m ed, digit a l • 5 Volt Su pply
com pu t er. It will eit h er dir ect ly oper a t e or pa r t ia lly • Veh icle Speed Sen sor
r egu la t e t h e: • E n gin e Speed/Cr a n k P osit ion Sen sor (r pm )
• Speed Con t r ol • Needle Movem en t Sen sor
• Speed Con t r ol la m p • St a r t er Sign a l
• F u el Tim in g Solen oid • Br a ke Swit ch
• Ch eck E n gin e Ligh t • Speed Con t r ol Swit ch
• Glow P lu g Rela y • P ower Gr ou n d
• Glow P lu gs • Ign it ion (key) Swit ch Sen se
• Glow P lu g La m p ECM Ou tp u ts :
• ASD Rela y Aft er in pu t s a r e r eceived by t h e E CM a n d P CM,
• Air Con dit ion in g cer t a in sen sor s, swit ch es a n d com pon en t s a r e con -
• Ta ch om et er t r olled or r egu la t ed by t h e E CM a n d P CM. Th ese a r e
• E lect r ic Va cu u m Modu la t or (E VM) con sider ed ECM Ou tp u ts . Th ese ou t pu t s a r e for :
Th e E CM ca n a da pt it s pr ogr a m m in g t o m eet • A/C Clu t ch Rela y (for A/C clu t ch oper a t ion )
ch a n gin g oper a t in g con dit ion s. • Speed Con t r ol La m p
Th e E CM r eceives in pu t sign a ls fr om va r iou s • ASD Rela y
swit ch es a n d sen sor s. Ba sed on t h ese in pu t s, t h e • 5 Volt s Su pply
E CM r egu la t es va r iou s en gin e a n d veh icle oper a t ion s • F u el Qu a n t it y Act u a t or
t h r ou gh differ en t syst em com pon en t s. Th ese com po- • F u el Tim in g Solen oid
n en t s a r e r efer r ed t o a s ECM Ou tp u ts . Th e sen sor s • F u el Sh u t down Solen oid
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 25
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
• Glow P lu g La m p t h e in t a ke m a n ifold. Wh en t h e in t a ke m a n ifold pr es-
• Ch eck E n gin e La m p (“On /Off” sign a l) su r e is low, t h e volt a ge is low, a n d wh en t h e pr essu r e
• E lect r ic Va cu u m Modu la t or (E VM) is h igh , t h e volt a ge is h igh . Th e P CM u ses t h e volt -
• Glow P lu g Rela y a ge sign a ls fr om t h e Boost P r essu r e Sen sor, a n d t h e
• Ta ch om et er In t a ke Air Tem per a t u r e Sen sor t o det er m in e t h e
Th e P CM sen ds a n d r ecieves sign a ls t o a n d fr om a m ou n t of a ir flowin g t h r ou gh t h e in t a ke m a n ifold.
t h e E CM con t r oller. P CM in p u ts a re :
• P ower Gou n d
- BOOST PRESSURE
• 5 Volt s Su pply SENSOR HARNESS -.....-n,~ffFT--u.l.illll
• Veh icle Speed Sen sor CONNECTOR
• Wa t er-In -F u el Sen sor
• Coola n t Tem per a t u r e Sen sor
• Low Coola n t Sen sor
• Sen sor Ret u r n
• F u el Level Sen sor
• Oil P r essu r e Sen sor
• Ta ch om et er Sign a l
• Glow P lu g La m p
• Ch eck E n gin e La m p (“On /Off” sign a l)
• Br a ke On /Off Swit ch
• Ba t t er y Volt a ge
• ASD Rela y
P CM Ou tp u ts :
• A/C On Sign a l
80b77066
• Veh icle Th eft Ala r m “Ok t o Ru n ” sign a l
• Body Con t r ol Modu le CCD Bu s (+) Fig. 3 Boost Pressure Sensor Location
• Body Con t r ol Modu le CCD Bu s (–)
• Sca n Tool Da t a Lin k Recieve VEHICLE THEFT ALARM
• Sca n Tool Da t a Lin k Tr a n sm it Th e P CM ca n lea r n if t h e veh icle h a s a Veh icle
• Low Coola n t La m p Th eft Ala r m (VTA) syst em . On ce it det ect s t h e veh i-
• Gen er a t or Con t r ol cle h a vin g VTA, th e c o n tro lle r c a n ON LY B E
U S ED ON VEHICLES WITH VTA.
BOOST / PRESSURE SENSOR If t h e P CM is pu t it on a veh icle wit h ou t VTA t h e
Th e Boost P r essu r e Sen sor is m ou n t ed t o t h e t op of Glow P lu g La m p will st a r t t o blin k a n d t h e veh icle
t h e in t a ke m a n ifold (F ig. 3). It is a sen sor t h a t m ea - will n ot st a r t .
su r es bot h m a n ifold va cu u m a n d t u r bo boost , a n d it Th e P CM ca n n ot be fla sh ed t o r em ove t h e VTA.
a lso con t a in s a n in t egr a t ed in t a ke a ir t em per a t u r e
sen sor. Th e Boost P r essu r e Sen sor t a kes t h e pla ce of BATTERY VOLTAGE—PCM INPUT
t h e Ma ss Air F low (MAF ). In t h e In t a ke Air Tem per- Th e ba t t er y volt a ge in pu t pr ovides power t o t h e
a t u r e Sen sor com pon en t , t h er e is a cer a m ic elem en t P CM. It a lso in for m s t h e P CM wh a t volt a ge level is
t h a t ch a n ges it s r esist a n ce ba sed on t em per a t u r e. bein g su pplied by t h e gen er a t or on ce t h e veh icle is
Th e cer a m ic elem en t is pa r t of a n elect r on ic cir cu it r u n n in g.
con n ect ed t o t h e P CM, a n d h a s a volt a ge a pplied t o Th e ba t t er y in pu t a lso pr ovides t h e volt a ge t h a t is
it . Th e cer a m ic elem en t is exposed t o t h e a ir in side n eeded t o keep t h e P CM m em or y a live. Th e m em or y
t h e in t a ke. Th is a ir h a s a coolin g effect on t h e st or es Dia gn ost ic Tr ou ble Code (DTC) m essa ges.
cer a m ic elem en t , a n d it s r esist a n ce ch a n ges. Th is Tr ou ble codes will st ill be st or ed even if t h e ba t t a r y
ca u ses t h e volt a ge flowin g t h r ou gh t h e in t a ke a ir volt a ge is lost .
t em per a t u r e cir cu it t o va r y. Th e volt a ge sign a l pr o-
du ced by t h e In t a ke Air Tem per a t u r e Sen sor ch a n ges SENSOR RETURN—ECM/PCM INPUT (ANALOG
in ver sely t o t h e t em per a t u r e, a n d is m ea su r ed by t h e GROUND)
P CM. As a gen er a l r u le, wh en t h e t em per a t u r e of t h e Sen sor Ret u r n pr ovides a low n oise An a log gr ou n d
a ir in t h e in t a ke is h igh , t h e volt a ge sign a l pr odu ced r efer en ce for a ll syst em sen sor s.
by t h e In t a ke Air Tem per a t u r e Sen sor is low. Th e
com pon en t of t h e Boost P r essu r e Sen sor t h a t m ea - IGNITION CIRCUIT SENSE—MSA/PCM INPUT
su r es m a n ifold va cu u m a n d t u r bo boost pr odu ces a
Th e ign it ion cir cu it sen se in pu t sign a ls t h e MSA
volt a ge sign a l t h a t is pr opor t ion a l t o t h e pr essu r e in
a n d P CM t h a t t h e ign it ion (key) swit ch h a s been
14 - 26 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
t u r n ed t o t h e ON posit ion . Th is sign a l in it ia t es t h e ENGINE COOLANT TEMPERATURE SENSOR—
glow plu g con t r ol r ou t in e t o begin t h e “pr e–h ea t ”
ECM/PCM INPUT
cycle.
Th e 0–5 volt in pu t fr om t h is sen sor t ells t h e E CM
a n d P CM t h e t em per a t u r e of t h e en gin e coola n t .
IGNITION CIRCUIT SENSE—PCM INPUT Ba sed on t h e volt a ge r eceived a t t h e E CM, it will
Th e ign it ion cir cu it sen se in pu t sign a ls t h e P CM t h en det er m in e oper a t ion of t h e fu el t im in g solen oid,
t h a t t h e ign it ion (key) swit ch h a s been t u r n ed t o t h e glow plu g r ela y, elect r ica l va cu u m m odu la t or (em is-
ON posit ion . Th is sign a l in it ia t es t h e glow plu g con - sion com pon en t ) a n d gen er a t or (ch a r gin g syst em ).
t r ol r ou t in e t o begin t h e “pr e–h ea t ” cycle. Th e sen sor is loca t ed on t h e side of t h e #3 cylin der
h ea d n ea r t h e r ea r of fu el in ject ion pu m p (F ig. 5).
POWER GROUND
P r ovides a com m on gr ou n d for power devices (sole- ECM r
n oid a n d r ela y devices). ENGINE COOLANT
TEMPERATUR~E '----
(ECT)
NEEDLE MOVEMENT OR INSTRUMENTED SENSOR
FIRST INJECTOR—ECM INPUT
Th is in pu t fr om t h e E CM su pplies a con st a n t 30
m A elect r ica l cu r r en t sou r ce for t h e fir st in ject or sen -
sor. It will va r y t h e volt a ge t o t h is sen sor wh en it
sen ses a m ech a n ica l m ovem en t wit h in t h e in ject or
n eedle (pin t le) of t h e n u m ber –1 cylin der fu el in ject or.
Wh en t h is volt a ge h a s been det er m in ed by t h e E CM,
it will t h en con t r ol a n ou t pu t t o t h e fu el t im in g sole-
n oid (t h e fu el t im in g solen oid is loca t ed on t h e fu el
in ject ion pu m p). Also r efer t o F u el In ject ion P u m p for
PCMECT
a ddit ion a l in for m a t ion . SENSOR
Th e fir st in ject or sen sor is a m a gn et ic (in du ct ive) ) HARNESS
t ype. -;;:.CONNECTOR
Th e fir st in ject or sen sor is u sed on ly on t h e fu el .,...,,,,. ..A:"\.~ "'

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

Fig. 4 Fuel Injector Sensor Fig. 6 Engine Speed Sensor Location


P r ovides a low n oise gr ou n d for t h e fu el in ject or
sen sor on ly.
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 27
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e en gin e speed sen sor pr odu ces it s own ou t pu t P CM will t h en r em ove t h e gr ou n d fr om t h e A/C r ela y.
sign a l. If t h is sign a l is n ot r eceived, t h e E CM will n ot Th is will dea ct iva t e t h e A/C com pr essor clu t ch . Also,
a llow t h e en gin e t o st a r t . if t h e en gin e coola n t r ea ch es a t em per a t u r e ou t side
Th e en gin e speed sen sor in pu t is u sed in con ju n c- n or m a l of it s n or m a l r a n ge, or it over h ea t s, t h e E CM
t ion wit h t h e fir st in ject or sen sor t o est a blish fu el will dea ct iva t e t h e A/C clu t ch .
in ject ion pu m p t im in g.
Th e flywh eel h a s fou r n ot ch es a t it s ou t er edge BRAKE SWITCH—ECM INPUT
(F ig. 7). E a ch n ot ch is spa ced equ a lly ever y 90°. Th e Wh en t h e br a ke ligh t swit ch is a ct iva t ed, t h e E CM
n ot ch es ca u se a pu lse t o be gen er a t ed wh en t h ey r eceives a n in pu t in dica t in g t h a t t h e br a kes a r e
pa ss u n der t h e speed sen sor (F ig. 7). Th ese pu lses bein g a pplied. Aft er r eceivin g t h is in pu t , t h e E CM is
a r e t h e in pu t t o t h e E CM. Th e in pu t fr om t h is sen sor u sed t o con t r ol t h e speed con t r ol syst em . Th er e is a
det er m in es cr a n ksh a ft posit ion (in degr ees) by m on i- P r im a r y a n d a Secon da r y br a ke swit ch . Th e Secon d-
t or in g t h e n ot ch es. a r y br a ke swit ch is closed u n t il t h e br a ke peda l is
pr essed.
ENGINE
SPEED
SENSOR DATA LINK CONNECTOR—PCM AND ECM
INPUT AND OUTPUT
Th e 16–wa y da t a lin k con n ect or (dia gn ost ic sca n
t ool con n ect or ) lin ks t h e Dia gn ost ic Rea dou t Box
FLYWHEEL (DRB) sca n t ool wit h t h e P CM a n d E 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
n ea r t h e bot t om of st eer in g colu m n (F ig. 8).

80a0c62f

Fig. 7 Speed Sensor Operation


Th e sen sor a lso gen er a t es a n r pm sign a l t o t h e
E CM. Th is sign a l is u sed a s a n in pu t for t h e con t r ol DATA LINK CONNECTOR
(LEFT SIDE OF COLUMN
of t h e gen er a t or field, veh icle speed con t r ol, a n d ABOVE BRAKE PEDAL)
in st r u m en t pa n el m ou n t ed t a ch om et er. 80a07536
If t h e en gin e speed sen sor sh ou ld fa il, t h e syst em
is u n a ble t o com pen sa t e for t h e pr oblem a n d t h e ca r Fig. 8 Data Link Connector Location
will st op.
VEHICLE SPEED SENSOR—ECM INPUT
AIR CONDITIONING (A/C) CONTROLS—ECM Th e veh icle speed sen sor is loca t ed in t h e ext en sion
h ou sin g of t h e t r a n sm ission (2WD) (F ig. 9) or on t h e
INPUTS t r a n sfer ca se ext en sion h ou sin g (F ig. 10). Th e sen sor
Th e A/C con t r ol syst em in for m a t ion a pplies t o fa c- in pu t is u sed by t h e E CM t o det er m in e veh icle speed
t or y in st a lled a ir con dit ion in g u n it s. a n d dist a n ce t r a veled.
A/C REQU ES T S IGN AL: Wh en eit h er t h e A/C or Th e speed sen sor gen er a t es 8 pu lses per sen sor
Defr ost m ode h a s been select ed a n d t h e A/C low a n d r evolu t ion . Th ese sign a ls, in con ju n ct ion wit h a
h igh –pr essu r e swit ch es a r e closed, a n in pu t sign a l is closed t h r ot t le sign a l fr om t h e a cceler a t or peda l posi-
sen t t o t h e E CM. Th e E CM u ses t h is in pu t t o cycle t ion sen sor, in dica t e a n idle deceler a t ion t o t h e E CM.
t h e A/C com pr essor t h r ou gh t h e A/C r ela y. Wh en t h e veh icle is st opped a t idle, a r elea sed peda l
If t h e A/C low or h igh –pr essu r e swit ch open s, t h e sign a l is r eceived by t h e E CM (bu t a speed sen sor
E CM will n ot r eceive a n A/C r equ est sign a l. Th e sign a l is n ot r eceived).
14 - 28 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
speed h a s been select ed. Th e Resu m e in pu t in dica t es
SENSOR
ELECTRICAL t o t h e E CM t h a t t h e pr eviou s fixed speed is
CONNECTOR r equ est ed.
Speed con t r ol oper a t ion will st a r t a t 50 km /h –142
km /h (35–85 m ph ). Th e u pper r a n ge of oper a t ion is
n ot r est r ict ed by veh icle speed. In pu t s t h a t effect
speed con t r ol oper a t ion a r e veh icle speed sen sor a n d
a cceler a t or peda l posit ion sen sor.
Refer t o Gr ou p 8H for fu r t h er speed con t r ol in for-
m a t ion .

ASD RELAY—ECM INPUT


A 12 volt sign a l a t t h is in pu t in dica t es t o t h e E CM
t h a t t h e ASD r ela y h a s been a ct iva t ed. Th e ASD
r ela y is loca t ed in t h e 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.
Th is in pu t is u sed on ly t o sen se t h a t t h e ASD r ela y
is en er gized. If t h e E CM does n ot see 12 volt s (+) a t
J9414-60
t h is in pu t wh en t h e ASD r ela y sh ou ld be a ct iva t ed, it
will set a Dia gn ost ic Tr ou ble Code (DTC).
Fig. 9 Vehicle Speed Sensor—Typical
SENSOR FIVE VOLT POWER—ECM/PCM OUTPUT
ELECTRICAL Th is cir cu it su pplies a ppr oxim a t ely 5 volt s t o
CONNECTOR power t h e Acceler a t or P eda l P osit ion Sen sor, a n d t h e
Boost / P r essu r e Sen sor.

ENGINE COOLANT GAUGE—PCM OUTPUT


Refer t o t h e In st r u m en t P a n el a n d Ga u ges gr ou p
for a ddit ion a l in for m a t ion .

ENGINE OIL PRESSURE GAUGE—PCM


OUTPUT
Refer t o t h e In st r u m en t P a n el a n d Ga u ges gr ou p
for a ddit ion a l in for m a t ion .

GLOW PLUG LAMP—PCM OUTPUT


4WD Th e Glow P lu g la m p (m a lfu n ct ion in dica t or la m p)
TRANSFER illu m in a t es on t h e m essa ge cen t er ea ch t im e t h e ign i-
VEHICLE CASE t ion (key) swit ch is t u r n ed on . It will st a y on for
SPEED EXTENSION a bou t t wo secon ds a s a bu lb t est .
SENSOR
80a35409

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.

TIMING SOLENOID—ECM OUTPUT


Th e t im in g solen oid is loca t ed on t h e bot t om of t h e
fu el in ject ion pu m p (F ig. 12).

80ad08f8

Fig. 13 Glow Plug Relay Location


plu g r ela y is a ct iva t ed, it will con t r ol t h e 12V+ 100
a m p cir cu it for t h e oper a t ion of t h e fou r glow plu gs.
Wit h a cold en gin e, t h e glow plu g r ela y a n d glow
plu gs m a y be a ct iva t ed for a m a xim u m t im e of 200
secon ds. Refer t o t h e followin g Glow P lu g Con t r ol
ch a r t for a t em per a t u r e/t im e com pa r ison of glow plu g
r ela y oper a t ion .
In t h is ch a r t , P r e–H ea t a n d P ost –H ea t t im es a r e
m en t ion ed. P r e–h ea t is t h e a m ou n t of t im e t h e glow
Fig. 12 Timing Solenoid plu g r ela y cir cu it is a ct iva t ed wh en t h e ign it ion (key)
swit ch is ON, bu t t h e en gin e h a s yet t o be st a r t ed.
Th is 12(+) volt , pu lse widt h m odu la t ed (du t y–cycle)
P ost –h ea t is t h e a m ou n t of t im e t h e glow plu g r ela y
ou t pu t con t r ols t h e a m ou n t of fu el t im in g (a dva n ce)
cir cu it is a ct iva t ed a ft er t h e en gin e is oper a t in g. Th e
in t h e fu el in ject ion pu m p. Th e h igh er t h e du t y–cy-
Glow P lu g la m p will n ot be illu m in a t ed du r in g t h e
cle, t h e lower t h e a dva n ce. Th e lower t h e du t y–cycle,
post –h ea t cycle.
t h e m or e a dva n ced t h e fu el t im in g.
Th e du t y–cycle is det er m in ed by t h e E CM fr om GLOW PLU G CON T ROL
in pu t s it r eceives fr om t h e fu el in ject or sen sor a n d
en gin e speed sen sor. ENGINE WAIT-TO-START PRE-HEAT POST-HEAT
COOLANT LAMP ON CYCLE(GLOW CYCLE
TACHOMETER—PCM OUTPUT TEMPERATURE
KEYON
(SECONDS) PLUGS ON)
(SECONDS)
(SECONDS)

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.

+10C 6SEC. 25SEC. 118 SEC.


GLOW PLUG RELAY—ECM OUTPUT
Wh en t h e ign it ion (key) swit ch is pla ced in t h e ON +30C 5SEC. 20SEC. 70 SEC.
posit ion , a sign a l is sen t t o t h e E CM r ela t in g cu r r en t
en gin e coola n t t em per a t u r e. Th is sign a l is sen t fr om +40C 4SEC. 16 SEC. 60 SEC.
t h e en gin e coola n t t em per a t u r e sen sor. +70C 3SEC. 16 SEC. 20 SEC.
Aft er r eceivin g t h is sign a l, t h e E CM will det er m in e
if, wh en a n d for h ow lon g a per iod t h e glow plu g
r ela y sh ou ld be a ct iva t ed. Th is is don e befor e, du r in g
80a0c517
a n d a ft er t h e en gin e is st a r t ed. Wh en ever t h e glow
14 - 30 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

GLOW PLUGS ASD RELAY TEST


Glow plu gs a r e u sed t o h elp st a r t a cold or cool To per for m a t est of t h e r ela y a n d it s r ela t ed cir-
en gin e. Th e plu g will h ea t u p a n d glow t o h ea t t h e cu it r y, r efer t o t h e DRB sca n t ool. To t est t h e r ela y
com bu st ion ch a m ber of ea ch cylin der. An in dividu a l on ly, r efer t o Rela ys—Oper a t ion /Test in g in t h is sec-
plu g is u sed for ea ch cylin der. E a ch plu g is t h r ea ded t ion of t h e gr ou p.
in t o t h e cylin der h ea d a bove t h e fu el in ject or (F ig. D ia g n o s tic Tro u ble Co d e s : Refer t o On -Boa r d
14). Dia gn ost ics in Gr ou p 25, E m ission Con t r ol Syst em
for a list of Dia gn ost ic Tr ou ble Codes (DTC’s) for cer-
t a in fu el syst em com pon en t s.

ENGINE SPEED SENSOR TEST


To per for m a t est of t h e en gin e speed sen sor a n d
it s r ela t ed cir cu it r y, r efer t o t h e DRB sca n t ool.
D ia g n o s tic Tro u ble Co d e s : Refer t o On -Boa r d
Dia gn ost ics in Gr ou p 25, E m ission Con t r ol Syst em
for a list of Dia gn ost ic Tr ou ble Codes (DTC’s) for cer-
t a in fu el syst em com pon en t s.

ENGINE COOLANT TEMPERATURE SENSOR


TEST
Th e sen sor is loca t ed on t h e side of cylin der h ea d
n ea r t h e r ea r of fu el in ject ion pu m p (F ig. 15).
PCM \ ECM r
Fig. 14 Glow Plug ENGINE COOLANT ENGINE COOLANT'----
E a ch plu g will m om en t a r ily dr a w a ppr oxim a t ely 25 TEMPERATURE TEMPERATUR~E
a m ps of elect r ica l cu r r en t du r in g t h e in it ia l key–on (ECT) (ECT)
cycle. Th is is on a cold or cool en gin e. Aft er h ea t in g, SENSOR SENSOR
t h e cu r r en t dr a w will dr op t o a ppr oxim a t ely 9–12
a m ps per plu g.
Tot a l m om en t a r y cu r r en t dr a w for a ll fou r plu gs is
a ppr oxim a t ely 100 a m ps on a cold en gin e dr oppin g t o
a t ot a l of a ppr oxim a t ely 40 a m ps a ft er t h e plu gs a r e
h ea t ed.
E lect r ica l oper a t ion of t h e glow plu gs a r e con -
t r olled by t h e glow plu g r ela y. Refer t o t h e pr eviou s
Glow P lu g Rela y—E CM Ou t pu t for a ddit ion a l in for- ,!]>?

m a t ion . .---- PCM ECT


1 SENSOR
ELECTRIC VACUUM MODULATOR (EVM)—ECM ) HARNESS
OUTPUT ,,,--: CONNE~~R'"
/.,...,,,,.
Th is cir cu it con t r ols oper a t ion of t h e E lect r ic Va c-
u u m Modu la t or (E VM). Th e E VM con t r ols oper a t ion Fig. 15 Engine Coolant Temperature Sensor
of t h e E GR va lve. Location
Refer t o Gr ou p 25, E m ission Con t r ol Syst em for F or a list of Dia gn ost ic Tr ou ble Codes (DTC’s) for
in for m a t ion . See E lect r ic Va cu u m Modu la t or. cer t a in fu el syst em com pon en t s, r efer t o On -Boa r d
Dia gn ost ics in Gr ou p 25, E m ission Con t r ol Syst em .
To t est t h e sen sor on ly, r efer t o t h e followin g:
DI AGN OSI S AN D T EST I N G (1) Discon n ect wir e h a r n ess con n ect or fr om coola n t
t em per a t u r e sen sor.
DIESEL DIAGNOSTICS (2) Test t h e r esist a n ce of t h e sen sor wit h a h igh
Th e E CM con t r oller s per for m en gin e off dia gn ost ic in pu t im peda n ce (digit a l) volt –oh m m et er. Th e r esis-
t est s, wh ich m a y be h ea r d for a bou t 60 secon ds a ft er t a n ce (a s m ea su r ed a cr oss t h e sen sor t er m in a ls)
t u r n in g t h e key off. sh ou ld be less t h a n 1340 oh m s wit h t h e en gin e
wa r m . Refer t o t h e followin g Sen sor Resist a n ce
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 31
DI AGN OSI S AN D T EST I N G (Cont inue d)
(OH MS) ch a r t . Repla ce t h e sen sor if it is n ot wit h in
t h e r a n ge of r esist a n ce specified in t h e ch a r t . INSERT GLOW
PLUG HERE OBSERVATION
SEN SOR RESI STAN CE (OH M S)
WINDOW

TEMPERATURE RESISTANCE (OHMS)

C F MIN MAX

-40 -40 291,490 381,710


-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
60 140 2,310 2,670
70 158 1,630 1,870 TESTER
80 176 1,170 1,340 BUTTON TEST LEADS
90 194 860 970 80a0c62d
100 212 640 720
110 230 480 540
370 410 Fig. 16 Typical Glow Plug Tester
120 248
(3) At t a ch t h e bla ck lea d of t h e t est er t o t h e 12V–
J928D-4 (n ega t ive) side of t h e ba t t er y.
(4) F it t h e glow plu g in t o t h e t op of t h e t est er a n d
(3) Test con t in u it y of t h e wir e h a r n ess. Do t h is
secu r e it wit h t h e spr in g loa ded ba r (F ig. 16).
bet ween t h e E CM wir e h a r n ess con n ect or a n d t h e
(5) At t a ch t h e t h ir d lea d wir e of t h e t est er t o t h e
sen sor con n ect or t er m in a l. Also t est con t in u it y of
elect r ica l t er m in a l a t t h e en d of t h e glow plu g.
wir e h a r n ess t o t h e sen sor con n ect or t er m in a l. Refer
(6) Wh en per for m in g t h e t est , t h e t est er bu t t on
t o Gr ou p 8W for wir in g con n ect or a n d cir cu it r y in for-
(F ig. 16) sh ou ld be h eld con t in u ou sly wit h ou t r elea se
m a t ion . Repa ir t h e wir e h a r n ess if a n open cir cu it is
for 20 secon ds a s in dica t ed by t h e 4 t im er la m ps.
in dica t ed.
E a ch illu m in a t ed la m p r epr esen t s a 5 secon d t im e
(4) Aft er t est s a r e com plet ed, con n ect elect r ica l
la pse.
con n ect or t o sen sor.
(a ) P r ess a n d h old t h e t est er bu t t on (F ig. 16)
a n d n ot e t h e a m p ga u ge r ea din g. Th e ga u ge r ea d-
GLOW PLUG TEST in g sh ou ld in dica t e a m om en t a r y, in it ia l cu r r en t
H a r d st a r t in g or a r ou gh idle a ft er st a r t in g m a y be dr a w (su r ge) of a ppr oxim a t ely 25 a m ps. Aft er t h e
ca u sed by on e or m or e defect ive glow plu gs. Befor e in it ia l su r ge, t h e a m p ga u ge r ea din g sh ou ld begin
t est in g t h e glow plu gs, a t est of t h e glow plu g r ela ys t o fa ll off. Th e glow plu g t ip sh ou ld st a r t t o glow
sh ou ld be per for m ed. Th is will en su r e t h a t 12V+ is a n or a n ge color a ft er 5 secon ds. If t h e t ip did n ot
a va ila ble a t t h e plu gs wh en st a r t in g t h e en gin e. glow a ft er 5 secon ds, r epla ce t h e glow plu g. Befor e
Refer t o t h e Glow P lu g Rela y Test for in for m a t ion . disca r din g t h e glow plu g, ch eck t h e posit ion of t h e
F or a ccu r a t e t est r esu lt s, t h e glow plu gs sh ou ld be cir cu it br ea ker on t h e bot t om of t h e plu g t est er. It
r em oved fr om t h e en gin e. Th e plu gs m u st be ch ecked m a y h a ve t o be r eset . Reset if n ecessa r y.
wh en cold. D o n o t c h e c k th e p lu g s if th e e n g in e (b) Con t in u e t o h old t h e t est er bu t t on wh ile
h a s re c e n tly be e n o p e ra te d . If p lu g s a re obser vin g t h e a m p ga u ge a n d t h e 4 t im er la m ps.
c h e c k e d w h e n w a rm , in c o rre c t a m p g a u g e Wh en a ll 4 la m ps a r e illu m in a t ed, in dica t in g a 20
re a d in g s w ill re s u lt. secon d t im e la pse, t h e a m p ga u ge r ea din g sh ou ld
Use Ch u r ch ill Glow P lu g Test er DX.900 or a n in dica t e a 9–12 a m p cu r r en t dr a w. If n ot , r epla ce
equ iva len t (F ig. 16) for t h e followin g t est s. Th is t h e glow plu g. Refer t o Glow P lu g Rem ova l/In st a l-
t est er is equ ipped wit h 4 t im er la m ps. la t ion .
(1) Rem ove t h e glow plu gs fr om t h e en gin e. Refer (7) Ch eck ea ch glow plu g in t h is m a n n er u sin g on e
t o Glow P lu g Rem ova l/In st a lla t ion . 20 secon d cycle. If t h e glow plu g is t o be r et est ed, it
(2) At t a ch t h e r ed lea d of t h e t est er t o t h e 12V+ m u st fir st be a llowed t o cool t o r oom t em per a t u r e.
(posit ive) side of t h e ba t t er y.
14 - 32 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
WARNING: THE GLOW PLUG WILL BECOME TES TIN G:
EXTREMELY HOT (GLOWING) DURING THESE Discon n ect a n d isola t e t h e elect r ica l con n ect or s
TESTS. BURNS COULD RESULT IF IMPROPERLY (F ig. 18) a t a ll fou r glow plu gs. Wit h t h e en gin e cool
HANDLED. ALLOW THE GLOW PLUG TO COOL or cold, a n d t h e key in t h e ON posit ion , ch eck for
BEFORE REMOVING FROM TESTER. 10–12 volt s + a t ea ch elect r ica l con n ect or. 10–12 volt s
+ sh ou ld be a t ea ch con n ect or wh en ever t h e E CM is
(8) Rem ove t h e glow plu g fr om t h e t est er. oper a t in g in t h e pr e–h ea t or post –h ea t cycles (r efer
t o t h e followin g Glow P lu g Con t r ol ch a r t ). B e v e ry
GLOW PLUG RELAY TEST c a re fu l n o t to a llo w a n y o f th e fo u r d is c o n -
Th e glow plu g r ela y is loca t ed in t h e en gin e com - n e c te d g lo w p lu g e le c tric a l c o n n e c to rs to c o n -
pa r t m en t on t h e left –in n er fen der (F ig. 17). ta c t a m e ta l s u rfa c e . Wh e n th e k e y is tu rn e d to
MOUNTING th e ON p o s itio n , a p p ro x im a te ly 100 a m p s a t 12
GLOW
BOLT v o lts is s u p p lie d to th e s e c o n n e c to rs . If 10–12
PLUG
RELAY volt s + is n ot a va ila ble a t ea ch con n ect or, ch eck con -
t in u it y of wir in g h a r n ess dir ect ly t o t h e r ela y. If con -
t in u it y is good dir ect ly t o t h e r ela y, t h e fa u lt is eit h er
wit h t h e r ela y or t h e r ela y in pu t fr om t h e E CM. To
t est t h e r ela y on ly, r efer t o Rela ys—Oper a t ion /Test -
in g in t h is sect ion of t h e gr ou p. If t h e r ela y t est is
good, r efer t o t h e DRB sca n t ool.
D ia g n o s tic Tro u ble Co d e s : Refer t o On -Boa r d
Dia gn ost ics in Gr ou p 25, E m ission Con t r ol Syst em
for a list of Dia gn ost ic Tr ou ble Codes (DTC’s) for cer-
t a in fu el syst em com pon en t s.

Fig. 17 Glow Plug Relay Location


Wh en t h e ign it ion (key) swit ch is pla ced in t h e ON
posit ion , a sign a l is sen t t o t h e E CM r ela t in g cu r r en t
en gin e coola n t t em per a t u r e. Th is sign a l is sen t fr om
t h e en gin e coola n t t em per a t u r e sen sor.
Aft er r eceivin g t h is sign a l, t h e E CM will det er m in e
if, wh en a n d for h ow lon g a per iod t h e glow plu g
r ela y sh ou ld be a ct iva t ed. Th is is don e befor e, du r in g
a n d a ft er t h e en gin e is st a r t ed. Wh en ever t h e glow
plu g r ela y is a ct iva t ed, it will con t r ol t h e 12V+ 100
a m p cir cu it for t h e oper a t ion of t h e fou r glow plu gs. Fig. 18 Wiring Connection at Glow Plug
Th e Glow P lu g la m p is t ied t o t h is cir cu it . La m p RELAYS—OPERATION/TESTING
oper a t ion is a lso con t r olled by t h e E CM. Th e fo llo w in g d e s c rip tio n o f o p e ra tio n a n d
Wit h a cold en gin e, t h e glow plu g r ela y a n d glow te s ts a p p ly o n ly to th e AS D a n d o th e r re la y s .
plu gs m a y be a ct iva t ed for a m a xim u m t im e of 200 Th e t er m in a ls on t h e bot t om of ea ch r ela y a r e n u m -
secon ds. Refer t o t h e Glow P lu g Con t r ol ch a r t for a ber ed (F ig. 19).
t em per a t u r e/t im e com pa r ison of glow plu g r ela y oper-
a t ion . OPERATION
In t h is ch a r t , P r e–H ea t a n d P ost –H ea t t im es a r e • Ter m in a l n u m ber 30 is con n ect ed t o ba t t er y volt -
m en t ion ed. P r e–h ea t is t h e a m ou n t of t im e t h e glow a ge. F or bot h t h e ASD a n d ot h er r ela ys, t er m in a l 30
plu g r ela y cir cu it is a ct iva t ed wh en t h e ign it ion (key) is con n ect ed t o ba t t er y volt a ge a t a ll t im es.
swit ch is ON, bu t t h e en gin e h a s yet t o be st a r t ed. • Th e E CM gr ou n ds t h e coil side of t h e r ela y
P ost –h ea t is t h e a m ou n t of t im e t h e glow plu g r ela y t h r ou gh t er m in a l n u m ber 85.
cir cu it is a ct iva t ed a ft er t h e en gin e is oper a t in g. Th e • Ter m in a l n u m ber 86 su pplies volt a ge t o t h e coil
Glow P lu g la m p will n ot be illu m in a t ed du r in g t h e side of t h e r ela y.
post –h ea t cycle.
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 33
DI AGN OSI S AN D T EST I N G (Cont inue d)
GLOW PLU G CON T ROL n a ls 85 a n d 86. Th e r esist a n ce sh ou ld be bet ween 75
!5 oh m s.
(3) Con n ect t h e oh m m et er bet ween t er m in a ls 30
ENGINE WAIT-TO-START PRE-HEAT POST-HEAT
COOLANT LAMP ON CYCLE(GLOW CYCLE a n d 87A. Th e oh m m et er sh ou ld sh ow con t in u it y
TEMPERATURE (SECONDS) PLUGS ON) (SECONDS) bet ween t er m in a ls 30 a n d 87A.
KEYON (SECONDS)
(4) Con n ect t h e oh m m et er bet ween t er m in a ls 87
a n d 30. Th e oh m m et er sh ou ld n ot sh ow con t in u it y a t
-30 C 15 SEC. 45SEC. 200 SEC. t h is t im e.
(5) Con n ect on e en d of a ju m per wir e (16 ga u ge or
-10 C 8SEC. 35SEC. 180 SEC. sm a ller ) t o r ela y t er m in a l 85. Con n ect t h e ot h er en d
of t h e ju m per wir e t o t h e gr ou n d side of a 12 volt
+10C 6SEC. 25SEC. 118 SEC.
power sou r ce.
+30C 5SEC. 20SEC. 70 SEC. (6) Con n ect on e en d of a n ot h er ju m per wir e (16
ga u ge or sm a ller ) t o t h e power side of t h e 12 volt
+40C 4SEC. 16 SEC. 60 SEC. power sou r ce. D o n o t a tta c h th e o th e r e n d o f th e
ju m p e r w ire to th e re la y a t th is tim e .
+70C 3SEC. 16 SEC. 20 SEC.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
80a0c517
(7) At t a ch t h e ot h er en d of t h e ju m per wir e t o
MOUNTING r ela y t er m in a l 86. Th is a ct iva t es t h e r ela y. Th e oh m -
BOLT m et er sh ou ld n ow sh ow con t in u it y bet ween r ela y t er-
m in a ls 87 a n d 30. Th e oh m m et er sh ou ld n ot sh ow
con t in u it y bet ween r ela y t er m in a ls 87A a n d 30.
(8) Discon n ect ju m per wir es.
(9) Repla ce t h e r ela y if it did n ot pa ss t h e con t in u -
it y a n d r esist a n ce t est s. If t h e r ela y pa ssed t h e t est s,
it oper a t es pr oper ly. Ch eck t h e r em a in der of t h e ASD
a n d ot h er r ela y cir cu it s. Refer t o gr ou p 8W, Wir in g
Dia gr a m s.

BOOST / PRESSURE SENSOR

- BOOST PRESSURE
SENSOR HARNESS _-rrT,-u-"ill"T-.cllll.W
ELECTRICAL
CONNECTOR
CONNECTOR
80ad08f8

Fig. 19 Glow Plug Relay Location


• Wh en t h e P CM de-en er gizes t h e ASD a n d ot h er
r ela ys, t er m in a l n u m ber 87A con n ect s t o t er m in a l 30.
Th is is t h e Off posit ion . In t h e off posit ion , volt a ge is
n ot su pplied t o t h e r est of t h e cir cu it . Ter m in a l 87A
is t h e cen t er t er m in a l on t h e r ela y.
• Wh en t h e E CM en er gizes t h e ASD a n d ot h er
r ela ys, t er m in a l 87 con n ect s t o t er m in a l 30. Th is is
t h e On posit ion . Ter m in a l 87 su pplies volt a ge t o t h e
r est of t h e cir cu it .

TESTING 80b77066

Th e followin g pr ocedu r e a pplies t o t h e ASD a n d


ot h er r ela ys. Fig. 20 Boost Pressure Sensor Location
(1) Rem ove r ela y fr om con n ect or befor e t est in g. If t h e boost pr essu r e sen sor fa ils, t h e P CM r ecor ds
(2) Wit h t h e r ela y r em oved fr om t h e veh icle, u se a DTC in t o m em or y a n d con t in u es t o oper a t e t h e
a n oh m m et er t o ch eck t h e r esist a n ce bet ween t er m i-
14 - 34 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
en gin e in on e of t h e t h r ee “lim p-in ” m odes. Wh en t h e
P CM is oper a t in g in t h is m ode, a loss of power will
be pr esen t , a s if t h e t u r boch a r ger wa s n ot oper a t in g.
Th e best m et h od for dia gn osin g fa u lt s wit h t h e boost
pr essu r e sen sor is wit h t h e DRB III sca n t ool. D ia g -
n o s tic Tro u ble Co d e s : Refer t o On -Boa r d Dia gn os-
t ics in Gr ou p 25, E m ission Con t r ol Syst em for a list
of Dia gn ost ic Tr ou ble Codes (DTC’s) for cer t a in fu el
syst em com pon en t s.

VEHICLE SPEED SENSOR TEST


.......___'::::",
To per for m a t est of t h e sen sor a n d it s r ela t ed cir- = '-..'-..
cu it r y, r efer t o DRB sca n t ool. -.,j__...;~J..i...."-- -------:I-
1
~~
D ia g n o s tic Tro u ble Co d e s : Refer t o On -Boa r d LEFT REAR /, 1
Dia gn ost ics in Gr ou p 25, E m ission Con t r ol Syst em OF ENGINE / MOUNTING BOLT($) 80a0c62e
for a list of Dia gn ost ic Tr ou ble Codes (DTC’s) for cer-
t a in fu el syst em com pon en t s. Fig. 21 Engine Speed Sensor

DIAGNOSTIC TROUBLE CODES ENGINE COOLANT TEMPERATURE SENSOR


Th e sen sor is loca t ed on t h e side of cylin der h ea d
F or a list of Dia gn ost ic Tr ou ble Codes (DTC’s),
n ea r t h e r ea r of fu el in ject ion pu m p.
r efer t o Gr ou p 25, E m ission Con t r ol Syst em for in for-
m a t ion . See On -Boa r d Dia gn ost ics.
REMOVAL

REM OVAL AN D I N STALLAT I ON WARNING: HOT, PRESSURIZED COOLANT CAN


CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ASD RELAY
ING THE COOLANT TEMPERATURE SENSOR.
Th e ASD r ela y is loca t ed in t h e P DC. F or t h e loca -
REFER TO GROUP 7, COOLING.
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. (1) P a r t ia lly dr a in coolin g syst em . Refer t o Gr ou p
7, Coolin g.
A/C CLUTCH RELAY (2) Discon n ect elect r ica l con n ect or fr om sen sor.
Th e A/C clu t ch r ela y is loca t ed in t h e P DC. F or t h e (3) Rem ove sen sor fr om cylin der h ea d.
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. INSTALLATION
(1) In st a ll a n ew copper ga sket t o sen sor.
ENGINE SPEED SENSOR (2) In st a ll sen sor t o cylin der h ea d.
Th e en gin e speed sen sor is m ou n t ed t o t h e t r a n s- (3) Tigh t en sen sor t o 18 N·m (13 ft . lbs.) t or qu e.
m ission bellh ou sin g a t t h e r ea r of t h e en gin e block (4) Con n ect elect r ica l con n ect or t o sen sor.
(F ig. 21). (5) Repla ce a n y lost en gin e coola n t . Refer t o Gr ou p
7, Coolin g Syst em .
REMOVAL
(1) Discon n ect t h e h a r n ess (on t h e sen sor ) fr om GLOW PLUGS
t h e m a in elect r ica l h a r n ess. Th e glow plu gs a r e loca t ed a bove ea ch fu el in ject or
(2) Rem ove t h e sen sor m ou n t in g bolt s. (F ig. 22). F ou r in dividu a l plu gs a r e u sed.
(3) Rem ove t h e sen sor.
REMOVAL
INSTALLATION (1) Discon n ect t h e n ega t ive ba t t er y ca ble a t t h e
(1) In st a ll t h e sen sor flu sh a ga in st t h e open in g in ba t t er y.
t h e t r a n sm ission h ou sin g. (2) Clea n t h e a r ea a r ou n d t h e glow plu g wit h com -
(2) In st a ll a n d t igh t en t h e sen sor m ou n t in g bolt t o pr essed a ir befor e r em ova l.
19 N·m (14 ft . lbs.) t or qu e. (3) Discon n ect elect r ica l con n ect or (F ig. 23) a t glow
(3) Con n ect t h e elect r ica l con n ect or t o t h e sen sor. plu g.
(4) Rem ove t h e glow plu g (F ig. 22) fr om cylin der
h ea d.
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 35
REM OVAL AN D I N STALLAT I ON (Cont inue d)
MOUNTING
GLOW BOLT
PLUG

~.~~'7-_~~_J

80a18d42

ELECTRICAL
Fig. 22 Glow Plug
CONNECTOR
80ad08f8

Fig. 24 Glow Plug Relay Location


(2) In st a ll elect r ica l con n ect or t o r ela y.
(3) In st a ll r ela y t o in n er fen der.
(4) Con n ect ba t t er y ca ble t o ba t t er y.

POWERTRAIN CONTROL MODULE (PCM)


Th e P CM is m ou n t ed t o a br a cket m ou n t ed t o t h e
in n er side of t h e r igh t fen der well beh in d t h e a ir
clea n er a ssem bly (F ig. 25).
POWERTRAIN MOUNTING
CONTROL BRACKET
MODULE
{PCM)

Fig. 23 Glow Plug Electrical Connector


INSTALLATION
(1) Apply h igh –t em per a t u r e a n t i–seize com pou n d
t o glow plu g t h r ea ds befor e in st a lla t ion .
(2) In st a ll t h e glow plu g in t o t h e cylin der h ea d.
Tigh t en t o 23 N·m (203 in . lbs.) t or qu e.
(3) Con n ect ba t t er y ca ble t o ba t t er y.

GLOW PLUG RELAY


Th e glow plu g r ela y is loca t ed in t h e en gin e com -
pa r t m en t on t h e left –in n er fen der (F ig. 24).

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

(3) Discon n ect elect r ica l con n ect or a t r ela y a n d


r em ove r ela y. Fig. 25 PCM Location
REMOVAL
INSTALLATION (1) Discon n ect t h e n ega t ive ba t t er y ca ble a t t h e
(1) Ch eck con dit ion of elect r ica l con n ect or for da m - ba t t er y.
a ge or cor r osion . Repa ir a s n ecessa r y.
14 - 36 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Loosen t h e 60–Wa y con n ect or (F ig. 25). Th e SENSOR
elect r ica l con n ect or h a s a slidin g ba r wh ich m oves ELECTRICAL
in wa r d t o lock or ou t wa r d t o u n lock. CONNECTOR
(3) Rem ove t h e elect r ica l con n ect or by pu llin g
st r a igh t ou t .
(4) Rem ove P CM.

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

Fig. 28 Sensor Removal/Installation—Typical


Fig. 26 Vehicle Speed Sensor Location—2 Wheel (5) P u ll t h e sen sor fr om t h e speedom et er pin ion
Drive gea r a da pt er for r em ova l.
REMOVAL
(1) Ra ise a n d su ppor t veh icle. INSTALLATION
(2) Clea n t h e a r ea a r ou n d t h e sen sor befor e (1) In st a ll n ew sen sor in t o speedom et er gea r
r em ova l. a da pt er.
(3) Discon n ect t h e elect r ica l con n ect or fr om t h e (2) Tigh t en sen sor m ou n t in g bolt . To pr even t da m -
sen sor (F ig. 28). a ge t o sen sor or speedom et er a da pt er, be su r e t h e
(4) Rem ove t h e sen sor m ou n t in g bolt (F ig. 28). sen sor is m ou n t ed flu sh t o t h e a da pt er befor e t igh t -
en in g.
(3) Con n ect elect r ica l con n ect or t o sen sor.
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 37

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.

TORQUE CHART—2.5L DIESEL

_ _ _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 STEERING . . . . . . . . . . . . . . . . . . . . . . . . 1 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . 23


POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 5 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 27
POWER STEERING GEAR . . . . . . . . . . . . . . . . . . 11

POWER ST EERI N G

INDEX
page page

GENERAL INFORMATION DIAGNOSIS AND TESTING


STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 POWER STEERING SYSTEM
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . . . . 2

GEN ERAL I N FORM AT I ON


STEERING SYSTEM
Th e power st eer in g syst em h a s a h ydr a u lic pu m p.
Th e 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 pu m p on t h e 4.0L en gin e h a s a
r eser voir m ou n t ed t o it (F ig. 1). Th e 2.5L en gin e h a s 4.0 L
a r em ot e m ou n t ed r eser voir. PUMP
Th e st eer in g gea r u sed is a r ecir cu la t in g ba ll t ype
gea r. Th e gea r a ct s a s a r ollin g t h r ea d bet ween t h e
wor m sh a ft a n d t h e r a ck pist on . Wh en t h e st eer in g
wh eel is t u r n ed t h e wor m sh a ft t u r n s wh ich m oves
t h e r a ck pist on . Th e r a ck pist on m ovem en t t u r n s t h e
pit m a n sh a ft wh ich is con n ect ed t o t h e st eer in g lin k-
a ge by t h e pit m a n a r m . Th is gea r is u sed on a ll m od-
els. 80a1c394
Th e power st eer in g syst em con sist s of:
• H ydr a u lic pu m p Fig. 1 Power Steering Gear & Pump - 4.0L
• Recir cu la t in g ba ll st eer in g gea r
NOTE: Right hand drive (RHD) and left hand drive
• St eer in g colu m n

-
(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

DI AGN OSI S AN D T EST I N G

POWER STEERING SYSTEM DIAGNOSIS CHARTS

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.

CONDITION POSSIBLE CAUSES CORRECTION

OBJECTIONAL HISS OR 1. Steering intermediate shaft to dash panel 1. Check and repair seal at dash
WHISTLE seal. panel.

2. Noisy valve in power steering gear. 2. Replace steering gear.

RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.


2. Loose or damaged suspension 2. Inspect and repair suspension.
components.
3. Loose or damaged steering linkage. 3. Inspect and repair steering
linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other 5. Reposition hose.
components.

CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.

WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.


2. Pressure hose in contact with other 2. Reposition hose.
components.
3. Internal pump noise. 3. Replace pump.

SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.


2. O-ring missing or damaged on hose 2. Replace o-ring.
fitting.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.

SCRUBBING OR 1. Wrong tire size. 1. Verify tire size.


KNOCKING 2. Wrong gear. 2. Verify gear.
XJ STEERING 19 - 3
DI AGN OSI S AN D T EST I N G (Cont inue d)
BI N DI N G AN D ST I CK I N G

CONDITION POSSIBLE CAUSE CORRECTION

DIFFICULT TO TURN WHEEL 1. Low fluid level. 1. Fill to proper level.


STICKS OR BINDS 2. Tire pressure. 2. Adjust tire pressure.
3. Steering component. 3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of 7. Repair or replace gear.
adjustment.

I N SU FFI CI EN T ASST. OR POOR RET U RN T O CEN T ER

CONDITION POSSIBLE CAUSE CORRECTION

HARD TURNING OR MOMENTARY 1. Tire pressure. 1. Adjust tire pressure.


INCREASE IN TURNING EFFORT 2. Low fluid level. 2. Fill to proper level.
3. Loose belt. 3. Adjust or replace.
4. Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure. 5. Pressure test and repair as
necessary.
6. Internal gear leak. 6. Pressure and flow test, and repair
as necessary.

STEERING WHEEL 1. Tire pressure. 1. Adjust tire pressure.


DOES NOT WANT TO RETURN TO 2. Wheel alignment. 2. Align front end.
CENTER POSITION
3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and adjust as necessary.
19 - 4 STEERING XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
LOOSE ST EERI N G AN D V EH I CLE LEAD

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Repair as necessary.


WHEEL steering components.

2. Worn or loose wheel bearings. 2. Repair as necessary.


3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Repair as necessary.

VEHICLE PULLS OR LEADS TO 1. Tire Pressure. 1. Adjust tire pressure.


ONE SIDE 2. Radial tire lead. 2. Cross front tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align vehicle.
5. Weak or broken spring. 5. Replace spring.
6. Loose or worn steering or 6. Repair as necessary.
suspension components.
XJ STEERING 19 - 5

POWER ST EERI N G PU M P

INDEX
page page

DESCRIPTION AND OPERATION PUMP RESERVOIR-2.5L . . . . . . . . . . . . . . . . . . . 8


POWER STEERING PUMP . . . . . . . .......... 5 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . 8
POWER FLOW AND PRESSURE . . . .......... 5 PUMP RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . 9
PUMP LEAKAGE DIAGNOSIS . . . . . .......... 6 FLOW CONTROL VALVE . . . . . . . . . . . . . . . . . . . 9
SERVICE PROCEDURES SPECIFICATIONS
POWER STEERING PUMP – INITIAL TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . .......... 6 SPECIAL TOOLS
REMOVAL AND INSTALLATION POWER STEERING PUMP . . . . . . . . . . . . . . . . . 10
POWER STEERING PUMP . . . . . . . .......... 7

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).

NOTE: Power steering pumps have different pres-


sure rates and are not interchangeable with other
pumps. Fig. 1 Pump With Integral Reservoir
FLOW AND PRESSURE TEST
(1) Ch eck t h e power st eer in g belt t o en su r e it is in
DI AGN OSI S AN D T EST I N G good con dit ion a n d a dju st ed pr oper ly.
(2) Con n ect pr essu r e ga u ge h ose fr om t h e P ower
POWER FLOW AND PRESSURE St eer in g An a lyzer t o Tu be 6865.
Th e followin g pr ocedu r e is u sed t o t est t h e oper a t ion (3) Con n ect Ada pt er 6826 t o P ower St eer in g An a -
of t h e power st eer in g syst em on t h e veh icle. Th is t est lyzer t est va lve en d.
will pr ovide t h e ga llon s per m in u t e (GP M) or flow r a t e (4) Discon n ect h igh pr essu r e h ose a t gea r or pu m p.
of t h e power st eer in g pu m p a lon g wit h t h e m a xim u m Use a con t a in er for dr ippin g flu id.
r elief pr essu r e. P er for m t est a n y t im e a power st eer in g (5) Con n ect Tu be 6865 t o t h e pu m p h ose fit t in g.
syst em pr oblem is pr esen t . Th is t est will det er m in e if (6) Con n ect t h e power st eer in g h ose fr om t h e
t h e power st eer in g pu m p or power st eer in g gea r is n ot st eer in g gea r t o Ada pt er 6826.
fu n ct ion in g pr oper ly. Th e followin g pr essu r e a n d flow
t est is per for m ed u sin g P ower St eer in g An a lyzer Tool
Kit 6815 (F ig. 2) a n d Ada pt er Kit 6893.
19 - 6 STEERING XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
CAUTION: Do not force the pump to operate
TUBE against the stops for more than 2 to 3 seconds at a
GAUGE time because, pump damage will result.
HOSE
PU M P SPECI FI CAT I ON S

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.

CAUTION: Do not run a vehicle with foamy fluid for INSTALLATION


an extended period. This may cause pump damage. (1) In st a ll pu lley on pu m p.
(2) In st a ll pu m p on en gin e.
(3) Tigh t en pu m p br a cket bolt s t o 47 N·m (35 ft .
lbs.).

PUMP PUMP
ASSEMBLY ASSEMBLY
2.SL 4.0L

PUMP BRACKET

80ae8361

Fig. 3 Pump Mounting


19 - 8 STEERING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

PUMP ASSEMBLY

BRACKET 80500554

Fig. 4 Pump Mounting 4.0L RHD


(4) In st a ll 3 pu m p m ou n t in g bolt s a n d t igh t en t o
27 N·m (20 ft . lbs.).
(5) In st a ll t h e pr essu r e a n d r et u r n h oses t o pu m p.
(6) In st a ll dr ive belt , r efer t o Gr ou p 7 Coolin g.
(7) Add power st eer in g flu id a n d per for m P ower SPECIAL TOOL
C-4333
St eer in g P u m p In it ia l Oper a t ion .

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

INSTALLATION Fig. 5 Pulley Removal


(1) Slide r eser voir down on t o fa n sh r ou d.
(2) In st a ll t h e pu sh -in fa st en er in t h e t op of fa n ASSEMBLY
sh r ou d. (1) Repla ce pu lley if ben t , cr a cked, or loose.
(3) In st a ll t h e pu m p h oses. (2) In st a ll pu lley on pu m p wit h In st a ller C-4063-B
(4) F ill r eser voir t o pr oper level. Refer t o P ower (F ig. 6) flu sh wit h t h e en d of t h e sh a ft . E n su r e t h e
St eer in g P u m p In it ia l Oper a t ion . t ool a n d pu lley r em a in a lign ed wit h t h e pu m p sh a ft .
(3) In st a ll pu m p a ssem bly.
(4) Wit h Ser pen t in e Belt , r u n en gin e u n t il wa r m (5
DI SASSEM BLY AN D ASSEM BLY m in .) a n d n ot e a n y belt ch ir p. If ch ir p exist s, m ove
pu lley ou t wa r d a ppr oxim a t ely 0.5 m m (0.020 in .). If
PUMP PULLEY n oise in cr ea ses, pr ess on 1.0 m m (0.040 in .). B e
c a re fu l th a t p u lle y d o e s n o t c o n ta c t m o u n tin g
DISASSEMBLY bo lts .
(1) Rem ove pu m p a ssem bly.
(2) Rem ove pu lley fr om pu m p wit h P u ller C-4333
(F ig. 5).
XJ STEERING 19 - 9
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
ASSEMBLY
(1) Lu br ica t e n ew O-r in g Sea l wit h Mopa r P ower
St eer in g F lu id or equ iva len t .
(2) In st a ll O-r in g sea l in h ou sin g.
(3) In st a ll r eser voir on t o h ou sin g.
POWER
STEERING PUMP (4) Slide a n d t a p in n e w r eser voir r et a in er clips
SPECIAL TOOL
DRIVE PULLEY
C-4063-B u n t il t a b locks t o h ou sin g.

~
(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 .

FLOW CONTROL VALVE


DISASSEMBLY
J9519-1
(1) Clea n a r ea a r ou n d fit t in g t o pr even t dir t fr om
en t er in g pu m p. Rem ove pr essu r e h ose fr om pu m p fit -
Fig. 6 Pulley Installation t in g.
PUMP RESERVOIR (2) Rem ove fit t in g fr om pu m p h ou sin g (F ig. 8).
P re v e n t flo w c o n tro l v a lv e a n d s p rin g fro m
DISASSEMBLY s lid in g o u t o f h o u s in g bo re .
(1) Rem ove power st eer in g pu m p. FLOW CONTROL SPRING
(2) Clea n ext er ior of pu m p.
(3) Cla m p t h e pu m p body in a soft ja w vice.
(4) P r y u p t a b a n d slide t h e r et a in in g clips off (F ig.
7).

NOTE: Use new retaining clips for installtion.

RESERVOIR

~
FITTING
TIGHTEN TO 75 N·m (55 FT. LBS) J9319-17

Fig. 8 Flow Control Valve


(3) Rem ove a n d disca r d O-r in g sea l.

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

Fig. 7 Pump Reservoir Clips


(5) Rem ove flu id r eser voir fr om pu m p body.
Rem ove a n d disca r d O-r in g sea l.
19 - 10 STEERING XJ

SPECI FI CAT I ON S
TORQUE CHART

D ES CRIP TION TORQU E


P o w e r S te e rin g P u m p
Br a cket t o P u m p . . . . . . . . . . . . . . . . . . . . 28 N·m
(21 ft . lbs.)
Br a cket t o E n gin e . . . . . . . . . . . . . . . . . . . 47 N·m
(35 ft . lbs.)
F low Con t r ol Va lve . . . . . . . . . . . . . . . . . . 75 N·m Installer, Power Steering Pulley C-4063–B
(55 ft . lbs.)
P r essu r e Lin e . . . . . . . . . . . . . . . . . . . . . . 28 N·m
(21 ft . lbs.)

SPECI AL T OOLS
POWER STEERING PUMP

Adapters, Power Steering Flow/Pressure Tester


6893

8011c95S

Analyzer Set, Power Steering Flow/Pressure 6815

Puller C-4333
XJ STEERING 19 - 11

POWER ST EERI N G GEAR

INDEX
page page

DESCRIPTION AND OPERATION SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 15


POWER STEERING GEAR . . . . . . . . . . . . . . . . . 11 RACK PISTON AND WORM SHAFT . . . . . . . . . . 17
DIAGNOSIS AND TESTING ADJUSTMENTS
POWER STEERING GEAR LEAKAGE STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SPECIFICATIONS
REMOVAL AND INSTALLATION POWER STEERING GEAR . . . . . . . . . . . . . . . . . 21
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 13 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 21
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . . 13 POWER STEERING GEAR . . . . . . . . . . . . . . . . . 22
PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . . 14

DESCRI PT I ON AN D OPERAT I ON r a ck pist on t eet h m esh wit h t h e pit m a n sh a ft . Tu r n -


in g t h e wor m sh a ft t u r n s t h e pit m a n sh a ft , wh ich
POWER STEERING GEAR t u r n s t h e st eer in g lin ka ge.
Th e power st eer in g gea r is a r ecir cu la t in g ba ll t ype
CAUTION: Components attached with a nut and
gea r (F ig. 1). Th e gea r a ct s a s a r ollin g t h r ea d
cotter pin must be torqued to specification. Then if
bet ween t h e wor m sh a ft a n d r a ck pist on . Th e wor m
the slot in the nut does not line up with the cotter
sh a ft is su ppor t ed by a t h r u st bea r in g a t t h e lower
pin hole, tighten nut until it is aligned. Never loosen
en d a n d a bea r in g a ssem bly a t t h e u pper en d. Wh en
the nut to align the cotter pin hole.
t h e wor m sh a ft is t u r n ed t h e r a ck pist on m oves. Th e
19 - 12 STEERING XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

KEY NO. PART NAME


1 •
RING, RETAINING
2 -
PLUG
3 -
SEAL, 0-RING
5 -
RING, TEFLON
6 -
SEAL, 0-RING 3
7 -
COVER, SIDE
8 -
NUT, ADJUSTER LOCK
10 - BOLT
11 - GASKET
12 - SHAFT, PITMAN
13 - SHAFT, WORM
15 - RACE, FLAT
16. BEARING, THRUST
17 • RACE, FLAT
18. VALVE, CHECK
20. HOUSING
21. SCREW
22. CLAMP
23 • GUIDE, BALL
25. BALLS
26 • PISTON, RACK
27 _ PLUG
28 • BEARING, NEEDLE
31 • WASHER, BACKUP
35 • RING, RETAINING
36 _ WASHER, LOCK
37 NUT
- SEAL
38 -
40 _ SHAFT, STUB
41 • SPOOL, VALVE
42 SEAL
- BODY, VALVE
:~ : SEAL, 0-RING VALVE BODY
RING
:~ : NUT, COUPLING SHIELD RETAINER AND LOCK
49 _ THRUST SUPPORT ASSEMBLY
SEAL, 0-RING
:~ : SEAL, PITMAN SHAFT
SEAL, DUST
:: : ADJUSTER NUT ASSEMBLY
49
80b3b290

Fig. 1 Recirculating Ball Type Gear


XJ STEERING 19 - 13

DI AGN OSI S AN D T EST I N G FRAME

POWER STEERING GEAR LEAKAGE DIAGNOSIS

~
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).

NOTE: The pitman shaft will not clear the housing


if it is not centered.

HOUSING END PLUG PRELOAD


0-RING SEAL
ADJUSTER NUT
HOUSING END PLUG
SIDE COVER

RETAINING RING J9319-30


GASKET SEAL
Fig. 4 End Plug Components
ASSEMBLY
(1) Lu br ica t e O-r in g wit h power st eer in g flu id a n d
in st a ll in t o t h e h ou sin g.
(2) In st a ll en d plu g by t a ppin g t h e plu g ligh t ly
wit h a pla st ic m a llet in t o t h e h ou sin g.
(3) In st a ll r et a in in g r in g so on e en d of t h e r in g
cover s t h e h ou sin g a ccess h ole (F ig. 5).

HOUSING
ASSEMBLY
80a3543f

Fig. 6 Side Cover and Pitman Shaft


(6) Rem ove pit m a n sh a ft fr om t h e side cover.
(7) Rem ove du st sea l fr om t h e h ou sin g wit h a sea l
pick (F ig. 7).
,---RETAINER
RING
CAUTION: Use care not to score the housing bore
when prying out seals and washer.

(8) Rem ove r et a in in g r in g wit h sn a p r in g plier s.


J9219-32 (9) Rem ove wa sh er fr om t h e h ou sin g.
(10) Rem ove oil sea l fr om t h e h ou sin g wit h a sea l
Fig. 5 Installing The Retaining Ring pick.
(11) Rem ove pit m a n sh a ft bea r in g fr om h ou sin g
wit h a bea r in g dr iver a n d h a n dle (F ig. 8).
XJ STEERING 19 - 15
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(9) In st a ll pr eloa d a dju st er n u t . D o n o t tig h te n
n u t u n til a fte r Ov e r-Ce n te r Ro ta tio n To rqu e
a d ju s tm e n t h a s be e n m a d e .
(10) In st a ll ga sket t o side cover a n d ben d t a bs
a r ou n d edges of side cover (F ig. 6).
(11) In st a ll pit m a n sh a ft a ssem bly a n d side cover
t o h ou sin g.
(12) In st a ll side cover bolt s a n d t igh t en t o 60 N·m
(44 ft . lbs.).
(13) P er for m over-cen t er r ot a t ion t or qu e a dju st m en t .

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).

Fig. 9 Lock Nut and Adjuster Nut


J9319-42

Fig. 8 Needle Bearing Removal


ASSEMBLY
(1) In st a ll pit m a n sh a ft bea r in g in t o h ou sin g wit h
a bea r in g dr iver a n d h a n dle.
(2) Coa t t h e oil sea l a n d wa sh er wit h s p e c ia l
g re a s e su pplied wit h t h e n ew sea l.
(3) In st a ll t h e oil sea l wit h a dr iver a n d h a n dle.
(4) In st a ll ba cku p wa sh er.
(5) In st a ll t h e r et a in er r in g wit h sn a p r in g plier s.

~
(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

Fig. 11 Valve Assembly With Stub Shaft Fig. 13 Spool Valve


(5) Rem ove st u b sh a ft fr om va lve a ssem bly by
ligh t ly t a ppin g sh a ft on a block of wood t o loosen
sh a ft . Th en disen ga ge st u b sh a ft pin fr om h ole in
spool va lve a n d sepa r a t e t h e va lve a ssem bly fr om
st u b sh a ft (F ig. 12).
STUB SHAFT

~\~
6mm (1/4")

Fig. 14 Valve Seals


ASSEMBLY
J9319-36 NOTE: Clean and dry all components, then lubri-
cate with power steering fluid.
Fig. 12 Stub Shaft
(6) Rem ove spool va lve fr om va lve body by pu llin g (1) In st a ll spool va lve spool O-r in g.
a n d r ot a t in g t h e spool va lve fr om t h e va lve body (F ig. (2) In st a ll spool va lve in va lve body by pu sh in g
13). a n d r ot a t in g. H ole in spool va lve for st u b sh a ft pin
(7) Rem ove spool va lve O-r in g a n d va lve body m u st be a ccessible fr om opposit e en d of va lve body.
t eflon r in gs a n d O-r in gs u n der n ea t h t h e t eflon r in gs (3) In st a ll st u b sh a ft in va lve spool a n d en ga ge
(F ig. 14). loca t in g pin on st u b sh a ft in t o spool va lve h ole (F ig.
(8) Rem ove t h e O-r in g bet ween t h e wor m sh a ft 15).
a n d t h e st u b sh a ft .
NOTE: Notch in stub shaft cap must fully engage
valve body pin and seat against valve body shoul-
der.
XJ STEERING 19 - 17
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

RACK PISTON AND WORM SHAFT


DISASSEMBLY
(1) Rem ove h ou sin g en d plu g.
(2) Rem ove r a ck pist on plu g (F ig. 17).
(3) Rem ove side cover a n d pit m a n sh a ft .
END PLUG

J9319-38

Fig. 15 Stub Shaft Installation


(4) In st a ll O-r in gs a n d t eflon r in gs over t h e
O-r in gs on va lve body.
(5) In st a ll O-r in g in t o t h e ba ck of t h e st u b sh a ft
ca p (F ig. 16). RACK
PISTON J9219-9

Fig. 17 Rack Piston End Plug


(4) Tu r n st u b sh a ft COUNTE RCLOCKWISE u n t il
t h e r a ck pist on begin s t o com e ou t of t h e h ou sin g.
(5) In ser t Ar bor C-4175 in t o bor e of r a ck pist on
(F ig. 18) a n d h old t ool t igh t ly a ga in st wor m sh a ft .
(6) Tu r n t h e st u b sh a ft wit h a 12 poin t socket
COUNTE RCLOCKWISE , t h is will for ce t h e r a ck pis-
t on on t o t h e t ool a n d h old t h e r a ck pist on ba lls in
pla ce.

80accfc0

Fig. 16 Stub Shaft Cap O-Ring


(6) In st a ll st u b sh a ft a n d va lve a ssem bly in t h e
h ou sin g. Lin e u p wor m sh a ft t o slot s in t h e va lve
a ssem bly.
(7) In st a ll t h r u st su ppor t a ssem bly.

NOTE: The thrust support is serviced as an assem-


bly. If any component of the thrust support is dam-
aged the assembly must be replaced.

(8) In st a ll a dju st er n u t a n d lock n u t .


(9) Adju st Th r u st Bea r in g P r eloa d a n d Over-Cen - Fig. 18 Rack Piston with Arbor
t er Rot a t in g Tor qu e.
19 - 18 STEERING XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(7) Rem ove t h e r a ck pist on a n d t ool t oget h er fr om BEARING
h ou sin g. RACE
(8) Rem ove t ool fr om r a ck pist on .
(9) Rem ove r a ck pist on ba lls.
(10) Rem ove cla m p bolt s, cla m p a n d ba ll gu ide
(F ig. 19).
(11) Rem ove t eflon r in g a n d O-r in g fr om t h e r a ck
pist on (F ig. 20).

~CLAMP

, I

80aa4bf5

BALL GUIDE
Fig. 21 Worm Shaft
ASSEMBLY
RACK
PISTON NOTE: Clean and dry all components and lubricate
with power steering fluid.

80aa4bf4 (1) Ch eck for scor es, n icks or bu r r s on t h e r a ck


pist on fin ish ed su r fa ce. Sligh t wea r is n or m a l on t h e
Fig. 19 Rack Piston wor m gea r su r fa ces.
(2) In st a ll O-r in g a n d t eflon r in g on t h e r a ck pis-
t on .
(3) In st a ll wor m sh a ft in t h e r a ck pist on a n d a lign
wor m sh a ft spir a l gr oove wit h r a ck pist on ba ll gu ide
h ole (F ig. 22).

INSTALL BALLS IN THIS HOLE


WHILE SLOWLY ROTATING
BACK-UP WORM COUNTERCLOCKWISE
O-RINGMUST
BE INSTALLED
UNDER PISTON
RING

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.

NOTE: Adjusting the steering gear in the vehicle is


not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.

WORM THRUST BEARING PRELOAD


(1) Mou n t t h e gea r ca r efu lly in t o a vise.

CAUTION: Do not overtighten the vise on the gear


case. This may affect the adjustment

(2) Rem ove a dju st er plu g lockn u t (F ig. 24).


(3) Rot a t e t h e st u b sh a ft ba ck a n d for t h wit h a 12
poin t socket t o dr a in t h e r em a in in g flu id.

BALLS J9319-40

Fig. 23 Balls in the Return Guide


(6) In st a ll t h e gu ide on t o r a ck pist on a n d in st a ll
cla m p a n d cla m p bolt s. Tigh t en bolt s t o 58 N·m (43
ft . lbs.).
(7) In ser t Ar bor C-4175 in t o bor e of r a ck pist on
a n d h old t ool t igh t ly a ga in st wor m sh a ft .
(8) Tu r n t h e wor m sh a ft COUNTE RCLOCKWISE
wh ile pu sh in g on t h e a r bor. Th is will for ce t h e r a ck
pist on on t o t h e a r bor a n d h old t h e r a ck pist on ba lls
in pla ce.
(9) In st a ll t h e r a ces a n d t h r u st bea r in g on t h e
wor m sh a ft a n d in st a ll sh a ft in t h e h ou sin g (F ig. 21).
(10) In st a ll t h e st u b sh a ft wit h spool va lve, t h r u st
su ppor t a ssem bly a n d a dju st er n u t in t h e h ou sin g. Fig. 24 Adjuster Lock Nut
(11) In st a ll t h e r a ck pist on a n d a r bor t ool in t o t h e
h ou sin g. (4) Tu r n t h e a dju st er in wit h Spa n n er Wr en ch
(12) H old a r bor t igh t ly a ga in st wor m sh a ft a n d C-4381. Tigh t en t h e plu g a n d t h r u st bea r in g in t h e
t u r n st u b sh a ft CLOCKWISE u n t il r a ck pist on is h ou sin g u n t il fir m ly bot t om ed in t h e h ou sin g a bou t
sea t ed on wor m sh a ft . 34 N·m (25 ft . lbs.).
(13) In st a ll pit m a n sh a ft a n d side cover in t h e (5) P la ce a n in dex m a r k on t h e h ou sin g even wit h
h ou sin g. on e of t h e h oles in a dju st er plu g (F ig. 25).
(14) In st a ll r a ck pist on plu g a n d t igh t en t o 150 (6) Mea su r e ba ck (cou n t er clockwise) 5.08 m m (0.20
N·m (111 ft . lbs.). in ) a n d m a r k h ou sin g (F ig. 26).
(15) In st a ll h ou sin g en d plu g. (7) Rot a t e a dju st m en t ca p ba ck (cou n t er clockwise)
(16) Adju st wor m sh a ft t h r u st bea r in g pr eloa d a n d wit h spa n n er wr en ch u n t il h ole is a lign ed wit h t h e
over-cen t er r ot a t in g t or qu e. secon d m a r k (F ig. 27).
19 - 20 STEERING XJ
ADJ U ST M EN T S (Cont inue d)
FIRST
MARK

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

Fig. 26 Second Marking On Housing


(8) In st a ll a n d t igh t en lockn u t t o 108 N·m (80 ft .
lbs.). Be su r e a dju st m en t ca p does n ot t u r n wh ile
t igh t en in g t h e lockn u t . J8919-62

OVER-CENTER Fig. 28 Steering Gear Centered


NOTE: Before performing this procedure, the worm (3) P la ce t h e t or qu e wr en ch in t h e ver t ica l posit ion
bearing preload adjustment must be performed. on t h e st u b sh a ft . Rot a t e t h e wr en ch 45 degr ees ea ch
side of t h e cen t er a n d r ecor d t h e h igh est r ot a t ion a l
(1) Rot a t e t h e st u b sh a ft wit h a 12 poin t socket t or qu e in t h is r a n ge (F ig. 29). Th is is t h e Over-Cen -
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. t er Rot a t in g Tor qu e.
XJ STEERING 19 - 21
ADJ U ST M EN T S (Cont inue d)
NOTE: The stub shaft must rotate smoothly without (8) P r even t t h e a dju st er scr ew fr om t u r n in g wh ile
sticking or binding. t igh t en in g a dju st er lock n u t . Tigh t en t h e a dju st er
lock n u t t o 49 N·m (36 ft . lbs.).
(4) Rot a t e t h e st u d sh a ft bet ween 90° a n d 180° t o
t h e left of cen t er a n d r ecor d t h e left off-cen t er pr e-
loa d. Repea t t h is t o t h e r igh t of cen t er a n d r ecor d t h e SPECI FI CAT I ON S
r igh t off-cen t er pr eloa d. Th e a ver a ge of t h ese t wo
r ecor ded r ea din gs is t h e P r eloa d Rot a t in g Tor qu e. POWER STEERING GEAR
(5) Th e Over-Cen t er Rot a t in g Tor qu e sh ou ld be
0.45-0.9 N·m (4-8 in . lbs.) h ig h e r t h a n t h e P r eloa d Steering Gear
Rot a t in g Tor qu e.
(6) If a n a dju st m en t t o t h e Over-Cen t er Rot a t in g Type . . . . . . . . . . . . . . . . . . . . . Recir cu la t in g Ba ll
Tor qu e is n ecessa r y, fir st loosen t h e a dju st er lock Ge a r Ra tio
n u t . Th en t u r n t h e pit m a n sh a ft a dju st er scr ew ba ck RH D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14:1
(COUNTE RCLOCKWISE ) u n t il fu lly ext en ded, t h en LH D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14:1
t u r n ba ck in (CLOCKWISE ) on e fu ll t u r n . Wo rm S h a ft B e a rin g
P r eloa d . . . . . . . . . . . . . . . . . . . . . 0.45–1.13 N·m
(4–10 in . lbs.)
P itm a n S h a ft Ov e rc e n te r D ra g
New Gea r (u n der 400 m iles) . . . . . 0.45–0.90 N·m
(4–8 in . lbs.)
+ Wor m Sh a ft P r eloa d
Used Gea r (over 400 m iles) . . . . . . . . 0.5–0.6 N·m
(4–5 in . lbs.)
+ Wor m Sh a ft P r eloa d
TORQUE CHART

D ES CRIP TION TORQU E


P o w e r S te e rin g Ge a r
Adju st m en t Ca p Lockn u t . . . . . . . . . . . . 108 N·m
(80 ft . lbs.)
Adju st m en t Scr ew Lockn u t . . . . . . . . . . . . 49 N·m
(36 ft . lbs.)
Gea r t o F r a m e Bolt s . . . . . . . . . . . . . . . . . 95 N·m
(70 ft . lbs.)
P it m a n Sh a ft Nu t . . . . . . . . . . . . . . . . . . 251 N·m
(185 ft . lbs.)
Fig. 29 Checking Over-center Rotation Torque Ra ck P ist on P lu g . . . . . . . . . . . . . . . . . . . 102 N·m
(75 ft . lbs.)
(7) Rem ea su r e Over-Cen t er Rot a t in g Tor qu e. If Side Cover Bolt s . . . . . . . . . . . . . . . . . . . . 60 N·m
n ecessa r y t u r n t h e a dju st er scr ew a n d r epea t m ea - (44 ft . lbs.)
su r em en t u n t il cor r ect Over-Cen t er Rot a t in g Tor qu e P r essu r e Lin e . . . . . . . . . . . . . . . . . . . . . . 28 N·m
is r ea ch ed. (21 ft . lbs.)
NOTE: To increase the Over-Center Rotating Torque Ret u r n Lin e . . . . . . . . . . . . . . . . . . . . . . . 28 N·m
turn the screw CLOCKWISE. (21 ft . lbs.)
Ret u r n Gu ide Cla m p Bolt . . . . . . . . . . . . . 58 N·m
(43 ft . lbs.)
19 - 22 STEERING XJ

SPECI AL T OOLS
POWER STEERING GEAR

Remover, Pitman Arm C-4150A

Remover/Installer, Steering Plug C-4381

Remover/Installer Steering Rack Piston C-4175


XJ STEERING 19 - 23

ST EERI N G LI N K AGE

INDEX
page page

GENERAL INFORMATION DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25


STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 23 STEERING DAMPER . . . . . . . . . . . . . . . . . . . . . 25
SERVICE PROCEDURES SPECIFICATIONS
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 23 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL AND INSTALLATION SPECIAL TOOLS
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 26
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

GEN ERAL I N FORM AT I ON SERV I CE PROCEDU RES


STEERING LINKAGE STEERING LINKAGE
Th e st eer in g lin ka ge con sist of a pit m a n a r m , dr a g Th e t ie r od en d a n d ba ll st u d sea ls sh ou ld be
lin k, t ie r od, t ie r od en ds a n d a st eer in g da m per (F ig. in spect ed du r in g a ll oil ch a n ges. If a sea l is da m a ged,
1) a n d (F ig. 2). Th e ser vice pr ocedu r es a n d t or qu e it sh ou ld be r epla ced. Befor e in st a llin g a n ew sea l,
specifica t ion s a r e t h e sa m e for LH D a n d RH D veh i- in spect ba ll st u d a t t h e t h r oa t open in g. Ch eck for
cles. lu br ica n t loss, con t a m in a t ion , ba ll st u d wea r or cor-
r osion . If t h ese con dit ion s exist , r epla ce t h e t ie r od. A
CAUTION: Components attached with a nut and r epla cem en t sea l ca n be in st a lled if lu br ica n t is in
cotter pin must be torqued to specification. Then if good con dit ion . Ot h er wise, a com plet e r epla cem en t
the slot in the nut does not line up with the cotter ba ll st u d en d sh ou ld be in st a lled.
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole. CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.

- STEERING DAMPENER J9502-7

Fig. 1 Steering Linkage—LHD


19 - 24 STEERING XJ
SERV I CE PROCEDU RES (Cont inue d)

ADJUSTMENT
SLEEVE

TIE ~--+-----DRAG
ROD LINK

J9502-6

Fig. 2 Steering Linkage—RHD


CAUTION: Components attached with a nut and REMOVAL
cotter pin must be torqued to specification. Then if (1) Rem ove t h e cot t er pin s a n d n u t s a t t h e t ie r od
the slot in the nut does not line up with the cotter ba ll st u ds a n d dr a g lin k.
pin hole, tighten nut until it is aligned. Never loosen (2) Loosen t h e ba ll st u ds wit h a pu ller t ool t o
the nut to align the cotter pin hole. r em ove t h e t ie r od.
(3) Loosen cla m p bolt s a n d u n t h r ea d t h e t ie r od
en d fr om t h e t u be.
REM OVAL AN D I N STALLAT I ON
INSTALLATION
(1) Th r ea d t h e t ie r od en d in t o t h e t u be a n d posi-
TIE ROD
t ion t h e cla m p t o it ’s or igin a l posit ion (F ig. 4).
CAUTION: Use a Puller tool C-3894-A for tie rod Tigh t en t h e cla m p bolt s t o 27 N·m (20 ft . lbs.).
removal. Failure to use this tool could damage the
ball stud and seal (Fig. 3).
PULLER
TOOL
C-3894-A

ADJUSTMENT
SLEEVE

Fig. 4 Tie Rod/Drag Link Clamps


(2) In st a ll t h e t ie r od on t h e dr a g lin k a n d st eer in g
Fig. 3 Ball Stud Puller kn u ckle. In st a ll t h e r et a in in g n u t s.
XJ STEERING 19 - 25
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Tigh t en t h e ba ll st u d n u t on t h e st eer in g (4) Rem ove dr a g lin k fr om t h e st eer in g kn u ckle
kn u ckle t o 47 N·m (35 ft . lbs.). Tigh t en t h e ba ll st u d a n d pit m a n a r m .
n u t t o dr a g lin k t o 88 N·m (65 ft . lbs.). In st a ll n ew
cot t er pin s. INSTALLATION
(1) In st a ll t h e dr a g lin k on t o st eer in g kn u ckle a n d
PITMAN ARM pit m a n a r m .
(2) In st a ll n u t a t st eer in g kn u ckle a n d t igh t en t o
REMOVAL 47 N·m (35 ft . lbs.). In st a ll n ew cot t er pin s.
(1) Rem ove t h e cot t er pin a n d n u t fr om t h e dr a g (3) In st a ll n u t a t pit m a n a r m a n d t igh t en t o 75
lin k a t t h e pit m a n a r m . N·m (55 ft . lbs.). In st a ll n ew cot t er pin s.
(2) Rem ove t h e dr a g lin k ba ll st u d fr om t h e pit - (4) In st a ll t ie r od on t o dr a g lin k a n d in st a ll n u t .
m a n a r m wit h a pu ller. Tigh t en n u t t o 75 N·m (55 ft . lbs.) a n d in st a ll n ew
(3) Rem ove t h e n u t a n d wa sh er fr om t h e st eer in g cot t er pin s.
gea r sh a ft . Ma r k t h e pit m a n sh a ft a n d pit m a n a r m (5) In st a ll st eer in g da m per on t o dr a g lin k a n d
for in st a lla t ion r efer en ce. Rem ove t h e pit m a n a r m in st a ll n u t . Tigh t en n u t t o 75 N·m (55 ft . lbs.) a n d
fr om st eer in g gea r wit h P u ller C-4150-A (F ig. 5). in st a ll a n ew cot t er pin .

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 .

"' Fig. 5 Pitman Arm Puller


J9519-2
SPECI FI CAT I ON S
TORQUE CHART
INSTALLATION
(1) Align a n d in st a ll t h e pit m a n a r m on st eer in g
D ES CRIP TION TORQU E
gea r sh a ft .
P itm a n Arm
(2) In st a ll t h e wa sh er a n d n u t on t h e sh a ft a n d
Sh a ft . . . . . . . . . . . . . . . . . . 251 N·m (185 ft . lbs.)
t igh t en n u t t o 251 N·m (185 ft . lbs.).
D ra g Lin k
(3) In st a ll dr a g lin k ba ll st u d t o pit m a n a r m
Ba ll St u ds . . . . . . . . . . . . . . . . 74 N·m (55 ft . lbs.)
in st a ll n u t a n d t igh t en t o 74 N·m (55 ft . lbs.). In st a ll
a n ew cot t er pin . Cla m p . . . . . . . . . . . . . . . . . . . 49 N·m (36 ft . lbs.)
Tie Ro d En d s
DRAG LINK Ba ll St u ds . . . . . . . . . . . . . . . . 74 N·m (55 ft . lbs.)
Cla m p . . . . . . . . . . . . . . . . . . . 27 N·m (20 ft . lbs.)
REMOVAL Tie Ro d
(1) Rem ove cot t er pin s a n d n u t s fr om dr a g lin k Ba ll St u d . . . . . . . . . . . . . . . . . 88 N·m (65 ft . lbs.)
(2) Rem ove t h e st eer in g da m per ba ll st u d fr om t h e S te e rin g D a m p e r
dr a g lin k. F r a m e . . . . . . . . . . . . . . . . . . . 74 N·m (55 ft . lbs.)
(3) Rem ove t ie r od fr om dr a g lin k Dr a g Lin k . . . . . . . . . . . . . . . . 74 N·m (55 ft . lbs.)
19 - 26 STEERING XJ

SPECI AL T OOLS
STEERING LINKAGE

Remover Pitman C-4150A

Puller C-3894–A
XJ STEERING 19 - 27

ST EERI N G COLU M N

INDEX
page page

GENERAL INFORMATION SPECIFICATIONS


STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 27 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL AND INSTALLATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 27

GEN ERAL I N FORM AT I ON REM OVAL AN D I N STALLAT I ON


STEERING COLUMN STEERING COLUMN
Th e st a n da r d n on -t ilt a n d t ilt st eer in g colu m n h a s
been design ed t o be ser viced a s a n a ssem bly. Th e key WARNING: BEFORE SERVICING THE STEERING
cylin der, swit ch es, clock spr in g, t r im sh r ou ds a n d COLUMN THE AIRBAG SYSTEM MUST BE DIS-
st eer in g wh eel a r e ser viced sepa r a t ely. On t h e n on - ARMED. REFER TO GROUP 8M RESTRAINT SYS-
t ilt colu m n t h e u pper m ou n t in g br a cket is a lso ser- TEMS FOR SERVICE PROCEDURES. FAILURE TO
viced sepa r a t ely. DO SO MAY RESULT IN ACCIDENTAL DEPLOY-
Th e colu m n is m ou n t ed t o t h e colu m n su ppor t MENT OF THE AIRBAG AND POSSIBLE PERSONAL
br a cket st u ds a n d secu r ed by fou r n u t s. Th e colu m n INJURY.
is con n ect ed t o t h e st eer in g gea r by a on e piece col-
la psible sh a ft wit h a cou pler a t ea ch en d. Th e cou -
pler s secu r e t h e sh a ft t o t h e st eer in g colu m n a n d REMOVAL
st eer in g gea r. (1) P osit ion fr on t wh eels s tra ig h t a h e a d .
(2) Rem ove a n d isola t e t h e n ega t ive ba t t er y
SERVICE PRECAUTIONS gr ou n d ca ble.
Sa fet y goggles sh ou ld be wor n a t a ll t im es wh en (3) Rem ove t h e a ir ba g, r efer t o Gr ou p 8M
wor kin g on st eer in g colu m n s. Rest r a in t Syst em s for ser vice pr ocedu r es.
To ser vice t h e st eer in g wh eel, swit ch es or a ir ba g,
NOTE: If equipped with cruise control, disconnect
r efer t o Gr ou p 8M a n d follow a ll WARNINGS a n d
clock spring harness from cruise switch harness on
CAUTIONS.
the steering wheel.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
(4) Rem ove t h e st eer in g wh eel wit h a n a ppr opr ia t e
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
pu ller (F ig. 1).
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST CAUTION: Ensure the puller bolts are fully engaged
FIRST DISCONNECT AND ISOLATE THE BATTERY into the steering wheel and not into the clock-
NEGATIVE (GROUND) CABLE. THEN WAIT TWO spring, before attempting to remove the wheel. Fail-
MINUTES FOR THE SYSTEM CAPACITOR TO DIS- ure to do so may damage the steering wheel.
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND (5) Tu r n ign it ion cylin der t o t h e on posit ion a n d
POSSIBLE PERSONAL INJURY. THE FASTENERS, r em ove cylin der by pr essin g r elea se t h r ou gh lower
SCREWS, AND BOLTS, ORIGINALLY USED FOR sh r ou d a ccess h ole (F ig. 2).
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT- (6) Rem ove kn ee blocker cover a n d kn ee blocker,
INGS AND ARE SPECIFICALLY DESIGNED FOR THE Refer t o Gr ou p 8E In st r u m en t P a n el Syst em s.
AIRBAG SYSTEM. THEY MUST NEVER BE (7) Rem ove scr ews fr om t h e lower colu m n sh r ou d
REPLACED WITH ANY SUBSTITUTES. ANYTIME A (F ig. 3) a n d r em ove lower sh r ou d.
NEW FASTENER IS NEEDED, REPLACE WITH THE (8) Rem ove t h e st eer in g cou pler bolt a n d colu m n
CORRECT FASTENERS PROVIDED IN THE SERVICE m ou n t in g n u t s (F ig. 4) t h en lower colu m n off t h e
PACKAGE OR FASTENERS LISTED IN THE PARTS m ou n t in g st u d.
BOOKS. (9) Rem ove u pper colu m n sh r ou d (F ig. 3).
19 - 28 STEERING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

STEERING
COLUMN

MOUNTING NUTS
80aac1 bb

Fig. 1 Steering Wheel Fig. 4 Tilt Steering Column Mounting

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.

(11) Rem ove colu m n .


(12) Rem ove n u t a n d bolt fr om t h e u pper colu m n
m ou n t in g br a cket on n on -t ilt colu m n (F ig. 6). Rem ove
t h e br a cket fr om t h e colu m n a n d n o te th e m o u n t-
in g lo c a tio n a n d o rie n ta tio n o f th e bra c k e t. .
(13) Rem ove clock spr in g, swit ch es, (SKIM if
equ ipped) a n d ign it ion key cylin der, r efer t o Gr ou p 8
E lect r ica l for ser vice pr ocedu r es.

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.).

NOTE: If equipped with cruise control, connect


clock spring harness to cruise switch harness on
the steering wheel.

(14) In st a ll a ir ba g, r efer t o Gr ou p 8M Rest r a in t


Syst em s for ser vice pr ocedu r es.
(15) In st a ll n ega t ive ba t t er y t er m in a l.

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

POWER STEERING PUMP—2.5L VM DIESEL . . . 2 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . 8


POWER STEERING—2.5L VM DIESEL . . . . . . . . 1

POWER ST EERI N G—2 .5 L V M DI ESEL

INDEX
page

GENERAL INFORMATION
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 1

GEN ERAL I N FORM AT I ON


POWER STEERING PUMP
-
Th e power st eer in g pu m p u sed wit h t h e 2.5L VM
Diesel en gin e oper a t es t h e sa m e wa y a s t h e power
st eer in g pu m p u sed wit h t h e 2.5/4.0L ga solin e
en gin es. Refer t o t h e Descr ipt ion a n d Oper a t ion sec-
t ion for t h e 2.5/4.0L ga solin e en gin e power st eer in g
pu m p for m or e in for m a t ion .
19 - 2 STEERING XJ

POWER ST EERI N G PU M P—2 .5 L V M DI ESEL

INDEX
page page

SERVICE PROCEDURES REMOVAL AND INSTALLATION


POWER STEERING PUMP – INITIAL POWER STEERING PUMP — LHD . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 POWER STEERING PUMP — RHD . . . . . . . . . . . 5

SERV I CE PROCEDU RES REM OVAL AN D I N STALLAT I ON


POWER STEERING PUMP – INITIAL POWER STEERING PUMP — LHD
OPERATION
Removal
WARNING: THE FLUID LEVEL SHOULD BE (1) Discon n ect t h e n ega t ive ba t t er y ca ble.
CHECKED WITH ENGINE OFF TO PREVENT INJURY (2) Rem ove t h e A/C lin e su ppor t br a cket fr om t h e
FROM MOVING COMPONENTS. r ea r of t h e r ocker cover.
(3) Discon n ect t h e A/C com pr essor elect r ica l con -
n ect or.
CAUTION: Use MOPAR Power Steering Fluid or (4) Rem ove t h e (2) en gin e m ou n t u pper sill pla t e
equivalent. Do not use automatic transmission fluid n u t s (F ig. 1).
and do not overfill.

Wipe filler ca p clea n , t h en ch eck t h e flu id level.


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 a m bien t t em per a t u r e.
(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.
(2) St a r t t h e en gin e a n d let r u n for a few secon ds
t h en t u r n en gin e off.
(3) Add flu id if n ecessa r y. Repea t t h e a bove pr oce-
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.
(5) Slowly t u r n t h e st eer in g wh eel r igh t a n d left ,
ligh t ly con t a ct in g t h e wh eel st ops a t lea st 20 t im es.
(6) Ch eck t h e flu id level a dd if n ecessa r y.
(7) Lower t h e veh icle, st a r t t h e en gin e a n d t u r n
t h e st eer in g wh eel slowly fr om lock t o lock.
(8) St op t h e en gin e a n d ch eck t h e flu id level a n d
r efill a s r equ ir ed.
ENGINE MOUNT
(9) If t h e flu id is ext r em ely foa m y or m ilky look-
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 80b9a4c1
r epea t t h e pr ocedu r e.
Fig. 1 Engine Mount Sill Plate Nuts
CAUTION: Do not run a vehicle with foamy fluid for (5) Ma ke su r e t h e st eer in g wh eel is in the
an extended period. This may cause pump damage. u n locked posit ion .
XJ STEERING 19 - 3
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(6) Ra ise t h e veh icle on a h oist . (15) Rem ove t h e r em a in in g 2 bolt s fr om t h e
(7) Rem ove t h e st eer in g sh a ft pin ch bolt a n d slide H -Block a n d r em ove t h e H -Block fr om t h e com pr es-
t h e st eer in g sh a ft st r a igh t off t h e gea r box in pu t sor.
sh a ft , posit ion t h e sh a ft a side. (16) Su ppor t t h e A/C com pr essor wit h m ech a n ics
wir e befor e pr ocedin g t o t h e n ext st ep.
CAUTION: Avoid turning the steering shaft while (17) Rem ove t h e (4) A/C com pr essor r et a in in g
disconnected from the steering gearbox. Damage to bolt s.
steering column clockspring could occur. (18) Rem ove t h e left en gin e m ou n t t h r ou gh bolt n u t
on ly. Do n ot r em ove t h e bolt a t t h is t im e.
(8) Rem ove t h e power st eer in g flu id su pply h ose (19) P osit ion a ja ck st a n d a n d r a ise weigh t off left
fr om t h e pu m p a n d let t h e flu id dr a in . en gin e m ou n t .
(9) Loosen t h e (4) H -Block r et a in in g bolt s. Do n ot (20) Rem ove t h e t r a ck ba r su ppor t br a cket r et a in -
r em ove t h e bolt s a t t h is t im e. in g bolt s a n d r em ove br a cket (F ig. 3).
(10) Rem ove t h e a ccessor y dr ive belt fr om t h e
power st eer in g pu m p pu lley. Refer t o Gr ou p 7, Cool- TRACK BAR SUPPORT
in g Syst em for pr ocedu r e. BRACKET RETAINING
(11) Rem ove t h e power st eer in g pu m p pu lley. Use BOLTS
a h ex socket t o secu r e t h e pu m p sh a ft wh ile r em ov- ~
in g t h e pu lley n u t wit h a box wr en ch (F ig. 2). ~

POWER STEERING
PUMP PULLEY

HEX WRENCH

ENGINE MOUNT SILL


PLATE BOLT
80b9a4be

Fig. 3 Engine Mount Retaining Bolts


(21) Rem ove t h e lower en gin e m ou n t bolt fr om t h e
sill pla t e (F ig. 3).
(22) Rem ove t h e (4) en gin e m ou n t br a cket bolt s
80b9a4c2
fr om t h e en gin e block.
Fig. 2 Removing the Power Steering Pump Pulley (23) Rem ove t h e en gin e m ou n t t h r ou gh bolt .
(24) Rem ove t h e en gin e m ou n t a n d en gin e m ou n t
NOTE: Mark the position of the H-Block in relation br a cket fr om t h e veh icle.
to the A/C Compressor so it may be reinstalled in (25) Rem ove t h e (2) power st eer in g pu m p r et a in in g
the same position. n u t s (F ig. 4).
(26) Rem ove t h e power st eer in g pu m p fr om t h e
(12) Rem ove t h e (2) bolt s r et a in in g t h e H -Block t o
veh icle.
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 t h e
Installation
cou pler t owa r ds t h e pu m p.
(14) Rem ove t h e power st eer in g pu m p pr essu r e WARNING: Power steering system fluid may be
lin e fr om t h e st eer in g gea r. Th is is m or e a ccessible, contaminated with metal shavings, overheated or
bu t will r equ ir e you t o in st a ll t h e pr essu r e lin e on improper fluid. All fluid should be drained from the
t h e n ew pu m p pr ior t o in st a lla t ion . system. After component replacement, system
should be flushed and filled with Mopar Power
Steering Fluid, or equivalent.
19 - 4 STEERING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(6) In st a ll, bu t do n ot t or qu e t h e en gin e m ou n t
~ ENGINE BLOCK
a n d t r a ck ba r su ppor t br a cket bolt s (F ig. 6).
Io~ TRACK BAR SUPPORT
BRACKET RETAINING
BOLTS
~
~

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 — RHD


POWER STEERING
Removal
PUMP PULLEY
(1) Discon n ect t h e n ega t ive ba t t er y ca ble.
(2) Rem ove t h e r efr iger en t lin e su ppor t br a cket
HEX WRENCH bolt fr om t h e t op of t h e r a dia t or.
(3) Rem ove t h e A/C filt er-dr ier a ssem bly su ppor t
br a cket n u t s fr om left fen der well.
(4) Discon n ect t h e A/C com pr essor elect r ica l con -
n ect or.
(5) Ra ise t h e veh icle on a h oist .
(6) Rem ove t h e power st eer in g flu id su pply h ose
fr om pu m p a n d dr a in flu id.
(7) Rem ove power st eer in g lin e su ppor t br a cket
bolt fr om below r a dia t or.
(8) Rem ove t h e en gin e m ou n t u pper sill pla t e n u t s.
(9) Loosen t h e (4) H -Block r et a in in g bolt s. Do n ot
r em ove a t t h is t im e.
(10) Rem ove t h e a ccessor y dr ive belt fr om t h e
power st eer in g pu m p pu lley. See Gr ou p 7, Coolin g
80b9a4c2 Syst em for pr ocedu r e.
(11) Rem ove t h e power st eer in g pu m p pu lley. Use
Fig. 7 Installing Pump Pulley a h ex socket t o secu r e t h e pu m p sh a ft wh ile r em ov-
in g t h e pu lley n u t wit h a box wr en ch (F ig. 9).

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

Fig. 11 Power Steering Pump


(4) In st a ll t h e en gin e m ou n t a n d en gin e m ou n t
br a cket in veh icle.
(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
POWER loose a t t h is t im e.
STEERING PUMP COUPLER COUPLER (6) In st a ll, do n ot t or qu e en gin e m ou n t sill pla t e
RETAINING NUTS PINCH BOLT 80b9a49b n u t s a n d bolt s.
(7) In st a ll (4) en gin e m ou n t br a cket t o en gin e
Fig. 10 Power Steering Pump block r et a in in g bolt s a n d Tor qu e t o 61 N·m (45 ft .
(22) Slide pu m p off m ou n t in g st u ds a n d posit ion so lbs.).
pr essu r e lin e ca n be r em oved. Th is will r equ ir e you (8) Tor qu e t h e en gin e m ou n t sill pla t e n u t s t o 41
t o in st a ll pr essu r e lin e on t h e n ew pu m p pr ior t o N·m (30 ft . lbs.).
in st a llin g it in t h e en gin e block. (9) Tor qu e t h e en gin e m ou n t sill pla t e bolt s t o 41
(23) Rem ove t h e power st eer in g pu m p fr om t h e N·m (30 ft . lbs.).
veh icle. (10) Rem ove 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
Installation t h e or igin a l posit ion a n d lea ve bolt s loose a t t h is
t im e.
WARNING: Power steering system fluid may be (12) P osit ion a n d in st a ll A/C com pr essor.
contaminated with metal shavings, overheated or (13) Slide t h e dr ive cou pler in t o it s or igin a l posi-
improper fluid. All fluid should be drained from the t ion a n d st a r t r em a in in g (2) H -Block bolt s.
system. After component replacement, system (14) In st a ll t h e power st eer in g pu m p pu lley (F ig.
should be flushed and filled with Mopar Power 12). Tor qu e n u t t o 166 N·m (120 ft . lbs.).
Steering Fluid, or equivalent.
XJ STEERING 19 - 7
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(15) In st a ll t h e a ccessor y dr ive belt . See Gr ou p 7,
Coolin g for pr ocedu r e.
POWER STEERING (16) Tor qu e a ll t h e H -Block bolt s.
PUMP PULLEY (17) Tor qu e t h e en gin e m ou n t t h r ou gh bolt n u t t o
65 N·m (48 ft . lbs.).
HEX WRENCH (18) In st a ll t h e power st eer in g flu id su pply h ose on
pu m p.
(19) In st a ll t h e power st eer in g lin e su ppor t
br a cket bolt .
(20) Lower t h e veh icle fr om h oist .
(21) In st a ll t h e r efr iger en t lin e su ppor t br a cket
a n d bolt on t h e t op of t h e r a dia t or.
(22) In st a ll t h e A/C filt er-dr ier a ssem bly su ppor t
br a cket n u t s on t h e left fen der well.
(23) Recon n ect t h e A/C com pr essor elect r ica l con -
n ect or.
(24) Re-fill t h e power st eer in g flu id. Refer t o
Gr ou p 19, St eer in g for P ower St eer in g P u m p-In it ia l
Oper a t ion for pr ocedu r e.
(25) Con n ect t h e n ega t ive ba t t er y ca ble.
80b9a4c2

Fig. 12 Installing Pump Pulley


19 - 8 STEERING XJ

ST EERI N G COLU M N

INDEX
page page

GENERAL INFORMATION REMOVAL AND INSTALLATION


STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 8 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING SPECIFICATIONS
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 9 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 11

GEN ERAL I N FORM AT I ON ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL


THE AIRBAG SYSTEM COMPONENTS YOU MUST
STEERING COLUMN FIRST DISARM THE AIRBAG FIRING MECHANISM.
Th e t ilt a n d st a n da r d colu m n (F ig. 1) h a s been FAILURE TO DO SO COULD RESULT IN ACCIDEN-
design ed t o be ser viced a s a n a ssem bly; less wir in g, TAL DEPLOYMENT OF THE AIRBAG AND POSSI-
swit ch es, sh r ou ds, st eer in g wh eel, et c. Most st eer in g BLE PERSONAL INJURY.
colu m n com pon en t s ca n be ser viced wit h ou t r em ov-
in g t h e st eer in g colu m n fr om t h e veh icle. WARNING: THE FASTENERS, SCREWS, AND
BOLTS, ORIGINALLY USED FOR THE AIRBAG COM-
SERVICE PRECAUTIONS PONENTS, HAVE SPECIAL COATINGS AND ARE
Sa fet y goggles sh ou ld be wor n a t a ll t im es wh en SPECIFICALLY DESIGNED FOR THE AIRBAG SYS-
wor kin g on st eer in g colu m n s. TEM. THEY MUST NEVER BE REPLACED WITH ANY
To ser vice t h e st eer in g wh eel, swit ch es or a ir ba g, SUBSTITUTES. ANYTIME A NEW FASTENER IS
r efer t o Gr ou p 8 M a n d follow a ll WARNINGS a n d NEEDED, REPLACE WITH THE CORRECT FASTEN-
CAUTIONS. ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE

DASH COLUMN
PANEL COUPLER

T
PANEL
BRACKET

--®--e

I /2

CLOCK
SPRING
STEERING
WHEEL

LOWER
SHROUD PARK-LOCK STEERING
ASSEMBLY GEAR J9519-54

Fig. 1 Steering Column


XJ STEERING 19 - 9
GEN ERAL I N FORM AT I ON (Cont inue d)
CAUTION: Do not attempt to remove the pivot pins
CAUTION: DO NOT
to disassemble the tilting mechanism. Do not FILE THIS AREA TO REMOVE
REMOVE IGNITION
remove ignition locking link, shaft lock plate or LOCKING LINK FLASHING AND PROVIDE
plate retainer. This will damage the column (Fig. 2) CLEARANCE TO ELIMINATE
and (Fig. 3). ~~--..,__-=- BINDING

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

Fig. 5 Steering Column


(16) Rem ove ign it ion swit ch .
(17) Rem ove 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.
(18) Rem ove t h e colu m n .

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

CLIP TROUGH CLIP TO KEY SWITCH J9519-57

Fig. 7 Steering Column Wiring Harness


(15) In st a ll lower in st r u m en t pa n el/kn ee blocker.
PLASTIC CAPSULE
(16) In st a ll clockspr in g, st eer in g wh eel a n d a ir ba g.
(SPACER) Refer t o Gr ou p 8M Rest r a in t Syst em s for ser vice pr o-
cedu r es.
(17) Rem ove t h e colu m n sh a ft sh ippin g lock pin
(in st a lled in ser vice colu m n ).
(18) Con n ect t h e ba t t er y gr ou n d (n ega t ive) ca ble.

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

GENERAL INFORMATION WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 4


WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS
DIAGNOSIS AND TESTING ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SUSPENSION AND STEERING SYSTEM . . . . . . . 3
SERVICE PROCEDURES
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Fig. 1 Wheel Alignment Measurements


XJ SUSPENSION 2-3

DI AGN OSI S AN D T EST I N G


SUSPENSION AND STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as


suspension components. necessary.

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.

2. Loose or worn steering or 2. Tighten or replace components as


suspension components. necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as


suspension components. necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.

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.

VEHICLE PULLS TO ONE 1. Tire pressure. 1. Adjust tire pressure.


SIDE 2. Alignment. 2. Align vehicle to specifications.
3. Loose or worn steering or 3. Tighten or replace components as
suspension components. necessary.
4. Radial tire lead. 4. Rotate or replace tire as necessary.
5. Brake pull. 5. Repair brake as necessary.
6. Weak or broken spring. 6. Replace spring.
2-4 SUSPENSION XJ

SERV I CE PROCEDU RES


PRE-ALIGNMENT
Befor e st a r t in g wh eel a lign m en t , t h e followin g
in spect ion a n d n ecessa r y cor r ect ion s m u st be com -
plet ed. Refer t o Su spen sion a n d St eer in g Syst em
Dia gn osis Ch a r t for a ddit ion a l in for m a t ion .
(1) In spect t ir es for size a n d t r ea d wea r.
(2) Set t ir e a ir pr essu r e.
(3) In spect fr on t wh eel bea r in gs for wea r.
(4) In spect fr on t wh eels for excessive r a dia l or la t -
er a l r u n ou t a n d ba la n ce.
(5) In spect ba ll st u ds, lin ka ge pivot poin t s a n d
st eer in g gea r for loosen ess, r ou gh n ess or bin din g.
(6) In spect su spen sion com pon en t s for wea r a n d
n oise. SUSPENSION
ARM
WHEEL ALIGNMENT
J8916-22
Befor e ea ch a lign m en t r ea din g, t h e veh icle sh ou ld
be jou n ced (r ea r fir st , t h en fr on t ). Gr a sp ea ch
Fig. 2 Caster Adjustment
bu m per a t t h e cen t er a n d jou n ce t h e veh icle u p a n d
down sever a l t im es. Alwa ys r elea se t h e bu m per in TOE POSITION (LHD)
t h e down posit ion . Set t h e fr on t en d a lign m en t t o
specifica t ion s wit h t h e veh icle a t it s NORMAL RIDE NOTE: The wheel toe position adjustment is the
H E IGH T. final adjustment. The engine must remain running
during the entire toe position adjustment.
CAMBER
Th e wh eel ca m ber a n gle is pr eset . Th is a n gle is n ot (1) St a r t t h e en gin e a n d t u r n wh eels bot h wa ys
a dju st a ble a n d ca n n ot be a lt er ed. befor e st r a igh t en in g t h e wh eels. Secu r e t h e st eer in g
wh eel wit h t h e fr on t wh eels in t h e st r a igh t -a h ea d
CASTER posit ion .
Befor e ch eckin g t h e ca st er of t h e fr on t a xle for cor- (2) Loosen t h e a dju st m en t sleeve cla m p bolt s (F ig.
r ect a n gle, be su r e t h e a xle is n ot ben t or t wist ed. 3).
Roa d t est t h e veh icle, m a ke left a n d r igh t t u r n s. If (3) Adju st t h e r igh t wh eel t oe posit ion wit h t h e
t h e st eer in g wh eel r et u r n s t o t h e cen t er posit ion dr a g lin k. Tu r n t h e sleeve u n t il t h e r igh t wh eel is a t
u n a ssist ed, t h e ca st er a n gle is cor r ect . If st eer in g cor r ect TOE -IN specifica t ion s. P osit ion t h e cla m p
wh eel does n ot r et u r n t owa r d t h e cen t er posit ion bolt s a s sh own (F ig. 4) a n d t igh t en t o 49 N·m (36 ft .
u n a ssist ed, a n in cor r ect ca st er a n gle is pr oba ble. lbs.).
Ca st er ca n be a dju st ed by in st a llin g t h e a ppr opr i-
NOTE: Make sure the toe setting does not change
a t e size sh im s (F ig. 2).
during clamp tightening.
NOTE: Changing caster angle will also change the
(4) Adju st t h e left wh eel t oe posit ion wit h t h e t ie
front propeller shaft angle. The propeller shaft
r od. Tu r n t h e sleeve u n t il t h e left wh eel is a t specifi-
angle has priority over caster. Refer to Group 3 Dif-
ca t ion s. P osit ion t h e cla m p bolt s a s sh own (F ig. 4)
ferential & Driveline for additional information.
a n d t igh t en t o 27 N·m (20 ft . lbs.).

NOTE: Make sure the toe setting does not change


during clamp tightening.

(5) Ver ify t h e r igh t t oe set t in g a n d t u r n off en gin e.


(6) Roa d t est t h e veh icle on a fla t level r oa d t o ver-
ify t h e st eer in g wh eel is cen t er ed.

NOTE: Once the toe setting is correct, the steering


wheel can be re-centered by adjusting only the drag
link.
XJ SUSPENSION 2-5
SERV I CE PROCEDU RES (Cont inue d)

ADJUSTMENT
SLEEVE

- STEERING DAMPENER 19502-7

Fig. 3 Steering Linkage (LHD)


TIE ROD bolt s t o t h eir or igin a l posit ion a n d t igh t en t o 49 N·m
CLAMP (36 ft . lbs.).

NOTE: Make sure the toe setting does not change


during clamp tightening.

(4) Adju st t h e r igh t wh eel t oe posit ion wit h t h e t ie


r od. Tu r n t h e sleeve u n t il t h e r igh t wh eel is a t cor-
r ect TOE -IN specifica t ion s. P osit ion t h e cla m p bolt s
t o t h eir or igin a l posit ion a n d t igh t en t o 27 N·m (20
ft . lbs.).

NOTE: Make sure the toe setting does not change


during clamp tightening.
DRAG LINK
CLAMPS (5) Ver ify t h e r igh t t oe set t in g a n d t u r n off en gin e.
I I

(6) Roa d t est t h e veh icle on a fla t level r oa d t o ver-


Fig. 4 Drag Link and Tie Rod Clamp (LHD) ify t h e st eer in g wh eel is cen t er ed.
TOE POSITION (RHD)
NOTE: Once the toe setting is correct, the steering
NOTE: The wheel toe position adjustment is the wheel can be re-centered by adjusting only the drag
final adjustment. The engine must remain running link.
during the entire toe position adjustment.

(1) St a r t t h e en gin e a n d t u r n wh eels bot h wa ys


befor e st r a igh t en in g t h e wh eels. Secu r e t h e st eer in g
wh eel wit h t h e fr on t wh eels in t h e st r a igh t -a h ea d
posit ion .
(2) Loosen t h e a dju st m en t sleeve cla m p bolt s (F ig.
5).
(3) Adju st t h e left wh eel t oe posit ion wit h t h e dr a g
lin k. Tu r n t h e sleeve u n t il t h e left wh eel is a t t h e
cor r ect TOE -IN specifica t ion s. P osit ion t h e cla m p
2-6 SUSPENSION XJ
SPECI FI CAT I ON S (Cont inue d)

-~-·-'=@ PITMAN
l ARM

ADJUSTMENT
SLEEVE

TIE
ROD

J9502-6

Fig. 5 Steering Linkage (RHD)


SPECI FI CAT I ON S ADJUSTMENT PREFERRED RANGE MAX RT/LT
DIFFERENCE
ALIGNMENT CAMBER − 0.25° − 0.75° to + 1.0°
(fixed angle) 0.5°
NOTE: All alignment specifications are in degrees. TOTAL 0° to +
TOE-IN + 0.25° 0.45° .05°

THRUST ANGLE 0° ! 0.15°


ADJUSTMENT PREFERRED RANGE MAX RT/LT
DIFFERENCE

CASTER + 7.0° + 5.25° to + 1.25°


8.5°
XJ SUSPENSION 2-7

FRON T SU SPEN SI ON

INDEX
page page

DESCRIPTION AND OPERATION FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . . . 10


SUSPENSION COMPONENTS . . . . . . . . . . . . . . . 7 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 8 FRONT HUB BEARING . . . . . . . . . . . . . . . . . . . 12
REMOVAL AND INSTALLATION WHEEL MOUNTING STUDS-FRONT . . . . . . . . . 12
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 9 SPECIFICATIONS
COIL SPRING/JOUNCE BUMPER . . . . . . . . . . . . 9 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 13
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 9 SPECIAL TOOLS
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 10 FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 13
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . 10

DESCRI PT I ON AN D OPERAT I ON • Du a l-a ct ion sh ock a bsor ber s


• Coil spr in gs
SUSPENSION COMPONENTS • Upper a n d lower su spen sion a r m s
Th e fr on t su spen sion is a lin k/coil design (F ig. 1). • St a bilizer ba r
Th is su spen sion is u se on Left H a n d Dr ive (LH D) • Tr a ck ba r
a n d Righ t H a n d Dr ive (RH D) veh icles. Th e su spen - • J ou n ce bu m per s
sion is com pr ised of: Lin k /Co il S u s p e n s io n : Th is su spen sion a llows
• Dr ive a xle (4WD), t u be a xle (2WD) ea ch wh eel t o a da pt t o differ en t r oa d su r fa ces wit h -

LINKS STABILIZER
BAR

J9302-12

Fig. 1 Suspension Components (LHD)


2-8 SUSPENSION XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
ou t gr ea t ly a ffect in g t h e opposit e wh eel. Wh eels a r e CAUTION: Suspension components with rubber/
a t t a ch ed t o a h u b/bea r in gs wh ich bolt s t o t h e kn u ck- urethane bushings (except stabilizer bar) should be
les. Th e h u b/bea r in g is n ot ser vicea ble a n d is tightened with the vehicle at normal ride height. It is
r epla ced a s a u n it . St eer in g kn u ckles pivot on important to have the springs supporting the weight
r epla cea ble ba ll st u ds a t t a ch ed t o t h e a xle t u be of the vehicle when the fasteners are torqued. If
yokes. springs are not at their normal ride position, vehicle
S h o c k Abs o rbe rs : Th e sh ocks da m pen jou n ce a n d ride comfort could be affected and premature bush-
r ebou n d of t h e veh icle over va r iou s r oa d con dit ion s. ing wear may occur.
Th e t op of t h e sh ock a bsor ber s a r e bolt ed t o t h e body.
Th e bot t om of t h e sh ocks a r e bolt ed t o t h e a xle
spr in g br a cket . NOTE: Periodic lubrication of the front suspension/
Co il S p rin g s : Th e spr in gs con t r ol r ide qu a lit y a n d steering system components may be required. Rub-
m a in t a in pr oper r ide h eigh t . Th e coil spr in gs m ou n t ber bushings must never be lubricated. Refer to
u p in t h e fen der sh ield t o a br a cket wh ich is pa r t of Group 0, Lubrication And Maintenance for the rec-
t h e u n it ized body. A r u bber isola t or is loca t ed ommended maintenance schedule.
bet ween t h e t op of t h e spr in g a n d t h e body. Th e bot -
t om of t h e spr in g sea t s on a a xle pa d a n d is r et a in ed
wit h a clip. DI AGN OSI S AN D T EST I N G
U p p e r & Lo w e r S u s p e n s io n Arm s : Th e su spen -
sion a r m s a r e differ en t len gt h s, wit h bu sh in gs a t SHOCK DIAGNOSIS
bot h en ds. Th ey bolt t h e a xle a ssem bly t o t h e body. A kn ockin g or r a t t lin g n oise fr om a sh ock a bsor ber
Th e lower a r m s u se sh im s a t t h e body m ou n t t o m a y be ca u sed by m ovem en t bet ween m ou n t in g
a llow for a dju st m en t of ca st er a n d dr ive sh a ft pin ion bu sh in gs a n d m et a l br a cket s or a t t a ch in g com po-
a n gle. Th e su spen sion a r m t r a vel is lim it ed t h r ou gh n en t s. Th ese n oises ca n u su a lly be st opped by t igh t -
t h e u se of jou n ce bu m per s in com pr ession a n d sh ocks en in g t h e a t t a ch in g n u t s. If t h e n oise per sist s,
a bsor ber s in r ebou n d. in spect for da m a ged a n d wor n bu sh in gs, a n d a t t a ch -
S ta bilize r B a r: Th e st a bilizer ba r is u sed t o m in - in g com pon en t s. Repa ir a s n ecessa r y if a n y of t h ese
im ize veh icle body r oll du r in g t u r n s. Th e spr in g st eel con dit ion s exist .
ba r h elps t o con t r ol t h e veh icle body in r ela t ion sh ip A squ ea kin g n oise fr om t h e sh ock a bsor ber m a y be
t o t h e su spen sion . Th e ba r ext en ds a cr oss t h e fr on t ca u sed by t h e h ydr a u lic va lvin g a n d m a y be in t er m it -
u n der side of t h e ch a ssis a n d con n ect s t o t h e body t en t . Th is con dit ion is n ot r epa ir a ble a n d t h e sh ock
r a ils. Lin ks a r e con n ect ed fr om t h e ba r t o t h e a xle a bsor ber m u st be r epla ced.
br a cket s. St a bilizer ba r m ou n t s a r e isola t ed by r u b- Th e sh ock a bsor ber s a r e n ot r efilla ble or a dju st -
ber bu sh in gs. a ble. If a m a lfu n ct ion occu r s, t h e sh ock a bsor ber
Tra c k B a r: Th e t r a ck ba r is u sed t o loca t e t h e m u st be r epla ced. To t est a sh ock a bsor ber, h old it in
a xle la t er a lly. Th e ba r is a t t a ch ed t o a body r a il a n u pr igh t posit ion a n d for ce t h e pist on in a n d ou t of
br a cket wit h a ba ll st u d a n d isola t ed wit h a bu sh in g t h e cylin der fou r or five t im es. Th e a ct ion t h r ou gh ou t
a t t h e a xle br a cket . ea ch st r oke sh ou ld be sm oot h a n d even .
Th e sh ock a bsor ber bu sh in gs do n ot r equ ir e a n y
CAUTION: Components attached with a nut and
t ype of lu br ica t ion . Do n ot a t t em pt t o st op bu sh in g
cotter pin must be torqued to specification. Then if
n oise by lu br ica t in g t h em . Gr ea se a n d m in er a l oil-
the slot in the nut does not line up with the cotter
ba se lu br ica n t s will det er ior a t e t h e bu sh in g.
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
XJ SUSPENSION 2-9

REM OVAL AN D I N STALLAT I ON (5) Rem ove t h e st a bilizer ba r lin k a n d sh ock


a bsor ber fr om t h e a xle.
SHOCK ABSORBER (6) Rem ove t h e t r a ck ba r fr om t h e body r a il
br a cket .
REMOVAL (7) Rem ove t h e dr a g lin k fr om t h e pit m a n a r m .
(1) Rem ove t h e n u t , r et a in er a n d gr om m et fr om (8) Lower t h e a xle u n t il t h e spr in g is fr ee fr om t h e
t h e u pper st u d in t h e en gin e com pa r t m en t (F ig. 2). u pper m ou n t . Rem ove t h e coil spr in g clip a n d r em ove
(2) Rem ove t h e lower n u t s a n d bolt s fr om t h e a xle t h e spr in g.
br a cket . (9) P u ll jou n ce bu m per ou t of m ou n t .
(3) Rem ove t h e sh ock a bsor ber.
INSTALLATION
INSTALLATION (1) In st a ll jou n ce bu m per in t o m ou n t .
(1) P osit ion t h e lower r et a in er a n d gr om m et on t h e (2) P osit ion t h e coil spr in g on t h e a xle pa d. In st a ll
sh ock st u d. In ser t t h e sh ock a bsor ber t h r ou gh t h e t h e spr in g clip a n d bolt . Tigh t en bolt t o 21 N·m (16
sh ock t ower h ole. ft . lbs.).
(2) In st a ll t h e lower bolt s a n d n u t s. Tigh t en n u t s (3) Ra ise t h e a xle in t o posit ion u n t il t h e spr in g
t o 23 N·m (17 ft . lbs.). sea t s in t h e u pper m ou n t .
(3) In st a ll t h e u pper gr om m et a n d r et a in er on t h e (4) In st a ll t h e st a bilizer ba r lin ks a n d sh ock
st u d. In st a ll t h e n u t a n d t igh t en t o 10 N·m (8 ft . a bsor ber s t o t h e a xle br a cket .
lbs.). (5) In st a ll t h e t r a ck ba r t o t h e body r a il br a cket .
(6) In st a ll t h e lower su spen sion a r m s t o t h e a xle.
COIL SPRING/JOUNCE BUMPER In st a ll m ou n t in g bolt s a n d n u t s fin ger t igh t .
(7) In st a ll t h e fr on t pr opeller sh a ft t o t h e a xle.
REMOVAL (8) In st a ll t h e wh eel a n d t ir e a ssem blies.
(1) Ra ise a n d su ppor t t h e veh icle. P osit ion a (9) Rem ove t h e su ppor t s a n d lower t h e veh icle.
h ydr a u lic ja ck u n der t h e a xle t o su ppor t it . (10) Tigh t en lower su spen sion a r m s n u t s t o 115
(2) Rem ove t h e wh eel a n d t ir e a ssem blies. N·m (85 ft . lbs.).
(3) Ma r k a n d discon n ect t h e fr on t pr opeller sh a ft
fr om t h e a xle. STEERING KNUCKLE
(4) Rem ove lower su spen sion a r m s m ou n t in g n u t s F or ser vice pr ocedu r es on t h e st eer in g kn u ckle a n d
a n d bolt s fr om t h e a xle (F ig. 2). ba ll join t s r efer t o Gr ou p 3 Differ en t ia ls An d Dr iv-
elin e.

VIEW IN DIRECTION
OFARROWW
VIEW IN DIRECTION
OFARROWZ
J9502-4

Fig. 2 Coil Spring & Shock Absorber


2 - 10 SUSPENSION XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

LOWER SUSPENSION ARM (4) Tigh t en t h e n u t a t t h e a xle t o 75 N·m (55 ft .


lbs.). Tigh t en t h e n u t a t t h e fr a m e br a cket t o 90 N·m
REMOVAL (66 ft . lbs.).
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e lower su spen sion a r m n u t a n d bolt FRONT AXLE BUSHING
fr om t h e a xle br a cket .
(3) Rem ove t h e n u t a n d bolt fr om t h e r ea r br a cket REMOVAL
a n d r em ove t h e lower su spen sion a r m (F ig. 3). (1) Rem ove t h e u pper su spen sion a r m fr om a xle.
(2) P osit ion Spa cer 7932-3 over t h e a xle bu sh in g
NUT
on a 4x2 veh icle a n d r igh t side on a 4x4 veh icle.
(3) P la ce Receiver 7932-1 over fla n ged en d of t h e
UPPER
ARM BOLT bu sh in g. (F ig. 4).
(4) P la ce sm a ll en d of Rem over /In st a ll 7932-2
(LT-4WD)

·. ]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

Fig. 3 Upper and Lower Suspension Arms


INSTALLATION 80b5cb7a
(1) P osit ion t h e lower su spen sion a r m a t t h e a xle
br a cket a n d r ea r br a cket . Fig. 4 Bushing Removal
(2) In st a ll t h e bolt s a n d fin ger t igh t en t h e n u t s.
(3) Rem ove su ppor t a n d lower t h e veh icle. (7) Rem ove n u t , bolt , r eceiver, r em over a n d bu sh -
(4) Tigh t en t h e fr on t a n d r ea r n u t s t o 115 N·m (85 in g.
ft . lbs.).
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 7932-3 in position for bushing instal-
UPPER SUSPENSION ARM lation.
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle. INSTALLATION
(2) Rem ove t h e u pper su spen sion a r m n u t a n d bolt (1) P la ce Receiver 7932-1on t h e ot h er side of t h e
a t t h e a xle br a cket . a xle br a cket .
(3) Rem ove t h e n u t a n d bolt a t t h e fr a m e r a il a n d (2) P osit ion n ew bu sh in g u p t o t h e a xle br a cket ,
r em ove t h e u pper su spen sion a r m (F ig. 3). a n d la r ge en d of Rem over /In st a ll 7932-2 a ga in st t h e
bu sh in g (F ig. 5).
INSTALLATION (3) In st a ll bolt 7604 t h r ou gh r eceiver, bu sh in g a n d
(1) P osit ion t h e u pper su spen sion a r m a t t h e a xle in st a ller.
a n d fr a m e r a il. (4) In st a ll Lon g Nu t 7603 a n d t igh t en n u t t o dr a w
(2) In st a ll t h e bolt s a n d fin ger t igh t en t h e n u t s. t h e bu sh in g in t o t h e a xle br a cket .
(3) Rem ove t h e su ppor t s a n d lower t h e veh icle. (5) Rem ove t ools a n d in st a ll t h e u pper su spen sion
arm.
XJ SUSPENSION 2 - 11
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) P osit ion t h e st a bilizer ba r on t h e body r a il a n d
AXLE BRACKET
in st a ll t h e bu sh in gs a n d cla m ps. E n su r e t h e ba r is
REMOVER/INSTALLER cen t er ed wit h equ a l spa cin g on bot h sides. Tigh t en
t h e bolt s t o 75 N·m (40 ft . lbs.).
(3) In st a ll t h e lin ks a n d gr om m et s on t o t h e st a bi-
lizer ba r a n d a xle br a cket s.
(4) Tigh t en t h e lin k n u t s a t t h e a xle br a cket t o 95
N·m (70 ft . lbs.).
(5) Tigh t en t h e lin k n u t s a t t h e st a bilizer ba r t o 36
N·m (27 ft . lbs.).
(6) Rem ove t h e su ppor t s a n d lower t h e veh icle.

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

NUT TRACK BAR


PLATE J9202-3

Fig. 7 Track Bar (LHD)


Fig. 6 Stabilizer Bar (LHD)
INSTALLATION
(3) Rem ove t h e lin ks m ou n t in g n u t s a n d bolt s (1) In st a ll t h e t r a ck ba r a t a xle t u be br a cket .
fr om t h e a xle br a cket s. Loosely in st a ll t h e r et a in in g bolt a n d fla g n u t .
(4) Rem ove t h e st a bilizer ba r cla m ps fr om t h e (2) It m a y be n ecessa r y t o pr y t h e a xle a ssem bly
body r a ils. Rem ove t h e st a bilizer ba r. over t o in st a ll t h e t r a ck ba r a t t h e body r a il. In st a ll
t r a ck ba r a t t h e body r a il br a cket . In st a ll t h e r et a in -
INSTALLATION in g n u t on t h e st u d.
(1) In spect st a bilizer ba r bu sh in gs. Repla ce bu sh - (3) Rem ove t h e su ppor t s a n d lower t h e veh icle.
in gs if cr a cked, cu t , dist or t ed, or wor n . (4) Tigh t en t h e r et a in in g bolt a t t h e a xle sh a ft
t u be br a cket t o 100 N·m (74 ft . lbs.).
2 - 12 SUSPENSION XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

BRAKE WASHER
SHIELD

RETAINER

COTTER PIN

TONE
WHEEL
(ABS) BOLT NUT J9302-43

Fig. 8 Hub Bearing & Knuckle


(5) Tigh t en t h e ba ll st u d n u t t o 81 N·m (60 ft . WHEEL MOUNTING STUDS-FRONT
lbs.). In st a ll a n ew cot t er pin .
REMOVAL
FRONT HUB BEARING (1) Ra ise a n d su ppor t veh icle.
(2) Rem ove wh eel a n d t ir e a ssem bly.
REMOVAL (3) Rem ove br a ke ca liper a n d r ot or, r efer t o Gr ou p
(1) Ra ise a n d su ppor t t h e veh icle. 5 Br a kes for pr ocedu r e.
(2) Rem ove t h e wh eel a n d t ir e a ssem bly. (4) Rem ove st u d fr om h u b wit h Rem over C-4150A
(3) Rem ove t h e br a ke ca liper, r ot or a n d ABS wh eel (F ig. 9).
speed sen sor, r efer t o Gr ou p 5 Br a kes.
(4) 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. 8).
(5) Rem ove t h e h u b bea r in g m ou n t in g bolt s fr om
t h e ba ck of t h e st eer in g kn u ckle. Rem ove h u b bea r-
in g fr om t h e st eer in g kn u ckle a n d off t h e a xle sh a ft .

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

Remover Tie Rod End MB-990635


2 - 14 SUSPENSION XJ

REAR SU SPEN SI ON

INDEX
page page

DESCRIPTION AND OPERATION STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 15


SUSPENSION COMPONENT . . . . . . . . . . . . . . . 14 LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING LEAF SPRING AND SHACKLE BUSHING . . . . . . 16
SPRING AND SHOCK DIAGNOSIS . . . . . . . . . . . 14 SPECIFICATIONS
REMOVAL AND INSTALLATION TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 17
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . 15

DESCRI PT I ON AN D OPERAT I ON of the vehicle when the fasteners are torqued. If


springs are not at their normal ride position, vehicle
SUSPENSION COMPONENT ride comfort could be affected and premature bush-
Th e r ea r su spen sion is com pr ised of: ing wear may occur.
• Dr ive Axle
• Lea f Spr in gs
• Du a l-Act ion Sh ock Absor ber s DI AGN OSI S AN D T EST I N G
• St a bilizer Ba r (opt ion a l)
• J ou n ce Bu m per s SPRING AND SHOCK DIAGNOSIS
Le a f S p rin g s : Th e r ea r su spen sion syst em u ses a A kn ockin g or r a t t lin g n oise fr om a sh ock a bsor ber
m u lt i-lea f spr in gs a n d a solid dr ive a xle. Th e for wa r d m a y be ca u sed by m ovem en t bet ween m ou n t in g
en d of t h e spr in gs a r e m ou n t ed t o t h e body r a il h a n g- bu sh in gs a n d m et a l br a cket s or a t t a ch in g com po-
er s t h r ou gh r u bber bu sh in gs. Th e r ea r wa r d en d of n en t s. Th ese n oises ca n u su a lly be st opped by t igh t -
t h e spr in gs a r e a t t a ch ed t o t h e body by t h e u se of en in g t h e a t t a ch in g n u t s. If t h e n oise per sist s,
sh a ckles. Th e spr in g a n d sh a ckles u se r u bber bu sh - in spect for da m a ged a n d wor n bu sh in gs, a n d a t t a ch -
in gs. Th e bu sh in g h elp t o isola t e r oa d n oise. Th e in g com pon en t s. Repa ir a s n ecessa r y if a n y of t h ese
sh a ckles a llow t h e spr in gs t o ch a n ge t h eir len gt h a s con dit ion s exist .
t h e veh icle m oves over va r iou s r oa d con dit ion s. A squ ea kin g n oise fr om t h e sh ock a bsor ber m a y be
S h o c k Abs o rbe rs : Ride con t r ol is a ccom plish ed ca u sed by t h e h ydr a u lic va lvin g a n d m a y be in t er m it -
t h r ou gh t h e u se of du a l-a ct ion sh ock a bsor ber s. Th e t en t . Th is con dit ion is n ot r epa ir a ble a n d t h e sh ock
sh ocks da m pen t h e jou n ce a n d r ebou n d a s t h e veh icle a bsor ber m u st be r epla ced.
t r a vels over va r iou s r oa d con dit ion s. Th e t op of t h e Th e sh ock a bsor ber s a r e n ot r efilla ble or a dju st -
sh ock a bsor ber s a r e bolt ed t o t h e body cr ossm em ber. a ble. If a m a lfu n ct ion occu r s, t h e sh ock a bsor ber
Th e bot t om of t h e sh ocks a r e bolt ed t o t h e a xle m u st be r epla ced. To t est a sh ock a bsor ber, h old it in
br a cket . a n u pr igh t posit ion a n d for ce t h e pist on in a n d ou t of
S ta bilize r B a r: Th e st a bilizer ba r is u sed t o m in - t h e cylin der fou r or five t im es. Th e a ct ion t h r ou gh ou t
im ize veh icle body r oll. Th e spr in g st eel ba r h elps t o ea ch st r oke sh ou ld be sm oot h a n d even .
con t r ol t h e veh icle body in r ela t ion sh ip t o t h e su s- Th e spr in g eye a n d sh ock a bsor ber bu sh in gs do n ot
pen sion . Th e ba r ext en ds a cr oss t h e u n der side of t h e r equ ir e a n y t ype of lu br ica t ion . Do n ot a t t em pt t o
veh icle a n d is bolt ed t o t h e a xle. Lin ks a t t h e en d of st op spr in g bu sh in g n oise by lu br ica t in g t h em .
t h e ba r a r e bolt ed t o t h e fr a m e. Gr ea se a n d m in er a l oil-ba se lu br ica n t s will det er io-
J o u n c e B u m p e rs : Th e jou n ce bu m per s a r e u sed r a t e t h e bu sh in g r u bber.
t o lim it t h e spr in g a n d a xle t r a vel. Th ey a r e bolt ed t o If t h e veh icle is u sed for sever e, off-r oa d oper a t ion ,
t h e fr a m e r a il a bove t h e a xle. t h e spr in gs sh ou ld be exa m in ed per iodica lly. Ch eck
for br oken a n d sh ift ed lea fs, loose a n d m issin g clips,
CAUTION: Suspension components with rubber/
a n d br oken cen t er bolt s. Refer t o Spr in g a n d Sh ock
urethane bushings (except stabilizer bar) should be
Absor ber Dia gn osis ch a r t for a ddit ion a l in for m a t ion .
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
XJ SUSPENSION 2 - 15
DI AGN OSI S AN D T EST I N G (Cont inue d)
SPRI N G AN D SH OCK ABSORBER DI AGN OSI S

CONDITION POSSIBLE CAUSES CORRECTION

SPRING SAGS 1. Broken leaf. 1. Replace spring.

2. Spring fatigue. 2. Replace spring.

SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.

2. Worn bushings. 2. Replace bushings.


3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.

SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.


2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.

REM OVAL AN D I N STALLAT I ON INSTALLATION


(1) In st a ll t h e sh ock a bsor ber lower eye on t h e
SHOCK ABSORBER spr in g br a cket st u d. In st a ll t h e sh ock a bsor ber a n d
u pper bolt s on t h e body br a cket .
REMOVAL (2) Tigh t en t h e lower n u t t o 62 N·m (46 ft . lbs.).
(1) Rem ove t h e sh ock a bsor ber u pper bolt s fr om (3) Tigh t en t h e u pper bolt s t o 23 N·m (17 ft . lbs.).
t h e body br a cket (F ig. 1).
(2) Rem ove lower a t t a ch in g n u t a n d wa sh er fr om STABILIZER BAR
t h e br a cket st u d. Rem ove t h e sh ock a bsor ber.
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.

J9503-6

Fig. 1 Rear Suspension Components


2 - 16 SUSPENSION XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Discon n ect st a bilizer ba r lin ks fr om spr in g (2) P osit ion t h e r ea r eye in t h e sh a ckle br a cket .
br a cket s (F ig. 2). 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
(3) Discon n ect t h e st a bilizer ba r br a cket s fr om t h e t igh t en a t t h is t im e.
body r a ils. Rem ove t h e st a bilizer ba r a n d lin ks. (3) P osit ion t h e a xle. In st a ll t h e spr in g br a cket ,
U-bolt s a n d n u t s. Tigh t en t h e n u t s t o 70 N·m (52 ft .
LINK
/BUSHING~ lbs.).
(4) Con n ect t h e st a bilizer ba r lin k t o t h e spr in g
br a cket .
GROMMET (5) Rem ove t h e h ydr a u lic ja ck.
(6) Lower t h e veh icle.
(7) Tigh t en t h e spr in g fr on t eye a t t a ch in g bolt s t o
156 N·m (115 ft . lbs.).
(8) Tigh t en t h e spr in g r ea r eye a t t a ch in g bolt s t o
108 N·m (80 ft . lbs.).
(9) Tigh t en t h e st a bilizer ba r lin k t o 74 N·m (55 ft .
lbs.).

LEAF SPRING AND SHACKLE BUSHING


F or fr on t bu sh in gs ben d t a bs DOWN befor e
r em ova l. Use a n a ppr opr ia t e dr iver t ool a n d for ce t h e
or igin a l bu sh in g ou t of t h e spr in g eye.
(1) Assem ble t ools sh own (F ig. 3). Tigh t en n u t a t
t h e socket wr en ch en d of t h e t h r ea ded r od u n t il t h e
bu sh in g is for ced ou t .
J9217-6 PIPE
NUT
(RECEIVER)
Fig. 2 Stabilizer Bar
INSTALLATION
(1) P osit ion t h e st a bilizer ba r lin ks a t t h e spr in g
br a cket s. In st a ll t h e a t t a ch in g bolt s a n d n u t s a n d
t igh t en t o 74 N·m (55 ft . lbs.).
(2) At t a ch t h e st a bilizer ba r t o t h e body r a il br a ck-
et s wit h t h e bolt s. Tigh t en t o 54 N·m (40 ft . lbs.).
(3) Rem ove t h e su ppor t s a n d lower t h e veh icle.

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.

(4) F or fr on t bu sh in gs ben d t a bs u p a ft er in st a lla - D ES CRIP TION TORQU E


t ion . S h o c k Abs o rbe r
Upper Bolt . . . . . . . . . . . . . . . 23 N·m (17 ft . lbs.)
Lower Nu t . . . . . . . . . . . . . . . . 62 N·m (46 ft . lbs.)
S ta bilize r B a r
Cla m p Bolt . . . . . . . . . . . . . . . 54 N·m (40 ft . lbs.)
Lin k Upper Bolt . . . . . . . . . . . . 12 N·m (9 ft . lbs.)
Lin k Lower Nu t . . . . . . . . . . . 74 N·m (55 ft . lbs.)
S p rin g
U-Bolt Nu t . . . . . . . . . . . . . . . 70 N·m (52 ft . lbs.)
F r on t P ivot Bolt . . . . . . . . . 156 N·m (115 ft . lbs.)
Upper Sh a ckle Bolt . . . . . . . 156 N·m (115 ft . lbs.)
Lower Sh a ckle Bolt . . . . . . . . 108 N·m (80 ft . lbs.)
XJ TRANSMISSION AND TRANSFER CASE 21 - 1

TRANSMISSION AND TRANSFER CASE


CON T EN T S

page page

AUTOMATIC TRANSMISSION—30RH . . . . . . . . 73 AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . 1


AW–4 AUTOMATIC TRANSMISSION . . . . . . . . 163 NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . 280
AX15 MANUAL TRANSMISSION . . . . . . . . . . . . 37 NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . 306

AX 5 M AN U AL T RAN SM I SSI ON

INDEX
page page

GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY


AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . 1 ADAPTER/EXTENSION HOUSING AND FRONT
GEAR RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BEARING RETAINER . . . . . . . . . . . . . . . . . . . . 8
RECOMMENDED LUBRICANT . . . . . . . . . . . . . . . 1 COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 26
TRANSMISSION ASSEMBLY INFORMATION . . . . 2 INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TRANSMISSION IDENTIFICATION . . . . . . . . . . . . 1 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING SEMI-SYNCHRONIZED REVERSE
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . .... 3 IDLER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 32
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . .... 3 SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 15
TRANSMISSION NOISE . . . . . . . . . . . . . . . . .... 4 CLEANING AND INSPECTION
REMOVAL AND INSTALLATION AX5 MANUAL TRANSMISSION COMPONENTS . . . 32
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . . 7 SPECIFICATIONS
EXTENSION HOUSING SEAL . . . . . . . . . . . . . . . 7 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FRONT BEARING RETAINER SEAL . . . . . . . . . . . 6 SPECIAL TOOLS
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

GEN ERAL I N FORM AT I ON 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.
AX5 MANUAL TRANSMISSION
Th e AX5 is a five speed m a n u a l t r a n sm ission wit h GEAR RATIOS
fift h gea r bein g t h e over dr ive r a n ge. An a da pt er Gea r r a t ios for t h e AX5 m a n u a l t r a n sm ission a r e
h ou sin g is u sed t o a t t a ch t h e t r a n sm ission t o t h e a s follows:
t r a n sfer ca se on 4-wh eel dr ive a pplica t ion s. A st a n - • F ir st gea r : 3.93:1
da r d st yle ext en sion h ou sin g is u sed for t h e 2-wh eel • Secon d gea r : 2.33:1
dr ive a pplica t ion s. Th e sh ift m ech a n ism is in t egr a l t o • Th ir d gea r : 1.45:1

-
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

TRANSMISSION IDENTIFICATION RECOMMENDED LUBRICANT


Th e AX5 iden t ifica t ion code is on t h e bot t om su r- Recom m en ded lu br ica n t for AX5 t r a n sm ission s is
fa ce of t h e t r a n sm ission ca se n ea r t h e fill plu g (F ig. Mopa r ! 75W–90, AP I Gr a de GL–3 gea r lu br ica n t , or
2). Th e fir st n u m ber is yea r of m a n u fa ct u r e. Th e sec- equ iva len t .
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-
21 - 2 TRANSMISSION AND TRANSFER CASE XJ
GEN ERAL I N FORM AT I ON (Cont inue d)

S0abfee7

Fig. 1 AX5 Manual Transmission


• 3.5 lit er s (3.70 qu a r t s) for 2–wh eel dr ive a pplica -
t ion s.

I.D. CODE
NEAR DRAOINN PLUG
CASE
J8921-4
80abfee5

Fig. 3 Fill Plug Location


Fig. 2 Transmission Identification
TRANSMISSION ASSEMBLY INFORMATION
Cor r ect lu br ica n t level is fr om t h e bot t om edge, t o
Lu br ica t e t h e t r a n sm ission com pon en t s wit h
n o m or e t h a n 6 m m (1/4 in .) below t h e bot t om edge of
Mopa r ! 75W–90, GL 3 gea r lu br ica n t du r in g a ssem -
t h e fill plu g h ole.
bly. Use pet r oleu m jelly t o lu br ica t e sea l lips a n d/or
Th e fill plu g is on t h e pa ssen ger side of t h e
h old pa r t s in pla ce du r in g in st a lla t ion .
a da pt er h ou sin g (F ig. 3). Th e dr a in plu g is on t h e
Refer t o (F ig. 4) du r in g a ssem bly for AX5 gea r
bot t om of t h e ca se.
a ssem bly iden t ifica t ion .
Appr oxim a t e dr y fill lu br ica n t ca pa cit y is:
• 3.3 lit er s (3.49 qu a r t s) for 4–wh eel dr ive a pplica -
t ion s.
XJ TRANSMISSION AND TRANSFER CASE 21 - 3
GEN ERAL I N FORM AT I ON (Cont inue d)

.~a~ SNAPRING
SLINGER

SNAP RING
COUNTER
GEAR

cou=•j,
GEAR

J9121-394

Fig. 4 Geartrain Components


DI AGN OSI S AN D T EST I N G t h e lu br ica n t level a ft er a n y a ddit ion of flu id t o a void
a n in cor r ect lu br ica n t level con dit ion .
LOW LUBRICANT LEVEL
A low t r a n sm ission lu br ica n t level is gen er a lly t h e HARD SHIFTING
r esu lt of a lea k, in a dequ a t e lu br ica n t fill, or a n in cor- H a r d sh ift in g is u su a lly ca u sed by a low lu br ica n t
r ect lu br ica n t level ch eck. level, im pr oper, or con t a m in a t ed lu br ica n t s. Th e con -
Lea ks ca n occu r a t t h e m a t in g su r fa ces of t h e gea r sequ en ce of u sin g n on –r ecom m en ded lu br ica n t s is
ca se, in t er m edia t e pla t e a n d a da pt or or ext en sion n oise, excessive wea r, in t er n a l bin d, a n d h a r d sh ift -
h ou sin g, or fr om t h e fr on t /r ea r sea ls. A su spect ed in g. Su bst a n t ia l lu br ica n t lea ks ca n r esu lt in gea r,
lea k cou ld a lso be t h e r esu lt of a n over fill con dit ion . sh ift r a il, syn ch r o, a n d bea r in g da m a ge. If a lea k
Lea ks a t t h e r ea r of t h e ext en sion or a da pt er h ou s- goes u n det ect ed for a n ext en ded per iod, t h e fir st in di-
in g will be fr om t h e h ou sin g oil sea ls. Lea ks a t com - 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 -
pon en t m a t in g su r fa ces will pr oba bly be t h e r esu lt of in g a n d n oise.
in a dequ a t e sea ler, ga ps in t h e sea ler, in cor r ect bolt Com pon en t da m a ge, in cor r ect clu t ch a dju st m en t ,
t igh t en in g, or u se of a n on –r ecom m en ded sea ler. or a da m a ged clu t ch pr essu r e pla t e or disc a r e a ddi-
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 t ion a l pr oba ble ca u ses of in cr ea sed sh ift effor t . In cor-
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. r ect a dju st m en t or a wor n /da m a ged pr essu r e pla t e or
Lu br ica n t m a y be seen dr ippin g fr om t h e clu t ch disc ca n ca u se in cor r ect r elea se. If t h e clu t ch pr oblem
h ou sin g a ft er ext en ded oper a t ion . If t h e lea k is is a dva n ced, gea r cla sh du r in g sh ift s ca n r esu lt .
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- Wor n or da m a ged syn ch r o r in gs ca n ca u se gea r cla sh
in g t h e disc t o slip, gr a b, a n d/or ch a t t er. wh en sh ift in g in t o a n y for wa r d gea r. In som e n ew or
A cor r ect lu br ica n t level ch eck ca n on ly be m a de 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
wh en t h e veh icle is level. Also a llow t h e lu br ica n t t o st ick sligh t ly ca u sin g h a r d or n oisy sh ift s. In m ost
set t le for a m in u t e or so befor e ch eckin g. Th ese r ec- ca ses, t h is con dit ion will declin e a s t h e r in gs wea r –
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 in .
a void a n u n der fill or over fill con dit ion . Alwa ys ch eck
21 - 4 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

TRANSMISSION NOISE (13) Secu r e t r a n sfer ca se, if equ ipped, t o ja ck wit h


Most m a n u a l t r a n sm ission s m a ke som e n oise du r- sa fet y ch a in s.
in g n or m a l oper a t ion . Rot a t in g gea r s gen er a t e a m ild (14) Discon n ect t r a n sfer ca se sh ift lin ka ge a t
wh in e t h a t is a u dible, bu t gen er a lly on ly a t ext r em e t r a n sfer ca se, if equ ipped.
speeds. (15) 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-
Sever e, h igh ly a u dible t r a n sm ission n oise is gen er- m ission , if equ ipped.
a lly t h e in it ia l in dica t or of a lu br ica n t pr oblem . (16) Rem ove t r a n sfer ca se, if equ ipped.
In su fficien t , im pr oper, or con t a m in a t ed lu br ica n t will (17) Rem ove cr a n ksh a ft posit ion sen sor (F ig. 6),
pr om ot e r a pid wea r of gea r s, syn ch r os, sh ift r a ils, (F ig. 7).
for ks a n d bea r in gs. Th e over h ea t in g ca u sed by a
lu br ica n t pr oblem , ca n a lso lea d t o gea r br ea ka ge.

REM OVAL AN D I N STALLAT I ON


TRANSMISSION
REMOVAL
(1) Sh ift t r a n sm ission in t o fir st or t h ir d gea r.
(2) Ra ise a n d su ppor t veh icle on su it a ble sa fet y
st a n ds.
(3) Discon n ect n ecessa r y exh a u st syst em com po-
n en t s.
(4) Rem ove skid pla t e, if equ ipped.
(5) Rem ove sla ve cylin der fr om clu t ch h ou sin g.
(6) Ma r k r ea r pr opeller sh a ft a n d r ea r a xle yokes
for in st a lla t ion a lign m en t (F ig. 5). RUBBER (; 0

REFERENCE MARKS
GROMMET
CRANKSHAFT \
I~ j -:,'-@__
POSITION \ MOUNTING
SENSOR NUTS (2) soa4s1s1

Fig. 6 Crankshaft Position Sensor—2.5L Engine

J9316-2

Fig. 5 Marking Propeller Shaft And Axle Yokes


(7) Ma r k fr on t pr opeller sh a ft , a xle, a n d t r a n sfer
ca se yokes for in st a lla t ion a lign m en t , if equ ipped.
(8) Rem ove pr opeller sh a ft (s).
(9) Un clip wir e h a r n esses fr om t r a n sm ission a n d
t r a n sfer ca se, if equ ipped.
RUBBER
(10) Discon n ect t r a n sfer ca se ven t h ose, if GROMMET
equ ipped.
(11) Disen ga ge a n y wir e con n ect or s a t t a ch ed t o CRANKSHAFT \
POSITION \
t r a n sm ission or t r a n sfer ca se, if equ ipped, com po-
SENSOR 80a43752
n en t s.
(12) Su ppor t t r a n sfer ca se, if equ ipped, wit h t r a n s- Fig. 7 Crankshaft Position Sensor —4.0L Engine
m ission ja ck.
XJ TRANSMISSION AND TRANSFER CASE 21 - 5
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.

(18) Su ppor t en gin e wit h a dju st a ble ja ck st a n d.


P osit ion wood block bet ween ja ck a n d oil pa n t o
a void da m a gin g pa n .
(19) Su ppor t t r a n sm ission wit h t r a n sm ission ja ck.
(20) Secu r e t r a n sm ission t o ja ck wit h sa fet y
ch a in s.
(21) Discon n ect r ea r cu sh ion a n d br a cket fr om
t r a n sm ission .
(22) Rem ove r ea r cr ossm em ber.
(23) Discon n ect t r a n sm ission sh ift lever a s follows:
(a ) Lower t r a n sm ission –t r a n sfer ca se a ssem bly
a ppr oxim a t ely 7–8 cm (3 in .) for a ccess t o sh ift
lever.
(b) Rea ch u p a n d a r ou n d t r a n sm ission ca se a n d
u n sea t sh ift lever du st boot fr om t r a n sm ission sh ift
t ower (F ig. 8). Move boot u pwa r d on sh ift lever for
a ccess t o r et a in er t h a t secu r es lever in sh ift t ower.
(c) Rea ch u p a n d a r ou n d t r a n sm ission ca se a n d
pr ess sh ift lever r et a in er down wa r d wit h fin ger
pr essu r e. Tu r n r et a in er cou n t er clockwise t o r elea se
it .
(d) Lift lever a n d r et a in er ou t of sh ift t ower (F ig.
8). Do n ot r em ove t h e sh ift lever fr om t h e floor con -
sole sh ift er boot s. Lea ve t h e lever in pla ce for Fig. 9 Clutch Housing
t r a n sm ission in st a lla t ion . INSTALLATION
(1) In st a ll clu t ch h ou sin g on t r a n sm ission . Tigh t en
/ h ou sin g bolt s t o 37 N·m (27 ft . lbs.) t or qu e.
(2) Lu br ica t e con t a ct su r fa ces of r elea se for k pivot
ba ll st u d a n d r elea se for k wit h h igh t em p gr ea se.
(3) In st a ll r elea se bea r in g, for k, a n d r et a in er clip.
(4) P osit ion a n d secu r e t r a n sm ission on t r a n sm is-
sion ja ck.
(5) Ligh t ly lu br ica t e pilot bea r in g a n d t r a n sm is-
sion in pu t sh a ft splin es wit h Mopa r ! h igh t em p
gr ea se.
(6) Ra ise t r a n sm ission a n d a lign t r a n sm ission
in pu t sh a ft a n d clu t ch disc splin es. Th en slide t r a n s-
m ission in t o pla ce.
(7) In st a ll a n d t igh t en clu t ch h ou sin g-t o-en gin e
bolt s t o 38 N·m (28 ft . lbs.) t or qu e (F ig. 9). B e s u re
th e h o u s in g is p ro p e rly s e a te d o n e n g in e blo c k
Fig. 8 Removing/Installing Shift Lever be fo re tig h te n in g bo lts .
(24) Rem ove clu t ch h ou sin g br a ce r od. (8) In st a ll clu t ch h ou sin g br a ce r od.
(25) Rem ove clu t ch h ou sin g-t o-en gin e bolt s. (9) Lower t r a n sm ission a ppr oxim a t ely 7–8 cm (3
(26) P u ll t r a n sm ission ja ck r ea r wa r d u n t il in pu t in .) for a ccess t o sh ift t ower. Be su r e t r a n sm ission is
sh a ft clea r s clu t ch . Th en slide t r a n sm ission ou t fr om in fir st or t h ir d gea r.
u n der veh icle. (10) Rea ch u p a n d a r ou n d t r a n sm ission a n d in ser t
(27) Rem ove clu t ch r elea se bea r in g, r elea se for k, sh ift lever in sh ift t ower. P r ess lever r et a in er down -
a n d r et a in er clip. wa r d a n d t u r n it clockwise t o lock it in pla ce. Th en
(28) Rem ove clu t ch h ou sin g fr om t r a n sm ission in st a ll lever du st boot on sh ift t ower.
(F ig. 9).
21 - 6 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(11) In st a ll r ea r cr ossm em ber. Tigh t en cr ossm em - (28) In st a ll a n d t igh t en pr opeller sh a ft U–join t
ber-t o-fr a m e bolt s t o 41 N·m (31 ft . lbs.) t or qu e. cla m p bolt s t o 19 N·m (170 in . lbs.) t or qu e.
(12) In st a ll fa st en er s t o h old r ea r cu sh ion a n d (29) In st a ll sla ve cylin der in clu t ch h ou sin g.
br a cket t o t r a n sm ission . Th en t igh t en t r a n sm ission - (30) In st a ll skid pla t e, if equ ipped. Tigh t en bolt s t o
t o-r ea r su ppor t bolt s/n u t s t o 45 N·m (33 ft . lbs.) 42 N·m (31 ft . lbs.) t or qu e. Tigh t en st u d n u t s t o 17
t or qu e. N·m (150 in . lbs.) t or qu e.
(13) Rem ove su ppor t st a n ds fr om en gin e a n d (31) F ill t r a n sm ission a n d t r a n sfer ca se, if
t r a n sm ission . equ ipped, wit h r ecom m en ded lu br ica n t s. Refer t o t h e
(14) In st a ll a n d con n ect cr a n ksh a ft posit ion sen sor. Lu br ica n t Recom m en da t ion sect ion s of t h e a ppr opr i-
(15) P osit ion t r a n sfer ca se on t r a n sm ission ja ck, if a t e com pon en t for cor r ect flu id.
equ ipped. (32) Lower veh icle.
(16) Secu r e t r a n sfer ca se t o ja ck wit h sa fet y
ch a in s, if equ ipped. FRONT BEARING RETAINER SEAL
(17) Ra ise t r a n sfer ca se, if equ ipped, a n d a lign
t r a n sfer ca se in pu t sh a ft t o t h e t r a n sm ission ou t pu t REMOVAL
sh a ft . (1) Rem ove r elea se bea r in g a n d lever fr om t h e
(18) Slide t r a n sfer ca se for wa r d u n t il ca se is t r a n sm ission .
sea t ed on t r a n sm ission , if n ecessa r y. (2) Rem ove t h e bolt s h oldin g t h e fr on t bea r in g
(19) In st a ll n u t s t o a t t a ch t r a n sfer ca se t o t r a n s- r et a in er t o t h e t r a n sm ission ca se.
m ission , if equ ipped. Tigh t en t r a n sfer ca se-t o-t r a n s- (3) Rem ove t h e fr on t bea r in g r et a in er fr om t h e
m ission n u t s t o 35 N·m (26 ft . lbs.) t or qu e. t r a n sm ission ca se.
(20) Con n ect t r a n sfer ca se sh ift lin ka ge a t t r a n sfer (4) Usin g a su it a ble pr y t ool, r em ove t h e fr on t
ca se, if equ ipped. bea r in g r et a in er sea l.
(21) Con n ect t r a n sfer ca se ven t h ose, if equ ipped.
(22) Secu r e wir e h a r n esses in clips/t ie st r a ps on INSTALLATION
t r a n sm ission a n d t r a n sfer ca se, if equ ipped. (1) Usin g Tool H a n dle C-4171 a n d Sea l In st a ller
(23) E n ga ge wir e con n ect or s a t t a ch ed t o a ll n eces- 8211, in st a ll n ew sea l in t o t h e fr on t bea r in g r et a in er
sa r y t r a n sm ission or t r a n sfer ca se, if equ ipped, com - (F ig. 11).
pon en t s.
(24) In st a ll r ea r pr opeller sh a ft slip yoke t o t r a n s-
m ission or t r a n sfer ca se, if equ ipped, ou t pu t sh a ft .
(25) Align m a r ks on r ea r pr opeller sh a ft a n d r ea r
a xle yokes (F ig. 10).

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 .

EXTENSION HOUSING SEAL


REMOVAL
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove pr opeller sh a ft . Refer t o Gr ou p 3, Dif-
fer en t ia l a n d Dr ivelin e, for pr oper pr ocedu r es.
I
EXTENSION
HOUSING
(3) Usin g a su it a ble sea l pu ller or scr ew wit h a 80b099c4
slide h a m m er, r em ove t h e ext en sion h ou sin g sea l
(F ig. 12). Fig. 13 Install Extension Housing Seal
SLIDE ADAPTER
HAMMER HOUSING
OIL SEAL

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.

ADAPTER HOUSING SEAL


REMOVAL
(1) H oist a n d su ppor t veh icle.
(2) Rem ove t r a n sfer ca se.
(3) Usin g a su it a ble pr y t ool, or a slide h a m m er
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. 14).
21 - 8 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

SPECIAL
TOOL SHIFT
8208 TOWER

J8921-1033

Fig. 17 Remove Shift Tower Gasket


(8) Rem ove det en t ba ll plu g (F ig. 19).
(9) Rem ove det en t spr in g a n d ba ll wit h pen cil
m a gn et (F ig. 20), (F ig. 21).
80b099cS

Fig. 15 Install Adapter Housing Seal


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. 18).
(4) Rem ove veh icle speed sen sor a n d speedom et er
a da pt er, if n ecessa r y.
(5) Remove bolts holding shift tower to transmission case.
(6) Remove shift tower from tra nsmission ca se (Fig. 16).
(7) Rem ove sh ift t ower ga sket fr om sh ift t ower or
t r a n sm ission ca se (F ig. 17).

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

Fig. 22 Shift Arm Retainer Bolt Removal


80abfeee
Fig. 20 Remove Detent Spring
(10) Rem ove sh ift a r m r et a in er bolt (F ig. 22).
(11) Rem ove sh ift a r m r est r ict or pin s (F ig. 23).
(12) Rem ove sh ift lever sh a ft plu g (F ig. 24).
(13) Rem ove sh ift er sh a ft wit h la r ge m a gn et
(F ig. 25).
(14) Rem ove t h e sh ift a r m fr om t h e a da pt er h ou s-
in g.
(15) Rem ove a da pt er /ext en sion h ou sin g bolt s.

Fig. 23 Shift Arm Rstrictor Pins


21 - 10 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

J8921-1043

Fig. 26 Loosen Adapter/Extension Housing

Fig. 24 Removing Shift Lever Shaft Plug

J8921-1044
LARGE
MAGNET Fig. 27 Remove Adapter/Extension Housing–Typical
SNAP LOCK---..-0 SNAP
~RING
RING~
J8921-1037

Fig. 25 Remove Shifter Shaft


OUTPUT
(16) Loosen a da pt er /ext en sion h ou sin g by t a ppin g SHAFT SPEEDOMETER
it loose wit h pla st ic m a llet (F ig. 26). GROOVES GEAR
(17) Rem ove a da pt er /ext en sion h ou sin g (F ig. 27).
(18) On 4x2 t r a n sm ission s;
(a ) Rem ove speedom et er gea r r et a in in g sn a p-
r in g fr om ou t pu t sh a ft .
(b) Rem ove speedom et er gea r fr om ou t pu t sh a ft
a n d r em ove speedom et er gea r lock ba ll fr om ou t pu t
sh a ft . J8921-1119
(c) Rem ove speedom et er dr ive gea r loca t in g
sn a p-r in g (F ig. 28). Fig. 28 Speedometer Drive Gear Assembly
(19) Rem ove t h e bolt s h oldin g t h e fr on t bea r in g (21) Rem ove in pu t sh a ft bea r in g sn a p-r in g (F ig.
r et a in er t o t h e t r a n sm ission ca se. 30).
(20) Rem ove t h e bea r in g r et a in er fr om t r a n sm is- (22) Rem ove cou n t er sh a ft fr on t bea r in g sn a p-r in g.
sion ca se (F ig. 29).
XJ TRANSMISSION AND TRANSFER CASE 21 - 11
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 39 Position Shift Arm in Adapter or Extension


Housing

Fig. 42 Shifter Arm Shaft Plug Installation

Fig. 40 Install Shifter Arm Shaft


Fig. 43 Install Shifter Restrictor Pins
21 - 14 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(16) In st a ll sh ift det en t ba ll in det en t open in g of
ca se (F ig. 44).
(17) In st a ll det en t spr in g in ca se (F ig. 45).
(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. 46).

PENCIL
~NET

Fig. 46 Install Detent Ball Plug

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.

SHIFT MECHANISM AND GEARTRAIN


DISASSEMBLY
(1) In st a ll su it a ble bolt s a n d wa sh er s in in t er m edi-
a t e pla t e (F ig. 49). Th en cla m p pla t e a n d gea r a ssem -
bly in vise. Use en ou gh wa sh er s t o pr even t bolt s
fr om t ou ch in g. Also be su r e vise ja ws a r e cla m ped on
bolt h ea ds.
INTERMEDIATE
PLATE

Fig. 50 Remove Fifth Gear Snap-ring


SHIFT FORK. ,.,..c---,\,-------4/
RETAINER
BOLT

80ac2c56

Fig. 51 Remove Shift Fork Retainer Bolt


NOTE: There are many lock balls, check balls,
J8921-15
interlock balls, and interlock pins used in various
Fig. 49 Positioning Intermediate Plate In Vise
places in the transmission. Whenever a pin or ball
(2) Rem ove cou n t er sh a ft fift h gea r r et a in in g sn a p- is removed, it should be identified in such a way
r in g (F ig. 50). that it can be reinstalled in the same location from
(3) Rem ove bolt h oldin g fift h gea r sh ift for k t o which it was removed.
sh ift r a il (F ig. 51).
(4) Rem ove fift h gea r blocker r in g fr om cou n t er- (9) Rem ove bolt h oldin g r ever se idler gea r sh a ft
sh a ft a ssem bly wit h P u ller L-4407 (F ig. 52). lock pla t e t o t h e in t er m edia t e pla t e.
(5) Rem ove fift h gea r syn ch r o r in g (F ig. 53). (10) Rem ove r ever se idler gea r sh a ft a n d r ever se
(6) Rem ove t h e cou n t er sh a ft fift h gea r a ssem bly idler gea r a ssem bly (F ig. 57).
fr om cou n t er sh a ft (F ig. 54).
(7) Rem ove fift h gea r t h r u st r in g fr om cou n t er- NOTE: Be sure to retrieve the pin and compression
sh a ft (F ig. 55). spring from the reverse idler shaft.
(8) Rem ove fift h gea r t h r u st r in g lock ba ll fr om
cou n t er sh a ft (F ig. 56).
21 - 16 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

LOCK
BALL
NOTCH

FIFTH
GEAR
THRUST
RING
Fig. 55 Remove Fifth Gear Thrust Ring

Fig. 52 Remove Fifth Gear Blocker Ring

-
J8921-1067

Fig. 56 Remove Fifth Gear Thrust Ring Lock Ball


(11) Rem ove bolt s h oldin g ou t pu t sh a ft r ea r bea r-
in g r et a in er t o t h e in t er m edia t e pla t e a n d r em ove
r et a in er (F ig. 58).

Fig. 53 Remove Fifth Gear Synchro Ring

COUNTER
FIFTH
GEAR

Fig. 57 Remove Reverse Idler Shaft


J8921-1065
(12) Rem ove bolt s h oldin g 1–2 a n d 3–4 sh ift for ks
Fig. 54 Remove Fifth Gear and Synchro Assembly t o t h e sh ift r a ils (F ig. 59) a n d disca r d bolt s.
XJ TRANSMISSION AND TRANSFER CASE 21 - 17
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

Fig. 58 Remove Output Shaft Rear Bearing Retainer


(13) Rem ove bolt s h oldin g r ever se sh ift arm
br a cket t o in t er m edia t e pla t e (F ig. 60).
3-4
SHIFT FORK

Fig. 60 Remove Reverse Shift Arm Bracket Bolts

Fig. 59 Remove Shift Fork To Shift Rail Bolts


(14) Rem ove sn a p-r in g h oldin g ou t pu t sh a ft r ea r
bea r in g in t o t h e in t er m edia t e pla t e (F ig. 61). ' COUNTERSHAFT
(15) Rem ove cou n t er sh a ft r ea r bea r in g sn a p-r in g. REAR BEARING
(16) Wit h a id of a n a ssist a n t , su ppor t t h e m a in - SNAP-RING
80ac2c6b
sh a ft a n d cou n t er sh a ft . Ta p on t h e r ea r of t h e m a in -
sh a ft a n d cou n t er sh a ft wit h a su it a ble pla st ic m a llet . Fig. 61 Remove Output Shaft Rear Bearing
Th is will r elea se t h e cou n t er sh a ft fr om t h e cou n t er- Snap-ring
sh a ft r ea r bea r in g a n d t h e m a in sh a ft r ea r bea r in g
fr om t h e in t er m edia t e pla t e. Th e cou n t er sh a ft will (17) Rem ove t h e m a in sh a ft by m ovin g t h e m a in -
r elea se fr om t h e cou n t er sh a ft bea r in g fir st a n d ca n sh a ft for wa r d u n t il t h e m a in sh a ft r ea r bea r in g is
be r em oved by m ovin g t h e cou n t er sh a ft r ea r wa r d a n d clea r of t h e in t er m edia t e pla t e a n d t h en r ot a t in g t h e
down wa r d (F ig. 62). m a in sh a ft down wa r d ou t of t h e sh ift for ks (F ig. 63).
(18) Rem ove t h e 3–4 sh ift for k fr om t h e 3–4 sh ift
r a il (F ig. 64).
21 - 18 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
INTERMEDIATE
PLATE 3-4
SHIFT
RAIL

.
=

COUNTERSHAFT
REAR BEARING
~ ~80ac2c6c

Fig. 62 Remove Countershaft and Countershaft


Rear Bearing
SHIFT \
FORKS
~
Fig. 64 Remove 3–4 Shift Fork
1-2
SHIFT
RAIL

Fig. 63 Remove Mainshaft


(19) Rem ove t h e sn a p-r in g fr om n ea r t h e en d of
t h e 1–2 sh ift r a il t o a llow t h e r em ova l of t h e 1–2
sh ift for k.
(20) Rem ove t h e 1–2 sh ift for k fr om t h e 1–2 a n d
t h e 3–4 sh ift r a ils (F ig. 65). Fig. 65 Remove 1–2 Shift Fork
(21) Rem ove t h r ea ded plu gs fr om in t er m edia t e (23) Rem ove fift h gea r sh ift r a il (F ig. 67).
pla t e. Th en r em ove lock ba ll a n d spr in g fr om plu g (24) Rem ove fift h gea r ch eck ba ll (F ig. 68) a n d
h oles wit h pen cil m a gn et (F ig. 66). Not e t h a t t h e bot - in t er lock pin .
t om spr in g is sh or t er in len gt h t h a n t h e ot h er t wo (25) Rem ove r ever se sh ift h ea d a n d r a il a ssem bly
spr in gs. (F ig. 69).
(22) Rem ove t h e in t er m edia t e pla t e fr om t h e vise, (26) Rem ove sn a p-r in g h oldin g r ever se sh ift r a il
r ot a t e t h e pla t e 180°, a n d r ein st a ll t h e pla t e in t h e in t o in t er m edia t e pla t e.
vise u sin g t h e sa m e bolt a n d wa sh er m ou n t in g set - (27) Rem ove r ever se sh ift r a il a n d r ever se sh ift
u p. for k a n d a r m a ssem bly fr om in t er m edia t e pla t e (F ig.
70).
CAUTION: The interlock balls and pins are different
sizes and shapes. Be sure to correctly identify
which position an item is removed from to ensure
that it is reinstalled in the same location.
XJ TRANSMISSION AND TRANSFER CASE 21 - 19
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

Fig. 68 Remove Fifth Gear Check Ball

PENCIL
MAGNET

80ac2c98

Fig. 66 Remove Lock Ball And Spring

"80ac2cc0

Fig. 69 Remove Reverse Shift Head And Rail


Assembly

Fig. 67 Remove Fifth Gear Shift Rail


(28) Rem ove in t er lock pin fr om r ever se sh ift r a il REVERSE
(F ig. 71). SHIFT RAIL AND
REVERSE FORK
(29) Rem ove r ever se elon ga t ed ch eck ba ll (F ig. 72).
ASSEMBLY
(30) Rem ove sn a p-r in g on 3–4 sh ift r a il.
(31) Rem ove 1–2 sh ift r a il fr om in t er m edia t e pla t e. \~ft
(32) Rem ove in t er lock pin fr om 1–2 sh ift r a il (F ig.
73). Fig. 70 Remove Reverse Shift Rail
(33) Rem ove 1–2 sh ift r a il elon ga t ed ch eck ba ll
fr om in t er m edia t e pla t e (F ig. 74).
(34) Rem ove 3–4 sh ift r a il fr om in t er m edia t e pla t e.
21 - 20 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

80b11958

Fig. 71 Remove Interlock Pin From Reverse Shift


Rail

Fig. 73 Remove 1–2 Shift Rail Interlock Pin

Fig. 74 Remove 1–2 Check Ball


(2) In st a ll t h e 1–2 elon ga t ed ch eck ba ll in t o t h e
in t er m edia t e pla t e (F ig. 76).
(3) In st a ll t h e in t er lock pin in t o t h e 1–2 sh ift r a il
Fig. 72 Remove Reverse Check Ball (F ig. 77).
ASSEMBLY (4) In st a ll t h e 1–2 sh ift r a il in t o t h e in t er m edia t e
Refer t o (F ig. 75) wh ile a ssem blin g a n d in st a llin g pla t e.
t h e sh ift r a il com pon en t s. Also, ver ify t h a t a ll sh ift
r a il com pon en t s a r e in t h eir n eu t r a l posit ion wh en
in st a llin g t h e ch eck ba lls a n d in t er lock pin s.
(1) In st a ll t h e 3–4 sh ift r a il in t o t h e in t er m edia t e
pla t e.
XJ TRANSMISSION AND TRANSFER CASE 21 - 21
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

1-2 FORK INTERMEDIATE


PLATE
3-4 FORK

3-4 SHIFT
RAIL

REVERSE SHIFT RAIL


1-2
SHIFT
RAIL

+
FIFTH GEAR
SHIFT RAIL
~
~ = INTERLOCK BALL
ORPIN
80b11956

Fig. 75 Shift Rail Components

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

Fig. 80 Install Reverse Arm Bracket to Fork

Fig. 78 Install Reverse Check Ball

REVERSE
SHIFT RAIL AND
REVERSE FORK
ASSEMBLY
\~ft
Fig. 81 Install Reverse Shift Rail

80b11958

Fig. 79 Install Reverse Interlock Pin


(9) In st a ll r ever se sh ift r a il in t o in t er m edia t e pla t e
a n d posit ion r ever se a r m br a cket t o in t er m edia t e
pla t e (F ig. 81).
(10) In st a ll sn a p-r in g on t o r ever se sh ift r a il (F ig.
82).
(11) In st a ll r ever se sh ift h ea d a n d r a il a ssem bly
in t o t h e in t er m edia t e pla t e.
(12) In st a ll t h e fift h gea r in t er lock ba ll a n d ch eck Fig. 82 Install Reverse Snap-ring
ba ll (F ig. 83). vise u sin g t h e sa m e bolt a n d wa sh er m ou n t in g set -
(13) In st a ll fift h gea r sh ift r a il (F ig. 84). u p.
(14) Rem ove t h e in t er m edia t e pla t e fr om t h e vise, (15) In st a ll t h e sh ift r a il det en t ba lls in t h e in t er-
r ot a t e t h e pla t e 180°, a n d r ein st a ll t h e pla t e in t h e m edia t e pla t e.
XJ TRANSMISSION AND TRANSFER CASE 21 - 23
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(19) In st a ll t h e sn a p-r in g on t o t h e 1–2 sh ift r a il.
(20) In st a ll t h e 3–4 sh ift for k on t o t h e 3–4 sh ift
r a il (F ig. 86).

3-4
SHIFT
RAIL

Fig. 83 Install Fifth Gear Check Ball

\
r:
80ac2c6e

Fig. 86 Install 3–4 Shift Fork


(21) In st a ll m a in sh a ft in t o t h e in t er m edia t e pla t e
by gu idin g t h e ou t pu t sh a ft t h r ou gh open in g in in t er-
m edia t e pla t e u n t il t h e sh ift for ks a r e a lign ed wit h
t h e a ppr opr ia t e syn ch r on izer sleeves. Th e m a in sh a ft
Fig. 84 Install Fifth Gear Shift Rail r ea r bea r in g will be st a r t ed in t h e in t er m edia t e pla t e
(16) In st a ll t h e sh ift r a il det en t spr in gs in t h e bu t n ot fu lly dr iven in a t t h is poin t .
in t er m edia t e pla t e. Not e t h a t t h e bot t om det en t (22) Wh ile a n a ssist a n t su ppor t s t h e m a in sh a ft ,
spr in g is sh or t er t h a n t h e ot h er s. a lign r ea r of cou n t er sh a ft wit h in n er r a ce of cou n t er-
(17) In st a ll t h e sh ift r a il det en t plu gs in t h e in t er- sh a ft r ea r bea r in g.
m edia t e pla t e. (23) Ra ise cou n t er sh a ft u pwa r d u n t il gea r s m esh
(18) In st a ll t h e 1–2 sh ift for k on t o t h e 1–2 a n d 3–4 wit h t h e m a t in g gea r s on t h e m a in sh a ft .
sh ift r a ils (F ig. 85). (24) Usin g a su it a ble r u bber m a llet , t a p on t h e
in pu t sh a ft a n d t h e fr on t of t h e cou n t er sh a ft equ a lly
1-2
t o in st a ll t h e m a in sh a ft r ea r bea r in g in t o t h e in t er-
SHIFT
m edia t e pla t e a n d t h e r ea r of t h e cou n t er sh a ft in t o
RAIL
t h e r ea r cou n t er sh a ft bea r in g. It m a y be n ecessa r y t o
occa sion a lly h old t h e cou n t er sh a ft in t o t h e in t er m edi-
a t e pla t e a n d t a p t h e cou n t er sh a ft r ea r bea r in g on t o
t h e cou n t er sh a ft a n d in t o t h e in t er m edia t e pla t e.
(25) In st a ll sn a p-r in gs on t o t h e r ea r m a in sh a ft a n d
cou n t er sh a ft bea r in gs.
(26) In st a ll t h e bolt s t o h old t h e r ever se sh ift a r m
br a cket t o t h e in t er m edia t e pla t e.
(27) In st a ll n ew bolt s t o h old t h e sh ift for ks t o t h e
sh ift r a ils (F ig. 87).
(28) P osit ion t h e m a in sh a ft r ea r bea r in g r et a in er
over t h e ou t pu t sh a ft a n d on t o t h e in t er m edia t e
pla t e.
Fig. 85 Install 1–2 Shift Fork (29) In st a ll n ew bolt s t o h old t h e bea r in g r et a in er
t o t h e in t er m edia t e pla t e.
21 - 24 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

~~-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 .

Fig. 90 Install Reverse Idler Shaft


sh a ft a n d will n eed t o be disa ssem bled in or der t o be
r em oved.
(35) Depr ess com pr ession spr in g a n d pin in
r ever se idler gea r sh a ft (F ig. 92).

Fig. 88 Reverse Shift Arm Position


(34) Align t h e pin wit h t h e a lign m en t n ot ch in t h e
r ever se idler gea r a ssem bly (F ig. 91). Th e a lign m en t
n ot ch in t h e r ever se idler gea r r a ce/h u b is a sm a ll
r elief cu t a bove on e of t h e m a in lon git u din a l slot s. Be
su r e t h a t t h e pin is a lign ed wit h t h e pr oper slot , t h e
opposit e slot h a s a n oil dr a in h ole wh ich t h e pin will 80b099ce
dr op in t o. Th e a ssem bly will t h en be locked on t o t h e Fig. 91 Align Idler Shaft Pin
XJ TRANSMISSION AND TRANSFER CASE 21 - 25
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 95 Install Fifth Gear Retainer Bolt


(48) Mea su r e cou n t er sh a ft fift h gea r t h r u st clea r-
J8921-1067 a n ce.
(49) Select a sn a p-r in g so t h a t t h e t h r u st clea r a n ce
Fig. 93 Install Fifth Gear Thrust Ring Lock Ball is 0.10–0.30 m m (0.004–0.010 in .).
(41) In st a ll fift h gea r sh ift for k t o t h e cou n t er sh a ft (50) In st a ll sn a p-r in g t o h old fift h gea r blocker
fift h gea r a ssem bly. r in g on t o cou n t er sh a ft .
(42) In st a ll t h e cou n t er sh a ft fift h gea r bea r in gs (51) Rem ove in t er m edia t e pla t e fr om vise a n d
in t o t h e cou n t er sh a ft fift h gea r a ssem bly. r em ove bolt s a n d wa sh er s fr om in t er m edia t e.
(43) P osit ion t h e cou n t er sh a ft fift h gea r a ssem bly
on t h e cou n t er sh a ft . E n su r e t h a t t h e fift h gea r for k is
in st a lled on t o t h e fift h gea r sh ift r a il.
(44) In st a ll t h e fift h gea r syn ch r o r in g.
(45) P osit ion t h e fift h gea r blocker r in g on t o t h e
cou n t er sh a ft .
21 - 26 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 97 Separate Input and Output Shafts


SYNCHRO
BEARING RING

I.D. SNAP RING THICKNESS


MARK MM (IN.)
1 2.05 - 2.10 (0.0807 - 0.0827)
2 2.10 - 2.15 (0.0827 - 0.0846)
3 2.15 - 2.20 (0.0846 - 0.0866)
4 2.20 - 2.25 (0.0866 - 0.0886)
5 2.25 - 2.30 (0.0886 - 0.0906)
6 2.30 - 2.35 (0.0906 - 0.0925)
80ac6a0a

Fig. 96 Countershaft Front Bearing Snap-ring


J8921-1091
ASSEMBLY
(1) Rem ove a n y n icks or bu r r s on cou n t er sh a ft h u b Fig. 98 Input Shaft Components
wit h fin e em er y or cr ocu s clot h . (5) Rem ove t h e select fit sn a p-r in g h oldin g t h e
(2) P osit ion cou n t er sh a ft fr on t bea r in g on en d of in pu t sh a ft bea r in g on t o t h e in pu t sh a ft .
cou n t er sh a ft . (6) Usin g Bea r in g Split t er P -334 a n d a sh op pr ess,
(3) Usin g Specia l Tool 8109 a n d a sh op pr ess, r em ove t h e bea r in g fr om t h e in pu t sh a ft .
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 ASSEMBLY
t h e sn a p-r in g gr oove of t h e cou n t er sh a ft (F ig. 96). (1) P osit ion in pu t sh a ft bea r in g on t o in pu t sh a ft .
(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 (2) Usin g Dr iver L-4507, dr ive bea r in g on t o in pu t
bea r in g on t o cou n t er sh a ft . sh a ft .
(3) Select t h e t h ickest sn a p-r in g t h a t will fit in t o
INPUT SHAFT t h e sn a p-r in g gr oove of t h e in pu t sh a ft (F ig. 99).
(4) Lu br ica t e ou t pu t sh a ft pilot bea r in g bor e of
DISASSEMBLY in pu t sh a ft wit h pet r oleu m jelly.
(1) Ver ify t h a t t h e 3–4 syn ch r on izer is in t h e n eu - (5) In st a ll ou t pu t sh a ft pilot bea r in g r oller s in
t r a l posit ion . in pu t sh a ft bor e (F ig. 100). E n su r e t o u se su fficien t
(2) Sepa r a t e in pu t sh a ft fr om ou t pu t sh a ft (F ig. pet r oleu m jelly t o h old r oller s in posit ion .
97). Not e t h a t t h e ou t pu t sh a ft pilot bea r in g is a n (6) In st a ll t h e fou r t h gea r syn ch r on izer r in g on t o
u n ca ged r oller t ype bea r in g. t h e in pu t sh a ft .
(3) Rem ove t h e ou t pu t sh a ft pilot bea r in g r oller s (7) In st a ll in pu t sh a ft t o ou t pu t sh a ft . Use ca r e
fr om t h e in pu t sh a ft a n d t h e ou t pu t sh a ft . wh en m a t in g t h e t wo sh a ft s n ot t o displa ce a n y ou t -
(4) Rem ove t h e fou r t h gea r syn ch r on izer r in g fr om pu t sh a ft pilot bea r in g r oller s.
t h e in pu t sh a ft (F ig. 98).
XJ TRANSMISSION AND TRANSFER CASE 21 - 27
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
INPUT
SHAFT

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 –

~\I 0.25 m m (0.004 – 0.010 in .).


3RD

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)

0 2.05-2.10 0.0807-0.0827 J8921-36


1 2.1 0-2.15 0.0827-0.0846
2 2.15-2.20 0.0846-0.0866
3 2.20-2.25 0.0866-0.0886 Fig. 101 Check Output Shaft Gear Thrust Clearance
4 2.25-2.30 0.0886-0.0906
5 2.30-2.35 0.0906-0.0925 (3) Rem ove ou t pu t sh a ft fift h gea r sn a p r in g wit h
J8921-50 t wo scr ewdr iver s (F ig. 102).
(4) Usin g Bea r in g Split t er P -334 or su it a ble pr ess
Fig. 99 Select Input Shaft Bearing Snap-ring pla t es posit ion ed u n der fir st gea r, pr ess fift h gea r,
r ea r bea r in g, fir st gea r, a n d fir st gea r bea r in g in n er
r a ce off ou t pu t sh a ft (F ig. 103).
21 - 28 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

LOCK
BALL

J8921-37

Fig. 102 Remove Fifth Gear Snap-ring Fig. 104 Remove First Gear Bearing Inner Race
Lock Ball

Fig. 103 Remove Fifth Gear, First Gear Bearing, And


Race Fig. 105 Remove Second Gear, Reverse Gear, And
1–2 Synchronizer
(5) Rem ove fir st gea r n eedle r oller bea r in g fr om
ou t pu t sh a ft . (9) Rem ove secon d gea r n eedle r oller bea r in g fr om
(6) Rem ove fir st gea r bea r in g in n er r a ce lock ba ll t h e ou t pu t sh a ft or secon d gea r.
wit h pen cil m a gn et (F ig. 104). (10) Rem ove select fit sn a p-r in g h oldin g t h e 3–4
(7) Rem ove fir st gea r syn ch r on izer r in g. syn ch r on izer on t o t h e ou t pu t sh a ft (F ig. 106).
(8) Usin g Bea r in g Split t er P -334 or su it a ble pr ess (11) Usin g Bea r in g Split t er P -334 or su it a ble pr ess
pla t es posit ion ed u n der secon d gea r, pr ess 1–2 syn - pla t es posit ion ed u n der t h ir d gea r, pr ess t h e 3–4 syn -
ch r on izer, r ever se gea r, a n d secon d gea r fr om ou t pu t ch r on izer a n d t h ir d gea r fr om ou t pu t sh a ft (F ig. 107).
sh a ft (F ig. 105).
XJ TRANSMISSION AND TRANSFER CASE 21 - 29
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SLEEVES

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).

Fig. 107 Remove 3–4 Synchronizer And Third Gear


(12) Rem ove t h ir d gea r n eedle r oller bea r in g fr om
ou t pu t sh a ft or gea r. I.D. Mark Snap Ring Thickness mm (in.)
C-1 1.75-1.80 0.0689-0.0709
ASSEMBLY D 1.80-1.85 0.0709-0.0728
(1) Lu br ica t e t r a n sm ission com pon en t s wit h speci- D-1 1.85-1. 90 0.0728-0.0748
E 1.90-1. 95 0.0748-0.07 68
fied gea r lu br ica n t . E-1 1.95-2.00 0.0768-0.0787
(2) If n ecessa r y, a ssem ble 1–2 a n d 3–4 syn ch r o- F 2.00-2.05 0.0788-0.0807)
F-1 2.05-2.1 0 0.0807-0.0827)
n izer h u bs, sleeves, spr in gs a n d key in ser t s (F ig.
108). J8921-55
(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 . Fig. 109 Select 3–4 Synchronizer Snap-ring
21 - 30 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(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 (14) P osit ion 1–2 syn ch r on izer a ssem bly on t o
ou t pu t sh a ft . splin es of 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 (15) Usin g Dr iver MD-998805, Ada pt er 6747-1A,
ga u ge (F ig. 110). Clea r a n ce sh ou ld be 0.10 – 0.25 m m a n d a sh op pr ess, pr ess t h e 1–2 syn ch r on izer on t o
(0.004 – 0.010 in .). If clea r a n ce is ou t of specifica t ion , t h e ou t pu t sh a ft .
r efer t o Clea n in g a n d In spect ion sect ion wit h in t h is (16) In st a ll fir st gea r syn ch r on izer r in g in t o 1–2
gr ou p. syn ch r on izer.
(17) In st a ll fir st gea r bea r in g in n er r a ce lock ba ll
FEELER THIRD
GAUGE GEAR in ou t pu t sh a ft (F ig. 111).
(18) In st a ll fir st gea r n eedle bea r in g on t o ou t pu t
sh a ft (F ig. 112).
(19) In st a ll fir st gea r on t o ou t pu t sh a ft a n d over
bea r in g.
(20) In st a ll fir st gea r bea r in g in n er r a ce on t o ou t -
pu t sh a ft a n d in side fir st gea r bea r in g. Rot a t e bea r-
in g r a ce u n t il r a ce in st a lls over lock ba ll.
(21) 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 .
(22) 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 .
(23) 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.

Fig. 110 Check Third Gear Clearance


(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-
on d gea r.

INNER RACE FIRST


GEAR

J8921-59

Fig. 112 First Gear Components

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

Fig. 113 Check First–Second Gear Thrust Clearance


(25) P osit ion fift h gea r on t o ou t pu t sh a ft wit h t h e
gea r ’s sh or t sh ou lder t owa r d t h e r ea r of sh a ft .
E n su r e t h a t t h e gea r a n d ou t pu t sh a ft splin es a r e
a lign ed.
(26) Usin g Ada pt er 6747-1A, Dr iver L-4507, a n d a
sh op pr ess, pr ess fift h gea r on t o ou t pu t sh a ft .
(27) 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. 114).
(28) In st a ll sn a p-r in g t o h old fift h gea r on t o ou t pu t
sh a ft .

I.D. Mark Snap Ring Thickness mm (in.)


A 2.67-2.72 (0.1051-0.1071
8 2.73-2.78 0.1075-0.1094
C 2.79-2.84 0.1098-0.1118
D 2.85-2.90 0.1122-0.1142
E 2.91-2.96 0.1146-0.1165
F 2.97-3.02 0.1169-0.1189
G 3.03-3.08 0.11 93-0. l 213
H 3.09-3.14 0.1217-0.1236
J 3.1 5-3.20 0.1 2 40-0. l 2 60
K 3.21-3.26 0.1264-0.1283
L 3.27-3.32 0.1287-0.1307

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)

SEMI-SYNCHRONIZED REVERSE IDLER GEAR REVERSE


REVERSE IDLER GEAR
DISASSEMBLY
SYNCHRONIZER /HUB
(1) Rem ove sn a p-r in g h oldin g t h e r ever se idler RING
gea r on t o t h e r ever se idler gea r h u b/r a ce (F ig. 115).
(2) Rem ove t h e pla t e wa sh er fr om t h e r ever se idler
gea r h u b/r a ce (F ig. 116).

REVERSE
IDLER GEAR
D
REVERSE
IDLER GEAR 80b099f3

Fig. 117 Remove Reverse Idler Gear

80b099f1

Fig. 115 Remove Reverse Idler Gear Snap-ring

Fig. 118 Remove Reverse Idler Gear Synchronizer


Ring
ch r on izer r in g a r e pr oper ly en ga ged in t o t h e r ecesses
of t h e r ever se idler gea r.
(3) In st a ll t h e pla t e wa sh er over t h e r ever se idler
gea r h u b/r a ce a n d on t o t h e r ever se idler gea r.
80b099f2
(4) In st a ll t h e sn a p-r in g t o h old t h e r eer se idler
Fig. 116 Remove Reverse Idler Gear Plate Washer gea r on t o t h e r ever se idler h u b/r a ce.
(3) Rem ove t h e r ever se idler gea r fr om t h e r ever se
idler gea r h u b/r a ce (F ig. 117). CLEAN I N G AN D I N SPECT I ON
(4) Rem ove t h e r ever se idler gea r syn ch r on izer
r in g fr om t h e r ever se idler gea r h u b/r a ce (F ig. 118). AX5 MANUAL TRANSMISSION COMPONENTS
ASSEMBLY GENERAL INFORMATION
(1) In st a ll t h e r ever se idler gea r syn ch r on izer r in g Clea n t h e t r a n sm ission com pon en t s in solven t . Dr y
on t o t h e r ever se idler gea r h u b/r a ce. Apply a film of t h e ca ses, gea r s, sh ift m ech a n ism a n d sh a ft s wit h
75W-90 GL-3 t r a n sm ission oil t o t h e con t a ct su r fa ce com pr essed a ir. Dr y t h e bea r in gs wit h clea n , dr y
of t h e syn ch r on izer r in g pr ior t o a ssem bly. sh op t owels on ly. Never u se com pr essed a ir on t h e
(2) In st a ll t h e r ever se idler gea r on t o t h e r ever se bea r in gs. Th is cou ld ca u se sever e da m a ge t o t h e
idler gea r h u b/r a ce. Apply a film of 75W-90 GL-3 bea r in g r oller a n d r a ce su r fa ces.
t r a n sm ission oil t o t h e r ever se idler gea r bu sh in g If ou t pu t sh a ft or in n er r a ce fla n ge t h ickn ess is
pr ior t o a ssem bly.Ver ify t h a t t h e t eet h on t h e syn - wit h in specifica t ion bu t a n y gea r t h r u st clea r a n ce is
XJ TRANSMISSION AND TRANSFER CASE 21 - 33
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
ou t of specifica t ion , r epla ce t h e n ecessa r y gea r a n d • Secon d gea r su r fa ce m in im u m dia m et er is
gea r n eedle bea r in g a s a n a ssem bly. 37.964 m m (1.495 in .)
• Th ir d gea r su r fa ce m in im u m dia m et er is 34.984
GEAR CASE, ADAPTER/EXTENSION HOUSING, m m (1.377 in .)
INTERMEDIATE PLATE Mea su r e dia m et er of t h e fir st gea r bea r in g in n er
Clea n t h e ca se, h ou sin g, a n d in t er m edia t e pla t e r a ce. Min im u m dia m et er is 38.985 m m (1.535 in .).
wit h solven t a n d dr y wit h com pr essed a ir. Repla ce Mea su r e ou t pu t sh a ft r u n ou t wit h a dia l in dica t or
t h e ca se if cr a cked, por ou s, or if a n y of t h e bea r in g (F ig. 120). Ru n ou t sh ou ld n ot exceed 0.05 m m (0.002
a n d gea r bor es a r e da m a ged. in .).
In spect t h e t h r ea ds in t h e ca se, h ou sin g, a n d pla t e.
Min or t h r ea d da m a ge ca n be r epa ir ed wit h st eel
t h r ea d in ser t s, if n ecessa r y. Do n ot a t t em pt t o r epa ir
a n y t h r ea ds wh ich sh ow eviden ce of cr a cks a r ou n d
t h e t h r ea ded h ole.

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

Fig. 120 Check Output Shaft Runout


Repla ce ou t pu t sh a ft or fir st gea r in n er bea r in g
'._OUTPUT SHAFT r a ce if m ea su r em en t of a n y su r fa ce is ou t of specifi-
FLANGE ca t ion . Do n ot a t t em pt t o r epa ir ou t of specifica t ion
com pon en t s.

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.

GEAR AND SYNCHRONIZER


In st a ll t h e n eedle bea r in g a n d in n er r a ce in t h e
fir st gea r. Th en ch eck oil clea r a n ce bet ween t h e gea r
a n d in n er r a ce (F ig. 121). Clea r a n ce sh ou ld be 0.009
J8921-43 – 0.032 m m (0.0004 – 0.0013 in .).
In st a ll t h e n eedle bea r in gs a n d t h e secon d, t h ir d
Fig. 119 Check Shaft And Bearing Race Flange a n d cou n t er fift h gea r s on t h e ou t pu t sh a ft . Th en
Thickness ch eck oil clea r a n ce bet ween t h e gea r s a n d sh a ft wit h
• Min im u m t h ickn ess for sh a ft fla n ge is 4.80 m m a dia l in dica t or (F ig. 122). Oil clea r a n ce for a ll t h r ee
(0.189 in .) gea r s is 0.009 – 0.0013 m m (0.0004 – 0.0013 in .).
• Min im u m t h ickn ess for fir st gea r bea r in g in n er Ch eck syn ch r on izer r in g wea r (F ig. 123). In ser t
r a ce fla n ge is 3.99 m m (0.157 in .) ea ch r in g in m a t ch in g gea r. Mea su r e clea r a n ce
Mea su r e dia m et er of t h e ou t pu t sh a ft jou r n a l su r- bet ween ea ch r in g a n d gea r wit h feeler ga u ge.
fa ces wit h a m icr om et er. Repla ce t h e sh a ft if eit h er of Repla ce r in g if clea r a n ce exceeds 2.0 m m (0.078 in .).
t h ese su r fa ces a r e wor n beyon d specified lim it s.
21 - 34 TRANSMISSION AND TRANSFER CASE XJ
CLEAN I N G AN D I N SPECT I ON (Cont inue d)

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

8211 Installer, Seal

C-3339 Dial Indicator Set

8212 Installer, Seal


21 - 36 TRANSMISSION AND TRANSFER CASE XJ
SPECI AL T OOLS (Cont inue d)

( Q)
8208 Installer, Seal
L-4507 Tube, Driver

P-334 Splitter, Bearing


6747–1A Adapter, Fixture

8109 Cup, Installer


MD-998805 Installer, Seal
XJ TRANSMISSION AND TRANSFER CASE 21 - 37

AX 1 5 M AN U AL T RAN SM I SSI ON

INDEX
page page

GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY


AX15 MANUAL TRANSMISSION . . . . . . . . . . . . . 37 ADAPTER/EXTENSION HOUSING AND FRONT
RECOMMENDED LUBRICANT . . . . . . . . . . . . . . 37 BEARING RETAINER . . . . . . . . . . . . . . . . . . . 44
TRANSMISSION ASSEMBLY INFORMATION . . . 38 COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 63
TRANSMISSION GEAR RATIOS . . . . . . . . . . . . . 37 INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 64
TRANSMISSION IDENTIFICATION . . . . . . . . . . . 37 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 64
DIAGNOSIS AND TESTING SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 51
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . 39 CLEANING AND INSPECTION
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . 38 AX15 MANUAL TRANSMISSION
TRANSMISSION NOISE . . . . . . . . . . . . . . . . . . . 40 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 69
REMOVAL AND INSTALLATION SPECIFICATIONS
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . 43 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
EXTENSION HOUSING SEAL . . . . . . . . . . . . . . . 43 SPECIAL TOOLS
FRONT BEARING RETAINER SEAL . . . . . . . . . . 42 AX15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 40

GEN ERAL I N FORM AT I ON TRANSMISSION GEAR RATIOS


Gea r r a t ios for t h e AX15 m a n u a l t r a n sm ission a r e
AX15 MANUAL TRANSMISSION a s follows:
Th e AX15 is a 5–speed, syn ch r om esh , m a n u a l • F ir st gea r : 3.83:1
t r a n sm ission . F ift h gea r is a n over dr ive r a n ge wit h a • Secon d gea r : 2.33:1
r a t io of 0.79:1. An a da pt er h ou sin g is u sed t o a t t a ch • Th ir d gea r : 1.44:1
t h e t r a n sm ission t o t h e t r a n sfer ca se on 4–wh eel • F ou r t h gea r : 1.00:1
dr ive m odels. A st a n da r d ext en sion h ou sin g is u sed • F ift h gea r : 0.79:1
on 2–wh eel dr ive m odels. Th e sh ift m ech a n ism is • Rever se: 4.22:1
in t egr a l a n d m ou n t ed in t h e sh ift t ower por t ion of
t h e a da pt er h ou sin g (F ig. 1). RECOMMENDED LUBRICANT
Recom m en ded lu br ica n t for AX15 t r a n sm ission s is
TRANSMISSION IDENTIFICATION Mopa r ! 75W–90, AP I Gr a de GL–3 gea r lu br ica n t , or
Th e AX15 iden t ifica t ion code n u m ber s a r e on t h e equ iva len t .
bot t om su r fa ce of t h e in t er m edia t e pla t e (F ig. 2). Cor r ect lu br ica n t level is fr om t h e bot t om edge, t o
Th e fir st n u m ber is yea r of m a n u fa ct u r e. Th e sec- n o m or e t h a n 6 m m (1/4 in .) below t h e bot t om edge of
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 h e fill plu g h ole.
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 Th e fill plu g is loca t ed on t h e dr iver ’s side of t h e
ser ia l n u m ber. t r a n sm ission ca se (F ig. 3). Th e dr a in plu g is loca t ed
on t h e pa ssen ger side of t h e t r a n sm ission ca se n ea r
t h e bot t om (F ig. 4).
21 - 38 TRANSMISSION AND TRANSFER CASE XJ
GEN ERAL I N FORM AT I ON (Cont inue d)

J8921-1023

Fig. 1 AX15 Manual Transmission


,-
@
INTERMEDIATE
PLATE :-'\

Js921-1024 ,

Fig. 2 Identification Code Number Location Fig. 3 Fill Plug Location


Appr oxim a t e dr y fill lu br ica n t ca pa cit y is: DI AGN OSI S AN D T EST I N G
• 3.10 lit er s (3.27 qt s.) for 4–wh eel dr ive a pplica -
t ion s. LOW LUBRICANT LEVEL
• 3.15 lit er s (3.32 qt s.) for 2–wh eel dr ive a pplica - A low t r a n sm ission lu br ica n t level is gen er a lly t h e
t ion s. r esu lt of a lea k, in a dequ a t e lu br ica n t fill, or a n in cor-
r ect lu br ica n t level ch eck.
TRANSMISSION ASSEMBLY INFORMATION Lea ks ca n occu r a t t h e m a t in g su r fa ces of t h e gea r
Lu br ica t e t h e t r a n sm ission com pon en t s wit h ca se, in t er m edia t e pla t e a n d a da pt or or ext en sion
Mopa r ! 75W–90, GL 3 gea r lu br ica n t du r in g a ssem - h ou sin g, or fr om t h e fr on t /r ea r sea ls. A su spect ed
bly. Use pet r oleu m jelly t o lu br ica t e sea l lips a n d/or lea k cou ld a lso be t h e r esu lt of a n over fill con dit ion .
h old pa r t s in pla ce du r in g in st a lla t ion . Lea ks a t t h e r ea r of t h e ext en sion or a da pt er h ou s-
Refer t o (F ig. 5) du r in g a ssem bly for AX15 gea r in g will be fr om t h e h ou sin g oil sea ls. Lea ks a t com -
a ssem bly iden t ifica t ion . pon en t m a t in g su r fa ces will pr oba bly be t h e r esu lt of
in a dequ a t e sea ler, ga ps in t h e sea ler, in cor r ect bolt
t igh t en in g, or u se of a n on –r ecom m en ded sea ler.
XJ TRANSMISSION AND TRANSFER CASE 21 - 39
DI AGN OSI S AN D T EST I N G (Cont inue d)
a void a n u n der fill or over fill con dit ion . Alwa ys ch eck
t h e lu br ica n t level a ft er a n y a ddit ion of flu id t o a void
a n in cor r ect lu br ica n t level con dit ion .

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

OUTPUT SHAFT (2WD)

REAR
BEARING

INSERT
SPRING

1 SNAP
RING
(SELECTIVE)

INSERT
(3)

NEEDLE SYNCHRO
BEARING RING J8921-1093

Fig. 5 Output Shaft and Gears


21 - 40 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

TRANSMISSION NOISE (13) Secu r e t r a n sfer ca se, if equ ipped, t o ja ck wit h


Most m a n u a l t r a n sm ission s m a ke som e n oise du r- sa fet y ch a in s.
in g n or m a l oper a t ion . Rot a t in g gea r s gen er a t e a m ild (14) Discon n ect t r a n sfer ca se sh ift lin ka ge a t
wh in e t h a t is a u dible, bu t gen er a lly on ly a t ext r em e t r a n sfer ca se, if equ ipped.
speeds. (15) 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-
Sever e, h igh ly a u dible t r a n sm ission n oise is gen er- m ission , if equ ipped.
a lly t h e in it ia l in dica t or of a lu br ica n t pr oblem . (16) Rem ove t r a n sfer ca se, if equ ipped.
In su fficien t , im pr oper, or con t a m in a t ed lu br ica n t will (17) Rem ove cr a n ksh a ft posit ion sen sor (F ig. 7),
pr om ot e r a pid wea r of gea r s, syn ch r os, sh ift r a ils, (F ig. 8).
for ks a n d bea r in gs. Th e over h ea t in g ca u sed by a
lu br ica n t pr oblem , ca n a lso lea d t o gea r br ea ka ge.

REM OVAL AN D I N STALLAT I ON


TRANSMISSION
REMOVAL
(1) Sh ift t r a n sm ission in t o fir st or t h ir d gea r.
(2) Ra ise a n d su ppor t veh icle on su it a ble sa fet y
st a n ds.
(3) Discon n ect n ecessa r y exh a u st syst em com po-
n en t s.
(4) Rem ove skid pla t e, if equ ipped.
(5) Rem ove sla ve cylin der fr om clu t ch h ou sin g.
(6) Ma r k r ea r pr opeller sh a ft a n d r ea r a xle yokes
for in st a lla t ion a lign m en t (F ig. 6). RUBBER (; 0

REFERENCE MARKS
GROMMET
CRANKSHAFT \
I~ j -:,'-@__
POSITION \ MOUNTING
SENSOR NUTS (2) soa4s1s1

Fig. 7 Crankshaft Position Sensor—2.5L Engine

J9316-2

Fig. 6 Marking Propeller Shaft And Axle Yokes


(7) Ma r k fr on t pr opeller sh a ft , a xle, a n d t r a n sfer
ca se yokes for in st a lla t ion a lign m en t , if equ ipped.
(8) Rem ove pr opeller sh a ft (s).
(9) Un clip wir e h a r n esses fr om t r a n sm ission a n d
t r a n sfer ca se, if equ ipped.
RUBBER
(10) Discon n ect t r a n sfer ca se ven t h ose, if GROMMET
equ ipped.
(11) Disen ga ge a n y wir e con n ect or s a t t a ch ed t o CRANKSHAFT \
POSITION \
t r a n sm ission or t r a n sfer ca se, if equ ipped, com po-
SENSOR 80a43752
n en t s.
(12) Su ppor t t r a n sfer ca se, if equ ipped, wit h t r a n s- Fig. 8 Crankshaft Position Sensor —4.0L Engine
m ission ja ck.
XJ TRANSMISSION AND TRANSFER CASE 21 - 41
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.

(18) Su ppor t en gin e wit h a dju st a ble ja ck st a n d.


P osit ion wood block bet ween ja ck a n d oil pa n t o
a void da m a gin g pa n .
(19) Su ppor t t r a n sm ission wit h t r a n sm ission ja ck.
(20) Secu r e t r a n sm ission t o ja ck wit h sa fet y
ch a in s.
(21) Discon n ect r ea r cu sh ion a n d br a cket fr om
t r a n sm ission .
(22) Rem ove r ea r cr ossm em ber.
(23) Discon n ect t r a n sm ission sh ift lever a s follows:
(a ) Lower t r a n sm ission –t r a n sfer ca se a ssem bly
a ppr oxim a t ely 7–8 cm (3 in .) for a ccess t o sh ift
lever.
(b) Rea ch u p a n d a r ou n d t r a n sm ission ca se a n d
u n sea t sh ift lever du st boot fr om t r a n sm ission sh ift
t ower (F ig. 9). Move boot u pwa r d on sh ift lever for
a ccess t o r et a in er t h a t secu r es lever in sh ift t ower.
(c) Rea ch u p a n d a r ou n d t r a n sm ission ca se a n d
pr ess sh ift lever r et a in er down wa r d wit h fin ger
pr essu r e. Tu r n r et a in er cou n t er clockwise t o r elea se
it .
(d) Lift lever a n d r et a in er ou t of sh ift t ower (F ig.
9). Do n ot r em ove t h e sh ift lever fr om t h e floor con -
sole sh ift er boot s. Lea ve t h e lever in pla ce for Fig. 10 Clutch Housing
t r a n sm ission in st a lla t ion . INSTALLATION
(1) In st a ll clu t ch h ou sin g on t r a n sm ission . Tigh t en
/ h ou sin g bolt s t o 37 N·m (27 ft . lbs.) t or qu e.
(2) Lu br ica t e con t a ct su r fa ces of r elea se for k pivot
ba ll st u d a n d r elea se for k wit h h igh t em p gr ea se.
(3) In st a ll r elea se bea r in g, for k, a n d r et a in er clip.
(4) P osit ion a n d secu r e t r a n sm ission on t r a n sm is-
sion ja ck.
(5) Ligh t ly lu br ica t e pilot bea r in g a n d t r a n sm is-
sion in pu t sh a ft splin es wit h Mopa r ! h igh t em p
gr ea se.
(6) Ra ise t r a n sm ission a n d a lign t r a n sm ission
in pu t sh a ft a n d clu t ch disc splin es. Th en slide t r a n s-
m ission in t o pla ce.
(7) In st a ll a n d t igh t en clu t ch h ou sin g-t o-en gin e
bolt s t o 38 N·m (28 ft . lbs.) t or qu e (F ig. 10). B e s u re
th e h o u s in g is p ro p e rly s e a te d o n e n g in e blo c k
Fig. 9 Removing/Installing Shift Lever be fo re tig h te n in g bo lts .
(24) Rem ove clu t ch h ou sin g br a ce r od. (8) In st a ll clu t ch h ou sin g br a ce r od.
(25) Rem ove clu t ch h ou sin g-t o-en gin e bolt s. (9) Lower t r a n sm ission a ppr oxim a t ely 7–8 cm (3
(26) P u ll t r a n sm ission ja ck r ea r wa r d u n t il in pu t in .) for a ccess t o sh ift t ower. Be su r e t r a n sm ission is
sh a ft clea r s clu t ch . Th en slide t r a n sm ission ou t fr om in fir st or t h ir d gea r.
u n der veh icle. (10) Rea ch u p a n d a r ou n d t r a n sm ission a n d in ser t
(27) Rem ove clu t ch r elea se bea r in g, r elea se for k, sh ift lever in sh ift t ower. P r ess lever r et a in er down -
a n d r et a in er clip. wa r d a n d t u r n it clockwise t o lock it in pla ce. Th en
(28) Rem ove clu t ch h ou sin g fr om t r a n sm ission in st a ll lever du st boot on sh ift t ower.
(F ig. 10).
21 - 42 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(11) In st a ll r ea r cr ossm em ber. Tigh t en cr ossm em - (29) In st a ll sla ve cylin der in clu t ch h ou sin g.
ber-t o-fr a m e bolt s t o 41 N·m (31 ft . lbs.) t or qu e. (30) In st a ll skid pla t e, if equ ipped. Tigh t en bolt s t o
(12) In st a ll fa st en er s t o h old r ea r cu sh ion a n d 42 N·m (31 ft . lbs.) t or qu e. Tigh t en st u d n u t s t o 17
br a cket t o t r a n sm ission . Th en t igh t en t r a n sm ission - N·m (150 in . lbs.) t or qu e.
t o-r ea r su ppor t bolt s/n u t s t o 45 N·m (33 ft . lbs.) (31) F ill t r a n sm ission a n d t r a n sfer ca se, if
t or qu e. equ ipped, wit h r ecom m en ded lu br ica n t s. Refer t o t h e
(13) Rem ove su ppor t st a n ds fr om en gin e a n d Lu br ica n t Recom m en da t ion sect ion s of t h e a ppr opr i-
t r a n sm ission . a t e com pon en t for cor r ect flu id.
(14) In st a ll a n d con n ect cr a n ksh a ft posit ion sen sor. (32) Lower veh icle.
(15) P osit ion t r a n sfer ca se on t r a n sm ission ja ck, if
equ ipped. FRONT BEARING RETAINER SEAL
(16) Secu r e t r a n sfer ca se t o ja ck wit h sa fet y
ch a in s, if equ ipped. REMOVAL
(17) Ra ise t r a n sfer ca se, if equ ipped, a n d a lign (1) Rem ove r elea se bea r in g a n d lever fr om t h e
t r a n sfer ca se in pu t sh a ft t o t h e t r a n sm ission ou t pu t t r a n sm ission .
sh a ft . (2) Rem ove t h e bolt s h oldin g t h e fr on t bea r in g
(18) Slide t r a n sfer ca se for wa r d u n t il ca se is r et a in er t o t h e t r a n sm ission ca se.
sea t ed on t r a n sm ission , if n ecessa r y. (3) Rem ove t h e fr on t bea r in g r et a in er fr om t h e
(19) In st a ll n u t s t o a t t a ch t r a n sfer ca se t o t r a n s- t r a n sm ission ca se.
m ission , if equ ipped. Tigh t en t r a n sfer ca se-t o-t r a n s- (4) Usin g a su it a ble pr y t ool, r em ove t h e fr on t
m ission n u t s t o 35 N·m (26 ft . lbs.) t or qu e. bea r in g r et a in er sea l.
(20) Con n ect t r a n sfer ca se sh ift lin ka ge a t t r a n sfer
ca se, if equ ipped. INSTALLATION
(21) Con n ect t r a n sfer ca se ven t h ose, if equ ipped. (1) Usin g Tool H a n dle C-4171 a n d Sea l In st a ller
(22) Secu r e wir e h a r n esses in clips/t ie st r a ps on 8209, in st a ll n ew sea l in t o t h e fr on t bea r in g r et a in er
t r a n sm ission a n d t r a n sfer ca se, if equ ipped. (F ig. 12).
(23) E n ga ge wir e con n ect or s a t t a ch ed t o a ll n eces-
sa r y t r a n sm ission or t r a n sfer ca se, if equ ipped, com -
pon en t s.
(24) In st a ll r ea r pr opeller sh a ft slip yoke t o t r a n s-
m ission or t r a n sfer ca se, if equ ipped, ou t pu t sh a ft .
(25) Align m a r ks on r ea r pr opeller sh a ft a n d r ea r
a xle yokes (F ig. 11).
REFERENCE MARKS SPECIAL
,~-----TOOL
C-4171

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

Fig. 14 Install Extension Housing Seal


21 - 44 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(7) Rem ove sh ift t ower ga sket fr om sh ift t ower or
SPECIAL
t r a n sm ission ca se (F ig. 18).
TOOL
8208

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

Fig. 19 Clutch 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

Fig. 21 Remove Detent Spring Fig. 24 Shift Arm Rstrictor Pins

SHIFT LEVER
SHAFT
PLUG

Fig. 22 Remove Detent Ball


(10) Rem ove sh ift a r m r et a in er bolt (F ig. 23).
(11) Rem ove sh ift a r m r est r ict or pin s (F ig. 24).
(12) Rem ove sh ift lever sh a ft plu g (F ig. 25).
(13) Rem ove sh ift er sh a ft wit h la r ge m a gn et (F ig.
26). J8921-l 2
(14) Rem ove t h e sh ift a r m fr om t h e a da pt er h ou s- Fig. 25 Removing Shift Lever Shaft Plug
in g.
21 - 46 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

LARGE
MAGNET

J8921-1037

Fig. 26 Remove Shifter Shaft


(15) Rem ove a da pt er /ext en sion h ou sin g bolt s (F ig.
27).
(16) Loosen a da pt er /ext en sion h ou sin g by t a ppin g
it loose wit h pla st ic m a llet (F ig. 28).
(17) Rem ove a da pt er /ext en sion h ou sin g (F ig. 29).
(18) On 4x2 t r a n sm ission s;
(a ) Rem ove speedom et er gea r r et a in in g sn a p-
r in g fr om ou t pu t sh a ft .
(b) Rem ove speedom et er gea r fr om ou t pu t sh a ft
a n d r em ove speedom et er gea r lock ba ll fr om ou t pu t
sh a ft .
(c) Rem ove speedom et er dr ive gea r loca t in g
sn a p-r in g (F ig. 30).
(19) Rem ove t h e bolt s h oldin g t h e fr on t bea r in g
r et a in er t o t h e t r a n sm ission ca se.
(20) Rem ove t h e bea r in g r et a in er fr om t r a n sm is-
sion ca se (F ig. 31).
(21) Rem ove in pu t sh a ft bea r in g sn a p-r in g (F ig.
32).
(22) Rem ove clu st er gea r bea r in g sn a p-r in g (F ig.
33).
(23) Sepa r a t e in t er m edia t e pla t e a n d t r a n sfer ca se
by t a ppin g t h em loose wit h pla st ic m a llet (F ig. 34).
(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. 35).

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

Fig. 28 Loosen Adapter/Extension Housing Fig. 31 Remove Front Bearing Retainer

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.

Fig. 38 Install Front Bearing Snap-rings


(5) Apply 1/8 in ch wide bea d of Th r eebon d! Liqu id
Ga sket TB1281, P /N 83504038, t o t h e fr on t bea r in g
r et a in er sea lin g su r fa ce.
GEAR
(6) In st a ll t h e fr on t bea r in g r et a in er (F ig. 39) a n d
CASE t igh t en bolt s t o 17 N·m (12 ft . lbs.).
(7) On 4x2 t r a n sm ission s;
(a ) In st a ll speedom et er dr ive gea r loca t in g sn a p-
r in g (F ig. 40).
(b) In st a ll speedom et er gea r lock ba ll in ou t pu t
sh a ft a n d in st a ll speedom et er gea r on t o ou t pu t
sh a ft .
(c) In st a ll speedom et er gea r r et a in in g sn a p-r in g
J8921-l 118
on t o ou t pu t sh a ft .
Fig. 36 Apply Sealer to Transmission Gear Case
XJ TRANSMISSION AND TRANSFER CASE 21 - 49
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 42 Position Shift Arm in Transmission Case


OUTPUT
SHAFT SPEEDOMETER
GROOVES GEAR

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

Fig. 47 Install Detent Ball

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).

Fig. 48 Install Detent Spring


XJ TRANSMISSION AND TRANSFER CASE 21 - 51
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

DETENT BACKUP
PLUG LAMP
SWITCH

Fig. 49 Install Detent Ball Plug J892l- l 00


(19) In st a ll sh ift t ower a n d n ew ga sket on h ou sin g Fig. 50 Installing Shift Tower And Backup Lamp
(F ig. 50). Tigh t en t ower bolt s t o 18 N·m (13 ft . lbs.) Switch
t or qu e.
(20) In st a ll n ew m et a l o-r in g t o t h e ba cku p la m p
SHIFT MECHANISM AND GEARTRAIN
swit ch .
(21) In st a ll ba cku p la m p swit ch (F ig. 50). Tigh t en DISASSEMBLY
swit ch t o 37 N·m (27 ft . lbs.) t or qu e. (1) In st a ll su it a ble bolt s a n d wa sh er s in in t er m edi-
(22) In st a ll n ew sea l in a da pt er /ext en sion h ou sin g. a t e pla t e (F ig. 51). Th en cla m p pla t e a n d gea r a ssem -
(23) In st a ll veh icle speed sen sor, if n ecessa r y. bly in vise. Use en ou gh wa sh er s t o pr even t bolt s
(24) In st a ll clu t ch h ou sin g, r elea se bea r in g, r elea se fr om t ou ch in g. Also be su r e vise ja ws a r e cla m ped on
for k a n d r et a in er clip. bolt h ea ds.

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

(\'\ 1\) J8921-1060

Fig. 54 Remove Fifth Gear Shift Fork


(7) Rem ove t h e r ever se sh ift h ea d a n d r a il a ssem -
bly fr om t h e in t er m edia t e pla t e (F ig. 55).
(8) Rem ove fift h gea r blocker r in g fr om cou n t er-
sh a ft a ssem bly wit h P u ller L-4407 (F ig. 56).

Fig. 52 Remove Fifth Gear Snap-ring


(4) Rem ove bolt h oldin g fift h gea r sh ift for k t o
sh ift r a il (F ig. 53).
SHIFT
FORK
SET REVERSE - - - - - - - - -
SHIFT -
SCREW~_;:::i,11...._
HEAD
AND
SHIFT
RAIL

FIFTH GEAR Fig. 55 Remove Reverse Shift Head Assembly


SHIFT FORK
(9) Rem ove fift h gea r syn ch r o r in g (F ig. 57).
(10) Rem ove t h e cou n t er sh a ft fift h gea r a ssem bly
fr om cou n t er sh a ft (F ig. 58).

Fig. 53 Remove Fifth Gear Shift Fork Retainer Bolt


(5) Move fift h gea r sh ift r a il for wa r d u n t il t h e r a il
is clea r of t h e sh ift for k.
(6) Rem ove t h e fift h gea r sh ift for k fr om t h e syn -
ch r on izer sleeve (F ig. 54).
XJ TRANSMISSION AND TRANSFER CASE 21 - 53
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

COUNTER
FIFTH
GEAR

J8921-1065

Fig. 58 Remove Fifth Gear And Synchro Assembly

Fig. 56 Remove Fifth Gear Blocker Ring

LOCK
BALL
NOTCH

FIFTH
GEAR
THRUST
RING

Fig. 59 Remove Fifth Gear Thrust Ring

Fig. 57 Remove Fifth Gear Synchro Ring


(11) Rem ove fift h gea r t h r u st r in g fr om cou n t er-
sh a ft (F ig. 59).
(12) Rem ove fift h gea r t h r u st r in g lock ba ll fr om
cou n t er sh a ft (F ig. 60).
-
NOTE: There are many lock balls, check balls,
interlock balls, and interlock pins used in various
\
places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way J8921-1067
that it can be reinstalled in the same location from
which it was removed.
Fig. 60 Remove Fifth Gear Thrust Ring Lock Ball
21 - 54 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(13) Rem ove bolt s h oldin g ou t pu t sh a ft r ea r bea r-
in g r et a in er t o in t er m edia t e pla t e (F ig. 61).

Fig. 63 Remove Reverse Idler Shaft And Gear

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

Fig. 64 Reverse Shift Arm Components

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

Fig. 65 Lock Ball Plug Locations


XJ TRANSMISSION AND TRANSFER CASE 21 - 55
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

MAGNET

Fig. 68 Remove Fifth Gear Shift Rail Lock Ball

Fig. 66 Remove Lock Ball And Spring


(19) Rem ove t h e fift h gea r sh ift r a il (F ig. 67).
(20) Ret r ieve t h e fift h gea r sh ift r a il lock ba ll fr om
t h e in t er m edia t e pla t e u sin g a m a gn et (F ig. 68).

FIFTH
GEAR SHIFT
RAIL

REVERSE
SHIFT
FORK J8921-1075

Fig. 67 Shift Rail Identification


21 - 56 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(21) Rem ove t h e 1–2 a n d 3–4 sh ift r a il c-r in gs (23) Rem ove t h e 3–4 sh ift r a il fr om t h e 1–2 a n d
u sin g t wo equ a lly sized scr ewdr iver s (F ig. 69). 3–4 sh ift for ks a n d t h e in t er m edia t e pla t e (F ig. 71).

Fig. 71 Remove 3–4 Shift Rail


(24) Rem ove t h e 3–4 sh ift r a il in t er lock plu g fr om
t h e in t er m edia t e pla t e wit h a sm a ll m a gn et (F ig. 72).
(25) Rem ove t h e 3–4 sh ift for k (F ig. 73).
3-4 SHIFT RAIL
INTERLOCK PLUG

Fig. 69 Remove Shift Rail C-rings


(22) Rem ove bolt s h oldin g 1–2 a n d 3–4 sh ift for ks
t o t h e sh ift r a ils (F ig. 70) a n d disca r d bolt s.
SHIFT FORK
SET SCREWS

Fig. 72 Remove 3–4 Shift Rail Interlock Plug

Fig. 70 Remove Shift Fork To Shift Rail Bolts


XJ TRANSMISSION AND TRANSFER CASE 21 - 57
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

J8921-l0?7

/ Fig. 75 Remove 1–2 Shift Rail Interlock Pin


l 2 SHIFT
RAIL INTERLOCK
PLUG

INTERMEDIATE
PLATE

Fig. 73 Remove Shift Forks


(26) Rem ove t h e 1–2 sh ift r a il fr om t h e 1–2 sh ift
for k a n d t h e in t er m edia t e pla t e (F ig. 74).
(27) Rem ove t h e 1–2 sh ift r a il in t er lock pin fr om
t h e 1–2 sh ift r a il (F ig. 75).
(28) Rem ove t h e 1–2 sh ift r a il in t er lock plu g fr om Fig. 76 Remove 1–2 Shift Rail Interlock Plug
t h e in t er m edia t e pla t e (F ig. 76).
(29) Rem ove t h e 1–2 sh ift for k (F ig. 73). (30) Rem ove t h e c-r in g h oldin g t h e r ever se sh ift
r a il in t o t h e in t er m edia t e pla t e u sin g t wo equ a lly
INTERMEDIATE sized scr ewdr iver s (F ig. 77).
PLATE
(31) Rem ove t h e r ever se sh ift r a il a n d for k fr om
t h e in t er m edia t e pla t e (F ig. 78).
(32) Rem ove t h e in t er lock pin fr om t h e r ever se
sh ift r a il (F ig. 79).
(33) Rem ove sn a p-r in g h oldin g ou t pu t sh a ft r ea r
bea r in g in t o t h e in t er m edia t e pla t e (F ig. 80).
(34) Rem ove cou n t er sh a ft r ea r bea r in g sn a p-r in g.
(35) Wit h a id of a n a ssist a n t , su ppor t t h e m a in -
sh a ft a n d cou n t er sh a ft . Ta p on t h e r ea r of t h e m a in -
sh a ft a n d cou n t er sh a ft wit h a su it a ble r u bber m a llet .
Th is will r elea se t h e cou n t er sh a ft fr om t h e cou n t er-
sh a ft r ea r bea r in g a n d t h e m a in sh a ft r ea r bea r in g
fr om t h e in t er m edia t e pla t e. Th e m a in sh a ft will
J8921-1076
r elea se fr om t h e in t er m edia t e pla t e fir st a n d ca n be
Fig. 74 Remove 1–2 Shift Rail r em oved by m ovin g t h e m a in sh a ft r ea r wa r d a n d
u pwa r d (F ig. 81).
21 - 58 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

INTERLOCK
PIN

Fig. 79 Remove Reverse Shift Rail Interlock Pin

J8921-1081

Fig. 77 Remove Reverse Shift Rail C-ring


COUNTERSHAFT
REAR BEARING
SNAP-RING
80ac2c6b

Fig. 80 Remove Output Shaft Rear Bearing


Snap-ring

J8921-1082

Fig. 78 Remove Reverse Shift Rail


(36) Rem ove t h e cou n t er sh a ft by m ovin g t h e cou n -
t er sh a ft r ea r wa r d u n t il t h e cou n t er sh a ft is clea r of
t h e in t er m edia t e pla t e.
(37) Rem ove t h e cou n t er sh a ft r ea r bea r in g fr om
t h e in t er m edia t e pla t e.
Fig. 81 Remove Mainshaft
ASSEMBLY (2) P osit ion t h e m a in sh a ft in t o t h e in t er m edia t e
(1) Lu br ica t e cou n t er sh a ft jou r n a l a n d r ea r bea r- pla t e.
in g wit h pet r oleu m jelly or gea r lu br ica n t .
XJ TRANSMISSION AND TRANSFER CASE 21 - 59
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(3) Ta p t h e m a in sh a ft a ssem bly r ea r bea r in g in t o
t h e in t er m edia t e pla t e wit h a su it a ble r u bber m a llet .
(4) In st a ll t h e cou n t er sh a ft t h r u t h e cou n t er sh a ft
r ea r bea r in g jou r n a l of t h e in t er m edia t e pla t e.
(5) Align a n d m esh t h e m a in sh a ft a n d cou n t er-
sh a ft gea r s a s m u ch a s possible.
(6) In st a ll t h e cou n t er sh a ft bea r in g over t h e cou n -
t er sh a ft bea r in g boss a n d in t o t h e in t er m edia t e pla t e.
Be su r e t o lea ve t h e sn a p-r in g gr oove in t h e bea r in g
fa cin g t h e r ea r of t h e u n it . It m a y be n ecessa r y t o t a p
on t h e bea r in g wit h a pla st ic m a llet t o fu lly sea t t h e
bea r in g in t o in t er m edia t e pla t e.
(7) Ver ify t h a t t h e m a in sh a ft a n d cou n t er sh a ft
gea r s a r e cor r ect ly m esh ed a n d r ot a t e pr oper ly.
(8) In st a ll sn a p-r in g t o h old ou t pu t sh a ft r ea r J8921-1082
bea r in g in t o t h e in t er m edia t e pla t e (F ig. 66).
(9) In st a ll cou n t er sh a ft r ea r bea r in g sn a p-r in g. Fig. 83 Install Reverse Shift Rail

NOTE: Coat all shift components with petroleum


jelly during assembly. Petroleum jelly will hold com-
ponents in position during installation.

(10) In st a ll in t er lock pin in r ever se sh ift r a il (F ig.


82).
(11) In st a ll t h e r ever se sh ift r a il in t h e in t er m edi-
a t e pla t e (F ig. 83).

/
INTERLOCK
PIN

Fig. 82 Install Reverse Shift Rail Interlock Pin


(12) In st a ll c-r in g t o h old t h e r ever se sh ift r a il in t o
t h e in t er m edia t e pla t e.
(13) In st a ll t h e 1–2 a n d 3–4 sh ift for ks in t o t h e Fig. 84 Install Shift Forks
syn ch r on izer sleeves (F ig. 84). (17) In st a ll 3–4 sh ift r a il in t er lock plu g in t o t h e
(14) In st a ll 1–2 sh ift r a il in t er lock plu g in t h e in t er m edia t e pla t e (F ig. 88).
in t er m edia t e pla t e (F ig. 85). (18) In st a ll t h e 3–4 sh ift r a il t h r ou gh t h e in t er m e-
(15) In st a ll in t er lock pin in 1–2 sh ift r a il (F ig. 86). dia t e pla t e, 1–2 a n d 3–4 sh ift for ks (F ig. 89).
(16) In st a ll 1–2 sh ift r a il t h r ou gh in t er m edia t e
pla t e a n d 1–2 sh ift for k (F ig. 87).
21 - 60 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
1-2 SHIFT 3-4 SHIFT RAIL
RAIL INTERLOCK INTERLOCK PLUG
PLUG

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

Fig. 94 Install Fifth Gear Shift Rail Lock Ball

Fig. 92 Install Reverse Idler Gear And Shaft


(26) In st a ll t h e fift h gea r t h r u st r in g lock ba ll in t o
t h e cou n t er sh a ft (F ig. 95).
(27) In st a ll fift h gea r t h r u st r in g on t o cou n t er sh a ft
a n d over lock ba ll (F ig. 96).
(28) In st a ll cou n t er sh a ft fift h gea r bea r in g h a lves
in t o cou n t er sh a ft fift h gea r a ssem bly (F ig. 97).
(29) In st a ll cou n t er sh a ft fift h gea r a ssem bly on t o
cou n t er sh a ft (F ig. 98).
(30) In st a ll fift h gea r syn ch r on izer r in g (F ig. 99).
(31) P osit ion fift h gea r blocker r in g on t o cou n t er-
sh a ft . Ver ify t h a t blocker r in g a n d cou n t er sh a ft Fig. 95 Install Fifth Gear Thrust Ring Lock Ball
splin es a r e a lign ed. (34) In st a ll sn a p-r in g t o h old t h e cou n t er sh a ft fift h
(32) Usin g a su it a ble dr iver a n d m a llet , sea t t h e gea r a ssem bly on t o t h e cou n t er sh a ft (F ig. 100).
blocker r in g on t o t h e cou n t er sh a ft .
(33) Select t h e t h ickest sn a p-r in g t h e 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 .
21 - 62 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 97 Install Countershaft Fifth Gear Bearings

I.D. SNAP RING MM(IN.)


MARK THICKNESS
A 2.85 - 2.90 (0.1122 - 0.1142)
COUNTER B 2.90 - 2.95 (0.1142 - 0.1161)
FIFTH C 2.95 - 3.00 (0.1161 - 0.1181)
GEAR D 3.00 - 3.05 (0. 1181-0. 1201)
E 3.05 - 3.10 (0. 1201 - 0. 1220)
F 3.10 - 3.15 (0.1220 - 0.1240)
G 3.15 - 3.20 (0. 1240 - 0. 1260)
H 3.20 - 3.25 0.1260 - 0.1280
J8921-1114

Fig. 100 Install Fifth Gear Snap-ring


(36) Move r ever se sh ift r a il for wa r d a s fa r a s pos-
sible a n d in st a ll fift h gea r sh ift for k on t o syn ch r o-
J8921 -1065 n izer sleeve (F ig. 102).
(37) In st a ll n ew bolt t o h old fift h gea r sh ift for k t o
Fig. 98 Install Countershaft Fifth Gear Assembly sh ift r a il (F ig. 103).
(38) In st a ll det en t ba lls a n d spr in gs in t o open in gs
(35) In st a ll t h e r ever se sh ift h ea d a n d r a il a ssem -
in t h e in t er m edia t e pla t e (F ig. 104).
bly (F ig. 101).
(39) In st a ll n ew lock ba ll plu gs in t o t h e in t er m edi-
a t e pla t e. Tigh t en plu gs t o 19 N·m (14 ft . lbs.).
XJ TRANSMISSION AND TRANSFER CASE 21 - 63
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

REVERSE
SHIFT
HEAD
AND
SHIFT
RAIL

Fig. 101 Install Reverse Shift Head And Rail


Assembly

Fig. 104 Install Detent Balls And Springs


FIFTH GEAR COUNTERSHAFT
SYNCHRO SLEEVE
DISASSEMBLY
(\'\ \ ~ J8921-1060 (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.
Fig. 102 Install Fifth Gear Shift Fork 105).
(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 .

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

I.D. SNAP RING THICKNESS


MARK MM (IN.}
J8921-1090
A 2.00 - 2.05 (0.0787 - 0.0807)
B 2.05 - 2.10 (0.0807 - 0.0827) Fig. 107 Remove Output Shaft Pilot Bearing
C 2.10 - 2.15 (0.0827 - 0.0846)
D 2.15 - 2.20 (0.0846 - 0.0866) SYNCHRO
E 2.20 - 2.25 (0.0866 - 0.0886) BEARING RING

80ac6a0b

Fig. 105 Countershaft Front Bearing Snap-ring


INPUT SHAFT
DISASSEMBLY
(1) Ver ify t h a t t h e 3–4 syn ch r on izer is in t h e n eu -
t r a l posit ion .
(2) Sepa r a t e in pu t sh a ft fr om ou t pu t sh a ft (F ig.
106).
J8921-1091

Fig. 108 Input Shaft Components


ASSEMBLY
(1) P osit ion in pu t sh a ft bea r in g on t o in pu t sh a ft .
Be su r e t h a t t h e sn a p-r in g gr oove in t h e bea r in g is
fa cin g for wa r d.
(2) Usin g Dr iver 6052, dr ive bea r in g on t o in pu t
sh a ft .
(3) 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 in pu t sh a ft (F ig. 109).
(4) Lu br ica t e ou t pu t sh a ft pilot bea r in g bor e of
in pu t sh a ft wit h pet r oleu m jelly.
(5) In st a ll ou t pu t sh a ft pilot bea r in g in in pu t sh a ft
J8921-1089
bor e (F ig. 107).
Fig. 106 Separate Input and Output Shafts (6) In st a ll t h e fou r t h gea r syn ch r on izer r in g on t o
t h e in pu t sh a ft .
(3) Rem ove t h e ou t pu t sh a ft pilot bea r in g fr om t h e (7) In st a ll in pu t sh a ft t o ou t pu t sh a ft .
in pu t sh a ft or ou t pu t sh a ft (F ig. 107).
(4) Rem ove t h e fou r t h gea r syn ch r on izer r in g fr om OUTPUT SHAFT
t h e in pu t sh a ft (F ig. 108). Refer t o (F ig. 110) for pa r t s iden t ifica t ion du r in g
(5) Rem ove t h e select fit sn a p-r in g h oldin g t h e disa ssem bly a n d a ssem bly of t h e ou t pu t sh a ft .
in pu t sh a ft bea r in g on t o t h e in pu t sh a ft .
(6) Usin g Bea r in g Split t er P -334 a n d a sh op pr ess,
r em ove t h e bea r in g fr om t h e in pu t sh a ft .
XJ TRANSMISSION AND TRANSFER CASE 21 - 65
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(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. 112). F ir st gea r clea r a n ce sh ou ld be
0.10 – 0.40 m m (0.004 – 0.0197 in .). Secon d a n d t h ir d
gea r clea r a n ce sh ou ld be 0.10 – 0.30 m m (0.003 –
0.0118 in .).

OUTPUT SHAFT \ INPUT SHAFT


PILOT BEARING ASSEMBLY

I.D. SNAP RING


MM(IN.)
MARK THICKNESS
A 2.10-2. 15 (0.0827 - 0.0846)
B 2.15 - 2.20 (0.0846 - 0.0866)
C 2.20 - 2.25 (0.0866 - 0.0886)
D 2.25 - 2.30 (0.0886 - 0.0906)
E 2.30 - .2.35 (0.0906 - 0.0925)
F 2.35 - 2..40 (0.0925 - 0.0945)
G 2.40 - 2.45 0.0945 - 0.0965
J8921-1097 J8921-1090

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

OUTPUT SHAFT (2WD)

REAR
BEARING

INSERT
SPRING

1 SNAP
RING
(SELECTIVE)

INSERT
(3)

NEEDLE SYNCHRO
BEARING RING J8921-1093

Fig. 110 Output Shaft And Gears


21 - 66 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

THRUST REVERSE 3-4


WASHER GEAR SYNCHRO
FIRST AND HUB SECOND SLEEVE
GEAR GEAR AND
HUB

OUTPUT
SHAFT
1ST 2ND FLANGE
CLEARANCE CLEARANCE
J8921-1092

Fig. 112 Check Output Shaft Gear Thrust Clearance


Fig. 114 Remove Fifth Gear, First Gear Bearing, And
Thrust Washer
(10) Usin g Bea r in g Split t er P -334 or su it a ble pr ess
pla t es posit ion ed u n der secon d gea r, pr ess 1–2 syn -
ch r on izer /r ever se gea r a n d secon d gea r fr om ou t pu t
sh a ft (F ig. 115).

J8921-37

Fig. 113 Remove Fifth Gear Snap-ring


r ea r bea r in g, fir st gea r, a n d fir st gea r t h r u st wa sh er
off ou t pu t sh a ft (F ig. 114).
(5) Rem ove fir st gea r t h r u st wa sh er loca t in g pin
fr om ou t pu t sh a ft . J8921-40
(6) Rem ove fir st gea r n eedle r oller bea r in g fr om
ou t pu t sh a ft . Fig. 115 Remove Second Gear And 1–2
(7) Rem ove fir st gea r spa cer fr om ou t pu t sh a ft . Synchronizer/Reverse Gear
(8) Rem ove fir st gea r syn ch r on izer r in g. (11) Rem ove secon d gea r n eedle r oller bea r in g
(9) Rem ove select fit sn a p-r in g h oldin g t h e 1–2 fr om t h e ou t pu t sh a ft or secon d gea r.
syn ch r on izer /r ever se gea r on t o t h e ou t pu t sh a ft .
XJ TRANSMISSION AND TRANSFER CASE 21 - 67
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(12) Rem ove select fit sn a p-r in g h oldin g t h e 3–4 ASSEMBLY
syn ch r on izer on t o t h e ou t pu t sh a ft (F ig. 116). (1) Lu br ica t e t r a n sm ission com pon en t s wit h speci-
fied gea r lu br ica n t du r in g a ssem bly.
(2) If n ecessa r y, a ssem ble 1–2 a n d 3–4 syn ch r o-
n izer h u bs, sleeves, spr in gs a n d key in ser t s (F ig.
3_4 SYNCHRONIZER 118).
SNAP RING
3-4 SLEEVE REVERSE GEAR
AND HUB......_ AND 1-2
'""--'== SLEEVE AND
HUB

-
FRONT

J8921-1099

J8921-41 Fig. 118 Synchronizer Identification

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

Fig. 120 Check Third Gear Clearance


(17) In st a ll sn a p-r in g t o h old 1–2 syn ch r on izer /r e-
ver se gea r on t o ou t pu t sh a ft .
(18) In st a ll fir st gea r syn ch r on izer r in g in t o 1–2
syn ch r on izer /r ever se gea r.
(19) In st a ll t h e fir st gea r spa cer on t o t h e in pu t
sh a ft a n d a ga in st t h e 1–2 syn ch r on izer /r ever se gea r
FIRST NEEDLE THRUST
sn a p-r in g. GEAR BEARING WASHER J8921-1103
(20) In st a ll fir st gea r n eedle bea r in g on t o ou t pu t
sh a ft (F ig. 122). Fig. 122 First And Fifth Gear Components
(21) In st a ll fir st gea r on t o ou t pu t sh a ft a n d over
bea r in g. (27) Ch eck fir st a n d secon d gea r t h r u st clea r a n ce
(22) In st a ll t h e fir st gea r t h r u st wa sh er loca t in g (F ig. 123). F ir st gea r clea r a n ce sh ou ld be 0.10 – 0.40
pin in t o t h e ou t pu t sh a ft . m m (0.003 – 0.0197 in .). Secon d gea r clea r a n ce
sh ou ld be 0.10 – 0.30 m m (0.003 – 0.0118 in .). If
XJ TRANSMISSION AND TRANSFER CASE 21 - 69
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
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.

THRUST REVERSE 3-4


GEAR TAP
WASHER SYNCHRO
FIRST AND HUB SECOND SNAP
SLEEVE
GEAR GEAR RING
AND
INTO
HUB
PLACE

I.D. SNAP RING


MARK THICKNESS MM(IN.)
A 2.75 - 2.80 (0.1083 - 0.1102)
B 2.80 - 2.85 (0.1002 - 0.1122)
C 2.85 - 2.90 (0.1122 - 0.1142)
OUTPUT D 2.90 - 2.95 (0. 1142 - 0. 1161 )
SHAFT E 2.95 - 3.00 (0.1161 - 0.1181)
1ST 2ND FLANGE F 3.00 - 3.05 (0. 1181 - 0. 1201)
CLEARANCE CLEARANCE G 3.05 - 3.10 (0. 1201 - 0. 1220)
H 3.10 - 3.15 (0. 1220 - 0. 1240)
J8921-1092 J 3.15 - 3.20 (0. 1240 - 0. 1260)
K 3.20 - 3.25 (0. 1260 - 0. 1280)
Fig. 123 Check First–Second Gear Thrust Clearance L 3.25 - 3.30 (0. 1280 - 0. 1299)
M 3.30 - 3.35 (0.1299 - 0.1319)
(28) P osit ion fift h gea r on t o ou t pu t sh a ft wit h t h e
J8921-1104
gea r ’s lon g sh ou lder t owa r d t h e r ea r of sh a ft . E n su r e
t h a t t h e gea r a n d ou t pu t sh a ft splin es a r e a lign ed. Fig. 124 Select/Install Fifth Gear Snap Ring
(29) Usin g Ada pt er 6761, Dr iver L-4507, a n d a
sh op pr ess, pr ess fift h gea r on t o ou t pu t sh a ft . GEAR CASE, ADAPTER/EXTENSION HOUSING,
(30) Select t h e t h ickest sn a p-r in g t h a t will fit in t o INTERMEDIATE PLATE
t h e sn a p-r in g gr oove of t h e ou t pu t sh a ft (F ig. 124). Clea n t h e ca se, h ou sin g, a n d in t er m edia t e pla t e
(31) In st a ll sn a p-r in g t o h old fift h gea r on t o ou t pu t wit h solven t a n d dr y wit h com pr essed a ir. Repla ce
sh a ft . t h e ca se if cr a cked, por ou s, or if a n y of t h e bea r in g
(32) In st a ll ou t pu t sh a ft pilot bea r in g in t o t h e a n d gea r bor es a r e da m a ged.
in pu t sh a ft . In spect t h e t h r ea ds in t h e ca se, h ou sin g, a n d pla t e.
(33) In st a ll t h e in pu t sh a ft t o t h e ou t pu t sh a ft s. Min or t h r ea d da m a ge ca n be r epa ir ed wit h st eel
t h r ea d in ser t s, if n ecessa r y. Do n ot a t t em pt t o r epa ir
a n y t h r ea ds wh ich sh ow eviden ce of cr a cks a r ou n d
CLEAN I N G AN D I N SPECT I ON t h e t h r ea ded h ole.

AX15 MANUAL TRANSMISSION COMPONENTS OUTPUT SHAFT


Ch eck t h ickn ess of t h e ou t pu t sh a ft fla n ge wit h a
GENERAL INFORMATION m icr om et er or ver n ier ca liper s (F ig. 125). Min im u m
Clea n t h e t r a n sm ission com pon en t s in solven t . Dr y a llowa ble fla n ge t h ickn ess is 4.70 m m (0.185 in .).
t h e ca ses, gea r s, sh ift m ech a n ism a n d sh a ft s wit h Ch eck dia m et er of t h e fir st , secon d, a n d t h ir d gea r
com pr essed a ir. Dr y t h e bea r in gs wit h clea n , dr y bea r in g su r fa ces on t h e ou t pu t sh a ft . Min im u m
sh op t owels on ly. Never u se com pr essed a ir on t h e dia m et er s a r e a s follows:
bea r in gs. Th is cou ld ca u se sever e da m a ge t o t h e • F ir st gea r bea r in g su r fa ce is 38.86 m m (1.529
bea r in g r oller a n d r a ce su r fa ces. in .).
If ou t pu t sh a ft fla n ge t h ickn ess is wit h in specifica - • Secon d gea r bea r in g su r fa ce is 46.86 m m (1.844
t ion bu t a n y gea r t h r u st clea r a n ce is ou t of specifica - in .).
t ion , r epla ce t h e n ecessa r y gea r a n d gea r n eedle • Th ir d gea r bea r in g su r fa ce is 37.86 m m (1.490
bea r in g a s a n a ssem bly. in .).
21 - 70 TRANSMISSION AND TRANSFER CASE XJ
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
Ch eck syn ch r on izer r in g wea r (F ig. 127). In ser t
ea ch r in g in m a t ch in g gea r. Mea su r e clea r a n ce
bet ween ea ch r in g a n d gea r wit h feeler ga u ge. Clea r-
a n ce sh ou ld be 0.06 – 1.6 m m (0.024 – 0.063 in .).
_ _ _ _ _ _ _ _ _ _ _ _ CLUSTER

GEAR
JOURNAL

J8921-1095

Fig. 125 Check Output Shaft Tolerances


Mea su r e ou t pu t sh a ft r u n ou t wit h a dia l in dica t or
a n d V-blocks (F ig. 125). Ru n ou t sh ou ld n ot exceed
0.06 m m (0.0024 in .).
Repla ce ou t pu t sh a ft if m ea su r em en t of a n y su r-
fa ce is ou t of specifica t ion . Do n ot a t t em pt t o r epa ir
ou t of specifica t ion com pon en t s.

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

Fig. 128 Check Fork–To–Hub Clearance


Ch eck t h e con dit ion of t h e r ever se idler gea r bu sh -
in g (F ig. 129). Repla ce t h e gea r if t h e bu sh in g is
Fig. 126 Check Gear–To–Shaft Oil Clearance da m a ged or wor n .
XJ TRANSMISSION AND TRANSFER CASE 21 - 71
SPECI FI CAT I ON S (Cont inue d)

CHECK REVERSE SPECI AL T OOLS


BUSHING IDLER
FOR WEAR GEAR
OR DAMAGE AX15

8011 d42b

J8921-1096 C-3339 Dial Indicator Set

Fig. 129 Reverse Idler Gear Bushing


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.)
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 C-4171 Handle, Universal Tool
(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 8209 Installer, Seal
(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
(22–30 ft .lbs.)

8212 Installer, Seal


21 - 72 TRANSMISSION AND TRANSFER CASE XJ
SPECI AL T OOLS (Cont inue d)

8208 Installer, Seal


6052 Tube, Driver

L-4407A Puller, Gear


6761 Adapter, Installer

P-334 Splitter, Bearing


MD-998805 Tube, Driver

(_Q)
8109 Cup, Installer

L-4507 Tube, Driver


XJ TRANSMISSION AND TRANSFER CASE 21 - 73

AU T OM AT I C T RAN SM I SSI ON —3 0 RH

INDEX
page page

GENERAL INFORMATION PARK LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 103


30RH AUTOMATIC TRANSMISSION . . . . . . . . . . 74 PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 99
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . . 74 SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . . 98
EFFECTS OF INCORRECT FLUID LEVEL . . . . . 74 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 96
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . 74 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 94
GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 76 VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 100
RECOMMENDED FLUID . . . . . . . . . . . . . . . . . . . 74 YOKE SEAL REPLACEMENT . . . . . . . . . . . . . . . 97
TORQUE CONVERTER—ELECTRONIC DISASSEMBLY AND ASSEMBLY
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 126
TRANSMISSION GEAR RATIOS . . . . . . . . . . . . . 76 FRONT SERVO PISTON . . . . . . . . . . . . . . . . . . 121
TRANSMISSION IDENTIFICATION . . . . . . . . . . . 74 GOVERNOR AND PARK GEAR . . . . . . . . . . . . 104
DESCRIPTION AND OPERATION OIL PUMP AND REACTION SHAFT SUPPORT . . 123
BRAKE TRANSMISSION SHIFT INTERLOCK OVERRUNNING CLUTCH/LOW-REVERSE
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 77 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
CONVERTER CLUTCH ENGAGEMENT . . . . . . . 77 PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 130
CONVERTER DRAINBACK VALVE . . . . . . . . . . . 77 REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 127
HYDRAULIC CONTROL SYSTEM . . . . . . . . . . . . 76 REAR SERVO PISTON . . . . . . . . . . . . . . . . . . . 122
DIAGNOSIS AND TESTING TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 112
AIR TESTING TRANSMISSION CLUTCH AND VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 105
BAND OPERATION . . . . . . . . . . . . . . . . . . . . . 82 CLEANING AND INSPECTION
ANALYZING ROAD TEST . . . . . . . . . . . . . . . . . . 79 EXTENSION HOUSING AND PARK LOCK . . . . 136
AUTOMATIC TRANSMISSION DIAGNOSIS . . . . . 77 FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 139
CONVERTER HOUSING FLUID LEAK FRONT SERVO . . . . . . . . . . . . . . . . . . . . . . . . 138
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 GOVERNOR AND PARK GEAR . . . . . . . . . . . . 134
CONVERTER STALL TEST . . . . . . . . . . . . . . . . . 81 OIL PUMP AND REACTION SHAFT
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . . . . . 83 SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 79 OVERRUNNING CLUTCH/LOW-REVERSE
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . . 80 DRUM/OVERDRIVE PISTON RETAINER . . . . 138
PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 78 PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 140
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . . . 77 REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 139
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 79 REAR SERVO . . . . . . . . . . . . . . . . . . . . . . . . . 138
STALL TEST ANALYSIS . . . . . . . . . . . . . . . . . . . 82 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 137
THROTTLE VALVE CABLE . . . . . . . . . . . . . . . . . 79 VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 136
SERVICE PROCEDURES ADJUSTMENTS
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 93 BRAKE TRANSMISSION SHIFT INTERLOCK
CONVERTER DRAINBACK CHECK VALVE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . 141
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 FRONT BAND ADJUSTMENT . . . . . . . . . . . . . . 142
FLUID AND FILTER REPLACEMENT . . . . . . . . . 91 GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 140
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . . 91 REAR BAND ADJUSTMENT . . . . . . . . . . . . . . . 143
FLUSHING COOLERS AND TUBES . . . . . . . . . . 93 TRANSMISSION THROTTLE VALVE CABLE
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 92 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 141
TRANSMISSION FILL PROCEDURE . . . . . . . . . . 92 VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 143
REMOVAL AND INSTALLATION SCHEMATICS AND DIAGRAMS
BRAKE TRANSMISSION SHIFT INTERLOCK . . 100 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . 144
EXTENSION HOUSING . . . . . . . . . . . . . . . . . . . 98 SPECIFICATIONS
EXTENSION HOUSING BUSHING . . . . . . . . . . . 97 30RH AUTOMATIC TRANSMISSION . . . . . . . . . 157
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 100 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
GOVERNOR AND PARK GEAR . . . . . . . . . . . . 102 SPECIAL TOOLS
OUTPUT SHAFT REAR BEARING . . . . . . . . . . 102 30RH TRANSMISSIONS . . . . . . . . . . . . . . . . . . 158
21 - 74 TRANSMISSION AND TRANSFER CASE XJ

GEN ERAL I N FORM AT I ON dr a in ba ck va lve, a da m a ged m a in cooler, or sever e


r est r ict ion s in t h e cooler s a n d lin es ca u sed by debr is
30RH AUTOMATIC TRANSMISSION or kin ked lin es.
Th e 30RH a u t om a t ic t r a n sm ission is u sed wit h t h e (2) H ea vy du t y oper a t ion wit h a veh icle n ot pr op-
2.5L en gin e (F ig. 1). Th e 30RH is a t h r ee speed er ly equ ipped for t h is t ype of oper a t ion . Tr a iler t ow-
t r a n sm ission s wit h a lock-u p clu t ch in t h e t or qu e in g or sim ila r h igh loa d oper a t ion will over h ea t t h e
con ver t er. Th e t or qu e con ver t er clu t ch is con t r olled t r a n sm ission flu id if t h e veh icle is im pr oper ly
by t h e P ower t r a in Con t r ol Modu le (P CM). Th e t or qu e equ ipped. Su ch veh icles sh ou ld h a ve a n a u xilia r y
con ver t er clu t ch is h ydr a u lica lly a pplied a n d is t r a n sm ission flu id cooler, a h ea vy du t y coolin g sys-
r elea sed wh en flu id is ven t ed fr om t h e h ydr a u lic cir- t em , a n d t h e en gin e/a xle r a t io com bin a t ion n eeded t o
cu it by t h e t or qu e con ver t er con t r ol (TCC) solen oid h a n dle h ea vy loa ds.
on t h e va lve body. Th e t or qu e con ver t er clu t ch
en ga ges in t h ir d gea r wh en t h e veh icle is cr u isin g on FLUID CONTAMINATION
a level pla n e a ft er t h e veh icle h a s wa r m ed u p. Th e Tr a n sm ission flu id con t a m in a t ion is gen er a lly a
t or qu e con ver t er clu t ch will disen ga ge wh en t h e veh i- r esu lt of:
cle begin s t o go u ph ill or t h e a cceler a t or is a pplied. • a ddin g in cor r ect flu id
Th e t or qu e con ver t er clu t ch fea t u r e in cr ea ses fu el • fa ilu r e t o clea n dipst ick a n d fill t u be wh en
econ om y a n d r edu ces t h e t r a n sm ission flu id t em per- ch eckin g level
a t u r e. Th e 30RH t r a n sm ission is cooled by a n in t e- • en gin e coola n t en t er in g t h e flu id
gr a l flu id cooler in side t h e r a dia t or. • in t er n a l fa ilu r e t h a t gen er a t es debr is
• over h ea t t h a t gen er a t es slu dge (flu id br ea k-
TRANSMISSION IDENTIFICATION down )
Tr a n sm ission iden t ifica t ion n u m ber s a r e st a m ped • fa ilu r e t o r ever se flu sh cooler a n d lin es a ft er
on t h e left side of t h e ca se ju st a bove t h e oil pa n ga s- r epa ir
ket su r fa ce (F ig. 2). Refer t o t h is in for m a t ion wh en • fa ilu r e t o r epla ce con t a m in a t ed con ver t er a ft er
or der in g r epla cem en t pa r t s. r epa ir.
Th e u se of n on r ecom m en ded flu ids ca n r esu lt in
RECOMMENDED FLUID 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
Mopa r ! ATF P lu s 3, Type 7176 a u t om a t ic t r a n s- sh ift s, slippa ge, a bn or m a l wea r a n d even t u a l fa ilu r e
m ission flu id is t h e r ecom m en ded flu id for Ch r ysler du e t o flu id br ea kdown a n d slu dge for m a t ion . Avoid
a u t om a t ic t r a n sm ission s. t h is con dit ion by u sin g r ecom m en ded flu ids on ly.
D e x ro n II flu id IS N OT re c o m m e n d e d . Clu tc h Th e dipst ick ca p a n d fill t u be sh ou ld be wiped
c h a tte r c a n re s u lt fro m th e u s e o f im p ro p e r clea n befor e ch eckin g flu id level. Dir t , gr ea se a n d
flu id . ot h er for eign m a t er ia l on t h e ca p a n d t u be cou ld fa ll
in t o t h e t u be if n ot r em oved befor eh a n d. Ta ke t h e
t im e t o wipe t h e ca p a n d t u be clea n befor e wit h dr a w-
EFFECTS OF INCORRECT FLUID LEVEL
in g t h e dipst ick.
A low flu id level a llows t h e pu m p t o t a ke in a ir
E n gin e coola n t in t h e t r a n sm ission flu id is gen er-
a lon g wit h t h e flu id. Air in t h e flu id will ca u se flu id
a lly ca u sed by a cooler m a lfu n ct ion . Th e on ly r em edy
pr essu r es t o be low a n d develop slower t h a n n or m a l.
is t o r epla ce t h e r a dia t or a s t h e cooler in t h e r a dia t or
If t h e t r a n sm ission is over filled, t h e gea r s ch u r n t h e
is n ot a ser vicea ble pa r t . If coola n t h a s cir cu la t ed
flu id in t o foa m . Th is a er a t es t h e flu id a n d ca u sin g
t h r ou gh t h e t r a n sm ission for som e t im e, a n over h a u l
t h e sa m e con dit ion s occu r r in g wit h a low level. In
m a y a lso be n ecessa r y; especia lly if sh ift pr oblem s
eit h er ca se, a ir bu bbles ca u se flu id over h ea t in g, oxi-
h a d developed.
da t ion a n d va r n ish bu ildu p wh ich in t er fer es wit h
Th e t r a n sm ission cooler a n d lin es sh ou ld be
va lve, clu t ch a n d ser vo oper a t ion . F oa m in g a lso
r ever se flu sh ed wh en ever a m a lfu n ct ion gen er a t es
ca u ses flu id expa n sion wh ich ca n r esu lt in flu id over-
slu dge a n d/or debr is. Th e t or qu e con ver t er sh ou ld
flow fr om t h e t r a n sm ission ven t or fill t u be. F lu id
a lso be r epla ced a t t h e sa m e t im e.
over flow ca n ea sily be m ist a ken for a lea k if in spec-
F a ilu r e t o flu sh t h e cooler a n d lin es will r esu lt in
t ion is n ot ca r efu l.
r econ t a m in a t ion . F lu sh in g a pplies t o a u xilia r y cool-
er s a s well. Th e t or qu e con ver t er sh ou ld a lso be
CAUSES OF BURNT FLUID r epla ced wh en ever a fa ilu r e gen er a t es slu dge a n d
Bu r n t , discolor ed flu id is a r esu lt of over h ea t in g
debr is. Th is is n ecessa r y beca u se n or m a l con ver t er
wh ich h a s t wo pr im a r y ca u ses.
flu sh in g pr ocedu r es will n ot r em ove a ll con t a m i-
(1) A r esu lt of r est r ict ed flu id flow t h r ou gh t h e
n a n t s.
m a in a n d/or a u xilia r y cooler. Th is con dit ion is u su -
a lly t h e r esu lt of a fa u lt y or im pr oper ly in st a lled
XJ TRANSMISSION AND TRANSFER CASE 21 - 75
GEN ERAL I N FORM AT I ON (Cont inue d)

2 3 4 5 6 7 8 9 10 11
20

18 17 16 15 14 13

CD CONVERTER @ OUTPUT SHAFT

® OIL PUMP @) SEAL

® FRONT CLUTCH @) ADAPTER HOUSING

0 REAR CLUTCH @ PARK LOCK ROD

@) FRONT PLANETARY GEAR SET @) VALVE BODY

® REAR PLANETARY GEAR SET @ SUN GEAR DRIVING SHELL

(j) LOW AND REVERSE (REAR) BAND @ OILFILTER

@ OVERRUNNING CLUTCH @ KICK DOWN (FRONTI BAND

® GOVERNOR @ INPUT SHAFT

@) BEARING (g_g) PARKGEAR

@) 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)

PART BUILD GEARSHIFT MECHANISM


NUMBER DATE Th e sh ift m ech a n ism is ca ble oper a t ed a n d pr o-
vides six sh ift posit ion s. Th e sh ift in dica t or is loca t ed
on t h e con sole n ext t o t h e gea r sh ift . Th e sh ift posi-
t ion s a r e:
• P a r k (P )
• Rever se (R)
• Neu t r a l (N)
• Dr ive (D)
• Ma n u a l Secon d (2)
• Ma n u a l Low (1)
Ma n u a l low (1) r a n ge pr ovides fir st gea r on ly. Over
r u n br a kin g is a lso pr ovided in t h is r a n ge. Ma n u a l
secon d (2) r a n ge pr ovides fir st a n d secon d gea r on ly.
80b11960 Dr ive r a n ge pr ovides fir st , secon d, a n d t h ir d gea r
r a n ges.
Fig. 2 Transmission Part And Serial Number
Location
DESCRI PT I ON AN D OPERAT I ON
TORQUE CONVERTER—ELECTRONIC CLUTCH
Th e t or qu e con ver t er is a h ydr a u lic device t h a t HYDRAULIC CONTROL SYSTEM
cou ples t h e en gin e cr a n ksh a ft t o t h e t r a n sm ission .
Th e t r a n sm ission h ydr a u lic con t r ol syst em per-
Th e t or qu e con ver t er con sist s of a n ou t er sh ell wit h
for m s fou r ba sic fu n ct ion s.
a n in t er n a l t u r bin e, a st a t or, a n over r u n n in g clu t ch ,
• pr essu r e su pply
a n im peller a n d a n elect r on ica lly a pplied con ver t er
• pr essu r e r egu la t ion
clu t ch . Tor qu e m u lt iplica t ion is cr ea t ed wh en t h e st a -
• flow con t r ol a n d lu br ica t ion
t or dir ect s t h e h ydr a u lic flow fr om t h e t u r bin e t o
• clu t ch /ba n d a pplica t ion
r ot a t e t h e im peller in t h e dir ect ion t h e en gin e cr a n k-
sh a ft is t u r n in g. Th e t u r bin e t r a n sfer s power t o t h e PRESSURE SUPPLY
pla n et a r y gea r set s in t h e t r a n sm ission . Th e t r a n sfer
Th e oil pu m p develops flu id pr essu r e for clu t ch /
of power in t o t h e im peller a ssist s t or qu e m u lt iplica -
ba n d a pplica t ion a n d for lu br ica t ion . Th e pu m p is
t ion . At low veh icle speed, t h e over r u n n in g clu t ch
dr iven by t h e t or qu e con ver t er. Th e con ver t er is
h olds t h e st a t or (du r in g t or qu e m u lt iplica t ion ) a n d
dr iven by a dr ivepla t e a t t a ch ed t o t h e en gin e cr a n k-
a llows t h e st a t or t o fr ee wh eel a t h igh veh icle speed.
sh a ft .
Th e con ver t er clu t ch pr ovides r edu ced en gin e speed
a n d gr ea t er fu el econ om y wh en en ga ged. Clu t ch Pressure Regulation
en ga gem en t a lso pr ovides r edu ced t r a n sm ission flu id
Th e pr essu r e r egu la t or va lve m a in t a in s lin e (oper-
t em per a t u r es. Th e con ver t er clu t ch en ga ges in t h ir d
a t in g) pr essu r e. Th e a m ou n t of pr essu r e developed is
gea r. Th e t or qu e con ver t er h u b dr ives t h e t r a n sm is-
con t r olled by t h r ot t le pr essu r e wh ich is depen den t on
sion oil (flu id) pu m p.
t h e degr ee of t h r ot t le open in g. Th e r egu la t or va lve is
Th e t or qu e con ver t er is a sea led, welded u n it t h a t
loca t ed in t h e va lve body.
is n ot r epa ir a ble a n d is ser viced a s a n a ssem bly.
Th e t h r ot t le va lve det er m in es t h r ot t le pr essu r e
CAUTION: The torque converter must be replaced if a n d sh ift speed. Gover n or pr essu r e in cr ea ses in pr o-
a transmission failure resulted in large amounts of por t ion t o veh icle speed. Th e t h r ot t le va lve con t r ols
metal or fiber contamination in the fluid. If the fluid u psh ift a n d down sh ift speeds by r egu la t in g pr essu r e
is contaminated, flush the fluid cooler and lines. a ccor din g t o t h r ot t le posit ion .

Flow Control And Lubrication


TRANSMISSION GEAR RATIOS Th e m a n u a l va lve is oper a t ed by t h e gea r sh ift lin k-
F or wa r d gea r r a t ios a r e: a ge a n d pr ovides t h e oper a t in g r a n ge select ed by t h e
• 2.74:1 (fir st gea r ) dr iver.
• 1.54:1 (secon d gea r ) Th e swit ch va lve con t r ols lin e pr essu r e t o t h e con -
• 1.00:1 (t h ir d gea r ) ver t er clu t ch . Th e va lve a lso dir ect s oil t o t h e coolin g
a n d lu br ica t ion cir cu it s. Th e swit ch va lve r egu la t es
oil pr essu r e t o t h e t or qu e con ver t er by lim it in g m a x-
im u m oil pr essu r e t o 130 psi.
XJ TRANSMISSION AND TRANSFER CASE 21 - 77
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e 1-2 sh ift va lve pr ovide 1-2 a n d 2-1 sh ift s a n d All va lves h a ve a n a r r ow (or sim ila r m a r k) t o in di-
t h e 2-3 sh ift va lve pr ovide 2-3 a n d 3-2 sh ift s. ca t e dir ect ion of flow t h r ou gh t h e va lve.
Th e 1-2 sh ift con t r ol va lve t r a n sm it s 1-2 sh ift pr es-
su r e t o t h e a ccu m u la t or pist on . Th is con t r ols kick- BRAKE TRANSMISSION SHIFT INTERLOCK
down ba n d ca pa cit y on 1-2 u psh ift s a n d 3-2 MECHANISM
down sh ift s. Th e Br a ke Tr a n sm ission Sh ift er /Ign it ion In t er lock
Th e 2-3 va lve t h r ot t le pr essu r e plu g pr ovides 3-2 (BTSI), is a ca ble a n d solen oid oper a t ed syst em . It
down sh ift s a t va r yin g t h r ot t le open in gs depen din g on in t er con n ect s t h e a u t om a t ic t r a n sm ission floor
veh icle speed. m ou n t ed sh ift er t o t h e st eer in g colu m n ign it ion
Th e kickdown va lve pr ovides for ced down sh ift s swit ch (F ig. 3). Th e syst em locks t h e sh ift er in t o t h e
depen din g on veh icle speed. Down sh ift s occu r wh en PARK posit ion . Th e In t er lock syst em is en ga ged
t h e t h r ot t le is open ed beyon d down sh ift det en t posi- wh en ever t h e ign it ion swit ch is in t h e LOCK or
t ion . Det en t is r ea ch ed ju st befor e wide open t h r ot t le ACCE SSORY posit ion . An a ddit ion a l elect r ica lly a ct i-
posit ion . va t ed fea t u r e will pr even t sh ift in g ou t of t h e PARK
Th e lim it va lve det er m in es m a xim u m speed a t posit ion u n less t h e br a ke peda l is depr essed a t lea st
wh ich a 3-2 pa r t t h r ot t le kickdown ca n be m a de. on e-h a lf a n in ch . A m a gn et ic h oldin g device in lin e
Som e t r a n sm ission s do n ot h a ve t h e lim it va lve a n d wit h t h e pa r k/br a ke in t er lock ca ble is en er gized
m a xim u m speed for a 3-2 kickdown is a t t h e det en t wh en t h e ign it ion is in t h e RUN posit ion . Wh en t h e
posit ion . key is in t h e RUN posit ion a n d t h e br a ke peda l is
Th e sh u t t le va lve h a s t wo fu n ct ion s. F ir st is fa st depr essed, t h e sh ift er is u n locked a n d will m ove in t o
fr on t ba n d r elea se a n d sm oot h en ga gem en t du r in g a n y posit ion . Th e in t er lock syst em a lso pr even t s t h e
“lift foot ” 2-3 u psh ift s. Secon d is t o r egu la t e fr on t ign it ion swit ch fr om bein g t u r n ed t o t h e LOCK or
clu t ch r elea se a n d ba n d a pplica t ion du r in g 3-2 down - ACCE SSORY posit ion (F ig. 4) u n less t h e sh ift er is
sh ift s. fu lly locked in t o t h e PARK posit ion .
Th e fa il sa fe va lve r est r ict s feed t o t h e con ver t er
clu t ch if fr on t clu t ch pr essu r e dr ops. It per m it s
clu t ch en ga gem en t on ly in dir ect (t h ir d) gea r a n d DI AGN OSI S AN D T EST I N G
pr ovides fa st clu t ch r elea se du r in g kickdown .
AUTOMATIC TRANSMISSION DIAGNOSIS
Clutch/Band Application Au t om a t ic t r a n sm ission pr oblem s ca n be a r esu lt of
Th e fr on t /r ea r clu t ch pist on s a n d ser vo pist on s a r e poor en gin e per for m a n ce, in cor r ect flu id level, in cor-
a ct u a t ed by lin e pr essu r e. Wh en lin e pr essu r e is r ect lin ka ge or ca ble a dju st m en t , ba n d or h ydr a u lic
r em oved, t h e pist on s a r e r elea sed by spr in g t en sion . con t r ol pr essu r e a dju st m en t s, h ydr a u lic syst em m a l-
On 2-3 u psh ift s, t h e fr on t ser vo pist on is r elea sed fu n ct ion s or elect r ica l/m ech a n ica l com pon en t m a l-
by spr in g t en sion a n d h ydr a u lic pr essu r e. Th e a ccu - fu n ct ion s. Begin dia gn osis by ch eckin g t h e ea sily
m u la t or con t r ols h ydr a u lic pr essu r e on t h e a pply side a ccessible it em s su ch a s: flu id level a n d con dit ion ,
of t h e fr on t ser vo du r in g 1-2 u psh ift s a n d a t a ll lin ka ge a dju st m en t s a n d elect r ica l con n ect ion s. A
t h r ot t le open in gs. r oa d t est will det er m in e if fu r t h er dia gn osis is n eces-
sa r y.
CONVERTER CLUTCH ENGAGEMENT
Con ver t er clu t ch en ga gem en t in t h ir d gea r is con - PRELIMINARY DIAGNOSIS
t r olled by sen sor in pu t s t o t h e power t r a in con t r ol Two ba sic pr ocedu r es a r e r equ ir ed. On e pr ocedu r e
m odu le. In pu t s t h a t det er m in e clu t ch en ga gem en t for veh icles t h a t a r e dr iva ble a n d a n a lt er n a t e pr oce-
a r e: coola n t t em per a t u r e, veh icle speed a n d t h r ot t le du r e for disa bled veh icles (will n ot ba ck u p or m ove
posit ion . Th e t or qu e con ver t er clu t ch is en ga ged by for wa r d).
t h e clu t ch solen oid on t h e va lve body. Th e clu t ch will
en ga ge a t a ppr oxim a t ely 56 km /h (35 m ph ) wit h ligh t VEHICLE IS DRIVEABLE
t h r ot t le, a ft er t h e sh ift t o t h ir d gea r. (1) Ch eck for t r a n sm ission fa u lt codes u sin g DRB
sca n t ool.
CONVERTER DRAINBACK VALVE (2) Ch eck flu id level a n d con dit ion .
Th e dr a in ba ck va lve is loca t ed in t h e t r a n sm ission (3) Adju st t h r ot t le a n d gea r sh ift lin ka ge if com -
cooler ou t let (pr essu r e) lin e. Th e va lve pr even t s flu id pla in t wa s ba sed on dela yed, er r a t ic, or h a r sh sh ift s.
fr om dr a in in g fr om t h e con ver t er in t o t h e cooler a n d (4) Roa d t est a n d n ot e h ow t r a n sm ission u psh ift s,
lin es wh en t h e veh icle is sh u t down for len gt h y per i- down sh ift s, a n d en ga ges.
ods. P r odu ct ion va lves h a ve a h ose n ipple a t on e en d, (5) P er for m st a ll t est if com pla in t is ba sed on slu g-
wh ile t h e opposit e en d is t h r ea ded for a fla r e fit t in g. gish a cceler a t ion . Or, if a bn or m a l t h r ot t le open in g is
21 - 78 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

PARK/BRAKE
INTERLOCK CABLE

SHIFT-~~-.,,...
CABLE

80a13876

Fig. 3 Ignition Interlock Cable Routing


(4) Ra ise a n d su ppor t veh icle on sa fet y st a n ds,
CAM RETURN
SPRING st a r t en gin e, sh ift t r a n sm ission in t o gea r, a n d n ot e

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.

GEARSHIFT CABLE Gearshift Lever Position


p R N D 2 1
(1) Th e floor sh ift er lever a n d ga t e posit ion s DRIVE
sh ou ld be in a lign m en t wit h a ll t r a n sm ission PARK, ELEMENTS 1 2 3 1 2
NE UTRAL, a n d gea r det en t posit ion s.
(2) E n gin e st a r t s m u st be possible wit h floor sh ift FRONT
CLUTCH • •
lever in PARK or NE UTRAL ga t e posit ion s on ly.
E n gin e st a r t s m u st n ot be possible in a n y ot h er gea r FRONT
posit ion . BAND • •
(KICKDOWN)
(3) Wit h floor sh ift lever h a n dle pu sh -bu t t on n ot I
I
depr essed a n d lever in : REAR
• • • • •
CLUTCH • '
(a ) PARK posit ion —Apply for wa r d for ce on cen -
t er of h a n dle a n d r em ove pr essu r e. E n gin e st a r t s REAR
m u st be possible. BAND
• •
(LOW-REV.)
(b) PARK posit ion —Apply r ea r wa r d for ce on cen -
t er of h a n dle a n d r em ove pr essu r e. E n gin e st a r t s OVER-
m u st be possible. RUNNING
I • • •
(c) NE UTRAL posit ion —Nor m a l posit ion . E n gin e CLUTCH
i
st a r t s m u st be possible.
(d) NE UTRAL posit ion —E n gin e r u n n in g a n d J9021-33
br a kes a pplied, a pply for wa r d for ce on cen t er of
sh ift h a n dle. Tr a n sm ission sh a ll n ot be a ble t o sh ift Fig. 5 Clutch And Band Application
fr om n eu t r a l t o r ever se. ANALYZING ROAD TEST
Refer t o t h e Clu t ch a n d Ba n d Applica t ion ch a r t
THROTTLE VALVE CABLE a n d n ot e wh ich elem en t s a r e in u se in t h e va r iou s
Tr a n sm ission t h r ot t le va lve ca ble a dju st m en t is gea r r a n ges.
ext r em ely im por t a n t t o pr oper oper a t ion . Th is a dju st - Ver ify t h a t t h e r ea r clu t ch is a pplied in a ll for wa r d
m en t posit ion s t h e t h r ot t le va lve, wh ich con t r ols sh ift r a n ges (D, 2, 1). Th e t r a n sm ission over r u n n in g clu t ch
speed, qu a lit y, a n d pa r t -t h r ot t le down sh ift sen sit ivit y. is a pplied in fir st gea r (D, 2 a n d 1 r a n ges) on ly. Th e
If ca ble set t in g is t oo loose, ea r ly sh ift s a n d slip- r ea r ba n d is a pplied in 1 a n d R r a n ge on ly.
pa ge bet ween sh ift s m a y occu r. If t h e set t in g is t oo Ver ify t h a t t h e over dr ive clu t ch is a pplied on ly in
t igh t , sh ift s m a y be dela yed a n d pa r t t h r ot t le down - fou r t h gea r a n d t h e over dr ive dir ect clu t ch a n d over-
sh ift s m a y be ver y sen sit ive. Refer t o t h e Adju st - r u n n in g clu t ch a r e a pplied in a ll r a n ges except fou r t h
m en t s sect ion for t h e pr oper a dju st m en t pr ocedu r e. gea r. F or exa m ple: If slippa ge occu r s in fir st gea r in
D a n d 2 r a n ge bu t n ot in 1 r a n ge, t h e t r a n sm ission
ROAD TESTING over r u n n in g clu t ch is fa u lt y. Sim ila r ly, if slippa ge
Befor e r oa d t est in g, be su r e t h e flu id level a n d con - occu r s in a n y t wo for wa r d gea r s, t h e r ea r clu t ch is
t r ol ca ble a dju st m en t s h a ve been ch ecked a n d slippin g.
a dju st ed if n ecessa r y. Ver ify t h a t dia gn ost ic t r ou ble Applyin g t h e sa m e m et h od of a n a lysis, ver ify t h a t
codes h a ve been r esolved. t h e fr on t a n d r ea r clu t ch es a r e a pplied sim u lt a -
Obser ve en gin e per for m a n ce du r in g t h e r oa d t est . n eou sly on ly in D r a n ge t h ir d gea r. If t h e t r a n sm is-
A poor ly t u n ed en gin e will n ot a llow a ccu r a t e a n a ly- sion slips in t h ir d gea r, eit h er t h e fr on t clu t ch or t h e
sis of t r a n sm ission oper a t ion . r ea r clu t ch is slippin g.
Oper a t e t h e t r a n sm ission in a ll gea r r a n ges. Ch eck If slippa ge occu r s du r in g t h e t h ir d gea r a n d t h e
for sh ift va r ia t ion s a n d en gin e fla r e wh ich in dica t es dir ect clu t ch wer e t o fa il, t h e t r a n sm ission wou ld lose
slippa ge. Not e if sh ift s a r e h a r sh , spon gy, dela yed, bot h r ever se gea r a n d over r u n br a kin g in 2 posit ion
ea r ly, or if pa r t t h r ot t le down sh ift s a r e sen sit ive. (m a n u a l secon d gea r ). If t h e t r a n sm ission slips in
Slippa ge in dica t ed by en gin e fla r e, u su a lly m ea n s a n y ot h er for wa r d gea r s, t h e t r a n sm ission r ea r clu t ch
clu t ch , ba n d or over r u n n in g clu t ch pr oblem s. If t h e is pr oba bly slippin g.
21 - 80 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
Th is pr ocess of elim in a t ion ca n be u sed t o iden t ify GOVERNOR
a slippin g u n it a n d ch eck oper a t ion . P r oper u se of PRESSURE PORT
t h e Clu t ch a n d Ba n d Applica t ion Ch a r t is t h e key.
Alt h ou gh r oa d t est a n a lysis will h elp det er m in e t h e
slippin g u n it , t h e a ct u a l ca u se of a m a lfu n ct ion u su -
a lly ca n n ot be det er m in ed u n t il h ydr a u lic a n d a ir
pr essu r e t est s a r e per for m ed. P r a ct ica lly a n y con di-
t ion ca n be ca u sed by lea kin g h ydr a u lic cir cu it s or
st ickin g va lves.
Un less a m a lfu n ct ion is obviou s, su ch a s n o dr ive
in D r a n ge fir st gea r, do n ot disa ssem ble t h e t r a n s-
m ission . P er for m t h e h ydr a u lic a n d a ir pr essu r e t est s Fig. 7 Pressure Test Ports At Rear Of Case—2WD
t o h elp det er m in e t h e pr oba ble ca u se.

HYDRAULIC PRESSURE TEST


H ydr a u lic t est pr essu r es r a n ge fr om a low of on e GOVERNOR
psi (6.895 kP a ) gover n or pr essu r e, t o 300 psi (2068 PRESSURE
PORT
kP a ) a t t h e r ea r ser vo pr essu r e por t in r ever se. PLUG
An a ccu r a t e t a ch om et er a n d t wo t est ga u ges a r e
r equ ir ed for t h e pr essu r e t est . Test Ga u ge C-3292
h a s a 100 psi r a n ge a n d is u sed a t t h e a ccu m u la t or,
gover n or, a n d fr on t ser vo pr essu r e por t s. Test Ga u ge
C-3293-SP h a s a 300 psi r a n ge a n d is u sed a t t h e J9421-l 70
r ea r ser vo por t a n d over dr ive t est por t s wh er e pr es- Fig. 8 Pressure Test Ports At Rear Of Case—4WD
su r es a r e h igh er. In ca ses wh er e t wo t est ga u ges a r e
r equ ir ed, t h e 300 psi ga u ge ca n be u sed a t a n y of t h e
PRESSURE TEST PROCEDURE
ot h er t est por t s. Test One - Transmission In 1 Range
Th is t est ch ecks pu m p ou t pu t , pr essu r e r egu la t ion ,
Pressure Test Port Locations
a n d con dit ion of t h e r ea r clu t ch a n d ser vo cir cu it .
P r essu r e t est por t s loca t ion s a r e pr ovided a t t h e
Test Ga u ges C-3292 a n d C-3293-SP a r e r equ ir ed for
a ccu m u la t or, fr on t ser vo, a n d r ea r ser vo, gover n or
t h is t est . Ga u ge C-3292 h a s a 100 psi r a n ge. Ga u ge
pa ssa ge, a n d over dr ive clu t ch pr essu r e pa ssa ge (F ig.
C-3293-SP h a s a 300 psi r a n ge.
6), (F ig. 7) a n d (F ig. 8).
(1) Con n ect 100 psi Ga u ge C-3292 t o a ccu m u la t or
Lin e pr essu r e is ch ecked a t t h e a ccu m u la t or por t
por t .
on t h e r igh t side of t h e ca se. Th e fr on t ser vo pr essu r e
(2) Con n ect 300 psi Ga u ge C-3293-SP t o r ea r ser vo
por t is a t t h e r igh t side of t h e ca se ju st beh in d t h e
por t (F ig. 6) a n d (F ig. 7).
filler t u be open in g.
(3) Discon n ect t h r ot t le a n d gea r sh ift r ods fr om
m a n u a l a n d t h r ot t le lever s.
(4) St a r t a n d r u n en gin e a t 1000 r pm .
(5) Move sh ift lever (on m a n u a l lever sh a ft ) a ll t h e
wa y for wa r d in t o 1 r a n ge.
(6) Move t r a n sm ission t h r ot t le lever fr om fu ll for-
wa r d t o fu ll r ea r wa r d posit ion a n d n ot e pr essu r es on
bot h ga u ges.
(7) Lin e pr essu r e a t a ccu m u la t or por t sh ou ld be
54-60 psi (372-414 kP a ) wit h t h r ot t le lever for wa r d
a n d gr a du a lly in cr ea se t o 90-96 psi (621-662 kP a ) a s
lever is m oved r ea r wa r d.
Fig. 6 Pressure Test Ports At Side Of Case (8) Rea r ser vo pr essu r e sh ou ld be sa m e a s lin e
Con n ect a t a ch om et er t o t h e en gin e. P osit ion t h e pr essu r e wit h in 3 psi (20.68 kP a ).
t a ch om et er so it ca n be obser ved fr om u n der t h e
veh icle. Ra ise t h e veh icle on a h oist t h a t will a llow Test Two - Transmission In 2 Range
t h e wh eels t o r ot a t e fr eely. Th is t est ch ecks pu m p ou t pu t a n d pr essu r e r egu la -
t ion . Use 100 psi Test Ga u ge C-3292 for t h is t est .
(1) Con n ect t est ga u ge t o a ccu m u la t or pr essu r e
por t (F ig. 6) a n d (F ig. 7).
XJ TRANSMISSION AND TRANSFER CASE 21 - 81
DI AGN OSI S AN D T EST I N G (Cont inue d)
(2) St a r t a n d r u n en gin e a t 1000 r pm . (3) St a r t a n d r u n en gin e a t cu r b idle speed a n d
(3) Move sh ift lever on va lve body m a n u a l lever n ot e pr essu r e. At idle a n d wit h veh icle st opped, pr es-
sh a ft , on e det en t r ea r wa r d fr om fu ll for wa r d posit ion . su r e sh ou ld be zer o t o 1.5 psi m a xim u m . If pr essu r e
Th is is 2 r a n ge. exceeds t h is figu r e, gover n or va lve or weigh t s a r e
(4) Move t r a n sm ission t h r ot t le lever fr om fu ll for- st ickin g open .
wa r d t o fu ll r ea r wa r d posit ion a n d r ea d pr essu r e a t (4) Slowly in cr ea se en gin e speed a n d obser ve
bot h ga u ges. speedom et er a n d pr essu r e t est ga u ge. Gover n or pr es-
(5) Lin e pr essu r e sh ou ld be 54-60 psi (372-414 su r e sh ou ld in cr ea se in pr opor t ion t o veh icle speed.
kP a ) wit h t h r ot t le lever for wa r d a n d gr a du a lly (5) P r essu r e r ise sh ou ld be sm oot h a n d dr op ba ck
in cr ea se t o 90-96 psi (621-662 kP a ) a s lever is m oved t o 0 t o 1.5 psi wh en wh eels st op r ot a t in g.
r ea r wa r d. (6) Com pa r e r esu lt s of pr essu r e t est s wit h a n a lysis
ch a r t s (F ig. 9).
Test Three - Transmission In D Range
Th is t est ch ecks pr essu r e r egu la t ion a n d con dit ion TEST CONDITION INDICATION
of t h e clu t ch cir cu it s. Use bot h pr essu r e Test Ga u ges Line pressure OK during Pump and regulator valve OK
C-3292 a n d C-3293-SP for t h is t est . any one test
(1) Con n ect t est ga u ges t o a ccu m u la t or a n d fr on t
ser vo por t s (F ig. 6) a n d (F ig. 7). Use eit h er t est Line pressure OK in R Leakage in rear clutch area
but low in D, 2, 1 (servo, clutch seals, governor
ga u ge a t t h e t wo por t s.
support seal rings on park gear)
(2) St a r t a n d r u n en gin e a t 1600 r pm for t h is t est .
(3) Move select or lever t o D r a n ge. Th is is t wo Pressure OK in l, 2 but Leakage in front clutch area
det en t s r ea r wa r d fr om fu ll for wa r d posit ion . low in D3 and R (servo, clutch seals, retainer
(4) Rea d pr essu r es on bot h ga u ges a s t r a n sm ission bore, pump seal rings)
t h r ot t le lever is m oved fr om fu ll for wa r d t o fu ll r ea r- Pressure OK in 2 but low in Leakage in rear servo
wa r d posit ion . Rand l
(5) Lin e pr essu r e sh ou ld be 54-60 psi (372-414
kP a ) wit h t h r ot t le lever for wa r d a n d gr a du a lly Front servo pressure in 2 Leakage in servo (broken servo
in cr ea se a s lever is m oved r ea r wa r d. ring or cracked servo piston)
(6) F r on t ser vo is pr essu r ized on ly in D r a n ge a n d Pressure low in all positions ClogPced filter, stuck pressure
sh ou ld be sa m e a s lin e pr essu r e wit h in 3 psi (21 kP a ) r!Ju ator valve, worn or
u p t o down sh ift poin t . de ective pump

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 .

CAUTION: Stalling the converter causes a rapid


increase in fluid temperature. To avoid fluid over-
heating, hold the engine at maximum rpm for no
more than 5 seconds. If engine exceeds 2500 rpm
during the test, release the accelerator pedal imme-
diately; transmission clutch slippage is occurring.

(7) If a secon d st a ll t est is r equ ir ed, cool down


flu id befor e pr oceedin g. Sh ift in t o NE UTRAL a n d r u n
en gin e a t 1000 r pm for 20-30 secon ds t o cool flu id.

STALL TEST ANALYSIS


Stall Speed Too High
If t h e st a ll speed exceeds 2500 r pm , t r a n sm ission
clu t ch slippa ge is in dica t ed.

Stall Speed Low


Low st a ll speed wit h a pr oper ly t u n ed en gin e in di-
ca t e a t or qu e con ver t er over r u n n in g clu t ch pr oblem . Fig. 10 Air Pressure Test Passages
Th e con dit ion sh ou ld be con fir m ed by r oa d t est in g. A
st a ll speed 250-350 r pm below n or m a l in dica t es t h e Front Clutch Air Test
con ver t er over r u n n in g clu t ch is slippin g. Th e veh icle 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 lso exh ibit s poor a cceler a t ion bu t oper a t es n or m a lly a pply a ir pr essu r e t h r ou gh fr on t clu t ch a pply pa s-
on ce h igh wa y cr u ise speeds a r e r ea ch ed. Tor qu e con - sa ge. P ist on m ovem en t ca n be felt a n d a soft t h u m p
ver t er r epla cem en t will be n ecessa r y. h ea r d a s t h e clu t ch a pplies.

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.

CONVERTER HOUSING FLUID LEAK


DIAGNOSIS
Wh en dia gn osin g con ver t er h ou sin g flu id lea ks,
t wo it em s m u st be est a blish ed befor e r epa ir.
(1) Ver ify t h a t a lea k con dit ion a ct u a lly exist s.
STARTER RING GEAR
(2) Det er m in ed t h e t r u e sou r ce of t h e lea k.
Som e su spect ed con ver t er h ou sin g flu id lea ks m a y Fig. 12 Converter Leak Points—Typical
n ot be lea ks a t a ll. Th ey m a y on ly be t h e r esu lt of (2) Tigh t en fr on t ba n d a dju st in g scr ew u n t il ba n d
r esidu a l flu id in t h e con ver t er h ou sin g, or excess is t igh t a r ou n d fr on t clu t ch r et a in er. Th is pr even t s
flu id spilled du r in g fa ct or y fill or fill a ft er r epa ir. fr on t /r ea r clu t ch es fr om com in g ou t wh en oil pu m p is
Con ver t er h ou sin g lea ks h a ve sever a l pot en t ia l r em oved.
sou r ces. Th r ou gh ca r efu l obser va t ion , a lea k sou r ce (3) Rem ove oil pu m p a n d r em ove pu m p sea l.
ca n be iden t ified befor e r em ovin g t h e t r a n sm ission In spect pu m p h ou sin g dr a in ba ck a n d ven t h oles for
for r epa ir. P u m p sea l lea ks t en d t o m ove a lon g t h e obst r u ct ion s. Clea r h oles wit h solven t a n d wir e.
dr ive h u b a n d on t o t h e r ea r of t h e con ver t er. P u m p (4) In spect pu m p bu sh in g a n d con ver t er h u b. If
O-r in g or pu m p body lea ks follow t h e sa m e pa t h a s a bu sh in g is scor ed, r epla ce it . If con ver t er h u b is
sea l lea k (F ig. 11). P u m p ven t or pu m p a t t a ch in g bolt scor ed, eit h er polish it wit h cr ocu s clot h or r epla ce
lea ks a r e gen er a lly deposit ed on t h e in side of t h e con ver t er.
con ver t er h ou sin g a n d n ot on t h e con ver t er it self (5) In st a ll n ew pu m p sea l, O-r in g, a n d ga sket .
(F ig. 11). P u m p sea l or ga sket lea ks u su a lly t r a vel Repla ce oil pu m p if cr a cked, por ou s or da m a ged in
down t h e in side of t h e con ver t er h ou sin g. F r on t ba n d a n y wa y. Be su r e t o loosen t h e fr on t ba n d befor e
lever pin plu g lea ks a r e gen er a lly deposit ed on t h e in st a llin g t h e oil pu m p, da m a ge t o t h e oil pu m p sea l
h ou sin g a n d n ot on t h e con ver t er. m a y occu r if t h e ba n d is st ill t igh t en ed t o t h e fr on t
clu t ch r et a in er.
(6) Loosen kickdown lever pin a ccess plu g t h r ee
t u r n s. Apply Loct it e 592, or P er m a t ex No. 2 t o plu g
t h r ea ds a n d t igh t en plu g t o 17 N·m (150 in . lbs.)
t or qu e.
(7) Adju st fr on t ba n d.
(8) Lu br ica t e pu m p sea l a n d con ver t er h u b wit h
t r a n sm ission flu id or pet r oleu m jelly a n d in st a ll con -
ver t er.
(9) In st a ll t r a n sm ission a n d con ver t er h ou sin g
du st sh ield.
(10) Lower veh icle.
REAR
MAIN DIAGNOSIS CHARTS
SEAL Th e dia gn osis ch a r t s pr ovide a ddit ion a l r efer en ce
LEAK CONVERTER wh en dia gn osin g a t r a n sm ission fa u lt . Th e ch a r t s
Fig. 11 Converter Housing Leak Paths pr ovide gen er a l in for m a t ion on a va r iet y of t r a n sm is-
TORQUE CONVERTER LEAK POINTS sion , over dr ive u n it a n d con ver t er clu t ch fa u lt con di-
P ossible sou r ces of con ver t er lea ks a r e: t ion s.
(1) Lea ks a t t h e weld join t a r ou n d t h e ou t side Th e h ydr a u lic flow ch a r t s, in t h e Sch em a t ics a n d
dia m et er weld (F ig. 12). Dia gr a m s sect ion of t h is gr ou p, ou t lin e flu id flow a n d
(2) Lea ks a t t h e con ver t er h u b weld (F ig. 12). h ydr a u lic cir cu it r y. Cir cu it oper a t ion is pr ovided for
n eu t r a l, t h ir d, fou r t h a n d r ever se gea r r a n ges. Nor-
CONVERTER HOUSING AREA LEAK CORRECTION m a l wor kin g pr essu r es a r e a lso su pplied for ea ch of
(1) Rem ove con ver t er. t h e gea r r a n ges.
21 - 84 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
DI AGN OSI S CH ART

CONDITION POSSIBLE CAUSES CORRECTION


HARSH ENGAGEMENT 1. Fluid Level Low. 1. Add Fluid.
FROM NEUTRAL TO 2. Throttle Linkage Misadjusted. 2. Adjust linkage - setting may be too long.
DRIVE OR REVERSE
3. Mount and Driveline Bolts Loose. 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.
4. U-Joint Worn/Broken. 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect. 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect. 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Misadjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary 10. Remove, disassemble and repair
component Damaged. transmission as necessary.
11. Converter Clutch (if equipped) 11. Replace converter and flush cooler and
Faulty. line before installing new converter.
DELAYED ENGAGEMENT 1. Fluid Level Low. 1. Correct level and check for leaks.
FROM NEUTRAL TO 2. Filter Clogged. 2. Change filter.
DRIVE OR REVERSE
3. Gearshift Linkage Misadjusted. 3. Adjust linkage and repair linkage if worn
or damaged.
4. Rear Band Misadjusted. 4. Adjust band.
5. Valve Body Filter Plugged. 5. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.
6. Oil Pump Gears Worn/Damaged. 6. Remove transmission and replace oil
pump.
7. Hydraulic Pressure Incorrect. 7. Perform pressure test, remove
transmission and repair as needed.
8. Reaction Shaft Seal Rings 8. Remove transmission, remove oil pump
Worn/Broken. and replace seal rings.
9. Rear Clutch/Input Shaft, Rear 9. Remove and disassemble transmission
Clutch Seal Rings Damaged. and repair as necessary.
10. Governor Valve Stuck. 10. Remove and inspect governor
components. Replace worn or damaged
parts.
11. Regulator Valve Stuck. 11. Clean.
12. Cooler Plugged. 12. Flush transmission cooler and inspect
convertor drainback valve.
XJ TRANSMISSION AND TRANSFER CASE 21 - 85
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


NO DRIVE RANGE 1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
(REVERSE OK) restored.
2. Gearshift Linkage/Cable 2. Repair or replace linkage components.
Loose/Misadjusted.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch 5. Remove and disassemble transmission.
Broken. Replace overrunning clutch.
6. Input Shaft Seal Rings Worn/ 6. Remove and disassemble transmission.
Damaged. Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR REVERSE 1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
(VEHICLE WILL NOT restored.
MOVE) 2. Gearshift Linkage/Cable 2. Inspect, adjust and reassemble linkage
Loose/Misadjusted. as needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case 3. Perform preliminary inspection procedure
Broken. for vehicle that will not move. Refer to
procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned. 6. Check press and inspect valve body.
Replace valve body (as assembly) if any
valve or bore is damaged. Clean and
reassemble correctly if all parts are in good
condition.
7. Transmission Internal Component 7. Remove and disassemble transmission.
Damaged. Repair or replace failed components as
needed. Remove and disassemble
transmission. Repair or replace failed
components as needed.
8. Park Sprag not Releasing. 8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Check Stall Speed, Worn/Damaged/
Stuck. Inspect and replace as required.
21 - 86 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


SHIFTS DELAYED OR 1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
ERRATIC (SHIFTS ALSO low.
HARSH AT TIMES) 2. Throttle Linkage Misadjusted. 2. Adjust linkage as described in service
section.
3. Throttle Linkage Binding. 3. Check cable for binding. Check for return
to closed throttle at transmission.
4. Gearshift Linkage/Cable 4. Adjust linkage/cable as described in
Misadjusted. service section.
5. Fluid Filter Clogged. 5. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.
6. Governor Valve Sticking. 6. Inspect, clean or repair.
7. Governor Seal Rings Worn/ 7. Inspect/replace.
Damaged.
8. Clutch or Servo Failure. 8. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.
9. Front Band Misadjusted. 9. Adjust band.
10. Pump Suction Passage Leak. 10. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.
NO REVERSE (D RANGES 1. Gearshift Linkage/Cable 1. Repair or replace linkage parts as
OK) Misadjusted/Damaged. needed.
2. Park Sprag Sticking. 2. Inspect and replace as necessary.
3. Rear Band Misadjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Front Clutch Burnt. 6. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
HAS FIRST/REVERSE 1. Governor Valve, Shaft, Weights or 1. Remove governor assembly and clean or
ONLY (NO 1-2 OR 2-3 Body Damaged/Stuck. repair as necessary.
UPSHIFT) 2. Valve Body Malfunction. 2. Stuck 1-2 shift valve or governor plug.
3. Front Servo/Kickdown Band 3. Repair/replace.
Damaged/Burned.
MOVES IN 2ND OR 3RD 1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for
GEAR, ABRUPTLY stuck 1-2 valve or governor plug.
DOWNSHIFTS TO LOW 2. Governor Valve Sticking. 2. Remove, clean and inspect. Replace
faulty parts.
XJ TRANSMISSION AND TRANSFER CASE 21 - 87
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


NO LOW GEAR (MOVES 1. Governor Valve Sticking. 1. Remove governor, clean, inspect and
IN 2ND OR 3RD GEAR repair as required.
ONLY) 2. Valve Body Malfunction. 2. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.
3. Front Servo Piston Cocked in 3. Inspect servo and repair as required.
Bore.
4. Front Band Linkage Malfunction. 4. Inspect linkage and look for bind in
linkage.
NO KICKDOWN OR 1. Throttle Linkage Misadjusted. 1. Adjust linkage.
NORMAL DOWNSHIFT 2. Accelerator Pedal Travel 2. Floor mat under pedal, accelerator cable
Restricted. worn or brackets bent.
3. Governor/Valve Body Hydraulic 3. Perform hydraulic pressure tests to
Pressures Too High or Too Low Due determine cause and repair as required.
to Sticking Governor, Valve Body Correct valve body pressure adjustments as
Malfunction or Incorrect Hydraulic required.
Control Pressure Adjustments.
4. Valve Body Malfunction. 4. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
5. Valve Body Malfunction. 5. Sticking 1-2, 2-3 shift valves, or governor
plugs.
STUCK IN LOW GEAR 1. Throttle Linkage Misadjusted/ 1. Adjust linkage and repair linkage if worn
(WILL NOT UPSHIFT) Stuck. or damaged. Check for binding cable or
missing return spring.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage and repair linkage if worn
or damaged.
3. Governor/Valve Body, Governor 3. Check line and governor pressures to
Valve Stuck Closed; Loose Output determine cause. Correct as required.
Shaft Support or Governor Housing
Bolts, Leaking Seal Rings or Valve
Body Problem (i.e., Stuck 1- 2 Shift
Valve/Gov. Plug).
4. Front Band Out of Adjustment . 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches
and bands. Repair faulty component.
CREEPS IN NEUTRAL 1. Gearshift Linkage Misadjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped 2. Disassemble and repair.
Welded.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to
determine cause and repair as required.
21 - 88 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


BUZZING NOISE 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Misassembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Misassembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.
4. Pump Passages Leaking. 4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.
6.Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage.
3. Rear Band Misadjusted. 3. Adjust band.
4. Rear Band Worn. 4. Replace as required.
5. Hydraulic Pressure Too Low. 5. Perform hydraulic pressure tests to
determine cause.
6. Rear Servo Leaking. 6. Air pressure check clutch-servo operation
and repair as required.
7. Band Linkage Binding. 7. Inspect and repair as required.
SLIPS IN FORWARD 1. Fluid Level Low. 1. Add fluid and check for leaks.
DRIVE RANGES 2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.
3. Throttle Linkage Misadjusted. 3. Adjust linkage.
4. Gearshift Linkage Misadjusted. 4. Adjust linkage.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to 6. Perform hydraulic and air pressure tests
Worn Pump, Incorrect Control to determine cause.
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking
Governor, Leaking Seal Rings,
Clutch Seals Leaking, Servo Leaks,
Clogged Filter or Cooler Lines.
7. Rear Clutch Malfunction, Leaking 7. Air pressure check clutch-servo operation
Seals or Worn Plates. and repair as required.
8. Overrunning Clutch Worn, Not 8. Replace Clutch.
Holding (Slips in 1 Only).
SLIPS IN LOW GEAR "D" Overrunning Clutch Faulty. Replace overrunning clutch.
ONLY, BUT NOT IN 1
POSITION
XJ TRANSMISSION AND TRANSFER CASE 21 - 89
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


GROWLING, GRATING OR 1. Drive Plate Broken. 1. Replace.
SCRAPING NOISES 2. Torque Converter Bolts Hitting 2. Dust shield bent. Replace or repair.
Dust Shield.
3. Planetary Gear Set Broken/ 3. Check for debris in oil pan and repair as
Seized. required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/ 5. Remove, inspect and repair as required.
Binding.
6. Output Shaft Bearing or Bushing 6. Remove, inspect and repair as required.
Damaged.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands 8. Adjust bands.
Misadjusted.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed. 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Misadjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage 5. Air pressure check servo operation and
Malfunction. repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow
check. Inspect pump for excessive side
clearance. Replace pump as required.
WHINE/NOISE RELATED 1. Fluid Level Low. 1. Add fluid and check for leaks.
TO ENGINE SPEED 2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
TORQUE CONVERTER Lockup Solenoid, Relay or Wiring Test solenoid, relay and wiring for
LOCKS UP IN SECOND Shorted/Open. continuity, shorts or grounds. Replace
AND/OR THIRD GEAR solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2 OR 2-3 Lockup Solenoid Malfunction. Remove valve body and replace solenoid
SHIFTS assembly.
21 - 90 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


NO START IN PARK OR 1. Gearshift Linkage/Cable 1. Adjust linkage/cable.
NEUTRAL Misadjusted.
2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
3. Neutral Switch Faulty. 3. Refer to service section for test and
replacement procedure.
4. Neutral Switch Connect Faulty. 4. Connectors spread open. Repair.
5. Valve Body Manual Lever 5. Inspect lever assembly and replace if
Assembly Bent/Worn/Broken. damaged.
NO REVERSE (OR SLIPS 1. Direct Clutch Pack (front clutch) 1. Disassemble unit and rebuild clutch
IN REVERSE) Worn. pack.
2. Rear Band Misadjusted. 2. Adjust band.
3. Front Clutch Malfunctioned/Burnt. 3. Air pressure test clutch operation.
Remove and rebuild if necessary.
OIL LEAKS (ITEMS 1. Speedometer Adapter Leaks. 1. Replace both adapter seals.
LISTED REPRESENT 2. Fluid Lines and Fittings Loose/ 2. Tighten fittings. If leaks persist, replace
POSSIBLE LEAK POINTS Leaks/Damaged. fittings and lines if necessary.
AND SHOULD ALL BE
3. Filler Tube (where tube enters 3. Replace O-ring seal. Inspect tube for
CHECKED.
case) Leaks/Damaged. cracks in tube.
4. Pressure Port Plug Loose 4. Tighten to correct torque. Replace plug
Loose/Damaged. or reseal if leak persists.
5. Pan Gasket Leaks. 5. Tighten pan screws to 150 inch pounds.
If leaks persist, replace gasket. Do no over
tighten screws.
6. Valve Body Manual Lever Shaft 6. Replace shaft seal.
Seal Leaks/Worn.
7. Rear Bearing Access Plate Leaks. 7. Replace gasket. Tighten screws.
8. Gasket Damaged or Bolts are 8. Replace bolts or gasket or tighten both.
Loose.
9. Adapter/Extension Gasket 9. Replace gasket.
Damaged Leaks/Damaged.
10. Neutral Switch Leaks/Damaged. 10. Replace switch and gasket.
11. Converter Housing Area Leaks. 11. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.
12. Pump Seal Leaks/Worn/ 12. Replace seal.
Damaged.
13. Torque Converter Weld 13. Replace converter.
Leak/Cracked Hub.
14. Case Porosity Leaks. 14. Replace case.
XJ TRANSMISSION AND TRANSFER CASE 21 - 91

SERV I CE PROCEDU RES REMOVAL


(1) H oist a n d su ppor t veh icle on sa fet y st a n ds.
FLUID LEVEL CHECK (2) P la ce a la r ge dia m et er sh a llow dr a in pa n
Tr a n sm ission flu id level sh ou ld be ch ecked m on t h ly ben ea t h t h e t r a n sm ission pa n .
u n der n or m a l oper a t ion . If t h e veh icle is u sed for (3) Rem ove bolt s h oldin g fr on t a n d sides of pa n t o
t r a iler t owin g or sim ila r h ea vy loa d h a u lin g, ch eck t r a n sm ission (F ig. 14).
flu id level a n d con dit ion weekly. F lu id level is (4) Loosen bolt s h oldin g r ea r of pa n t o t r a n sm is-
ch ecked wit h t h e en gin e r u n n in g a t cu r b idle speed, sion .
t h e t r a n sm ission in NE UTRAL a n d t h e t r a n sm ission (5) Slowly sepa r a t e fr on t of pa n a wa y fr om t r a n s-
flu id a t n or m a l oper a t in g t em per a t u r e. m ission a llowin g t h e flu id t o dr a in in t o dr a in pa n .
(6) H old u p pa n a n d r em ove r em a in in g bolt s h old-
FLUID LEVEL CHECK PROCEDURE in g pa n t o t r a n sm ission .
(1) Tr a n sm ission flu id m u st be a t n or m a l oper a t - (7) Wh ile h oldin g pa n level, lower pa n a wa y fr om
in g t em per a t u r e for a ccu r a t e flu id level ch eck. Dr ive t r a n sm ission .
veh icle if n ecessa r y t o br in g flu id t em per a t u r e u p t o (8) P ou r r em a in in g flu id in pa n in t o dr a in pa n .
n or m a l h ot oper a t in g t em per a t u r e of 82°C (180°F ). (9) Rem ove scr ews h oldin g filt er t o va lve body
(2) P osit ion veh icle on level su r fa ce. (F ig. 15).
(3) St a r t a n d r u n en gin e a t cu r b idle speed. (10) Sepa r a t e filt er fr om va lve body a n d pou r flu id
(4) Apply pa r kin g br a kes. in filt er in t o dr a in pa n .
(5) Sh ift t r a n sm ission m om en t a r ily in t o a ll gea r (11) Dispose u sed t r a n s flu id a n d filt er pr oper ly.
r a n ges. Th en sh ift t r a n sm ission ba ck t o Neu t r a l.
(6) Clea n t op of filler t u be a n d dipst ick t o keep GASKET
dir t fr om en t er in g t u be.
(7) Rem ove dipst ick (F ig. 13) a n d ch eck flu id level
a s follows:
(a ) Cor r ect a ccept a ble level is in cr ossh a t ch a r ea .
(b) Cor r ect m a xim u m level is t o MAX a r r ow
m a r k.
(c) In cor r ect level is a t or below MIN lin e.
(d) If flu id is low, a dd on ly en ou gh Mopa r ! ATF
P lu s 3 t o r est or e cor r ect level. Do n ot over fill.

CAUTION: Do not overfill the transmission. Overfill-


ing may cause leakage out the pump vent which
can be mistaken for a pump seal leak. Overfilling
will also cause fluid aeration and foaming as the PAN aob1?oe?

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

Fig. 13 Dipstick Fluid Level Marks—Typical


FLUID AND FILTER REPLACEMENT
Refer t o t h e Ma in t en a n ce Sch edu les in Gr ou p 0,
Lu br ica t ion a n d Ma in t en a n ce, for pr oper ser vice 80b170e8
in t er va ls. Th e ser vice flu id fill a ft er a filt er ch a n ge is
a ppr oxim a t ely 3.8 lit er s (4.0 qu a r t s). Fig. 15 Transmission Filter
21 - 92 TRANSMISSION AND TRANSFER CASE XJ
SERV I CE PROCEDU RES (Cont inue d)
INSPECTION is equ a l on bot h sides of t h e dipst ick. If on e side is
In spect bot t om of pa n a n d m a gn et for excessive n ot ica bly h igh er t h a n t h e ot h er, t h e dipst ick h a s
a m ou n t s of m et a l or fiber con t a m in a t ion . A ligh t picked u p som e oil fr om t h e dipst ick t u be. Allow t h e
coa t in g of clu t ch or ba n d m a t er ia l on t h e bot t om of oil t o dr a in down t h e dipst ick t u be a n d r e-ch eck.
t h e pa n does n ot in dica t e a pr oblem u n less a ccom pa - (7) Dr ive veh icle u n t il t r a n sm ission flu id is a t n or-
n ied by slippin g con dit ion or sh ift la g. If flu id a n d m a l oper a t in g t em per a t u r e.
pa n a r e con t a m in a t ed wit h excessive a m ou n t s or (8) Wit h t h e en gin e r u n n in g a t cu r b idle speed, t h e
debr is, r efer t o t h e dia gn osis sect ion of t h is gr ou p. gea r select or in NE UTRAL, a n d t h e pa r kin g br a ke
Ch eck t h e a dju st m en t of t h e fr on t a n d r ea r ba n ds, a pplied, ch eck t h e t r a n sm ission flu id level.
a dju st if n ecessa r y. Refer t o Adju st m en t sect ion of
t h is gr ou p for pr oper pr ocedu r e. CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
CLEANING
(9) Add flu id t o br in g level u p t o MAX a r r ow
(1) Usin g a su it a ble solven t , clea n pa n a n d m a g-
m a r k.
n et .
Wh en flu id level is cor r ect , sh u t en gin e off, r elea se
(2) Usin g a su it a ble ga sket scr a per, clea n ga sket
pa r k br a ke, r em ove fu n n el, a n d in st a ll dipst ick in fill
m a t er ia l fr om ga sket su r fa ce of t r a n sm ission ca se
t u be.
a n d t h e ga sket fla n ge a r ou n d t h e pa n .

INSTALLATION CONVERTER DRAINBACK CHECK VALVE


(1) P la ce r epla cem en t filt er in posit ion on va lve SERVICE
body. Th e con ver t er dr a in ba ck ch eck va lve is loca t ed in
(2) In st a ll scr ews t o h old filt er t o va lve body (F ig. t h e cooler ou t let (pr essu r e) lin e n ea r t h e r a dia t or
15). Tigh t en scr ews t o 4 N·m (35 in . lbs.) t or qu e. t a n k. Th e va lve pr even t s flu id dr a in ba ck wh en t h e
(3) P la ce n ew ga sket in posit ion on pa n . a n d veh icle is pa r ked for len gt h y per iods. Th e va lve ch eck
in st a ll pa n on t r a n sm ission . ba ll is spr in g loa ded a n d h a s a n open in g pr essu r e of
(4) P la ce pa n in posit ion on t r a n sm ission . a ppr oxim a t ely 2 psi.
(5) In st a ll scr ews t o h old pa n t o t r a n sm ission (F ig. Th e va lve is ser viced a s a n a ssem bly; it is n ot
14). Tigh t en bolt s t o 17 N·m (150 in . lbs.) t or qu e. r epa ir a ble. Do n ot clea n t h e va lve if r est r ict ed, or
(6) Lower veh icle a n d fill t r a n sm ission wit h con t a m in a t ed by slu dge, or debr is. If t h e va lve fa ils,
Mopa r ! ATF P lu s 3, t ype 7176 flu id. or if a t r a n sm ission m a lfu n ct ion occu r s t h a t gen er-
a t es sign ifica n t a m ou n t s of slu dge a n d/or clu t ch pa r-
TRANSMISSION FILL PROCEDURE t icles a n d m et a l sh a vin gs, t h e va lve m u st be
To a void over fillin g t r a n sm ission a ft er a flu id r epla ced.
ch a n ge or over h a u l, per for m t h e followin g pr ocedu r e: Th e va lve m u st be r em oved wh en ever t h e cooler
(1) Rem ove dipst ick a n d in ser t clea n fu n n el in a n d lin es a r e r ever se flu sh ed. Th e va lve ca n be flow
t r a n sm ission fill t u be. t est ed wh en n ecessa r y. Th e pr ocedu r e is exa ct ly t h e
(2) Add followin g in it ia l qu a n t it y of Mopa r ! ATF sa m e a s for flow t est in g a cooler.
P lu s 3 t o t r a n sm ission : If t h e va lve is r est r ict ed, in st a lled ba ckwa r ds, or in
(a ) If on ly flu id a n d filt er wer e ch a n ged, a dd 3 t h e wr on g lin e, it will ca u se a n over h ea t in g con dit ion
p in ts (1-1/2 qu a rts ) of ATF P lu s 3 t o t r a n sm is- a n d possible t r a n sm ission fa ilu r e.
sion .
(b) If t r a n sm ission wa s com plet ely over h a u led, CAUTION: The drainback valve is a one-way flow
t or qu e con ver t er wa s r epla ced or dr a in ed, a n d device. It must be properly oriented in terms of flow
cooler wa s flu sh ed, a dd 12 p in ts (6 qu a rts ) of ATF direction for the cooler to function properly. The
P lu s 3 t o t r a n sm ission . valve must be installed in the pressure line. Other-
(3) Apply pa r kin g br a kes. wise flow will be blocked and would cause an over-
(4) St a r t a n d r u n en gin e a t n or m a l cu r b idle heating condition and eventual transmission failure.
speed.
(5) Apply ser vice br a kes, sh ift t r a n sm ission OIL PUMP VOLUME CHECK
t h r ou gh a ll gea r r a n ges t h en ba ck t o NE UTRAL, set Aft er t h e n ew or r epa ir ed t r a n sm ission h a s been
pa r kin g br a ke, a n d lea ve en gin e r u n n in g a t cu r b idle in st a lled, fill t o t h e pr oper level wit h Mopa r ! ATF
speed. P LUS 3 (Type 7176) a u t om a t ic t r a n sm ission flu id.
(6) Rem ove fu n n el, in ser t dipst ick a n d ch eck flu id Th e volu m e sh ou ld be ch ecked u sin g t h e followin g
level. If level is low, a d d flu id to brin g le v e l to pr ocedu r e:
MIN m a rk o n d ip s tic k . Ch eck t o see if t h e oil level
XJ TRANSMISSION AND TRANSFER CASE 21 - 93
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 .

(2) Ru n t h e en gin e a t c u rb id le s p e e d , wit h t h e NOTE: When flushing transmission cooler and


sh ift select or in n eu t r a l. lines, ALWAYS reverse flush.
(3) If flu id flow is in t er m it t en t or it t a kes m or e
t h a n 20 secon ds t o collect on e qu a r t of ATF P LUS 3,
discon n ect t h e To Co o le r lin e a t t h e t r a n sa xle. NOTE: The converter drainback valve must be
(4) Refill t h e t r a n sa xle t o pr oper level a n d r ech eck removed and an appropriate replacement hose
pu m p volu m e. installed to bridge the space between the transmis-
(5) If flow is fou n d t o be wit h in a ccept a ble lim it s, sion cooler line and the cooler fitting. Failure to
r epla ce t h e cooler. Th en fill t r a n sm ission t o t h e remove the drainback valve will preventreverse
pr oper level, u sin g Mopa r ! ATF P LUS 3 (Type 7176) flushing the system.
a u t om a t ic t r a n sm ission flu id.
(6) If flu id flow is st ill fou n d t o be in a dequ a t e, (5) Con n ect t h e BLUE pr essu r e lin e t o t h e OUT-
ch eck t h e lin e pr essu r e u sin g t h e Tr a n sa xle H ydr a u - LE T (F r om ) cooler lin e.
lic P r essu r e Test pr ocedu r e. (6) Con n ect t h e CLE AR r et u r n lin e t o t h e INLE T
(To) cooler lin e.
FLUSHING COOLERS AND TUBES (7) Tu r n pu m p ON for t wo t o t h r ee m in u t es t o
flu sh cooler (s) a n d lin es. Mon it or pr essu r e r ea din gs
Wh en a t r a n sm ission fa ilu r e h a s con t a m in a t ed t h e
a n d clea r r et u r n lin es. P r essu r e r ea din gs sh ou ld st a -
flu id, t h e oil cooler (s) m u st be flu sh ed. Th e t or qu e
bilize below 20 psi. for veh icles equ ipped wit h a sin -
con ver t er m u st a lso be r epla ced. Th is will in su r e t h a t
gle cooler a n d 30 psi. for veh icles equ ipped wit h du a l
m et a l pa r t icles or slu dged oil a r e n ot la t er t r a n s-
cooler s. If flow is in t er m it t en t or exceeds t h ese pr es-
fer r ed ba ck in t o t h e r econ dit ion ed (or r epla ced) t r a n s-
su r es, r epla ce cooler.
m ission .
(8) Tu r n pu m p OF F.
Th e on ly r ecom m en ded pr ocedu r e for flu sh in g cool-
(9) Discon n ect CLE AR su ct ion lin e fr om r eser voir
er s a n d lin es is t o u se Tool 6906 Cooler F lu sh er.
a t cover pla t e. Discon n ect CLE AR r et u r n lin e a t
WARNING: WEAR PROTECTIVE EYEWEAR THAT cover pla t e, a n d pla ce it in a dr a in pa n .
MEETS THE REQUIREMENTS OF OSHA AND ANSI (10) Tu r n pu m p ON for 30 secon ds t o pu r ge flu sh -
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB- in g solu t ion fr om cooler a n d lin es. Tu r n pu m p OF F.
BER GLOVES. (11) P la ce CLE AR su ct ion lin e in t o a on e qu a r t
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, con t a in er of Mopa r ! ATF P lu s 3, t ype 7176 a u t om a t ic
AND OTHER IGNITION SOURCES AWAY FROM THE t r a n sm ission flu id.
AREA TO PREVENT THE IGNITION OF COMBUSTI- (12) Tu r n pu m p ON u n t il a ll t r a n sm ission flu id is
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE r em oved fr om t h e on e qu a r t con t a in er a n d lin es. Th is
EXTINGUISHER IN THE AREA WHERE THE pu r ges a n y r esidu a l clea n in g solven t fr om t h e t r a n s-
FLUSHER WILL BE USED. m ission cooler a n d lin es. Tu r n pu m p OF F.
KEEP THE AREA WELL VENTILATED. (13) Discon n ect a lliga t or clips fr om ba t t er y. Recon -
DO NOT LET FLUSHING SOLVENT COME IN CON- n ect flu sh er lin es t o cover pla t e, a n d r em ove flu sh in g
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM- a da pt er s fr om cooler lin es.
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED ALUMINUM THREAD REPAIR
CLOTHING AND WASH AFFECTED SKIN WITH Da m a ged or wor n t h r ea ds in t h e a lu m in u m t r a n s-
SOAP AND WATER. SEEK MEDICAL ATTENTION. m ission ca se a n d va lve body ca n be r epa ir ed by t h e
u se of H eli-Coils, or equ iva len t . Th is r epa ir con sist s
of dr illin g ou t t h e wor n -ou t da m a ged t h r ea ds. Th en
COOLER FLUSH USING TOOL 6906 t a p t h e h ole wit h a specia l H eli-Coil t a p, or equ iva -
(1) Rem ove cover pla t e filler plu g on Tool 6906. len t , a n d in st a llin g a H eli-Coil in ser t , or equ iva len t ,
F ill r eser voir 1/2 t o 3/4 fu ll of fr esh flu sh in g solu t ion . in t o t h e h ole. Th is br in gs t h e h ole ba ck t o it s or igin a l
F lu sh in g solven t s a r e pet r oleu m ba sed solu t ion s gen - t h r ea d size.
er a lly u sed t o clea n a u t om a t ic t r a n sm ission com po-
21 - 94 TRANSMISSION AND TRANSFER CASE XJ
SERV I CE PROCEDU RES (Cont inue d)
H eli-Coil, or equ iva len t , t ools a n d in ser t s a r e
r ea dily a va ila ble fr om m ost a u t om ot ive pa r t s su ppli-
er s.

REM OVAL AN D I N STALLAT I ON


TRANSMISSION
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter drive plate, pump TRANSMISSION
BELLHOUSING
bushing, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal.

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)

B 33 N·m (24 ft-lbs)

C 57 N·m (42 ft-lbs)


D 16 N·m (138 in-lbs)
E 49 N·m (36 ft-lbs)

D----
FILL
TUBE
0-RING
TORQUE
SHAFT
BRACKET

J9121-374

Fig. 19 Transmission Attachment


(32) Adju st gea r sh ift lin ka ge a n d t h r ot t le va lve (3) P u ll t h e t or qu e con ver t er for wa r d u n t il t h e cen -
ca ble if n ecessa r y. t er h u b clea r s t h e oil pu m p sea l.
(33) Align a n d con n ect pr opeller sh a ft (s). (4) Sepa r a t e t h e t or qu e con ver t er fr om t h e t r a n s-
(34) In st a ll skid pla t e, r ea r cu sh ion a n d br a cket , if m ission .
r em oved.
(35) F ill t r a n sfer ca se t o bot t om edge of fill plu g INSTALLATION
h ole. Ch eck con ver t er h u b a n d dr ive n ot ch es for sh a r p
(36) Lower veh icle a n d fill t r a n sm ission t o cor r ect edges, bu r r s, scr a t ch es, or n icks. P olish t h e h u b a n d
level wit h Mopa r ! ATF P lu s 3, t ype 7176 flu id. n ot ch es wit h 320/400 gr it pa per or cr ocu s clot h if n ec-
essa r y. Th e h u b m u st be sm oot h t o a void da m a gin g
TORQUE CONVERTER t h e pu m p sea l a t in st a lla t ion .
(1) Lu br ica t e con ver t er h u b a n d oil pu m p sea l lip
REMOVAL wit h t r a n sm ission flu id.
(1) Rem ove t r a n sm ission a n d t or qu e con ver t er (2) P la ce t or qu e con ver t er in posit ion on t r a n sm is-
fr om veh icle. sion .
(2) P la ce a su it a ble dr a in pa n u n der t h e con ver t er
h ou sin g en d of t h e t r a n sm ission . CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
CAUTION: Verify that transmission is secure on the transmission.
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con- (3) Align t or qu e con ver t er t o oil pu m p sea l open -
verter is removed creating an unstable condition. in g.
The torque converter is a heavy unit. Use caution (4) In ser t t or qu e con ver t er h u b in t o oil pu m p.
when separating the torque converter from the (5) Wh ile pu sh in g t or qu e con ver t er in wa r d, r ot a t e
transmission. con ver t er u n t il con ver t er is fu lly sea t ed in t h e oil
pu m p gea r s.
XJ TRANSMISSION AND TRANSFER CASE 21 - 97
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(6) Ch eck con ver t er sea t in g wit h a sca le a n d SPECIAL
st r a igh t edge (F ig. 20). Su r fa ce of con ver t er lu gs TOOL
sh ou ld be 1/2 in . t o r ea r of st r a igh t edge wh en con -
ver t er is fu lly sea t ed.
C-39\
(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.

Fig. 21 Removing Extension Housing Yoke Seal

SPECIAL
SPECIAL TOOL TOOL
C-4171 C-3995-A

80a983a7

Fig. 20 Checking Torque Converter Seating


Fig. 22 Installing Extension Housing Yoke Seal
YOKE SEAL REPLACEMENT
REMOVAL
(1) Ra ise veh icle.
(2) Ma r k pr opeller sh a ft a n d a xle yoke for a lign -
m en t r efer en ce.
(3) Discon n ect a n d r em ove pr opeller sh a ft .
(4) Rem ove old sea l wit h Sea l Rem over C-3985-B
(F ig. 21) fr om ext en sion h ou sin g.

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

Fig. 26 Speedometer Pinion Adapter Components


(7) Not e in dex n u m ber s on a da pt er body (F ig. 27). PARK/NEUTRAL POSITION SWITCH
Th ese n u m ber s will cor r espon d t o n u m ber of t eet h on
pin ion . REMOVAL
(8) In st a ll speedom et er a ssem bly in h ou sin g. (1) Ra ise veh icle a n d posit ion dr a in pa n u n der
(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 swit ch .
a r e a t 6 o’clock posit ion . Be su r e r a n ge in dex n u m - (2) Discon n ect swit ch wir es.
ber s cor r espon d t o n u m ber of t eet h on pin ion gea r. (3) Rem ove swit ch fr om ca se.
(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 INSTALLATION
in . lbs.) t or qu e. (1) Move sh ift lever t o P a r k a n d Neu t r a l posit ion s.
(11) Con n ect wir es t o veh icle speed sen sor. Ver ify t h a t swit ch oper a t in g lever fin ger s a r e cen -
(12) Lower veh icle a n d t op off t r a n sm ission flu id t er ed in swit ch open in g in ca se (F ig. 28).
level, if n ecessa r y.

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.

INSTALLATION Fig. 29 Brake/Park Interlock Cable


(1) Rou t e ca ble t h r ou gh h ole in da sh pa n el. F u lly
sea t ca ble gr om m et in t o da sh pa n el. (9) Discon n ect a n d r em ove t h e ca ble fr om t h e sh ift
(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 - br a cket .
t r ol lever in “P a r k” det en t (r ea r m ost ) posit ion a n d
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. INSTALLATION
(3) Con n ect sh ift ca ble t o sh ift er m ech a n ism by (1) Rou t e r epla cem en t ca ble beh in d in st r u m en t
sn a ppin g ca ble r et a in in g ea r s in t o sh ift er br a cket pa n el a n d u n der floor con sole a r ea t o sh ift m ech a -
a n d pr ess ca ble en d fit t in g on t o lever ba ll st u d. n ism (F ig. 30).
(4) P la ce t h e floor sh ift er lever in pa r k posit ion . (2) In ser t ca ble en d in t o open in g in st eer in g col-
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 u m n h u b u n der ign it ion lock. P u sh ca ble in wa r d
t h e a dju st m en t ga u ge clip. u n t il lock t a b en ga ges.
(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 (3) Con n ect t h e ca ble en d eyelet on t o sh ift er
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 bellcr a n k pin .
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. (4) P la ce gea r select or in PARK.
(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 . VALVE BODY
(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) Ra ise veh icle.
st eer in g colu m n (F ig. 29). (2) Rem ove oil pa n a n d dr a in flu id.
(6) P u ll ca ble en d fr om st eer in g colu m n . (3) Loosen cla m p bolt s a n d r em ove t h r ot t le a n d
(7) Rem ove t h e floor con sole a n d r ela t ed t r im . m a n u a l va lve lever s fr om m a n u a l lever sh a ft .
Refer t o Gr ou p 23, Body, for pr oper pr ocedu r e. (4) Rem ove pa r k/n eu t r a l posit ion swit ch .
(5) Rem ove filt er fr om va lve body.
XJ TRANSMISSION AND TRANSFER CASE 21 - 101
REM OVAL AN D I N STALLAT I ON (Cont inue d)

PARK/BRAKE
INTERLOCK CABLE

SHIFT-~~-.,,...
CABLE

80a13876

Fig. 30 Cable and Shifter


(6) Depr ess r et a in in g clip a n d pu ll solen oid wir e (11) Lower va lve body, r ot a t e it a wa y fr om ca se,
fr om ca se con n ect or (F ig. 31). pu ll pa r k lock r od ou t of spr a g, a n d r em ove va lve
body (F ig. 33).

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.

Fig. 33 Valve Body


(4) Use scr ewdr iver t o pu sh pa r k spr a g in t o
en ga gem en t wit h pa r k gea r. Th is m a kes clea r a n ce for
kn ob on lock r od t o m ove pa st spr a g wh en va lve body
is in st a lled. Rot a t e ou t pu t sh a ft t o ver ify spr a g
en ga gem en t . Fig. 34 Output Shaft Rear Bearing—Typical
(5) P osit ion a ccu m u la t or spr in g bet ween a ccu m u la -
t or pist on a n d va lve body. GOVERNOR AND PARK GEAR
(6) P osit ion va lve body on t r a n sm ission a n d wor k
kn ob on pa r k lock r od pa st spr a g. Be su r e a ccu m u la - REMOVAL
t or pist on a n d spr in g r em a in in posit ion . (1) H oist a n d su ppor t veh icle on sa fet y st a n ds.
(7) H old va lve body in posit ion a n d in st a ll va lve (2) Ma r k pr opeller sh a ft a n d a xle yoke for a ssem -
body scr ews fin ger t igh t . bly r efer en ce. Th en discon n ect a n d r em ove sh a ft .
(8) In st a ll pa r k/n eu t r a l posit ion swit ch . (3) Discon n ect pa r kin g br a ke ca ble a t equ a lizer
(9) Tigh t en va lve body scr ews a lt er n a t ely a n d a n d discon n ect exh a u st com pon en t s a s n ecessa r y.
even ly t o 11 N·m (100 in . lbs.) t or qu e. (4) Su ppor t t r a n sm ission on a su it a ble lift in g
(10) In st a ll n ew flu id filt er on va lve body. In st a ll device.
a n d t igh t en filt er scr ews t o 4 N·m (35 in . lbs.) t or qu e. (5) Rem ove skid pla t e a n d r ea r t r a n sm ission
(11) Con n ect solen oid wir e t o ca se con n ect or. m ou n t .
(12) In st a ll m a n u a l a n d t h r ot t le lever s on t h r ot t le (6) Rem ove ext en sion h ou sin g.
lever sh a ft . Tigh t en lever cla m p scr ews a n d ch eck for (7) Loosen bu t do n ot r em ove bolt s t h a t h old gov-
fr ee oper a t ion . Sh a ft a n d lever s m u st oper a t e fr eely er n or body t o pa r k gea r.
wit h ou t a n y bin d. (8) Rot a t e t r a n sm ission ou t pu t sh a ft u n t il gover-
(13) In st a ll oil pa n a n d n ew ga sket . Tigh t en pa n n or weigh t a ssem bly is a ccessible.
bolt s t o 17 N·m (150 in . lbs.) t or qu e. In st a ll ga sket (9) Rem ove E -clip a t en d of gover n or va lve sh a ft
dr y; do n ot u se sea ler. (F ig. 35).
(14) Con n ect pa r k/n eu t r a l posit ion swit ch a n d con - (10) Rem ove gover n or va lve a n d sh a ft fr om gover-
ver t er clu t ch solen oid wir es. n or body (F ig. 35).
(15) In st a ll speedom et er pin ion gea r, a da pt er a n d (11) Rem ove sn a p r in gs a n d spa cer t h a t r et a in
speed sen sor. gover n or body a n d pa r k gea r a ssem bly on ou t pu t
(16) Lower veh icle. sh a ft (F ig. 36).
(17) F ill t r a n sm ission wit h Mopa r ! ATF P lu s 3, (12) Rem ove bolt s h oldin g gover n or body t o pa r k
Type 7176 flu id. gea r (F ig. 37).
(18) Adju st gea r sh ift a n d t h r ot t le ca ble if n eces- (13) Sepa r a t e gover n or fr om pa r k gea r.
sa r y. (14) P u ll pa r k gea r fr om r ea r su ppor t .

OUTPUT SHAFT REAR BEARING INSTALLATION


(1) In st a ll pa r k gea r in t o r ea r su ppor t so cr own on
REMOVAL cu r ved boss is in lin e wit h h ole t h r ou gh ou t pu t sh a ft .
(1) Rem ove ext en sion h ou sin g. (2) In st a ll gover n or filt er in pa r k gea r.
XJ TRANSMISSION AND TRANSFER CASE 21 - 103
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(5) In st a ll gover n or body-pa r k gea r sn a p r in gs a n d
wa sh er on ou t pu t sh a ft a s follows:
(a ) In st a ll t h in sn a p r in g fir st . Th en in st a ll
t h r u st wa sh er secon d, a n d t h ick sn a p r in g la st
(F ig. 36).
(b) Ver ify cor r ect posit ion of sn a p r in gs. B e s u re
fla t s id e o f e a c h s n a p rin g is to w a rd g o v e rn o r
bo d y.
(6) In ser t gover n or va lve a n d sh a ft t h r ou gh gover-
n or a n d in st a ll E -clip (F ig. 35).
(7) In st a ll ext en sion h ou sin g a n d ga sket on t r a n s-
m ission . Tigh t en h ou sin g bolt s t o 32 N·m (24 ft . lbs.).
(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.
GOVERNOR (9) In st a ll speed sen sor a n d speedom et er com po-
VALVE 80a47384
n en t s a n d con n ect speed sen sor wir es.
(10) Con n ect exh a u st com pon en t s a n d br a ke ca ble,
Fig. 35 Governor Valve if r em oved.
(11) In st a ll pr opeller sh a ft .
(12) Rem ove su ppor t s a n d lower veh icle.
(13) Ch eck t r a n sm ission flu id level. Add flu id if
n ecessa r y.

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

Fig. 41 Inner Weight Snap Ring


ASSEMBLY
PARK
GEAR CAUTION: Exercise care when installing the rings.
They are easily broken if overspread or twisted dur-
ing installation.

If it wa s n ecessa r y t o r em ove t h e pa r k gea r,


in spect t h e sea l r in gs a n d bor e in r ea r su ppor t .
In st a ll n ew sea l r in gs on pa r k gea r h u b on ly if or ig-
in a l r in gs a r e da m a ged, or wor n . In st a ll r in g wit h
in t er lock en ds fir st a n d r in g wit h pla in en ds la st .
Slip ea ch r in g on h u b a n d sea t t h em in gr ooves. Ver-
J9521-31 ify t h a t r ea r r in g en ds a r e secu r ely in t er locked befor e
pr oceedin g. If t h e bor e in r ea r su ppor t is da m a ged,
Fig. 39 Governor Filter r epla ce t h e r ea r su ppor t .
XJ TRANSMISSION AND TRANSFER CASE 21 - 105
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(2) Rem ove a dju st in g scr ew br a cket , lin e pr essu r e
a dju st in g scr ew (F ig. 44).
(3) Rem ove 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,
a n d t h r ot t le va lve fr om va lve body (F ig. 44).
(4) Secu r e det en t ba ll a n d spr in g in h ou sin g wit h
Ret a in er Tool 6583 (F ig. 45).
(5) Rem ove m a n u a l sh a ft E -clip, wa sh er, a n d sea l
(F ig. 46).
(6) P u ll m a n u a l sh a ft a n d pa r k r od a ssem bly
- - - INNER u pwa r d ou t of va lve body a n d off t h r ot t le lever
WEIGHT
(F ig. 46).
(7) Rem ove m a n u a l va lve fr om va lve body
(F ig. 47).
80a47367
(8) Rem ove Ret a in er Tool 6583. Th en r em ove a n d
r et a in det en t ba ll a n d spr in g (F ig. 46).
Fig. 42 Intermediate and Inner Governor Weights (9) Rem ove t h r ot t le lever (F ig. 46).
(1) Lu br ica t e gover n or com pon en t s wit h Mopa r !
ATF P lu s 3, Type 7176 t r a n sm ission flu id befor e
a ssem bly.
(2) Clea n a n d in spect gover n or weigh t s a n d bor es
for scor in g or wea r. Repla ce t h e gover n or body a n d
weigh t s if da m a ged. Refer t o Clea n in g a n d In spect ion
sect ion of t h is gr ou p for pr oper pr ocedu r e.
(3) In ser t spr in g in t o in t er m edia t e weigh t .
(4) In ser t in n er weigh t in t o in t er m edia t e weigh t
a n d in st a ll sn a p-r in g (F ig. 42). Ver ify sn a p-r in g is
fu lly sea t ed in gr oove in in t er m edia t e weigh t (F ig.
41).
(5) Assem ble gover n or weigh t s in t o gover n or body
(F ig. 40).
(6) In st a ll wa sh er a n d sn a p r in g t o h old weigh t s in
gover n or body.
(7) In st a ll gover n or body in t r a n sm ission . Fig. 43 Valve Body Assembly
PRESSURE
VALVE BODY REGULATOR
VALVE
DISASSEMBLY ADJUSTER LINE
P osit ion t h e va lve body on a clea n wor k su r fa ce t o BRACKET PRESSURE
a void con t a m in a t ion .
ADJUSTER
CAUTION: Do not clamp any part of the valve body
assembly (Fig. 43) in a vise. This practice will dis-
tort the valve body and transfer plate resulting in
valve bind. Slide valves and plugs out carefully. Do
not use force at any time. The valves and valve
body will be damaged if force is used. Also tag or
mark the valve body springs for reference as they
are removed. Do not allow them to become inter- THROTTLE
mixed. PRESSURE ADJUSTER 80a3f1ea

(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

Fig. 48 Park Rod

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

Fig. 50 Clutch Module And Connecting Tube

T~~~~~~~ODULE
NVERTER
COVER
PLATE

Fig. 53 Transfer And Separator Plates

REAR TRANSFER
SERVO PLATE
CHECK
BALL
MODULE CONNECTING
TUBE 80a410c0

Fig. 51 Converter Clutch and Fail Safe Valves

REAR
CLUTCH
CHECK
BALL
B0a47396

Fig. 54 Rear Servo and Rear Clutch Check Balls

SHUTTLE
VALVE
END PLATE
i
VALVE I
BODY
J
'
1
el,§

B0a47394

Fig. 52 Valve Body Transfer Plate Screws B0a47397

(21) Rem ove sh u t t le va lve en d pla t e (F ig. 55).


Fig. 55 Shuttle Valve End Plate
(23) Rem ove gover n or plu g en d pla t e (F ig. 57).
21 - 108 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(28) Rem ove 2-3 sh ift va lve a n d spr in g fr om va lve
body (F ig. 57).
(29) Rem ove 1-2 sh ift va lve a n d spr in g fr om va lve
body (F ig. 57).
(30) Rem ove t h r ot t le pr essu r e plu g fr om kickdown
lim it va lve body (F ig. 57).
(31) Rem ove r et a in er fr om en d of kickdown lim it
va lve body (F ig. 57).
(32) Rem ove kickdown lim it va lve a n d spr in g fr om
kickdown lim it va lve body (F ig. 57).
(33) Rem ove r egu la t or va lve en d pla t e fr om va lve
body (F ig. 57).
(34) Rem ove r egu la t or va lve lin e pr essu r e plu g,
pr essu r e plu g sleeve, r egu la t or va lve t h r ot t le pr es-
su r e plu g a n d spr in g (F ig. 57).

Fig. 56 Shuttle Valve E-Clip And Secondary Spring ASSEMBLY


Clea n a n d in spect a ll va lve body com pon en t s for
(24) Rem ove 1-2 a n d 2-3 sh ift va lve gover n or plu gs da m a ge or wea r. Refer t o t h e Clea n in g a n d In spec-
fr om va lve body (F ig. 57). t ion sect ion of t h is gr ou p for pr oper pr ocedu r e.
(25) Rem ove sh u t t le va lve t h r ot t le plu g, pr im a r y
spr in g a n d sh u t t le va lve fr om va lve body (F ig. 57).
(26) Rem ove scr ews a t t a ch in g kickdown lim it
va lve body t o va lve body (F ig. 57).
(27) Rem ove 1-2 sh ift con t r ol va lve a n d spr in g
fr om va lve body (F ig. 57).

GOVERNOR PLUG 1-2 VALVE REGULATOR VALVE


END PLATE GOVERNOR BODY THROTTLE PRESSURE PLUG
SHUTTLE PLUG
VALVE

SHUTTLE
VALVE
THROTTLE
PLUG

2-3
GOVERNOR
PLUG

2-3 SHIFT
VALVE
END
PLATE
KICKDOWN LIMIT
VALVE BODY
80a13872

Fig. 57 Control Valves, Shift Valves, And Governor Plugs


XJ TRANSMISSION AND TRANSFER CASE 21 - 109
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
CAUTION: Do not force valves or plugs into place (20) P la ce sh u t t le va lve en d pla t e in posit ion on
during reassembly. If the valve body bores, valves, va lve body (F ig. 59).
and plugs are free of distortion or burrs, the valve (21) In st a ll scr ews t o a t t a ch sh u t t le va lve en d
body components should all slide into place easily. pla t e t o va lve body (F ig. 59).
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the valve body resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.

(1) Lu br ica t e va lve body bor es, va lves a n d plu gs


wit h Mopa r ! ATF P lu s 3, Type 7176, t r a n sm ission
flu id.
(2) In st a ll r egu la t or va lve lin e pr essu r e plu g, pr es-
su r e plu g sleeve, r egu la t or va lve t h r ot t le pr essu r e
plu g, a n d spr in g in t o va lve body (F ig. 57). Ver ify
va lve com pon en t s slide fr eely.
(3) In st a ll r egu la t or va lve en d pla t e on va lve body
(F ig. 57).
(4) In st a ll kickdown lim it va lve a n d spr in g in kick-
down lim it va lve body (F ig. 57). Ver ify va lve com po- Fig. 58 Shuttle Valve E-Clip And Secondary Spring
n en t s slide fr eely.
SHUTTLE
(5) Com pr ess spr in g in t o kickdown lim it va lve
body. VALVE
END PLATE
i
(6) In st a ll r et a in er in gr ooves a t en d of kickdown
VALVE I
lim it va lve body (F ig. 57).
(7) In st a ll t h r ot t le pr essu r e plu g in kickdown lim it
BODY '
J--- 1
va lve body (F ig. 57).
(8) In st a ll 1-2 sh ift va lve a n d spr in g in t o va lve
body (F ig. 57).
(9) In st a ll 2-3 sh ift va lve a n d spr in g in t o va lve
body (F ig. 57).
(10) In st a ll 1-2 sh ift con t r ol va lve a n d spr in g in t o
va lve body (F ig. 57).
(11) Ver ify va lve com pon en t s slide fr eely.
(12) P la ce kickdown lim it va lve body a n d en d pla t e
80a47397
in posit ion on va lve body a n d com pr ess spr in gs (F ig.
57). Fig. 59 Shuttle Valve End Plate
(13) In st a ll scr ews t o a t t a ch kickdown lim it va lve
(22) In st a ll r ea r clu t ch ser vo a n d r ea r ser vo ch eck
body t o va lve body (F ig. 57).
ba lls in pr oper ca vit ies in t r a n sfer pla t e (F ig. 60).
(14) In st a ll sh u t t le va lve t h r ot t le plu g, pr im a r y
(23) In ser t filt er in t o open in g in sepa r a t or pla t e
spr in g a n d sh u t t le va lve in t o va lve body (F ig. 57).
(F ig. 61).
Ver ify va lve com pon en t s slide fr eely.
(24) P la ce sepa r a t or pla t e in posit ion on t r a n sfer
(15) In st a ll 1-2 a n d 2-3 sh ift va lve gover n or plu gs
pla t e a n d in st a ll scr ews t o a t t a ch sepa r a t or pla t e t o
in t o va lve body (F ig. 57). Ver ify va lve com pon en t s
t r a n sfer pla t e (F ig. 61).
slide fr eely.
(25) P la ce on e 11/32 in . ch eck ba ll a n d six 1/4 in .
(16) P la ce gover n or plu g en d pla t e in posit ion on
ch eck ba lls in t h e pr oper ca vit ies in t h e va lve body
va lve body a n d com pr ess spr in g.
(F ig. 62).
(17) In st a ll scr ews t o a t t a ch gover n or plu g en d
(26) P la ce t r a n sfer pla t e in posit ion on va lve body
pla t e t o va lve body (F ig. 57).
(F ig. 63).
(18) Assem ble sh u t t le va lve spr in g a n d gu ides
(27) In st a ll scr ews t o a t t a ch t r a n sfer pla t e t o va lve
(F ig. 57). P la ce spr in g a n d gu ides in posit ion on sh u t -
body (F ig. 63).
t le va lve st em .
(28) Tu r n va lve body over t o expose t h e sepa r a t or
(19) Com pr ess spr in g a n d in st a ll E -clip in gr oove
pla t e.
on sh u t t le va lve st em (F ig. 58).
21 - 110 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
1/4" CHECK BALLS (6)
REAR TRANSFER
SERVO PLATE
CHECK
BALL

REAR
CLUTCH
CHECK
BALL
80a47396

Fig. 60 Rear Servo and Rear Clutch Check Balls

11/32" CHECK BALL (1) J9121-183

Fig. 62 Correct Position Of Valve Body Check Balls

TRANSFER
PLATE

Fig. 61 Transfer And Separator Plates


'
(29) In ser t con ver t er clu t ch va lve a n d spr in g in t o
con ver t er clu t ch va lve m odu le (F ig. 64). Ver ify va lve
com pon en t s slide fr eely.
(30) In ser t spr in g a n d fa il-sa fe va lve in t o con ver t er
clu t ch va lve m odu le (F ig. 64). Ver ify va lve com po-
n en t s slide fr eely.
(31) P la ce cover pla t e in posit ion on con ver t er
clu t ch va lve m odu le (F ig. 64).
(32) In st a ll scr ews t o a t t a ch cover t o con ver t er
clu t ch va lve m odu le (F ig. 64). 80a47394

(33) In ser t con n ect in g t u be in t o con ver t er clu t ch


va lve m odu le (F ig. 64). Fig. 63 Valve Body Transfer Plate Screws
(34) In ser t con n ect in g t u be in t o va lve body open - (38) In st a ll scr ew t o a t t a ch solen oid t o t r a n sfer
in g (F ig. 65). pla t e (F ig. 66).
(35) P la ce con ver t er clu t ch va lve m odu le in posi- (39) If n ecessa r y, in ser t pa r k r od en d in t o m a n u a l
t ion on sepa r a t or pla t e. In st a ll scr ews t o a t t a ch con - lever a n d in st a ll E -clip (F ig. 67).
ver t er clu t ch m odu le t o va lve body (F ig. 65). (40) In ser t det en t spr in g a n d ba ll in t o open in g in
(36) If n ecessa r y, in st a ll a n ew O-r in g on con ver t er va lve body a n d in st a ll Ret a in er Tool 6583 (F ig. 68).
clu t ch solen oid (F ig. 66). (41) In st a ll m a n u a l va lve in t o va lve body (F ig. 69).
(37) In ser t con ver t er clu t ch solen oid in t o t r a n sfer (42) In ser t t h r ot t le lever t h r ou gh t r a n sfer pla t e
pla t e (F ig. 66). side of va lve body a n d u pwa r d (F ig. 70).
XJ TRANSMISSION AND TRANSFER CASE 21 - 111
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

COVER
PLATE

~E-CLIP

MODULE CONNECTING
PARK
TUBE ROD J9121-81
80a410c0

Fig. 64 Converter Clutch Valve Module Fig. 67 Park Rod


(46) P la ce a dju st in g scr ew br a cket a n d lin e pr es-
su r e a dju st in g scr ew in posit ion on va lve body a n d
com pr ess spr in gs (F ig. 44).
(47) In st a ll scr ews t o a t t a ch a dju st er br a cket t o
va lve body.

J9121-178

Fig. 65 Clutch Module And Connecting Tube

DETENT BALL AND SPRING HOUSING J9321-121

Fig. 68 Securing Detent Ball And Spring With


Retainer Tool

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

Fig. 71 Manual Valve And Throttle Lever Alignment


PRESSURE
REGULATOR 80a4836c

VALVE
ADJUSTER LINE Fig. 73 Repair Stand
BRACKET PRESSURE NEUTRAL
ADJUSTER SWITCH

THROTTLE
PRESSURE ADJUSTER 80a3f1ea

Fig. 72 Adjusting Screw Bracket, Springs, and


Valves
J9121-114

Fig. 74 Park/Neutral Position Switch


XJ TRANSMISSION AND TRANSFER CASE 21 - 113
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

Fig. 75 Accumulator Piston And Spring


(12) Loosen fr on t ba n d a dju st in g scr ew lock n u t
(F ig. 76) 4-5 t u r n s. Th en t igh t en ba n d a dju st in g
scr ew u n t il ba n d is t igh t a r ou n d fr on t clu t ch . Th is
pr even t s fr on t /r ea r clu t ch es fr om com in g ou t wit h Fig. 77 Oil Pump/Reaction Shaft Support
pu m p a n d possibly da m a gin g clu t ch or pu m p com po-
n en t s.
(13) Rem ove oil pu m p bolt s.
(14) Th r ea d bolt s of Slide H a m m er Tools C-3752
in t o t h r ea ded h oles in pu m p body fla n ge (F ig. 77).
(15) Bu m p slide h a m m er weigh t s ou t wa r d t o
r em ove pu m p a n d r ea ct ion sh a ft su ppor t a ssem bly
fr om ca se (F ig. 77).
(16) Loosen fr on t ba n d a dju st in g scr ew u n t il ba n d
is com plet ely loose (F ig. 76).
(17) Squ eeze fr on t ba n d t oget h er a n d r em ove ba n d
st r u t (F ig. 78).

Fig. 78 Front Band Strut


(22) Rem ove fr on t ba n d fr om ca se (F ig. 82).
(23) Rem ove ext en sion h ou sin g fr om t r a n sm ission
ca se.
(24) Rem ove gover n or body a n d pa r k gea r fr om
ou t pu t sh a ft .
(25) Rem ove ou t pu t sh a ft a n d pla n et a r y gea r t r a in
a s a ssem bly (F ig. 83). Su ppor t gea r t r a in wit h bot h
h a n ds du r in g r em ova l. Do n ot a llow m a ch in ed su r-
fa ces on ou t pu t sh a ft t o becom e n icked or scr a t ch ed.
(26) Loosen r ea r ba n d a dju st in g scr ew 4-5 t u r n s
Fig. 76 Front Band Adjusting Screw Lock Nut (F ig. 84).
(27) Rem ove sn a p r in g t h a t secu r es low-r ever se
(18) Rem ove fr on t a n d r ea r clu t ch u n it s a s a n
dr u m t o r ea r su ppor t h u b, h owever do n ot r em ove
a ssem bly. Gr a sp in pu t sh a ft , h old clu t ch u n it s
dr u m (F ig. 85).
t oget h er a n d r em ove t h em fr om ca se (F ig. 79).
(28) Rem ove bolt s a t t a ch in g r ea r su ppor t t o t r a n s-
(19) Lift fr on t clu t ch off r ea r clu t ch (F ig. 80). Set
m ission ca se a n d pu ll su ppor t fr om low-r ever se dr u m
clu t ch u n it s a side for over h a u l.
(F ig. 86).
(20) Rem ove ou t pu t sh a ft t h r u st wa sh er fr om ou t -
(29) Rem ove bolt s a t t a ch in g over r u n n in g clu t ch
pu t sh a ft (or fr om r ea r clu t ch h u b) (F ig. 81).
ca m a n d low-r ever se dr u m t o t r a n sm ission ca se (F ig.
(21) Rem ove ou t pu t sh a ft t h r u st pla t e a n d wa sh er
87).
fr om ou t pu t sh a ft h u b (F ig. 81).
21 - 114 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

FRONT
CLUTCH
AND
DRUM

THRUST
PLATE
80a3b191

Fig. 79 Front/Rear Clutch Assemblies Fig. 81 Output Shaft Thrust Plate and Washer

TRANSMISSION
//HOUSING
//" 80a3b192

Fig. 82 Front Band

Fig. 80 Separating Front Clutch From Rear Clutch


(30) Usin g sn a p-r in g plier, pu ll r ea r ba n d a n ch or
pin (loca t ed on t h e ser vo side of t h e r ea r su ppor t )
fr om t r a n sm ission ca se.
(31) Rem ove r ea r ba n d a n d lin k fr om t r a n sm ission
(F ig. 88).
(32) Sepa r a t e lin k fr om r ea r ba n d (F ig. 89).
(33) If n ecessa r y r em ove fr on t a n d r ea r ba n d ser vo
lever s. All t r a n sm ission com pon en t s ca n be ser viced
wit h ou t r em ovin g t h e lever s.
(a ) Usin g a 1/4 in ch dr ive ext en sion r em ove
fr on t ba n d r ea ct ion pin a ccess plu g (F ig. 90). Fig. 83 Planetary Geartrain
(b) Rem ove fr on t ba n d r ea ct ion pin wit h pen cil (d) Usin g sn a p-r in g plier, pu ll r ea r ba n d lever
m a gn et . P in is a ccessible fr om con ver t er h ou sin g pivot fr om t r a n sm ission ca se (F ig. 93).
side of ca se (F ig. 91). (e) Sepa r a t e r ea r ba n d ser vo lever fr om t r a n s-
(c) Rem ove fr on t ba n d lever (F ig. 92). m ission .
XJ TRANSMISSION AND TRANSFER CASE 21 - 115
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

Fig. 84 Rear Band Adjuster Location


J9121-134

Fig. 87 Overrunning Clutch Cam Bolt Locations

_J9121-132 Fig. 88 Rear Band and Link

Fig. 85 Low-Reverse Drum Snap Ring


OIL PAN
FACE------~~

TRANSMISSION
HOUSING

J9421-186

Fig. 89 Rear Band and Link


(35) Rem ove fr on t ser vo r od gu ide sn a p r in g (F ig.
94). Ex e rc is e c a u tio n w h e n re m o v in g s n a p rin g .
S e rv o bo re c a n be s c ra tc h e d o r n ic k e d if c a re is
n o t e x e rc is e d .
80a3b195
(36) Rem ove com pr essor t ools a n d r em ove fr on t
Fig. 86 Rear Support ser vo r od gu ide, spr in g a n d ser vo pist on .
(37) Com pr ess r ea r ser vo spr in g r et a in er a bou t
(34) Com pr ess fr on t ser vo r od gu ide a bou t 1/8 in .
1/16 in . wit h C-cla m p a n d Tool C-4470 or SP -5560
wit h la r ge C-cla m p a n d Tool C-4470, or Spr in g Com -
(F ig. 95). Va lve Spr in g Com pr essor C-3422-B ca n a lso
pr essor Tool C-3422-B (F ig. 94).
be u sed t o com pr ess spr in g r et a in er.
21 - 116 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

Fig. 90 Front Band Reaction Pin Access Plug


PENCIL
MAGNET

Fig. 93 Rear Band Servo Lever Pin

Fig. 91 Front Band Reaction Pin

J9121-136

Fig. 94 Compressing Front Servo


Spr in g Com pr essor C-3422-B a n d in st a ll ser vo sn a p
r in g (F ig. 94).
(3) Assem ble lin k ba r t o ba n d. Not ch ed side of lin k
t owa r d ba n d (F ig. 93).
(4) In ser t r ea r ba n d t h r ou gh pa n open in g in t r a n s-
Fig. 92 Front Band Lever m ission ca se.
(38) Rem ove r ea r ser vo spr in g r et a in er sn a p r in g. (5) In ser t h ook on ba n d on t o a dju st er lever.
Th en r em ove com pr essor t ools a n d r em ove r ea r ser vo (6) Align h oles in lin k ba r wit h h ole in t r a n sm is-
spr in g a n d pist on . sion ca se ou t boa r d of r ea r su ppor t open in g (F ig. 92).
(7) In ser t a n ch or pin in t o ca se t h r ou gh lin k ba r.
ASSEMBLY (8) E xa m in e bolt h oles in over r u n n in g clu t ch ca m .
(1) In st a ll r ea r ser vo pist on , spr in g a n d spr in g Not e t h a t on e h ole is n o t th re a d e d (F ig. 96). Th is
r et a in er. Com pr ess r ea r ser vo spr in g a n d r et a in er h ole m u st a lign wit h bla n k a r ea in clu t ch ca m bolt
wit h Com pr essor Tool C-3422-B (F ig. 95) or a la r ge cir cle.
C-cla m p.
(2) In st a ll fr on t ser vo pist on , spr in g, a n d r od NOTE: The bolt holes in cam are slightly counter-
gu ide. Com pr ess fr on t ser vo r od gu ide wit h Va lve sunk on one side. This side of cam faces rearward
(toward rear support).
XJ TRANSMISSION AND TRANSFER CASE 21 - 117
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

~
OVERRUNNING
CLUTCH
I

Fig. 96 Clutch Cam Alignment


(21) In st a ll a n d t igh t en r ea r su ppor t bolt s t o 17
N·m (150 in . lbs.) t or qu e.
Fig. 95 Compressing Rear Servo Spring (22) In st a ll sn a p r in g t o r et a in low-r ever se dr u m
(9) Lu br ica t e over r u n n in g clu t ch r oller s, spr in gs t o h u b of r ea r su ppor t (F ig. 98).
a n d ca m wit h Mopa r ! ATF P lu s 3, t ype 7176, t r a n s-
m ission flu id.
(10) P osit ion over r u n n in g clu t ch on a clea n , fla t
wor k su r fa ce wit h cou n t er su n k h oles down wa r d.
(11) P la ce r ea r of low-r ever se dr u m over over r u n -
n in g clu t ch a n d a lign clu t ch r oller s t o h u b of dr u m . TRANSMISSION
(12) Wh ile sligh t ly pivot in g low-r ever se dr u m , HOUSING
pu sh h u b of dr u m in t o over r u n n in g clu t ch . Ver ify
t h a t cou n t er su n k h oles a r e fa cin g ou t wa r d. Ca m
s h o u ld be a ble to ro ta te in th e d ru m c lo c k w is e
o n ly.
(13) In ser t a su it a ble a wl t h r ou gh t h e r ea r su ppor t
m ou n t in g h ole closest t o t h e pa n sea lin g fa ce. Th e
a wl sh ou ld be n ext t o t h e wide spa ce a r ea a t t h e
ba ck of t r a n sm ission ca se.
80a3b195
(14) In ser t low-r ever se dr u m a n d over r u n n in g
clu t ch in t o fr on t of t r a n sm ission ca se a n d in t o r ea r Fig. 97 Rear Support
ba n d.
(15) In ser t a wl t ip in t o t h e t h r ea ded h ole n ext t o
t h e n on -t h r ea ded h ole in t h e over r u n n in g clu t ch ca m .
Ver ify t h a t n on -t h r ea ded h ole is a lign ed wit h wide
spa ce a r ea on t r a n sm ission ca se.
(16) P u sh low-r ever se dr u m r ea r wa r d t o close ga p
bet ween ca m a n d ca se.
(17) In st a ll over r u n n in g clu t ch ca m bolt s. Clu tc h
c a m bo lts a re s h o rte r th a n re a r s u p p o rt bo lts .
Tigh t en ca m bolt s t o 17 N·m (150 in . lbs. or 13 ft .
lbs.) t or qu e.
(18) H old low-r ever se dr u m in posit ion so r ea r su p-
por t will n ot pu sh it ou t of over r u n n in g clu t ch .
(19) In ser t r ea r su ppor t in t o open in g a t r ea r of
t r a n sm ission ca se (F ig. 97).
(20) Align su ppor t wit h t h e em bossed a r r ow in t h e
dir ect ion of t h e pa n fa ce.
Fig. 98 Low-Reverse Drum Snap Ring
21 - 118 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(23) Lu br ica t e ou t pu t sh a ft , r ea r su ppor t bor e a n d
low-r ever se dr u m h u b wit h t r a n sm ission flu id. TEFLON
SEAL
(24) In st a ll a ssem bled ou t pu t sh a ft a n d pla n et a r y RING
gea r t r a in in ca se (F ig. 99).
(25) Align dr ive lu gs on r ea r pla n et a r y gea r wit h
slot s in low-r ever se dr u m (F ig. 99). Th en sea t pla n e-
t a r y a ssem bly in dr u m .
(26) In st a ll gover n or on ou t pu t sh a ft .

Fig. 100 Input Shaft Seal Ring Location

Fig. 99 Output Shaft And Planetary Geartrain


(27) Tu r n a n d secu r e t r a n sm ission so t h a t fr on t
open in g is u pwa r d. FRONT
(28) Assem ble fr on t a n d r ea r clu t ch es t oget h er. CLUTCH
(a ) Ch eck in pu t sh a ft sea l r in gs (F ig. 100). Ver ify
t h a t dia gon a l-cu t en ds of Teflon # sea l r in g a r e
pr oper ly join ed a n d en ds of m et a l r in g a r e cor r ect ly
h ooked t oget h er. Also be su r e r in gs a r e in st a lled in
sequ en ce sh own .
(b) Align t eet h on clu t ch discs in lin e. Fig. 101 Front and Rear Clutches
(c) In ser t in pu t sh a ft on r ea r clu t ch in t o cen t er
of fr on t clu t ch (F ig. 101).
(d) E n ga ge t eet h on r ea r clu t ch h u b in t o t eet h
on clu t ch (F ig. 103). Rot a t e fr on t clu t ch r et a in er
ba ck a n d for t h u n t il com plet ely sea t ed on r ea r
clu t ch .
(29) In st a ll ou t pu t sh a ft t h r u st pla t e on sh a ft h u b
in pla n et a r y gea r t r a in dr ivin g sh ell (F ig. 102). Use
pet r oleu m jelly t o h old t h r u st pla t e in pla ce.
(30) Ch eck r ea r clu t ch t h r u st wa sh er. Use a ddi-
t ion a l pet r oleu m jelly t o h old wa sh er in pla ce if n ec-
essa r y.
(31) Coa t ou t pu t sh a ft t h r u st wa sh er wit h pet r o-
leu m jelly. In st a ll wa sh er in r ea r clu t ch h u b (F ig.
\
OUTPUT
SHAFT
104). Use en ou gh pet r oleu m jelly t o h old wa sh er in THRUST
pla ce. B e s u re g ro o v e d s id e o f w a s h e r fa c e s PLATE
re a rw a rd (to w a rd o u tp u t s h a ft) a s s h o w n . Als o
n o te th a t w a s h e r o n ly fits o n e w a y in c lu tc h Fig. 102 Output Shaft Thrust Plate
h u b. (33) In ser t fr on t ba n d in t o open in g a t fr on t of
(32) Align dr ive t eet h on r ea r clu t ch discs wit h t r a n sm ission ca se (F ig. 106).
sm a ll scr ewdr iver (F ig. 105). Th is will m a ke in st a lla - (34) In st a ll fr on t a n d r ea r clu t ch u n it s a s a ssem bly
t ion in t o fr on t of pla n et a r y gea r t r a in ea sier. (F ig. 107). Align r ea r clu t ch wit h fr on t a n n u lu s gea r
XJ TRANSMISSION AND TRANSFER CASE 21 - 119
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(35) Ca r efu lly wor k a ssem bled clu t ch es ba ck a n d
for t h t o en ga ge a n d sea t r ea r clu t ch discs on fr on t
a n n u lu s gea r. Ver ify t h a t fr on t clu t ch dr ive lu gs a r e
fu lly en ga ged in slot s of dr ivin g sh ell a ft er in st a lla -
t ion .

Fig. 103 Assembling Front And Rear Clutch Units

TRANSMISSION
//HOUSING
//" 80a3b192

Fig. 106 Front Band

FRONT
CLUTCH
AND
DRUM

Fig. 104 Output Shaft Thrust Washer

80a3b191

Fig. 107 Installing Front/Rear Clutch


(36) E n ga ge fr on t ba n d on a dju st in g scr ew a n d
h old ba n d in pla ce.
(37) In st a ll st r u t bet ween ba n d lever a n d fr on t
ba n d (F ig. 108).
(38) Tigh t en fr on t ba n d a dju st in g scr ew u n t il ba n d
USE ju st gr ips clu t ch r et a in er. Ver ify t h a t fr on t /r ea r
SMALL
SCREWDRIVER clu t ch es a r e st ill sea t ed befor e con t in u in g.
TO (39) Ver ify t h a t r ea ct ion sh a ft su ppor t h u b sea l
ALIGN r in gs a r e h ooked t oget h er (F ig. 109).
CLUTCH DISC
TEETH (40) Coa t fr on t clu t ch t h r u st wa sh er wit h pet r o-
leu m jelly t o h old it in pla ce. Th en in st a ll wa sh er
Fig. 105 Aligning Rear Clutch Disc Lugs over r ea ct ion sh a ft h u b a n d sea t it on pu m p (F ig.
110).
a n d in st a ll a ssem bly in dr ivin g sh ell. B e s u re o u t-
p u t s h a ft th ru s t w a s h e r a n d th ru s t p la te a re
n o t d is p la c e d d u rin g in s ta lla tio n .
21 - 120 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
CAUTION: The thrust washer bore (I.D.), is cham- (41) Th r ea d t wo P ilot St u d Tools C-3288-B in t o
fered on one side. Make sure the chamfered side is bolt h oles in oil pu m p fla n ge (F ig. 111).
installed so it faces the pump. (42) Align a n d in st a ll oil pu m p ga sket (F ig. 111).
(43) Lu br ica t e oil pu m p sea ls wit h Mopa r ! Door-
BAND
STRUT E a se, or Ru -Glyde, Door E ze, or ATF P lu s 3.
(44) In st a ll oil pu m p (F ig. 112). Align a n d posit ion
pu m p on pilot st u ds. Slide pu m p down st u ds a n d
wor k it in t o fr on t clu t ch h u b a n d ca se by h a n d. Th en
in st a ll t wo or t h r ee pu m p bolt s t o h old pu m p in
pla ce.
(45) Rem ove pilot st u d t ools a n d in st a ll r em a in in g
oil pu m p bolt s. Tigh t en bolt s a lt er n a t ely in dia gon a l
pa t t er n t o 20 N·m (15 ft . lbs.).

PILOT
Fig. 108 Front Band Linkage Installation STUD
TOOLS
C-3288-B

J9121-195

Fig. 111 Installing Pilot Studs And Oil Pump Gasket


SEAL
RINGS

Fig. 109 Reaction Shaft Support Seal Rings

Fig. 112 Installing Oil Pump And Reaction Shaft


Fig. 110 Front Clutch Thrust Washer Installation Support
(46) Mea su r e in pu t sh a ft en d pla y (F ig. 113).
XJ TRANSMISSION AND TRANSFER CASE 21 - 121
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or output shaft thrust
washer and/or thrust plate are worn and need to be
changed.

(a ) At t a ch dia l in dica t or (C-3339) t o con ver t er


h ou sin g. P osit ion in dica t or plu n ger a ga in st in pu t
sh a ft a n d zer o in dica t or.
(b) Move in pu t sh a ft in a n d ou t a n d r ecor d r ea d-
in g. E n d pla y sh ou ld be 0.56 - 2.31 m m (0.022 -
0.091 in .).

Fig. 114 Removing Overrunning Clutch From


Low-Reverse Drum
(b) In st a ll clu t ch a ssem bly on low-r ever se dr u m
wit h t wist in g m ot ion (F ig. 117).
(c) In st a ll dr u m -clu t ch a ssem bly in ca se a n d
in st a ll clu t ch ca m bolt s.
(d) In st a ll r ea r su ppor t a n d su ppor t a t t a ch in g
bolt s.
(e) Ch eck low-r ever se dr u m r ot a t ion . D ru m
s h o u ld ro ta te fre e ly in c lo c k w is e d ire c tio n
Fig. 113 Checking Input Shaft End Play a n d lo c k w h e n tu rn e d in c o u n te rc lo c k w is e
d ire c tio n (a s v ie w e d fro m fro n t o f c a s e ).
(47) P osit ion t r a n sm ission on wor k su r fa ce wit h
pa n fa ce u pwa r d.
(48) In st a ll va lve body.
(49) Adju st fr on t a n d r ea r ba n ds.
(50) In st a ll flu id filt er a n d pa n .
(51) In st a ll r ea r ext en sion h ou sin g.
(52) In st a ll t or qu e con ver t er.

OVERRUNNING CLUTCH/LOW-REVERSE DRUM


DISASSEMBLY
(1) If t h e clu t ch a ssem bly ca m e ou t wit h t h e low-
r ever se dr u m , t h r ea d t wo clu t ch ca m bolt s in t o t h e
ca m . Th en lift t h e ca m ou t of t h e dr u m wit h t h e bolt s
(F ig. 114). Rot a t e t h e ca m ba ck a n d for t h t o ea se
r em ova l if n ecessa r y. J9121-139
(2) Rem ove t h e clu t ch r oller a n d spr in g a ssem bly
fr om t h e over r u n n in g clu t ch r a ce. Fig. 115 Overrunning Clutch Rollers, Springs,
Retainer
ASSEMBLY
(1) Assem ble clu t ch r oller s a n d spr in gs in r et a in er
FRONT SERVO PISTON
if n ecessa r y (F ig. 115).
DISASSEMBLY
(2) In st a ll over r u n n in g clu t ch r oller, spr in g a n d
(1) Rem ove sea l r in g fr om r od gu ide (F ig. 119).
r et a in er a ssem bly in clu t ch ca m (F ig. 116).
(2) Rem ove sm a ll sn a p r in g fr om ser vo pist on r od.
(3) Tem por a r ily a ssem ble a n d ch eck over r u n n in g
Th en r em ove pist on r od, spr in g a n d wa sh er fr om pis-
clu t ch oper a t ion a s follows:
t on .
(a ) Assem ble ca m a n d clu t ch .
21 - 122 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
LOW-REVERSE DRUM OVERRUNNING
CLUTCH
CAM

CLUTCH
1/L - ' J ~ - - - RACE

HUB OF
LOW-REVERSE
DRUM

Fig. 116 Assembling Overrunning Clutch And Cam


J9121-140

Fig. 118 Assembled Overrunning Clutch


PISTON
RINGS

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)

PISTON (6) If pu m p sea l wa s n ot r em oved du r in g t r a n sm is-


SEAL sion disa ssem bly, r em ove sea l wit h pu n ch a n d h a m -
m er.
(7) Rem ove fr on t clu t ch t h r u st wa sh er fr om su p-
por t h u b (F ig. 125).
PUMP
HOUSING

J9121-64

Fig. 120 Rear Servo Components


OIL PUMP AND REACTION SHAFT SUPPORT
DISASSEMBLY
J9321-213
(1) Rem ove sea l r in g fr om h ou sin g a n d r ea ct ion
sh a ft su ppor t (F ig. 121).
Fig. 123 Separating Pump Housing From Reaction
(2) Ma r k pu m p h ou sin g a n d su ppor t a ssem bly for
Shaft Support
a lign m en t r efer en ce.
(3) Rem ove bolt s a t t a ch in g pu m p body t o su ppor t
(F ig. 122).
INNER OUTER
GEAR GEAR
PUMP
HOUSING
SEAL
RING

J9321-214

Fig. 124 Pump Gear Removal


J9321-211
BUSHING
Fig. 121 Removing Pump Seal Ring

REACTION
SHAFT
y
SUPPORT I
'

Fig. 125 Support Hub Thrust Washer


80a483e7
OIL PUMP BUSHING REPLACEMENT
Fig. 122 Pump Support Bolts (1) Rem ove pu m p bu sh in g wit h Tool H a n dle
C-4171 a n d Bu sh in g Rem over SP -3551 fr om Tool Set
(4) Sepa r a t e su ppor t fr om pu m p h ou sin g (F ig. C-3887-J (F ig. 126).
123). (2) In st a ll n ew pu m p bu sh in g wit h Tool H a n dle
(5) Rem ove in n er a n d ou t er gea r s fr om r ea ct ion C-4171 a n d Bu sh in g In st a ller SP -5117 (F ig. 126).
sh a ft su ppor t (F ig. 124). Bu sh in g sh ou ld be flu sh wit h pu m p h ou sin g bor e.
21 - 124 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(3) St a ke n ew pu m p bu sh in g in t wo pla ces wit h (5) Assem ble Bu sh in g In st a ller Tools C-4171 a n d
blu n t pu n ch (F ig. 127). Rem ove bu r r s fr om st a ke SP -5325 (F ig. 128).
poin t s wit h kn ife bla de a ft er wa r d. (6) Slide n ew bu sh in g on t o In st a ller Tool SP -5325.
(7) P osit ion r ea ct ion sh a ft su ppor t u pr igh t on a
SPECIAL
TOOL clea n sm oot h su r fa ce.
C-4171 (8) Align bu sh in g in bor e. Th en t a p bu sh in g in t o
pla ce u n t il Bu sh in g In st a ller SP -5325 bot t om s.
. - - - - - SPECIAL TOOL (9) Clea n r ea ct ion sh a ft su ppor t t h or ou gh ly a ft er
SP-3551
PUMP HOUSING in st a llin g bu sh in g.
SPECIAL
BUSHING TOOL
SP-1191

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).

CAUTION: The pump inner gear is a one way fit.


The bore on one side of the gear inside diameter
(I.D.) is chamfered. Be sure the chamfered side
Fig. 127 Staking Oil Pump Bushing faces forward (to front of pump).

REACTION SHAFT SUPPORT BUSHING REMOVAL (6) In st a ll n ew t h r u st wa sh er on h u b of r ea ct ion


(1) Assem ble Bu sh in g Rem over Tools SP -1191, sh a ft su ppor t . Lu br ica t e wa sh er wit h t r a n sm ission
3633 a n d 5324 (F ig. 128). D o n o t c la m p a n y p a rt flu id or pet r oleu m jelly.
o f re a c tio n s h a ft o r s u p p o rt in v is e . (7) If r ea ct ion sh a ft sea l r in gs a r e bein g r epla ced,
(2) H old Cu p Tool SP -3633 fir m ly a ga in st r ea ct ion in st a ll n ew sea l r in gs on su ppor t h u b (F ig. 131).
sh a ft a n d t h r ea d r em over SP -5324 in t o bu sh in g a s Lu br ica t e sea l r in gs wit h t r a n sm ission flu id or pet r o-
fa r a s possible by h a n d. Th en t h r ea d r em over t ool 3-4 leu m jelly a ft er in st a lla t ion . Squ eeze ea ch r in g u n t il
a ddit ion a l t u r n s in t o bu sh in g wit h a wr en ch . r in g en ds a r e secu r ely h ooked t oget h er.
(3) Tu r n r em over t ool h ex n u t down a ga in st
r em over cu p t o pu ll bu sh in g fr om sh a ft . Clea n a ll
ch ips fr om sh a ft a ft er bu sh in g r em ova l.
(4) Ligh t ly gr ip old bu sh in g in vise or wit h plier s
a n d ba ck r em over t ool ou t of bu sh in g.
XJ TRANSMISSION AND TRANSFER CASE 21 - 125
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(8) In st a ll r ea ct ion sh a ft su ppor t on pu m p h ou sin g
OUTER
GEAR (F ig. 132).
(9) Align r ea ct ion su ppor t on pu m p h ou sin g. Use
a lign m en t m a r ks m a de a t disa ssem bly. Or, r ot a t e
su ppor t u n t il bolt h oles in su ppor t a n d pu m p h ou sin g
a r e a ll a lign ed (h oles a r e offset for on e-wa y fit ).

REACTION
SHAFT
PUMP SUPPORT
HOUSING

J9321-219

Fig. 129 Supporting Pump And Installing Outer Gear

Fig. 132 Assembling Reaction Shaft Support And


INNER
GEAR
Pump Housing
OUTER
GEAR (10) In st a ll a ll bolt s t h a t a t t a ch su ppor t t o pu m p
h ou sin g. Th en t igh t en bolt s fin ger t igh t .
(11) Tigh t en su ppor t -t o-pu m p bolt s t o r equ ir ed
t or qu e a s follows:
(a ) Rever se pu m p a ssem bly a n d in st a ll it in
t r a n sm ission ca se. P osit ion pu m p so bolt s a r e fa c-
in g ou t a n d a r e a ccessible.
(b) Secu r e pu m p a ssem bly in ca se wit h 2 or 3
bolt s, or wit h pilot st u ds.
(c) Tigh t en su ppor t -t o-pu m p bolt s t o 20 N·m (15
ft . lbs.).
J9321-465 (d) Rem ove pu m p a ssem bly fr om t r a n sm ission
ca se.
Fig. 130 Pump Inner Gear Installation (12) In st a ll n ew oil sea l in pu m p wit h Specia l Tool
C-4193 a n d Tool H a n dle C-4171 (F ig. 133). Be su r e
CAUTION: The reaction shaft support seal rings
sea l lip fa ces in wa r d.
will break if overspread, or twisted. If new rings are
(13) In st a ll n ew sea l r in g a r ou n d pu m p h ou sin g.
being installed, spread them only enough for instal-
Be su r e sea l is pr oper ly sea t ed in gr oove.
lation. Also be very sure the ring ends are securely
(14) Lu br ica t e lip of pu m p oil sea l a n d O-r in g sea l
hooked together after installation. Otherwise, the
wit h t r a n sm ission flu id.
rings will either prevent pump installation, or break
during installation.

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

Fig. 134 Front Clutch Components


FRONT CLUTCH Th en lu br ica t e r et a in er h u b, bor e a n d pist on wit h
ligh t coa t of t r a n sm ission flu id.
DISASSEMBLY (4) In st a ll clu t ch pist on in r et a in er (F ig. 136). Use
(1) Rem ove wa ved sn a p r in g a n d r em ove pr essu r e t wist in g m ot ion t o sea t pist on in bot t om of r et a in er. A
pla t e, clu t ch pla t es a n d clu t ch discs (F ig. 134). t h in st r ip of pla st ic (a bou t 0.020" t h ick), ca n be u sed
(2) Com pr ess clu t ch pist on spr in g wit h Com pr essor t o gu ide sea ls in t o pla ce if n ecessa r y.
Tool C-3575-A (F ig. 135). Be su r e legs of t ool a r e
CAUTION: Never push the clutch piston straight in.
sea t ed squ a r ely on spr in g r et a in er befor e com pr ess-
This will fold the seals over causing leakage and
in g spr in g.
clutch slip. In addition, never use any type of metal
(3) Rem ove r et a in er sn a p r in g a n d r em ove com -
tool to help ease the piston seals into place. Metal
pr essor t ool.
tools will cut, shave, or score the seals.
(4) Rem ove spr in g r et a in er a n d clu t ch spr in g. Not e
posit ion of r et a in er on spr in g for a ssem bly r efer en ce. (5) P osit ion spr in g in clu t ch pist on (F ig. 137).
(5) Rem ove clu t ch pist on fr om clu t ch r et a in er. (6) P osit ion spr in g r et a in er on t op of pist on spr in g
Rem ove pist on by r ot a t in g it u p a n d ou t of r et a in er. (F ig. 138). Ma k e s u re re ta in e r is p ro p e rly
(6) Rem ove sea ls fr om clu t ch pist on a n d clu t ch in s ta lle d . S m a ll ra is e d ta bs s h o u ld be fa c in g
r et a in er h u b. Disca r d bot h sea ls a s t h ey a r e n ot r eu s- u p w a rd . S e m ic irc u la r lu g s o n u n d e rs id e o f
a ble. re ta in e r a re fo r p o s itio n in g re ta in e r in s p rin g .
(7) Com pr ess pist on spr in g a n d r et a in er wit h Com -
ASSEMBLY pr essor Tool C-3575-A (F ig. 135). Th en in st a ll n ew
(1) Soa k clu t ch discs in t r a n sm ission flu id wh ile sn a p r in g t o secu r e spr in g r et a in er a n d spr in g.
a ssem blin g ot h er clu t ch pa r t s. (8) In st a ll clu t ch pla t es a n d discs (F ig. 134).
(2) In st a ll n ew sea ls on pist on a n d in h u b of In st a ll st eel pla t e t h en disc u n t il a ll pla t es a n d discs
r et a in er. Be su r e lip of ea ch sea l fa ces in t er ior of a r e in st a lled. Th e fr on t clu t ch u ses 4 clu t ch discs.
clu t ch r et a in er.
(3) Lu br ica t e lips of pist on a n d r et a in er sea ls wit h
liber a l qu a n t it y of Mopa r ! Door E a se, or Ru -Glyde.
XJ TRANSMISSION AND TRANSFER CASE 21 - 127
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

SMALL TABS
ON RETAINER
FACE
UPWARD

J9321-224

Fig. 138 Correct Spring Retainer Installed Position


(a ) P osit ion ga u ge ba r a cr oss t h e clu t ch dr u m
wit h t h e dia l in dica t or poin t er on t h e pr essu r e
pla t e (F ig. 139).
(b) Usin g t wo sm a ll scr ew dr iver s, lift t h e pr es-
/J9121-147 su r e pla t e a n d com pr ess t h e wa ved sn a p-r in g. Th is
will a ssu r e t h a t t h e sn a p-r in g is a t t h e t op of t h e
Fig. 135 Compressing Front Clutch Piston Spring gr oove.
(c) Relea se t h e pr essu r e pla t e a n d zer o t h e dia l
FRONT
in dica t or.
CLUTCH (d) Lift t h e pr essu r e pla t e u n t il it con t a ct s t h e
RETAINER wa ved sn a p-r in g a n d r ecor d t h e dia l in dica t or r ea d-
CLUTCH in g.
PISTON-----~,f4,f.,-4 Clea r a n ce sh ou ld be 1.70 t o 3.40 m m (0.067 t o
0.134 in .). If clea r a n ce is in cor r ect , clu t ch discs,
pla t es pr essu r e pla t es a n d sn a p r in g m a y h a ve t o be
ch a n ged.

J9121-146

Fig. 136 Front Clutch Piston Installation


RETAINER

PISTON 80a483e9

Fig. 139 Measuring Front Clutch Pack Clearance


REAR CLUTCH
J9321-466
DISASSEMBLY
Fig. 137 Clutch Piston Spring Installation (1) Rem ove t h r u st wa sh er fr om for wa r d side of
(9) In st a ll pr essu r e pla t e a n d wa ved sn a p r in g clu t ch r et a in er.
(F ig. 134). (2) Rem ove in pu t sh a ft fr on t /r ea r sea l r in gs.
(10) Usin g a su it a ble ga u ge ba r a n d dia l in dica t or, (3) Rem ove select ive clu t ch pa ck sn a p r in g (F ig.
m ea su r e clu t ch pla t e clea r a n ce (F ig. 139). 140).
21 - 128 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

,,....,.,...,.,__ REAR
REAR CLUTCH
CLUTCH THRUST
RETAINER SHAFT WASHER
FRONT (FIBER)
SEAL
RING
(TEFLON) CLUTCH
PACK
SNAP
RING
(SELECTIVE)

WAVE
SPRING

J9121-539

Fig. 140 Rear Clutch Components


(4) Rem ove t op pr essu r e pla t e, clu t ch discs, st eel
pla t es, bot t om pr essu r e pla t e a n d wa ve sn a p r in g
a n d wa ve spr in g (F ig. 140).
(5) Rem ove clu t ch pist on wit h r ot a t in g m ot ion .
(6) Rem ove a n d disca r d pist on sea ls.
(7) Rem ove in pu t sh a ft sn a p-r in g (F ig. 141). It
m a y be n ecessa r y t o pr ess t h e in pu t sh a ft in sligh t ly
t o r elieve t en sion on t h e sn a p-r in g.
(8) P r ess in pu t sh a ft ou t of r et a in er wit h sh op
pr ess a n d su it a ble size pr ess t ool. Use a su it a bly
sized pr ess t ool t o su ppor t t h e r et a in er a s close t o t h e
in pu t sh a ft a s possible.

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

Fig. 143 Input Shaft Seal Ring Identification

INPUT
SHAFT
SEAL
RINGS

J9121-538

Fig. 142 Rear Clutch Retainer And Input Shaft Seal


Ring Installation
(11) In st a ll bot t om pr essu r e pla t e (F ig. 140).
Ridged side of pla t e fa ces down wa r d (t owa r d pist on )
a n d fla t side t owa r d clu t ch pa ck.
(12) In st a ll fir st clu t ch disc in r et a in er on t op of
bot t om pr essu r e pla t e. Th en in st a ll a clu t ch pla t e fol-
lowed by a clu t ch disc u n t il en t ir e clu t ch pa ck is
in st a lled (4 discs a n d 3 pla t es a r e r equ ir ed) (F ig.
140).
(13) In st a ll t op pr essu r e pla t e.
(14) In st a ll select ive sn a p r in g. Be su r e sn a p r in g Fig. 144 Pressing Input Shaft Into Rear Clutch
is fu lly sea t ed in r et a in er gr oove. Retainer
(15) Usin g a su it a ble ga u ge ba r a n d dia l in dica t or, (d) Lift t h e pr essu r e pla t e u n t il it con t a ct s t h e
m ea su r e clu t ch pa ck clea r a n ce (F ig. 146). sn a p-r in g a n d r ecor d t h e dia l in dica t or r ea din g.
(a ) P osit ion ga u ge ba r a cr oss t h e clu t ch dr u m Clea r a n ce sh ou ld be 0.64 - 1.14 m m (0.025 - 0.045
wit h t h e dia l in dica t or poin t er on t h e pr essu r e in .). If clea r a n ce is in cor r ect , st eel pla t es, discs, selec-
pla t e (F ig. 146). t ive sn a p r in g a n d pr essu r e pla t es m a y h a ve t o be
(b) Usin g t wo sm a ll scr ew dr iver s, lift t h e pr es- ch a n ged.
su r e pla t e a n d r elea se it . Th e select ive sn a p r in g t h ickn esses a r e:
(c) Zer o t h e dia l in dica t or. • .107–.109 in .
21 - 130 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 146 Checking Rear Clutch Pack Clearance


J9421-175
PLANETARY GEARTRAIN/OUTPUT SHAFT
Fig. 148 Front Annulus And Planetary Assembly
DISASSEMBLY Removal
(1) Rem ove pla n et a r y sn a p r in g (F ig. 148).
(2) Rem ove fr on t a n n u lu s a n d pla n et a r y a ssem bly ASSEMBLY
fr om dr ivin g sh ell (F ig. 148). (1) Lu br ica t e ou t pu t sh a ft a n d pla n et a r y com po-
(3) Rem ove sn a p r in g t h a t r et a in s fr on t pla n et a r y n en t s wit h t r a n sm ission flu id. Use pet r oleu m jelly t o
gea r in a n n u lu s gea r (F ig. 149). lu br ica t e a n d h old t h r u st wa sh er s a n d pla t es in posi-
(4) Rem ove t a bbed t h r u st wa sh er a n d t a bbed t ion .
t h r u st pla t e fr om h u b of fr on t a n n u lu s (F ig. 150). (2) Assem ble r ea r a n n u lu s gea r a n d su ppor t if dis-
a ssem bled. Be su r e su ppor t sn a p r in g is sea t ed a n d
XJ TRANSMISSION AND TRANSFER CASE 21 - 131
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(4) In st a ll r ea r a n n u lu s over a n d on t o r ea r pla n e-
t a r y gea r (F ig. 152).
(5) In st a ll a ssem bled r ea r pla n et a r y a n d a n n u lu s
gea r on ou t pu t sh a ft (F ig. 153). Ver ify t h a t a ssem bly
FRONT is fu lly sea t ed on sh a ft .
ANNULUS
GEAR (6) In st a ll fr on t t h r u st wa sh er on r ea r pla n et a r y
gea r (F ig. 154). Use en ou gh pet r oleu m jelly t o h old
wa sh er on gea r. Be su r e a ll fou r wa sh er t a bs a r e
sea t ed in slot s.
(7) In st a ll spa cer on su n gea r (F ig. 155).
J9421-176
(8) In st a ll t h r u st pla t e on su n gea r (F ig. 156). Not e
t h a t dr ivin g sh ell t h r u st pla t es a r e in t er ch a n gea ble.
Fig. 149 Front Planetary Snap Ring Removal
Use eit h er pla t e on su n gea r a n d a t fr on t /r ea r of
sh ell.

REAR
ANNULUS
GEAR

THRUST TABBED
WASHER THRUST
WASHER
FRONT
FRONT THRUST
PLANETARY WASHER
REAR
PLANETARY
J9421-177

Fig. 150 Front Planetary And Annulus Gear J9121-156


Disassembly
Fig. 152 Assembling Rear Annulus And Planetary
REAR
Gear
PLANETARY
REAR ANNULUS
AND PLANETARY GEAR
ASSEMBLY

J9421-178

Fig. 151 Removing Driving Shell, Rear Planetary J9121-157


And Rear Annulus
t h a t sh ou lder-side of su ppor t fa ces r ea r wa r d (F ig. Fig. 153 Installing Rear Annulus And Planetary On
152). Output Shaft
(3) In st a ll r ea r t h r u st wa sh er on r ea r pla n et a r y (9) H old su n gea r in pla ce a n d in st a ll t h r u st pla t e
gea r. Use en ou gh pet r oleu m jelly t o h old wa sh er in over su n gea r a t r ea r of dr ivin g sh ell (F ig. 157).
pla ce. Also be su r e a ll fou r wa sh er t a bs a r e pr oper ly (10) P osit ion wood block on ben ch a n d su ppor t su n
en ga ged in gea r slot s. gea r on block (F ig. 158). Th is m a kes it ea sier t o a lign
a n d in st a ll su n gea r lock r in g. Keep wood block
21 - 132 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
FRONT (11) Align r ea r t h r u st pla t e on dr ivin g sh ell a n d
TABBED in st a ll su n gea r lock r in g. Be su r e r in g is fu lly sea t ed
THRUST in su n gea r r in g gr oove (F ig. 159).
WASHER
(12) In st a ll a ssem bled dr ivin g sh ell a n d su n gea r
on ou t pu t sh a ft (F ig. 160).
(13) In st a ll r ea r t h r u st wa sh er on fr on t pla n et a r y
gea r (F ig. 161). Use en ou gh pet r oleu m jelly t o h old
wa sh er in pla ce a n d be su r e a ll fou r wa sh er t a bs a r e
sea t ed.

J9121-158

Fig. 154 Installing Rear Planetary Front Thrust


Washer

REAR
THRUST
PLATE J9121-162

Fig. 157 Installing Driving Shell Rear Thrust Plate

J9121-159

Fig. 155 Installing Spacer On Sun Gear

WOOD
BLOCK

J9121-163
SPACER

Fig. 158 Supporting Sun Gear On Wood Block


(14) In st a ll fr on t pla n et a r y gea r on ou t pu t sh a ft
a n d in dr ivin g sh ell (F ig. 162).
(15) In st a ll fr on t t h r u st wa sh er on fr on t pla n et a r y
SUN
gea r. Use en ou gh pet r oleu m jelly t o h old wa sh er in
GEAR pla ce a n d be su r e a ll fou r wa sh er t a bs a r e sea t ed.
J9121-161 (16) Assem ble fr on t a n n u lu s gea r a n d su ppor t , if
n ecessa r y. Be su r e su ppor t sn a p r in g is sea t ed.
Fig. 156 Installing Driving Shell Front Thrust Plate (17) In st a ll fr on t a n n u lu s on fr on t pla n et a r y (F ig.
On Sun Gear 162).
(18) P osit ion t h r u st pla t e on fr on t a n n u lu s gea r
h a n dy a s it will a lso be u sed for gea r t r a in en d pla y su ppor t (F ig. 163). N o te th a t p la te h a s tw o ta bs
ch eck. o n it. Th e s e ta bs fit in n o tc h e s o f a n n u lu s h u b.
XJ TRANSMISSION AND TRANSFER CASE 21 - 133
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(19) In st a ll t h r u st wa sh er in fr on t a n n u lu s (F ig.
164). Alig n fla t o n w a s h e r w ith fla t o n p la n e ta ry
LOCK
RING h u b. Als o be s u re w a s h e r ta b is fa c in g u p .
GROOVE (20) In st a ll fr on t a n n u lu s sn a p r in g (F ig. 165). Use
sn a p r in g plier s t o a void dist or t in g r in g du r in g
in st a lla t ion . Also be su r e r in g is fu lly sea t ed.
(21) In st a ll pla n et a r y select ive sn a p r in g wit h
sn a p r in g plier s (F ig. 166). Be su r e r in g is fu lly
sea t ed.
(22) Tu r n pla n et a r y gea r t r a in a ssem bly over so
dr ivin g sh ell is fa cin g wor kben ch . Th en su ppor t
gea r t r a in on wood block posit ion ed u n der for wa r d
en d of ou t pu t sh a ft . Th is a llows gea r t r a in com po-
DRIVING n en t s t o m ove for wa r d for a ccu r a t e en d pla y ch eck.
SHELL (23) Ch eck pla n et a r y gea r t r a in en d pla y wit h
feeler ga u ge (F ig. 167). Ga u ge goes bet ween sh ou lder
on ou t pu t sh a ft a n d en d of r ea r a n n u lu s su ppor t .
Fig. 159 Installing Sun Gear Lock Ring
(24) Gea r t r a in en d pla y sh ou ld be 0.12 t o 1.22 m m
SUN GEAR/ (0.005 t o 0.048 in .). If en d pla y is in cor r ect , sn a p r in g
DRIVING SHELL (or t h r u st wa sh er s) m a y h a ve t o be r epla ced. Sn a p
ASSEMBLY
r in g is a va ila ble in t h r ee differ en t t h ickn esses for
a dju st m en t pu r poses.

FRONT
PLANETARY
GEAR

J9121-165

Fig. 160 Installing Assembled Sun Gear And Driving FRONT


Shell On Output Shaft ANNULUS
GEAR

J9121-167

Fig. 162 Installing Front Planetary And Annulus


Gears

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

Fig. 164 Installing Front Annulus Thrust Washer

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

Fig. 166 Installing Planetary Selective Snap Ring


XJ TRANSMISSION AND TRANSFER CASE 21 - 135
CLEAN I N G AN D I N SPECT I ON (Cont inue d)

INTERMEDIATE
WEIGHT

SNAP
RING

INNER
WEIGHT
SPRING

INNER
WEIGHT J9521-23

Fig. 168 Governor Weights


SEAL
RING
(HOOK PARK
END) GEAR

SEAL
GOVERNOR
RING
BODY
(PLAIN
END)

~
FILTER'

~
{f~HIN) SNAP
RING

.
.

1
GOVERNOR
SNAP
RING
(THICK)

GOVERNOR
WEIGHT
ASSEMBLY

Fig. 169 Governor Components


BODY
BOLTS(4)

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)

EXTENSION HOUSING AND PARK LOCK


Clea n t h e h ou sin g a n d pa r k lock com pon en t s in
solven t a n d dr y t h em wit h com pr essed a ir.
E xa m in e t h e pa r k lock com pon en t s in t h e h ou sin g.
If r epla cem en t is n ecessa r y, r em ove t h e sh a ft wit h
pa r a llel ja w sn a p r in g plier s (F ig. 170) a n d r em ove
t h e spr a g a n d spr in g. Th en r em ove t h e spr in g clip
a n d r ea ct ion plu g (F ig. 171). Co m p re s s th e re a c -
tio n p lu g s p rin g c lip o n ly e n o u g h to re m o v e
a n d in s ta ll it. D o n o t d is to rt th e c lip d u rin g
re m o v a l o r in s ta lla tio n .
Be su r e a r epla cem en t spr a g is in st a lled so t h e
spr a g lockin g lu g will fa ce t h e pa r k gea r (F ig. 172).
Also be su r e t h e spr in g is cor r ect ly posit ion ed a s
sh own (F ig. 172). Th e spr a g m a y n ot r et r a ct if t h e
spr in g is im pr oper ly in st a lled.

J9121-46

Fig. 171 Park Sprag Reaction Plug And Spring


Location

PARALLEL
JAW
SNAP
RING
PLIERS

J9121-45

Fig. 170 Park Sprag, Shaft And Spring


SPRAG
VALVE BODY LOCKING
LUG
Ser vicea ble va lve body com pon en t s a r e:
• pa r k lock r od a n d E -clip
• swit ch va lve a n d spr in g
• pr essu r e a dju st in g scr ew br a cket
J9121-47
• t h r ot t le va lve lever
• m a n u a l lever Fig. 172 Correct Position Of Sprag And Spring
• m a n u a l lever sh a ft sea l, wa sh er, E -clip a n d
pr essed a ir. Ma ke su r e a ll pa ssa ges a r e clea n a n d
det en t ba ll
fr ee fr om obst r u ct ion s.
• flu id filt er
• con ver t er clu t ch solen oid NOTE: Do not use rags or shop towels to wipe off
Th e r em a in in g va lve body com pon en t s a r e ser viced valve body components. Lint from these materials
on ly a s pa r t of a com plet e va lve body a ssem bly. will adhere to the valve body components. Lint will
Clea n t h e va lve body com pon en t s in a pa r t s clea n - interfere with valve operation and may clog filters
in g solu t ion on ly. Do n ot u se ga solin e, ker osen e, or and fluid passages.
a n y t ype of ca u st ic solu t ion . Dr y t h e pa r t s wit h com -
XJ TRANSMISSION AND TRANSFER CASE 21 - 137
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
In spect t h e t h r ot t le a n d m a n u a l va lve lever s a n d TRANSMISSION
sh a ft s. Do n ot a t t em pt t o st r a igh t en a ben t sh a ft or Clea n t h e ca se in a solven t t a n k. F lu sh t h e ca se
cor r ect a loose lever. Repla ce t h ese com pon en t s if bor es a n d flu id pa ssa ges t h or ou gh ly wit h solven t .
wor n , ben t , loose or da m a ged in a n y wa y. Dr y t h e ca se a n d a ll flu id pa ssa ges wit h com pr essed
In spect a ll of t h e va lve body m a t in g su r fa ces for a ir. Be su r e a ll solven t is r em oved fr om t h e ca se a n d
scr a t ch es, n icks, bu r r s, or dist or t ion . Use a st r a igh t - t h a t a ll flu id pa ssa ges a r e clea r.
edge t o ch eck su r fa ce fla t n ess. Min or scr a t ch es m a y
be r em oved wit h cr ocu s clot h u sin g on ly ver y ligh t NOTE: Do not use shop towels or rags to dry the
pr essu r e. case (or any other transmission component) unless
Min or dist or t ion of a va lve body m a t in g su r fa ce they are made from lint-free materials. Lint will
m a y be cor r ect ed by sm oot h in g t h e su r fa ce wit h cr o- readily adhere to case surfaces and transmission
cu s clot h . Th e clot h sh ou ld be in sh eet for m a n d be components and will circulate throughout the trans-
posit ion ed on a su r fa ce pla t e, sh eet of pla t e gla ss, or mission after assembly. A sufficient quantity of lint
equ a lly fla t su r fa ce. H owever, if dist or t ion is sever e can block fluid passages and interfere with valve
or a n y su r fa ces a r e h ea vily scor ed, t h e va lve body body operation.
will h a ve t o be r epla ced.
In spect t h e ca se for cr a cks, por ou s spot s, wor n
CAUTION: Many of the valve body valves and plugs ser vo bor es, or da m a ged t h r ea ds. H owever, t h e ca se
are made of coated aluminum. Aluminum compo- will h a ve t o be r epla ced if it exh ibit s da m a ge or wea r.
nents can be identified by the dark color of the spe- Lu br ica t e t h e fr on t ba n d a dju st in g scr ew a n d lock-
cial coating applied to the surface (or by testing n u t wit h pet r oleu m jelly a n d t h r ea d it pa r t wa y in t o
with a magnet). DO NOT polish or sand aluminum t h e ca se. Be su r e t h e scr ew t u r n s fr eely a n d does n ot
valves or plugs with any type of material, or under bin d. In st a ll t h e lockn u t on t h e scr ew a ft er ch eckin g
any circumstances. This practice might damage the scr ew t h r ea d oper a t ion .
special coating and cause the valves and plugs to In spect a ll t h e t r a n sm ission bu sh in gs du r in g over-
stick and bind. h a u l. Bu sh in g con dit ion is im por t a n t a s wor n , scor ed
bu sh in gs con t r ibu t e t o low pr essu r es, clu t ch slip a n d
In spect t h e va lves a n d plu gs for scr a t ch es, bu r r s, a cceler a t ed wea r of ot h er com pon en t s. Repla ce wor n ,
n icks, or scor es. Also in spect t h e coa t in g on t h e a lu - or scor ed bu sh in gs, or if dou bt exist s a bou t bu sh in g
m in u m va lves a n d plu gs (F ig. 173). If t h e coa t in g is con dit ion .
da m a ged or wor n t h r ou gh , t h e va lve (or va lve body) Use r ecom m en ded t ools t o r epla ce bu sh in gs. Th e
sh ou ld be r epla ced. t ools a r e sized a n d design ed t o r em ove, in st a ll a n d
Alu m in u m va lves a n d plu gs sh ou ld n ot be sa n ded sea t bu sh in gs cor r ect ly. Th e bu sh in g r epla cem en t
or polish ed u n der a n y cir cu m st a n ces. H owever, m in or t ools a r e in clu ded in Bu sh in g Tool Set s C-3887-B, or
bu r r s or scr a t ch es on st eel va lves a n d plu gs ca n be C-3887-J .
r em oved wit h cr ocu s clot h bu t do n ot r ou n d off t h e P r e-sized ser vice bu sh in gs a r e a va ila ble for
va lve or plu g edges. Squ a r en ess of t h ese edges is r epla cem en t pu r poses. On ly t h e su n gea r bu sh in gs
vit a lly im por t a n t . Th ese edges pr even t for eign m a t t er a r e n ot ser viced. Repla ce t h e gea r a s a n a ssem bly if
fr om lodgin g bet ween t h e va lves, plu gs a n d bor e. t h e bu sh in gs a r e sever ely scor ed, or wor n .
In spect a ll t h e va lve a n d plu g bor es in t h e va lve H eli-Coil in ser t s a r e r ecom m en ded for r epa ir in g
body. Use a pen ligh t t o view t h e bor e in t er ior s. da m a ged, st r ipped or wor n t h r ea ds in a lu m in u m
Repla ce t h e va lve body if a n y bor es a r e dist or t ed or pa r t s. St a in less st eel in ser t s a r e pr efer r ed.
scor ed. In spect a ll of t h e va lve body spr in gs. Th e Th e u se of cr ocu s clot h is per m issible wh er e n eces-
spr in gs m u st be fr ee of dist or t ion , wa r pa ge or br oken sa r y, pr ovidin g it is u sed ca r efu lly. Wh en u sed on
coils. va lves, u se ext r em e ca r e t o a void r ou n din g off sh a r p
Tr ia l fit ea ch va lve a n d plu g in it s bor e t o ch eck edges. Sh a r p edges a r e vit a l a s t h ey pr even t for eign
fr eedom of oper a t ion . Wh en clea n a n d dr y, t h e va lves m a t t er fr om get t in g bet ween t h e va lve a n d va lve
a n d plu gs sh ou ld dr op fr eely in t o t h e bor es. Va lve bor e.
body bor es do n ot ch a n ge dim en sion a lly wit h u se. If Do n ot r eu se oil sea ls, ga sket s, sea l r in gs, or
t h e va lve body fu n ct ion ed cor r ect ly wh en n ew, it will O-r in gs du r in g over h a u l. Repla ce t h ese pa r t s a s a
con t in u e t o oper a t e pr oper ly a ft er clea n in g a n d m a t t er of cou r se. Also do n ot r eu se sn a p r in gs or
in spect ion . It sh ou ld n ot be n ecessa r y t o r epla ce a E -clips t h a t a r e ben t or dist or t ed. Repla ce t h ese pa r t s
va lve body a ssem bly u n less it is da m a ged in h a n - a s well.
dlin g. Lu br ica t e t r a n sm ission pa r t s wit h Mopa r ! ATF
P lu s 3, Type 7176 t r a n sm ission flu id du r in g a ssem -
bly. Use Mopa r ! Door E a se, or Ru -Glyde t o lu br ica t e
21 - 138 TRANSMISSION AND TRANSFER CASE XJ
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
GOVERNOR PLUG 1-2 VALVE REGULATOR VALVE
END PLATE GOVERNOR BODY THROTTLE PRESSURE PLUG
SHUTTLE PLUG
VALVE

SHUTTLE
VALVE
THROTTLE
PLUG

2-3
GOVERNOR
PLUG

2-3 SHIFT
VALVE
END
PLATE
KICKDOWN LIMIT
VALVE BODY
80a13872

Fig. 173 Valve Body Components


pist on sea ls a n d O-r in gs. Use pet r oleu m jelly on FRONT SERVO
t h r u st wa sh er s a n d t o h old pa r t s in pla ce du r in g Clea n t h e ser vo pist on com pon en t s wit h solven t
r ea ssem bly. a n d dr y t h em wit h com pr essed a ir. Wipe t h e ba n d
clea n wit h lin t fr ee sh op t owels.
OVERRUNNING CLUTCH/LOW-REVERSE Repla ce t h e fr on t ba n d if dist or t ed, lin in g is
DRUM/OVERDRIVE PISTON RETAINER bu r n ed, fla kin g off, or wor n t o t h e poin t wh er e t h e
Clea n t h e over r u n n in g clu t ch a ssem bly, clu t ch ca m , gr ooves in t h e lin in g m a t er ia l a r e n o lon ger visible.
low-r ever se dr u m , a n d over dr ive pist on r et a in er in In spect t h e ser vo com pon en t s (F ig. 174). Repla ce
solven t . Dr y t h em wit h com pr essed a ir a ft er clea n - t h e spr in gs if colla psed, dist or t ed or br oken . Repla ce
in g. t h e gu ide, r od a n d pist on if cr a cked, ben t , or wor n .
In spect con dit ion of ea ch clu t ch pa r t a ft er clea n in g. Disca r d t h e ser vo sn a p r in g if dist or t ed or wa r ped.
Repla ce t h e over r u n n in g clu t ch r oller a n d spr in g Ch eck t h e ser vo pist on bor e for wea r. If t h e bor e is
a ssem bly if a n y r oller s or spr in gs a r e wor n or da m - sever ely scor ed, or da m a ged, it will be n ecessa r y t o
a ged, or if t h e r oller ca ge is dist or t ed, or da m a ged. r epla ce t h e ca se.
Repla ce t h e ca m if wor n , cr a cked or da m a ged. Repla ce a n y ser vo com pon en t if dou bt exist s a bou t
Repla ce t h e low-r ever se dr u m if t h e clu t ch r a ce, con dit ion . Do n ot r eu se su spect pa r t s.
r oller su r fa ce or in side dia m et er is scor ed, wor n or
da m a ged. D o n o t re m o v e th e c lu tc h ra c e fro m REAR SERVO
th e lo w -re v e rs e d ru m u n d e r a n y c irc u m s ta n c e s . Rem ove a n d disca r d t h e ser vo pist on sea l r in g (F ig.
Re p la c e th e d ru m a n d ra c e a s a n a s s e m bly if 175). Th en clea n t h e ser vo com pon en t s wit h solven t
e ith e r c o m p o n e n t is d a m a g e d . a n d dr y wit h com pr essed a ir. Repla ce eit h er spr in g if
E xa m in e t h e over dr ive pist on r et a in er ca r efu lly for colla psed, dist or t ed or br oken . Repla ce t h e plu g a n d
wea r, cr a cks, scor in g or ot h er da m a ge. Be su r e t h e pist on if cr a cked, ben t , or wor n . Disca r d t h e ser vo
r et a in er h u b is a sn u g fit in t h e ca se a n d dr u m . sn a p r in gs a n d u se a n ew on es a t a ssem bly.
Repla ce t h e r et a in er if wor n or da m a ged.
XJ TRANSMISSION AND TRANSFER CASE 21 - 139
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
PISTON (II) P osit ion a n a ppr opr ia t e piece of P la st i-
RINGS ga ge# a cr oss bot h gea r s.
(III) Align t h e pla st iga ge t o a fla t a r ea on t h e
SEAL r ea ct ion sh a ft h ou sin g.
RING PISTON (IV) In st a ll t h e r ea ct ion sh a ft t o t h e pu m p
h ou sin g.
ROD
GUIDE (V) Sepa r a t e t h e r ea ct ion sh a ft h ou sin g fr om
t h e pu m p h ou sin g a n d m ea su r e t h e P la st iga ge#
SERVO followin g t h e in st r u ct ion s su pplied wit h it .
PISTON (b) Clea r a n ce bet ween in n er gea r t oot h a n d
ou t er gea r sh ou ld be 0.08 t o 0.19 m m (0.0035 t o
0.0075 in .). Mea su r e clea r a n ce wit h a n a ppr opr ia t e
SERVO feeler ga u ge.
SPRING
(c) Clea r a n ce bet ween ou t er gea r a n d pu m p
h ou sin g sh ou ld a lso be 0.010 t o 0.19 m m (0.0035 t o
0.0075 in .). Mea su r e clea r a n ce wit h a n a ppr opr ia t e
Fig. 174 feeler ga u ge.

SNAP FRONT CLUTCH


Clea n a n d in spect t h e fr on t clu t ch com pon en t s.

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.

PLANETARY GEARTRAIN/OUTPUT SHAFT


Clea n t h e in t er m edia t e sh a ft a n d pla n et a r y com po-
n en t s in solven t a n d dr y t h em wit h com pr essed a ir.
Do n ot spin t h e pla n et a r y pin ion gea r s wit h com -
pr essed a ir.
In spect t h e pla n et a r y gea r set s a n d a n n u lu s gea r s.
J9121-368 Th e pla n et a r y pin ion s, sh a ft s, wa sh er s, a n d r et a in in g
pin s a r e ser vicea ble. H owever, if a pin ion ca r r ier is
Fig. 176 Front Clutch Piston Retainer Check Ball da m a ged, t h e en t ir e pla n et a r y gea r set m u st be
Location r epla ced a s a n a ssem bly.
Repla ce t h e a n n u lu s gea r s if t h e t eet h a r e ch ipped,
br oken , or wor n , or t h e gea r is cr a cked. Repla ce t h e
pla n et a r y t h r u st pla t es a n d t h e t a bbed t h r u st wa sh -
er s if cr a cked, scor ed or wor n .
In spect t h e m a ch in ed su r fa ces of t h e ou t pu t sh a ft .
Be su r e t h e oil pa ssa ges a r e open a n d clea r. Repla ce
t h e sh a ft if scor ed, pit t ed, or da m a ged.
In spect t h e su n gea r a n d dr ivin g sh ell. If eit h er
com pon en t is wor n or da m a ged, r em ove t h e su n gea r
r ea r r et a in in g r in g a n d sepa r a t e t h e su n gea r a n d
FRONT
t h r u st pla t e fr om t h e dr ivin g sh ell. Th en r epla ce t h e
CLUTCH n ecessa r y com pon en t .
RETAINER Repla ce t h e su n gea r a s a n a ssem bly if t h e gea r
BUSHINGS
(NON-SERVICEABLE)
t eet h a r e ch ipped or wor n . Also r epla ce t h e gea r a s
J9321-223 a n a ssem bly if t h e bu sh in gs a r e scor ed or wor n . Th e
su n gea r bu sh in gs a r e n ot ser vicea ble. Repla ce t h e
Fig. 177 Retainer Bushing Location/Inspection t h r u st pla t e if wor n , or sever ely scor ed. Repla ce t h e
dr ivin g sh ell if dist or t ed, cr a cked, or da m a ged in a n y
Repla ce t h e clu t ch discs if wa r ped, wor n , scor ed, wa y.
bu r n ed/ch a r r ed, t h e lu gs a r e da m a ged, or if t h e fa c- Repla ce a ll sn a p r in gs du r in g gea r t r a in a ssem bly.
in g is fla kin g off. Reu sin g sn a p r in gs is n ot r ecom m en ded.
Repla ce t h e st eel pla t es a n d t h e pr essu r e pla t e if
h ea vily scor ed, wa r ped, or br oken . Be su r e t h e dr iv-
in g lu gs on t h e discs a n d pla t es a r e a lso in good con - ADJ U ST M EN T S
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. GEARSHIFT CABLE
Repla ce t h e pist on spr in g a n d wa ve spr in g if eit h er Ch eck a dju st m en t by st a r t in g t h e en gin e in P a r k
pa r t is dist or t ed, wa r ped or br oken . a n d Neu t r a l. Adju st m en t is OK if t h e en gin e st a r t s
Ch eck t h e lu g gr ooves in t h e clu t ch r et a in er. Th e on ly in t h ese posit ion s. Adju st m en t is in cor r ect if t h e
st eel pla t es sh ou ld slide fr eely in t h e slot s. Repla ce en gin e st a r t s in on e bu t n ot bot h posit ion s. If t h e
t h e r et a in er if t h e gr ooves a r e wor n or da m a ged. Also en gin e st a r t s in a n y posit ion ot h er t h a n P a r k or Neu -
ch eck a ct ion of t h e r et a in er ch eck ba ll. Th e ba ll m u st t r a l, or if t h e en gin e will n ot st a r t a t a ll, t h e pa r k/
m ove fr eely a n d n ot st ick. n eu t r a l posit ion swit ch m a y be fa u lt y.
In spect t h e pist on a n d r et a in er sea l su r fa ces for
n icks or scr a t ch es. Min or scr a t ch es ca n be r em oved Gearshift Adjustment Procedure
wit h cr ocu s clot h . H owever, r epla ce t h e pist on a n d/or (1) Sh ift t r a n sm ission in t o P a r k.
r et a in er if t h e sea l su r fa ces a r e ser iou sly da m a ged. (2) Ra ise veh icle.
XJ TRANSMISSION AND TRANSFER CASE 21 - 141
ADJ U ST M EN T S (Cont inue d)
(3) Relea se ca ble a dju st er cla m p (a t t r a n sm ission
en d of ca ble) t o u n lock ca ble.
(4) Un sn a p ca ble fr om ca ble m ou n t in g br a cket on PARK
t r a n sm ission (F ig. 178). LOCK
CABLE
(5) Slide ca ble eyelet off t r a n sm ission sh ift lever.
(6) Ver ify t r a n sm ission sh ift lever is in P a r k
det en t by m ovin g lever fu lly r ea r wa r d. La st r ea r wa r d
det en t is P a r k posit ion .
(7) Ver ify posit ive en ga gem en t of t r a n sm ission
pa r k lock by a t t em pt in g t o r ot a t e pr opeller sh a ft .
Sh a ft will n ot r ot a t e wh en pa r k lock is en ga ged.
(8) Slide ca ble eyelt on t o t r a n sm ission sh ift lever.
(9) Sn a p sh ift ca ble a dju st er in t o m ou n t in g
br a cket on t r a n sm ission .
(10) Lock sh ift ca ble by pr essin g ca ble a dju st er J9321-250
cla m p down u n t il it sn a ps in t o pla ce.
(11) Lower veh icle a n d ch eck en gin e st a r t in g. Fig. 179 Park Lock Cable Attachment
E n gin e sh ou ld st a r t on ly in P a r k a n d Neu t r a l. (a ) Ch eck m ovem en t of r elea se sh ift h a n dle bu t -
t on (floor sh ift ) or r elea se lever (colu m n sh ift ). You
THROTTLE sh ou ld n ot be a ble t o pr ess bu t t on in wa r d or m ove
VALVE
CABLE
colu m n lever.
(b) Tu r n ign it ion swit ch t o RUN posit ion .
(c) Sh ift in g ou t of pa r k sh ou ld n ot be possible.
(d) Apply t h e br a ke a n d a t t em pt t o sh ift ou t of
PARK. Sh ift in g sh ou ld be possible.
(e) Wh ile t h e t r a n sm ission is sh ift ed ou t of
PARK, r elea se t h e br a ke a n d a t t em pt t o sh ift
t h r ou gh a ll gea r s. Relea se t h e sh ift bu t t on a t lea st
on ce du r in g t h is pr ocedu r e. Th e ign it ion key sh ou ld
n ot go t o t h e LOCK posit ion .
(f) Ret u r n t r a n sm ission t o t h e PARK posit ion
' wit h ou t a pplyin g t h e br a ke.

( (8) Move sh ift lever ba ck t o PARK a n d ch eck ign i-


t ion swit ch oper a t ion . You sh ou ld be a ble t o t u r n
swit ch t o LOCK posit ion a n d sh ift lever r elea se bu t -

~
t on /lever sh ou ld n ot m ove.

TRANSMISSION THROTTLE VALVE CABLE


SHIFT TRANSMISSION
CABLE SHIFT LEVER J9321-417 ADJUSTMENT
Th e t r a n sm ission t h r ot t le va lve is oper a t ed by a
Fig. 178 Shift Cable Attachment At ca m on t h e t h r ot t le lever. Th e t h r ot t le lever is oper-
Transmission–Typical a t ed by a n a dju st a ble ca ble (F ig. 180). Th e ca ble is
a t t a ch ed t o a n a r m m ou n t ed on t h e t h r ot t le lever
BRAKE TRANSMISSION SHIFT INTERLOCK sh a ft . A r et a in in g clip a t t h e en gin e-en d of t h e ca ble
CABLE ADJUSTMENT is r em oved t o pr ovide for ca ble a dju st m en t . Th e
(1) Sh ift t r a n sm ission in t o PARK. r et a in in g clip is t h en in st a lled ba ck on t o t h e t h r ot t le
(2) Rem ove sh ift lever bezel a n d con sole scr ews. va lve ca ble t o lock in t h e a dju st m en t .
Ra ise bezel a n d con sole for a ccess t o ca ble. A cor r ect ly a dju st ed t h r ot t le va lve ca ble will ca u se
(3) P u ll ca ble lock bu t t on u p t o r elea se ca ble (F ig. t h e t h r ot t le lever on t h e t r a n sm ission t o m ove sim u l-
179). t a n eou sly wit h t h e t h r ot t le body lever fr om t h e idle
(4) Tu r n ign it ion swit ch t o LOCK posit ion . posit ion . P r oper a dju st m en t will a llow sim u lt a n eou s
(5) Use a spa cer t o cr ea t e a on e m illim et er ga p m ovem en t wit h ou t ca u sin g t h e t r a n sm ission t h r ot t le
bet ween t h e sh ift er pa wl a n d t op of t h e sh ift ga t e. lever t o eit h er m ove a h ea d of, or la g beh in d t h e lever
(6) P u ll ca ble for wa r d. Th en r elea se ca ble a n d on t h e t h r ot t le body.
pr ess ca ble lock bu t t on down u n t il it sn a ps in pla ce.
(7) Ch eck a dju st m en t a s follows:
21 - 142 TRANSMISSION AND TRANSFER CASE XJ
ADJ U ST M EN T S (Cont inue d)

TRANSMISSION ACCELERATOR • If bot h lever s m ove sim u lt a n eou sly fr om idle t o


THROTTLE CABLE h a lf-t h r ot t le a n d ba ck t o idle posit ion , a dju st m en t is
VALVE CABLE cor r ect .
CABLE ENGINE • If t r a n sm ission t h r ot t le lever m oves a h ea d of, or
la gs beh in d t h r ot t le body lever, ca ble a dju st m en t will
be n ecessa r y. Or, if t h r ot t le body lever pr even t s
t r a n sm ission lever fr om r et u r n in g t o closed posit ion ,
ca ble a dju st m en t will be n ecessa r y.

Throttle Valve Cable Adjustment Procedure


(1) Tu r n ign it ion swit ch t o OF F posit ion .
(2) Rem ove a ir clea n er if n ecessa r y.
(3) Discon n ect ca ble en d fr om a t t a ch m en t st u d.
Ca re fu lly s lid e c a ble o ff s tu d . D o n o t p ry o r p u ll
c a ble o ff.
Fig. 180 Throttle Cable Attachment At Engine
(4) Ver ify t h a t t r a n sm ission t h r ot t le lever is in
Checking Throttle Valve Cable Adjustment fu lly closed posit ion . Th en be su r e lever on t h r ot t le
(1) Tu r n ign it ion key t o OF F posit ion . body is a t cu r b idle posit ion .
(2) Rem ove a ir clea n er. (5) In ser t a sm a ll scr ewdr iver u n der edge of
(3) Ver ify t h a t lever on t h r ot t le body is a t cu r b idle r et a in in g clip a n d r em ove r et a in in g clip.
posit ion . Th en ver ify t h a t t r a n sm ission t h r ot t le lever (6) Cen t er ca ble en d on a t t a ch m en t st u d t o wit h in
(F ig. 181) is a lso a t idle (fu lly for wa r d) posit ion . 1 m m (0.039 in .).

NOTE: Be sure that as the cable is pulled forward


and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.

(7) In st a ll r et a in in g clip on t o ca ble h ou sin g.


(8) Ch eck ca ble a dju st m en t . Ver ify t r a n sm ission
t h r ot t le lever a n d lever on t h r ot t le body m ove sim u l-
t a n eou sly.

FRONT BAND ADJUSTMENT


Th e fr on t (kickdown ) ba n d a dju st in g scr ew is
SHIFT CABLE
BRACKET
J9321-414 loca t ed on t h e left side of t h e t r a n sm ission ca se
a bove t h e m a n u a l va lve a n d t h r ot t le va lve lever s.
Fig. 181 Throttle Cable Attachment At Transmission (1) Ra ise veh icle.
(2) Loosen ba n d a dju st in g scr ew lockn u t (F ig. 182).
(4) Slide ca ble off a t t a ch m en t st u d on t h r ot t le body
Th en ba ck lockn u t off 3-5 t u r n s. Be su r e a dju st in g
lever.
scr ew t u r n s fr eely in ca se. Apply lu br ica n t t o scr ew
(5) Com pa r e posit ion of ca ble en d t o a t t a ch m en t
t h r ea ds if n ecessa r y.
st u d on t h r ot t le body lever :
(3) Tigh t en ba n d a dju st in g scr ew t o 8 N·m (72 in .
• Ca ble en d a n d a t t a ch m en t st u d sh ou ld be
lbs.) t or qu e wit h In ch P ou n d Tor qu e Wr en ch
a lign ed (or cen t er ed on on e a n ot h er ) t o wit h in 1 m m
C-3380-A, a 3-in . ext en sion a n d 5/16 socket .
(0.039 in .) in eit h er dir ect ion .
• If ca ble en d a n d a t t a ch m en t st u d a r e m isa lign ed CAUTION: If Adapter C-3705 is needed to reach the
(off cen t er ), ca ble will h a ve t o be a dju st ed a s adjusting screw (Fig. 183), tighten the screw to only
descr ibed in Th r ot t le Va lve Ca ble Adju st m en t pr oce- 5 N·m (47-50 in. lbs.) torque.
du r e.
(6) Recon n ect ca ble en d t o a t t a ch m en t st u d. Th en (4) Ba ck off fr on t ba n d a dju st in g scr ew 2-1/2
wit h a id of a h elper, obser ve m ovem en t of t r a n sm is- t u r n s.
sion t h r ot t le lever a n d lever on t h r ot t le body. (5) H old a dju st er scr ew in posit ion a n d t igh t en
lockn u t t o 41 N·m (30 ft . lbs.) t or qu e.
(6) Lower veh icle.
XJ TRANSMISSION AND TRANSFER CASE 21 - 143
ADJ U ST M EN T S (Cont inue d)

~I

Fig. 182 Front Band Adjustment Screw Location


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.

On e com plet e t u r n of t h e a dju st in g scr ew ch a n ges


VALVE BODY lin e pr essu r e a ppr oxim a t ely 1-2/3 psi (9 kP a ).
Tu r n in g t h e a dju st in g scr ew cou n t er clockwise
CONTROL PRESSURE ADJUSTMENTS in cr ea ses pr essu r e wh ile t u r n in g t h e scr ew clockwise
Th er e a r e t wo con t r ol pr essu r e a dju st m en t s on t h e decr ea ses pr essu r e.
va lve body;
• Lin e P r essu r e
• Th r ot t le P r essu r e
21 - 144 TRANSMISSION AND TRANSFER CASE XJ
ADJ U ST M EN T S (Cont inue d)
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
SPECIAL TOOL
C-3763
(POSITIONED
HEX BETWEEN
WRENCH THROTTLE
(IN THROTTLE LEVER AND
LEVER -,- ~l~KDOWN VALVE)
ADJUSTING --- =
SCREW)

Fig. 185 Line Pressure Adjustment


THROTTLE PRESSURE ADJUSTMENT J9521-109
In ser t Ga u ge Tool C-3763 bet ween t h e t h r ot t le
lever ca m a n d t h e kickdown va lve st em (F ig. 186). Fig. 186 Throttle Pressure Adjustment
P u sh t h e ga u ge t ool in wa r d t o com pr ess t h e kick-
down va lve a ga in st t h e spr in g a n d bot t om t h e t h r ot -
SCH EM AT I CS AN D DI AGRAM S
t le va lve.
Ma in t a in pr essu r e a ga in st kickdown va lve spr in g. HYDRAULIC SCHEMATICS
Tu r n t h r ot t le lever st op scr ew u n t il t h e scr ew h ea d
t ou ch es t h r ot t le lever t a n g a n d t h e t h r ot t le lever ca m
t ou ch es ga u ge t ool.
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
XJ
TO
UBRICATION

- - - OIL PRESSURES - - -

LINE 57-63 PSI 11111 CONVERTER 57-63 PSI ~

PUMP SUCTION t::::::::I LUBRICATION 5-30 PSI L::::H


SELECTOR LEVER IN THROTTLE 0-10 PSI ~ TORQUE CONVERTER
NEUTRAL
OIL FILTER ENGINE RUNNING

TRANSMISSION AND TRANSFER CASE


- OIL PRESSURES -

LINE 0-30 PSI -

PUMP SUCTION !:::::=:::~


SELECTOR LEVER IN
PARK
ENGINE RUNNING

'
'-> 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

TRANSMISSION AND TRANSFER CASE


Tb
LUBRICATION

- - - 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)

TRANSMISSION AND TRANSFER CASE


TO
LUBRICATION

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

TRANSMISSION AND TRANSFER CASE


CONVERTER
CLUTCH
VALVE

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)

TRANSMISSION AND TRANSFER CASE


~1:P SUCT~::

THROTTLE
4

PSI

0-94 PSI ~
=
- - - O I L PRESSURES---

I ~:B::CE:~:N :~:: ::: ~


GOVERNOR 6-94 PSI IDDD
TORQUE CONVERTER
SELECTOR LEVER IN

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

TRANSMISSION AND TRANSFER CASE


CONVERTER
CLUTCH
VALVE

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

.. . .. ... . ... . . OIL FILTER GOVERNOR 6-40 PSI IDID


SELECTOR LEVER IN DRIVE TORQUE CONVERTER
(PART THROTTLE KICKDOWN)
BELOW 40 M.P.H. J9521-83

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)

TRANSMISSION AND TRANSFER CASE


TO
LUBRICATION

- - - 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

TRANSMISSION AND TRANSFER CASE


CONVERTER
CLUTCH
VALVE

-::=...--=---=------=--~ -,--_-_-_-_-_-_-_-_-_-~--._,. . . ,
'-'--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

TRANSMISSION AND TRANSFER CASE


TO
LUBRICATION

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 ~

, , .. , .. , . .. .. , ...... OIL FILTER GOVERNOR 0-30 PSI IIIDDD TORQUE CONVERTER-~~~


SELECTOR LEVER IN

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

TRANSMISSION AND TRANSFER CASE


CONVERTER
CLUTCH
VALVE

::=--=----=----=----=-----=------=--,-.----------------------_-_~-r,~ - ,- - -- _- _- _-----__,~~-----~~~~~-=:r-.---- ;.==========l 11 :: / ,1

-~--------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/

TRANSMISSION AND TRANSFER CASE


LUBE PRESSURE
(5-57 psi)

!::::::::::;::::::::~
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

TRANSMISSION AND TRANSFER CASE


LINE PRESSURE
", ..,,,d (55-62 psi)

~
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

SEIECIOR lEVER IN MANUAL 2


SECOND GEAR
CLOSED lliROmE

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

COMPONENT METRIC INCH


Oil pump gear tip clearance 0.089-0.190 mm 0.0035-0.0075 in.
Planetary end play 0.125-1.19 mm 0.001-0.047 in.
Input shaft end play 0.56-2.31 mm 0.022-0.091 in.
Clutch pack clearance/Front 4-disc. 1.70-3.40 mm 0.067-0.134 in.
Clutch pack clearance/Rear 4-disc. 0.559-0.940 mm 0.022-0.037 in.
Front clutch spring usage 1 spring
30RH-Front Band adjustment from 72 in. lbs. Back off 2.5 turns
30RH-Rear Band adjustment from 41 in. lbs. Back off 7 turns
Recommended fluid Mopar$, ATF Plus 3, Type 7176

THRUST WASHER/SPACER/SNAP RING DIMENSIONS

COMPONENT METRIC INCH


Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Output shaft thrust plate (output shaft pilot hub) 1.5-1.6mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.7-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.086 in.
Rear clutch pack snap ring 1.5-1.6 mm 0.06-0.062 in.
1.7-1.8 mm 0.068-0.070 in.
1.9-2.0 mm 0.076-0.078 in.
1.0-1.1 mm 0.040-0.044 in.
Planetary geartrain snap ring
1.6-1.7 mm 0.062-0.066 in.
(at front of output shaft)
2.1-2.2 mm 0.082-0.086 in.

PRESSURE TEST—ALL

ITEM RANGE PRESSURE


Line pressure (at Closed throttle 372-414 kPa (54-60 psi).
accumulator)
Front servo Third gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi) at 1600
rpm.
Governor D range closed Pressure should respond smoothly to changes in mph and return
throttle to 0-7 kPa (0-1.5 psi) when stopped with transmission in D, 1, 2.
Pressure above 7 kPa (1.5 psi) at stand still will prevent
transmission from downshifting.
21 - 158 TRANSMISSION AND TRANSFER CASE XJ
SPECI FI CAT I ON S (Cont inue d)

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)

Pressure Gauge—C-3293SP Spring Compressor—C-3575-A

Dial Indicator—C-3339 Spring Compressor—C-3863-A

Spring Compressor—C-3422-B Adapter, Band Adjuster—C-3705

Transmission Repair Stand—C-3750-B


Fixture, Engine Support—C-3487-A
21 - 160 TRANSMISSION AND TRANSFER CASE XJ
SPECI AL T OOLS (Cont inue d)

Puller, Slide Hammer—C-3752 Cup, Remover—SP-3633

Gauge, Throttle Setting—C-3763 Remover, Bushing—SP-5301

Seal Installer—C-3860-A Installer, Bushing—SP-5118

Bushing Remover/Installer—C-3887-J Installer, Bushing—SP-5302


XJ TRANSMISSION AND TRANSFER CASE 21 - 161
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

Nut, Bushing Remover—SP-1191


XJ TRANSMISSION AND TRANSFER CASE 21 - 163

AW–4 AU T OM AT I C T RAN SM I SSI ON

INDEX
page page

GENERAL INFORMATION TRANSMISSION SOLENOID TESTING . . . . . . 180


AW–4 AUTOMATIC TRANSMISSION . . . . . . . . . 164 SERVICE PROCEDURES
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . 165 ALUMINUM THREAD REPAIR . . . . . . . . . . . . . 186
EFFECTS OF INCORRECT FLUID LEVEL . . . . 164 CHECKING FLUID CONDITION . . . . . . . . . . . . 185
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . 165 CHECKING FLUID LEVEL . . . . . . . . . . . . . . . . 185
RECOMMENDED FLUID CAPACITY . . . . . . . . . 164 FLUSHING COOLERS AND TUBES . . . . . . . . . 186
TRANSMISSION IDENTIFICATION . . . . . . . . . . 164 OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . 185
TRANSMISSION RANGES AND SHIFT LEVER REFILLING AFTER OVERHAUL OR FLUID/
POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 165 FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . 185
DESCRIPTION AND OPERATION TRANSMISSION CONTROL MODULE (TCM)
BRAKE TRANSMISSION SHIFT INTERLOCK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . 176 REMOVAL AND INSTALLATION
ELECTRONIC CONTROLS . . . . . . . . . . . . . . . . 166 ACCUMULATOR PISTONS AND SPRINGS . . . . 199
FIRST/SECOND/THIRD/REVERSE GEAR ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . 189
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 167 BRAKE TRANSMISSION SHIFT INTERLOCK . . 193
FOURTH GEAR OVERDRIVE GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 192
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 166 MANUAL VALVE SHAFT SEAL . . . . . . . . . . . . . 198
GEARTRAIN OPERATION AND APPLICATION OIL PUMP SEAL . . . . . . . . . . . . . . . . . . . . . . . . 203
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 PARK ROD AND PAWL . . . . . . . . . . . . . . . . . . . 201
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 169 PARK/NEUTRAL POSITION SWITCH . . . . . . . . 191
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 SECOND COAST BRAKE SERVO . . . . . . . . . . 200
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 SOLENOID HARNESS ADAPTER SEAL . . . . . . 196
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . 166 SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . 189
TRANSMISSION CONTROL MODULE (TCM) . . 166 SPEED SENSOR ROTOR-SPEEDOMETER
TRANSMISSION COOLER . . . . . . . . . . . . . . . . 176 DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 190
TRANSMISSION VALVE BODY SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . 189
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 169 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . 188
TRANSMISSION VALVE BODY SOLENOIDS . . 166 TRANSMISSION AND TORQUE
DIAGNOSIS AND TESTING CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . 187
FLOW TESTING TRANSMISSION MAIN TRANSMISSION CONTROL MODULE . . . . . . . 196
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 TRANSMISSION THROTTLE CABLE . . . . . . . . 202
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 183 TRANSMISSION VALVE BODY . . . . . . . . . . . . . 194
GENERAL DIAGNOSIS INFORMATION . . . . . . . 177 TRANSMISSION VALVE BODY SOLENOIDS . . 193
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . 179 DISASSEMBLY AND ASSEMBLY
MANUAL SHIFTING TEST . . . . . . . . . . . . . . . . 178 DIRECT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 243
PARK/NEUTRAL POSITION SWITCH . . . . . . . . 183 FORWARD CLUTCH . . . . . . . . . . . . . . . . . . . . . 247
PRELIMINARY INSPECTION AND FRONT PLANETARY GEAR . . . . . . . . . . . . . . . 252
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 177 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
PRESSURE TEST ANALYSIS . . . . . . . . . . . . . . 179 OVERDRIVE PLANETARY GEAR AND
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . . . 180 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
SPEED SENSOR TESTING . . . . . . . . . . . . . . . 183 OVERDRIVE SUPPORT . . . . . . . . . . . . . . . . . . 240
STALL SPEED TEST ANALYSIS . . . . . . . . . . . . 180 PLANETARY/BRAKE PACK/OUTPUT SHAFT . . 260
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . 180 SECOND BRAKE . . . . . . . . . . . . . . . . . . . . . . . 256
THROTTLE VALVE CABLE . . . . . . . . . . . . . . . . 183 SUN GEAR AND NO. 1 ONE–WAY CLUTCH . . . 254
TIME LAG TEST . . . . . . . . . . . . . . . . . . . . . . . . 180 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 204
TIME LAG TEST ANALYSIS . . . . . . . . . . . . . . . 180 TRANSMISSION VALVE BODY . . . . . . . . . . . . . 264
TORQUE CONVERTER STALL TEST . . . . . . . . 179 CLEANING AND INSPECTION
TORQUE CONVERTER STATOR CLUTCH TRANSMISSION PARTS CLEANING AND
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 184 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 267
21 - 164 TRANSMISSION AND TRANSFER CASE XJ

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

GEN ERAL I N FORM AT I ON


AW–4 AUTOMATIC TRANSMISSION
Th e AW–4 is a 4–speed, elect r on ica lly con t r olled
a u t om a t ic t r a n sm ission (F ig. 1).
Th e r u n n in g gea r con sist s of a n oil pu m p, pla n e-
t a r y gea r set s, clu t ch a n d br a ke u n it s, h ydr a u lic
a ccu m u la t or s, a va lve body wit h elect r ica l solen oids,
a n d a t r a n sm ission con t r ol m odu le (TCM). Ca bles a r e
u sed t o pr ovide sh ift a n d t h r ot t le pr essu r e con t r ol
in for m a t ion . A pa r k/n eu t r a l posit ion swit ch per m it s
en gin e st a r t in g in t h e P a r k a n d Neu t r a l r a n ges on ly.
Th e va lve body solen oids a r e con t r olled by sign a ls
fr om t h e t r a n sm ission con t r ol m odu le (TCM). Sign a l J8921-400
sequ en ce is det er m in ed by in pu t s fr om va r iou s sen -
sor s t o t h e TCM. Fig. 2 Transmission Identification
F ou r t h gea r is a n 0.75:1 r a t io over dr ive r a n ge.
F ir st , secon d, t h ir d a n d r ever se gea r a r e con ven t ion a l RECOMMENDED FLUID CAPACITY
r a n ges. Th ir d gea r r a t io is 1:1. A sepa r a t e pla n et a r y Recom m en ded a n d pr efer r ed flu id for t h e AW–4
gea r set pr ovides over dr ive oper a t ion in fou r t h gea r. t r a n sm ission is Mopa r Dexr on IIE /Mer con .
Mopa r Dexr on II ca n be u sed bu t on ly in em er-
TRANSMISSION IDENTIFICATION gen cy sit u a t ion s wh er e Mer con flu id is n ot a va ila ble.
Th e t r a n sm ission I.D. pla t e is a t t a ch ed t o t h e ca se Appr oxim a t e r efill ca pa cit y for t h e AW–4 is 8.0
(F ig. 2). Th e pla t e con t a in s t h e t r a n sm ission ser ia l lit er s (16.9 pin t s).
a n d m odel n u m ber s. Refer t o t h e in for m a t ion on t h is
pla t e wh en or der in g ser vice pa r t s. EFFECTS OF INCORRECT FLUID LEVEL
A low flu id level a llows t h e pu m p t o t a ke in a ir
a lon g wit h t h e flu id. Air in t h e flu id will ca u se flu id
pr essu r es t o be low a n d develop slower t h a n n or m a l.

J8921-398

Fig. 1 AW–4 Automatic Transmission


XJ TRANSMISSION AND TRANSFER CASE 21 - 165
GEN ERAL I N FORM AT I ON (Cont inue d)
If t h e t r a n sm ission is over filled, t h e gea r s ch u r n t h e is t o r epla ce t h e r a dia t or a s t h e cooler in t h e r a dia t or
flu id in t o foa m . Th is a er a t es t h e flu id a n d ca u sin g is n ot a ser vicea ble pa r t . If coola n t h a s cir cu la t ed
t h e sa m e con dit ion s occu r r in g wit h a low level. In t h r ou gh t h e t r a n sm ission for som e t im e, a n over h a u l
eit h er ca se, a ir bu bbles ca u se flu id over h ea t in g, oxi- m a y a lso be n ecessa r y; especia lly if sh ift pr oblem s
da t ion a n d va r n ish bu ildu p wh ich in t er fer es wit h h a d developed.
va lve, clu t ch a n d ser vo oper a t ion . F oa m in g a lso Th e t r a n sm ission cooler a n d lin es sh ou ld be
ca u ses flu id expa n sion wh ich ca n r esu lt in flu id over- r ever se flu sh ed wh en ever a m a lfu n ct ion gen er a t es
flow fr om t h e t r a n sm ission ven t or fill t u be. F lu id slu dge a n d/or debr is. Th e t or qu e con ver t er sh ou ld
over flow ca n ea sily be m ist a ken for a lea k if in spec- a lso be r epla ced a t t h e sa m e t im e.
t ion is n ot ca r efu l. F a ilu r e t o flu sh t h e cooler a n d lin es will r esu lt in
r econ t a m in a t ion . F lu sh in g a pplies t o a u xilia r y cool-
CAUSES OF BURNT FLUID er s a s well. Th e t or qu e con ver t er sh ou ld a lso be
Bu r n t , discolor ed flu id is a r esu lt of over h ea t in g r epla ced wh en ever a fa ilu r e gen er a t es slu dge a n d
wh ich h a s t wo pr im a r y ca u ses. debr is. Th is is n ecessa r y beca u se n or m a l con ver t er
(1) A r esu lt of r est r ict ed flu id flow t h r ou gh t h e flu sh in g pr ocedu r es will n ot r em ove a ll con t a m i-
m a in a n d/or a u xilia r y cooler. Th is con dit ion is u su - n a n t s.
a lly t h e r esu lt of a fa u lt y or im pr oper ly in st a lled
dr a in ba ck va lve, a da m a ged m a in cooler, or sever e TRANSMISSION RANGES AND SHIFT LEVER
r est r ict ion s in t h e cooler s a n d lin es ca u sed by debr is POSITIONS
or kin ked lin es. Th e AW–4 t r a n sm ission h a s six r a n ges a n d sh ift
(2) H ea vy du t y oper a t ion wit h a veh icle n ot pr op- lever posit ion s. P a r k, Rever se a n d Neu t r a l a r e con -
er ly equ ipped for t h is t ype of oper a t ion . Tr a iler t ow- ven t ion a l a n d m ech a n ica lly oper a t ed. Th e 1–2, 3 a n d
in g or sim ila r h igh loa d oper a t ion will over h ea t t h e D r a n ges pr ovide elect r on ica lly con t r olled sh ift in g.
t r a n sm ission flu id if t h e veh icle is im pr oper ly Th e 1–2 posit ion pr ovides fir st a n d secon d gea r
equ ipped. Su ch veh icles sh ou ld h a ve a n a u xilia r y on ly. Th e 3 posit ion pr ovides fir st , secon d a n d t h ir d
t r a n sm ission flu id cooler, a h ea vy du t y coolin g sys- gea r.
t em , a n d t h e en gin e/a xle r a t io com bin a t ion n eeded t o Th e D r a n ge pr ovides fir st t h r ou gh fou r t h gea r.
h a n dle h ea vy loa ds. Over dr ive fou r t h gea r r a n ge is a va ila ble on ly wh en
t h e sh ift lever is in D posit ion (F ig. 3).
FLUID CONTAMINATION
Tr a n sm ission flu id con t a m in a t ion is gen er a lly a
r esu lt of:
• a ddin g in cor r ect flu id
p PARK

• fa ilu r e t o clea n dipst ick a n d fill t u be wh en


ch eckin g level
• en gin e coola n t en t er in g t h e flu id
R REVERSE

• in t er n a l fa ilu r e t h a t gen er a t es debr is


• over h ea t t h a t gen er a t es slu dge (flu id br ea k-
down )
N NEUTRAL

• fa ilu r e t o r ever se flu sh cooler a n d lin es a ft er FIRST THROUGH FOURTH


r epa ir
• fa ilu r e t o r epla ce con t a m in a t ed con ver t er a ft er
D GEAR (FOURTH GEAR
OVERDRIVE)

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)

sh ift s, slippa ge, a bn or m a l wea r a n d even t u a l fa ilu r e


du e t o flu id br ea kdown a n d slu dge for m a t ion . Avoid
t h is con dit ion by u sin g r ecom m en ded flu ids on ly.
1-2 FIRST-SECOND GEAR
(MANUAL)

Th e dipst ick ca p a n d fill t u be sh ou ld be wiped


clea n befor e ch eckin g flu id level. Dir t , gr ea se a n d J8921-399
ot h er for eign m a t er ia l on t h e ca p a n d t u be cou ld fa ll
in t o t h e t u be if n ot r em oved befor eh a n d. Ta ke t h e
Fig. 3 AW–4 Shift Lever Positions And Transmission
t im e t o wipe t h e ca p a n d t u be clea n befor e wit h dr a w-
Ranges
in g t h e dipst ick.
E n gin e coola n t in t h e t r a n sm ission flu id is gen er-
a lly ca u sed by a cooler m a lfu n ct ion . Th e on ly r em edy
21 - 166 TRANSMISSION AND TRANSFER CASE XJ

DESCRI PT I ON AN D OPERAT I ON Th e swit ch is m ou n t ed on t h e br a ke peda l br a cket


a n d sign a ls t h e t r a n sm ission con t r ol m odu le wh en
ELECTRONIC CONTROLS t h e peda l is pr essed or r elea sed.
Th e AW–4 is elect r on ica lly con t r olled in 1, 2, 3 a n d
D r a n ges. Con t r ols con sist of t h e t r a n sm ission con t r ol TORQUE CONVERTER
m odu le (TCM), va lve body solen oids a n d va r iou s sen - A t h r ee elem en t t or qu e con ver t er is u sed for a ll
sor s. Th e sen sor s m on it or veh icle speed, t h r ot t le a pplica t ion s. Th e con ver t er con t a in s a n im peller, st a -
open in g, sh ift lever posit ion a n d br a ke peda l a pplica - t or, a n d t u r bin e.
t ion . Th e AW–4 con ver t er s a r e a ll equ ipped wit h a con -
ver t er clu t ch m ech a n ism . Th e clu t ch con sist s of a
TRANSMISSION CONTROL MODULE (TCM) slidin g clu t ch pist on , clu t ch spr in gs a n d t h e clu t ch
Th e m odu le det er m in es sh ift a n d con ver t er clu t ch disc m a t er ia l (F ig. 4). Th e clu t ch pr ovides opt im u m
en ga gem en t t im in g ba sed on sign a ls fr om sen sor s. t or qu e t r a n sfer a n d econ om y wh en en ga ged.
Th e va lve body solen oids a r e a ct iva t ed, or dea ct i-
va t ed a ccor din gly.
Th e TCM h a s a self dia gn ost ic pr ogr a m . Com po-
n en t a n d cir cu it r y m a lfu n ct ion s ca n be dia gn osed
wit h t h e DRB sca n t ool. On ce a m a lfu n ct ion is n ot ed
a n d st or ed in con t r ol m odu le m em or y, it is r et a in ed
even a ft er t h e pr oblem h a s been cor r ect ed. To ca n cel
a st or ed m a lfu n ct ion , discon n ect a n d r econ n ect t h e
"Tr a n s." fu se in t h e m odu le h a r n ess.

TRANSMISSION VALVE BODY SOLENOIDS


Th e solen oids a r e m ou n t ed on t h e va lve body a n d
oper a t ed by t h e TCM. Th e solen oids con t r ol oper a t ion
of t h e con ver t er clu t ch a n d sh ift va lves in r espon se t o
in pu t sign a ls fr om t h e m odu le.

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

Fig. 5 Fourth Gear Overdrive Components


a pplied t h r ou gh t r a n sm ission va lve body solen oid FIRST/SECOND/THIRD/REVERSE GEAR
n u m ber t wo.
COMPONENTS
In fou r t h gea r, t h e over dr ive br a ke pr even t s t h e
F ir st t h r ou gh t h ir d a n d r ever se gea r com pon en t s
over dr ive su n gea r fr om t u r n in g. Th e over dr ive in pu t
a r e ou t lin ed in (F ig. 6).
sh a ft a n d pla n et a r y ca r r ier r ot a t e a s a u n it . Th e su n
Th e in pu t sh a ft is m esh ed wit h t h e dir ect clu t ch
gea r a n d over dr ive dir ect clu t ch dr u m a r e in m esh
h u b a n d t h e for wa r d clu t ch dr u m . Th ese elem en t s
a n d oper a t e a s a sin gle u n it . Th e dir ect clu t ch
r ot a t e a s a u n it . Th e for wa r d clu t ch h u b r ot a t es a s a
splin es fu n ct ion a s t h e h u b for t h e over dr ive br a ke.
u n it wit h t h e fr on t pla n et a r y r in g gea r. Th e dir ect
Th e on e–wa y clu t ch ou t er r a ce is in m esh wit h t h e
clu t ch dr u m is m esh ed wit h t h e for wa r d en d of t h e
pla n et a r y ca r r ier. Th e in n er r a ce is fixed t o t h e su n
pla n et a r y su n gea r.
gea r sh a ft .
Th e secon d br a ke h u b ser ves a s t h e ou t er r a ce of
on e–wa y clu t ch No. 1. Th e clu t ch in n er r a ce is locked
wit h t h e fr on t /r ea r su n gea r. Th e in n er r a ce of on e–
wa y clu t ch No. 2 is splin ed t o t h e t r a n sm ission ca se

REAR PLANETARY CARRIER

FRONT PLANETARY
CARRIER

INPUT SHAFT ONE-WAY CLUTCH NO. 2 J8921-403

Fig. 6 First/Second/Third/Reverse Gear Components


21 - 168 TRANSMISSION AND TRANSFER CASE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
a n d is locked. Th e ou t er r a ce r ot a t es a s a u n it wit h Th e Com pon en t F u n ct ion Ch a r t descr ibes ba sic
t h e r ea r pla n et a r y ca r r ier. fu n ct ion of va r iou s gea r t r a in elem en t s. Th e Com po-
Th e r ea r pla n et a r y r in g gea r is splin ed t o t h e ou t - n en t Applica t ion Ch a r t in dica t es wh ich elem en t s
pu t sh a ft . Th e fr on t pla n et a r y ca r r ier a n d r ea r ca r- (in clu din g va lve body solen oids), a r e a pplied in t h e
r ier r in g gea r a r e m esh ed a n d r ot a t e a s a u n it wit h va r iou s gea r r a n ges.
t h e ou t pu t sh a ft .

GEARTRAIN OPERATION AND APPLICATION


CHARTS
Oper a t ion a n d a pplica t ion of t h e fir st t h r ou gh
fou r t h a n d r ever se gea r elem en t s a r e ou t lin ed in t h e
fu n ct ion a n d a pplica t ion ch a r t s.

COM PON EN T FU N CT I ON CH ART

COMPONENT NAME COMPONENT FUNCTION


Overdrive Direct Clutch Connects overdrive sun gear and overdrive carrier.
Overdrive Brake Prevents overdrive sun gear from turning either clockwise or
counter-clockwise.
Overdrive One-Way Clutch When transmission is driven by engine, connects overdrive sun gear
and overdrive carrier.
Forward Clutch Connects input shaft and front ring gear.
Direct Clutch Connects input shaft to the front and rear ring gears.
Second Coast Brake Prevents front and rear sun gear from turning either clockwise or
counter-clockwise.
Second Brake Prevents outer race of number 1 one-way clutch from turning either
clockwise or counter-clockwise, thus preventing the front and rear sun
gears from turning counter-clockwise.
First/Reverse Brake Prevents the rear planetary carrier from turning either clockwise or
counter-clockwise.
Number 1 One-way Clutch When second brake is operating, prevents the front and rear sun
gears from turning counter-clockwise.
Number 2 One-Way Clutch Prevents the rear planetary carrier from turning counter-clockwise.
XJ TRANSMISSION AND TRANSFER CASE 21 - 169
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

HYDRAULIC SYSTEM body sect ion (F ig. 8). Th e r em a in in g con t r ol a n d sh ift


COM PON EN T APPLI CAT I ON CH ART

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 .

OIL PUMP LOWER


A gea r –t ype oil pu m p is u sed. Th e pu m p gea r s a r e GASKET
m ou n t ed in t h e pu m p body. Th e pu m p dr ive gea r is
oper a t ed by t h e t or qu e con ver t er h u b. Dr ive t a n gs on
t h e h u b en ga ge in dr ive slot s in t h e dr ive gea r.
80aef261
TRANSMISSION VALVE BODY COMPONENTS
Tr a n sm ission oper a t in g pr essu r e is su pplied t o t h e Fig. 7 Two–Section Transmission Valve Body
clu t ch a n d br a ke a pply cir cu it s t h r ou gh t h e t r a n sm is- va lves plu s ch eck ba lls a n d on e a ddit ion a l oil
sion va lve body. Th e va lve body con sist s of a n u pper st r a in er a r e loca t ed in t h e u pper body sect ion
body, lower body, sepa r a t or pla t e a n d u pper a n d (F ig. 9).
lower ga sket s (F ig. 7). Th e va r iou s spool va lves,
sleeves, plu gs a n d spr in gs a r e loca t ed wit h in t h e t wo
body sect ion s.
Th e m a n u a l va lve, 1–2 sh ift va lve, pr im a r y r egu la -
t or va lve, a ccu m u la t or con t r ol va lve, ch eck ba lls,
solen oids a n d oil st r a in er s a r e loca t ed in t h e lower
21 - 170 TRANSMISSION AND TRANSFER CASE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

0
LOWER 0
BODY

ACCUMULATOR
CONTROL
VALVE

~~!----1-2 SHIFT VALVE

PRIMARY
REGULATOR
VALVE

MANUAL VALVE
80aef262

Fig. 8 Upper Body Components

DOWNSHIFT PLUG

UPPER
BODY

CUT-BACK VALVE

80aef263

Fig. 9 Lower Body Components


MANUAL VALVE en gin e loa d. Th e va lve is a ct u a t ed by t h r ot t le va lve
Th e m a n u a l va lve is oper a t ed by t h e gea r sh ift lin k- pr essu r e.
a ge. Th e va lve diver t s flu id t o t h e a pply cir cu it s Du r in g h igh loa d oper a t ion , t h e va lve in cr ea ses
a ccor din g t o sh ift lever posit ion (F ig. 10). lin e pr essu r e t o m a in t a in posit ive clu t ch a n d br a ke
en ga gem en t . At ligh t loa d, t h e va lve decr ea ses lin e
PRIMARY REGULATOR VALVE pr essu r e ju st en ou gh t o m a in t a in sm oot h en ga ge-
Th e pr im a r y r egu la t or va lve (F ig. 11) m odu la t es m en t .
lin e pr essu r e t o t h e clu t ch es a n d br a kes a ccor din g t o
XJ TRANSMISSION AND TRANSFER CASE 21 - 171
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
THROTTLE VALVE AND DOWNSHIFT PLUG
Th e t h r ot t le va lve a n d down sh ift plu g (F ig. 12)
LINE PRESSURE con t r ol t h r ot t le pr essu r e t o t h e pr im a r y r egu la t or
(FROM OIL PUMP) va lve.

"R" RANGE Vo, E, 1-2 RANGE


DRAIN t 1-2

~-'1=----=------___J---,_L....1t ====== lJGE THROTTLE


VALVE
CAM


DRAIN
CUT-BACK
DOWNSHIFT
l:WI----PLUG

30R~-2,
RANGE
PRESSURE
(FROM CUT-BACK
VALVE)
¢--------'
DRAIN
80aef265

Fig. 10 Manual Valve LINE


PRESSURE
¢~~-~

¢: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.

CONVERTERPRESS:RE SECONDARY REGULATOR VALVE


(TO SECONDARY REGULATOR VALVE) 80aef264 Th e secon da r y r egu la t or va lve (F ig. 14) r egu la t es
con ver t er clu t ch a n d t r a n sm ission lu br ica t ion pr es-
Fig. 11 Primary Regulator Valve
su r e. Wh en pr im a r y r egu la t or va lve pr essu r e exceeds
r equ ir em en t s for clu t ch en ga gem en t or t r a n sm ission
lu br ica t ion , t h e secon da r y r egu la t or va lve is m oved
u pwa r d exposin g t h e dr a in por t . E xcess pr essu r e
21 - 172 TRANSMISSION AND TRANSFER CASE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

SOLENOID VALVE NO. 3

¢: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

CONVERTER LINE PRESSURE


¢:i (FROM PUMP)
CLUTCH
RELAY
80aef267
VALVE 80aef26b

Fig. 13 Cut–Back Valve


Fig. 15 Converter Clutch Relay Valve
t h en bleeds off a s n eeded. As pr essu r e dr ops, spr in g
t en sion m oves t h e va lve down wa r d closin g t h e dr a in 1–2 SHIFT VALVE
por t . Th e 1–2 sh ift va lve (F ig. 16) con t r ols t h e 1–2
u psh ift s a n d down sh ift s. Th e va lve is oper a t ed by t h e
No. 2 va lve body solen oid a n d lin e pr essu r e fr om t h e
m a n u a l va lve, secon d coa st m odu la t or va lve a n d t h e
2–3 sh ift va lve.
Wh en t h e t r a n sm ission con t r ol m odu le dea ct iva t es
t h e solen oid, lin e pr essu r e a t t h e t op of t h e va lve
m oves t h e va lve down closin g t h e secon d br a ke a ccu -
m u la t or feed por t . As t h e solen oid is a ct iva t ed a n d
t h e dr a in por t open s, spr in g for ce m oves t h e va lve u p
exposin g t h e secon d br a ke feed por t for t h e sh ift t o
secon d gea r.

2–3 SHIFT VALVE


Th e 2–3 sh ift va lve (F ig. 17) con t r ols t h e 2–3
u psh ift s a n d down sh ift s. Th e va lve is a ct u a t ed by t h e
CONVERTER No. 1 va lve body solen oid a n d by lin e pr essu r e fr om

.
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

Fig. 16 1–2 Shift Valve


LINE PRESSURE c:::::>
(FROM SOLENOID
VALVE NO.1)
LINE PRESSURE
(FROM MANUAL TO LINE PRESSURE
VALVE IN _5-L-,.--------'---------,.1-2 (FROM MANUAL
1-2 POSITION) c:::::> SHIFT VALVE IN
_ __,---'------'-,-__J VALVE
1-2 POSITION)
TO 3-4 SHIFT VALVE•
===:J
LINE PRESSURE c:::::>_~'-----'-,......J LINE PRESSURE c:::::> TO DIRECT CLUTCH
(FROM PRIMARY (FROM PRIMARY ,.ACCUMULATOR
REGUALTOR VALVE) L..__r---"--....,___ AND 1-2
REGULATOR
VALVE) 2 SHIFT VALVE
, . TO LOW COAST
MODULATOR VALVE

LINE PRESSURE
(FROM MANUAL =c:::::>=------~
VALVE)

2NDGEARf------L-___,_____,
80aef26d

Fig. 17 2–3 Shift Valve


3–4 SHIFT VALVE De–en er gizin g t h e solen oid ca u ses t h e dr a in por t t o
Th e 3–4 sh ift va lve (F ig. 18) is oper a t ed by t h e No. close. Lin e pr essu r e t h en m oves t h e va lve down
2 solen oid a n d by lin e pr essu r e fr om t h e m a n u a l exposin g t h e over dr ive br a ke a ccu m u la t or feed por t
va lve, 2–3 va lve a n d pr im a r y r egu la t or va lve. for t h e sh ift t o fou r t h gea r.
E n er gizin g t h e No. 2 solen oid ca u ses lin e pr essu r e In t h e 1–2 or 3 gea r sh ift lever posit ion s, lin e pr es-
a t t h e t op of t h e 3–4 va lve t o be r elea sed t h r ou gh t h e su r e fr om t h e 2–3 sh ift va lve is a pplied t o t h e lower
solen oid va lve dr a in por t . Spr in g t en sion m oves t h e en d of t h e 3–4 va lve. Th is h olds t h e va lve u pwa r d,
va lve u p exposin g t h e over dr ive clu t ch a ccu m u la t or closin g off t h e over dr ive br a ke feed por t pr even t in g a
feed por t t o a pply t h e clu t ch . sh ift in t o fou r t h gea r.
21 - 174 TRANSMISSION AND TRANSFER CASE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

TO OVERDRIVE • LINE LINE PRESSURE


CLUTCH t------'-~~ PRESSURE ¢ (FROM SOLENOID
ACCUMULATOR VALVE NO. 2)

~ .-------L..,---- LINE PRESSURE


(FROM PRIMARY
~ REGULATOR ~ ¢>------L....,-.,....J-,
~¢>_,--'--~
VALVE) ~
LINE PRESSURE
(FROM PRIMARY
REGULATOR VALVE) ~ ·~---,----J---,
TO OVER DRIVE BRAKE
ACCUMULATOR
LINE PRESSURE
(FROM 2-3
SHIFT o:::::==::D 4TH GEAR
VALVE) ¢> o:::::==::D 3RD GEAR -----'=~_JOVERDRIVE 80aef26e

Fig. 18 3–4 Shift Valve


SECOND COAST MODULATOR VALVE t h is a ct ion cu sh ion s a pplica t ion of t h e fir st /r ever se
Th e secon d coa st m odu la t or va lve (F ig. 19) m om en - br a ke. Th e m odu la t or va lve oper a t es wh en t h e sh ift
t a r ily r edu ces lin e pr essu r e fr om t h e 1–2 sh ift va lve. lever a n d m a n u a l va lve a r e in t h e 1–2 posit ion .
Th is cu sh ion s a pplica t ion of t h e secon d coa st br a ke.
Th e va lve is oper a t ive wh en t h e sh ift lever a n d m a n -
u a l va lve a r e in t h e 3 posit ion . LINE PRESSURE I
I
I
I

(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

0 0 Fig. 20 Low Coast Modulator Valve


0 0
80aef26f

Fig. 19 Second Coast Modulator Valve


LOW COAST MODULATOR VALVE
Th e low coa st m odu la t or va lve (F ig. 20) m om en -
t a r ily r edu ces lin e pr essu r e fr om t h e 2–3 sh ift va lve;
XJ TRANSMISSION AND TRANSFER CASE 21 - 175
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
ACCUMULATOR CONTROL VALVE OVERDRIVE
Th e a ccu m u la t or con t r ol va lve (F ig. 21) cu sh ion s CLUTCH
t h e t r a n sm ission clu t ch a n d br a ke a pplica t ion s. Th is
is a ch ieved by r edu cin g ba ck pr essu r e t o t h e a ccu m u -
la t or s wh en t h r ot t le open in g is sm a ll. Th e va lve is
oper a t ed by lin e a n d t h r ot t le pr essu r e.

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).

TRANSMISSION VALVE BODY SOLENOIDS


Th r ee solen oids a r e u sed (F ig. 23). Th e No. 1 a n d 2
solen oids con t r ol sh ift va lve oper a t ion by a pplyin g or
r elea sin g lin e pr essu r e. Th e sign a l t o a pply or r elea se
pr essu r e is pr ovided by t h e t r a n sm ission con t r ol
LINE PRESSURE 1J 80aef273

m odu le. Fig. 23 Transmission Valve Body Solenoids


Th e No. 3 solen oid con t r ols oper a t ion of t h e t or qu e
con ver t er clu t ch . Th e solen oid oper a t es in r espon se t o Wh en t h e No. 1 a n d 2 solen oids a r e a ct iva t ed, t h e
sign a ls fr om t h e t r a n sm ission con t r ol m odu le. solen oid plu n ger is m oved off it s sea t open in g t h e
dr a in por t t o r elea se lin e pr essu r e. Wh en eit h er sole-
n oid is dea ct iva t ed, t h e plu n ger closes t h e dr a in por t .
21 - 176 TRANSMISSION AND TRANSFER CASE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e No. 3 solen oid oper a t es in r ever se. Wh en t h e COOLER SERVICE
solen oid is dea ct iva t ed, t h e solen oid plu n ger is m oved Th e m a in cooler (a n d r a dia t or ) a n d t h e a u xilia r y
off it s sea t open in g t h e dr a in por t t o r elea se lin e cooler ca n be r em oved for ser vice or a ccess t o ot h er
pr essu r e. Wh en t h e solen oid is a ct iva t ed, t h e plu n ger com pon en t s. Au xilia r y cooler r em ova l r equ ir es t h a t
closes t h e dr a in por t . t h e fr on t bu m per a n d r a dia t or su ppor t be r em oved
for a ccess t o t h e cooler lin es a n d a t t a ch in g br a cket .
TRANSMISSION COOLER
BRAKE TRANSMISSION SHIFT INTERLOCK
MAIN COOLER MECHANISM
Th e t r a n sm ission m a in cooler is loca t ed in t h e
Th e Br a ke Tr a n sm ission Sh ift er /Ign it ion In t er lock
r a dia t or. Th e m a in cooler ca n be flu sh ed wh en n eces-
(BTSI), is a ca ble a n d solen oid oper a t ed syst em . It
sa r y, h owever, t h e cooler is n ot a r epa ir a ble com po-
in t er con n ect s t h e a u t om a t ic t r a n sm ission floor
n en t . If t h e cooler is da m a ged, plu gged, or lea kin g,
m ou n t ed sh ift er t o t h e st eer in g colu m n ign it ion
t h e r a dia t or will h a ve t o be r epla ced.
swit ch (F ig. 25). Th e syst em locks t h e sh ift er in t o t h e
PARK posit ion . Th e In t er lock syst em is en ga ged
AUXILIARY COOLER wh en ever t h e ign it ion swit ch is in t h e LOCK or
Th e a u xilia r y cooler is m ou n t ed in fr on t of t h e
ACCE SSORY posit ion . An a ddit ion a l elect r ica lly a ct i-
r a dia t or a t t h e dr iver side of t h e veh icle (F ig. 24).
va t ed fea t u r e will pr even t sh ift in g ou t of t h e PARK
Th e cooler ca n be flu sh ed wh en n ecessa r y, wh ile
posit ion u n less t h e br a ke peda l is depr essed a t lea st
m ou n t ed in t h e veh icle. Th e cooler ca n a lso be
on e-h a lf a n in ch . A m a gn et ic h oldin g device in lin e
r em oved for a ccess, r epa ir, or r epla cem en t a s n eeded.
wit h t h e pa r k/br a ke in t er lock ca ble is en er gized
Th e m a in a n d a u xilia r y cooler s sh ou ld bot h be
wh en t h e ign it ion is in t h e RUN posit ion . Wh en t h e
flu sh ed wh en ever a t r a n sm ission or con ver t er clu t ch
key is in t h e RUN posit ion a n d t h e br a ke peda l is
m a lfu n ct ion gen er a t es slu dge, debr is, or pa r t icles of
depr essed, t h e sh ift er is u n locked a n d will m ove in t o
clu t ch fr ict ion m a t er ia l.
a n y posit ion . Th e in t er lock syst em a lso pr even t s t h e
ign it ion swit ch fr om bein g t u r n ed t o t h e LOCK or

COOLER
LINE
BRACKET

COOLER
RETURN
LINE
u

RADIATOR

RETURN
LINE
(TO
TRANSMISSION) J9221-53

Fig. 24 Auxiliary Cooler Mounting (Left Hand Drive)


XJ TRANSMISSION AND TRANSFER CASE 21 - 177
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

PARK/BRAKE
INTERLOCK CABLE

SHIFT-~~-.,,...
CABLE

80a13876

Fig. 25 Ignition Interlock Cable Routing


ACCE SSORY posit ion (F ig. 26) u n less t h e sh ift er is Dia gn osis sh ou ld begin wit h t h e P r elim in a r y
fu lly locked in t o t h e PARK posit ion . In spect ion An d Adju st m en t pr ocedu r e. It is will h elp
det er m in e if a pr oblem is m ech a n ica l or elect r ica l.
Th e fir st pr ocedu r e st ep is In it ia l In spect ion a n d
Adju st m en t .

PRELIMINARY INSPECTION AND ADJUSTMENT


(1) Ch eck a n d a dju st t r a n sm ission sh ift ca ble if
n ecessa r y.
(2) Ver ify t r a n sm ission t h r ot t le ca ble oper a t ion .
Repa ir or r epla ce ca ble if n ecessa r y.
(3) Ch eck en gin e t h r ot t le oper a t ion . Oper a t e a ccel-
J9319-47 er a t or peda l a n d obser ve in ject or t h r ot t le pla t e m ove-
m en t . Adju st lin ka ge if t h r ot t le pla t e does n ot r ea ch
Fig. 26 Ignition Key Cylinder Actuation wide open posit ion .
DI AGN OSI S AN D T EST I N G (4) Ch eck t r a n sm ission flu id level wh en flu id is a t
n or m a l oper a t in g t em per a t u r e. St a r t en gin e. Sh ift
GENERAL DIAGNOSIS INFORMATION t r a n sm ission t h r ou gh a ll gea r r a n ges t h en ba ck t o
Neu t r a l. Cor r ect level is t o F u ll or Add m a r k on dip-
Sh ift poin t s a r e con t r olled by t h e t r a n sm ission con -
st ick wit h en gin e a t cu r b idle speed.
t r ol m odu le (TCM). Befor e a t t em pt in g r epa ir, det er-
(5) Ch eck a n d a dju st pa r k/n eu t r a l posit ion swit ch
m in e if a m a lfu n ct ion is elect r ica l or m ech a n ica l.
if n ecessa r y.
Th e TCM u sed wit h t h e AW–4 t r a n sm ission h a s a
(6) Ch eck t h r ot t le posit ion sen sor a dju st m en t a n d
self–dia gn ost ic pr ogr a m com pa t ible wit h t h e DRBIII
oper a t ion . Adju st t h e sen sor if n ecessa r y.
sca n t ool. Th e t est er will iden t ify fa u lt s in t h e elec-
t r ica l con t r ol syst em .
21 - 178 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

PERFORM INITIAL INSPECTION REPAIR OR


AND ADJUSTMENT REPLACE
PROCEDURE OUTLINED IN -NO COMPONENTS AS
THIS SECTION NEEDED

.
PERFORM MANUAL SHIFTING NOT OK---,
TEST

,i,

CONNECT DRB TESTER


PERFORM TEST PROCEDURE
OUTLINED IN TESTER MANUAL.

ELECTRICAL CONTROL PERFORM HYDRAULIC


SYSTEM CHECK PRESSURE TEST, STALL TEST
AND TIME LAG TEST

I
NOT OK

~
REPAIR OR REPLACE PROBLEM REPAIR TRANSMISSION AS
COMPONENTS NECESSARY

J8921-423

Preliminary Diagnosis Check Procedure


MANUAL SHIFTING TEST difficu lt t o dist in gu ish (a ll feel t h e sa m e), or veh icle
(1) Th is t est det er m in es if pr oblem is r ela t ed t o wou ld n ot ba ck u p, r efer t o dia gn osis ch a r t s. Do n ot
m ech a n ica l or elect r ica l com pon en t . per for m st a ll or t im e la g t est s.
(2) St op en gin e a n d discon n ect t r a n sm ission con -
CAUTION: Do not over speed the engine during the
t r ol m odu le or m odu le fu se.
next test step. Ease off the throttle and allow the
(3) Roa d t est veh icle. Sh ift t r a n sm ission in t o ea ch
vehicle to slow before downshifting.
gea r r a n ge. Tr a n sm ission sh ou ld oper a t e a s follows:
• lock in P a r k (5) Con t in u e r oa d t est . Ma n u a lly down sh ift t r a n s-
• ba ck u p in Rever se m ission fr om D t o 3, a n d fr om 3 t o 1–2 posit ion .
• n ot m ove in Neu t r a l Th en m a n u a lly u psh ift t r a n sm ission t h r ou gh for wa r d
• pr ovide fir st gea r on ly wit h sh ift lever in 1–2
r a n ges a ga in .
posit ion
(6) If t r a n sm ission oper a t ion is OK, per for m st a ll,
• oper a t e in t h ir d gea r on ly wit h sh ift lever in 3 t im e la g a n d pr essu r e t est s. If t r a n sm ission sh ift in g
posit ion pr oblem is en cou n t er ed, r efer t o dia gn osis ch a r t s.
• oper a t e in over dr ive fou r t h gea r in D posit ion .
(7) If a pr oblem st ill exist s, con t in u e t est in g wit h
(4) If t r a n sm ission oper a t es a s descr ibed, pr oceed DRB sca n t ool.
t o n ext st ep. H owever, if for wa r d gea r r a n ges wer e
XJ TRANSMISSION AND TRANSFER CASE 21 - 179
DI AGN OSI S AN D T EST I N G (Cont inue d)

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

CONDITION POSSIBLE CAUSE CORRECTION

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

SHIFT LEVER POSITION Shift cable out of adjustment Adjust cable


INCORRECT Manual valve and lever faulty Repair valve body

HARSH ENGAGEMENT Throttle cable out of adjustment Adjust throttle cable


Valve body or primary regulator faulty Repair valve body
Accumulator pistons faulty Repair pistons
Transmission 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

HARSH DOWN-SHIFT Throttle cable out of adjustment Adjust cable


Throttle cable and cam faulty Replace cable and cam
Accumulator pistons faulty Repair pistons
Valve body faulty Repair valve body
Transmission faulty Disassemble and repair transmission

NO DOWN-SHIFT WHEN Valve body faulty Repair valve body


COASTING Solenoid faulty Replace solenoid
Electronic control problem Locate problem with DRB Tester

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

CONDITION POSSIBLE CAUSE CORRECTION

DOWN-SHIFT LATE OR EARLY Throttle cable faulty Replace cable


DURING COAST Valve body faulty Repair valve body
Transmission faulty Disassemble and repair transmission
Solenoid faulty Replace solenoid
Electronic control problem Locate problem with DRB Tester

NO 4-3, 3-2 OR 2-1 Solenoid faulty Replace solenoid


KICKDOWN Electronic control problem Locate problem with DRB Tester
Valve body faulty Repair valve body

NO ENGINE BRAKING IN 1-2 Solenoid faulty Replace solenoid


POSITION Electronic control problem Locate problem with DRB Tester
Valve body faulty Repair valve body
Transmission faulty Disassemble and repair transmission

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

Tow vehicle overloaded (exceeding vehicle Be sure vehicle is properly equipped to


tow capacity) handle load; do not tow Class Ill-type
loads with a vehicle that is only rated
for Class I or II operation

Air flow to auxiliary cooler blocked bb Remove or reposition item causing


snow plow, front mounted spare tire, ug air flow blockage
screen, or similar item

OIL COMES OUT FILLER TUBE Transmission overfilled Drain fluid to correct level; remove neutral
switch and drain through switch hole
with suction gun

Breather vent in oil pump blocked Inspect and clear blockage

Fluid cooler or cooler lines plugged Flush cooler and lines

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

WIRE TERMINAL p v-- r-v


R u -
N
- -
D

J8921-435 1-2
-
Fig. 28 Testing Transmission Valve Body Solenoid J8921-429

PARK/NEUTRAL POSITION SWITCH Fig. 29 Park/Neutral Position Switch Terminals And


Testing
SWITCH TESTING
(c) NE UTRAL posit ion —Nor m a l posit ion . E n gin e
Test swit ch con t in u it y wit h a n oh m m et er. Discon -
st a r t s m u st be possible.
n ect t h e swit ch a n d ch eck con t in u it y a t t h e con n ect or
(d) NE UTRAL posit ion —E n gin e r u n n in g a n d
t er m in a l posit ion s a n d in t h e gea r r a n ges in dica t ed
br a kes a pplied, a pply for wa r d for ce on cen t er of
in F igu r e 3. Swit ch con t in u it y sh ou ld be a s follows:
sh ift h a n dle. Tr a n sm ission sh a ll n ot be a ble t o sh ift
• Con t in u it y sh ou ld exist bet ween t er m in a ls
fr om n eu t r a l t o r ever se.
B a n d C wit h t h e t r a n sm ission in P a r k a n d Neu t r a l
on ly (F ig. 29).
• Con t in u it y sh ou ld exist bet ween t er m in a ls A a n d
THROTTLE VALVE CABLE
Tr a n sm ission t h r ot t le va lve ca ble a dju st m en t is
E wit h t h e t r a n sm ission in Rever se (F ig. 29).
ext r em ely im por t a n t t o pr oper oper a t ion . Th is a dju st -
• Con t in u it y sh ou ld exist bet ween t er m in a ls A a n d
m en t posit ion s t h e t h r ot t le va lve, wh ich con t r ols sh ift
G wit h t h e t r a n sm ission in t h ir d gea r (F ig. 29).
speed, qu a lit y, a n d pa r t -t h r ot t le down sh ift sen sit ivit y.
• Con t in u it y sh ou ld exist bet ween t er m in a ls A a n d
If ca ble set t in g is t oo loose, ea r ly sh ift s a n d slip-
H wit h t h e t r a n sm ission in fir st a n d/or secon d gea r
pa ge bet ween sh ift s m a y occu r. If t h e set t in g is t oo
(F ig. 29).
t igh t , sh ift s m a y be dela yed a n d pa r t t h r ot t le down -
• Con t in u it y sh ou ld n ot exist in D posit ion .
sh ift s m a y be ver y sen sit ive. Refer t o t h e Adju st -
m en t s sect ion for t h e pr oper a dju st m en t pr ocedu r e.
GEARSHIFT CABLE
(1) Th e floor sh ift er lever a n d ga t e posit ion s
sh ou ld be in a lign m en t wit h a ll t r a n sm ission PARK,
SPEED SENSOR TESTING
Test t h e speed sen sor wit h a n oh m m et er. P la ce t h e
NE UTRAL, a n d gea r det en t posit ion s.
oh m m et er lea ds on t h e t er m in a ls in t h e sen sor con -
(2) E n gin e st a r t s m u st be possible wit h floor sh ift
n ect or (F ig. 30).
lever in PARK or NE UTRAL ga t e posit ion s on ly.
Rot a t e t h e t r a n sm ission ou t pu t sh a ft a n d obser ve
E n gin e st a r t s m u st n ot be possible in a n y ot h er gea r
t h e oh m m et er n eedle. Th e n eedle sh ou ld deflect in di-
posit ion .
ca t in g t h e swit ch is open in g/closin g a s t h e r ot or
(3) Wit h floor sh ift lever h a n dle pu sh -bu t t on n ot
m oves pa st t h e sen sor (F ig. 30). Repla ce t h e sen sor if
depr essed a n d lever in :
t h e oh m m et er does n ot displa y a n y kin d of r ea din g.
(a ) PARK posit ion —Apply for wa r d for ce on cen -
If a digit a l oh m m et er is bein g u sed, t h e sen sor
t er of h a n dle a n d r em ove pr essu r e. E n gin e st a r t s
sh ou ld gen er a t e a n oh m m et er r ea dou t ea ch t im e t h e
m u st be possible.
swit ch open s a n d closes.
(b) PARK posit ion —Apply r ea r wa r d for ce on cen -
t er of h a n dle a n d r em ove pr essu r e. E n gin e st a r t s
m u st be possible.
21 - 184 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONNECTOR ROTATING
TOOL

STOPPER
TOOL
ROTOR
J8921-462

Fig. 30 Speed Sensor Testing


FLOW TESTING TRANSMISSION MAIN
COOLER
Cooler flow is ch ecked by m ea su r in g t h e a m ou n t of
flu id flow t h r ou gh t h e cooler in a 20 secon d t im e
per iod. Th e t est is per for m ed wit h t h e en gin e r u n -
n in g a n d t r a n sm ission in n eu t r a l. F lu id is t h en
pu m ped t h r ou gh t h e cooler by t h e t r a n sm ission oil
pu m p.
(1) Discon n ect cooler in let lin e a t t r a n sm ission fit -
t in g.
(2) Secu r ely a t t a ch h ose t o en d of in let lin e a n d
ROTATING
posit ion lin e in a on e qu a r t t est con t a in er. TOOL (TURN BOTH DIRECTIONS)
(3) Add ext r a qu a r t of flu id t o t r a n sm ission .
(4) Use st opwa t ch t o ch eck flow t est t im e.
(5) Sh ift t r a n sm ission in t o n eu t r a l a n d set pa r kin g
br a ke. STOPPER
(6) St a r t a n d r u n en gin e a t cu r b idle speed a n d TOOL
im m edia t ely n ot e cooler flow. Appr oxim a t ely on e (SEATED IN
HUB NOTCH)
qu a r t of flu id sh ou ld flow in t o t est con t a in er in 20
secon d per iod.
(7) If cooler flow is in t er m it t en t , flows less t h a n
on e qu a r t in 20 secon ds, or does n ot flow a t a ll,
cooler is fa u lt y a n d m u st be r epla ced.

TORQUE CONVERTER STATOR CLUTCH


INSPECTION
(1) In ser t Rot a t in g Tool 7547 in t o con ver t er h u b
a n d sea t t ool in on e–wa y clu t ch (F ig. 31).
(2) In ser t St opper Tool 7548 in on e con ver t er h u b J8921-470
n ot ch a n d in t o ou t er r a ce of r ot a t in g t ool.
(3) Tu r n r ot a t in g t ool clockwise. Con ver t er clu t ch Fig. 31 Checking Operation Of Torque Converter
sh ou ld r ot a t e fr eely a n d sm oot h ly. Less t h a n 2.5 N·m Stator One–Way Clutch
XJ TRANSMISSION AND TRANSFER CASE 21 - 185
DI AGN OSI S AN D T EST I N G (Cont inue d)
(22 in . lbs.) of t or qu e sh ou ld be r equ ir ed t o r ot a t e Tr a n sm ission oper a t ion sh ou ld a lso be ch ecked if
clu t ch in clockwise dir ect ion . t h e flu id is sever ely discolor ed a n d con t a in s qu a n t i-
(4) Tu r n r ot a t in g t ool in cou n t er clockwise dir ec- t ies of for eign m a t er ia l, m et a l pa r t icles, or clu t ch disc
t ion . Con ver t er clu t ch sh ou ld lock. fr ict ion m a t er ia l.
(5) Repla ce con ver t er if clu t ch bin ds or will n ot A s m a ll qu a n tity o f fric tio n m a te ria l o r m e ta l
lock. p a rtic le s in th e o il p a n is n o rm a l. Th e p a rtic le s
a re u s u a lly g e n e ra te d d u rin g th e bre a k –in
p e rio d a n d in d ic a te n o rm a l s e a tin g o f th e v a ri-
SERV I CE PROCEDU RES o u s tra n s m is s io n c o m p o n e n ts .

CHECKING FLUID LEVEL REFILLING AFTER OVERHAUL OR FLUID/


(1) Be su r e t r a n sm ission flu id is a t n or m a l oper a t -
FILTER CHANGE
in g t em per a t u r e. Nor m a l oper a t in g t em per a t u r e is
Th e best wa y t o r efill t h e t r a n sm ission a ft er a flu id
r ea ch ed a ft er a ppr oxim a t ely 15 m iles (25 km ) of
ch a n ge or over h a u l is a s follows:
oper a t ion .
(1) If t r a n sm ission h a s been over h a u led, in st a ll
(2) P osit ion veh icle on level su r fa ce. Th is is im por-
t r a n sm ission in veh icle.
t a n t for a n a ccu r a t e flu id level ch eck.
(2) Rem ove dipst ick a n d in ser t clea n fu n n el in
(3) Sh ift t r a n sm ission t h r ou gh a ll gea r r a n ges a n d
t r a n sm ission fill t u be.
ba ck t o P a r k.
(3) Add followin g in it ia l qu a n t it y of Mopa r Dexr on
(4) Apply pa r kin g br a kes.
IIE /Mer con t o t r a n sm ission :
(5) Ver ify t h a t t r a n sm ission is in P a r k.
(4) If flu id/filt er ch a n ge wa s per for m ed, a dd 4
(6) Wipe off dipst ick h a n dle t o pr even t dir t fr om
p in ts (2 qu a rts ) of flu id t o t r a n sm ission .
en t er in g fill t u be. Th en r em ove dipst ick a n d ch eck
(a ) If t r a n sm ission wa s com plet ely over h a u led
flu id level a n d con dit ion .
a n d t or qu e con ver t er wa s r epla ced or dr a in ed, a dd
(7) Cor r ect flu id level is to F U LL m a rk o n d ip -
10 p in ts (5 qu a rts ) of flu id t o t r a n sm ission .
s tic k w h e n flu id is a t n o rm a l o p e ra tin g te m p e r-
(b) Rem ove fu n n el a n d in st a ll dipst ick.
a tu re (F ig. 32).
(5) Oper a t e veh icle u n t il flu id r ea ch es n or m a l
TRANSMISSION oper a t in g t em per a t u r e.
DIPSTICK (6) Apply pa r kin g br a kes.

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 .

(2) Ru n t h e en gin e a t c u rb id le s p e e d , wit h t h e NOTE: When flushing transmission cooler and


sh ift select or in n eu t r a l. lines, ALWAYS reverse flush.
(3) If flu id flow is in t er m it t en t or it t a kes m or e
t h a n 20 secon ds t o collect on e qu a r t of ATF P LUS 3,
discon n ect t h e To Co o le r lin e a t t h e t r a n sa xle. NOTE: The converter drainback valve must be
(4) Refill t h e t r a n sa xle t o pr oper level a n d r ech eck removed and an appropriate replacement hose
pu m p volu m e. installed to bridge the space between the transmis-
(5) If flow is fou n d t o be wit h in a ccept a ble lim it s, sion cooler line and the cooler fitting. Failure to
r epla ce t h e cooler. Th en fill t r a n sm ission t o t h e remove the drainback valve will preventreverse
pr oper level, u sin g Mopa r ! ATF P LUS 3 (Type 7176) flushing the system.
a u t om a t ic t r a n sm ission flu id.
(6) If flu id flow is st ill fou n d t o be in a dequ a t e, (5) Con n ect t h e BLUE pr essu r e lin e t o t h e OUT-
ch eck t h e lin e pr essu r e u sin g t h e Tr a n sa xle H ydr a u - LE T (F r om ) cooler lin e.
lic P r essu r e Test pr ocedu r e. (6) Con n ect t h e CLE AR r et u r n lin e t o t h e INLE T
(To) cooler lin e
FLUSHING COOLERS AND TUBES (7) Tu r n pu m p ON for t wo t o t h r ee m in u t es t o
flu sh cooler (s) a n d lin es. Mon it or pr essu r e r ea din gs
Wh en a t r a n sm ission fa ilu r e h a s con t a m in a t ed t h e
a n d clea r r et u r n lin es. P r essu r e r ea din gs sh ou ld st a -
flu id, t h e oil cooler (s) m u st be flu sh ed. Th e t or qu e
bilize below 20 psi. for veh icles equ ipped wit h a sin -
con ver t er m u st a lso be r epla ced. Th is will in su r e t h a t
gle cooler a n d 30 psi. for veh icles equ ipped wit h du a l
m et a l pa r t icles or slu dged oil a r e n ot la t er t r a n s-
cooler s. If flow is in t er m it t en t or exceeds t h ese pr es-
fer r ed ba ck in t o t h e r econ dit ion ed (or r epla ced) t r a n s-
su r es, r epla ce cooler.
m ission .
(8) Tu r n pu m p OF F.
Th e on ly r ecom m en ded pr ocedu r e for flu sh in g cool-
(9) Discon n ect CLE AR su ct ion lin e fr om r eser voir
er s a n d lin es is t o u se Tool 6906 Cooler F lu sh er.
a t cover pla t e. Discon n ect CLE AR r et u r n lin e a t
WARNING: WEAR PROTECTIVE EYEWEAR THAT cover pla t e, a n d pla ce it in a dr a in pa n .
MEETS THE REQUIREMENTS OF OSHA AND ANSI (10) Tu r n pu m p ON for 30 secon ds t o pu r ge flu sh -
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB- in g solu t ion fr om cooler a n d lin es. Tu r n pu m p OF F.
BER GLOVES. (11) P la ce CLE AR su ct ion lin e in t o a on e qu a r t
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES, con t a in er of Mopa r ! ATF P lu s 3, t ype 7176 a u t om a t ic
AND OTHER IGNITION SOURCES AWAY FROM THE t r a n sm ission flu id.
AREA TO PREVENT THE IGNITION OF COMBUSTI- (12) Tu r n pu m p ON u n t il a ll t r a n sm ission flu id is
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE r em oved fr om t h e on e qu a r t con t a in er a n d lin es. Th is
EXTINGUISHER IN THE AREA WHERE THE pu r ges a n y r esidu a l clea n in g solven t fr om t h e t r a n s-
FLUSHER WILL BE USED. m ission cooler a n d lin es. Tu r n pu m p OF F.
KEEP THE AREA WELL VENTILATED. (13) Discon n ect a lliga t or clips fr om ba t t er y. Recon -
DO NOT LET FLUSHING SOLVENT COME IN CON- n ect flu sh er lin es t o cover pla t e, a n d r em ove flu sh in g
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM- a da pt er s fr om cooler lin es.
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED ALUMINUM THREAD REPAIR
CLOTHING AND WASH AFFECTED SKIN WITH Da m a ged or wor n t h r ea ds in t h e a lu m in u m t r a n s-
SOAP AND WATER. SEEK MEDICAL ATTENTION. m ission ca se a n d va lve body ca n be r epa ir ed by t h e
u se of H eli-Coils, or equ iva len t . Th is r epa ir con sist s
of dr illin g ou t t h e wor n -ou t da m a ged t h r ea ds. Th en
COOLER FLUSH USING TOOL 6906 t a p t h e h ole wit h a specia l H eli-Coil t a p, or equ iva -
(1) Rem ove cover pla t e filler plu g on Tool 6906. len t , a n d in st a llin g a H eli-Coil in ser t , or equ iva len t ,
F ill r eser voir 1/2 t o 3/4 fu ll of fr esh flu sh in g solu t ion . in t o t h e h ole. Th is br in gs t h e h ole ba ck t o it s or igin a l
F lu sh in g solven t s a r e pet r oleu m ba sed solu t ion s gen - t h r ea d size.
er a lly u sed t o clea n a u t om a t ic t r a n sm ission com po-
XJ TRANSMISSION AND TRANSFER CASE 21 - 187
SERV I CE PROCEDU RES (Cont inue d)
H eli-Coil, or equ iva len t , t ools a n d in ser t s a r e CAUTION: The crankshaft position sensor can be
r ea dily a va ila ble fr om m ost a u t om ot ive pa r t s su ppli- damaged during transmission removal (or installa-
er s. tion) if the sensor is still bolted to the engine block.
To avoid damage, remove the sensor before remov-
ing the transmission.
REM OVAL AN D I N STALLAT I ON
TRANSMISSION AND TORQUE CONVERTER
REMOVAL
(1) Ra ise veh icle.
(2) Dr a in t r a n sm ission flu id a n d r ein st a ll oil pa n
dr a in plu g.
(3) On m odels wit h 2–piece fill t u be, r em ove u pper
h a lf of t u be (F ig. 33).

Fig. 34 Crankshaft Position Sensor


(15) Rem ove st a r t er m ot or.
(16) Rem ove bolt s a t t a ch in g con ver t er t o dr ive
pla t e.
(17) Rem ove bolt s a t t a ch in g con ver t er h ou sin g t o
en gin e.
(18) Secu r e t r a n sm ission t o ja ck wit h sa fet y
ch a in s.
(19) P u ll t r a n sm ission r ea r wa r d for a ccess t o con -
ver t er. Th en secu r e con ver t er in pu m p wit h C–cla m p
or st r a p bolt ed t o con ver t er h ou sin g.
(20) Rem ove t r a n sm ission fr om u n der veh icle.
(21) Rem ove t or qu e con ver t er if con ver t er or oil
~\~8921-469 pu m p sea l a r e t o be ser viced.

Fig. 33 Transmission Fill Tube (Two–Piece) INSTALLATION


(4) Discon n ect cooler lin es a t t r a n sm ission . (1) Mou n t t r a n sm ission on t r a n sm ission ja ck. Th en
(5) Su ppor t en gin e wit h sa fet y st a n d a n d su ppor t secu r e t r a n sm ission t o ja ck wit h sa fet y ch a in s.
t r a n sm ission wit h ja ck. (2) Lu br ica t e con ver t er dr ive h u b a n d oil pu m p
(6) Discon n ect t r a n sm ission a n d t r a n sfer ca se sh ift sea l lip wit h t r a n sm ission flu id. Th en in st a ll con -
lin ka ge. ver t er. Be su r e con ver t er is fu lly sea t ed in oil pu m p
(7) Rem ove n ecessa r y exh a u st com pon en t s. gea r s befor e pr oceedin g. H old con ver t er in pla ce wit h
(8) Discon n ect veh icle speed sen sor wir es C–cla m p or st r a p a t t a ch ed t o con ver t er h ou sin g.
(9) Ma r k posit ion of fr on t a n d r ea r pr opeller sh a ft s (3) Align a n d posit ion t r a n sm ission a n d con ver t er
for a lign m en t r efer en ce. Th en r em ove sh a ft s fr om on en gin e.
veh icle. (4) Rem ove cla m p or st r a p u sed t o h old t or qu e con -
(10) Rem ove r ea r cr ossm em ber. ver t er in pla ce.
(11) Discon n ect t r a n sm ission sh ift ca ble a t t r a n s- (5) Move t r a n sm ission for wa r d sea t a n d it on
m ission . Th en discon n ect t r a n sm ission t h r ot t le va lve en gin e. Be su r e t or qu e con ver t er h u b is fu lly sea t ed.
ca ble a t en gin e. (6) In st a ll con ver t er h ou sin g–t o–en gin e bolt s (F ig.
(12) Discon n ect n ecessa r y va cu u m a n d flu id h oses. 35).
(13) Rem ove t r a n sfer ca se fr om t r a n sm ission . (7) In st a ll con ver t er-t o-dr ive pla t e bolt s.
(14) Discon n ect a n d r em ove cr a n ksh a ft posit ion (8) In st a ll a n d con n ect st a r t er m ot or.
sen sor (F ig. 34). (9) In st a ll a n d con n ect cr a n ksh a ft posit ion sen sor.
21 - 188 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

BOLT SET-TO SERVICE TORQUE

A 58 N-m (43 ft-lbs)


B 20 N-m (181 in-lbs)

TRANSMISSION
FILL
TUBE

BRACKET
BRACKET B J9121-397

Fig. 35 Transmission Mounting


(10) In st a ll t r a n sfer ca se on t r a n sm ission . (2) P la ce a su it a ble dr a in pa n u n der t h e con ver t er
(11) Con n ect t r a n sfer ca se sh ift lin ka ge a n d va c- h ou sin g en d of t h e t r a n sm ission .
u u m h oses.
(12) Con n ect exh a u st com pon en t s. CAUTION: Verify that transmission is secure on the
(13) In st a ll r ea r cr ossm em ber a n d r em ove ja ck lifting device or work surface, the center of gravity
u sed t o su ppor t t r a n sm ission a ssem bly. of the transmission will shift when the torque con-
(14) Con n ect speed sen sor wir e h a r n ess t o sen sor. verter is removed creating an unstable condition.
(15) Con n ect wir e h a r n ess t o pa r k/n eu t r a l posit ion The torque converter is a heavy unit. Use caution
swit ch . when separating the torque converter from the
(16) Align a n d con n ect fr on t a n d r ea r pr opeller transmission.
sh a ft s.
(17) Con n ect t r a n sm ission wir e h a r n esses a n d (3) P u ll t h e t or qu e con ver t er for wa r d u n t il t h e cen -
t r a n sfer ca se va cu u m a n d wir e h a r n esses. t er h u b clea r s t h e oil pu m p sea l.
(18) Con n ect t r a n sm ission cooler lin es. (4) Sepa r a t e t h e t or qu e con ver t er fr om t h e t r a n s-
(19) Con n ect t r a n sm ission t h r ot t le ca ble a t en gin e. m ission .
(20) In st a ll n ew O–r in g sea l on u pper h a lf of
t r a n sm ission fill t u be. Th en con n ect u pper a n d lower INSTALLATION
t u be h a lves. Ch eck con ver t er h u b a n d dr ive n ot ch es for sh a r p
(21) Lower veh icle. edges, bu r r s, scr a t ch es, or n icks. P olish t h e h u b a n d
(22) F ill t r a n sm ission wit h Mopa r Dexr on IIE /Mer- n ot ch es wit h 320/400 gr it pa per or cr ocu s clot h if n ec-
con a u t om a t ic t r a n sm ission flu id. essa r y. Th e h u b m u st be sm oot h t o a void da m a gin g
t h e pu m p sea l a t in st a lla t ion .
TORQUE CONVERTER (1) Lu br ica t e con ver t er h u b a n d oil pu m p sea l lip
wit h t r a n sm ission flu id.
REMOVAL (2) P la ce t or qu e con ver t er in posit ion on t r a n sm is-
sion .
(1) Rem ove t r a n sm ission a n d t or qu e con ver t er
fr om veh icle.
XJ TRANSMISSION AND TRANSFER CASE 21 - 189
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CAUTION: Do not damage oil pump seal or bushing OIL 2WD
while inserting torque converter into the front of the 4WD TUBE EXTENSION HOUSING
transmission. ADAPTOR
HOUSING
(3) Align t or qu e con ver t er t o oil pu m p sea l open -
in g.
(4) In ser t t or qu e con ver t er h u b in t o oil pu m p.
(5) Wh ile pu sh in g t or qu e con ver t er in wa r d, r ot a t e
con ver t er u n t il con ver t er is fu lly sea t ed in t h e oil
pu m p gea r s.
(6) Ch eck con ver t er sea t in g wit h a sca le a n d
st r a igh t edge (F ig. 36). Su r fa ce of con ver t er lu gs ..:6J t,
sh ou ld be 1/2 in . t o r ea r of st r a igh t edge wh en con - ' ~

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

Fig. 37 Adapter Housing Seals


INSTALLATION
(1) In st a ll n ew a da pt er h ou sin g sea l wit h Sea l
In st a ller 7888.
(2) On 4X2 veh icles, in st a ll du st sh ield u sin g Spe-
cia l Tool D-187-B.
(3) Rein st a ll com pon en t s r em oved t o ga in a ccess t o
sea l.
(4) Top off t r a n sm ission flu id if n ecessa r y.

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.

SPEED SENSOR ROTOR-SPEEDOMETER DRIVE


GEAR
REMOVAL
(1) Ra ise veh icle.
(2) Rem ove com pon en t s n ecessa r y t o ga in a ccess t o
r ot or a n d dr ive gea r su ch a s pr opeller sh a ft , t r a n sfer
ca se, cr ossm em ber, a n d sh ift lin ka ge.
(3) Disen ga ge wir e con n ect or fr om t h e ou t pu t
J8921-463 speed sen sor.
(4) Rem ove t h e bolt h oldin g t h e ou t pu t speed sen -
Fig. 38 Transmission Speed Sensor Removal/ sor t o t h e a da pt er h ou sin g.
Installation (5) Rem ove t h e ou t pu t speed sen sor fr om t h e
(4) Rem ove speed sen sor a n d speedom et er a da pt er a da pt er h ou sin g.
a s a ssem bly. (6) Rem ove t h e bolt s h oldin g t h e a da pt er h ou sin g
(5) Rem ove speed sen sor r et a in in g scr ew a n d t o t h e t r a n sm ission ca se.
r em ove sen sor fr om a da pt er. (7) Ta p t h e a da pt er h ou sin g a t t h e join t lin e gen t ly
(6) Rem ove speedom et er pin ion fr om a da pt er. wit h a r u bber m a llet t o sepa r a t e t h e a da pt er h ou sin g
(7) In spect sen sor a n d a da pt er O-r in gs (F ig. 39). fr om t h e t r a n sm ission ca se.
Rem ove a n d disca r d O-r in gs if wor n or da m a ged. (8) Rem ove t h e a da pt er h ou sin g fr om t h e t r a n s-
(8) In spect t er m in a l pin s in speed sen sor. Clea n m ission ca se.
pin s wit h Mopa r ! elect r ica l spr a y clea n er if dir t y or (9) Rem ove speedom et er dr ive gea r sn a p r in g (F ig.
oxidized. Repla ce sen sor if fa u lt y, or pin s a r e loose, 41).
sever ely cor r oded, or da m a ged. (10) Rem ove t h e speedom et er dr ive gea r a n d
spa cer, if equ ipped.
INSTALLATION (11) Rem ove r ot or fr om t h e ou t pu t sh a ft . It m a y be
(1) Th or ou gh ly clea n a da pt er fla n ge a n d a da pt er n ecessa r y t o u se a wood dowel or h a m m er h a n dle
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 (F ig. 42) t o gen t ly pr y t h e r ot or fr om t h e ou t pu t
for pr oper a da pt er a lign m en t a n d speedom et er oper- sh a ft . Be su r e t o r et r ieve t h e r ot or loca t in g key fr om
a t ion . t h e ou t pu t sh a ft or r ot or.
(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. 39). INSTALLATION
(3) Lu br ica t e sen sor a n d a da pt er O-r in gs wit h (1) Clea n sea lin g su r fa ces of t r a n sm ission ca se a n d
t r a n sm ission flu id. ext en sion /a da pt or h ou sin g.
(4) In st a ll veh icle speed sen sor in speedom et er (2) In st a ll r ot or, spa cer (if equ ipped) a n d dr ive
a da pt er. Tigh t en sen sor a t t a ch in g scr ew t o 2-3 N·m gea r on ou t pu t sh a ft . Th en in st a ll dr ive gea r sn a p
(15-27 in . lbs.) t or qu e. r in g (F ig. 41).
(5) In st a ll speedom et er pin ion in a da pt er. (3) Apply 1/8 3/16 in ch wide bea d of Th r eebon d!
(6) Cou n t n u m ber of t eet h on speedom et er pin ion . Liqu id Ga sket TB1281, P /N 83504038, t o t r a n sm is-
Do t h is befor e in st a llin g a ssem bly in h ou sin g. Th en sion ca se sea lin g su r fa ce a n d in st a ll ext en sion /
lu br ica t e pin ion t eet h wit h t r a n sm ission flu id. a da pt er h ou sin g on ca se.
(7) Not e in dex n u m ber s on a da pt er body (F ig. 40). (4) Tigh t en a da pt or h ou sin g bolt s t o 34 N·m (25 ft .
Th ese n u m ber s will cor r espon d t o n u m ber of t eet h on lbs.) t or qu e.
pin ion . (5) In st a ll com pon en t s r em oved t o ga in a ccess t o
(8) In st a ll speedom et er a ssem bly in h ou sin g. r ot or a n d dr ive gea r.
XJ TRANSMISSION AND TRANSFER CASE 21 - 191
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

\
SPEEDOMETER
PINION

VEHICLE
SPEED
SENSOR J9321-385

Fig. 39 Speedometer Pinion Adapter Components


ROTOR

SPEEDOMETER DRIVE
GEAR

J9321-386 SNAP
RING
Fig. 40 Index Numbers On Speedometer Pinion
Adapter
PARK/NEUTRAL POSITION SWITCH J8921-464

REMOVAL Fig. 41 Removing/Installation Speedometer Drive


(1) Ra ise veh icle. Gear
(2) Discon n ect swit ch wir e h a r n ess con n ect or. (2) Rot a t e m a n u a l sh ift lever a ll t h e wa y r ea r-
(3) P r y wa sh er lock t a bs u pwa r d a n d r em ove wa r d. Th en r ot a t e lever for wa r d t wo det en t posit ion s
swit ch a t t a ch in g n u t a n d t a bbed wa sh er (F ig. 43). t o Neu t r a l.
(4) Rem ove swit ch a dju st in g bolt (F ig. 43). (3) In st a ll swit ch on m a n u a l va lve sh a ft a n d
(5) Slide swit ch off m a n u a l va lve sh a ft . in st a ll swit ch a dju st in g bolt fin ger t igh t . Do n ot
t igh t en bolt a t t h is t im e.
INSTALLATION (4) In st a ll t a bbed wa sh er on m a n u a l va lve sh a ft
(1) Discon n ect sh ift lin ka ge r od fr om sh ift lever on a n d in st a ll swit ch a t t a ch in g n u t . Tigh t en n u t t o 6.9
left side of t r a n sm ission . N·m (61 in . lbs.) t or qu e bu t do n ot ben d wa sh er lock
t a bs over n u t a t t h is t im e.
21 - 192 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

ADJUSTING
BOLT

OUTPUT
J8921-431
SHAFT

J8921-465 Fig. 44 Park/Neutral Position Switch Adjustment


(10) Con n ect sh ift lin ka ge r od t o sh ift lever on left
Fig. 42 Removing Speed Sensor Rotor side of ca se.
(11) Con n ect swit ch wir es t o h a r n ess a n d lower
veh icle.
TABBED (12) Ch eck swit ch oper a t ion . E n gin e sh ou ld st a r t
WASHER in P a r k a n d Neu t r a l on ly.

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

Fig. 46 Cable and Shifter


OIL SOLENOID WIRE
SCREEN CONNECTORS

_ _ _----'J9121-376
0 0
....____ _o _ _0_ _ _

Fig. 47 Oil Screen Removal/Installation


TRANSMISSION VALVE BODY
J8921-433
REMOVAL Fig. 48 Solenoid Wire Connectors
(1) Rem ove oil pa n plu g a n d dr a in t r a n sm ission
flu id. (4) Rem ove va lve body oil t u bes (F ig. 51). Ca r efu lly
(2) Rem ove oil pa n a n d oil scr een . Clea n pa n a n d pr y t u bes ou t of va lve body wit h scr ewdr iver.
scr een in solven t a n d dr y t h em wit h com pr essed a ir. (5) Discon n ect t h r ot t le ca ble fr om t h r ot t le ca m
(3) Discon n ect solen oid wir e con n ect or s (F ig. 50). (F ig. 52).
Ma r k wir es for a ssem bly r efer en ce.
XJ TRANSMISSION AND TRANSFER CASE 21 - 195
REM OVAL AN D I N STALLAT I ON (Cont inue d)

VALVE BODY
SOLENOIDS

J892l-434

Fig. 49 Transmission Valve Body Solenoids


SOLENOID WIRE
CONNECTORS

J892l-437

Fig. 51 Removing Transmission Valve Body Oil


Tubes

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.

TRANSMISSION CONTROL MODULE SOLENOID HARNESS ADAPTER SEAL


Th e t r a n sm ission con t r ol m odu le is m ou n t ed u n der
t h e in st r u m en t pa n el. On left h a n d dr ive m odels, it is REMOVAL
a t t h e dr iver side of t h e lower fin ish pa n el (F ig. 58). (1) Rem ove oil pa n a n d oil scr een .
On r igh t h a n d dr ive m odels, it is a t t h e pa ssen ger (2) Discon n ect solen oid wir e con n ect or s (F ig. 60).
side of t h e lower fin ish pa n el (F ig. 59).
XJ TRANSMISSION AND TRANSFER CASE 21 - 197
REM OVAL AN D I N STALLAT I ON (Cont inue d)

SOLENOID WIRE
CONNECTORS

~
L
M
OIL
TUBES
(INSTALL
Li AS SHOWN)
M

J8921-443

Fig. 57 Installing Transmission Valve Body Oil J8921-433


Tubes
Fig. 60 Solenoid Wire Connectors

J9421-150

Fig. 58 TCM Location (Left Hand Drive)

J8921-436

Fig. 61 Harness Adapter Removal/Installation


(4) Con n ect wir es t o solen oids.
(5) In st a ll oil scr een .
(6) Apply bea d of Th r eebon d! Liqu id Ga sket
Fig. 59 TCM Location (Right Hand Drive) TB1281, P /N 83504038, t o oil pa n sea l su r fa ce.
(3) Rem ove br a cket secu r in g solen oid h a r n ess Sea ler bea d sh ou ld be a t lea st 3 m m (1/8 in .) wide.
a da pt or (F ig. 61) t o ca se. (7) In st a ll oil pa n on t r a n sm ission . Tigh t en pa n
(4) P u ll h a r n ess a da pt er a n d wir es ou t of ca se. bolt s t o 7 N·m (65 in . lbs.) t or qu e.
(5) Rem ove a n d disca r d a da pt er O–r in g. (8) In st a ll a n d t igh t en oil pa n dr a in plu g t o 20
N·m (15 ft . lbs.) t or qu e.
INSTALLATION (9) F ill t r a n sm ission wit h Mopa r Dexr on IIE /Mer-
(1) Lu br ica t e n ew O–r in g a n d in st a ll it on a da pt er. con .
(2) In st a ll solen oid wir e h a r n ess a n d a da pt er in
ca se.
(3) In st a ll a da pt er br a cket a n d br a cket bolt .
21 - 198 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

MANUAL VALVE SHAFT SEAL


REMOVAL

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

Fig. 65 Cutting Spacer Sleeve


PARK ROD (7) Rem ove sh a ft a n d sect or fr om ca se.
BRACKET (8) P r y sh a ft sea ls ou t of ca se (F ig. 66).

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

Fig. 67 Installing Manual Valve Shaft Seals J8921-451


(3) In st a ll n ew spa cer sleeve on sect or (F ig. 68).
(4) Lu br ica t e m a n u a l va lve sh a ft wit h pet r oleu m Fig. 69 Installing Park Rod Bracket
jelly a n d in st a ll it t h r ou gh t h e left side of t h e t r a n s- (10) In st a ll va lve body, oil scr een a n d oil pa n .
m ission ca se. (11) In st a ll pa r k/n eu t r a l posit ion swit ch .
(5) Lu br ica t e sect or a n d sleeve wit h pet r oleu m
jelly a n d in st a ll t h em on sh a ft . ACCUMULATOR PISTONS AND SPRINGS
(6) In st a ll t h e m a n u a l va lve sh a ft t h r ou gh t h e
r em a in der of t h e t r a n sm ission ca se. REMOVAL
(7) Align h ole in spa cer sleeve wit h n ot ch in sect or. (1) Rem ove va lve body.
Th en in st a ll sh ift sect or r oll pin . Ta p pin in t o sect or (2) Rem ove a ccu m u la t or pist on s wit h com pr essed
a n d sh a ft a n d secu r ely st a ke sleeve t o sect or a n d a ir (F ig. 70). Apply a ir t h r ou gh sm a ll feed h ole n ext
sh a ft .
21 - 200 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
t o ea ch pist on bor e. Ca t ch ea ch pist on in a sh op ACCUMULATOR SMALL
t owel a s it exit s bor e. PISTON (TYPICAL) CUSHION
SPRING

RETAINER
CLIP

J9121-414

Fig. 71 Small Cushion Spring Retention

Fig. 70 Accumulator Piston Removal


CAUTION: Use only enough air pressure to ease
each piston out of the bore. In addition, remove the
pistons one at a time and tag the pistons and
springs for assembly reference. Do not intermix
them.

(3) Rem ove a n d disca r d pist on O–r in g sea ls. Th en


clea n pist on s a n d spr in gs wit h solven t .

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

Fig. 75 Second Coast Brake Servo Components


J8921-457
(5) In st a ll va lve body, oil scr een a n d oil pa n .
Fig. 73 Removing/Installing Servo Piston Cover
Snap Ring PARK ROD AND PAWL
REMOVAL
(1) Rem ove va lve body a s ou t lin ed in t h is sect ion .
(2) 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. 76).

PARK
ROD
BRACKET

J8921-458

Fig. 74 Removing Servo Cover And Piston


INSTALLATION
(1) In st a ll n ew sea ls on cover a n d pist on . J8921-451
(2) Lu br ica t e ser vo com pon en t s wit h t r a n sm ission
flu id. Fig. 76 Removing/Installing Park Rod Bracket
(3) Assem ble a n d in st a ll ser vo com pon en t s in ca se.
Be su r e ser vo pist on r od is pr oper ly en ga ged in t h e
secon d coa st br a ke ba n d.
(4) Com pr ess cover a n d pist on a n d in st a ll cover
sn a p r in g.
21 - 202 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

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

Fig. 79 Transmission Throttle Cable Attachment


XJ TRANSMISSION AND TRANSFER CASE 21 - 203
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Ra ise veh icle. (4) In st a ll ca ble br a cket on ca se a n d t igh t en
(3) Rem ove t r a n sm ission oil pa n . a t t a ch in g bolt t o 10 N·m (7 ft . lbs.) t or qu e (F ig. 81).
(4) Disen ga ge ca ble fr om t h r ot t le va lve ca m (F ig. (5) In st a ll pa n a n d t igh t en pa n bolt s t o 7 N·m (65
80). in . lbs.) t or qu e.
(6) In st a ll n ew ga sket on oil pa n dr a in plu g.
In st a ll a n d t igh t en plu g t o 20 N·m (15 ft . lbs.) t or qu e.
(7) Con n ect ca ble t o en gin e br a cket a n d t h r ot t le
lin ka ge.
(8) F ill t r a n sm ission wit h Mopa r ! Dexr on /Mer con
IIE .
(9) Adju st t h e ca ble a s descr ibed in ca ble a dju st -
m en t pr ocedu r e.

OIL PUMP SEAL


REMOVAL
(1) Rem ove con ver t er.
THROTTLE (2) Rem ove old sea l. Use blu n t pu n ch t o colla pse
CABLE sea l a n d pr y sea l ou t of pu m p h ou sin g. Do n ot
scr a t ch or da m a ge sea l bor e.
J8921-438

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

Fig. 81 Removing/Installing Transmission Throttle Fig. 82 Installing Oil Pump Seal


Cable And Bracket (2) Lu br ica t e con ver t er dr ive h u b wit h t r a n sm is-
(6) Rem ove a n d disca r d ca ble sea l. sion flu id.
(3) Align a n d in st a ll con ver t er n oil pu m p.
INSTALLATION
(1) Lu br ica t e a n d in st a ll n ew sea l on ca ble.
(2) In ser t ca ble in t r a n sm ission ca se.
(3) At t a ch ca ble t o t h r ot t le ca m (F ig. 80).
21 - 204 TRANSMISSION AND TRANSFER CASE XJ

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 .

Fig. 85 Removing Oil Screen


(9) Rem ove va lve body oil feed t u bes (F ig. 86).

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

Fig. 86 Valve Body Oil Tube Removal


(10) Discon n ect va lve body solen oid wir es (F ig. 87).
(11) Rem ove h a r n ess br a cket bolt a n d r em ove h a r-
n ess a n d br a cket (F ig. 88).

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)

SOLENOID WIRE • =BOLT LOCATIONS


CONNECTORS

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

Fig. 92 Accumulator Piston Removal


XJ TRANSMISSION AND TRANSFER CASE 21 - 207
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

OIL
PUMP J8921-481

Fig. 93 Oil Pump Removal J8921-483

OIL Fig. 95 Removing Overdrive Planetary And Clutch


PUMP
Assembly

PLANETARY
(OVERDRIVE)

RACE
J8921-482

Fig. 94 Oil Pump Race Removal

J8921-484

Fig. 96 Fourth Gear Planetary Race Removal


21 - 208 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(23) Rem ove t h r u st bea r in g, r a ce a n d over dr ive (27) Rem ove t h e in pu t speed sen sor fr om t h e
pla n et a r y r in g gea r (F ig. 97). t r a n sm ission ca se.
(28) Rem ove over dr ive br a ke pa ck sn a p r in g (F ig.
RACE
98).
OVERDRIVE
PLANETARY
RING GEAR
~~

J8921-485

Fig. 97 Removing Bearing, Race And Planetary Ring


Gear J8921-487

(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

Fig. 102 Removing Overdrive Support


J8921-491

Fig. 100 Overdrive Support Snap Ring Removal/


Installation
(Q)-RACE
(32) Rem ove over dr ive su ppor t bolt s (F ig. 101).
OVERDRIVE
SUPPORT

J8921-493

Fig. 103 Remove Overdrive Support Race


(35) Rem ove secon d coa st br a ke pist on sn a p r in g
J8921-490 wit h Sn a p Rin g P lier Tool 7540. Th en r em ove pist on
cover a n d pist on a ssem bly.
Fig. 101 Overdrive Support Bolt Removal (36) Disa ssem ble secon d coa st br a ke pist on (F ig.
(33) Rem ove over dr ive su ppor t (F ig. 102) wit h 104), if n ecessa r y.
br idge–t ype P u ller 7536.
(34) Rem ove r a ce fr om h u b of over dr ive su ppor t
(F ig. 103).
21 - 210 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 104 Second Coast Brake Piston Components


Fig. 106 Bearing And Race Removal From Clutch
(37) Rem ove dir ect a n d for wa r d clu t ch a ssem bly Hub
(F ig. 105).
DIRECT AND
FORWARD
CLUTCH
ASSEMBLY

BRAKE BAND
E-RING
SECOND
COAST
BRAKE
BAND

J8921-496

Fig. 105 Removing Direct And Forward Clutch


Assembly
(38) Rem ove t h r u st bea r in g a n d r a ce fr om clu t ch
h u b (F ig. 106). J8921-498
(39) Rem ove secon d coa st br a ke ba n d E –r in g fr om
ba n d pin a n d r em ove pin a n d br a ke ba n d (F ig. 107). Fig. 107 Second Coast Brake Band Removal
(40) Rem ove fr on t pla n et a r y bea r in g r a ce a n d
r em ove fr on t pla n et a r y r in g gea r (F ig. 108).
XJ TRANSMISSION AND TRANSFER CASE 21 - 211
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
RING GE (44) Rem ove pla n et a r y sn a p r in g a n d r em ove pla n -
@ RACE (FR~~~tRING et a r y gea r (F ig. 110).

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

Fig. 117 Checking First–Reverse Brake Clutch Pack


Clearance
REMOVER
TOOL

J8921-507
Fig. 115 Removing Park Rod And Bracket

PISTON
SLEEVE

JB921-509

Fig. 118 Removing Second Brake Piston Sleeve


(57) Mea su r e in side dia m et er of t r a n sm ission ca se
r ea r bu sh in g wit h bor e ga u ge or in side m icr om et er
(F ig. 121). Ma xim u m a llowa ble dia m et er is 38.18 m m
(1.5031 in .). Re p la c e tra n s m is s io n c a s e if bu s h -
in g I.D . is g re a te r th a n s p e c ifie d . B u s h in g is n o t
s e rv ic e a ble .
Fig. 116 Removing Park Pawl, Pin And Spring
(56) Rem ove secon d br a ke dr u m ga sket fr om ca se
wit h scr ewdr iver.
21 - 214 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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)

J8921-616 LOW-PRESSURE AIR


J8921-617

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

Fig. 123 Removing/Installing Piston Snap Ring J8921-620

(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

Fig. 124 Removing/Installing Reaction Sleeve


21 - 216 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 129 Output Shaft/Rear Planetary Assembly


Installation
J8921-670
Fig. 127 Installing Thrust Bearing And No. 10 Race

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

Fig. 131 Checking First–Reverse Brake Pack J8921-677


Clearance Fig. 133 Park Lock Pin, Spring And Pawl Installation

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

Fig. 138 Second Brake Pack Installation


(29) In st a ll secon d br a ke pa ck r et a in er wit h
r ou n ded edge of r et a in er fa cin g disc.
(30) In st a ll secon d br a ke pa ck sn a p r in g.
(31) Ch eck br a ke pa ck clea r a n ce wit h feeler ga u ge
(F ig. 139). Clea r a n ce sh ou ld be 0.062 – 1.98 m m
(0.024 – 0.078 in .). If br a ke pa ck clea r a n ce is n ot cor-
r ect , br a ke pa ck com pon en t s a r e n ot sea t ed. Rea s-
sem ble br a ke pa ck if n ecessa r y.

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

Fig. 144 Installing Second Coast Brake Band


(38) In st a ll pin in secon d coa st br a ke ba n d. Th en
in st a ll r et a in in g r in g on pin (F ig. 145).
(39) In st a ll t h r u st bea r in g a n d r a ce in for wa r d–di-
r ect clu t ch (F ig. 146). Coa t bea r in g/r a ce wit h pet r o-
leu m jelly t o h old t h em in pla ce.
(40) Ver ify for wa r d–dir ect clu t ch t h r u st bea r in g
size.
• Ra ce ou t er dia m et er is 48.9 m m (1.925 in .) a n d
in side dia m et er is 26.0 m m (1.024 in .).
• Bea r in g ou t er dia m et er is 46.7 m m (1.839 in .)
a n d in side dia m et er is 26.0 m m (1.024 in .).
(41) Coa t fr on t pla n et a r y r in g gea r r a ce wit h
pet r oleu m jelly a n d in st a ll it in r in g gea r (F ig. 147). J8921-690
(42) Ver ify r in g gea r r a ce size. Ou t er dia m et er is Fig. 145 Installing Second Coast Brake Band
47.0 m m (1.850 in .) a n d in side dia m et er is 26.5 m m Retaining Pin
(1.045 in .).
(43) Align for wa r d–dir ect clu t ch disc splin es wit h
scr ewdr iver (F ig. 148).
(44) Align a n d in st a ll fr on t pla n et a r y r in g gea r in
for wa r d–dir ect clu t ch (F ig. 149).
(45) Coa t bea r in g a n d r a ce wit h pet r oleu m jelly
a n d in st a ll t h em in r in g gea r (F ig. 150). Ver ify bea r-
in g/r a ce size.
21 - 222 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

THRUST
BEARING

RING
GEAR

RACE

• FRONT FORWARD-DIRECT
CLUTCH ASSEMBLY
d-~,~~"b"'"""'""·1;l'tg

J8921-691

Fig. 146 Installing Forward–Direct Clutch Thrust J8921-694


Bearing And Race
Fig. 149 Installing Front Planetary Ring Gear

RACE
THRUST
BEARING

~
u
J8921-692

Fig. 147 Installing Planetary Ring Gear Race

-,t.FRONT

J8921-695

Fig. 150 Installing Ring Gear Bearing And Race


• Bea r in g ou t er dia m et er is 47.7 m m (1.878 in .)
a n d in side dia m et er is 32.6 m m (1.283 in .).
• Ra ce ou t er dia m et er is 53.6 m m (2.110 in .) a n d
in side dia m et er is 30.6 m m (1.205 in .).
(46) In st a ll a ssem bled pla n et a r y gea r /for wa r d–di-
r ect clu t ch (F ig. 151).
(47) Ch eck clea r a n ce bet ween su n gea r in pu t dr u m
a n d dir ect clu t ch dr u m (F ig. 152). Clea r a n ce sh ou ld
J8921-693 be 9.8 – 11.8 m m (0.386 – 0.465 in .). If clea r a n ce is
in cor r ect , pla n et a r y gea r /for wa r d–dir ect clu t ch
Fig. 148 Aligning Forward–Direct Clutch Splines a ssem bly is n ot sea t ed or is im pr oper ly a ssem bled.
Rem ove, a n d cor r ect if n ecessa r y.
XJ TRANSMISSION AND TRANSFER CASE 21 - 223
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

PISTON
ROD

J8921-699

Fig. 153 Assembling Second Coast Brake Piston


FRONT PLANETARY AND (51) In st a ll r epla cem en t sea ls on secon d coa st
FORWARD-DIRECT
CLUTCH ASSEMBLY br a ke pist on cover a n d in st a ll cover in ca se.
(52) In st a ll secon d coa st br a ke pist on sn a p r in g
J8921-696
wit h sn a p r in g plier t ool (F ig. 154).

Fig. 151 Installing Front Planetary And


Forward–Direct Clutch Assembly

CLEARANCE SHOULD BE:


9.8-11.8 mm J8921-700
(0.386-0.465 in.)

Fig. 154 Installing Second Coast Brake Piston Snap


Ring
(53) Ch eck secon d coa st br a ke pist on st r oke a s fol-
lows:
J8921-697 (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-
Fig. 152 Checking Input Drum–To–Direct Clutch m ission ca se.
Drum Clearance (b) Apply 57–114 psi a ir pr essu r e t h r ou gh pist on
(48) Coa t t h r u st bea r in g a n d r a ce a ssem bly wit h feed h ole a n d ch eck st r oke len gt h wit h Ga u ge Tool
pet r oleu m jelly a n d in st a ll it on clu t ch sh a ft . Bea r in g 7552.
fa ces u p a n d t owa r d ca se fr on t a s sh own . Ver ify bea r- (c) St r oke len gt h sh ou ld be 1.5 – 3.0 m m (0.059
in g/r a ce size. Bea r in g a n d r a ce ou t er dia m et er is 47.8 – 0.118 in .).
m m (1.882 in .) a n d in side dia m et er is 33.6 m m (1.301 (d) If st r oke len gt h is in cor r ect , pist on , cover or
in .). sn a p r in g is n ot sea t ed. Rea ssem ble a n d ch eck
(49) Assem ble secon d coa st br a ke pist on com po- st r oke a ga in if n ecessa r y.
n en t s (F ig. 153). (54) Coa t t h r u st r a ce a n d t a bbed wa sh er wit h
(50) In st a ll a ssem bled secon d coa st br a ke pist on in pet r oleu m jelly a n d in st a ll t h em on over dr ive su ppor t
ca se. Ver ify t h a t t h e pist on r od con t a ct s t h e secon d (F ig. 157). Ver ify r a ce size. Ra ce ou t er dia m et er is
coa st br a ke ba n d. 50.9 m m (2.004 in .) a n d in side dia m et er is 36.2 m m
(1.426 in .).
21 - 224 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
BRAKE
r r PISTON ROD
0----_THRUST
RACE

J8921-701

Fig. 155 Marking Brake Piston Rod


J8921-703
PISTON
ROD Fig. 157 Installing Overdrive Support Thrust Race
REFERENCE
And Washer

I
(' (' MARK

J8921-702

Fig. 156 Checking Second Coast Brake Piston


Stroke
(55) In st a ll over dr ive su ppor t in ca se. Use t wo lon g J8921-704
bolt s t o h elp a lign a n d gu ide su ppor t in t o posit ion
(F ig. 158). Fig. 158 Installing Overdrive Support
(56) In st a ll over dr ive su ppor t sn a p r in g wit h Sn a p
(58) Ch eck ou t pu t sh a ft en d pla y wit h dia l in dica -
Rin g P lier Tool 7540 (F ig. 159). Ch a m fer ed side of
t or (F ig. 161). E n d pla y sh ou ld be 0.27 – 0.86 m m
sn a p r in g fa ces u p a n d t owa r d ca se fr on t . S n a p rin g
(0.0106 – 0.0339 in .).
e n d s m u s t be a lig n e d w ith c a s e o p e n in g w ith
(59) If ou t pu t sh a ft en d pla y is in cor r ect , on e or
rin g e n d s a p p ro x im a te ly 24 m m (0.94 in .) fro m
m or e of in st a lled com pon en t s is n ot sea t ed. Rea ssem -
c e n te r lin e o f c a s e o p e n in g .
ble a s n ecessa r y a n d ch eck en d pla y a ga in .
(57) In st a ll a n d t igh t en over dr ive su ppor t bolt s t o
(60) In st a ll over dr ive br a ke clu t ch pa ck (F ig. 162).
25 N·m (19 ft . lbs.) t or qu e (F ig. 160).
In st a ll t h ickest clu t ch pla t e fir st . Rou n ded edge of
pla t e fa ces u p. In st a ll fir st disc followed by a n ot h er
pla t e u n t il fou r discs a n d t h r ee pla t es a r e in st a lled.
XJ TRANSMISSION AND TRANSFER CASE 21 - 225
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

SNAP RING TOOL


. . FRONT

SNAP
RING
J8921-708

J8921-705 Fig. 162 Installing Overdrive Brake Clutch Pack


Fig. 159 Installing Overdrive Support Snap Ring (61) In st a ll st epped r in g r et a in er pla t e wit h fla t
side fa cin g disc. Th en in st a ll br a ke pa ck sn a p r in g
(F ig. 163).

J8921-706

Fig. 160 Installing Overdrive Support Bolts J8921-709

Fig. 163 Installing Overdrive Brake Snap Ring


(62) Ch eck over dr ive br a ke pist on st r oke a s fol-
lows:
(a ) Mou n t dia l in dica t or on ca se u sin g Miller
Tool C-3339 a n d a su it a ble bolt t h r ea ded in t o t h e
t r a n sm ission ca se.
(b) Ver ify t h a t t h e dia l in dica t or is m ou n t ed sol-
J8921-707
idly a n d squ a r e t o t h e dir ect ion of t h e pist on
Fig. 161 Checking Output Shaft End Play t r a vel.
21 - 226 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(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) If st r oke is in cor r ect , br a ke pa ck or pist on is
in st a lled in cor r ect ly. Ch eck a n d cor r ect a s n eces-
sa r y a n d m ea su r e pist on st r oke a ga in .
(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 .
(63) Coa t over dr ive lower r a ce, t h r u st bea r in g a n d
u pper r a ce wit h pet r oleu m jelly a n d in st a ll t h em in
over dr ive su ppor t (F ig. 164). Be su r e r a ces a n d bea r-
in g a r e a ssem bled a n d in st a lled a s sh own .

• FRONT

LOWER J8921-713
RACE
Fig. 165 Installing Overdrive Planetary Ring Gear

J8921-712

Fig. 164 Installing Overdrive Support Thrust Bearing


And Races
(64) Ver ify bea r in g/r a ce sizes befor e pr oceedin g.
Bea r in g r a ce sizes a r e:
• Ou t er dia m et er of lower r a ce is 47.8 m m (1.882
in .) a n d in side dia m et er is 34.3 m m (1.350 in .).
• Ou t er dia m et er of bea r in g is 47.7 m m (1.878 in .)
a n d in side dia m et er is 32.7 m m (1.287 in .).
J8921-714
• Ou t er dia m et er of u pper r a ce is 47.8 m m (1.882
in .) a n d in side dia m et er is 30.7 m m (1.209 in .). Fig. 166 Installing Ring Gear Thrust Bearing And
(65) In st a ll over dr ive pla n et a r y r in g gea r in su p- Race
por t (F ig. 165).
dia m et er is 41.8 m m (1.646 in .) a n d in side dia m et er
(66) Coa t r in g gea r t h r u st r a ce a n d t h r u st bea r in g
is 27.1 m m (1.067 in .).
a ssem bly wit h pet r oleu m jelly a n d in st a ll t h em in
(69) In st a ll a ssem bled over dr ive pla n et a r y gea r
gea r (F ig. 166).
a n d clu t ch (F ig. 168).
(67) Ver ify bea r in g/r a ce size befor e pr oceedin g.
(70) Coa t t h r u st bea r in g a n d r a ce a ssem bly wit h
• Ou t er dia m et er of r in g gea r r a ce–bea r in g is 47.8
pet r oleu m jelly a n d in st a ll it on clu t ch in pu t sh a ft
m m (1.882 in .) a n d in side dia m et er is 24.2 m m (0.953
(F ig. 169). Bea r in g a n d r a ce ou t er dia m et er is 50.2
in .).
m m (1.976 in .) a n d in side dia m et er is 28.9 m m (1.138
• Ou t er dia m et er of bea r in g is 46.8 m m (1.844 in .)
in .).
a n d in side dia m et er is 26.0 m m (1.024 in .).
(71) Coa t t h r u st bea r in g r a ce wit h pet r oleu m jelly
(68) Coa t t a bbed t h r u st r a ce wit h pet r oleu m jelly
a n d in st a ll it in oil pu m p (F ig. 170). Bea r in g r a ce
a n d in st a ll it on pla n et a r y gea r (F ig. 167). Ra ce ou t er
XJ TRANSMISSION AND TRANSFER CASE 21 - 227
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

OVERDRIVE THRUST
THRUST PLANETARY BEARING
RACE AND RACE
(TABBED) ASSEMBLY
• FRONT

L-~--CLUTCHINPUT
~~lb.::: SHAFT

J8921-715

Fig. 167 Installing Planetary thrust Race

J8921-717

Fig. 169 Installing Input Shaft Thrust Bearing And


Race Assembly
OIL PUMP

PUMP
THRUST
RACE

TO PUMP

Fig. 168 Installing Overdrive Planetary And Clutch c:::::'I


t- lb-,
Assembly
ou t er dia m et er is 47.2 m m (1.858 in .) a n d in side J8921-720
dia m et er is 28.1 m m (1.106 in .).
(72) Lu br ica t e a n d in st a ll r epla cem en t O–r in g on Fig. 170 Installing Oil Pump Thrust Race
oil pu m p body. (76) Lu br ica t e a n d in st a ll n ew O–r in g on t r a n s-
(73) In st a ll oil pu m p in ca se. Align pu m p a n d ca se m ission t h r ot t le ca ble a da pt er a n d in st a ll ca ble in
bolt h oles a n d ca r efu lly ea se pu m p in t o pla ce. ca se (F ig. 171).
(77) Ch eck clu t ch a n d br a ke oper a t ion . Oper a t e
CAUTION: Do not use force to seat the pump. The clu t ch es a n d br a kes wit h com pr essed a ir a pplied
seal rings on the stator shaft could be damaged if t h r ou gh feed h oles in ca se (F ig. 172). List en for
they bind or stick to the direct clutch drum. clu t ch a n d br a ke a pplica t ion . If you do n ot h ea r a
clu t ch or br a ke a pply, disa ssem ble t r a n sm ission a n d
(74) Tigh t en oil pu m p bolt s t o 22 N·m (16 ft . lbs.)
r epa ir fa u lt befor e pr oceedin g. It is n e c e s s a ry to
t or qu e.
blo c k th e o v e rd riv e c lu tc h a c c u m u la to r fe e d
(75) Ver ify in pu t sh a ft r ot a t ion . Sh a ft sh ou ld
h o le N o . 8 (F ig . 172) in o rd e r to c h e c k d ire c t
r ot a t e sm oot h ly a n d n ot bin d.
c lu tc h o p e ra tio n .
21 - 228 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

@ SECOND BRAKE ACCUMULATOR PISTON


@ DIRECT CLUTCH ACCUMULATOR PISTON
© OVERDRIVE BRAKE ACCUMULATOR PISTON
@ OVERDRIVE CLUTCH ACCUMULATOR PISTON

THROTTLE
CAM
J8921-478

Fig. 171 Installing Transmission Throttle Cable


6

J9121-421

Fig. 173 Accumulator Piston And Spring Installation


CHECK BALL
BODY AND SPRING

1. OVERDRIVE DIRECT CLUTCH FEED


2. DIRECT CLUTCH FEED
3. FORWARD CLUTCH FEED
4. OVERDRIVE BRAKE FEED
5. SECOND COAST BRAKE FEED
6. SECOND BRAKE FEED
7 FIRST-REVERSE BRAKE FEED
a· OVERDRIVE CLUTCH ACCUMULATOR PISTON HOLE (BLOCK THIS
. HOLE WHEN CHECKING DIRECT CLUTCH OPERATION)

J8921-721

Fig. 172 Clutch And Brake Feed Hole Locations


(78) Lu br ica t e a n d in st a ll n ew O–r in gs on a ccu m u -
la t or pist on s (F ig. 173). J8921-723
(79) Assem ble a n d in st a ll a ccu m u la t or pist on s a n d
spr in gs (F ig. 173). Fig. 174 Installing Check Ball Body And Spring
(80) In st a ll n ew ch eck ba ll body a n d spr in g (F ig.
(83) Align m a n u a l va lve, det en t spr in g a n d sh ift
174).
sect or (F ig. 175).
(81) P osit ion va lve body on ca se (F ig. 175).
(84) Con n ect t r a n sm ission t h r ot t le ca ble t o t h r ot t le
(82) In st a ll det en t spr in g (F ig. 175).
va lve ca m (F ig. 176).
XJ TRANSMISSION AND TRANSFER CASE 21 - 229
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 187 Oil Pump Components


OIL PUMP
BORE
DISASSEMBLY GAUGE
(1) Rem ove pu m p body O–r in g (F ig. 187).
(2) Rem ove pu m p sea l.
(3) Rem ove pu m p sea l r in gs (F ig. 187).
(4) Rem ove bolt s a t t a ch in g st a t or sh a ft t o pu m p
body a n d sepa r a t e com pon en t s.
(5) Rem ove dr ive gea r a n d dr iven gea r fr om pu m p
body (F ig. 187).

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

Fig. 190 Installing Pump Seal


(8) In st a ll n ew O–r in g on pu m p body a n d n ew sea l
r in gs on st a t or sh a ft .
(9) In st a ll pu m p in t or qu e con ver t er a n d ch eck
pu m p gea r r ot a t ion (F ig. 191). Gea r s m u st r ot a t e
BODY-TO-
DRIVEN GEAR CLEARANCE sm oot h ly wh en t u r n ed clockwise a n d cou n t er clock-
wise.
(10) Lu br ica t e pu m p O–r in g a n d sea l r in gs wit h
pet r oleu m jelly.
OIL
PUMP

GEAR-TO-GEAR
TOOTH CLEARANCE

TORQUE
CONVERTER
J8921-520

CHECKING Fig. 191 Checking Pump Gear Rotation


GEAR
END PLAY

Fig. 189 Checking Pump Gear Clearances


21 - 234 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

OVERDRIVE PLANETARY GEAR AND CLUTCH


DISASSEMBLY
CLUTCH
DISCS
CLUTCH PISTON
CLUTCH DRUM

0
\
CLUTCH DRUM
BEARING AND
RACE ASSEMBLY
CLUTCH
PLATES

BEARING

ONE-WAY CLUTCH
OUTER RACE

RETAINING PLATE

RACE
PLANETARY
RING GEAR
J8921-521

Overdrive Planetary Gear And Clutch Components

(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

Fig. 192 Checking One–Way Clutch


Fig. 194 Assembling Converter, Pump And Clutch
OVERDRIVE For Test
CLUTCH

THRUST BEARING
AND RACE

~I'
PLANETARY

GEAR
', t! )f

J8921-523

Fig. 193 Removing Overdrive Clutch From Gear


(4) Rem ove t h r u st bea r in g a n d r a ce a ssem bly fr om
J8921-524
clu t ch dr u m (F ig. 195).
(5) Rem ove clu t ch pa ck sn a p r in g a n d r em ove t h e Fig. 195 Removing Clutch Drum Bearing And Race
clu t ch pa ck (F ig. 196).
(6) Mea su r e over dr ive clu t ch disc t h ickn ess. Min i- (7) If t h e clu t ch pa ck st r oke len gt h is ou t of speci-
m u m a llowa ble t h ickn ess is 1.84 m m (0.0724 in .). fica t ion or a n y clu t ch disc fa ils t o m eet t h e m in im u m
t h ickn ess, n ew discs will n eed t o be in st a lled du r in g
a ssem bly.
21 - 236 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

J8921-527

Fig. 196 Removing Clutch Pack Snap Ring J8921-529

(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

Fig. 200 Testing Clutch Piston Check Ball J8921-530

(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

Fig. 201 Checking Clutch Drum Bushings


(15) Rem ove bea r in g a n d r a ce fr om r in g gea r (F ig.
202). J8921-531
(16) Rem ove sn a p r in g fr om r in g gea r a n d r em ove
r in g gea r h u b (F ig. 203). Fig. 203 Removing Ring Gear Hub
21 - 238 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(17) Rem ove r a ce fr om pla n et a r y gea r (F ig. 204).

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

Fig. 206 Removing One–Way Clutch

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

Fig. 220 Removing/Installing Piston Snap Ring


J8921-551
(6) Mou n t su ppor t in dir ect clu t ch a n d r em ove
br a ke pist on wit h com pr essed a ir. Apply a ir t o sa m e Fig. 222 Removing Support Seal Rings
feed h ole u sed wh en ch eckin g pist on oper a t ion .
(7) Rem ove a n d disca r d su ppor t O–r in gs (F ig. 221). ASSEMBLY
(8) Rem ove su ppor t sea l r in gs (F ig. 222). (1) Lu br ica t e n ew su ppor t sea l r in gs. Th en com -
(9) Mea su r e fr ee len gt h of pist on r et u r n spr in gs pr ess r in gs a n d in st a ll t h em on su ppor t (F ig. 224).
wit h spr in gs m ou n t ed in r et a in er (F ig. 223). Len gt h (2) Lu br ica t e a n d in st a ll n ew O–r in gs on br a ke
sh ou ld be 17.23 m m (0.678 in .). pist on . Th en ca r efu lly sea t pist on in su ppor t .
(10) Clea n su ppor t com pon en t s a n d dr y t h em wit h (3) In st a ll r et u r n spr in gs on br a ke pist on .
com pr essed a ir. (4) Com pr ess r et u r n spr in gs wit h Spr in g Com pr es-
(11) In spect over dr ive su ppor t a n d br a ke pist on . sor 7537 (F ig. 220) a n d in st a ll pist on sn a p r in g.
Repla ce su ppor t a n d pist on if eit h er pa r t is wor n or (5) In st a ll su ppor t bea r in g r a ce a n d clu t ch dr u m
da m a ged. t h r u st wa sh er (F ig. 219).

PISTON BRAKE PISTON FRONT REAR


SNAP RING RACE RACE

THRUST
BEARING

SUPPORT SEAL CLUTCH DRUM


RINGS THRUST WASHER

BRAKE PISTON
PISTON RETURN SPRING O-RINGS

J8921-546

Fig. 221 Overdrive Support Components


XJ TRANSMISSION AND TRANSFER CASE 21 - 243
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 224 Installing Support Seal Rings


(6) In st a ll t h r u st bea r in g a n d fr on t a n d r ea r bea r-
in g r a ces. Th r u st bea r in g r oller s sh ou ld fa ce u pwa r d
a s sh own (F ig. 224).
(7) Ver ify t h r u st bea r in g/r a ce sizes (F ig. 225). FORWARD
• F r on t r a ce ou t er dia m et er is 47.8 m m (1.882 in .) CLUTCH
a n d in side dia m et er is 30.7 m m (1.209 in .). J8921-555
• Rea r r a ce ou t er dia m et er is 47.8 m m (1.882 in .)
a n d in side dia m et er is 34.3 m m (1.350 in .). Fig. 226 Separate Direct Clutch From Forward
• Bea r in g ou t er dia m et er is 47.7 m m (1.878 in .) Clutch
a n d in side dia m et er is 32.7 m m (1.287 in .).
(2) Rem ove clu t ch dr u m t h r u st wa sh er (F ig. 227).
21 - 244 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 228 Mount Direct Clutch On Overdrive Support J8921-559


(5) Mou n t dia l in dica t or on clu t ch a n d posit ion
in dica t or plu n ger on clu t ch pist on (F ig. 229). Fig. 230 Removing Clutch Pack Snap Ring
(6) Apply 57–114 psi a ir pr essu r e t h r ou gh feed (9) Com pr ess clu t ch pist on r et u r n spr in gs wit h t ool
h ole in over dr ive su ppor t a n d n ot e pist on st r oke 7538 a n d r em ove clu t ch pist on sn a p r in g (F ig. 231).
len gt h (F ig. 229). Ch eck st r oke a t lea st t wice. (10) Rem ove com pr essor t ool a n d r et u r n spr in g.
(7) P ist on st r oke len gt h sh ou ld be 1.37 m m – 1.67 (11) Rem ove clu t ch pist on . Rem ou n t clu t ch on
m m (0.054 – 0.065 in .). If st r oke len gt h is in cor r ect , over dr ive su ppor t (F ig. 232). Apply com pr essed a ir
XJ TRANSMISSION AND TRANSFER CASE 21 - 245
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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)

DIRECT CLUTCH DRUM

CLUTCH PACK
SNAP RING
CLUTCH PACK RETAINER

CLUTCH
'6-CYLINDER CLUTCH DISC'
FOUR DISCS.USES FOUR PLATES - PLATE'

J8921-554

Fig. 235 Direct Clutch Components


(2) In st a ll clu t ch pist on in dr u m a n d in st a ll r et u r n CLUTCH
spr in gs on pist on . DISCS
(3) Com pr ess pist on r et u r n spr in gs wit h Tool 7538
a n d in st a ll sn a p r in g (F ig. 231). Be su r e sn a p r in g
en d ga p is n ot a lign ed wit h spr in g r et a in er t a b.
(4) In st a ll clu t ch discs a n d pla t es (F ig. 236).
In st a ll pla t e t h en disc u n t il a ll pla t es a n d discs a r e
in st a lled. F ou r pla t es a n d discs a r e r equ ir ed.

J8921-563

Fig. 236 Installing Direct Clutch Discs And Plates


XJ TRANSMISSION AND TRANSFER CASE 21 - 247
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(5) In st a ll clu t ch pa ck r et a in er in dr u m (F ig. 237).
(6) In st a ll clu t ch pa ck sn a p r in g (F ig. 237).
HEIGHT
SHOULD BE
70.3-71.5 mm
(2.767-2.815 in.)

FORWARD
CLUTCH J8921-566

Fig. 239 Checking Direct Clutch Assembled Height


J8921-564
(10) If a ssem bled h eigh t is in cor r ect , clu t ch es a r e
Fig. 237 Install Clutch Pack Retainer n ot sea t ed.
(7) Ch eck sn a p r in g posit ion . If n ecessa r y, sh ift
sn a p r in g u n t il en d ga p is n o t a lign ed wit h a n y FORWARD CLUTCH
n ot ch es in clu t ch dr u m (F ig. 238).
DISASSEMBLY
CLUTCH PACK SNAP RING (1) Ch eck clu t ch pist on st r oke a s ou t lin ed in fol-
lowin g st eps.
(2) P osit ion over dr ive su ppor t on wood blocks a n d
m ou n t for wa r d clu t ch dr u m on su ppor t (F ig. 241).
(3) Rem ove bea r in g a n d r a ce fr om for wa r d clu t ch
dr u m (F ig. 241).
(4) In st a ll a su it a ble t h r ea ded bolt /r od in t o t h e
side of t h e over dr ive su ppor t .
SHIFT SNAP RING END GAP (5) Mou n t Miller Tool C-3339 dia l in dica t or com po-
AWAY FROM DRUM NOTCHES n en t s on t o t h e t h r ea ded r od a s n ecessa r y.
(6) P osit ion dia l in dica t or plu n ger squ a r ely a ga in st
clu t ch pist on .
(7) Apply com pr essed a ir t h r ou gh r igh t side feed
h ole in su ppor t a n d n ot e pist on st r oke len gt h on dia l
in dica t or.
(8) St r oke len gt h sh ou ld be 3.55 – 3.73 m m (0.1348
– 0.1469 in .).
(9) Repla ce clu t ch discs if st r oke len gt h is in cor-
r ect .
J8921-565 (10) Rem ove clu t ch pa ck sn a p r in g a n d r em ove
r et a in er a n d clu t ch pa ck (F ig. 242).
Fig. 238 Adjusting Clutch Pack Snap Ring Position (11) Rem ove clu t ch pa ck cu sh ion pla t e (F ig. 243).
(8) Lu br ica t e clu t ch dr u m t h r u st wa sh er wit h (12) Com pr ess clu t ch spr in gs wit h Tool 7538 a n d
pet r oleu m jelly a n d in st a ll it in dr u m (F ig. 228). r em ove pist on sn a p r in g.
(9) Mou n t dir ect clu t ch a ssem bly on for wa r d clu t ch (13) Rem ove spr in g com pr essor t ool a n d pist on
a ssem bly a n d ch eck a ssem bled h eigh t (F ig. 239). r et u r n spr in gs.
H eigh t sh ou ld be 70.3 t o 71.5 m m (2.767 t o 2.815 (14) Rem ou n t for wa r d clu t ch dr u m on over dr ive
in .). su ppor t (F ig. 244).
21 - 248 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

FORWARD CLUTCH DRUM O-RINGS


PISTON
SNAP RING
·~y
THRUST

BEARING

=\
AND RACE

Q)O
\
BEARING
RACE

00 PISTON RETURN SPRINGS

FORWAR D CLUTCH PISTON

SEAL RINGS

CLUTCH PACK RETAINER

CUSHION PLATE

I
CLUTCH PACK
SNAP RING

*6-CYLINDER M PLATE*
PLATES AND Dgg~~S USE SIX

JS921-567

Fig. 240 Forward Clutch Components


(15) Apply com pr essed a ir t h r ou gh feed h ole in (20) Mea su r e clu t ch disc t h ickn ess (F ig. 248). Min -
su ppor t t o r em ove pist on (F ig. 244). Use on ly en ou gh im u m a llowa ble t h ickn ess is 1.51 m m (0.0595 in .).
a ir pr essu r e t o ea se pist on ou t of dr u m . Repla ce clu t ch pa ck if a n y disc fa lls below specified
(16) Rem ove a n d disca r d clu t ch pist on O–r in gs m in im u m t h ickn ess.
(F ig. 245). (21) Mea su r e fr ee len gt h of pist on r et u r n spr in gs
(17) Rem ove clu t ch dr u m O–r in g fr om r ea r h u b of wit h spr in gs m ou n t ed in r et a in er (F ig. 249). Len gt h
dr u m . sh ou ld be 19.47 m m (0.767 in .). Repla ce spr in gs a n d
(18) Rem ove t h r ee sea l r in gs fr om clu t ch dr u m r et a in er if len gt h is in cor r ect .
sh a ft (F ig. 246). (22) In spect clu t ch pist on ch eck ba ll (F ig. 250).
(19) Rem ove t h r u st bea r in g a n d r a ce a ssem bly Ba ll sh ou ld m ove fr eely wit h in pist on . Ch eck ba ll
fr om clu t ch dr u m (F ig. 247). sea t in g by a pplyin g low pr essu r e com pr essed a ir t o
XJ TRANSMISSION AND TRANSFER CASE 21 - 249
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

0-- THRUST BEARING

BEARING RACE

FORWARD
CLUTCH
DRUM

J8921-571

Fig. 243 Removing Cushion Plate

Fig. 241 Positioning Drum And Support On Wood CLUTCH


PISTON
Blocks

SNAP
RING

FEED
HOLE

J8921-572

Fig. 244 Removing Forward Clutch Piston


J8921-570
251). Ra ce side of a ssem bly fa ces down wa r d a n d
Fig. 242 Removing Retainer And Clutch Pack t owa r d dr u m . Bea r in g r oller s fa ce u p (F ig. 251)
(2) Coa t n ew clu t ch dr u m sh a ft sea l r in gs wit h
ba ll feed h ole. Ba ll sh ou ld sea t fir m ly a n d n ot lea k pet r oleu m jelly. Befor e in st a llin g dr u m sh a ft sea l
a ir. r in gs, squ eeze ea ch r in g so r in g en ds over la p (F ig.
(23) Mea su r e in side dia m et er of bu sh in g in clu t ch 252). Th is t igh t en s r in g m a kin g clu t ch in st a lla t ion
dr u m h u b. Ma xim u m a llowa ble dia m et er is 24.08 ea sier.
m m (0.9480 in .). Repla ce clu t ch dr u m if bu sh in g (3) In st a ll sea l r in gs on sh a ft . Keep r in gs closed a s
in side dia m et er is gr ea t er t h a n specified. t igh t ly a s possible du r in g in st a lla t ion . Avoid over-
spr ea din g t h em .
ASSEMBLY (4) Mou n t clu t ch dr u m on over dr ive su ppor t .
(1) Lu br ica t e bea r in g a n d r a ce a ssem bly wit h (5) Lu br ica t e a n d in st a ll n ew O–r in g on clu t ch
pet r oleu m jelly a n d in st a ll it in clu t ch dr u m (F ig. dr u m h u b (F ig. 245).
21 - 250 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

CLUTCH
DRUM
HUB

THRUST
BEARING
AND
RACE
ASSEMBLY

J8921-573 J8921-575

Fig. 245 Removing/Installing Clutch Drum O–Ring


Fig. 247 Removing Clutch Drum Thrust Bearing
SEAL Assembly
RINGS

\.-__ CLUTCH
DISC

MICROMETER

J8921-574

Fig. 246 Removing Clutch Drum Seal Rings


(6) Lu br ica t e n ew clu t ch pist on O–r in gs wit h J8921-576
Mopa r Door E a se, or Ru –Glyde. In st a ll r in gs on
clu t ch pist on a n d in st a ll pist on in dr u m . Fig. 248 Measuring Clutch Disc Thickness
(7) In st a ll pist on r et u r n spr in gs. r equ ir ed n u m ber of pla t es a n d discs a r e in st a lled.
(8) Com pr ess pist on r et u r n spr in gs wit h Tool 7538 Use six pla t es a n d discs.
a n d sh op pr ess a n d in st a ll pist on sn a p r in g. Be su r e (11) In st a ll clu t ch pa ck sn a p r in g.
sn a p r in g en d ga p is n ot a lign ed wit h a n y n ot ch es in (12) Rech eck clu t ch pist on st r oke len gt h u sin g
dr u m . sa m e m et h od ou t lin ed a t begin n in g of disa ssem bly
(9) In st a ll cu sh ion pla t e in dr u m . Con ca ve side of pr ocedu r e. If st r oke len gt h is n ot wit h in specified
pla t e fa ces down wa r d (F ig. 243). lim it s, r epla ce clu t ch discs.
(10) In st a ll clu t ch discs, pla t es a n d r et a in er (F ig. (13) Lu br ica t e r a ce a n d bea r in g wit h pet r oleu m
253). In st a ll t a bbed pla t e followed by disc u n t il jelly a n d in st a ll t h em in clu t ch dr u m (F ig. 254). Be
XJ TRANSMISSION AND TRANSFER CASE 21 - 251
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

BEARING
ROLLERS
FACE UP

FORWARD
CLUTCH

J8921-536

Fig. 249 Checking Return Spring Length


PISTON
CHECK BALL Fig. 251 Installing Thrust Bearing And Race

USE LOW
AIR PRESSURE
FOR TEST

J8921-577

Fig. 250 Testing Piston Check Ball


su r e bea r in g r oller s fa ce u p a n d r a ce lip sea t s in J8921-579
dr u m a s sh own .
(14) Ver ify bea r in g a n d r a ce size. Fig. 252 Installing Clutch Drum Shaft Seal Rings
• Ou t er dia m et er of bea r in g is 46.7 m m (1.839 in ).
• Ou t er dia m et er of r a ce is 48.9 m m (1.925 in .).
• In n er dia m et er of bea r in g a n d r a ce is 26.0 m m
(1.024 in .).
(15) Mou n t for wa r d clu t ch on dir ect clu t ch a n d
ch eck a ssem bled h eigh t (F ig. 255). H eigh t sh ou ld be
70.3 – 71.5 m m (2.767 – 2.815 in .).
21 - 252 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

FRONT PLANETARY GEAR

J8921-583

Fig. 256 Front Planetary Gear Components


ASSEMBLY
(1) Lu br ica t e pla n et a r y a n d r in g gea r bea r in gs a n d
r a ces wit h pet r oleu m jelly.
(2) Iden t ify pla n et a r y bea r in gs a n d r a ces befor e REAR
BEARING
in st a lla t ion . (F ig. 256). Bea r in gs a n d r a ces ca n be AND
iden t ified by followin g dim en sion s: RACE
• Ou t er dia m et er of r ea r bea r in g is 47.7 m m
(1.878 in .). In n er dia m et er is 35.5 m m (1.398 in .).
• Ou t er dia m et er of r ea r r a ce 47.6 m m (1.874 in .).
In n er dia m et er is 33.7 m m (1.327 in .).
• Ou t er dia m et er of fr on t r a ce is 53.6 m m (2.110
in .). In n er dia m et er is 30.5 m m (1.201 in .).
• Ou t er dia m et er of fr on t bea r in g is 47.7 m m
(1.878 in .). In n er dia m et er is 32.6 (1.283 in .).
• Ou t er dia m et er of for wa r d r a ce is 47.0 m m
(1.850 in .). In n er dia m et er is 26.5 m m 1.043 in .).
(3) In st a ll r ea r r a ce a n d bea r in g in gea r (F ig. 257).
(4) Tu r n pla n et a r y over a n d in st a ll t h r u st r a ce
(F ig. 258).
(5) In st a ll fr on t r a ce a n d bea r in g a n d for wa r d r a ce
J8921-584
in r in g gea r (F ig. 259).
Fig. 257 Front Planetary Rear Bearing and Race
Installation
21 - 254 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

TABBED
THRUST FRONT
RACE BEARING
AND
RACE

- ·
PLANETARY
I I
GEAR

~ . I
·~·
6~o

J9121-399

Fig. 258 Front Planetary Thrust Race Installation

J8921-586

Fig. 259 Front Planetary Front Bearing And Races


Installation
SUN GEAR AND NO. 1 ONE–WAY CLUTCH
THRUST WASHER
SUN GEAR INPUT DRUM

SUN GEAR

SNAP RING
ONE-WAY CLUTCH
AND SECOND BRAKE
HUB ASSEMBLY

SNAP RING

SEAL RINGS

J9121-400

Sun Gear And One–Way Clutch Components


XJ TRANSMISSION AND TRANSFER CASE 21 - 255
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
DISASSEMBLY
(1) H old su n gea r a n d t u r n secon d br a ke h u b
clockwise a n d cou n t er clockwise (F ig. 260). H u b
sh ou ld r ot a t e fr eely clockwise bu t lock wh en t u r n ed
cou n t er clockwise. Repla ce on e–wa y clu t ch a n d h u b if
t h ey do n ot oper a t e pr oper ly.
SECOND
BRAKE
HUB

J8921-590

Fig. 262 Removing/Installing Thrust Washer


SEAL
RINGS (2)
J8921-588

Fig. 260 Checking One–Way Clutch Operation


(2) Rem ove on e–wa y clu t ch /secon d br a ke hub
a ssem bly fr om dr u m (F ig. 261).
HUB AND
CLUTCH
ASSEMBLY

0 0

J8921-591

DRUM Fig. 263 Removing/Installing Sun Gear Seal Rings


(5) Su ppor t su n gea r on wood block (F ig. 264).
Th en r em ove fir st su n gea r sn a p r in g a n d sepa r a t e
J8921-589 dr u m fr om gea r.
(6) Rem ove r em a in in g sn a p r in g fr om su n gea r
Fig. 261 Removing/Installing Brake Hub And Clutch (F ig. 265).
Assembly (7) Mea su r e in side dia m et er of su n gea r bu sh in gs
(3) Rem ove t h r u st wa sh er fr om dr u m (F ig. 262). wit h bor e ga u ge or in side m icr om et er (F ig. 266).
(4) Rem ove t wo sea l r in gs fr om su n gea r (F ig. Ma xim u m a llowa ble dia m et er is 27.08 m m (1.0661
263). in .). Repla ce su n gea r if bu sh in g in side dia m et er is
gr ea t er t h a n specified.
21 - 256 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

.,__ _ SUN
GEAR

Fig. 266 Checking Sun Gear Bushings


CLUTCH
AND HUB
ASSEMBLY

J8921-592

Fig. 264 Removing/Installing Sun Gear

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)

PISTON RETURN SPRINGS

~ SPRING RETAINER

SNAP RING

THRUST WASHER

SECOND BRAKE PISTON


J8921-596

Second Brake Components


SECOND BRAKE
ASSEMBLY

J8921-597

Fig. 268 Removing/Installing Second Brake


J8921-598
Assembly
(5) Rem ove secon d br a ke pist on a n d sleeve fr om Fig. 269 Removing/Installing Second Brake Drum
dr u m wit h com pr essed a ir (F ig. 271). Use on ly Thrust Washer
en ou gh a ir pr essu r e t o ea se pist on ou t of dr u m .
(6) Rem ove a n d disca r d br a ke pist on O–r in gs. (7) 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 m ou n t ed in r et a in er (F ig. 272). Len gt h
sh ou ld be a ppr oxim a t ely 16.05 m m (0.632 in .).
Repla ce r et u r n spr in gs if len gt h is less t h a n speci-
fied.
21 - 258 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
COMPRESSOR
TOOL

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

Fig. 271 Removing/Installing Piston And Sleeve


ASSEMBLY
J8921-601
(1) Lu br ica t e a n d in st a ll n ew O–r in gs on br a ke
pist on . Th en in st a ll br a ke pist on in dr u m . Fig. 273 Checking Second Brake Piston Operation
(2) In st a ll r et u r n spr in gs a n d r et a in er on br a ke
pist on .
(3) Com pr ess r et u r n spr in gs wit h sh op pr ess a n d
Com pr essor Tool 7538. In st a ll pist on sn a p r in g a n d
r em ove br a ke a ssem bly fr om pr ess.
XJ TRANSMISSION AND TRANSFER CASE 21 - 259
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(5) Coa t t h r u st wa sh er wit h pet r oleu m jelly a n d
in st a ll it in dr u m . Be su r e wa sh er n ot ch es a r e
a lign ed wit h t a bs on spr in g r et a in er (F ig. 274).

SPRING
RETAINER
TABS

J8921-602

Fig. 274 Installing Second Brake Thrust Washer


21 - 260 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

PLANETARY/BRAKE PACK/OUTPUT SHAFT


REAR PLANETARY GEAR
NO. 2 ONE-WAY
CLUTCH
FIRST-REVERSE
BRAKE PACK ~ R E A R THRUST WASHER

ONE-WAY CLUTCH
INNER RACE

RACES
SNAP RING

RING GEAR HUB

REAR PLANETARY RING GEAR

THRUST
BEARING
OUTPUT SHAFT

J8921-603

Rear Planetary, Brake Pack, Output Shaft Components

DISASSEMBLY GEAR ASSEMBLY


(1) Rem ove ou t pu t sh a ft fr om gea r a ssem bly
(F ig. 275).
(2) Rem ove a n d disca r d sh a ft sea l r in g (F ig. 276).
(3) Rem ove br a ke pa ck fr om pla n et a r y gea r
(F ig. 277).
(4) Rem ove pla n et a r y gea r fr om r in g gea r
(F ig. 278).

J8921-604

Fig. 275 Removing/Installing Output Shaft


XJ TRANSMISSION AND TRANSFER CASE 21 - 261
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

0-- SEAL
RING

J8921-605

Fig. 276 Removing/Installing Shaft Seal Ring RING


GEAR
FIRST-REVERSE
BRAKE
PACK

J8921-607

Fig. 278 Removing/Installing Rear Planetary

REAR
PLANETARY
GEAR

J8921-606

Fig. 277 Removing/Installing First–Reverse Brake PLANETARY


Pack GEAR

(5) Ch eck No. 2 on e–wa y clu t ch (F ig. 279). H old


pla n et a r y gea r a n d t u r n clu t ch in n er r a ce in bot h
dir ect ion s. Ra ce sh ou ld t u r n fr eely cou n t er clockwise, J8921-608
bu t lock wh en t u r n ed clockwise. Repla ce on e–wa y
clu t ch if n ecessa r y. Fig. 279 Checking No. 2 One–Way Clutch Operation
(6) Rem ove clu t ch in n er r a ce fr om pla n et a r y gea r
(F ig. 280).
(7) Rem ove clu t ch sn a p r in g a n d r em ove No. 2
on e–wa y clu t ch t op en d ca p fr om pla n et a r y.
(8) Rem ove No. 2 on e–wa y clu t ch fr om pla n et a r y
(F ig. 281).
21 - 262 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 281 Removing/Installing One–Way Clutch


XJ TRANSMISSION AND TRANSFER CASE 21 - 263
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

REAR
THRUST
WASHER

SNAP
RING

J8921-611

Fig. 282 Removing/Installing Rear Planetary Thrust


Washers

J8921-613

Fig. 284 Removing/Installing Ring Gear Hub


• Ou t er dia m et er of bot t om r a ce is 44.8 m m (1.764
in .) a n d in n er dia m et er is 27.6 m m (1.087 in .).
• Ou t er dia m et er of bea r in g is 44.7 m m (1.760 in .)
a n d in n er dia m et er is 30.1 m m (1.185 in .).
• Ou t er dia m et er of u pper r a ce is 44.8 m m (1.764
in .) a n d in n er dia m et er is 28.8 m m (1.134 in .).
(4) Lu br ica t e r in g gea r t h r u st bea r in g a n d r a ces
wit h pet r oleu m jelly a n d in st a ll t h em in r in g gea r
(F ig. 283).
RING GEAR
(5) Coa t pla n et a r y t h r u st wa sh er s wit h pet r oleu m
jelly a n d in st a ll t h em in gea r (F ig. 282).
(6) In st a ll No. 2 on e–wa y clu t ch bot t om en d ca p
in t o t h e pla n et a r y gea r.
J8921-612
(7) In st a ll No. 2 on e–wa y clu t ch in pla n et a r y gea r.
Be su r e fla n ged side of clu t ch fa ces u pwa r d (F ig.
Fig. 283 Removing/Installing Ring Gear Thrust 285).
Bearing And Races (8) In st a ll No. 2 on e–wa y clu t ch t op en d ca p in t o
t h e pla n et a r y gea r.
ASSEMBLY (9) In st a ll clu t ch r et a in in g sn a p r in g a n d in st a ll
(1) Mea su r e t h ickn ess of ea ch br a ke pa ck disc. clu t ch in n er r a ce (F ig. 280). Tu r n r a ce cou n t er clock-
Min im u m t h ickn ess is 1.51 m m (0.0594 in .). Repla ce wise t o ea se in st a lla t ion .
a ll discs if a n y disc is t h in n er t h a n specified. (10) Ver ify on e–wa y clu t ch oper a t ion . H old gea r
(2) In st a ll h u b a n d sn a p r in g in r in g gea r (F ig. a n d t u r n in n er r a ce in bot h dir ect ion s. Ra ce sh ou ld
284) t u r n fr eely cou n t er clockwise, bu t lock wh en t u r n ed
(3) Iden t ify r in g gea r t h r u st bea r in g a n d r a ces by clockwise.
followin g dim en sion s (F ig. 283): (11) In st a ll pla n et a r y gea r in r in g gea r.
21 - 264 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(14) In st a ll br a ke pa ck on pla n et a r y gea r (F ig.
277).
(15) In st a ll n ew sea l r in g on ou t pu t sh a ft (F ig.
276). Be su r e r in g en ds a r e in t er locked a s sh own .

TRANSMISSION VALVE BODY


Th e va lve body a ssem bly con sist s of t wo sect ion s
wh ich a r e t h e u pper body a n d lower body (F ig. 286)
a n d (F ig. 287). Disa ssem bly, in spect ion a n d over h a u l
pr ocedu r es for ea ch sect ion a r e ou t lin ed sepa r a t ely.
Refer t o t h e a ppr opr ia t e pr ocedu r e a s n eeded.

REAR
PLANETARY
J8921-614

Fig. 285 Installing No. 2 One–Way Clutch


(12) In st a ll t h r u st bea r in g a n d wa sh er s on t o t h e
r in g gea r (F ig. 283).
(13) Assem ble clu t ch discs a n d clu t ch pla t es (F ig.
277). Sequ en ce is disc fir st , t h en a pla t e. Use seven
discs a n d pla t es.
XJ TRANSMISSION AND TRANSFER CASE 21 - 265
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

NO. 2 SOLEN0 1D AND 0-RING

PRESSURE
RELIEF VALVE

MULATOR
tc5~¥ROL VALVE

J9121-384

Fig. 286 Lower Body Components


21 - 266 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
PLUG LOW COAST MODULATOR
2-3 SHIFT VALVE ~ VALVE AND SPRING
AND SPRING

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

THROTTLE VALVE PIN DOWNSHIFT


AND SPRING PLUG

J8921-625

Fig. 287 Upper Body Components


XJ TRANSMISSION AND TRANSFER CASE 21 - 267

CLEAN I N G AN D I N SPECT I ON (10) Lock sh ift ca ble by pr essin g ca ble a dju st er


cla m p down u n t il it sn a ps in t o pla ce.
TRANSMISSION PARTS CLEANING AND (11) Lower veh icle a n d ch eck en gin e st a r t in g.
E n gin e sh ou ld st a r t on ly in P a r k a n d Neu t r a l.
INSPECTION
Clea n t h e t r a n sm ission com pon en t s wit h solven t THROTTLE
a n d dr y t h em wit h com pr essed a ir on ly. Do n ot u se VALVE
sh op t owels or r a gs. CABLE
Blow com pr essed a ir t h r ou gh a ll oil feed pa ssa ges
a n d ch a n n els t o be su r e t h ey a r e clea r. In spect t h e
t r a n sm ission com pon en t s for wea r a n d da m a ge.
Repla ce com pon en t s t h a t a r e da m a ged or wor n
beyon d t h e lim it s specified in t h e in dividu a l over h a u l
pr ocedu r es.
Repla ce a ll O–r in gs, ga sket s a n d sea ls. Th ese com -
pon en t s a r e n ot r eu sa ble. Also r epla ce a n y sn a p r in g
t h a t is dist or t ed or da m a ged.
Du r in g over h a u l a ssem bly oper a t ion s, lu br ica t e t h e
t r a n sm ission com pon en t s wit h Mopa r Mer con # a u t o- '
m a t ic t r a n sm ission flu id or pet r oleu m jelly a s in di-
ca t ed. P et r oleu m jelly sh ou ld be u sed t o pr elu br ica t e
(
~
t h r u st bea r in gs, wa sh er s a n d r a ces. It ca n a lso be
u sed t o h old pa r t s in posit ion du r in g a ssem bly.
S o a k re p la c e m e n t c lu tc h a n d bra k e p a c k
c o m p o n e n ts in tra n s m is s io n flu id fo r a t le a s t 30 SHIFT TRANSMISSION
m in u te s be fo re in s ta lla tio n . CABLE SHIFT LEVER J9321-417

Fig. 288 Shift Cable Attachment At


ADJ U ST M EN T S Transmission–Typical
GEARSHIFT CABLE BRAKE TRANSMISSION SHIFT INTERLOCK
Ch eck a dju st m en t by st a r t in g t h e en gin e in P a r k CABLE ADJUSTMENT
a n d Neu t r a l. Adju st m en t is OK if t h e en gin e st a r t s (1) Sh ift t r a n sm ission in t o PARK.
on ly in t h ese posit ion s. Adju st m en t is in cor r ect if t h e (2) Rem ove sh ift lever bezel a n d con sole scr ews.
en gin e st a r t s in on e bu t n ot bot h posit ion s. If t h e Ra ise bezel a n d con sole for a ccess t o ca ble.
en gin e st a r t s in a n y posit ion ot h er t h a n P a r k or Neu - (3) P u ll ca ble lock bu t t on u p t o r elea se ca ble (F ig.
t r a l, or if t h e en gin e will n ot st a r t a t a ll, t h e pa r k/ 289).
n eu t r a l posit ion swit ch m a y be fa u lt y. (4) Tu r n ign it ion swit ch t o LOCK posit ion .

Gearshift Adjustment Procedure


(1) Sh ift t r a n sm ission in t o P a r k.
PARK
(2) Ra ise veh icle.
LOCK
(3) Relea se ca ble a dju st er cla m p (a t t r a n sm ission CABLE
en d of ca ble) t o u n lock ca ble.
(4) Un sn a p ca ble fr om ca ble m ou n t in g br a cket on
t r a n sm ission (F ig. 288).
(5) Slide ca ble eyelet off t r a n sm ission sh ift lever.
(6) Ver ify t r a n sm ission sh ift lever is in P a r k
det en t by m ovin g lever fu lly r ea r wa r d. La st r ea r wa r d
det en t is P a r k posit ion .
(7) Ver ify posit ive en ga gem en t of t r a n sm ission
pa r k lock by a t t em pt in g t o r ot a t e pr opeller sh a ft .
Sh a ft will n ot r ot a t e wh en pa r k lock is en ga ged. J9321-250
(8) Slide ca ble eyelt on t o t r a n sm ission sh ift lever.
(9) Sn a p sh ift ca ble a dju st er in t o m ou n t in g Fig. 289 Park Lock Cable Attachment
br a cket on t r a n sm ission .
21 - 268 TRANSMISSION AND TRANSFER CASE XJ
ADJ U ST M EN T S (Cont inue d)
(5) Use a spa cer t o cr ea t e a on e m illim et er ga p TRANSMISSION ACCELERATOR
bet ween t h e sh ift er pa wl a n d t op of t h e sh ift ga t e. THROTTLE CABLE
(6) P u ll ca ble for wa r d. Th en r elea se ca ble a n d VALVE CABLE
pr ess ca ble lock bu t t on down u n t il it sn a ps in pla ce. CABLE ENGINE
(7) Ch eck a dju st m en t a s follows:
(a ) Ch eck m ovem en t of r elea se sh ift h a n dle bu t -
t on (floor sh ift ) or r elea se lever (colu m n sh ift ). You
sh ou ld n ot be a ble t o pr ess bu t t on in wa r d or m ove
colu m n lever.
(b) Tu r n ign it ion swit ch t o RUN posit ion .
(c) Sh ift in g ou t of pa r k sh ou ld n ot be possible.
(d) Apply t h e br a ke a n d a t t em pt t o sh ift ou t of
PARK. Sh ift in g sh ou ld be possible.
(e) Wh ile t h e t r a n sm ission is sh ift ed ou t of
PARK, r elea se t h e br a ke a n d a t t em pt t o sh ift
Fig. 290 Throttle Cable Attachment At Engine
t h r ou gh a ll gea r s. Relea se t h e sh ift bu t t on a t lea st
on ce du r in g t h is pr ocedu r e. Th e ign it ion key sh ou ld
n ot go t o t h e LOCK posit ion .
(f) Ret u r n t r a n sm ission t o t h e PARK posit ion
wit h ou t a pplyin g t h e br a ke.
(8) Move sh ift lever ba ck t o PARK a n d ch eck ign i-
t ion swit ch oper a t ion . You sh ou ld be a ble t o t u r n
swit ch t o LOCK posit ion a n d sh ift lever r elea se bu t -
t on /lever sh ou ld n ot m ove.

TRANSMISSION THROTTLE VALVE CABLE


ADJUSTMENT
Th e t r a n sm ission t h r ot t le va lve is oper a t ed by a
ca m on t h e t h r ot t le lever. Th e t h r ot t le lever is oper-
a t ed by a n a dju st a ble ca ble (F ig. 290). Th e ca ble is SHIFT CABLE
a t t a ch ed t o a n a r m m ou n t ed on t h e t h r ot t le lever J9321-414
BRACKET
sh a ft . A r et a in in g clip a t t h e en gin e-en d of t h e ca ble
is r em oved t o pr ovide for ca ble a dju st m en t . Th e Fig. 291 Throttle Cable Attachment At Transmission
r et a in in g clip is t h en in st a lled ba ck on t o t h e t h r ot t le • If ca ble en d a n d a t t a ch m en t st u d a r e m isa lign ed
va lve ca ble t o lock in t h e a dju st m en t . (off cen t er ), ca ble will h a ve t o be a dju st ed a s
A cor r ect ly a dju st ed t h r ot t le va lve ca ble will ca u se descr ibed in Th r ot t le Va lve Ca ble Adju st m en t pr oce-
t h e t h r ot t le lever on t h e t r a n sm ission t o m ove sim u l- du r e.
t a n eou sly wit h t h e t h r ot t le body lever fr om t h e idle (6) Recon n ect ca ble en d t o a t t a ch m en t st u d. Th en
posit ion . P r oper a dju st m en t will a llow sim u lt a n eou s wit h a id of a h elper, obser ve m ovem en t of t r a n sm is-
m ovem en t wit h ou t ca u sin g t h e t r a n sm ission t h r ot t le sion t h r ot t le lever a n d lever on t h r ot t le body.
lever t o eit h er m ove a h ea d of, or la g beh in d t h e lever • If bot h lever s m ove sim u lt a n eou sly fr om idle t o
on t h e t h r ot t le body. h a lf-t h r ot t le a n d ba ck t o idle posit ion , a dju st m en t is
cor r ect .
Checking Throttle Valve Cable Adjustment • If t r a n sm ission t h r ot t le lever m oves a h ea d of, or
(1) Tu r n ign it ion key t o OF F posit ion . la gs beh in d t h r ot t le body lever, ca ble a dju st m en t will
(2) Rem ove a ir clea n er. be n ecessa r y. Or, if t h r ot t le body lever pr even t s
(3) Ver ify t h a t lever on t h r ot t le body is a t cu r b idle t r a n sm ission lever fr om r et u r n in g t o closed posit ion ,
posit ion . Th en ver ify t h a t t r a n sm ission t h r ot t le lever ca ble a dju st m en t will be n ecessa r y.
(F ig. 291) is a lso a t idle (fu lly for wa r d) posit ion .
(4) Slide ca ble off a t t a ch m en t st u d on t h r ot t le body Throttle Valve Cable Adjustment Procedure
lever. (1) Tu r n ign it ion swit ch t o OF F posit ion .
(5) Com pa r e posit ion of ca ble en d t o a t t a ch m en t (2) Rem ove a ir clea n er if n ecessa r y.
st u d on t h r ot t le body lever : (3) Discon n ect ca ble en d fr om a t t a ch m en t st u d.
• Ca ble en d a n d a t t a ch m en t st u d sh ou ld be Ca re fu lly s lid e c a ble o ff s tu d . D o n o t p ry o r p u ll
a lign ed (or cen t er ed on on e a n ot h er ) t o wit h in 1 m m c a ble o ff.
(0.039 in .) in eit h er dir ect ion .
XJ TRANSMISSION AND TRANSFER CASE 21 - 269
ADJ U ST M EN T S (Cont inue d)
(4) Ver ify t h a t t r a n sm ission t h r ot t le lever is in (7) In st a ll r et a in in g clip on t o ca ble h ou sin g.
fu lly closed posit ion . Th en be su r e lever on t h r ot t le (8) Ch eck ca ble a dju st m en t . Ver ify t r a n sm ission
body is a t cu r b idle posit ion . t h r ot t le lever a n d lever on t h r ot t le body m ove sim u l-
(5) In ser t a sm a ll scr ewdr iver u n der edge of t a n eou sly.
r et a in in g clip a n d r em ove r et a in in g clip.
(6) Cen t er ca ble en d on a t t a ch m en t st u d t o wit h in
1 m m (0.039 in .). SPECI FI CAT I ON S
NOTE: Be sure that as the cable is pulled forward AW-4 AUTOMATIC TRANSMISSION
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
21 - 270 TRANSMISSION AND TRANSFER CASE XJ
SPECI FI CAT I ON S (Cont inue d)
AW-4 GENERAL SPECIFICATIONS
Gear Ratios:
First ... ........ . ..... .. ..... . ... .. ... ... .... ... .... . ........... . ... . ... ... . . ... . ..... . . . 2.804: 1
Second ..... . . .. . . .. . . .. . . . . . . . . . . .. .... . .... . .. . .. . .... .. .......... . . . .............. .. .. 1.531:1
Third ..... .. ............................................ . ... . . .. ... . ..... . .... . ...... . .. 1.000:1
Fourth (Overdrive) . . .... .. . ...... . . . . ... . . ............. . . . ..... . . . . . . . .. . . ....... .... . .. ... 0 .753: 1
Reverse ... .. .... .. .... . ..... . ............... . ........... . .... . ..... . ..... . ..... . ........ 2.393: 1

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)

Time Lag Test:

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.)

TPS Output Voltage


4-Cylinder ........ . .... . .......... .. ............................................. 0.2 Volts (approx.)
6-Cylinder . . .. . .. .. . ..... . . . .. .... ... .. .. . . .... . .. ... ..... . .. . .. .. .. .. . . . . .. ... .. 4.2 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:

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11-0.14 mm (0.0043-0.0055 in.)

Maximum Allowance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.01 2 in.)

Gear-ta-Pump Body

End Clearance:

Standard ..... .. ..... . .... .. .... ... ... .. ..... .... .. . . . ... .. ....... . ................ . .. ............. 0.02-0.05 mm (0.0008-0.0020 in.)

Maximum Allowance. . . . . . . . . . . . . . . . . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (0.004 in.)

Driven Gear-ta-Pump

Body Clearance:

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07-0.15 mm (0.0028-0.0059 in.)

Maximum Allowance . . ... .... . .. . .. . . .. . . . . .... ... ..... ... . . . ... . .. . ... . .. . . . ... . ... . ... .. . ... . . . .. . . .. .... ..... . . . 0.3 mm (0.01 2 in.)
18921-740

AW-4 CLUTCH DISC AND PLATE THICKNESS

Component Minimum Allowable Thickness

Clutch Disc (all except first-reverse and forward clutch discs) 1.84 mm (0.0724 in.)

6-Cylinder Forward Clutch Disc 1.51 mm (0.0594 in.)

6 Cylinder Direct Clutch Plates:


Thin Plate (1) 2.3 mm (0.905 in.)
Thick Plates (3) 3.0 mm (0.118 in.)

6-Cylinder Forward Clutch Plate 1.8 mm (0.070 in.)

First-Reverse Brake Disc (all) 1.51 mm (0.0594 in.)

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)

Bushing Location Maximum Allowance Inside Diameter

Extension Housing 38.09 mm (1..4996 in.)

Direct Clutch Drum 53 .97 mm (2.12.48 in.)

Overdrive Planetary Gear 11.27 mm (..4.437 in .)

Overdrive Direct Clutch Drum 27.11 mm (1.0673 in .)

Stator Shaft (Front) 21.58 mm (.8.496 in.)

Stator Shaft (Rear) 27.08 mm (1.0661 in.)

Oil Pump Body 38.19 mm (1.5035 in.)

Transmission Case 38.18 mm (1.5031 in.)

PISTON STROKE LENGTH

Piston Location Specification

Direct Clutch (all) 1.37-1.67 mm (.0539-.0657 in.)

6-Cylinder Overdrive Brake 1..40-1.70 mm (.0551-.0669 in.)

Second Coast Brake (all) 1.5-3.0 mm (.059-.118 in.)

6-Cylinder Forward Clutch 3.55-3.73 (.1397-.1.468 in.)

Overdrive Direct Clutch (all) 1.85-2.15 mm (.0728-.08.46 in.)

END PLAY AND CLEARANCE

Component Specification

Output Shaft End Play .27-.86 mm (.0106-.0339 in.)

6-Cylinder First-Reverse Brake Pack Clearance .70-1.20 mm (.028-.0.47 in.)

6-Cylinder Second Brake Pack Clearance .62-1. 98 mm (.02.4-.078 in.)

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

Retainer No. Thickness Retainer No. Thickness

26 3.3 mm (.130 in.) 11 3.8 mm (.150 in.)

25 3.5 mm (.138 in.) 23 3.9 mm (.154 in.)

12 3.6 mm (.142 in.) Not Marked 4.0 mm (.157 in.)

24 3.7 mm (.146 in.) - -


DIRECT CLUTCH RETAINER SELECTION

Retainer No. Thickness Retainer No. Thickness

33 3.0 mm (.118 in.) 29 3.4 mm (.134 in.)

32 3.1 mm (.122 in.-) 28 3.5 mm (.138 in.)

31 3.2 mm (.126 in.) 27 3.6 mm (.142 in.)

30 3.3 mm (.130 in.) 34 3.7 mm (.146 in.)

OVERDRIVE CLUTCH RETAINER SELECTION

Retainer No. Thickness Retainer No. Thickness

16 3.6 mm (.142 in.) 19 3.3 mm (.130 in.)

17 3.5 mm (.138 in.) 20 3.2 mm (.126 in.)

18 3.4 mm (.134 in.) 21 3.1 mm (.122 in.)

SECOND COAST BRAKE PISTON ROD SELECTION

Rod Rod Length

No. 1 71.4 mm (2.811 in.)

No. 2 72.9 mm (2.870 in.)

FORWARD CLUTCH RETAINER SELECTION

Retainer No. Thickness Retainer No. Thickness


42 4.0 mm (.157 in.) 61 3.0 mm (.118 in.)

44 3.8 mm (.149 in.) 62 3.6 mm (.142 in.)

45 3.4 mm (.134 in.) 63 4.2 mm (.165 in.)

60 3.2 mm (.126 in.) 64 4.4 mm (.173 in.)

FIRST-REVERSE BRAKE CLEARANCE SELECTION

Retainer No. Thickness Retainer No. Thickness


50 5.0 mm (.197 in.) 53 4.4 mm (.173 in.)

51 4.8 mm (.189 in.) 54 4.2 mm (.165 in.)

52 4.6 mm (.181 in.) 55 4.0 mm (.157 in.)


J9121-404
21 - 274 TRANSMISSION AND TRANSFER CASE XJ
SPECI FI CAT I ON S (Cont inue d)
AW-4 VALVE BODY BALL DIMENSIONS

Check Ball Diameter

® Rubber Ball 6.35 mm (0.250 in.)

® Rubber Ball 5.535 mm (.218 in.)

J9121-A05

AW-4 CLUTCH AND BRAKE PACK REQUIREMENTS

Component Discs Required Plates Required Retainers Required

6-Cylinder Overdrive Brake A 3 2

6-Cylinder Second Brake 5 5 1

6-Cylinder Overdrive Direct Clutch 2 2 1

6-Cylinder Direct Clutch A A 1

6-Cylinder Forward Clutch 6 6 1

6-Cylinder First-Reverse Brake 7 7 1

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.)

(3) 3-4 Shift Valve 30.8 mm (1.212 in.)

:--~ 0001111 ~ (4) Second Coast Modulator Valve 25 .3 mm (.996 in.)


~- --- ---- -- --- - - - - ----,
(5) Lockup Relay Valve 21.4 mm (.843 in.)

(6)Secondary Regulator Valve 30.9 mm (1.217 in.)

(7) Cut-Back Valve 21.8 mm (.858 in.)

(8) 2-3 Shift Valve 30.8 mm (1.212 in.)


(7)
K1Mffll - - D=CJ>- -[J:D (9) Low Coast Modulator Valve 27.8 mm (1.094) .

(8)
[]::D:t]::D:0::- -~ - -00

(9)
O=[:]II:::::J- - ~--Dll

Spring Spring Length


9 9
i,1 I ! 121 (1) Check Valve 20.2 mm (.797 in.)

(2) Pressure Relief Valve 11.2 mm (.441 in.)

(3) 1-2 Shift Valve 30.8 mm (1.213 in .)

(4) Primary Regulator Valve 62.3 mm (2.453 in.)

{5) Accumulator Control Valve 29.8 mm (1.173 in.)

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

SECOND BRAKE ACCUMULATOR SPRING A 14.17 mm (.558 in.)


PISTON B 36.9 mm fl.453 in.)
SPRING( 19.91 mm (.784 in.)

DIRECT CLUTCH ACCUMULATOR SPRINGD 12.07 mm (.475 in.)


PISTONE 36.9 mm (1.453 in.)
SPRING F 20.19 mm (.795 in.)
SPRINGG 14.81 mm (.583 in.)

OVERDRIVE BRAKE ACCUMULATOR SPRINGH 14.10 mm (.555 in.)


PISTONJ 31.9 mm (1.256 in.)
SPRING K 19.99 mm (.785 in.)
OVERDRIVE CLUTCH ACCUMULATOR SPRINGL 14.0 mm (0.551 in.J
SPRINGM 20.3 mm (0.799 in.)
PISTON N 29.9mm(l.177in.)

,~ 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-484 Snap Ring Plier

7536 Puller, Oil Pump

C-3293-SP Gauge

'
7538 Compressor, Piston #2 Spring
8011d42b

C-3339 Dial Indicator Set

7539 Compressor, Piston #3 Spring

C-4959 Caliper, Metric Vernier


XJ TRANSMISSION AND TRANSFER CASE 21 - 279
SPECI AL T OOLS (Cont inue d)

7540 Pliers, Large Snap Ring 7549 Installer, Seal

7542 Puller, Reaction Sleeve 7552 Gauge, 3.0 mm Wire

7543 Puller, Piston #1 7554 Adapter, Pressure Port

7544 Installer, Brake Drum Seal


21 - 280 TRANSMISSION AND TRANSFER CASE XJ

N V 2 3 1 T RAN SFER CASE

INDEX
page page

GENERAL INFORMATION TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 282


NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . 280 DISASSEMBLY AND ASSEMBLY
RECOMMENDED LUBRICANT AND FILL NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . 285
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 CLEANING AND INSPECTION
TRANSFER CASE IDENTIFICATION . . . . . . . . . 280 NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . 299
DIAGNOSIS AND TESTING ADJUSTMENTS
NV231 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 281 SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . 303
REMOVAL AND INSTALLATION SPECIFICATIONS
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . 283 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 282 SPECIAL TOOLS
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 282 NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

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

DI AGN OSI S AN D T EST I N G


NV231 DIAGNOSIS
DI AGN OSI S CH ART

Condition Possible Cause Correction


Transfer case difficult to shift or will 1) Vehicle speed to great to permit 1) Slow vehicle and shift into
not shift into desired range. shifting. desired range.
2) If vehicle was operated for an 2) Stop vehicle and shift transfer
extended period in 4H mode on dry case to Neutral position. Transfer
surface, driveline torque load may case can then be shifted to the
cause difficulty. desired mode.
3) Transfer case shift linkage 3) Repair or replace linkage as
binding. necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill transfer case with
the correct type and quantity of
lubricant.
5) Internal transfer case 5) 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.
Transfer case noisy while in, or 1) Transfer case not completely 1) Slow vehicle, shift transfer case
jumps out of, 4L mode. engaged in 4L position. to the Neutral position, and then
shift into the 4L mode.
2) Transfer case shift linkage out of 2) Adjust linkage as necessary.
adjustment.
3) Transfer case shift linkage loose 3) Repair, replace, or tighten linkage
or binding. components as necessary.
4) Range fork damaged, inserts 4) Repair or replace components as
worn, or fork is binding on the shift necessary.
rail.
5) Low range gear worn or 5) Repair or replace components as
damaged. necessary.
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.
Abnormal tire wear. 1) Extended operation in 4H mode 1) Operate vehicle in 2H mode on
on dry surfaces, dry surfaces.
21 - 282 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. 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

Fig. 3 Shift Linkage


(4) Rem ove speed sen sor a n d speedom et er a da pt er (6) Cou n t n u m ber of t eet h on speedom et er pin ion .
a s a n a ssem bly. Do t h is befor e in st a llin g a ssem bly in h ou sin g. Th en
(5) Rem ove speed sen sor r et a in in g scr ew a n d lu br ica t e pin ion t eet h wit h t r a n sm ission flu id.
r em ove sen sor fr om a da pt er. (7) Not e in dex n u m ber s on a da pt er body (F ig. 5).
(6) Rem ove speedom et er pin ion fr om a da pt er. Th ese n u m ber s will cor r espon d t o n u m ber of t eet h on
Repla ce pin ion if ch ipped, cr a cked, or wor n . pin ion .
(7) In spect sen sor a n d a da pt er O-r in gs (F ig. 4). (8) In st a ll speedom et er a ssem bly in h ou sin g.
Rem ove a n d disca r d O-r in gs if wor n or da m a ged. (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
(8) In spect t er m in a l pin s in speed sen sor. Clea n a r e a t 6 o-clock posit ion . Be su r e r a n ge in dex n u m -
pin s wit h Mopa r ! elect r ica l spr a y clea n er if dir t y or ber s cor r espon d t o n u m ber of t eet h on pin ion gea r.
oxidized. Repla ce sen sor if fa u lt y, or if pin s a r e loose, (10) In st a ll speedom et er a da pt er cla m p a n d r et a in -
sever ely cor r oded, or da m a ged. 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.
INSTALLATION AND INDEXING (11) Con n ect wir es t o veh icle speed sen sor.
(1) Th or ou gh ly clea n a da pt er fla n ge a n d a da pt er (12) Lower veh icle a n d t op off t r a n sm ission flu id
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 level if n ecessa r y.
for pr oper a da pt er a lign m en t a n d speedom et er oper-
a t ion . FRONT OUTPUT SHAFT SEAL
(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 (F ig. 4), if n ecessa r y. REMOVAL
(3) Lu br ica t e sen sor a n d a da pt er O-r in gs wit h (1) Ra ise veh icle.
t r a n sm ission flu id. (2) Rem ove fr on t pr opeller sh a ft . Refer t o Gr ou p 3,
(4) In st a ll veh icle speed sen sor in speedom et er Differ en t ia l a n d Dr ivelin e, for pr oper pr ocedu r e.
a da pt er. Tigh t en sen sor a t t a ch in g scr ew t o 2-3 N·m (3) Rem ove fr on t ou t pu t sh a ft yoke.
(15-27 in . lbs.) t or qu e. (4) Rem ove sea l fr om fr on t ca se wit h pr y t ool (F ig.
(5) In st a ll speedom et er pin ion in a da pt er. 6).
21 - 284 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

ITEM TORQUE ADAPTER


A 2-3 N•m (15-27 in. lbs.) O-RING

\~B~
B 10-12 N•m (90-110 in. lbs.)
SENSOR

\
SPEEDOMETER
PINION

VEHICLE
SPEED
SENSOR J9321-385

Fig. 4 Speedometer Components

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

___ ___, ____


TRANSFER
CASE
80a9b39e

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 RETAINER AND OIL PUMP REMOVAL


(1) Rem ove t h e speedom et er a da pt er.
(2) Spr ea d ba n d cla m p wh ich h olds ou t pu t sh a ft
boot t o slin ger wit h a su it a ble a wl, or equ iva len t .
(3) Rem ove ou t pu t sh a ft boot fr om slin ger a n d ou t -
pu t sh a ft .
(4) Usin g P u ller MD-998056-A, r em ove r ea r
slin ger (F ig. 8).
(5) Rem ove slin ger st op spa cer a n d sn a p-r in g fr om
ou t pu t sh a ft (F ig. 9).
SPECIAL
-_ /TOOL
TRANSFER MD998056-A 80a50354
CASE~

~ Fig. 10 Rear Retainer Seal


~ (9) Ta p r ea r r et a in er wit h r a wh ide or r u bber m a l-
let t o loosen sea ler bea d.
(10) Rem ove r ea r r et a in er fr om r ea r ca se h a lf (F ig.
12).
(11) Rem ove sn a p-r in g h oldin g oil pu m p in posit ion
on ou t pu t sh a ft .
(12) Disen ga ge oil picku p t u be fr om oil pu m p a n d
r em ove oil pu m p a ssem bly. Rem ove oil pu m p by t ilt -
in g t h e edge of t h e oil pu m p fr om u n der t h e edge of
80a50352 t h e r ea r ca se h a lf a n d slidin g t h e pu m p (F ig. 13).
(13) Rem ove pick-u p t u be o-r in g fr om oil pu m p
Fig. 8 Rear Slinger Removal (F ig. 14), if n ecessa r y. Do n ot disa ssem ble t h e oil
pu m p, it is n ot ser vicea ble.
21 - 286 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
OIL PUMP

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

Fig. 12 Rear Retainer Removal


800010957
OIL

J PUMP
Fig. 15 Yoke Nut Removal

D
80010966

Fig. 13 Oil Pump Removal


YOKE AND RANGE LEVER REMOVAL
(1) Rem ove t r a n sfer ca se in dica t or swit ch .
(2) Rem ove fr on t yoke n u t a s follows:
(a ) Move r a n ge lever t o 4L posit ion .
(b) Th en r em ove n u t wit h socket a n d im pa ct
80010977
wr en ch (F ig. 15).
(3) Rem ove yoke. If yoke is difficu lt t o r em ove by Fig. 16 Yoke Removal
h a n d, r em ove it wit h bea r in g split t er, or wit h st a n -
XJ TRANSMISSION AND TRANSFER CASE 21 - 287
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(4) Rem ove sea l wa sh er fr om fr on t ou t pu t sh a ft .
Disca r d wa sh er a s it sh ou ld n ot be r eu sed.
(5) Rem ove n u t a n d wa sh er t h a t a t t a ch r a n ge
lever t o sect or sh a ft . Th en m ove sect or t o n eu t r a l
posit ion a n d r em ove r a n ge lever fr om sh a ft (F ig. 17).

Fig. 19 Loosening Rear Case


Fig. 17 Range Lever Removal
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Su ppor t t r a n sfer ca se so r ea r ca se is fa cin g
u pwa r d.
(2) Rem ove bolt s h oldin g fr on t ca se t o r ea r ca se.
Th e ca se a lign m en t bolt s r equ ir e fla t wa sh er s (F ig.
18).
(3) Loosen r ea r ca se wit h fla t bla de scr ewdr iver t o
br ea k sea ler bea d. In ser t pr y t ool bla de on ly in t o
n ot ch es pr ovided a t ea ch en d of ca se (F ig. 19).
(4) Rem ove r ea r ca se fr om fr on t ca se.

SPLINE HEAD
BOLT (1) PICKUP PICKUP
DOWEL BOLT TUBE SCREEN
80010979
AND
WASHER (2)
Fig. 20 Oil Pickup Tube Removal

MODE-----~~
SPRING

80010969

Fig. 18 Rear Case Alignment Bolt Locations


(5) Rem ove oil picku p t u be fr om r ea r ca se (F ig.
20).
(6) Rem ove m ode for k spr in g (F ig. 21).
(7) P u ll fr on t ou t pu t sh a ft u pwa r d a n d ou t of fr on t RR21 F29
ou t pu t sh a ft bea r in g (F ig. 22).
Fig. 21 Mode Fork Spring Removal
(8) Rem ove fr on t ou t pu t sh a ft a n d ch a in .
(2) Rem ove m a in sh a ft fr om m ode sleeve a n d in pu t
SHIFT FORKS AND MAINSHAFT REMOVAL gea r pilot bea r in g.
(1) Rem ove det en t plu g, O-r in g, det en t spr in g a n d
det en t plu n ger (F ig. 23).
21 - 288 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

MODE
SLEEVE

FRONT
OUTPUT
SHAFT

SHAFT
FRONT
BEARING 80010971

Fig. 24 Mode Fork And Sleeve Removal

RANGE
FORK
8001096b

Fig. 22 Remove Front Output Shaft And Chain

80010973

Fig. 25 Range Fork And Hub Removal

POPPET BORE
(IN CASE)
8001096a

Fig. 23 Detent Plug, Spring And Plunger Removal


(3) Rem ove m ode for k a n d sleeve a s a n a ssem bly
(F ig. 24). Not e posit ion of sleeve for a ssem bly r efer-
en ce. Th e sh or t side of t h e sleeve fa ces u pwa r d.
(4) Rem ove r a n ge for k a n d h u b a s a n a ssem bly
(F ig. 25). Not e for k posit ion for in st a lla t ion r efer en ce.
(5) Rem ove sh ift sect or fr om fr on t ca se (F ig. 26).
(6) Rem ove sh ift sect or bu sh in g a n d O-r in g (F ig.
27).

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

Fig. 35 Input Gear Snap-Ring Removal

80010944

Fig. 33 Removing Input Gear Retaining Ring LOW


(5) P la ce fr on t ca se in h or izon t a l posit ion . Th en RANGE
GEAR
r em ove in pu t gea r a n d low r a n ge gea r a s a n a ssem -
bly (F ig. 34). Ta p gea r ou t of bea r in g wit h pla st ic
m a llet if n ecessa r y.

Fig. 36 Input Gear Retainer Removal

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

Fig. 38 Input Gear Removal Fig. 40 Front Output Seal Removal

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

CAUTION: The bearing bores in various transfer


case components contain oil feed holes. Make sure
replacement bearings do not block the holes.

(1) Rem ove t h e fr on t ou t pu t sh a ft sea l fr om ca se


wit h pr y t ool (F ig. 40).
(2) Rem ove t h e fr on t ou t pu t sh a ft bea r in g r et a in -
in g r in g wit h scr ewdr iver (F ig. 41).
(3) Rem ove bea r in g wit h Tool H a n dle C-4171 a n d
Tool 5065 (F ig. 42).
(4) In st a ll fr on t ou t pu t sh a ft fr on t bea r in g in ca se
wit h Tool H a n dle C-4171 a n d In st a ller 5064 (F ig. 43).
(5) In st a ll ou t pu t sh a ft fr on t bea r in g r et a in in g
r in g (F ig. 44). St a r t r in g in t o pla ce by h a n d. Th en
u se sm a ll scr ewdr iver t o wor k r in g in t o ca se gr oove.
Be su r e r in g is fu lly sea t ed befor e pr oceedin g.
Fig. 42 Front Output Shaft Bearing Removal
(6) 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: (b) St a r t sea l in bor e wit h ligh t t a ps fr om h a m -
(a ) P la ce n ew sea l on t ool. Ga rte r s p rin g o n m er (F ig. 45). On ce sea l is st a r t ed, con t in u e t a p-
s e a l g o e s to w a rd in te rio r o f c a s e .
21 - 292 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
ch a m fer ed a t t h e t op. In st a ll t h e bea r in g so it is
flu sh wit h t h e lower edge of t h is ch a m fer (F ig. 48).

SPECIAL TOOL
L-4454-1
AND
L-4454-3

Fig. 43 Front Output Shaft Bearing Installation

S0a98366

Fig. 46 Output Shaft Rear Bearing Removal

Fig. 44 Installing Output Shaft Front Bearing


Retaining Ring
pin g sea l in t o bor e u n t il in st a ller t ool bot t om s
a ga in st ca se.

HANDLE
C-4171

--- 'TRANSFER
CASE
---- S0a11094

80a9b39e Fig. 47 Output Shaft Rear Bearing Installation


(9) Usin g Rem over C-4210 a n d H a n dle C-4171,
Fig. 45 Front Output Seal Installation
dr ive in pu t sh a ft bea r in g fr om in side t h e a n n u lu s
(7) Rem ove t h e ou t pu t sh a ft r ea r bea r in g wit h t h e gea r open in g in t h e ca se. (F ig. 49).
scr ew a n d ja ws fr om Rem over L-4454 a n d Cu p 8148 (10) In st a ll loca t in g r in g on n ew bea r in g.
(F ig. 46). (11) P osit ion ca se so for wa r d en d is fa cin g u pwa r d.
(8) In st a ll n ew bea r in g wit h Tool H a n dle C-4171 (12) Usin g Rem over C-4210 a n d H a n dle C-4171,
a n d In st a ller 5066 (F ig. 47). Th e bea r in g bor e is dr ive in pu t sh a ft bea r in g in t o ca se. Th e bea r in g
XJ TRANSMISSION AND TRANSFER CASE 21 - 293
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(13) Rem ove in pu t gea r pilot bea r in g by in ser t in g
a su it a bly sized dr ift in t o t h e splin ed en d of t h e in pu t
gea r a n d dr ivin g t h e bea r in g ou t wit h t h e dr ift a n d a
h a m m er (F ig. 51).
(14) In st a ll n ew pilot bea r in g wit h In st a ller 5065
a n d H a n dle C-4171 (F ig. 52).

__,._ ~ )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

Fig. 52 Install Input Gear Pilot Bearing


(15) Rem ove fr on t bea r in g r et a in er sea l wit h su it -
a ble pr y t ool.
J8921-219
Fig. 50 Seating Input Shaft Bearing
21 - 294 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(16) In st a ll n ew fr on t bea r in g r et a in er sea l wit h
SPECIAL
In st a ller 7884 (F ig. 53).
TOOL --__...l-- SPECIAL
TOOL
C-4171 5064

800bdfa9

Fig. 55 Installing Rear Bearing In Retainer


(2) In st a ll fir st t h r u st wa sh er in low r a n ge gea r
(F ig. 56). Be su r e wa sh er t a bs a r e pr oper ly a lign ed in
gea r n ot ch es.
(3) In st a ll in pu t gea r in low r a n ge gea r. Be su r e
in pu t gea r is fu lly sea t ed.
J9521-41 (4) In st a ll r em a in in g t h r u st wa sh er in low r a n ge
gea r a n d on t op of in pu t gea r. Be su r e wa sh er t a bs
Fig. 53 Install Front Bearing Retainer Seal a r e pr oper ly a lign ed in gea r n ot ch es.
(17) Rem ove sea l fr om oil pu m p h ou sin g wit h a (5) In st a ll r et a in er on in pu t gea r a n d in st a ll sn a p-
su it a ble pr y t ool. r in g.
(18) In st a ll n ew sea l in oil pu m p h ou sin g wit h SNAP RETAINER INPUT
In st a ller 7888 (F ig. 54). RING PLATE GEAR

OIL PUMP
FEED
SPECIAL HOUSING
TOOL
7888 ....._
HOUSING
SEAL

LOW RANGE
GEAR

J9521-35

Fig. 54 Oil Pump Seal Installation


(19) Rem ove r ea r r et a in er bea r in g wit h In st a ller THRUST
J9321-60
WASHERS
8128 a n d H a n dle C-4171.
(20) In st a ll r ea r bea r in g in r et a in er wit h H a n dle Fig. 56 Input/Low Range Gear Components
C-4171 a n d In st a ller 5064 (F ig. 55).
INPUT GEAR AND LOW RANGE GEAR INSTALLATION
INPUT AND LOW RANGE GEAR ASSEMBLY (1) Align a n d in st a ll low r a n ge/in pu t gea r a ssem -
(1) Lu br ica t e gea r s a n d t h r u st wa sh er s (F ig. 56) bly in fr on t ca se (F ig. 57). Be su r e low r a n ge gea r
wit h r ecom m en ded t r a n sm ission flu id. pin ion s a r e en ga ged in a n n u lu s gea r a n d t h a t in pu t
gea r sh a ft is fu lly sea t ed in fr on t bea r in g.
XJ TRANSMISSION AND TRANSFER CASE 21 - 295
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(2) In st a ll sn a p-r in g t o h old in pu t /low r a n ge gea r
in t o fr on t bea r in g (F ig. 58).
ANNULUS
GEAR

Fig. 59 Install Front Bearing Retainer


J9321-61
(3) Slide m ode h u b on t o m a in sh a ft .
Fig. 57 Input/Low Range Gear Installation (4) In st a ll m ode h u b r et a in in g r in g. Ver ify t h a t t h e
r et a in in g r in g is fu lly sea t ed in m a in sh a ft gr oove.
INPUT GEAR
SHIFT FORKS AND MAINSHAFT INSTALLATION
(1) In st a ll n ew sect or sh a ft O-r in g a n d bu sh in g
(F ig. 60).

Fig. 58 Install Snap-Ring


(3) Clea n ga sket sea ler r esidu e fr om r et a in er a n d
in spect r et a in er for cr a cks or ot h er da m a ge.
(4) Apply a 3 m m (1/8 in .) bea d of Mopa r ! ga sket
m a ker or silicon e a dh esive t o sea lin g su r fa ce of
r et a in er.
(5) Align ca vit y in sea l r et a in er wit h flu id r et u r n
h ole in fr on t of ca se.

CAUTION: Do not block fluid return cavity on seal-


ing surface of retainer when applying Mopar$ gas- Fig. 60 Sector O-Ring And Bushing Installation
ket maker or silicone adhesive sealer. Seal failure
and fluid leak can result. (2) In st a ll sh ift sect or in ca se (F ig. 61). Lu br ica t e
sect or sh a ft wit h t r a n sm ission flu id befor e in st a lla -
(6) In st a ll bolt s t o h old r et a in er t o t r a n sfer ca se t ion .
(F ig. 59). Tigh t en t o 21 N·m (16 ft . lbs.) of t or qu e. (3) In st a ll r a n ge lever, wa sh er, a n d n u t on sect or
sh a ft (F ig. 62). Tigh t en r a n ge lever n u t t o 27–34 N.m
MAINSHAFT ASSEMBLY (20–25 ft . lbs.) t or qu e.
(1) Lu br ica t e m a in sh a ft splin es wit h r ecom m en ded (4) Assem ble a n d in st a ll r a n ge for k a n d h u b (F ig.
t r a n sm ission flu id. 63). Be su r e h u b is pr oper ly sea t ed in low r a n ge gea r
(2) Slide dr ive spr ocket on t o m a in sh a ft . a n d en ga ged t o t h e in pu t gea r.
21 - 296 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

MODE
DRIVE HUB
SPROCKET

8001096c

Fig. 64 Mainshaft Assembly Installation

MODE
SLEEVE

Fig. 61 Shift Sector Installation

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

Fig. 63 Install Range Fork And Hub Assembly


(6) In st a ll a ssem bled m a in sh a ft (F ig. 64). Be su r e
sh a ft is sea t ed in pilot bea r in g a n d in pu t gea r. Fig. 66 Mode Fork And Sleeve Installation
(7) In st a ll n ew pa ds on m ode for k if n ecessa r y. (10) Rot a t e sect or t o Neu t r a l posit ion .
(8) In ser t m ode sleeve in m ode for k m ode for k. Be (11) In st a ll n ew O-r in g on det en t plu g (F ig. 67).
su r e lon g side of sleeve is t owa r d lon g en d of sh ift (12) Lu br ica t e det en t plu n ger wit h t r a n sm ission
r a il (F ig. 65). flu id or ligh t coa t of pet r oleu m jelly.
XJ TRANSMISSION AND TRANSFER CASE 21 - 297
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(13) In st a ll det en t plu n ger, spr in g a n d plu g (F ig. DRIVE
67). CHAIN
(14) Ver ify t h a t plu n ger is pr oper ly en ga ged in sec-
t or.

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).

OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION


(1) In st a ll m a gn et in fr on t ca se pocket (F ig. 70).
(2) Assem ble oil picku p scr een , con n ect in g h ose,
a n d t u be.
(3) In st a ll n ew picku p t u be O-r in g in oil pu m p
(F ig. 71). RR21 F29
(4) In ser t oil picku p t u be in oil pu m p in let .
Fig. 69 Install Mode Fork Spring
(5) P osit ion a ssem bled oil pu m p a n d picku p t u be
in r ea r ca se. Be su r e picku p scr een is secu r ely sea t ed (9) Tigh t en ca se bolt s t o 27-34 N·m (20-25 ft . lbs.)
in ca se slot . Also be su r e oil pu m p loca t in g t a bs a r e t or qu e.
ou t side r ea r ca se (F ig. 72).
(6) Apply 3 m m (1/8 in .) wide bea d of Mopa r ! ga s- YOKE AND RANGE LEVER INSTALLATION
ket m a ker or silicon e a dh esive sea ler t o m ou n t in g (1) In st a ll in dica t or swit ch in fr on t ca se. Tigh t en
fla n ge of fr on t ca se. Wor k sea ler bea d a r ou n d bolt swit ch t o 20–34 N·m (15–25 ft . lbs.) t or qu e.
h oles. (2) In st a ll r a n ge lever, wa sh er a n d lockn u t on sec-
(7) Lift r ea r ca se a n d oil pu m p a n d ca r efu lly posi- t or sh a ft (F ig. 74). Tigh t en lockn u t t o 27-34 N·m
t ion a ssem bly on fr on t ca se. Be su r e ca se dowels a r e (20-25 ft . lbs.) t or qu e.
a lign ed a n d t h a t m ode for k r a il ext en ds t h r ou gh r ea r (3) In st a ll n ew sea l wa sh er on fr on t ou t pu t sh a ft
ca se befor e sea t in g r ea r ca se on fr on t ca se. (F ig. 76).
(8) In st a ll ca se a t t a ch in g bolt s. Align m en t bolt s a t (4) Lu br ica t e yoke h u b wit h t r a n sm ission flu id a n d
ea ch en d of ca se a r e on ly on es r equ ir in g wa sh er s in st a ll yoke on fr on t sh a ft .
(F ig. 73). (5) In st a ll n ew sea l wa sh er on fr on t sh a ft .
21 - 298 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

Fig. 73 Alignment Bolt Location

MAGNET

J892l-288

Fig. 70 Installing Case Magnet


OIL PUMP

Fig. 74 Range Lever Installation


(7) Tigh t en yoke n u t t o 122-176 N·m (90-130 ft .
lbs.) t or qu e. Use Tool C-3281, or sim ila r t ool t o h old
yoke wh ile t igh t en in g yoke n u t .

O-RING

Fig. 71 Pickup Tube O-Ring Position

YOKE
NUT

J9321-1

Fig. 75 Output Shaft Yoke Installation


REAR RETAINER INSTALLATION
800bdl98 (1) Apply bea d of Mopa r ! Sea ler P /N 82300234, or
Loct it e# Ult r a Gr a y, t o m a t in g su r fa ce of r ea r
Fig. 72 Oil Pump And Pickup Tube Installation r et a in er. Sea ler bea d sh ou ld be a m a xim u m of 3/16
(6) In st a ll yoke a n d n ew yoke n u t on fr on t ou t pu t in ch .
sh a ft (F ig. 75). (2) In st a ll r ea r r et a in er on r ea r ca se. Tigh t en
r et a in er bolt s t o 20–27 N·m (15–20 ft . lbs.) t or qu e.
XJ TRANSMISSION AND TRANSFER CASE 21 - 299
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

YOKE SPECIAL TOOL


SEAL
WASHER MD998323

Fig. 76 Yoke Seal Washer Installation


(3) In st a ll r ea r bea r in g I.D. r et a in in g r in g a n d
spa cer on ou t pu t sh a ft .
(4) Apply liber a l qu a n t it y of pet r oleu m jelly t o n ew
r ea r sea l a n d t o ou t pu t sh a ft . P et r oleu m jelly is
n eeded t o pr ot ect sea l lips du r in g in st a lla t ion .
(5) Slide sea l on t o Sea l P r ot ect or 6992 (F ig. 77). Fig. 78 Rear Seal Installation
Slide sea l pr ot ect or a n d sea l on t o ou t pu t sh a ft .
(6) Slide In st a ller C-4076-B on t o sea l pr ot ect or
wit h t h e r ecessed side of t h e t ool t owa r d t h e sea l.
Dr ive sea l in t o r ea r bea r in g r et a in er wit h in st a ller
C-4076-B a n d h a n dle MD-998323 (F ig. 78).

Fig. 79 Slinger Boot Installation


TRANSFER CASE 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
80a50355
a n d a llow it t o a ir dr y. Do n ot u se com pr essed a ir.

Fig. 77 Output Shaft Seal and Protector MAINSHAFT/SPROCKET/HUB INSPECTION


(7) In st a ll r ea r slin ger wit h in st a ller C-4076-A a n d 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
h a n dle MD-998323 (F ig. 78). t eet h on t h e spr ocket (F ig. 80). Min or n icks a n d
(8) In st a ll boot on ou t pu t sh a ft slin ger a n d cr im p scr a t ch es ca n be sm oot h ed wit h a n oilst on e. H owever,
r et a in in g cla m p wit h t ool C-4975-A (F ig. 79). r epla ce a n y pa r t t h a 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
CLEAN I N G AN D I N SPECT I ON 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.
NV231 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 INPUT GEAR AND PLANETARY CARRIER
pa r t s clea n in g solven t . Rem ove a ll t r a ces of sea ler Ch eck t h e t eet h on t h e gea r (F ig. 81). Min or n icks
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 3M ca n be dr essed off wit h a n oilst on e bu t r epla ce t h e
a ll pu r pose clea n er. Use com pr essed a ir t o r em ove gea r if a n y t eet h a r e br oken , cr a cked, or ch ipped. Th e
solven t r esidu e fr om oil feed pa ssa ges in t h e ca se bea r in g su r fa ce on t h e gea r ca n be sm oot h ed wit h
h a lves, r et a in er s, gea r s, a n d sh a ft s. 300–400 gr it em er y clot h if n ecessa r y.
E xa m in e t h e ca r r ier body a n d pin ion gea r s for
wea r or da m a ge. Th e ca r r ier will h a ve t o be r epla ced
21 - 300 TRANSMISSION AND TRANSFER CASE XJ
CLEAN I N G AN D I N SPECT I ON (Cont inue d)

MODE DRIVE
HUB SPROCKET

MAINSHAFT

MODE HUB
RETAINING RING 80010947

Fig. 80 Mainshaft, Mode Hub, And Drive Sprocket


a s a n a ssem bly if t h e body, pin ion pin s, or pin ion SHIFT FORKS/HUBS/SLEEVES
gea r s a r e da m a ged. Ch eck con dit ion of t h e sh ift for ks a n d m ode for k
Ch eck t h e lock r in g a n d bot h t h r u st wa sh er s for sh ift r a il (F ig. 82). Min or n icks on t h e sh ift r a il ca n
wea r or cr a cks. Repla ce t h em if n ecessa r y. Also be sm oot h ed wit h 320–400 gr it em er y clot h .
r epla ce t h e lock r et a in in g r in g if ben t , dist or t ed, or In spect t h e sh ift for k wea r pa ds (F ig. 83). Th e
br oken . m ode for k pa ds a r e ser vicea ble a n d ca n be r epla ced if
n ecessa r y. Th e r a n ge for k pa ds a r e n ot ser vicea ble.

REAR
THRUST
WASHER

FRONT
THRUST CARRIER
WASHER LOCK CARRIER
RING LOCK
RETAINING
RING

PLANETARY
CARRIER
INPUT
GEAR

8001b751

Fig. 81 Input Gear And Carrier Components


XJ TRANSMISSION AND TRANSFER CASE 21 - 301
CLEAN I N G AN D I N SPECT I ON (Cont inue d)

MODEFORK REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN


AND RAIL Ch eck con dit ion of t h e sea l con t a ct su r fa ces of t h e
yoke slin ger (F ig. 85). Th is su r fa ce m u st be clea n a n d
sm oot h t o en su r e pr oper sea l life. Repla ce t h e yoke
n u t a n d sea l wa sh er a s n eit h er pa r t sh ou ld be
r eu sed.
In spect t h e sh a ft t h r ea ds, spr ocket t eet h , a n d bea r-
in g su r fa ces. Min or n icks on t h e t eet h ca n be
sm oot h ed wit h a n oilst on e. Use 320–400 gr it em er y
t o sm oot h m in or scr a t ch es on t h e sh a ft bea r in g su r-
fa ces. Rou gh t h r ea ds on t h e sh a ft ca n be ch a sed if
n ecessa r y. Repla ce t h e sh a ft if t h e t h r ea ds a r e da m -
a ged, bea r in g su r fa ces a r e scor ed, or if a n y spr ocket
t eet h a r e cr a cked or br oken .
80010948 E xa m in e t h e dr ive ch a in a n d sh a ft bea r in gs.
Repla ce t h e ch a in a n d bot h spr ocket s if t h e ch a in is
Fig. 82 Shift forks st r et ch ed, dist or t ed, or if a n y of t h e lin ks bin d.
Th e for k m u st be r epla ced a s a n a ssem bly if t h e pa ds Repla ce t h e bea r in gs if r ou gh , or n oisy.
a r e wor n or da m a ged.
LOW RANGE ANNULUS GEAR
In spect a n n u lu s gea r con dit ion ca r efu lly. Th e gea r
is on ly ser viced a s pa r t of t h e fr on t ca se. If t h e gea r
is da m a ged, it will be n ecessa r y t o r epla ce t h e gea r
a n d fr on t ca se a s a n a ssem bly. Do n ot a t t em pt t o
r em ove t h e gea r (F ig. 86).

FRONT-REAR CASES AND FRONT RETAINER


In spect t h e ca ses a n d r et a in er for wea r a n d da m -
a ge. Clea n t h e sea lin g su r fa ces wit h a scr a per a n d
3M a ll pu r pose clea n er. Th is will en su r e pr oper
sea ler a dh esion a t a ssem bly. Repla ce t h e in pu t
r et a in er sea l; do n ot r eu se it .
Ch eck ca se con dit ion . If lea ks wer e a pr oblem , look
WEAR PADS for gou ges a n d sever e scor in g of ca se sea lin g su r-
(NON-SERVICEABLE) 8001097c fa ces. Also m a ke su r e t h e fr on t ca se m ou n t in g st u ds
a r e in good con dit ion .
Fig. 83 Shift Fork And Wear Pad Locations Ch eck t h e fr on t ca se m ou n t in g st u ds a n d ven t
Ch eck bot h of t h e sleeves for wea r or da m a ge, t u be. Th e t u be ca n be secu r ed wit h Loct it e 271 or
especia lly on t h e in t er ior t eet h . Repla ce t h e sleeves if 680 if loose. Th e st u d t h r ea ds ca n be clea n ed u p wit h
wea r or da m a ge is eviden t . a die if n ecessa r y. Also ch eck con dit ion of t h e fill/
dr a in plu g t h r ea ds in t h e r ea r ca se. Th e t h r ea ds ca n
REAR RETAINER/BEARING/SEAL/SLINGER/BOOT be r epa ir ed wit h a t h r ea d ch a ser or t a p if n ecessa r y.
In spect t h e r et a in er com pon en t s (F ig. 84). Repla ce Or t h e t h r ea ds ca n be r epa ir ed wit h H elicoil st a in less
t h e bea r in g if r ou gh or n oisy. Ch eck t h e r et a in er for st eel in ser t s if r equ ir ed.
cr a cks or wea r in t h e bea r in g bor e. Clea n t h e
r et a in er sea lin g su r fa ces wit h a scr a per a n d 3M a ll OIL PUMP/OIL PICKUP
pu r pose clea n er. Th is will en su r e pr oper a dh esion of E xa m in e t h e oil pu m p picku p pa r t s. Repla ce t h e
t h e sea ler du r in g r ea ssem bly. pu m p if a n y pa r t a ppea r s t o be wor n or da m a ged. Do
Repla ce t h e slin ger a n d sea l ou t r igh t ; do n ot r eu se n ot disa ssem ble t h e pu m p a s in dividu a l pa r t s a r e n ot
eit h er pa r t . a va ila ble. Th e pu m p is on ly a va ila ble a s a com plet e
In spect t h e r et a in in g r in gs a n d wa sh er s. Repla ce a ssem bly. Th e picku p scr een , h ose, a n d t u be a r e t h e
a n y pa r t if dist or t ed, ben t , or br oken . Reu se is n ot on ly ser vicea ble pa r t s a n d a r e a va ila ble sepa r a t ely.
r ecom m en ded. Also r epla ce t h e boot if cu t or t or n .
Repla ce t h e boot ba n d cla m ps, do n ot r eu se t h em .
21 - 302 TRANSMISSION AND TRANSFER CASE XJ
CLEAN I N G AN D I N SPECT I ON (Cont inue d)

BOOT

REAR
SLINGER
LOCATING
REAR WASHER
REAR SEAL
RETAINER

REAR SLINGER
SLINGER
LOCATING
RING
REAR
BEARING O.D.
REAR RETAINING
BEARING RING

80010949

Fig. 84 Rear Retainer Components

FRONT SLINGER SEAL CONTACT


(PART OF YOKE) SURFACE MUST
BE CLEAN AND
SMOOTH

8001094b

Fig. 85 Seal Contact Surface Of Yoke Slinger Fig. 86 Low Range Annulus Gear
XJ TRANSMISSION AND TRANSFER CASE 21 - 303

ADJ U ST M EN T S SPECI FI CAT I ON S


SHIFT LINKAGE ADJUSTMENT TORQUE
(1) Sh ift t r a n sfer ca se in t o 4L posit ion .
(2) Ra ise veh icle. D ES CRIP TION TORQU E
(3) Loosen lock bolt on a dju st in g t r u n n ion (F ig. P lu g, Det en t . . . . . . . . . . 16–24 N·m (12–18 ft . lbs.)
87). P lu g, Dr a in /F ill . . . . . . . . 20–34 N·m (15–25 ft . lbs.)
(4) Be su r e lin ka ge r od slides fr eely in t r u n n ion . Bolt , F r on t Br g. Ret a in er . . . . . . 21 N·m (16 ft . lbs.)
Clea n r od a n d a pply spr a y lu be if n ecessa r y. Bolt , F r on t Br g. Ret a in er . . . . . . 21 N·m (16 ft . lbs.)
(5) Ver ify t h a t t r a n sfer ca se r a n ge lever is fu lly Bolt , Ca se H a lf . . . . . . . . 27–34 N·m (20–25 ft . lbs.)
en ga ged in 4L posit ion . Nu t , F r on t Yoke . . . . . 122–176 N·m (90–130 ft . lbs.)
(6) Tigh t en a dju st in g t r u n n ion lock bolt . Nu t , Ra n ge Lever . . . . . . 27–34 N·m (20–25 ft . lbs.)
(7) Lower veh icle. Bolt , Rea r Ret a in er . . . . . 35–46 N·m (26–34 ft . lbs.)
Nu t s, Mou n t in g . . . . . . . . 35–47 N·m (26–35 ft . lbs.)
Swit ch , In dica t or . . . . . . . 20–34 N·m (15–25 ft . lbs.)

SPECI AL T OOLS
NV231

FLOORPAN

LINKAGE
BRACKET
Installer—C-4076-B

•RANGE~

TORQUE LEVER
SHAFT ROD
TORQUE SHAFT /
BRACKET J9521-163

Fig. 87 Shift Linkage

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, Boot Clamp—C-4975-A


Installer, Bearing—5064

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)

Installer, Bearing—8128 Cup—8148

Remover—L-4454 Installer, Seal—7884

Installer, Pump Housing Seal—7888


21 - 306 TRANSMISSION AND TRANSFER CASE XJ

N V 2 4 2 T RAN SFER CASE

INDEX
page page

GENERAL INFORMATION TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 308


NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . 306 DISASSEMBLY AND ASSEMBLY
RECOMMENDED LUBRICANT AND FILL NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . 311
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 CLEANING AND INSPECTION
TRANSFER CASE IDENTIFICATION . . . . . . . . . 306 NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . 330
DIAGNOSIS AND TESTING ADJUSTMENTS
NV242 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 307 SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . 333
REMOVAL AND INSTALLATION SPECIFICATIONS
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . 309 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 308 SPECIAL TOOLS
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 308 NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

GEN ERAL I N FORM AT I ON oper a t ed by a dr ive ch a in t h a t con n ect s t h e sh a ft t o a


dr ive spr ocket on t h e m a in sh a ft . Th e dr ive spr ocket
NV242 TRANSFER CASE is en ga ged/disen ga ged by t h e m ode for k, wh ich oper-
Th e NV242 is a fu ll a n d pa r t -t im e t r a n sfer ca se a t es t h e m ode sleeve a n d h u b. Th e sleeve a n d h u b
(F ig. 1). It pr ovides fu ll t im e 2-wh eel, or 4-wh eel a r e n ot equ ipped wit h a syn ch r o m ech a n ism for sh ift -
dr ive oper a t ion . in g.
A differ en t ia l in t h e t r a n sfer ca se is u sed t o con t r ol 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
t or qu e t r a n sfer t o t h e fr on t a n d r ea r a xles. A low 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 a n ge gea r pr ovides in cr ea sed low speed t or qu e ca pa - 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
bilit y for off r oa d oper a t ion . Th e low r a n ge pr ovides a h ou sin gs bolt ed t o t h e ca se h a lves.
2.72:1 r edu ct ion r a t io.
OPERATING RANGES
NV242 oper a t in g r a n ges a r e 2WD (2-wh eel dr ive),
4x4 pa r t -t im e, 4x4 fu ll t im e, a n d 4 Lo.
Th e 2WD a n d 4x4 fu ll t im e r a n ges ca n be u sed a t
a n y t im e a n d on a n y r oa d su r fa ce.
Th e 4x4 pa r t -t im e a n d 4 Lo r a n ges a r e for off r oa d
u se on ly. Th e on ly t im e t h ese r a n ges ca n be u sed on
h a r d su r fa ce r oa ds, is wh en t h e su r fa ce is cover ed
wit h sn ow a n d ice.

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.

J8921-243 TRANSFER CASE IDENTIFICATION


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
Fig. 1 NV242 Transfer Case ea ch t r a n sfer ca se (F ig. 2). Th e ID t a g pr ovides t h e
Th e in pu t gea r is splin ed t o t h e t r a n sm ission ou t - t r a n sfer ca se m odel n u m ber, a ssem bly n u m ber, ser ia l
pu t sh a ft . It dr ives t h e m a in sh a ft t h r ou gh t h e pla n - n u m ber, a n d low r a n ge r a t io.
et a r y gea r a n d r a n ge h u b. Th e fr on t ou t pu t sh a ft is Th e t r a n sfer ca se ser ia l n u m ber a lso r epr esen t s
t h e da t e of bu ild.
XJ TRANSMISSION AND TRANSFER CASE 21 - 307
GEN ERAL I N FORM AT I ON (Cont inue d)
Appr oxim a t e lu br ica n t fill ca pa cit y is 1.35 lit er s (2.85
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
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.

DRAIN PLUG 80b09a60

Fig. 2 Fill/Drain Plug And I.D. Tag Locations


RECOMMENDED LUBRICANT AND FILL LEVEL
Recom m en ded lu br ica n t for t h e NV242 t r a n sfer
ca se is Mopa r ! Dexr on II, or ATF P lu s, t ype 7176.

DI AGN OSI S AN D T EST I N G


NV242 DIAGNOSIS
DI AGN OSI S CH ART

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

Fig. 4 Shift Linkage


(4) Rem ove speed sen sor a n d speedom et er a da pt er (6) Cou n t n u m ber of t eet h on speedom et er pin ion .
a s a n a ssem bly. Do t h is befor e in st a llin g a ssem bly in h ou sin g. Th en
(5) Rem ove speed sen sor r et a in in g scr ew a n d lu br ica t e pin ion t eet h wit h t r a n sm ission flu id.
r em ove sen sor fr om a da pt er. (7) Not e in dex n u m ber s on a da pt er body (F ig. 6).
(6) Rem ove speedom et er pin ion fr om a da pt er. Th ese n u m ber s will cor r espon d t o n u m ber of t eet h on
Repla ce pin ion if ch ipped, cr a cked, or wor n . pin ion .
(7) In spect sen sor a n d a da pt er O-r in gs (F ig. 5). (8) In st a ll speedom et er a ssem bly in h ou sin g.
Rem ove a n d disca r d O-r in gs if wor n or da m a ged. (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
(8) In spect t er m in a l pin s in speed sen sor. Clea n a r e a t 6 o-clock posit ion . Be su r e r a n ge in dex n u m -
pin s wit h Mopa r ! elect r ica l spr a y clea n er if dir t y or ber s cor r espon d t o n u m ber of t eet h on pin ion gea r.
oxidized. Repla ce sen sor if fa u lt y, or if pin s a r e loose, (10) In st a ll speedom et er a da pt er cla m p a n d r et a in -
sever ely cor r oded, or da m a ged. 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.
INSTALLATION AND INDEXING (11) Con n ect wir es t o veh icle speed sen sor.
(1) Th or ou gh ly clea n a da pt er fla n ge a n d a da pt er (12) Lower veh icle a n d t op off t r a n sm ission flu id
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 level if n ecessa r y.
for pr oper a da pt er a lign m en t a n d speedom et er oper-
a t ion . FRONT OUTPUT SHAFT SEAL
(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 (F ig. 5), if n ecessa r y. REMOVAL
(3) Lu br ica t e sen sor a n d a da pt er O-r in gs wit h (1) Ra ise veh icle.
t r a n sm ission flu id. (2) Rem ove fr on t pr opeller sh a ft . Refer t o Gr ou p 3,
(4) In st a ll veh icle speed sen sor in speedom et er Differ en t ia l a n d Dr ivelin e, for pr oper pr ocedu r e.
a da pt er. Tigh t en sen sor a t t a ch in g scr ew t o 2-3 N·m (3) Rem ove fr on t ou t pu t sh a ft yoke.
(15-27 in . lbs.) t or qu e. (4) Rem ove sea l fr om fr on t ca se wit h pr y t ool
(5) In st a ll speedom et er pin ion in a da pt er. (F ig. 7).
21 - 310 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

ITEM TORQUE ADAPTER


A 2-3 N•m (15-27 in. lbs.) O-RING

\~B~
B 10-12 N•m (90-110 in. lbs.)
SENSOR

\
SPEEDOMETER
PINION

VEHICLE
SPEED
SENSOR J9321-385

Fig. 5 Speedometer Components

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

Fig. 8 Front Output Seal Installation Fig. 10 Rear Slinger Removal


DI SASSEM BLY AN D ASSEM BLY SNAP-RING

NV242 TRANSFER CASE


DISASSEMBLY
REAR RETAINER REMOVAL
(1) Rem ove ou t pu t sh a ft boot . Spr ea d ba n d cla m p
t h a t secu r es boot on slin ger wit h a su it a ble a wl.
Th en slide boot off sh a ft (F ig. 9).

80a50353

Fig. 11 Slinger Stop Spacer and Snap-ring

Fig. 9 Output Boot—Typical


(2) Usin g pu ller MD-998056-A, r em ove r ea r slin ger
(F ig. 10).
(3) Rem ove slin ger st op spa cer a n d sn a p-r in g fr om
ou t pu t sh a ft (F ig. 11).
80a50354
(4) Rem ove r ea r sea l fr om r et a in er (F ig. 12). Use
pr y t ool, or colla pse sea l wit h pu n ch t o r em ove it . Fig. 12 Rear Seal Removal
(5) Rem ove r ea r ou t pu t bea r in g I.D. r et a in in g r in g
(F ig. 13). (8) Rem ove r ea r r et a in er. Ta p r et a in er wit h m a llet
(6) Rem ove speedom et er a da pt er. a n d pr y u pwa r d t o br ea k sea ler bea d. Th en slide
(7) Rem ove r ea r r et a in er bolt s. r et a in er off ca se a n d ou t pu t sh a ft (F ig. 14).
21 - 312 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
OIL PUMP

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)

Fig. 14 Rear Retainer Removal


(9) Rem ove r ea r bea r in g O.D. r et a in in g r in g wit h
sn a p r in g plier s. Th en t ilt pu m p a n d slide it off ou t -
pu t sh a ft (F ig. 15). 80010969

OIL Fig. 17 Spline And Dowel Bolt Locations

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.

CAUTION: Do not pry on the sealing surface of


either case half as the surfaces will become dam-
aged.
80010966

(14) Rem ove oil picku p t u be a n d scr een fr om r ea r


Fig. 15 Oil Pump Removal ca se (F ig. 19).
(10) Rem ove picku p t u be O-r in g fr om pu m p (F ig.
YOKE AND RANGE LEVER REMOVAL
16) bu t do n ot disa ssem ble pu m p; it is n ot a r epa ir-
(1) Rem ove fr on t yoke n u t :
a ble pa r t .
(a ) Move r a n ge lever t o 4L posit ion .
(11) Rem ove sea l fr om oil pu m p wit h pr y t ool.
(b) Rem ove n u t wit h socket a n d im pa ct wr en ch
(F ig. 20).
XJ TRANSMISSION AND TRANSFER CASE 21 - 313
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

MAINSHAFT posit ion ed on yoke a n d n ot on slin ger a s slin ger will


be da m a ged.

FRONT
CASE

RP1099

Fig. 18 Loosening/Removing Rear case


80010977

Fig. 21 Yoke Removal


(3) Rem ove sea l wa sh er fr om fr on t ou t pu t sh a ft .
Disca r d wa sh er a s it sh ou ld n ot be r eu sed.
(4) Rem ove n u t a n d wa sh er t h a t a t t a ch r a n ge
lever t o sect or sh a ft . Th en m ove sect or t o n eu t r a l
posit ion a n d r em ove r a n ge lever fr om sh a ft (F ig. 22).

PICKUP PICKUP
TUBE SCREEN
80010979

Fig. 19 Oil Pickup Screen, Hose And Tube Removal

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).

SHIFT FORKS AND MAINSHAFT REMOVAL AND


DISASSEMBLY
(1) Rem ove sh ift det en t plu g, spr in g a n d pin (F ig.
26).
(2) Rem ove sea l plu g fr om low r a n ge for k lockpin
a ccess h ole. Th en m ove sh ift sect or t o a lign low r a n ge
800010957
for k lockpin wit h a ccess h ole.
(3) Rem ove r a n ge for k lockpin wit h size n u m ber
Fig. 20 Yoke Nut Removal on e ea sy-ou t t ool a s follows:
(2) Rem ove yoke. If yoke is difficu lt t o r em ove by (a ) In ser t ea sy-ou t t ool t h r ou gh a ccess h ole in
h a n d, r em ove it wit h bea r in g split t er, or wit h st a n - side of t r a n sfer ca se a n d in t o lock-pin .
da r d t wo ja w pu ller (F ig. 21). Be su r e pu ller t ool is (b) Ta p ea sy-ou t t ool in t o lock-pin wit h h a m m er
u n t il t ool is secu r ely en ga ged in t o t h e lock-pin .
21 - 314 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

J8921-253
J8921-251
Fig. 25 Removing Front Output Shaft
Fig. 23 Drive Sprocket Snap-Ring Removal

PLUNGER

PLUG

0-RING

Fig. 26 Detent Component Removal


(5) Rem ove m ode for k a n d m a in sh a ft a s a ssem bly
(F ig. 28).
(6) Rem ove m ode sh ift sleeve a n d m ode for k
a ssem bly fr om m a in sh a ft (F ig. 29). Not e posit ion of
Fig. 24 Drive Sprocket And Chain Removal m ode sleeve in for k a n d r em ove sleeve.
(c) In st a ll a t -h a n dle, su ch a s fr om a t a p a n d die
set , on t o t h e ea sy-ou t t ool.
(d) Secu r ely t igh t en t h e t -h a n dle on t o t h e t ool.
(e) In on e m ot ion , pu ll u pwa r d a n d t u r n t h e
t -h a n dle cou n t er-clockwise t o r em ove t h e lock-pin .
(4) Rem ove sh ift r a il by pu llin g it st r a igh t u p a n d
ou t of for k (F ig. 27).
XJ TRANSMISSION AND TRANSFER CASE 21 - 315
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

SHIFT
RAIL

MODE
FORK

J8921-255

Fig. 27 Shift Rail Removal

J8921-257

Fig. 29 Mode Fork And Sleeve Removal

INTERMEDIATE
CLUTCH
SHAFT

Fig. 28 Mode Fork And Mainshaft Removal


(7) Rem ove in t er m edia t e clu t ch sh a ft sn a p-r in g
(F ig. 30).
(8) Rem ove clu t ch sh a ft t h r u st r in g (F ig. 31).
(9) Rem ove in t er m edia t e clu t ch sh a ft (F ig. 32). J8921-258
(10) Rem ove differ en t ia l sn a p-r in g (F ig. 33).
Fig. 30 Intermediate Clutch Shaft Snap-Ring
Removal
21 - 316 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 32 Intermediate Clutch Shaft Removal Fig. 34 Differential Removal


(11) Rem ove differ en t ia l (F ig. 34). (14) Rem ove low r a n ge for k a n d h u b (F ig. 36).
(12) Rem ove differ en t ia l n eedle bea r in gs a n d bot h (15) Rem ove sh ift sect or (F ig. 37).
n eedle bea r in g t h r u st wa sh er s fr om m a in sh a ft . (16) Rem ove sh ift sect or bu sh in g a n d O-r in g
(13) Slide low r a n ge for k pin ou t of sh ift sect or slot (F ig. 38).
(F ig. 35).
XJ TRANSMISSION AND TRANSFER CASE 21 - 317
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

J8921-263 J8921-263

Fig. 35 Disengaging Low Range Fork Fig. 37 Shift Sector Position

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

Fig. 41 Input And Low Range Gear Assembly


Removal
J8921-266

Fig. 39 Front Bearing Retainer Removal

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

Fig. 43 Low Range Gear Disassembly

CASE SLOTS J8921-271

Fig. 45 Separating Differential Case Halves

Fig. 44 Inspecting Low Range Annulus Gear


ASSEMBLY
Lu br ica t e t r a n sfer ca se com pon en t s wit h a u t om a t ic J8921-272
t r a n sm ission flu id or pet r oleu m jelly (wh er e in di-
ca t ed) du r in g a ssem bly. Fig. 46 Planet Gears And Thrust Washer Removal
CAUTION: The bearing bores in various transfer (2) In st a ll n ew fr on t ou t pu t sh a ft fr on t bea r in g
case components contain oil feed holes. Make sure wit h Tool H a n dle C-4171 a n d In st a ller 8033A wit h
replacement bearings do not block the holes. t h e t a per ed con e u pwa r d (F ig. 49).
(3) In st a ll fr on t bea r in g sn a p-r in g (F ig. 48).
(4) Rem ove fr on t ou t pu t sh a ft sea l u sin g a n a ppr o-
BEARING AND SEAL INSTALLATION pr ia t e pr y t ool (F ig. 50) or slide-h a m m er m ou n t ed
(1) Rem ove sn a p-r in g t h a t r et a in s fr on t ou t pu t scr ew.
sh a ft fr on t bea r in g in ca se (F ig. 48). Th en r em ove (5) In st a ll n ew fr on t ou t pu t sh a ft oil sea l wit h
bea r in g. Use h a m m er h a n dle, or h a m m er a n d br a ss In st a ller 6952-A (F ig. 51).
pu n ch t o t a p bea r in g ou t of ca se.
21 - 320 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SPECIAL
TOOL SPECIAL
C-4171 TOOL
8033A

SPROCKET GEAR

Fig. 49 Front Output Shaft Front Bearing Installation

J8921-273

Fig. 47 Mainshaft And Sprocket Gear Removal

Fig. 50 Remove Front Output Shaft Seal

J8921-274

Fig. 48 Front Output Shaft Front Bearing Snap-Ring


Removal
_____ __,

(6) Rem ove in pu t gea r bea r in g wit h Tool H a n dle


TRANSFER
CASE
-------
C-4171 a n d Rem over C-4210 (F ig. 52). 80a98363
(7) In st a ll sn a p-r in g on n ew in pu t gea r bea r in g.
(8) In st a ll n ew in pu t gea r bea r in g wit h Tool H a n - Fig. 51 Install Front Output Shaft Seal
dle C-4171 a n d Rem over C-4210. In st a ll bea r in g fa r
in pu t gea r a n d dr ivin g t h e bea r in g ou t wit h t h e dr ift
en ou gh t o sea t sn a p-r in g a ga in st ca se (F ig. 53).
a n d a h a m m er (F ig. 54).
(9) Rem ove t h e in pu t gea r pilot bea r in g by in ser t -
(10) In st a ll n ew pilot bea r in g wit h In st a ller 8128
in g a su it a bly sized dr ift in t o t h e splin ed en d of t h e
a n d H a n dle C-4171 (F ig. 55).
XJ TRANSMISSION AND TRANSFER CASE 21 - 321
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

SPECIAL
TOOL
C-4210

J9521-43 INPUT GEAR

Fig. 52 Input Gear Bearing Removal

80a11090

Fig. 54 Remove Input Gear Pilot Bearing

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

Fig. 59 Oil Pump Seal Installation


(5) Align a n d posit ion differ en t ia l t op ca se on bot -
t om ca se (F ig. 63). Align u sin g scr ibe m a r ks m a de a t
disa ssem bly.
80a98366 (6) Wh ile h oldin g differ en t ia l ca se h a lves t oget h er,
in ver t t h e differ en t ia l a n d st a r t t h e differ en t ia l ca se
Fig. 57 Remove Front Output Shaft Rear Bearing bolt s.
DIFFERENTIAL ASSEMBLY (7) Tigh t en differ en t ia l ca se bolt s t o specified
(1) Lu br ica t e differ en t ia l com pon en t s wit h a u t o- t or qu e.
m a t ic t r a n sm ission flu id.
(2) In st a ll spr ocket gea r in differ en t ia l bot t om ca se
(F ig. 61).
(3) In st a ll differ en t ia l pla n et gea r s a n d n ew t h r u st
wa sh er s (F ig. 62). B e s u re th ru s t w a s h e rs a re
in s ta lle d a t to p a n d bo tto m o f e a c h p la n e t g e a r.
(4) In st a ll differ en t ia l m a in sh a ft gea r (F ig. 62).
XJ TRANSMISSION AND TRANSFER CASE 21 - 323
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 61 Installing Differential Sprocket Gear Fig. 63 Differential Case Assembly


21 - 324 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Assem ble low r a n ge gea r, in pu t gea r t h r u st
wa sh er s, in pu t gea r a n d in pu t gea r r et a in er (F ig. 64).
(2) In st a ll low r a n ge gea r sn a p r in g (F ig. 65).
THRUST
WASHERS

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

Fig. 67 Installing Front Bearing Retainer


J8921-269
SHIFT FORKS AND MAINSHAFT INSTALLATION
Fig. 65 Install Low Range Gear Snap Ring (1) In st a ll n ew sect or sh a ft O-r in g a n d bu sh in g
(F ig. 68).
(3) Lu br ica t e in pu t gea r a n d low r a n ge gea r s wit h
(2) In st a ll sh ift sect or.
a u t om a t ic t r a n sm ission flu id.
(3) In st a ll n ew pa ds on low r a n ge for k, if n eces-
(4) St a r t in pu t gea r sh a ft in t o fr on t ca se bea r in g.
sa r y, (F ig. 69).
(5) P r ess in pu t gea r sh a ft in t o fr on t bea r in g.
(4) Assem ble low r a n ge for k a n d h u b (F ig. 69).
(6) In st a ll n ew in pu t gea r sn a p r in g (F ig. 66).
(5) P osit ion low r a n ge for k a n d h u b in ca se. Be
(7) Apply 3 m m (1/8 in .) wide bea d of Mopa r ! ga s-
su r e low r a n ge for k pin is en ga ged in sh ift sect or slot
ket m a ker or silicon e a dh esive sea ler t o sea l su r fa ce
(F ig. 70).
of fr on t bea r in g r et a in er.
XJ TRANSMISSION AND TRANSFER CASE 21 - 325
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

J8921-263

Fig. 68 Sector O-Ring And Bushing Installation


Fig. 70 Positioning Low Range Fork

MAINSHAFT
BEARING
ROLLERS

J8921-278

Fig. 69 Assembling Low Range Fork And Hub


(6) In st a ll fir st m a in sh a ft bea r in g spa cer on m a in -
sh a ft (F ig. 71).
(7) In st a ll bea r in g r oller s on m a in sh a ft (F ig. 71).
Co a t be a rin g ro lle rs w ith g e n e ro u s qu a n tity o f Fig. 71 Installing Mainshaft Bearing Rollers and
p e tro le u m je lly to h o ld th e m in p la c e . Spacers
(8) In st a ll r em a in in g bea r in g spa cer on m a in sh a ft
(F ig. 71). Do n ot displa ce a n y bea r in gs wh ile in st a ll-
in g spa cer.
21 - 326 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(9) In st a ll differ en t ia l (F ig. 72). D o n o t d is p la c e
m a in s h a ft be a rin g s w h e n in s ta llin g d iffe re n tia l.
(10) In st a ll differ en t ia l sn a p-r in g (F ig. 73).
(11) In st a ll in t er m edia t e clu t ch sh a ft (F ig. 74).

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.

Fig. 72 Differential Installation

CLUTCH
SHAFT
THRUST
RING

J8921-259

J8921-261 Fig. 75 Installing Clutch Shaft Thrust Washer


(15) In st a ll m ode sleeve in m ode for k (F ig. 78).
Fig. 73 Installing Differential Snap-Ring Th en in st a ll a ssem bled sleeve a n d for k on m a in sh a ft .
(12) In st a ll clu t ch sh a ft t h r u st wa sh er (F ig. 75). Be su r e m ode sleeve splin es a r e en ga ged in differ en -
(13) In st a ll clu t ch sh a ft sn a p-r in g (F ig. 76). t ia l splin es.
(14) In spect m ode for k a ssem bly (F ig. 77). Repla ce (16) In st a ll m ode for k a n d m a in sh a ft a ssem bly in
pa ds a n d bu sh in g if n ecessa r y. Repla ce for k t u be if ca se (F ig. 79). Rot a t e m a in sh a ft sligh t ly t o en ga ge
bu sh in gs in side t u be a r e wor n or da m a ged. Also sh a ft wit h low r a n ge gea r s.
XJ TRANSMISSION AND TRANSFER CASE 21 - 327
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

INTERMEDIATE
CLUTCH
SHAFT

J8921-258

Fig. 76 Installing Clutch Shaft Snap-Ring

J8921-257

Fig. 78 Installing Mode Fork And Sleeve

J8921-284

Fig. 77 Mode Fork Assembly Inspection


(17) Rot a t e m ode for k pin in t o sh ift sect or slot .
(18) In st a ll sh ift r a il (F ig. 80). B e s u re ra il is
s e a te d in bo th s h ift fo rk s .
(19) Rot a t e sh ift sect or t o a lign lockpin h ole in low
r a n ge for k wit h a ccess h ole in ca se.
(20) In ser t a n ea sy-ou t in r a n ge for k lockpin t o
h old it secu r ely for in st a lla t ion (F ig. 81). Lo c k p in is
s lig h tly ta p e re d o n o n e e n d . In s e rt ta p e re d e n d Fig. 79 Assembled Mainshaft And Mode Fork
in to fo rk a n d ra il. Installation
(21) In ser t lockpin t h r ou gh a ccess h ole a n d in t o (22) In st a ll plu g in lockpin a ccess h ole.
sh ift for k (F ig. 81). Th en r em ove ea sy-ou t a n d sea t (23) In st a ll det en t plu n ger, det en t spr in g a n d
t h e pin wit h pin pu n ch . det en t plu g in ca se (F ig. 82).
21 - 328 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

PLUNGER

Fig. 82 Detent Pin, Spring And Plug Installation

J8921-255

Fig. 80 Shift Rail Installation

LOW RANGE FORK


LOCK PIN

J8921-285

Fig. 83 Drive Chain And Sprocket Installation


OIL PUMP AND REAR CASE INSTALLATION
(1) In ser t oil picku p t u be in oil pu m p a n d a t t a ch
J8921-254 oil scr een a n d con n ect or h ose t o picku p t u be. Th en
in st a ll a ssem bled pu m p, t u be a n d scr een in r ea r ca se
Fig. 81 Installing Low Range Fork Lockpin (F ig. 85). Be su r e scr een is sea t ed in ca se slot a s
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION sh own .
(1) In st a ll fr on t ou t pu t sh a ft (F ig. 83). (2) In st a ll m a gn et in fr on t ca se pocket (F ig. 86).
(2) In st a ll dr ive ch a in (F ig. 83). E n ga ge ch a in wit h (3) Apply 3 m m (1/8 in .) wide bea d of Mopa r ga s-
fr on t ou t pu t sh a ft spr ocket t eet h . ket m a ker or silicon e a dh esive sea ler t o sea l su r fa ce
(3) In st a ll dr ive spr ocket (F ig. 83). E n ga ge dr ive of fr on t ca se.
spr ocket t eet h wit h ch a in . Th en en ga ge spr ocket (4) Align a n d in st a ll r ea r ca se on fr on t ca se. Be
splin es wit h m a in sh a ft splin es. su r e ca se loca t in g dowels a r e in pla ce a n d t h a t m a in -
(4) In st a ll dr ive spr ocket sn a p-r in g (F ig. 84). sh a ft splin es a r e en ga ged in oil pu m p in n er gea r.
(5) In st a ll a n d t igh t en fr on t ca se-t o-r ea r ca se bolt s
t o 41 N·m (30 ft . lbs.) t or qu e. B e s u re to in s ta ll a
XJ TRANSMISSION AND TRANSFER CASE 21 - 329
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

MAGNET

J8921-288

Fig. 86 Installing Case Magnet

J8921-251 SPECIAL SPECIAL


TOOL -----1~ TOOL
Fig. 84 Drive Sprocket Snap-Ring Installation C-4171 5064
OIL PUMP

11~----- REAR
RETAINER

800bdfa9

Fig. 87 Installing Rear Bearing In Retainer

REAR SNAP
BEARING O.D. ,,...._ _ _ RING
OIL RETAINING PLIERS
SCREEN RING

J8921-287

Fig. 85 Oil Screen And Pickup Tube Installation


w a s h e r u n d e r e a c h bo lt u s e d a t c a s e d o w e l
lo c a tio n s .

REAR RETAINER INSTALLATION


(1) Rem ove r ea r bea r in g in r et a in er u sin g In st a ller
8128 a n d H a n dle C-4171.
(2) In st a ll r ea r bea r in g in r et a in er wit h Tools 800bdfae

C-4171 a n d 5064 (F ig. 87).


(3) In st a ll r ea r bea r in g O.D. r et a in in g r in g wit h Fig. 88 Rear Bearing Retaining Ring Installation
sn a p-r in g plier s (F ig. 88). Be su r e r et a in in g r in g is (4) Apply bea d of Mopa r ! Sea ler P /N 82300234, or
fu lly sea t ed in r et a in er gr oove. Loct it e# Ult r a Gr a y, t o m a t in g su r fa ce of r ea r
21 - 330 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
r et a in er. Sea ler bea d sh ou ld be a m a xim u m of 3/16
in .
(5) In st a ll r ea r r et a in er on r ea r ca se. Tigh t en
r et a in er bolt s t o 20–27 N·m (15–20 ft . lbs.) t or qu e. SLINGER
(6) In st a ll r ea r bea r in g I.D. r et a in in g r in g a n d
spa cer on ou t pu t sh a ft .
(7) Apply liber a l qu a n t it y of pet r oleu m jelly t o n ew
r ea r sea l a n d t o ou t pu t sh a ft . P et r oleu m jelly is
n eeded t o pr ot ect sea l lips du r in g in st a lla t ion .
(8) Slide sea l on t o Sea l P r ot ect or 6992 (F ig. 89).
Slide sea l pr ot ect or a n d sea l on t o ou t pu t sh a ft .
(9) Slide In st a ller C-4076-B on t o sea l pr ot ect or
wit h t h e r ecessed side of t h e t ool t owa r d t h e sea l.
Dr ive sea l in t o r ea r bea r in g r et a in er wit h in st a ller
C-4076-B a n d h a n dle MD-998323 (F ig. 90). 80a50357

Fig. 91 Slinger Boot Installation


FRONT YOKE AND SWITCH INSTALLATION
(1) In st a ll in dica t or swit ch in fr on t ca se. Tigh t en
swit ch t o 20–34 N·m (15–25 ft . lbs.) t or qu e.
(2) Lu br ica t e yoke h u b wit h t r a n sm ission flu id a n d
in st a ll yoke on fr on t sh a ft .
(3) In st a ll n ew sea l wa sh er on fr on t sh a ft .
(4) In st a ll yoke on fr on t sh a ft . Secu r e yoke wit h
n ew n u t .

TRANSFER CASE CLEAN I N G AN D I N SPECT I ON

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

Fig. 92 Input Gear And Carrier Components


E xa m in e t h e ca r r ier body a n d pin ion gea r s for In spect t h e sh ift for k wea r pa ds. Th e m ode for k
wea r or da m a ge. Th e ca r r ier will h a ve t o be r epla ced pa ds a r e ser vicea ble a n d ca n be r epla ced if n ecessa r y.
a s a n a ssem bly if t h e body, pin ion pin s, or pin ion Th e r a n ge for k pa ds a r e a lso ser vicea ble.
gea r s a r e da m a ged. Ch eck bot h of t h e sleeves for wea r or da m a ge,
Ch eck t h e lock r in g a n d bot h t h r u st wa sh er s for especia lly on t h e in t er ior t eet h . Repla ce t h e sleeves if
wea r or cr a cks. Repla ce t h em if n ecessa r y. Also wea r or da m a ge is eviden t .
r epla ce t h e lock r et a in in g r in g if ben t , dist or t ed, or
br oken . REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
In spect t h e r et a in er com pon en t s (F ig. 94). Repla ce
SHIFT FORKS/HUBS/SLEEVES t h e bea r in g if r ou gh or n oisy. Ch eck t h e r et a in er for
Ch eck con dit ion of t h e sh ift for ks a n d m ode for k cr a cks or wea r in t h e bea r in g bor e. Clea n t h e
sh ift r a il (F ig. 93). Min or n icks on t h e sh ift r a il ca n r et a in er sea lin g su r fa ces wit h a scr a per a n d a ll pu r-
be sm oot h ed wit h 320–400 gr it em er y clot h . pose clea n er. Th is will en su r e pr oper a dh esion of t h e
sea ler du r in g r ea ssem bly.
MODEFORK Repla ce t h e slin ger a n d sea l ou t r igh t ; do n ot r eu se
AND RAIL
eit h er pa r t .
In spect t h e r et a in in g r in gs a n d wa sh er s. Repla ce
a n y pa r t if dist or t ed, ben t , or br oken . Reu se is n ot
r ecom m en ded. Also r epla ce t h e boot if cu t or t or n .
Repla ce t h e boot ba n d cla m ps, do n ot r eu se t h em .

REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN


Ch eck con dit ion of t h e sea l con t a ct su r fa ces of t h e
yoke slin ger (F ig. 95). Th is su r fa ce m u st be clea n a n d
sm oot h t o en su r e pr oper sea l life. Repla ce t h e yoke
n u t a n d sea l wa sh er a s n eit h er pa r t sh ou ld be
r eu sed.
In spect t h e sh a ft t h r ea ds, spr ocket t eet h , a n d bea r-
80010948
in g su r fa ces. Min or n icks on t h e t eet h ca n be
Fig. 93 Shift forks sm oot h ed wit h a n oilst on e. Use 320–400 gr it em er y
t o sm oot h m in or scr a t ch es on t h e sh a ft bea r in g su r-
fa ces. Rou gh t h r ea ds on t h e sh a ft ca n be ch a sed if
n ecessa r y. Repla ce t h e sh a ft if t h e t h r ea ds a r e da m -
21 - 332 TRANSMISSION AND TRANSFER CASE XJ
CLEAN I N G AN D I N SPECT I ON (Cont inue d)

BOOT

REAR
SLINGER
LOCATING
REAR WASHER
REAR SEAL
RETAINER

REAR SLINGER
SLINGER
LOCATING
RING
REAR
BEARING O.D.
REAR RETAINING
BEARING RING

80010949

Fig. 94 Rear Retainer Components


a ged, bea r in g su r fa ces a r e scor ed, or if a n y spr ocket is da m a ged, it will be n ecessa r y t o r epla ce t h e gea r
t eet h a r e cr a cked or br oken . a n d fr on t ca se a s a n a ssem bly. Do n ot a t t em pt t o
E xa m in e t h e dr ive ch a in a n d sh a ft bea r in gs. r em ove t h e gea r (F ig. 96).
Repla ce t h e ch a in a n d bot h spr ocket s if t h e ch a in is
st r et ch ed, dist or t ed, or if a n y of t h e lin ks bin d.
Repla ce t h e bea r in gs if r ou gh , or n oisy.

FRONT SLINGER SEAL CONTACT


(PART OF YOKE) SURFACE MUST
BE CLEAN AND
SMOOTH

Fig. 96 Low Range Annulus Gear


8001094b FRONT-REAR CASES AND FRONT RETAINER
In spect t h e ca ses a n d r et a in er for wea r a n d da m -
Fig. 95 Seal Contact Surface Of Yoke Slinger
a ge. Clea n t h e sea lin g su r fa ces wit h a scr a per a n d a ll
LOW RANGE ANNULUS GEAR pu r pose clea n er. Th is will en su r e pr oper sea ler a dh e-
In spect a n n u lu s gea r con dit ion ca r efu lly. Th e gea r sion a t a ssem bly. Repla ce t h e in pu t r et a in er sea l; do
is on ly ser viced a s pa r t of t h e fr on t ca se. If t h e gea r n ot r eu se it .
XJ TRANSMISSION AND TRANSFER CASE 21 - 333
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
Ch eck ca se con dit ion . If lea ks wer e a pr oblem , look
for gou ges a n d sever e scor in g of ca se sea lin g su r-
fa ces. Also m a ke su r e t h e fr on t ca se m ou n t in g st u ds
a r e in good con dit ion .
Ch eck t h e fr on t ca se m ou n t in g st u ds a n d ven t
t u be. Th e t u be ca n be secu r ed wit h Loct it e# 271 or
680 if loose. Th e st u d t h r ea ds ca n be clea n ed u p wit h
a die if n ecessa r y. Also ch eck con dit ion of t h e fill/
dr a in plu g t h r ea ds in t h e r ea r ca se. Th e t h r ea ds ca n
be r epa ir ed wit h a t h r ea d ch a ser or t a p if n ecessa r y. FLOORPAN
Or t h e t h r ea ds ca n be r epa ir ed wit h H elicoil st a in less
st eel in ser t s if r equ ir ed.

OIL PUMP/OIL PICKUP


E xa m in e t h e oil pu m p picku p pa r t s. Repla ce t h e
pu m p if a n y pa r t a ppea r s t o be wor n or da m a ged. Do
LINKAGE
n ot disa ssem ble t h e pu m p a s in dividu a l pa r t s a r e n ot BRACKET
a va ila ble. Th e pu m p is on ly a va ila ble a s a com plet e
a ssem bly. Th e picku p scr een , h ose, a n d t u be a r e t h e
on ly ser vicea ble pa r t s a n d a r e a va ila ble sepa r a t ely.

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—5066 Seal Protector—6992

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)

Installer, Pump Housing Seal—7888 Installer, Bearing—8033-A

Installer, Boot Clamp—C-4975-A


XJ TRANSMISSION AND TRANSFER CASE 21 - 1

TRANSMISSION AND TRANSFER CASE


CON T EN T S

page page

AX15 MANUAL TRANSMISSION . . . . . . . . . . . . . 1 NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . . 7

AX 1 5 M AN U AL T RAN SM I SSI ON

INDEX
page page

GENERAL INFORMATION DIAGNOSIS AND TESTING


AX 15 MANUAL TRANSMISSION . . . . . . . . . . . . . 1 HARD SHIFTING . . . . . . . . . . ............... 3
TRANSMISSION ASSEMBLY INFORMATION . . . . 3 LOW LUBRICANT LEVEL . . . . ............... 3

-
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

GEN ERAL I N FORM AT I ON r a t io of 0.79:1. Th e sh ift m ech a n ism is in t egr a l a n d


m ou n t ed in t h e sh ift t ower por t ion of t h e a da pt er
AX 15 MANUAL TRANSMISSION h ou sin g (F ig. 1).
Th e AX 15 is a 5–speed, syn ch r om esh , m a n u a l
t r a n sm ission . F ift h gea r is a n over dr ive r a n ge wit h a

J8921-1023

Fig. 1 AX 15 Manual Transmission


21 - 2 TRANSMISSION AND TRANSFER CASE XJ
GEN ERAL I N FORM AT I ON (Cont inue d)

TRANSMISSION IDENTIFICATION Cor r ect lu br ica n t level is fr om t h e bot t om edge, t o


Th e AX 15 iden t ifica t ion code n u m ber s a r e on t h e n o m or e t h a n 6 m m (1/4 in .) below t h e bot t om edge of
bot t om su r fa ce of t h e t r a n sm ission gea r ca se (F ig. 2). t h e fill plu g h ole.
Th e fir st n u m ber is yea r of m a n u fa ct u r e. Th e sec- Appr oxim a t e dr y fill lu br ica n t ca pa cit y is:
,- • 3.10 lit er s (3.27 qt s.) in 4–wh eel dr ive m odels
@ TRANSMISSION SWITCH AND PLUG
INTERMEDIATE
LOCATIONS
PLATE :-'\ Th e fill plu g is a t t h e dr iver side of t h e gea r ca se
(F ig. 4).

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. '

TRANSMISSION SHIFT PATTERN


Th e AX 15 sh ift pa t t er n is sh own in (F ig. 3). F ir st
a n d secon d a n d t h ir d a n d fou r t h gea r r a n ges a r e in
' Fig. 4 Fill Plug Location
Th e dr a in plu g a n d ba cku p ligh t swit ch a r e on t h e
lin e for im pr oved sh ift in g. F ift h a n d r ever se gea r pa ssen ger side of t h e gea r ca se (F ig. 5).
r a n ges a r e a lso in lin e a t t h e ext r em e r igh t of t h e
pa t t er n (F ig. 3).

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)

TRANSMISSION GEAR RATIOS Su bst a n t ia l lu br ica n t lea ks ca n r esu lt in gea r, sh ift


AX 15 gea r r a t ios a r e: 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 dica -
F ir st gea r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.83:1 t ion s of a pr oblem a r e u su a lly h a r d sh ift in g a n d
Secon d gea r . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33:1 n oise.
Th ir d gea r . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44:1 In cor r ect or con t a m in a t ed lu br ica n t s ca n a lso con -
F ou r t h gea r . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1 t r ibu t e t o h a r d sh ift in g. Th e con sequ en ce of u sin g
F ift h gea r . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.79:1 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.
Rever se . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22:1
Im pr oper clu t ch r elea se is a fr equ en t ca u se of h a r d
TRANSMISSION ASSEMBLY INFORMATION sh ift in g. In cor r ect a dju st m en t or a wor n , da m a ged
Lu br ica t e t h e t r a n sm ission com pon en t s wit h gea r pr essu r e pla t e or disc ca n ca u se in cor r ect r elea se. If
lu br ica n t du r in g a ssem bly. Use pet r oleu m jelly t o t h e clu t ch pr oblem is a dva n ced, gea r cla sh du r in g
lu br ica t e sea l lips a n d/or h old pa r t s in pla ce du r in g sh ift s ca n r esu lt .
in st a lla t ion . Wor n or da m a ged syn ch r o r in gs ca n ca u se gea r
cla sh wh en sh ift in g in t o a n y for wa r d gea r. In som e
n ew or r ebu ilt t r a n sm ission s, n ew syn ch r o r in gs m a y
DI AGN OSI S AN D T EST I N G t en d t o st ick sligh t ly ca u sin g h a r d or n oisy sh ift s. In
m ost ca ses, t h is con dit ion will declin e a s t h e r in gs
LOW LUBRICANT LEVEL wea r –in .
A low t r a n sm ission lu br ica n t level is gen er a lly t h e
r esu lt of a lea k, in a dequ a t e lu br ica n t fill, or a n in cor- TRANSMISSION NOISE
r ect lu br ica n t level ch eck. Most m a n u a l t r a n sm ission s m a ke som e n oise du r-
Lea ks ca n occu r a t t h e m a t in g su r fa ces of t h e gea r in g n or m a l oper a t ion . Rot a t in g gea r s ca n gen er a t e a
ca se, in t er m edia t e pla t e a n d a da pt er or ext en sion m ild wh in e t h a t m a y on ly be a u dible a t ext r em e
h ou sin g, or fr om t h e fr on t /r ea r sea ls. A su spect ed speeds.
lea k cou ld a lso be t h e r esu lt of a n over fill con dit ion . Sever e, obviou sly a u dible t r a n sm ission n oise is
Lea ks a t t h e r ea r of t h e ext en sion or a da pt er h ou s- gen er a lly t h e r esu lt of a lu br ica n t pr oblem . In su ffi-
in g will be fr om t h e h ou sin g oil sea ls. Lea ks a t com - cien t , im pr oper, or con t a m in a t ed lu br ica n t ca n pr o-
pon en t m a t in g su r fa ces will u su a lly be t h e r esu lt of m ot e r a pid wea r of gea r s, syn ch r os, sh ift r a ils, for ks
in a dequ a t e sea ler, ga ps in t h e sea ler, in cor r ect bolt a n d bea r in gs. Th e over h ea t in g ca u sed by a lu br ica n t
t igh t en in g, or u se of a n on –r ecom m en ded sea ler. pr oblem , ca n a lso lea d t o gea r br ea ka ge.
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
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.
Lu br ica n t m a y be seen dr ippin g fr om t h e clu t ch REM OVAL AN D I N STALLAT I ON
h ou sin g a ft er ext en ded oper a t ion . If t h e lea k is
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- TRANSMISSION
in g slip, gr a b a n d ch a t t er.
Tr a n sm ission s filled fr om a ir or elect r ica lly pow- REMOVAL
er ed lu br ica n t con t a in er s ca n be u n der filled. Th is 1. Discon n ect t h e ba t t er y n ega t ive ca ble.
gen er a lly h a ppen s wh en t h e con t a in er deliver y m ech - 2. Rem ove t h e sh ift er boot a n d sh ift er.
a n ism is im pr oper ly ca libr a t ed. Alwa ys ch eck t h e 3. Ra ise t h e veh icle on a h oist .
lu br ica n t level a ft er fillin g t o a void a n u n der fill con - 4. Dr a in t h e t r a n sm ission flu id (F ig. 6).
dit ion . 5. Su ppor t t h e en gin e a n d t r a n sm ission wit h a n
A cor r ect lu br ica n t level ch eck ca n on ly be m a de a dju st a ble ja ck st a n d.
wh en t h e veh icle is level; u se a dr ive–on h oist t o 6. Rem ove exh a u st pipe a n d h ea t sh ield.
en su r e t h is. Also a llow t h e lu br ica n t t o set t le for a 7. Ma r k t h e fr on t a n d r ea r pr opeller sh a ft s for
m in u t e or so befor e ch eckin g. Th ese r ecom m en da - in st a lla t ion a lign m en t (F ig. 7).
t ion s will en su r e a n a ccu r a t e ch eck a n d a void a n 8. Rem ove t h e fr on t pr opeller sh a ft .
u n der –or –over fill con dit ion . 9. Rem ove t h e r ea r pr opeller sh a ft .
10. Rem ove t h e t r a n sm ission skid pla t e.
HARD SHIFTING 11. Discon n ect t h e t r a n sfer ca se lin ka ge a n d veh i-
H a r d sh ift in g is u su a lly ca u sed by a low lu br ica n t cle speed sen sor elect r ica l con n ect or a n d ven t t u be
level, im pr oper or con t a m in a t ed lu br ica n t s, com po- h ose (F ig. 8).
n en t da m a ge, in cor r ect clu t ch a dju st m en t , or by a 12. Reposit ion t h e a dju st a ble ja ckst a n d u n der t h e
da m a ged clu t ch pr essu r e pla t e or disc. en gin e.
21 - 4 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
SENSOR
ELECTRICAL
CONNECTOR

4WD
Fig. 6 Drain Plug and Backup Light Switch Location TRANSFER
VEHICLE CASE
SPEED EXTENSION
SENSOR
80a35409

Fig. 8 Vehicle Speed Sensor

Fig. 7 Marking Propeller Shaft and Axle Yoke


13. P la ce a t r a n sm ission ja ck u n der t h e t r a n sm is-
sion a n d secu r e t h e t r a n sm ission wit h sa fet y ch a in s.
14. Rem ove t h e r ea r t r a n sm ission m ou n t .
15. Rem ove t h e r ea r cr ossm em ber.
16. Rem ove t h e t r a n sfer ca se a ssem bly. Refer t o
Fig. 9 Engine Speed Sensor
Tr a n sfer Ca se r em ova l la t er in t h is Gr ou p.
17. Lower t h e en gin e a n d t r a n sm ission n o m or e 2. In st a ll t h e t r a n sm ission t o t h e veh icle (F ig. 10).
t h a n 7.6 cm . 3. In st a ll t h e t wo (2) lower t r a n sm ission bolt s.
18. Rem ove t h e t wo (2) u pper a n d t wo (2) m id Tigh t en t h e bolt s t o 74.6 N·m .
clu t ch h ou sin g t o en gin e bolt s. 4. In st a ll t h e clu t ch sla ve cylin der t o t h e clu t ch
19. Rem ove t h e en gin e speed sen sor (cr a n ksh a ft h ou sin g.
posit ion sen sor ) (F ig. 9). 5. In st a ll t h e en gin e speed sen sor (cr a n ksh a ft posi-
20. Rem ove t h e clu t ch sla ve cylin der fr om t h e t ion sen sor ) t o t h e veh icle (F ig. 9).
clu t ch h ou sin g. 6. In st a ll t h e t wo (2) u pper clu t ch h ou sin g t o
21. Rem ove t h e lower t r a n sm ission bolt s. en gin e bolt s. Tigh t en t h e bolt s t o 36.6 N·m .
22. Rem ove t h e t r a n sm ission a ssem bly fr om t h e 7. In st a ll t h e t wo (2) m id clu t ch h ou sin g t o en gin e
veh icle. bolt s. Tigh t en t h e bolt s t o 58.3 N·m .
8. Ra ise t h e en gin e a n d t r a n sm ission wit h t h e
INSTALLATION a dju st a ble ja ckst a n d.
1. Mou n t t h e t r a n sm ission on a t r a n sm ission ja ck 9. In st a ll t h e t r a n sfer ca se a ssem bly. Refer t o
a n d secu r e t h e t r a n sm ission wit h sa fet y ch a in s. Tr a n sfer Ca se in st a lla t ion la t er in t h is Gr ou p.
10. In st a ll t h e r ea r cr ossm em ber.
XJ TRANSMISSION AND TRANSFER CASE 21 - 5
REM OVAL AN D I N STALLAT I ON (Cont inue d)

CLUTCH HOUSING
AND TRANSMISSION

CLUTCH COVER
80abfe70

Fig. 10 Transmission to Engine Mounting


TRANSMISSION 13. In st a ll t h e t r a n sm ission skid pla t e.
14. Align a n d in st a ll t h e fr on t a n d r ea r pr opeller
sh a ft s.
15. In st a ll t h e exh a u st pipe a n d h ea t sh ield.
16. Rem ove t h e t r a n sm ission ja ck.
17. F ill t h e t r a n sm ission wit h t h e pr oper flu id
(F ig. 12).

CLUTCH
HOUSING BOLT 80ad087e

Fig. 11 Clutch Housing to Transmission


11. In st a ll t h e r ea r t r a n sm ission m ou n t . Fig. 12 Fill Plug Location
12. Con n ect t h e t r a n sfer ca se lin ka ge a n d veh icle 18. Rem ove t h e a dju st a ble ja ckst a n d fr om u n der
speed sen sor elect r ica l con n ect or a n d ven t t u be (F ig. t h e en gin e.
8).
21 - 6 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
19. Lower t h e veh icle fr om t h e h oist . SPECI FI CAT I ON S
20. In st a ll t h e sh ift er boot a n d sh ift er.
21. Recon n ect t h e ba t t er y n ega t ive ca ble. TORQUE
D ES CRIP TION TORQU E
Clu t ch H ou sin g t o E n gin e Top (2) Bolt s . . . 36.6 N·m
(27 ft . lbs.)
Clu t ch H ou sin g t o E n gin e Mid-P oin t (2) Bolt s . 58.3
N·m (43 ft . lbs.)
Clu t ch H ou sin g t o E n gin e Bot t om (2) Bolt s . . . 74.6
N·m (55 ft . lbs.)
Clu t ch H ou sin g t o Tr a n sm ission bolt s . 38.0 N·m (28
ft . lbs.)
Tr a n sfer Ca se t o Tr a n sm ission At t a ch in g Nu t s . . 35
N·m (26 ft . lbs.)
P r opeller Sh a ft Bolt s . . . . . . 26.5 N·m (19.5 ft . lbs.)
XJ TRANSMISSION AND TRANSFER CASE 21 - 7

N V 2 3 1 T RAN SFER CASE

INDEX
page page

GENERAL INFORMATION REAR RETAINER BUSHING AND SEAL . . . . . . . 11


NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . . 7 SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RECOMMENDED LUBRICANT AND FILL LEVEL . 7 SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 9
TRANSFER CASE IDENTIFICATION . . . . . . . . . . 7 TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING SPECIFICATIONS
NV231 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 8 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL AND INSTALLATION SPECIAL TOOLS
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . . . 11 SPECIAL TOOLS—NV231 . . . . . . . . . . . . . . . . . 12

GEN ERAL I N FORM AT I ON 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
NV231 TRANSFER CASE sh ift lever. Th e sh ift lever is con n ect ed t o t h e t r a n s-
Th e NV231 is a pa r t -t im e t r a n sfer ca se wit h a low fer ca se r a n ge lever by a n a dju st a ble lin ka ge r od. A
r a n ge r edu ct ion gea r syst em . Th e NV231 h a s t h r ee st r a igh t lin e sh ift pa t t er n is u sed. Ra n ge posit ion s
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 a r e m a r ked on t h e sh ift er bezel cover pla t e.
syst em pr ovides a r edu ct ion r a t io for in cr ea sed low
speed t or qu e ca pa bilit y. TRANSFER CASE IDENTIFICATION
Th e in pu t gea r is splin ed t o t h e t r a n sm ission ou 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
pu t sh a ft . Th e in pu t gea r dr ives t h e m a in sh a ft ea ch t r a n sfer ca se (F ig. 1). Th e ID t a g pr ovides t h e
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 t r a n sfer ca se m odel n u m ber, a ssem bly n u m ber, ser ia l
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 n u m ber, a n d low r a n ge r a t io.
con n ect s t h e sh a ft t o a dr ive spr ocket on t h e m a in - Th e t r a n sfer ca se ser ia l n u m ber a lso r epr esen t s
sh a ft . Th e dr ive spr ocket is en ga ged/disen ga ged by t h e da t e of bu ild.
t h e m ode for k, wh ich oper a t es t h e m ode sleeve a n d
h u b. Th e sleeve a n d h u b a r e n ot equ ipped wit h a
syn ch r on izer m ech a n ism for sh ift in g.
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. 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

DI AGN OSI S AN D T EST I N G

NV231 DIAGNOSIS
DI AGN OSI S CH ART

Condition Possible Cause Correction


Transfer case difficult to shift or will 1) Vehicle speed to great to permit 1) Slow vehicle and shift into
not shift into desired range. shifting. desired range.
2) If vehicle was operated for an 2) Stop vehicle and shift transfer
extended period in 4H mode on dry case to Neutral position. Transfer
surface, driveline torque load may case can then be shifted to the
cause difficulty. desired mode.
3) Transfer case shift linkage 3) Repair or replace linkage as
binding. necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill transfer case with
the correct type and quantity of
lubricant.
5) Internal transfer case 5) 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.
Transfer case noisy while in, or 1) Transfer case not completely 1) Slow vehicle, shift transfer case
jumps out of, 4L mode. engaged in 4L position. to the Neutral position, and then
shift into the 4L mode.
2) Transfer case shift linkage out of 2) Adjust linkage as necessary.
adjustment.
3) Transfer case shift linkage loose 3) Repair, replace, or tighten linkage
or binding. components as necessary.
4) Range fork damaged, inserts 4) Repair or replace components as
worn, or fork is binding on the shift necessary.
rail.
5) Low range gear worn or 5) Repair or replace components as
damaged. necessary.
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.
Abnormal tire wear. 1) Extended operation in 4H mode 1) Operate vehicle in 2H mode on
on dry surfaces. dry surfaces.
XJ TRANSMISSION AND TRANSFER CASE 21 - 9

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.

NOTE: Do no reuse bearing straps or bolts. Discard


REMOVAL
and replace with new.
(1) Sh ift t r a n sfer ca se in t o Neu t r a l.
(2) Ra ise veh icle. (8) Align a n d con n ect pr opeller sh a ft s. Tigh t en
(3) Dr a in t r a n sfer ca se lu br ica n t . sh a ft a t t a ch in g bolt s t o 26.5 N·m t or qu e.
(4) Ma r k fr on t a n d r ea r pr opeller sh a ft yokes for (9) F ill t r a n sfer ca se wit h cor r ect flu id. Refer t o
a lign m en t r efer en ce. Recom m en ded Lu br ica n t An d F ill Level sect ion for
(5) Su ppor t t r a n sm ission wit h ja ck st a n d. pr oper flu id a n d ca pa cit y.
(6) Rem ove r ea r cr ossm em ber a n d skid pla t e, if (10) In st a ll r ea r cr ossm em ber a n d skid pla t e, if
equ ipped. equ ipped. Tigh t en cr ossm em ber bolt s.
(7) Discon n ect a n d su ppor t fr on t /r ea r pr opeller (11) Rem ove t r a n sm ission ja ck a n d su ppor t st a n d.
sh a ft s a t t r a n sfer ca se. (12) Con n ect sh ift r od t o t r a n sfer ca se r a n ge lever.
(8) Discon n ect veh icle speed sen sor wir es. (13) Adju st t r a n sfer ca se sh ift lin ka ge.
(9) Discon n ect t r a n sfer ca se lin ka ge r od fr om (14) Lower veh icle a n d ver ify t r a n sfer ca se sh ift
r a n ge lever. oper a t ion .
(10) Discon n ect t r a n sfer ca se ven t h ose (F ig. 2)
a n d in dica t or swit ch h a r n ess, if n ecessa r y. SHIFT LEVER
(11) Su ppor t t r a n sfer ca se wit h t r a n sm ission ja ck.
(12) Secu r e t r a n sfer ca se t o ja ck wit h ch a in s. REMOVAL
(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- (1) Sh ift t r a n sfer ca se in t o 4L.
m ission . (2) Rem ove t r a n sfer ca se sh ift er kn ob ca p.
(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 - (3) Rem ove n u t h oldin g sh ift er kn ob t o sh ift lever.
ga ge t r a n sfer ca se. (4) Rem ove sh ift er kn ob.
(15) Rem ove t r a n sfer ca se fr om u n der veh icle. (5) Ra ise a n d su ppor t veh icle.
(6) Loosen a dju st in g t r u n n ion lock bolt a n d slide
sh ift r od ou t of t r u n n ion (F ig. 3). If r od la cks en ou gh
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
sh ift lever.
(7) Rem ove bolt s h oldin g sh ift lever t o t r a n sm is-
sion .
(8) Sepa r a t e sh ift lever fr om veh icle.

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.

INSTALLATION AND INDEXING


(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 (F ig. 4), if n ecessa r y.
(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.
(4) In st a ll veh icle speed sen sor in speedom et er
SHIFT a da pt er. Tigh t en sen sor a t t a ch in g scr ew t o 2-3 N·m
LEVER (15-27 in . lbs.) t or qu e.
(5) In st a ll speedom et er pin ion in a da pt er.
(6) Cou n t n u m ber of t eet h on speedom et er pin ion .
Do t h is befor e in st a llin g a ssem bly in h ou sin g. Th en
80a9b39c
lu br ica t e pin ion t eet h wit h t r a n sm ission flu id.
(7) Not e in dex n u m ber s on a da pt er body (F ig. 5).
Fig. 3 Shift Lever Th ese n u m ber s will cor r espon d t o n u m ber of t eet h on
pin ion .
(3) Rem ove a da pt er cla m p a n d scr ew (F ig. 4).
(8) In st a ll speedom et er a ssem bly in h ou sin g.
(4) Rem ove speed sen sor a n d speedom et er a da pt er
a s a n a ssem bly.

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

Fig. 4 Speedometer Components


XJ TRANSMISSION AND TRANSFER CASE 21 - 11
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(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 INSTALLATION
a r e a t 6 o-clock posit ion . Be su r e r a n ge in dex n u m - (1) In st a ll n ew fr on t ou t pu t sea l in fr on t ca se wit h
ber s cor r espon d t o n u m ber of t eet h on pin ion gea r. In st a ller Tool 8143 a s follows:
(10) In st a ll speedom et er a da pt er cla m p a n d r et a in - (a ) P la ce n ew sea l on t ool. Ga r t er spr in g on sea l
in g scr ew. Tigh t en cla m p scr ew t o 10-12 N·m (90-110 goes t owa r d in t er ior of ca se.
in . lbs.) t or qu e. (b) St a r t sea l in bor e wit h ligh t t a ps fr om h a m -
(11) Con n ect wir es t o veh icle speed sen sor. m er (F ig. 7). On ce sea l is st a r t ed, con t in u e t a ppin g
(12) Lower veh icle a n d t op off t r a n sm ission flu id 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.
level if n ecessa r y.
SPEEDOMETER
ADAPTER

-----------------
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

Fig. 8 Rear Retainer Bushing Removal


Fig. 6 Remove Front Output Shaft Seal
21 - 12 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION SPECI AL T OOLS
(1) Clea n flu id r esidu e fr om sea lin g su r fa ce a n d
in spect for defect s. SPECIAL TOOLS—NV231
(2) P osit ion r epla cem en t bu sh in g in r ea r r et a in er
wit h flu id por t in bu sh in g a lign ed wit h slot in r et a in er.
(3) Usin g In st a ller 8160, dr ive bu sh in g in t o
r et a in er u n t il in st a ller sea t s a ga in st ca se (F ig. 9).
(4) Usin g In st a ller C-3995-A, in st a ll sea l in r ea r
r et a in er (F ig. 10).

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.

SPECI FI CAT I ON S Installer, Seal—C-3995-A

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

TIRES AND WHEELS


CON T EN T S

page page

TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

T I RES

INDEX
page page

DESCRIPTION AND OPERATION TIRE WEAR PATTERNS . . . . ................ 3


RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . . . . 2 TREAD WEAR INDICATORS ................ 3
REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . . . 3 SERVICE PROCEDURES
SPARE TIRE–TEMPORARY . . . . . . . . . . . . . . . . . 2 MATCH MOUNTING . . . . . . . ................ 4
TIRE INFLATION PRESSURES . . . . . . . . . . . . . . 2 REPAIRING LEAKS . . . . . . . ................ 5
TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . . . 1 ROTATION . . . . . . . . . . . . . . ................ 4
TIRE PRESSURE FOR HIGH SPEED CLEANING AND INSPECTION
OPERATION . . . . . . . . . . . . . . . . . .......... 3 CLEANING TIRES . . . . . . . . ................ 6
DIAGNOSIS AND TESTING SPECIFICATIONS
PRESSURE GAUGES . . . . . . . . . . . .......... 3 TIRE SIZE . . . . . . . . . . . . . . ................ 6
TIRE NOISE OR VIBRATION . . . . . . .......... 4

DESCRI PT I ON AN D OPERAT I ON TIRE IDENTIFICATION


Tir e t ype, size, a spect r a t io a n d speed r a t in g a r e
TIRE INFORMATION en coded in t h e let t er s a n d n u m ber s im pr in t ed on t h e
Tir es a r e design ed a n d en gin eer ed for ea ch specific side wa ll of t h e t ir e. Refer t o t h e ch a r t t o deciph er
veh icle. Th ey pr ovide t h e best over a ll per for m a n ce t h e t ir e iden t ifica t ion code (F ig. 1).
for n or m a l oper a t ion . Th e r ide a n d h a n dlin g ch a r a c- P er for m a n ce t ir es h a ve a speed r a t in g let t er a ft er
t er ist ics m a t ch t h e veh icle’s r equ ir em en t s. Wit h t h e a spect r a t io n u m ber.
pr oper ca r e t h ey will give excellen t r elia bilit y, t r a c-
t ion , skid r esist a n ce, a n d t r ea d life. LETTER SPEED RATING
Dr ivin g h a bit s h a ve m or e effect on t ir e life t h a n S 180 km/h (112 mph)
a n y ot h er fa ct or. Ca r efu l dr iver s will obt a in in m ost T 190 km/h (118 mph)
ca ses, m u ch gr ea t er m ilea ge t h a n sever e u se or ca r e-
U 200 km/h (124 mph)
less dr iver s. A few of t h e dr ivin g h a bit s wh ich will
sh or t en t h e life of a n y t ir e a r e: H 210 km/h (130 mph)
• Ra pid a cceler a t ion V 240 km/h (149 mph)
• Sever e br a ke a pplica t ion s W 270 km/h (168 mph)
• H igh speed dr ivin g
• E xcessive speeds on t u r n s
• St r ikin g cu r bs a n d ot h er obst a cles
Ra dia l-ply t ir es a r e m or e pr on e t o ir r egu la r t r ea d
wea r. It is im por t a n t t o follow t h e t ir e r ot a t ion in t er-
va l sh own in t h e sect ion on Tir e Rot a t ion . Th is will
h elp t o a ch ieve a gr ea t er t r ea d life.
Y

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

Tir e sn ow ch a in s m a y be u sed on c e rta in m odels.


-
Refer t o t h e Own er ’s Ma n u a l for m or e in for m a t ion .
22 - 2 TIRES AND WHEELS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

METRIC TIRE SIZES TIRE INFLATION PRESSURES


P 205 / 75 R 15 Un der in fla t ion will ca u se r a pid sh ou lder wea r, 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

SECTION Fig. 2 Under Inflation Wear


HEIGHT
Over in fla t ion will ca u se r a pid cen t er wea r a n d

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

WARNING: OVER OR UNDER INFLATED TIRES PRESSURE GAUGES


CAN AFFECT VEHICLE HANDLING AND TREAD A qu a lit y a ir pr essu r e ga u ge is r ecom m en ded t o
WEAR. THIS MAY CAUSE THE TIRE TO FAIL SUD- ch eck t ir e pr essu r e. Aft er ch eckin g t h e a ir pr essu r e,
DENLY, RESULTING IN LOSS OF VEHICLE CON- r epla ce va lve ca p fin ger t igh t .
TROL.
TREAD WEAR INDICATORS
Tr ea d wea r in dica t or s a r e m olded in t o t h e bot t om
TIRE PRESSURE FOR HIGH SPEED of t h e t r ea d gr ooves. Wh en t r ea d dept h is 1.6 m m
OPERATION (1/16 in .), t h e t r ea d wea r in dica t or s will a ppea r a s a
Ch r ysler Cor por a t ion a dvoca t es dr ivin g a t sa fe 13 m m (1/2 in .) ba n d (F ig. 4).
speeds wit h in post ed speed lim it s. Wh er e speed lim - Tir e r epla cem en t is n ecessa r y wh en in dica t or s
it s a llow t h e veh icle t o be dr iven a t h igh speeds, cor- a ppea r in t wo or m or e gr ooves or if loca lized ba ldin g
r ect t ir e in fla t ion pr essu r e is ver y im por t a n t . F or occu r s.
speeds u p t o a n d in clu din g 120 km /h (75 m ph ), t ir es TREAD TREAD
m u st be in fla t ed t o t h e pr essu r es sh own on t h e t ir e ACCEPTABLE UNACCEPTABLE ,_
pla ca r d.
Veh icles loa ded t o t h e m a xim u m ca pa cit y sh ou ld
n ot be dr iven a t con t in u ou s speeds a bove 75 m ph
- ""-

(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)

CONDITION CRACKED TREADS BALD SPOTS SCALLOPED WEAR

EFFECT

UNBALANCED
EXCESSIVE CAMBER INCORRECT TOE
WHEEL LACK OF
ROTATION

It
UNDER-INFLATION / OF TIRES
CAUSE OR OR

EXCESSIVE SPEED* WORN OR OUT-


OF-ALIGNMENT
SUSPENSION.
OR TIRE DEFECT*
ADJUST PRESSURE TO
ADJUST CAMBER ADJUST TOE-IN DYNAMIC OR ROTATE TIRES AND
CORRECTION SPECIFICATIONS WHEN
TIRES ARE COOL TO TO STATIC INSPECT SUSPENSION
ROTATE TIRES SPECIFICATIONS SPECIFICATIONS BALANCE WHEELS SEE GROUP 2

*HAVE TIRE INSPECTED FOR FURTHER USE. RN797

Fig. 5 Tire Wear Patterns


TIRE NOISE OR VIBRATION
Ra dia l-ply t ir es a r e sen sit ive t o for ce im pu lses
ca u sed by im pr oper m ou n t in g, vibr a t ion , wh eel
defect s, or possibly t ir e im ba la n ce. ( ] ( ]
To fin d ou t if t ir es a r e ca u sin g t h e n oise or vibr a -
t ion , dr ive t h e veh icle over a sm oot h r oa d a t va r yin g FRONT
speeds. Not e t h e n oise level du r in g a cceler a t ion ,
deceler a t ion a n d sligh t left a n d r igh t st eer in g in pu t s.
( ] ( ]
SERV I CE PROCEDU RES
8031e864
ROTATION
Tir es on t h e fr on t a n d r ea r oper a t e a t differ en t Fig. 6 Tire Rotation Pattern
loa ds a n d per for m differ en t st eer in g, dr ivin g, a n d r im a n d a dot on t h e in side of t h e r im . If t h e ou t side
br a kin g fu n ct ion s. F or t h ese r ea son s t h ey wea r a t la bel h a s been r em oved t h e t ir e will h a ve t o be
u n equ a l r a t es a n d t en d t o develop ir r egu la r wea r r em oved t o loca t e t h e dot on t h e in side of t h e r im .
pa t t er n s. Th ese effect s ca n be r edu ced by r ot a t in g Befor e dism ou n t in g a t ir e fr om it s wh eel, a r efer-
t h e t ir es a t r egu la r in t er va ls. Th e ben efit s of t ir e en ce m a r k sh ou ld be pla ced on t h e t ir e a t t h e va lve
r ot a t ion a r e: st em loca t ion . Th is r efer en ce will en su r e t h a t it is
• In cr ea se t r ea d life r em ou n t ed in t h e or igin a l posit ion on t h e wh eel.
• Ma in t a in t r a ct ion levels (1) Use a dia l in dica t or t o loca t e t h e h igh spot of
• A sm oot h , qu iet r ide t h e t ir e on t h e cen t er t r ea d r ib (F ig. 7). Recor d t h e
Th e su ggest ed m et h od of t ir e r ot a t ion is (F ig. 6). in dica t or r ea din g a n d m a r k t h e h igh spot on t h e t ir e.
Ot h er r ot a t ion m et h ods ca n be u sed, bu t t h ey will P la ce a m a r k on t h e t ir e a t t h e va lve st em loca t ion
n ot pr ovide a ll t h e t ir e lon gevit y ben efit s. (F ig. 8).
(2) Br ea k down t h e t ir e a n d r em ou n t it 180
MATCH MOUNTING degr ees on t h e r im (F ig. 9).
Tir es a n d wh eels a r e cu r r en t ly m a t ch m ou n t ed a t (3) Mea su r e t h e t ot a l r u n ou t a ga in a n d m a r k t h e
t h e fa ct or y. Ma t ch m ou n t in g is a t ech n iqu e u sed t o t ir e t o in dica t e t h e h igh spot .
r edu ce r u n ou t in t h e wh eel/t ir e a ssem bly. Th is m ea n s (4) If r u n ou t is st ill excessive u se t h e followin g
t h a t t h e h igh spot of t h e t ir e is a lign ed wit h t h e low pr ocedu r es.
spot on t h e wh eel r im . Th e h igh spot on t h e t ir e is (a ) If t h e h igh spot is wit h in 101.6 m m (4.0 in .)
m a r ked wit h a pa in t m a r k or a br igh t color ed a dh e- of t h e fir st spot a n d is st ill excessive, r epla ce t h e
sive la bel on t h e ou t boa r d sidewa ll. Th e low spot on t ir e.
t h e r im is iden t ified wit h a la bel on t h e ou t side of t h e
XJ TIRES AND WHEELS 22 - 5
SERV I CE PROCEDU RES (Cont inue d)

VALVE STEM

Fig. 7 Dial Indicator

REFERENCE 1ST MEASUREMENT


MARK HIGH SPOT MARK
TIRE AND RIM

VALVE
STEM I REFERENCE
MARK J9322-4

Fig. 9 Remount Tire 180 Degrees


2ND HIGH SPOT
ON TIRE

J9322-3

Fig. 8 First Measurement On Tire


(b) If t h e h igh spot is wit h in 101.6 m m (4.0 in .)
of t h e fir st spot on t h e wh eel, t h e wh eel m a y be ou t
of specifica t ion s. Refer t o Wh eel a n d Tir e Ru n ou t .
(c) If t h e h igh spot is NOT wit h in 101.6 m m (4.0
in .) of eit h er h igh spot , dr a w a n a r r ow on t h e t r ea d J9322-5
fr om secon d h igh spot t o fir st . Br ea k down t h e t ir e
a n d r em ou n t it 90 degr ees on r im in t h a t dir ect ion
Fig. 10 Remount Tire 90 Degrees In Direction of
(F ig. 10). Th is pr ocedu r e will n or m a lly r edu ce t h e
Arrow
r u n ou t t o a n a ccept a ble a m ou n t .
solu t ion wh en dism ou n t in g or m ou n t in g t ir e. Use
REPAIRING LEAKS t ools fr ee of bu r r s or sh a r p edges wh ich cou ld da m -
F or pr oper r epa ir in g, a r a dia l t ir e m u st be r em oved a ge t h e t ir e or wh eel r im .
fr om t h e wh eel. Repa ir s sh ou ld on ly be m a de if t h e Befor e m ou n t in g t ir e on wh eel, m a ke su r e a ll r u st
defect , or pu n ct u r e, is in t h e t r ea d a r ea (F ig. 11). Th e is r em oved fr om t h e r im bea d a n d r epa in t if n eces-
t ir e sh ou ld be r epla ced if t h e pu n ct u r e is loca t ed in sa r y.
t h e sidewa ll. In st a ll wh eel on veh icle, a n d t igh t en t o pr oper
Defla t e t ir e com plet ely befor e r em ovin g t h e t ir e t or qu e specifica t ion .
fr om t h e wh eel. Use lu br ica t ion su ch a s a m ild soa p
22 - 6 TIRES AND WHEELS XJ
SERV I CE PROCEDU RES (Cont inue d)

....---- REPAIRABLE -------. CLEAN I N G AN D I N SPECT I ON


AREA

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.

NOTE: DO NOT use gasoline, mineral oil, oil-based


solvent or wire brush for cleaning.

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

DESCRIPTION AND OPERATION SERVICE PROCEDURES


WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TIRE AND WHEEL BALANCE . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . 8
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . . 7 SPECIFICATIONS
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . 7 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 10

DESCRI PT I ON AN D OPERAT I ON of t h e wh eels. Do n ot u se r epla cem en t st u ds or n u t s


wit h a differ en t design or lesser qu a lit y.
WHEEL
Th e r im size is on t h e veh icle sa fet y cer t ifica t ion DI AGN OSI S AN D T EST I N G
la bel loca t ed on t h e dr iver s door sh u t fa ce. Th e size
of t h e r im is det er m in ed by t h e dr ivet r a in pa cka ge.
WHEEL INSPECTION
Or igin a l equ ipm en t wh eels/r im s a r e design ed for
In spect wh eels for :
oper a t ion u p t o t h e specified m a xim u m veh icle ca pa c-
• E xcessive r u n ou t
it y.
• Den t s or cr a cks
All m odels u se st a m ped st eel, ca st a lu m in u m or
• Da m a ged wh eel lu g n u t h oles
for ged a lu m in u m wh eels. E ver y wh eel h a s r a ised sec-
• Air Lea ks fr om a n y a r ea or su r fa ce of t h e r im
t ion s bet ween t h e r im fla n ges a n d r im dr op well
ca lled sa fet y h u m ps (F ig. 1). NOTE: Do not attempt to repair a wheel by ham-
mering, heating or welding.

If a wh eel is da m a ged a n or igin a l equ ipm en t


r epla cem en t wh eel sh ou ld be u sed. Wh en obt a in in g
r epla cem en t wh eels, t h ey sh ou ld be equ iva len t in
loa d ca r r yin g ca pa cit y. Th e dia m et er, widt h , offset ,
pilot h ole a n d bolt cir cle of t h e wh eel sh ou ld be t h e
sa m e a s t h e or igin a l wh eel.

WARNING: FAILURE TO USE EQUIVALENT


REPLACEMENT WHEELS MAY ADVERSELY AFFECT
THE SAFETY AND HANDLING OF THE VEHICLE.
USED WHEELS ARE NOT RECOMMENDED. THE
SERVICE HISTORY OF THE WHEEL MAY HAVE
INCLUDED SEVERE TREATMENT OR VERY HIGH
MILEAGE. THE RIM COULD FAIL WITHOUT WARN-
ING.

Fig. 1 Safety Rim TIRE AND WHEEL RUNOUT


In it ia l in fla t ion of t h e t ir e for ces t h e bea d over Ra dia l r u n ou t is t h e differ en ce bet ween t h e h igh
t h ese r a ised sect ion s. In ca se of r a pid loss of a ir pr es- a n d low poin t s on t h e t ir e or wh eel (F ig. 2).
su r e, t h e r a ised sect ion s h elp h old t h e t ir e on t h e La t er a l r u n ou t is t h e w o bble of t h e t ir e or wh eel.
wh eel. Ra dia l r u n ou t of m or e t h a n 1.5 m m (.060 in ch )
Th e wh eel st u ds a n d n u t s a r e design ed for specific m ea su r ed a t t h e cen t er lin e of t h e t r ea d m a y ca u se
a pplica t ion s. All a lu m in u m a n d som e st eel wh eels t h e veh icle t o sh a ke.
h a ve wh eel st u d n u t s wit h a n en la r ged n ose. Th is La t er a l r u n ou t of m or e t h a n 2.0 m m (.080 in ch )
en la r ged n ose is n ecessa r y t o en su r e pr oper r et en t ion m ea su r ed n ea r t h e sh ou lder of t h e t ir e m a y ca u se t h e
veh icle t o sh a ke.
22 - 8 TIRES AND WHEELS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

MOUNTING
CONE

SPINDLE
SHAFT
/

LATERAL
RUNOUT WING NUT

PLASTIC
CUP
DIAL INDICATOR 80a611da

J9022-4 Fig. 3 Radial Runout

Fig. 2 Checking Tire/Wheel/Hub Runout


MOUNTING
Som et im es r a dia l r u n ou t ca n be r edu ced. Reloca t e
CONE
t h e wh eel a n d t ir e a ssem bly on t h e m ou n t in g st u ds
(See Met h od 1). If t h is does n ot r edu ce r u n ou t t o a n
SPINDLE
a ccept a ble level, t h e t ir e ca n be r ot a t ed on t h e wh eel. SHAFT
(See Met h od 2).

METHOD 1 (RELOCATE WHEEL ON HUB)


(1) Dr ive veh icle a sh or t dist a n ce t o elim in a t e t ir e
fla t spot t in g fr om a pa r ked posit ion . WING NUT
(2) Ch eck wh eel bea r in gs a n d a dju st if a dju st a ble
or r epla ce if n ecessa r y. PLASTIC
(3) Ch eck t h e wh eel m ou n t in g su r fa ce. CUP
(4) Reloca t e wh eel on t h e m ou n t in g, t wo st u ds
over fr om t h e or igin a l posit ion . DIAL INDICATOR~ 80a611db
(5) Tigh t en wh eel n u t s u n t il a ll a r e pr oper ly
t or qu ed, t o elim in a t e br a ke dist or t ion . Fig. 4 Lateral Runout
(6) Ch eck r a dia l r u n ou t . If st ill excessive, m a r k
t ir e sidewa ll, wh eel, a n d st u d a t poin t of m a xim u m
SERV I CE PROCEDU RES
r u n ou t a n d pr oceed t o Met h od 2.
WHEEL INSTALLATION
METHOD 2 (RELOCATE TIRE ON WHEEL) Th e wh eel st u ds a n d n u t s a r e design ed for specific
a pplica t ion s. Th ey m u st be r epla ced wit h equ iva len t
NOTE: Rotating the tire on wheel is particularly pa r t s. Do n ot u se r epla cem en t pa r t s of lesser qu a lit y
effective when there is runout in both tire and or a su bst it u t e design . All a lu m in u m a n d som e st eel
wheel. wh eels h a ve wh eel st u d n u t s wh ich fea t u r e a n
en la r ged n ose. Th is en la r ged n ose is n ecessa r y t o
(1) Rem ove t ir e fr om wh eel a n d m ou n t wh eel on en su r e pr oper r et en t ion of t h e a lu m in u m wh eels.
ser vice dyn a m ic ba la n ce m a ch in e.
(2) Ch eck wh eel r a dia l r u n ou t (F ig. 3) a n d la t er a l NOTE: Do not use chrome plated lug nuts with
r u n ou t (F ig. 4). chrome plated wheels.
• STE E L WH E E LS: Ra dia l r u n ou t 0.040 in ., La t -
er a l r u n ou t 0.045 in . (m a xim u m ) Befor e in st a llin g t h e wh eel, be su r e t o r em ove a n y
• ALUMINUM WH E E LS: Ra dia l r u n ou t 0.030 in ., bu ild u p of cor r osion on t h e wh eel m ou n t in g su r fa ces.
La t er a l r u n ou t 0.035 in . (m a xim u m ) E n su r e wh eels a r e in st a lled wit h good m et a l-t o-m et a l
(3) If poin t of gr ea t est wh eel la t er a l r u n ou t is n ea r
or igin a l ch a lk m a r k, r em ou n t t ir e 180 degr ees.
Rech eck r u n ou t , Refer t o m a t ch m ou n t in g pr ocedu r e.
XJ TIRES AND WHEELS 22 - 9
SERV I CE PROCEDU RES (Cont inue d)
con t a ct . Im pr oper in st a lla t ion cou ld ca u se loosen in g • Dia m et er
of wh eel n u t s. Th is cou ld a ffect t h e sa fet y a n d h a n - • Widt h
dlin g of you r veh icle. • Offset
To in st a ll t h e wh eel, fir st posit ion it pr oper ly on • Mou n t in g con figu r a t ion
t h e m ou n t in g su r fa ce. All wh eel n u t s sh ou ld t h en be F a ilu r e t o u se equ iva len t r epla cem en t wh eels m a y
t igh t en ed ju st sn u g. Gr a du a lly t igh t en t h em in a ffect t h e sa fet y a n d h a n dlin g of you r veh icle.
sequ en ce t o t h e pr oper t or qu e specifica t ion (F ig. 5). Repla cem en t wit h u s e d wh eels is n ot r ecom m en ded.
N e v e r u s e o il o r g re a s e o n s tu d s o r n u ts . Th eir ser vice h ist or y m a y h a ve in clu ded sever e t r ea t -
m en t .

TIRE AND WHEEL BALANCE


It is r ecom m en ded t h a t a t wo pla n e ser vice
dyn a m ic ba la n cer be u sed wh en a t ir e a n d wh eel
a ssem bly r equ ir e ba la n cin g. Refer t o ba la n cer oper a -
t ion in st r u ct ion s for pr oper con e m ou n t in g pr oce-
du r es. Typica lly u se fr on t con e m ou n t in g m et h od for
st eel wh eels. F or a lu m in u m wh eel u se ba ck con e
m ou n t in g m et h od wit h ou t con e spr in g.

NOTE: Static should be used only when a two


plane balancer is not available.

NOTE: Cast aluminum and forged aluminum wheels


Fig. 5 Lug Nut Tightening Pattern require coated balance weights and special align-
ment equipment.
WHEEL REPLACEMENT
Wh eels m u st be r epla ced if t h ey h a ve: Wh eel ba la n cin g ca n be a ccom plish ed wit h eit h er
• E xcessive r u n ou t on or off veh icle equ ipm en t . Wh en u sin g on -veh icle
• Ben t or den t ed ba la n cin g equ ipm en t , r em ove t h e opposit e wh eel/t ir e.
• Lea k a ir t h r ou gh welds Off-veh icle ba la n cin g is r ecom m en ded.
• H a ve da m a ged bolt h oles F or st a t ic ba la n cin g, fin d loca t ion of h ea vy spot
Wh eel r epa ir s em ployin g h a m m er in g, h ea t in g, or ca u sin g t h e im ba la n ce. Cou n t er ba la n ce wh eel
weldin g a r e n ot a llowed. dir ect ly opposit e t h e h ea vy spot . Det er m in e weigh t
Or igin a l equ ipm en t wh eels a r e a va ila ble t h r ou gh r equ ir ed t o cou n t er ba la n ce t h e a r ea of im ba la n ce.
you r dea ler. Repla cem en t wh eels fr om a n y ot h er P la ce h a lf of t h is weigh t on t h e in n e r r im fla n ge a n d
sou r ce sh ou ld be equ iva len t in : t h e ot h er h a lf on t h e o u te r r im fla n ge (F ig. 6).
• Loa d ca r r yin g ca pa cit y F or dyn a m ic ba la n cin g, t h e ba la n cin g equ ipm en t is
design ed t o loca t e t h e a m ou n t of weigh t t o be a pplied
t o bot h t h e in n er a n d ou t er r im fla n ge (F ig. 7).
22 - 10 TIRES AND WHEELS XJ
SERV I CE PROCEDU RES (Cont inue d)

ADD BALANCE
WEIGHTS HERE
't
OF SPINDLE

---..-----+

'---~
L. • • ., .....

TIRE OR WHEEL TRAMP, CORRECTIVE


OR WHEEL HOP WEIGHT
LOCATION
J8922-8

Fig. 6 Static Unbalance & Balance


ADD BALANCE
WEIGHTS HERE

<i
OF SPINDLE

CORRECTIVE WEIGHT
LOCATION
HEAVY SPOT
WHEEL SHIMMY
AND VIBRATION
J8922-9

Fig. 7 Dynamic Unbalance & Balance


SPECI FI CAT I ON S
TORQUE CHART

D ES CRIP TION TORQU E


Lu g N u t
1/2 X 20 wit h 60° Con e . . . . . . . . . . . 115-150 N·m
(85-115 ft . lbs.)
XJ BODY 23 - 1

BODY
CON T EN T S

page page

BODY COMPONENT SERVICE . . . . . . . . . . . . . . 17 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10


GENERAL SERVICE INFORMATION . . . . . . . . . . . 1 STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . . 4
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GEN ERAL SERV I CE I N FORM AT I ON


GEN ERAL I N FORM AT I ON Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
SAFETY PRECAUTIONS AND WARNINGS Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
WARNING: EYE PROTECTION SHOULD BE USED to finish or color can result.
WHEN SERVICING GLASS COMPONENTS. PER- Do not hammer or pound on plastic trim panel
SONAL INJURY CAN RESULT. when servicing interior trim. Plastic panels can
USE A OSHA APPROVED BREATHING FILTER break.
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT. Ch r ysler Cor por a t ion u ses m a n y differ en t t ypes of
AVOID PROLONGED SKIN CONTACT WITH pu sh -in fa st en er s t o secu r e t h e in t er ior a n d ext er ior
PETROLEUM OR ALCOHOL – BASED CLEANING t r im t o t h e body. Most of t h ese fa st en er s ca n be
SOLVENTS. PERSONAL INJURY CAN RESULT. r eu sed t o a ssem ble t h e t r im du r in g va r iou s r epa ir
DO NOT STAND UNDER A HOISTED VEHICLE pr ocedu r es. At t im es, a pu sh -in fa st en er ca n n ot be
THAT IS NOT PROPERLY SUPPORTED ON SAFETY r em oved wit h ou t da m a gin g t h e fa st en er or t h e com -
STANDS. PERSONAL INJURY CAN RESULT. pon en t it is h oldin g. If it is n ot possible t o r em ove a
fa st en er wit h ou t da m a gin g a com pon en t or body, cu t
or br ea k t h e fa st en er a n d u se a n ew on e wh en
CAUTION: When holes must be drilled or punched in st a llin g t h e com pon en t . Never pr y or pou n d on a
in an inner body panel, verify depth of space to the pla st ic or pr essed-boa r d t r im com pon en t . Usin g a
outer body panel, electrical wiring, or other compo- su it a ble for k-t ype pr yin g device, pr y t h e fa st en er
nents. Damage to vehicle can result. fr om t h e r et a in in g h ole beh in d t h e com pon en t bein g
Do not weld exterior panels unless combustible r em oved. Wh en in st a llin g, ver ify fa st en er a lign m en t
material on the interior of vehicle is removed from wit h t h e r et a in in g h ole by h a n d. P u sh dir ect ly on or
the repair area. Fire or hazardous conditions, can over t h e fa st en er u n t il it sea t s. Apply a low-for ce pu ll
result. t o t h e pa n el t o ver ify t h a t it is secu r e.
Always have a fire extinguisher ready for use Wh en it is n ecessa r y t o r em ove com pon en t s t o ser-
when welding. vice a n ot h er, it sh ou ld n ot be n ecessa r y t o a pply
Disconnect the negative (-) cable clamp from the excessive for ce or ben d a com pon en t t o r em ove it .
battery when servicing electrical components that Befor e da m a gin g a t r im com pon en t , ver ify h idden
are live when the ignition is OFF. Damage to electri- fa st en er s or ca pt u r ed edges h oldin g t h e com pon en t in
cal system can result. pla ce.

-
23 - 2 BODY XJ

PAI N T

INDEX
page page

GENERAL INFORMATION WET SANDING, BUFFING, AND POLISHING . . . . 2


BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . . 2 SPECIFICATIONS
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AFTERMARKET PAINT REPAIR PRODUCTS . . . . 3
PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . 2

GEN ERAL I N FORM AT I ON PAINTED SURFACE TOUCH-UP


Wh en a pa in t ed m et a l su r fa ce h a s been scr a t ch ed
PAINT CODE or ch ipped, it sh ou ld be t ou ch ed-u p a s soon a s possi-
E xt er ior veh icle body color s a r e iden t ified on t h e ble t o a void cor r osion . F or best r esu lt s, u se Mopa r !
Body Code pla t e. Th e pla t e is loca t ed on t h e left side Scr a t ch F iller /P r im er, Tou ch -Up P a in t s a n d Clea r Top
of t h e da sh pa n el in t h e en gin e com pa r t m en t . Refer Coa t . Refer t o In t r odu ct ion gr ou p of t h is m a n u a l for
t o t h e In t r odu ct ion sect ion a t t h e fr on t of t h is m a n - Body Code P la t e in for m a t ion .
u a l for body code pla t e descr ipt ion . Th e pa in t code is
a lso iden t ified on t h e Veh icle Sa fet y Cer t ifica t ion TOUCH-UP PROCEDURE
La bel wh ich is loca t ed on t h e dr iver s door sh u t fa ce. (1) Scr a pe loose pa in t a n d cor r osion fr om in side
Th e color n a m es pr ovided in t h e P a in t a n d Tr im scr a t ch or ch ip.
Code Descr ipt ion ch a r t a r e t h e color n a m es u sed on (2) Clea n a ffect ed a r ea wit h Mopa r ! Ta r /Roa d Oil
m ost r epa ir pr odu ct con t a in er s. Rem over, a n d a llow t o dr y.
(3) F ill t h e in side of t h e scr a t ch or ch ip wit h a coa t
BASE COAT/CLEAR COAT FINISH of filler /pr im er. Do n ot over la p pr im er on t o good su r-
On m ost veh icles a t wo-pa r t pa in t a pplica t ion (ba se fa ce fin ish . Th e a pplica t or br u sh sh ou ld be wet
coa t /clea r coa t ) is u sed. Color pa in t t h a t is a pplied t o en ou gh t o pu ddle-fill t h e defect wit h ou t r u n n in g. Do
pr im er is ca lled ba se coa t . Th e clea r coa t pr ot ect s t h e n ot st r oke br u sh a pplica t or on body su r fa ce. Allow
ba se coa t fr om u lt r a violet ligh t a n d pr ovides a du r a - t h e filler /pr im er t o dr y h a r d.
ble h igh -gloss fin ish . (4) Cover t h e filler /pr im er wit h color t ou ch -u p
pa in t . Do n ot over la p t ou ch -u p color on t o t h e or igin a l
WET SANDING, BUFFING, AND POLISHING color coa t a r ou n d t h e scr a t ch or ch ip. Bu t t t h e n ew
Min or a cid et ch in g, or a n ge peel, or sm u dgin g in color t o t h e or igin a l color, if possible. Do n ot st r oke
clea r coa t or sin gle-st a ge fin ish es ca n be r edu ced a pplica t or br u sh on body su r fa ce. Allow t ou ch -u p
wit h ligh t wet sa n din g, h a n d bu ffin g, a n d polish in g. pa in t t o dr y h a r d.
If th e fin is h h a s be e n w e t s a n d e d in th e p a s t, it (5) On veh icles wit h ou t clea r coa t , t h e t ou ch -u p
c a n n o t be re p e a te d . We t s a n d in g o p e ra tio n color ca n be ligh t ly wet sa n ded (1500 gr it ) a n d pol-
s h o u ld be p e rfo rm e d by a tra in e d a u to m o tiv e ish ed wit h r u bbin g com pou n d.
p a in t te c h n ic ia n . (6) On veh icles wit h clea r coa t , a pply clea r t op coa t
t o t ou ch -u p pa in t wit h t h e sa m e t ech n iqu e a s
CAUTION: Do not remove clear coat finish, if descr ibed in St ep 4. Allow clea r t op coa t t o dr y h a r d.
equipped. Base coat paint must retain clear coat for If desir ed, St ep 5 ca n be per for m ed on clea r t op coa t .
durability.
XJ BODY 23 - 3

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

NOTE: *Herberts Standox, Spies Hecker, and BASF


use the Chrysler paint code as listed on the Body
Code Plate and the Vehicle Safety Certification
label. ** S-W = Sherwin-Williams, M-S = Martin
Senour, ICI = ICI Autocolor.
23 - 4 BODY XJ

STAT I ON ARY GLASS

INDEX
page page

DESCRIPTION AND OPERATION REAR DOOR STATIONARY WINDOW GLASS . . . 7


SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 4 REAR QUARTER WINDOW GLASS . . . . . . . . . . . 8
REMOVAL AND INSTALLATION WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . . 9

DESCRI PT I ON AN D OPERAT I ON Be careful not to damage painted surfaces when


removing moldings or cutting urethane around
SAFETY PRECAUTIONS windshield.

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).

CAUTION: Avoid spilling or dripping primer on


painted surfaces. Clean spills or drips immediately.
The primer will damage the paint if it remains on
the surface for any length of time.

(10) If t h e r epla cem en t win dsh ield gla ss does n ot


h a ve bla ckou t pr im er :
• At t a ch a 25 m m (1 in ) wide m a skin g t a pe ba n d
a r ou n d t h e in t er ior side of t h e gla ss 16 m m (5/8 in )
Fig. 1 Cutting Urethane Around Windshield—Typical fr om t h e edge of t h e gla ss (F ig. 3).
• Do n ot a t t a ch t a pe a lon g t h e bot t om of t h e gla ss
INSTALLATION—SHORT METHOD a n d a tta c h it o n ly to th e in s id e o f th e g la s s .
• Clea n t h e 16-m m (5/8-in ) wide su r fa ce a r ea
WARNING: REVIEW ALL WARNINGS AND CAU-
a r ou n d t h e gla ss wit h isopr opyl a lcoh ol.
TIONS IN THIS GROUP BEFORE PRECEDING WITH
• Th or ou gh ly m ix a n d a pply gla ss bla ckou t pr im er
INSTALLATION.
t o t h e 16 m m (5/8 in ) su r fa ce a r ea a r ou n d t h e in t e-
(1) Tr im t h e u r et h a n e fr om t h e pin ch weld fla n ges. r ior side of t h e gla ss (F ig. 4).
Lea ve a 3 m m (0.1 in .) level ba se of u r et h a n e on t h e • Allow t h e pr im er t o dr y for a t lea st 10-12 m in -
pin ch weld fla n ges. u t es.
(11) Apply a sm a ll a m ou n t of a dh esive t o t h e bot -
WARNING: DO NOT USE SOLVENT BASED GLASS t om su ppor t spa cer s a n d a t t a ch t h e su ppor t spa cer s
CLEANER TO CLEAN WINDSHIELD BEFORE t o t h e bot t om of t h e win dsh ield, 170 m m in boa r d
APPLYING GLASS PREP AND PRIMER. POOR fr om t h e ou t er win dsh ield edge (F ig. 5).
ADHESION CAN RESULT. (12) Cu t t h e u r et h a n e a dh esive a pplica t or n ozzle
(F ig. 6).
(2) Clea n in side of win dsh ield wit h a m m on ia ba sed
gla ss clea n er a n d lin t -fr ee clot h . CAUTION: Be prepared to install the glass immedi-
(3) P r im e ou t er per im et er of in t er ior side of gla ss ately after applying the adhesive, as the adhesive
16 m m (5/8 in ch ) fr om edge. Use a wipe-off t ype u r e- will begin to cure in less than 10 minutes.
t h a n e pr im er a n d wipe gla ss dr y a ft er pr im er a ppli-
ca t ion . (13) Apply a con t in u ou s, 6-m m (1/4-in ) dia m et er
bea d of u r et h a n e a dh esive t o t h e su r fa ce a r ea .
NOTE: The reveal molding has an adhesive applied (14) Align t h e gla ss wit h t h e r efer en ce m a r ks a n d
to the windshield contact surface to help secure the posit ion t h e gla ss on t h e pin ch weld fla n ges. E n su r e
molding to the windshield during the installation t h a t t h e win dsh ield gla ss is cor r ect ly sea t ed on t h e
procedure. su ppor t spa cer s.
(15) F or ce t h e win dsh ield gla ss in wa r d ju st en ou gh
(4) Apply t h e m oldin g t o t h e win dsh ield: t o wet -ou t a n d set t h e u r et h a n e. Use ca r e t o a void
• Wit h t h e m oldin g a t r oom t em per a t u r e, pr ess excessive squ eeze-ou t of a dh esive.
t h e m oldin g on t o t h e win dsh ield cor n er s. (16) Wa t er t est t h e win dsh ield wit h a wa t er spr a y
• 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 ft er in st a lla t ion . Do n ot dir ect h igh pr essu r e
cen t er of ea ch side. (Som e st r et ch in g of t h e m oldin g st r ea m s of wa t er dir ect ly a t u r et h a n e. If a n y lea ks
m a y be r equ ir ed du r in g t h is pr ocedu r e.) a r e det ect ed, a pply u r et h a n e a s n ecessa r y.
(5) P la ce t h e gla ss on t h e pin ch weld fla n ges a n d (17) If u sed, r em ove t h e m a skin g t a pe fr om t h e
in spect for ga ps in t h e u r et h a n e. Ga ps in excess of 3 in n er su r fa ce of t h e gla ss.
m m (1/8 in ch ) m u st be filled wit h u r et h a n e. (18) In st a ll a ll com pon en t s a n d clea n t h e veh icle.
23 - 6 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(19) Open t h e veh icle win dows t o pr even t in t er ior
pr essu r e wh ile t h e u r et h a n e is cu r in g. If n o t
v e n te d , p re s s u re in th e in te rio r o f th e v e h ic le
m a y in te rfe re w ith p ro p e r g la s s bo n d in g .
(20) In st a ll t h e r ea r view m ir r or.

WINDSHIELD
AND
MOLDINGS

"
80a28c10

Fig. 2 Work Surface Set up


Fig. 4 Blackout Primer Application
_;.L,___POSITION TAPE 5/a INCH
// - FROM EDGE OF GLASS

SUPPORT
SPACERS
1-INCH WIDE
MASKING TAPE

J8923-76

Fig. 3 Masking Tape Location For Blackout Primer


INSTALLATION—EXTENDED METHOD
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION. 80ac2bd6

(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.

(12) Align t h e win dsh ield wit h t h e wa x pen cil


in st a lla t ion a lign m en t r efer en ce m a r ks (or t h e t a pe
CUT NOZZLE THIS SHAPE st r ips). P osit ion t h e win dsh ield on pin ch weld fla n ges
FOR SHORT PROCEDURE a n d spa cer s.
(13) F or ce t h e win dsh ield in wa r d ju st en ou gh t o
wet -ou t a n d set t h e u r et h a n e. Use ca r e t o a void
excessive squ eeze-ou t of a dh esive.
(14) Wa t er t est t h e win dsh ield wit h a wa t er spr a y
a ft er in st a lla t ion . Do n ot dir ect h igh pr essu r e
st r ea m s of wa t er dir ect ly a t t h e u r et h a n e. If a n y
J8923-79 lea ks a r e det ect ed, a pply u r et h a n e a s n ecessa r y.
(15) If u sed, r em ove t h e m a skin g t a pe fr om t h e
Fig. 6 Applicator Nozzle Preparation in n er su r fa ce of gla ss.
• Mea su r e t h e ga p bet ween t h e pin ch weld fla n ges (16) In st a ll a ll com pon en t s a n d clea n t h e veh icle.
a n d gla ss a r ou n d per im et er of t h e gla ss a n d fla n ge. If n ecessa r y, r efer t o t h e in st a lla t ion pr ocedu r es.
• Th e r evea l m oldin g sh ou ld equ a lly cover t h e (17) Open t h e veh icle win dows t o pr even t in t er ior
A-P illa r s on bot h sides. pr essu r e wh ile t h e u r et h a n e a dh esive is cu r in g. If
• Th e fla n ges sh ou ld a lso ext en d a bove t h e gla ss n o t v e n te d , p re s s u re in th e in te rio r o f v e h ic le
edge equ a lly a r ou n d t h e per im et er of t h e open in g. w ill in te rfe re w ith g la s s bo n d in g .
(6) If t h e pin ch weld fla n ges r equ ir e r epa ir, r em ove (18) In st a ll t h e r ea r view m ir r or on t h e br a cket .
t h e win dsh ield gla ss a n d st r a igh t en , a lign , or r epa ir
t h e fla n ge(s) a s n ecessa r y. REAR DOOR STATIONARY WINDOW GLASS
(7) P osit ion t h e win dsh ield in t h e open in g a n d
in spect t h e win dsh ield fit a ga in . Ma r k t h e win dsh ield REMOVAL
fin a l posit ion on t h e gla ss a n d body wit h a wa x pen - Th e r ea r door st a t ion a r y win dow gla ss is bon ded t o
cil (or u se m a skin g t a pe). Th e m a r ks (or m a skin g t h e division ba r a n d is ser viced a s a n a ssem bly.
t a pe) will be u sed for in st a lla t ion a lign m en t r efer- (1) Lower t h e win dow gla ss.
en ce. (2) Rem ove t h e in n er a n d ou t er belt lin e wea t h er-
(8) If t h e r epla cem en t win dsh ield does n ot h a ve st r ip.
bla ckou t pr im er : (3) Rem ove t h e t r im pa n el a n d wa t er da m fr om
• At t a ch a 25-m m (1-in ) wide m a skin g t a pe ba n d door in n er pa n el.
a r ou n d t h e in t er ior side of gla ss 16 m m (5/8 in ) fr om (4) Rem ove t h e scr ews a t t a ch in g t h e division ba r /
edge of gla ss (F ig. 3). gla ss t o t h e door (F ig. 7).
• Do n ot a t t a ch t a pe a lon g t h e bot t om of t h e gla ss (5) Tilt t h e division ba r /gla ss for wa r d a n d r em ove
a n d a tta c h o n ly to th e in s id e o f g la s s . it fr om t h e door.
• Th or ou gh ly m ix a n d a pply bla ckou t pr im er t o
t h e 16 m m (5/8 in ) su r fa ce a r ea a r ou n d t h e in t er ior
side of t h e gla ss (F ig. 4).
• Allow t h e pr im er t o dr y for a t lea st 10-12 m in -
u t es.
(9) Apply a sm a ll a m ou n t of a dh esive t o t h e bot -
t om su ppor t spa cer s a n d a t t a ch t h e su ppor t spa cer s
t o t h e bot t om of t h e win dsh ield, 170 m m in boa r d
fr om t h e ou t er win dsh ield edge (F ig. 5). DIVISION
(10) Cu t t h e u r et h a n e a pplica t or n ozzle (F ig. 6). BAR
(11) Apply a con t in u ou s bea d of u r et h a n e t o t h e
su r fa ce a r ea wit h bla ckou t pr im er on t h e in t er ior LOWER
side of gla ss. Th e bea d sh ou ld be 9-m m (3/8-in ) wide SCREW
by 12.7-m m (1/2-in ) deep for best r esu lt s.
80ac2bd7

Fig. 7 Division Bar/Stationary Glass


23 - 8 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION • In ser t t h e cor d in t o t h e win dow open in g fla n ge
(1) P osit ion t h e division ba r /gla ss in t h e door. ch a n n el in t h e wea t h er st r ip sea l.
(2) In st a ll t h e scr ews a t t a ch in g t h e division ba r / (4) Apply a 6-m m (1/4-in ) dia m et er bea d of sea la n t
gla ss t o t h e door. F in ger t igh t en t h e scr ews. t o t h e win dow open in g fla n ges.
(3) Tigh t en t h e u pper scr ew t o 6 N·m (5 ft -lbs) (5) F or t wo-door veh icles, a pply a 3-m m (1/8-in )
t or qu e. dia m et er bea d of sea la n t a t t h e qu a r t er pa n el a ppli-
(4) Tigh t en t h e lower scr ew t o 6 N·m (5 ft -lbs) qu e a n d lift ga t e pilla r sea m .
t or qu e. (6) P osit ion t h e qu a r t er win dow gla ss a n d t h e
(5) In st a ll t h e belt lin e wea t h er st r ip. wea t h er st r ip sea l in t h e win dow open in g (F ig. 10)
(6) In st a ll t h e door wa t er da m a n d t r im pa n el. wit h t h e fr ee en ds of t h e cor d in side t h e veh icle (F ig.
11).
REAR QUARTER WINDOW GLASS (7) P u ll on ea ch en d of t h e cor d t o pu ll t h e wea t h -
er st r ip sea l ch a n n el lip over t h e win dow open in g
REMOVAL fla n ges.
(1) If equ ipped, r em ove t h e qu a r t er win dow r evea l (8) Test t h e ven t win dow for wa t er lea ks.
m oldin g (F ig. 8). (9) In st a ll t h e in t er ior t r im cover.
(2) Rem ove t h e qu a r t er win dow in t er ior t r im cov- (10) If equ ipped, in st a ll t h e qu a r t er win dow r evea l
er s. m oldin g.
(3) Sepa r a t e t h e wea t h er st r ip sea l lip fr om t h e
WINDOW
win dow open in g fla n ges. Use a pr y t ool a n d ca r efu lly GLASS
pu sh t h e win dow gla ss a n d sea l ou t wa r d. WEATHERSTRIP
(4) Rem ove t h e wea t h er st r ip sea l a n d win dow SEAL
gla ss fr om win dow open in g.
(5) Rem ove t h e wea t h er st r ip sea l fr om t h e win dow
gla ss. ---.Ill//,;,~/
/~~

WINDOW
GLASS
INSTALLATION
CORD
J9223-118

Fig. 9 Weatherstrip Seal and Cord Installation

QUARTER
WINDOW
WNENT

J9123-54

Fig. 8 Quarter Window Reveal Molding, Glass and


Seal ~~----r-WEATHERSTRIP
SEAL
INSTALLATION
(1) Clea n t h e or igin a l sea la n t fr om t h e wea t h er-
st r ip ch a n n els a n d win dow open in g fla n ges.
(2) Apply a 4-m m (1/6-in ) dia m et er bea d of sea la n t
t o t h e win dow ch a n n el in t h e wea t h er st r ip sea l.
(3) In st a ll t h e wea t h er st r ip on t h e win dow gla ss. INSTALLATION CORD 80abac2d

In st a ll t h e sea l in st a lla t ion cor d in t h e win dow open -


in g fla n ge ch a n n el (F ig. 9) a s follows: Fig. 10 Quarter Window With Vent
• Moist en a len gt h of 6-m m (1/4-in ) dia m et er cor d
wit h a soa p a n d wa t er solu t ion .
• E n su r e t h a t t h e cor d is lon g en ou gh t o go a ll t h e
wa y a r ou n d t h e per im et er of t h e wea t h er st r ip.
XJ BODY 23 - 9
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) St a r t in g in t h e cor n er s, pr ess r evea l m oldin g
on t o gla ss.
(3) P la ce r epla cem en t gla ss in t o lift ga t e open in g
a n d posit ion gla ss in t h e cen t er of t h e open in g
a ga in st fla n ge.
(4) Ver ify t h e gla ss la ys even ly a ga in st t h e fen ce a t
WEATHERSTRIP t h e sides, t op a n d bot t om . If n ot , t h e fla n ge m u st be
1/4-INCH
/ for m ed t o t h e sh a pe of t h e n ew gla ss.
DIAMETER (5) Usin g a gr ea se pen cil or equ iva len t , m a ke r ef-
CORD (POSITION er en ces m a r ks on t h e gla ss a n d body.
IN WEATHERSTRIP
GLASS CHANNEL) (6) Rem ove r epla cem en t gla ss fr om lift ga t e open -
in g.
(7) P osit ion t h e gla ss in side u p on a su it a ble wor k
su r fa ce.

WARNING: DO NOT USE SOLVENT BASED GLASS


CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.

(8) Clea n in side of gla ss wit h Mopa r Gla ss Clea n er


a n d lin t -fr ee clot h .
Fig. 11 Quarter Window Glass and Seal Installation (9) Apply P VC (vin yl) pr im er 25 m m (1 in .) wide
a r ou n d edge of gla ss. Wipe wit h clea n /dr y lin t -fr ee
LIFTGATE GLASS clot h .
(10) If n ecessa r y, a pply fen ce pr im er a r ou n d edge
REMOVAL of fen ce. Allow a t lea st eigh t een m in u t es dr yin g t im e.
(1) Open lift ga t e. (11) Apply a 10 m m (0.4 in .) bea d of u r et h a n e
(2) Rem ove lift ga t e t r im pa n el. a r ou n d gla ss bor der.
(3) Discon n ect h ea t ed ba cklit e (H BL) con n ect or. (12) P osit ion gla ss in t o lift ga t e open in g a n d r efer-
(4) Rem ove wiper a r m . en ce m a r ks.
(5) Rem ove CH MSL len s. (13) P u sh t h e gla ss in wa r d u n t il t h e r evea l m old-
(6) Usin g a r a zor kn ife, slide t h e bla de bet ween in g is sea t ed on t o t h e lift ga t e fr a m e. Use ca r e t o
t h e lift ga t e gla ss a n d t h e in boa r d edge of t h e r evea l a void excessive squ eeze-ou t of a dh esive.
m oldin g. (14) Open win dows t o pr even t pr essu r e bu ild-u p
(7) 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 wh ile t h e u r et h a n e is cu r in g.
m oldin g a n d sever e t h e ca p of t h e r evea l m oldin g. (15) Apply 150 m m (6 in .) len gt h s of 50 m m (2 in .)
(8) Usin g a cold kn ife, cu t u r et h a n e bon din g fr om m a skin g t a pe spa ced 250 m m (10 in .) a pa r t t o h old
a r ou n d lift ga t e gla ss. A pn eu m a t ic cu t t in g device ca n gla ss in pla ce u n t il u r et h a n e cu r es.
be u sed if a va ila ble. (16) In st a ll t h e wiper a r m .
(9) Sepa r a t e gla ss fr om Lift ga t e. (17) In st a ll CH MSL len s.
(18) Con n ect h ea t ed ba cklit e (H BL) con n ect or.
INSTALLATION (19) Aft er u r et h a n e h a s cu r ed, r em ove t a pe st r ips
a n d wa t er t est t o ver ify r epa ir.
CAUTION: Open a window before installing glass. (20) In st a ll lift ga t e t r im pa n el.
This will avoid pressurizing the passenger compart-
ment. If a door or liftgate is slammed before ure-
thane is cured, water leaks can result.

(1) Tr im t h e u r et h a n e fr om t h e lift ga t e gla ss open -


in g fla n ges. Lea ve a 3 m m (0.1 in .) level ba se of u r e-
t h a n e on t h e fla n ges.
23 - 10 BODY XJ

SEAT S

INDEX
page page

REMOVAL AND INSTALLATION HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . . . . 10


BUCKET SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REAR SEAT CUSHION . . . . . . . . . . . . . . . . . . . . 14
BUCKET SEAT CUSHION COVER . . . . . . . . . . . 13 REAR SEAT CUSHION COVER . . . . . . . . . . . . . 15
BUCKET SEAT PLATFORM . . . . . . . . . . . . . . . . 12 REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . . 15
BUCKET SEAT RECLINER . . . . . . . . . . . . . . . . . 14 REAR SEATBACK COVER . . . . . . . . . . . . . . . . . 16
BUCKET SEAT TRACK . . . . . . . . . . . . . . . . . . . . 12 REAR SEATBACK LATCH STRIKER AND
BUCKET SEATBACK . . . . . . . . . . . . . . . . . . . . . 13 BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BUCKET SEATBACK COVER . . . . . . . . . . . . . . . 12 SPECIAL TOOLS
HEAD RESTRAINT COVER . . . . . . . . . . . . . . . . 11 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

REM OVAL AN D I N STALLAT I ON


HEAD RESTRAINT SLEEVE
REMOVAL
NOTE: When replacing a head restraint sleeve, the
retaining tabs on the sleeve will be damaged during EXTRACTOR HEAD RESTRAINT
the removal process. Check the availability of TOOL SLEEVE
replacement parts before servicing. 6773
SEAT
(1) Ra ise h ea d r est r a in t t o t h e fu ll u p posit ion . BACK
(2) Tu r n h ea d r est r a in t lock t h u m bwh eel t o r elea se
h ea d r est r a in t a n d pu ll h ea d r est r a in t u pwa r d t o
r em ove fr om sea t ba ck. 8031e846
(3) In ser t h ea d r est r a in t sleeve ext r a ct or (specia l
t ool 6773) (F ig. 1) a n d (F ig. 2) in t o t h e sea t ba ck. Fig. 1 Head Restraint Sleeve Extractor
(4) Th e r et a in in g t a bs a r e posit ion ed on ea ch side
of t h e sleeve, wh en in ser t in g t h e ext r a ct or, en su r e
t h a t t h e fla t of t h e colla r is fa cin g t h e side of t h e
sea t ba ck (F ig. 3).
(5) Usin g a sm a ll h a m m er, t a p ext r a ct or down -
wa r d t o r elea se sleeve r et a in in g t a b.
(6) Rem ove ext r a ct or t ool fr om sleeve, r ot a t e t ool
180 degr ees (F ig. 4) a n d r epea t st eps 3 a n d 4.
(7) Rem ove ext r a ct or t ool fr om sleeve a n d r em ove EXTRACTOR
sleeve fr om sea t ba ck. TOOL-----~
6773
INSTALLATION I
SEAT
(1) P osit ion t h e sleeve in t h e sea t ba ck. : HEAD RESTRAINT BACK
(2) F ir m ly, pu sh sleeve down t o sn a p in t o pla ce.
! SLEEVE
(3) In st a ll h ea d r est r a in t .

Fig. 2 Head Restraint Sleeve Extractor Installation


XJ BODY 23 - 11
REM OVAL AN D I N STALLAT I ON (Cont inue d)

HEAD
RESTRAINT

EXTRACTOR
TOOL
6773

SEAT
BACK

;----: ~ ~\

( '\ LOCK RELEASE


THUMBWHEEL 8031e848 BEZEL
Fig. 3 Head Restraint Sleeve Extractor Positioning

80aa980b

Fig. 5 Head Restraint


HEAD RESTRAINT

-------- COVER

LOCK RELEASE
~~\---~ )
THUMBWHEEL so31es41

Fig. 4 Head Restraint Sleeve Extractor Positioning


HEAD RESTRAINT COVER
REMOVAL
HEAD RESTRAINT
(1) Rem ove h ea d r est r a in t fr om t h e bu cket sea t . CUSHION 80aa980c
(2) Rem ove t h e scr ews a t t a ch in g t h e bezel a n d
a dju st er ba r t o t h e h ea d r est r a in t (F ig. 5). Fig. 6 Head Restraint Cover
(3) P u ll t h e a dju st er ba r fr om t h e h ea d r est r a in t .
(4) Roll t h e cover u pwa r d a n d sepa r a t e fr om t h e BUCKET SEAT
h ea d r est r a in t cu sh ion (F ig. 6).
REMOVAL
INSTALLATION (1) Rem ove bolt s a t t a ch in g sea t t o floor pa n (F ig.
(1) P osit ion t h e cover on t h e h ea d r est r a in t cu sh - 7).
ion a n d r oll t h e cover down wa r d. (2) Rem ove n u t a t t a ch in g sea t t o floor pa n .
(2) P osit ion t h e a dju st er ba r in t h e h ea d r est r a in t . (3) F or power sea t , discon n ect wir e h a r n ess con -
(3) In st a ll t h e scr ews a t t a ch in g t h e bezel a n d n ect or. If equ ipped, discon n ect wir e h a r n ess for
a dju st er ba r t o t h e h ea d r est r a in t . h ea t ed sea t .
(4) In st a ll h ea d r est r a in t in t h e bu cket sea t . (4) Discon n ect sea t belt bu ckle wa r n in g wir e h a r-
n ess con n ect or.
(5) Sepa r a t e sea t fr om floor pa n el.

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 SEAT PLATFORM


Bu cket sea t pla t for m s a r e n ot r epa ir a ble. If t h e
sea t pla t for m is da m a ged, r epla ce pla t for m a s a u n it .

BUCKET SEATBACK COVER


REMOVAL
(1) Rem ove h ea d r est r a in t , if equ ipped.
B0abd26f
(2) Rem ove scr ews a t t a ch in g side sh ield t r im cover
Fig. 7 Bucket Seat—Power Seat t o bu cket sea t .
(3) If equ ipped, disen ga ge power sea t wir e con n ec-
(2) Con n ect sea t belt bu ckle wa r n in g wir e h a r n ess t or fr om power sea t swit ch .
con n ect or. (4) Rem ove t h e in boa r d sea t ba ck pivot bolt .
(3) F or power sea t s, con n ect wir e h a r n ess con n ec- (5) P osit ion t h e sea t ba ck in t h e fu ll for wa r d or fu ll
t or. If equ ipped, con n ect h a r n ess for h ea t ed sea t . r eclin e posit ion .
(4) In st a ll fr on t fa st en er s a t t a ch in g sea t t o floor (6) Rem ove t h e sea t ba ck cover zipper fr om t h e
pa n . Tigh t en t o 27 N·m (20 ft . lbs.) t or qu e. ba se of t h e sea t ba ck.
(5) In st a ll r ea r fa st en er s a t t a ch in g sea t t o floor (7) Disen ga ge t h e cover zipper a n d r ou t e t h e zip-
pa n . Tigh t en t o 27 N·m (20 ft . lbs.) t or qu e. per en d bet ween t h e in boa r d sea t ba ck a n d sea t cu sh -
(6) In st a ll n u t a t t a ch in g sea t t o floor pa n . Tigh t en ion fr a m e.
t o 40 N·m (30 ft . lbs.) t or qu e. (8) Roll t h e sea t ba ck cover u pwa r d (F ig. 8).
(9) Disen ga ge t h e h ogr in gs a t t a ch in g t h e sea t ba ck
BUCKET SEAT TRACK cover t o t h e sea t ba ck cu sh ion su ppor t wir es (F ig. 9).
(10) Roll t h e sea t ba ck cover u pwa r d a n d disen ga ge
REMOVAL t h e h ook a n d loop fa st en er (F ig. 10).
(11) Roll sea t ba ck cover u p a n d over t h e h ea d
NOTE: If the vehicle is equipped with manually
r est r a in t sleeves, if equ ipped a n d sepa r a t e fr om t h e
adjusted bucket seats, the inboard or outboard seat
sea t ba ck.
track may be serviced separately.

(1) Rem ove bu cket sea t fr om veh icle. INSTALLATION


(2) Rem ove scr ews a t t a ch in g t h e side sh ield t r im (1) P osit ion t h e sea t ba ck cover on t h e sea t ba ck
cover fr om t h e sea t . cu sh ion a n d r oll sea t ba ck cover down over t h e h ea d
(3) If equ ipped, disen ga ge t h e power sea t con n ec- r est r a in t sleeves. Rou t e t h e sleeves t h r ou gh t h e
t or fr om t h e power sea t swit ch . a ccess h oles in t h e cover, if equ ipped.
(4) Rem ove 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 (2) Roll t h e sea t ba ck cover down wa r d a n d en ga ge
t h e bu cket sea t pla t for m . t h e h ook a n d loop fa st en er.
(5) Wh en sepa r a t in g t h e sea t t r a ck fr om t h e pla t - (3) Con t in u e r ollin g t h e cover down wa r d a n d
for m , r ou t e t h e power sea t swit ch con n ect or t h r ou gh en ga ge t h e h ogr in gs a t t a ch in g t h e sea t ba ck cover t o
t h e a ccess h ole in t h e sea t cu sh ion fr a m e, if t h e sea t ba ck cu sh ion su ppor t wir es.
equ ipped. (4) Rou t e t h e zipper en d bet ween t h e in boa r d sea t ba ck
a n d sea t cu sh ion fr a m e a n d en ga ge t h e cover zipper.
(5) In st a ll t h e in boa r d sea t ba ck pivot bolt .
(6) In st a ll t h e side sh ield t r im cover.
(7) In st a ll h ea d r est r a in t , if equ ipped.
XJ BODY 23 - 13
REM OVAL AN D I N STALLAT I ON (Cont inue d)

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.

SEAT BACK~--- _.,.,_...,_.,

80aafb05

Fig. 8 Seatback Cover

SEAT BACK
CUSHION

' INSTALLATION
Fig. 11 Bucket Seatback

(1) P osit ion sea t ba ck on sea t cu sh ion fr a m e.


(2) In st a ll in boa r d sea t ba ck pivot bolt .
(3) In st a ll bolt s a t t a ch in g r eclin er t o sea t cu sh ion
fr a m e.
(4) In st a ll side sh ield t r im cover.

80aafb04 BUCKET SEAT CUSHION COVER


Fig. 9 Hog Ring
REMOVAL
(1) Rem ove sea t fr om veh icle.
(2) Rem ove side sh ield t r im cover.
(3) Rem ove sea t ba ck.
(4) Wit h t h e cu sh ion side down , disen 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.
(5) Disen 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.
(6) Tu r n t h e cu sh ion over a n d r oll t h e cover off t h e
cu sh ion .
(7) Rem ove t h e h og r in gs a t t a ch in g t h e cover t o
t h e cu sh ion su ppor t wir es (F ig. 12).
(8) Sepa r a t e t h e cover fr om t h e cu sh ion .

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)

REAR SEAT CUSHION


REMOVAL
(1) Disen ga ge sea t cu sh ion a t r ea r by pu llin g
u pwa r d on r elea se st r a p (F ig. 14).
(2) Tilt sea t cu sh ion for wa r d.
(3) Disen ga ge sea t cu sh ion la t ch wit h r igh t side
r elea se lever. Sepa r a t e r igh t side la t ch a n d left side
sea t br a cket fr om floor a n ch or bolt s, a n d r em ove
cu sh ion fr om veh icle (F ig. 15).

SEAT CUSHION

/ 80aafb06

Fig. 12 Seat Cushion Cover Hog Rings


(5) In st a ll sea t ba ck.
(6) In st a ll side sh ield t r im cover.
(7) In st a ll sea t .

BUCKET SEAT RECLINER


REMOVAL
(1) Rem ove side sh ield t r im cover.
(2) Disen ga ge sea t ba ck cover zipper.
(3) Roll ou t er sea t ba ck cover u pwa r d.
(4) Rem ove bolt s a t t a ch in g r eclin er t o sea t ba ck
a n d sea t cu sh ion fr a m es (F ig. 13).
(5) Sepa r a t e r eclin er fr om sea t .
J8923-94

Fig. 14 Seat Cushion Release Strap


SEAT BACK SEAT BACK
LATCH STRIKER LATCH STRIKER
BRACKET

Fig. 13 Bucket Seat Recliner


INSTALLATION
(1) P osit ion r eclin er on sea t .
(2) In st a ll bolt s a t t a ch in g r eclin er t o sea t ba ck a n d
sea t cu sh ion fr a m es (F ig. 13).
(3) Roll sea t ba ck cover down wa r d. SEAT
(4) E n ga ge sea t ba ck cover zipper. CUSHION 80aa0fd2
(5) In st a ll side sh ield t r im cover.
Fig. 15 Rear Seat Cushion/Seat Back
XJ BODY 23 - 15
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION
(1) P osit ion sea t cu sh ion in veh icle.
(2) In ser t left pivot in a n ch or gr om m et .
(3) F or ce r igh t side la t ch on t o a n ch or bolt a n d
REMOVER TOOL
pivot sea t cu sh ion t o h or izon t a l posit ion .
(4) Lock sea t cu sh ion in -pla ce by pr essin g fir m ly
on cen t er of cu sh ion u n t il la t ch en ga ges.

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.
/

REAR SEAT CUSHION COVER /


/

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)

SEAT BACK SEAT BACK


LATCH STRIKER LATCH STRIKER
BRACKET

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.

REAR SEATBACK COVER


REMOVAL
(1) Rem ove t h e sea t ba ck fr om t h e veh icle.
(2) Rem ove t h e sea t ba ck la t ch r elea se h a n dle a n d
bezel fr om t h e sea t ba ck.
(3) Disen ga ge t h e cover zipper s.
(4) Disen ga ge t h e J -st r a p a t t a ch in g t h e cover t o
t h e sea t ba ck fr a m e (F ig. 19). Extractor Head Restraint Sleeve 6773
(5) Rem ove t h e cover fr om t h e sea t ba ck pa d.

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

BODY COM PON EN T SERV I CE

INDEX
page page

DIAGNOSIS AND TESTING HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52


WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . 18 HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SERVICE PROCEDURES HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . . . 19 HOOD LATCH STRIKER . . . . . . . . . . . . . . . . . . . 22
REMOVAL AND INSTALLATION HOOD RELEASE CABLE . . . . . . . . . . . . . . . . . . 22
A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . 44 HOOD SAFETY LATCH . . . . . . . . . . . . . . . . . . . 23
AIR EXHAUST GRILLE . . . . . . . . . . . . . . . . . . . . 43 HOOD SILENCER PAD . . . . . . . . . . . . . . . . . . . . 23
ASSIST HANDLE . . . . . . . . . . . . . . . . . . . . . . . . 45 LEFT FRONT FENDER . . . . . . . . . . . . . . . . . . . . 27
B-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . 45 LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
BODY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . 24 LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . . . . . 54
BODY SIDE MOLDING . . . . . . . . . . . . . . . . . . . . 42 LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . . . . 55
C-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . 45 LIFTGATE LATCH STRIKER . . . . . . . . . . . . . . . . 56
COWL GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . 24 LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . . . 55
COWL WEATHERSTRIP . . . . . . . . . . . . . . . . . . . 24 LIFTGATE OPENING UPPER TRIM . . . . . . . . . . 47
DOOR SILL SCUFF PLATE . . . . . . . . . . . . . . . . . 45 LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . . . 55
DRIP RAIL MOLDING . . . . . . . . . . . . . . . . . . . . . 42 LIFTGATE PILLAR TRIM . . . . . . . . . . . . . . . . . . 47
EXTERIOR NAMEPLATES . . . . . . . . . . . . . . . . . 25 LIFTGATE SCUFF PLATE . . . . . . . . . . . . . . . . . . 48
FRONT CARPET/MAT . . . . . . . . . . . . . . . . . . . . 50 LIFTGATE SUPPORT ROD BALL STUD . . . . . . 55
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 30 LIFTGATE SUPPORT ROD CYLINDER . . . . . . . . 54
FRONT DOOR GLASS . . . . . . . . . . . . . . . . . . . . 35 LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . . . . 53
FRONT DOOR GLASS EXTERIOR MOLDING . . . 34 LIFTGATE WEATHERSTRIP . . . . . . . . . . . . . . . . 56
FRONT DOOR GLASS RUN CHANNEL LOWER A-PILLAR COWL TRIM . . . . . . . . . . . . . 44
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 33 LUGGAGE RACK . . . . . . . . . . . . . . . . . . . . . . . . 43
FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . . . 30 QUARTER PANEL TRIM AND WHEELHOUSE
FRONT DOOR INNER BELT WEATHERSTRIP . . 32 COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
FRONT DOOR INSIDE HANDLE ACTUATOR . . . 32 QUARTER PANEL TRIM EXTENSION . . . . . . . . . 46
FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . . . 31 QUARTER WINDOW APPLIQUE . . . . . . . . . . . . . 42
FRONT DOOR LATCH STRIKER . . . . . . . . . . . . 32 REAR CARPET/MAT . . . . . . . . . . . . . . . . . . . . . 50
FRONT DOOR LOCK CYLINDER . . . . . . . . . . . . 31 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FRONT DOOR OPENING SECONDARY REAR DOOR GLASS EXTERIOR MOLDING . . . . 40
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 33 REAR DOOR GLASS RUN CHANNEL
FRONT DOOR OPENING WEATHERSTRIP . . . . 33 WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 39
FRONT DOOR OUTER BELT REAR DOOR HINGE . . . . . . . . . . . . . . . . . . . . . 38
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 32 REAR DOOR INNER BELT WEATHERSTRIP . . . 39
FRONT DOOR OUTSIDE HANDLE . . . . . . . . . . . 31 REAR DOOR INSIDE HANDLE ACTUATOR . . . . 39
FRONT DOOR RESTRAINT . . . . . . . . . . . . . . . . 30 REAR DOOR LATCH . . . . . . . . . . . . . . . . . . . . . 38
FRONT DOOR SPACER BLOCKS—TWO-DOOR REAR DOOR LATCH STRIKER . . . . . . . . . . . . . 39
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 REAR DOOR OUTER BELT
FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . . . 28 WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 39
FRONT DOOR WATERDAM . . . . . . . . . . . . . . . . 29 REAR DOOR OUTSIDE HANDLE . . . . . . . . . . . . 38
FRONT DOOR WINDOW REGULATOR . . . . . . . 34 REAR DOOR RESTRAINT . . . . . . . . . . . . . . . . . 37
FRONT FENDER FLARE . . . . . . . . . . . . . . . . . . 26 REAR DOOR TRIM PANEL . . . . . . . . . . . . . . . . . 36
FRONT INNER SCUFF PLATE . . . . . . . . . . . . . . 45 REAR DOOR WATERDAM . . . . . . . . . . . . . . . . . 37
FRONT SHOULDER BELT/BUCKLE . . . . . . . . . . 48 REAR DOOR WEATHERSTRIP . . . . . . . . . . . . . 40
FRONT WHEELHOUSE LINER . . . . . . . . . . . . . . 27 REAR DOOR WINDOW GLASS . . . . . . . . . . . . . 41
FULL FLOOR CONSOLE . . . . . . . . . . . . . . . . . . 50 REAR DOOR WINDOW REGULATOR . . . . . . . . 40
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 REAR FENDER FLARE . . . . . . . . . . . . . . . . . . . 42
GRILLE OPENING PANEL (GOP) . . . . . . . . . . . . 20 REAR SHOULDER/LAP BELT/BUCKLE . . . . . . . . 49
23 - 18 BODY XJ

REARVIEW MIRROR . . . . . . . . ......... . . . . 51 REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . . 58


REARVIEW MIRROR SUPPORT BRACKET . . . . 51 SPECIFICATIONS
RIGHT FRONT FENDER . . . . . ......... . . . . 27 BODY GAP AND FLUSH MEASUREMENTS . . . 117
SAFETY LATCH STRIKER . . . . ......... . . . . 23 BODY LUBRICANTS . . . . . . . . . . . . . . . . . . . . . 58
SIDE VIEW MIRROR . . . . . . . . ......... . . . . 26 BODY OPENING DIMENSIONS . . . . . . . . . . . . 118
SUNVISORS . . . . . . . . . . . . . . ......... . . . . 52 BODY SEALING LOCATIONS . . . . . . . . . . . . . . 102
ADJUSTMENTS STRUCTURAL ADHESIVE LOCATIONS . . . . . . 114
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 125
DOOR LATCH ADJUSTMENT . . . . . . . . . . . . . . . 57 WELD LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 59
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 SPECIAL TOOLS
LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

DI AGN OSI S AN D T EST I N G • If a lea k occu r s wh ile dr ivin g a t h igh wa y speeds


in a st ea dy r a in , t est t h e lea k a r ea wit h a r ea son a ble
WATER LEAKS velocit y st r ea m or fa n spr a y of wa t er. Dir ect t h e
Wa t er lea ks ca n be ca u sed by poor sea lin g, spr a y in a dir ect ion com pa r a ble t o a ct u a l con dit ion s.
im pr oper body com pon en t a lign m en t , body sea m • If a lea k occu r s wh en t h e veh icle is pa r ked on a n
por osit y, m issin g plu gs, or blocked dr a in h oles. Cen - in clin e, h oist t h e en d or side of t h e veh icle t o sim u -
t r ifu ga l a n d gr a vit a t ion a l for ce ca n ca u se wa t er t o la t e t h is con dit ion . Th is m et h od ca n be u sed wh en
dr ip fr om a loca t ion a wa y fr om t h e a ct u a l lea k poin t , t h e lea k occu r s wh en t h e veh icle a cceler a t es, st ops or
m a kin g lea k det ect ion difficu lt . All body sea lin g t u r n s. If t h e lea k occu r s on a cceler a t ion , h oist t h e
poin t s sh ou ld be wa t er t igh t in n or m a l wet -dr ivin g fr on t of t h e veh icle. If t h e lea k occu r s wh en br a kin g,
con dit ion s. Wa t er flowin g down wa r d fr om t h e fr on t of h oist t h e ba ck of t h e veh icle. If t h e lea k occu r s on left
t h e veh icle sh ou ld n ot en t er t h e pa ssen ger or lu gga ge t u r n s, h oist t h e left side of t h e veh icle. If t h e lea k
com pa r t m en t . Movin g sea lin g su r fa ces will n ot occu r s on r igh t t u r n s, h oist t h e r igh t side of t h e veh i-
a lwa ys sea l wa t er t igh t u n der a ll con dit ion s. At cle. F or h oist in g r ecom m en da t ion s r efer t o Gr ou p 0,
t im es, side gla ss or door sea ls will a llow wa t er t o Lu br ica t ion a n d Ma in t en a n ce, Gen er a l In for m a t ion
en t er t h e pa ssen ger com pa r t m en t du r in g h igh pr es- sect ion .
su r e wa sh in g or h a r d dr ivin g r a in (sever e) con di-
t ion s. Over com pen sa t in g on door or gla ss WATER LEAK DETECTION
a dju st m en t s t o st op a wa t er lea k t h a t occu r s u n der To det ect a wa t er lea k poin t -of-en t r y, do a wa t er
sever e con dit ion s ca n ca u se pr em a t u r e sea l wea r a n d t est a n d wa t ch for wa t er t r a cks or dr oplet s for m in g
excessive closin g or la t ch in g effor t . Aft er com plet in g on t h e in side of t h e veh icle. If n ecessa r y, r em ove in t e-
a r epa ir, wa t er-t est veh icle t o ver ify lea k h a s st opped r ior t r im cover s or pa n els t o ga in visu a l a ccess t o t h e
befor e r et u r n in g veh icle t o u se. lea k a r ea . If t h e h ose ca n n ot be posit ion ed wit h ou t
bein g h eld, h a ve som eon e h elp do t h e wa t er t est .
VISUAL INSPECTION BEFORE WATER LEAK TESTS Som e wa t er lea ks m u st be t est ed for a con sider a ble
Ver ify t h a t floor a n d body plu gs a r e in pla ce, body len gt h of t im e t o becom e a ppa r en t . Wh en a lea k
dr a in s a r e clea r, a n d body com pon en t s a r e pr oper ly a ppea r s, fin d t h e h igh est poin t of t h e wa t er t r a ck or
a lign ed a n d sea led. If com pon en t a lign m en t or sea l- dr op. Th e h igh est poin t u su a lly will sh ow t h e poin t of
in g is n ecessa r y, r efer t o t h e a ppr opr ia t e sect ion of en t r y. Aft er lea k poin t h a s been fou n d, r epa ir t h e
t h is gr ou p for pr oper pr ocedu r es. lea k a n d wa t er t est t o ver ify t h a t t h e lea k h a s
st opped.
WATER LEAK TESTS Loca t in g t h e en t r y poin t of wa t er t h a t is lea kin g
in t o a ca vit y bet ween pa n els ca n be difficu lt . Th e
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS t r a pped wa t er m a y spla sh or r u n fr om t h e ca vit y,
OR TOOLS IN WATER TEST AREA. PERSONAL oft en a t a dist a n ce fr om t h e en t r y poin t . Most wa t er
INJURY CAN RESULT. lea ks of t h is t ype becom e a ppa r en t a ft er a cceler a t in g,
st oppin g, t u r n in g, or wh en on a n in clin e.
Wh en t h e con dit ion s ca u sin g a wa t er lea k h a ve
been det er m in ed, sim u la t e t h e con dit ion s a s closely MIRROR INSPECTION METHOD
a s possible. Wh en a lea k poin t a r ea is visu a lly obst r u ct ed, u se
• If a lea k occu r s wit h t h e veh icle pa r ked in a a su it a ble m ir r or t o ga in visu a l a ccess. A m ir r or ca n
st ea dy ligh t r a in , flood t h e lea k a r ea wit h a n open - a lso be u sed t o deflect ligh t t o a lim it ed-a ccess a r ea
en ded ga r den h ose. t o a ssist in loca t in g a lea k poin t .
XJ BODY 23 - 19
DI AGN OSI S AN D T EST I N G (Cont inue d)
BRIGHT LIGHT LEAK TEST METHOD ROAD TESTING WIND NOISE
Som e wa t er lea ks in t h e lu gga ge com pa r t m en t ca n (1) Dr ive t h e veh icle t o ver ify t h e gen er a l loca t ion
be det ect ed wit h ou t wa t er t est in g. P osit ion t h e veh i- of t h e win d n oise.
cle in a br igh t ly lit a r ea . F r om in side t h e da r ken ed (2) Apply 50 m m (2 in .) m a skin g t a pe in 150 m m
lu gga ge com pa r t m en t in spect a r ou n d sea ls a n d body (6 in .) len gt h s a lon g wea t h er st r ips, weld sea m s or
sea m s. If n ecessa r y, h a ve a h elper dir ect a dr op ligh t m oldin gs. Aft er ea ch len gt h is a pplied, dr ive t h e veh i-
over t h e su spect ed lea k a r ea s a r ou n d t h e lu gga ge cle. If n oise goes a wa y a ft er a piece of t a pe is a pplied,
com pa r t m en t . If ligh t is visible t h r ou gh a n or m a lly r em ove t a pe, loca t e, a n d r epa ir defect .
sea led loca t ion , wa t er cou ld en t er t h r ou gh t h e open -
in g. POSSIBLE CAUSE OF WIND NOISE
• Moldin gs st a n din g a wa y fr om body su r fa ce ca n
PRESSURIZED LEAK TEST METHOD ca t ch win d a n d wh ist le.
Wh en a wa t er lea k in t o t h e pa ssen ger com pa r t - • Ga ps in sea led a r ea s beh in d over h a n gin g body
m en t ca n n ot be det ect ed by wa t er t est in g, pr essu r ize fla n ges ca n ca u se win d-r u sh in g sou n ds.
t h e pa ssen ger com pa r t m en t a n d soa p t est ext er ior of • Misa lign ed m ova ble com pon en t s.
t h e veh icle. To pr essu r ize t h e pa ssen ger com pa r t - • Missin g or im pr oper ly in st a lled plu gs in pilla r s.
m en t , close a ll door s a n d win dows, st a r t en gin e, a n d • Weld bu r n t h r ou gh h oles.
set h ea t er con t r ol t o h igh blower in H E AT posit ion . If
en gin e ca n n ot be st a r t ed, con n ect a ch a r ger t o t h e
ba t t er y t o en su r e a dequ a t e volt a ge t o t h e blower. SERV I CE PROCEDU RES
Wit h in t er ior pr essu r ized, a pply dish det er gen t solu -
t ion t o su spect ed lea k a r ea on t h e ext er ior of t h e BODY LUBRICATION
veh icle. Apply det er gen t solu t ion wit h spr a y device or All m ech a n ism s a n d lin ka ges sh ou ld be lu br ica t ed
soft br ist le br u sh . If soa p bu bbles occu r a t a body wh en n ecessa r y. Th is will m a in t a in ea se of oper a t ion
sea m , join t , sea l or ga sket , t h e lea k en t r y poin t cou ld a n d pr ovide pr ot ect ion a ga in st r u st a n d excessive
be a t t h a t loca t ion . wea r. Th e wea t h er st r ip sea ls sh ou ld be lu br ica t ed t o
pr olon g t h eir life a s well a s t o im pr ove door sea lin g.
WIND NOISE All a pplica ble ext er ior a n d in t er ior veh icle oper a t -
Win d n oise is t h e r esu lt of m ost a ir lea ks. Air lea ks in g m ech a n ism s sh ou ld be in spect ed a n d clea n ed.
ca n be ca u sed by poor sea lin g, im pr oper body com po- P ivot /slidin g con t a ct a r ea s on t h e m ech a n ism s sh ou ld
n en t a lign m en t , body sea m por osit y, or m issin g plu gs t h en be lu br ica t ed.
in t h e en gin e com pa r t m en t or door h in ge pilla r a r ea s. (1) Wh en n ecessa r y, lu br ica t e t h e oper a t in g m ech -
All body sea lin g poin t s sh ou ld be a ir t igh t in n or m a l a n ism s wit h t h e specified lu br ica n t s.
dr ivin g con dit ion s. Movin g sea lin g su r fa ces will n ot (2) Apply silicon e lu br ica n t t o a clot h a n d wipe it
a lwa ys sea l a ir t igh t u n der a ll con dit ion s. At t im es, on door sea ls t o a void over-spr a y t h a t ca n soil pa s-
side gla ss or door sea ls will a llow win d n oise t o be sen ger ’s clot h in g.
n ot iced in t h e pa ssen ger com pa r t m en t du r in g h igh (3) Befor e a pplyin g lu br ica n t , t h e com pon en t
cr oss win ds. Over com pen sa t in g on door or gla ss sh ou ld be wiped clea n . Aft er lu br ica t ion , a n y excess
a dju st m en t s t o st op win d n oise t h a t occu r s u n der lu br ica n t sh ou ld be r em oved.
sever e con dit ion s ca n ca u se pr em a t u r e sea l wea r a n d (4) Th e h ood la t ch , la t ch r elea se m ech a n ism , la t ch
excessive closin g or la t ch in g effor t . Aft er a r epa ir pr o- st r iker, a n d sa fet y la t ch sh ou ld be lu br ica t ed per iod-
cedu r e h a s been per for m ed, t est veh icle t o ver ify ica lly.
n oise h a s st opped befor e r et u r n in g veh icle t o u se. (5) Th e door lock cylin der s sh ou ld be lu br ica t ed
Win d n oise ca n a lso be ca u sed by im pr oper ly fit t ed t wice ea ch yea r (pr efer a bly a u t u m n a n d spr in g):
ext er ior m oldin gs or body or n a m en t a t ion . Loose • Spr a y a sm a ll a m ou n t of lock cylin der lu br ica n t
m oldin gs ca n flu t t er, cr ea t in g a bu zzin g or ch a t t er in g dir ect ly in t o t h e lock cylin der.
n oise. An open ca vit y or pr ot r u din g edge ca n cr ea t e a • Apply a sm a ll a m ou n t t o t h e key a n d in ser t it
wh ist lin g or h owlin g n oise. In spect t h e ext er ior of t h e in t o t h e lock cylin der.
veh icle t o ver ify t h a t t h ese con dit ion s do n ot exist . • Rot a t e it t o t h e locked posit ion a n d t h en ba ck t o
t h e u n locked posit ion sever a l t im es.
VISUAL INSPECTION BEFORE TESTS • Rem ove t h e key. Wipe t h e lu br ica n t fr om it wit h
Ver ify t h a t floor a n d body plu gs a r e in pla ce a n d a clea n clot h t o a void soilin g of clot h in g.
body com pon en t s a r e a lign ed a n d sea led. If com po-
n en t a lign m en t or sea lin g is n ecessa r y, r efer t o t h e
a ppr opr ia t e sect ion of t h is gr ou p for pr oper pr oce-
du r es.
23 - 20 BODY XJ

REM OVAL AN D I N STALLAT I ON


GRILLE
REMOVAL
(1) Rem ove t h e h ea dla m p/pa r k la m p bezels.
(2) Rem ove t h e scr ews a t t a ch in g t h e gr ille t o t h e
gr ille open in g pa n el (GOP ) (F ig. 1).
(3) Sepa r a t e t h e gr ille fr om t h e GOP.

NUT
BODY

80b8982b

Fig. 2 Grille Opening Panel


(5) In st a ll n u t s a t t a ch in g GOP t o su ppor t br a cket .
Tigh t en n u t s t o 4 N·m (38 in -lbs) t or qu e.
(6) In st a ll h ea dla m ps a n d pa r k/t u r n sign a l la m ps.
(7) In st a ll gr ille.
(8) In st a ll side m a r ker la m ps.
(9) In st a ll h ea dla m p bezels.
GRILLE
(10) Adju st h ea dla m p a im , if n ecessa r y.
80aafb27

Fig. 1 Grille HOOD


INSTALLATION REMOVAL
(1) P osit ion t h e gr ille in t h e GOP. (1) Ra ise h ood.
(2) In st a ll t h e scr ews. (2) Discon n ect u n der h ood la m p wir e h a r n ess con -
(3) In st a ll t h e h ea dla m p/pa r k la m p bezels. n ect or, if equ ipped.
(3) Discon n ect r elea se ca ble fr om la t ch r elea se
GRILLE OPENING PANEL (GOP) bellcr a n k.
(4) Rem ove la t ch r elea se ca ble clips a n d r em ove
REMOVAL ca ble fr om h ood (F ig. 3).
(1) Rem ove h ea dla m p bezels. (5) Ma r k loca t ion of h ood, h in ges a n d h in ge sh im s
(2) Rem ove gr ille. for in st a lla t ion .
(3) Rem ove side m a r ker la m ps. (6) Rem ove bolt s t h a t a t t a ch h in ges t o h ood.
(4) Rem ove h ea dla m ps a n d pa r k/t u r n sign a l (7) Rem ove h ood fr om veh icle wit h a id of a h elper.
la m ps.
(5) Open h ood. INSTALLATION
(6) Rem ove n u t s t h a t a t t a ch GOP t o fr on t fen der s (1) P osit ion h ood on sh im s a n d h in ges; fin ger-
(F ig. 2). t igh t en h in ge bolt s.
(7) Rem ove n u t s a t t a ch in g GOP t o su ppor t (2) Align h in ges a n d sh im s wit h r efer en ce m a r ks
br a cket . a n d t igh t en h in ge bolt s.
(8) P u ll GOP for wa r d a n d discon n ect h a r n ess clips (3) Con n ect la t ch r elea se ca ble a n d la t ch con n ect -
a n d fr on t la m p h a r n ess con n ect or s. in g r od t o bellcr a n k.
(9) Rem ove GOP fr om veh icle. (4) At t a ch la t ch r elea se ca ble t o clips.
(5) Con n ect u n der h ood la m p wir e h a r n ess con n ec-
INSTALLATION t or.
(1) P la ce GOP on bu m per a n d secu r e a ll h a r n ess
clips. HOOD HINGE
(2) Con n ect a ll la m p wir e h a r n ess con n ect or s.
(3) P osit ion GOP on veh icle. REMOVAL
(4) In st a ll n u t s a t t a ch in g GOP t o fr on t fen der s. (1) Ra ise a n d su ppor t h ood.
Tigh t en n u t s t o 4 N·m (38 in -lbs) t or qu e.
XJ BODY 23 - 21
REM OVAL AN D I N STALLAT I ON (Cont inue d)

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

Fig. 3 Hood Components


23 - 22 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Usin g a gr ea se pen cil or equ iva len t , m a r k posi- HOOD RETAINER CLIP
t ion of h ood.
(3) Rem ove sea l fr om h in ge ba se (F ig. 4).
(4) Rem ove h in ge r et a in in g n u t s fr om st u ds.

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

Fig. 6 Hood Release Cable Bellcrank


(3) P osit ion ca ble br a cket on cowl side pa n el a n d
in st a ll scr ews.
(4) In st a ll left cowl side t r im pa n el.
(5) Con n ect ca ble a n d la t ch r od t o bellcr a n k.
(6) P osit ion bellcr a n k on h ood a n d in st a ll r ivet s.
(7) At t a ch ca ble t o clips. Fig. 8 Hood Safety Latch Striker
(8) Test r elea se ca ble for pr oper oper a t ion .
INSTALLATION
HOOD SAFETY LATCH (1) P osit ion st r iker on r a dia t or su ppor t cr ossm em -
ber a n d in st a ll scr ews.
REMOVAL (2) Test sa fet y la t ch oper a t ion .
(1) Open a n d su ppor t h ood.
(2) Rem ove t h e n u t s a t t a ch in g t h e sa fet y la t ch t o HOOD SILENCER PAD
t h e in n er h ood pa n el (F ig. 7).
(3) Sepa r a t e t h e sa fet y la t ch fr om t h e h ood. REMOVAL
(1) Open a n d su ppor t h ood.
HOOD (2) Rem ove t h e h ood la t ch r elea se bellcr a n k.
(3) Rem ove t h e clips a t t a ch in g t h e la t ch con n ect -
in g r od t o t h e h ood in n er pa n el.
NUT (4) Rem ove t h e r et a in er s a t t a ch in g t h e h ood
silen cer pa d t o t h e in n er h ood pa n el (F ig. 9).
(5) Sepa r a t e t h e h ood silen cer pa d fr om t h e h ood.

80ab5cde

Fig. 7 Hood Safety Latch


INSTALLATION
(1) P osit ion t h e sa fet y la t ch on t h e h ood.
(2) In st a ll t h e n u t s a t t a ch in g t h e sa fet y la t ch t o
RETAINER ~
t h e in n er h ood pa n el.
80ab5ceb
(3) Close h ood.
Fig. 9 Hood Silencer Pad
23 - 24 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION PLASTIC NOZZLE
(1) P osit ion t h e h ood silen cer pa d on t h e h ood PUSH-RIVET
in n er pa n el.
(2) In st a ll t h e r et a in er s a t t a ch in g t h e h ood
silen cer pa d t o t h e in n er h ood pa n el.
(3) In st a ll t h e clips a t t a ch in g t h e la t ch con n ect in g GRILLE
r od t o t h e h ood in n er pa n el.
(4) In st a ll t h e h ood la t ch r elea se bellcr a n k.
(5) Close h ood.

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).

NOTE: Force the cowl grille rearward while tighten-


ing the screws.

(4) In st a ll t h e win dsh ield wiper a r m s on t h e piv-


ot s.

@ 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)

1 SIDE VIEW MIRROR


REMOVAL
(1) Rem ove t h e door t r im pa n el.
(2) Rem ove t h e scr ew a t t a ch in g t h e m ir r or t r im
cover /spea ker gr ille t o t h e door in n er pa n el.
(3) r em ove pu sh -in fa st en er a t t a ch in g t r im cover
t o door in n er pa n el (u se specia l t ool C-4829).
(4) Discon n ect t h e power m ir r or wir e con n ect or, if
equ ipped.
(5) Rem ove t h e scr ews a t t a ch in g t h e m ir r or t o t h e
door (F ig. 16).
(6) Sepa r a t e t h e m ir r or fr om t h e door.
1 = SPORT 3=4X4
2 = CHEROKEE COUNTRY 4 = 4.0L 80b8982c SIDE VIEW
MIRROR
Fig. 14 Body Decals WIRE
HARNESS
(1) Apply a len gt h of m a skin g t a pe on t h e body,
pa r a llel t o t h e t op edge of t h e n a m epla t e t o u se a s a
gu ide, if n ecessa r y.
(2) If t em per a t u r e is below 21°C (70°F ) wa r m
em blem wit h a h ea t la m p or gu n . Do n ot exceed 52°C
(120°F ) wh en h ea t in g em blem .
(3) In ser t a pla st ic t r im st ick or a h a r d wood
wedge beh in d t h e em blem t o sepa r a t e t h e a dh esive
ba ckin g fr om t h e body.
(4) Clea n a dh esive r esidu e fr om body wit h MOPAR
Su per Clea n solven t or equ iva len t .
80aafb5f

INSTALLATION Fig. 16 Side View Mirror


(1) Rem ove pr ot ect ive cover fr om a dh esive t a pe on
ba ck of em blem . INSTALLATION
(2) P osit ion em blem pr oper ly on body (F ig. 15). (1) P osit ion t h e m ir r or on t h e door.
(3) P r ess em blem fir m ly t o body wit h pa lm of (2) In st a ll t h e scr ews a t t a ch in g t h e m ir r or t o t h e
h a n d. door.
(4) If t em per a t u r e is below 21°C (70°F ) wa r m (3) Con n ect t h e power m ir r or wir e con n ect or, if
em blem wit h a h ea t la m p or gu n t o a ssu r e a dh esion . equ ipped.
Do n ot exceed 52°C (120°F ) wh en h ea t in g em blem . (4) In st a ll n ew pu sh -in fa st en er.
(5) In st a ll t h e m ir r or t r im cover /spea ker gr ille.
(6) In st a ll t h e door t r im pa n el.

FRONT FENDER FLARE


REMOVAL
(1) Rem ove t h e scr ew a t t a ch in g t h e lower pa r t of
fla r e t o t h e bot t om of t h e fen der.
(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 spla sh sh ield (F ig. 17).
(3) Rem ove t h e lin er fr om t h e fen der.
(4) Rem ove t h e fa st en er s a t t a ch in g t h e fen der fla r e
a n d r et a in er t o t h e fen der.
(5) 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
fen der.

Fig. 15 Exterior Nameplates


XJ BODY 23 - 27
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) In st a ll t ir e.
FENDER (4) Lower veh icle.

RIGHT FRONT FENDER


REMOVAL
(1) Ra ise a n d su ppor t t h e h ood.
(2) Rem ove t h e gr ille open in g pa n el (GOP ).
(3) If equ ipped, r em ove t h e r a dio a n t en n a m a st ,
a n d com pon en t s fr om t h e fen der.
(4) Rem ove t h e coola n t r ecover y bot t le.
(5) Ra ise a n d su ppor t t h e veh icle.
(6) Rem ove t h e r igh t fr on t wh eel.
(7) Rem ove t h e fr on t bu m per en d ca p.
RETAINER 80aafb58 (8) Rem ove t h e wh eelh ou se lin er.
(9) Rem ove t h e fen der fla r e a n d r et a in er s.
Fig. 17 Fender Flare (10) Discon n ect a ll wir e h a r n ess con n ect or s.
(11) Rem ove t h e a ir deflect or.
INSTALLATION
(12) Rem ove t h e fen der lower scr ews (F ig. 19).
(1) P osit ion t h e fen der fla r e a n d r et a in er on t h e
(13) Rem ove t h e fen der t op, fr on t a n d t h e r ea r
fen der.
scr ews.
(2) In st a ll t h e n u t s a t t a ch in g t h e fen der fla r e a n d
(14) Rem ove t h e scr ews a t t a ch in g t h e fen der t o t h e
r et a in er t o t h e wh eelh ou se fen der.
in n er su ppor t br a cket (F ig. 20).
(3) In st a ll t h e scr ew a t t a ch in g t h e lower pa r t of
(15) Sepa r a t e t h e fen der fr om t h e in n er fen der
fla r e t o t h e bot t om of t h e fen der.
pa n el.
FRONT WHEELHOUSE LINER INSTALLATION
(1) P osit ion t h e fen der on t h e in n er fen der pa n el.
REMOVAL (2) In st a ll a ll fen der scr ews fin ger-t igh t .
(1) H oist veh icle.
(3) Align t h e fen der wit h t h e body pa n els a n d
(2) Rem ove t ir e.
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
(3) Rem ove t h e pu sh -in fa st en er s a t t a ch in g t h e
pa n els.
wh eelh ou se lin er t o t h e in n er fen der.
(4) In st a ll t h e a ir deflect or.
(4) Sepa r a t e t h e wh eelh ou se lin er fr om t h e fen der
(5) In st a ll t h e fen der fla r e a n d r et a in er s.
(F ig. 18).
(6) In st a ll t h e wh eelh ou se lin er.
(7) In st a ll t h e fr on t bu m per en d ca p.
(8) In st a ll t h e wh eel, r em ove t h e su ppor t a n d
lower t h e veh icle.
(9) In st a ll t h e gr ille open in g pa n el (GOP ).
(10) In st a ll t h e r a dio a n t en n a .

LEFT FRONT FENDER


REMOVAL
(1) Ra ise a n d su ppor t t h e h ood.
(2) Rem ove t h e gr ille open in g pa n el (GOP ).
(3) Ra ise a n d su ppor t t h e veh icle.
(4) Rem ove t h e left fr on t wh eel.
RETAINER (5) Rem ove t h e fr on t bu m per en d ca p.
80aafb59 (6) Rem ove t h e fen der fla r e a n d r et a in er s.
(7) Rem ove t h e wh eelh ou se lin er.
Fig. 18 Front Wheelhouse Liner (8) Rem ove t h e a ir deflect or.
INSTALLATION (9) Rem ove t h e fen der lower scr ews.
(10) Rem ove t h e fen der t op, fr on t a n d t h e r ea r
(1) P osit ion t h e wh eelh ou se lin er in t h e fen der.
scr ews.
(2) In st a ll n ew pu sh -in fa st en er s a t t a ch in g t h e
wh eelh ou se lin er t o t h e in n er fen der.
23 - 28 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

HOOD
BUMPER

SCREW

80ae8355

Fig. 19 Right Front Fender


(8) In st a ll t h e wh eel, r em ove t h e su ppor t a n d
lower t h e veh icle.
(9) In st a ll t h e gr ille open in g pa n el (GOP ).

FRONT DOOR TRIM PANEL


REMOVAL
(1) Roll win dow down .
(2) Rem ove win dow cr a n k, if equ ipped (F ig. 21).
(3) Rem ove t h e scr ews a t t a ch in g t h e t r im pa n el t o
t h e door in n er pa n el (F ig. 22) a n d (F ig. 23).
(4) Sepa r a t e t h e t r im pa n el fa st en er s fr om door
in n er pa n el wit h a pr y t ool (u se specia l t ool C-4829)
(F ig. 24).
(5) Lift t h e t r im pa n el u p a n d ou t wa r d t o sepa r a t e
fr om t h e in n er belt sea l.
Fig. 20 Inner Support Bracket (6) Move t h e door t r im pa n el ou t wa r d a n d discon -
(11) Rem ove t h e scr ews a t t a ch in g t h e fen der t o t h e n ect t h e h a n dle-t o-la t ch r ods.
in n er su ppor t br a cket . (7) Discon n ect t h e power door locks/win dows/m ir-
(12) Sepa r a t e t h e fen der fr om t h e in n er fen der r or s wir e h a r n ess con n ect or s, if equ ipped.
pa n el. (8) Rem ove t h e t r im pa n el fr om door.

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

Fig. 21 Window Crank—Typical

J898S-8
Fig. 24 Detaching Trim Panel Push-In Fasteners

Fig. 22 Front Door Trim Panel-Manual Window

Fig. 25 Push-In Fasteners


FRONT DOOR WATERDAM
REMOVAL
Th e wa t er da m is a t t a ch ed t o t h e door in n er pa n el
wit h a bu t ly a dh esive. If coh esive sepa r a t ion of t h e
bu t ly bet ween t h e wa t er da m a n d door in n er pa n el
occu r s du r in g t h e r em ova l pr ocess, cu t t h e st r a n ds of
bu t ly wit h a r a zor kn ife or equ iva len t .
(1) Rem ove door t r im pa n el.
(2) Disen ga ge clips a t t a ch in g wir e h a r n esses t o t h e
PUSH-IN
door in n er pa n el.
FASTENER
80all4de (3) P u sh t h e h a r n esses/con n ect or s t h r ou gh t h e
wa t er da m a n d in t o t h e door.
Fig. 23 Front Door Trim Panel-Power Window (4) Gr a sp t h e u pper a n d lower r ea r wa r d cor n er s of
(6) In st a ll t h e scr ews a t t a ch in g t h e t r im pa n el t o t h e wa t er da m a n d r a pidly peel ba ck t h e wa t er da m
t h e door in n er pa n el. fr om t h e door in n er pa n el.
(7) In st a ll t h e win dow cr a n k, if equ ipped. (5) Sepa r a t e t h e wa t er da m fr om t h e door in n er
pa n el.
23 - 30 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION
(1) Rou t e t h e la t ch r ods t h r ou gh t h e wa t er da m .
(2) P osit ion t h e wa t er da m on t h e door, a pply a dh e- UPPER
sive a s n ecessa r y a n d pr ess in t o pla ce. HINGE
(3) Rou t e t h e h a r n esses/con n ect or s t h r ou gh t h e
wa t er da m .
(4) E n ga ge clips a t t a ch in g wir e h a r n esses t o t h e
door in n er pa n el.
(5) In st a ll door t r im pa n el.

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 .

FRONT DOOR RESTRAINT


REMOVAL
(1) Rem ove door t r im pa n el.
(2) Rem ove door r a dio spea ker fr om door in n er
LOWER pa n el.
HINGE (3) Rem ove door r est r a in t (ch eck) r et a in in g pin
fr om br a cket wit h a pu n ch .
(4) Rem ove n u t s a n d r em ove r est r a in t via spea ker
80abac4a open in g. (F ig. 28).
RETAINING
Fig. 26 Front Door Hinge PIN
INSTALLATION
(1) P osit ion door in body open in g. DOOR
(2) Align door h in ges, pla t es a n d sh im s a n d in st a ll RESTRAINT

~
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.

FRONT DOOR HINGE


REMOVAL SPEAKER
OPENING J9223-283
(1) Rem ove door r est r a in t (ch eck) r et a in in g pin .
(2) Rem ove door h in ge bolt s a n d sh im s (F ig. 27).
Fig. 28 Door Restraint (Check)
(3) Ret a in door h in ge sh im s for cor r ect in st a lla -
t ion .
XJ BODY 23 - 31
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION FRONT DOOR LOCK CYLINDER
(1) P osit ion door r est r a in t in door by wa y of open -
in g a n d in st a ll n u t s. REMOVAL
(1) Rem ove t h e door t r im pa n el.
NOTE: Ensure the spring on the door restraint is (2) P eel ba ck wa t er da m t o a ccess lock cylin der.
facing outward. (3) Discon n ect t h e door la t ch -t o-lock cylin der r od
a t t h e door la t ch (F ig. 30).
(2) P osit ion door r est r a in t in br a cket wit h h oles
(4) Rem ove t h e lock cylin der r et a in er clip.
a lign ed a n d in ser t r et a in in g pin .
(5) Rem ove t h e lock cylin der.
(3) In st a ll r a dio spea ker a n d door t r im pa n el.
(6) If a pplica ble, r em ove t h e door la t ch -t o-lock cyl-
in der r od fr om t h e or igin a l lock cylin der. Con n ect it
FRONT DOOR OUTSIDE HANDLE t o t h e r epla cem en t lock cylin der.
REMOVAL
(1) Rem ove t h e door t r im pa n el a n d wa t er da m .
(2) Rem ove t h e a ccess h ole cover a n d r em ove t h e
r ea r wa r d n u t a t t a ch in g t h e door h a n dle t o t h e door.
(F ig. 29).
(3) Discon n ect t h e h a n dle-t o-la t ch r od fr om t h e
h a n dle la t ch r elea se lever a r m .
(4) Rem ove t h e for wa r d n u t a t t a ch in g t h e h a n dle
t o t h e door.
(5) Sepa r a t e t h e h a n dle fr om t h e door.

Fig. 30 Door Lock Cylinder


INSTALLATION
(1) P osit ion t h e lock cylin der a n d in t h e door open -
OUTSIDE in g.
HANDLE (2) In st a ll t h e r et a in er clip.
TO LATCH (3) Con n ect t h e door la t ch -t o-lock cylin der r od t o
ROD t h e door la t ch .
(4) P r ess t h e wa t er da m in t o posit ion .
DOOR LATCH 80aa4ad4 (5) In st a ll t h e door t r im pa n el.

Fig. 29 Front Door Outside Handle FRONT DOOR LATCH


INSTALLATION REMOVAL
(1) P osit ion t h e h a n dle in t h e door.
(1) Rem ove door t r im pa n el a n d wa t er da m .
(2) In st a ll t h e for wa r d n u t a t t a ch in g t h e h a n dle t o
(2) Rem ove scr ews a t t a ch in g la t ch t o door.
t h e door. (3) Discon n ect a ll r ods fr om la t ch (F ig. 31).
(3) Con n ect t h e la t ch t o h a n dle r od, t o t h e h a n dle
(4) Discon n ect power lock m ot or wir e con n ect or, if
la t ch r elea se lever a r m . equ ipped.
(4) In st a ll t h e r ea r wa r d n u t a t t a ch in g t h e door
(5) Rem ove la t ch fr om door fa ce.
h a n dle t o t h e door.
(5) In st a ll t h e a ccess h ole cover. INSTALLATION
(6) In st a ll t h e door wa t er da m a n d t r im pa n el. (1) P osit ion la t ch on door fa ce.
(2) Con n ect power lock m ot or wir e con n ect or, if
equ ipped.
(3) Con n ect a ll r ods t o la t ch .
(4) In st a ll scr ews a t t a ch in g la t ch t o door. Tigh t en
scr ews t o 11 N·m (8 ft . lbs.) t or qu e.
23 - 32 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(1) Rem ove t h e door t r im pa n el.
(2) Usin g a n X-ACTO kn ife or equ iva len t , cu t t h e
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
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
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

Fig. 33 Front Door Inner/Outer Belt Weatherstrip


INSTALLATION
(1) P osit ion t h e wea t h er st r ip on t h e door.
(2) P u sh wea t h er st r ip down t o sea t on t o door.
STRIKER (3) In st a ll door t r im pa n el.

80aa4ad3 FRONT DOOR OUTER BELT WEATHERSTRIP


Fig. 32 Front Door Latch Striker REMOVAL
INSTALLATION (1) Roll win dow down .
(1) P osit ion a n d a lign st r iker on B-pilla r. (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
(2) In st a ll scr ews a t t a ch in g st r iker t o B-pilla r. of t h e wea t h er st r ip.
Tigh t en scr ews t o 28 N·m (20 ft . lbs.) t or qu e. (3) Lift t h e wea t h er st r ip u p t o sepa r a t e fr om t h e
door (F ig. 33).
FRONT DOOR INSIDE HANDLE ACTUATOR
INSTALLATION
REMOVAL (1) P osit ion t h e wea t h er st r ip on t h e door.
Th e fr on t door in side h a n dle a ct u a t or is h ea t (2) P u sh wea t h er st r ip down t o sea t on t o door.
st a ked t o t h e fr on t door t r im pa n el du r in g t h e m a n -
u fa ct u r in g pr ocess.
XJ BODY 23 - 33
REM OVAL AN D I N STALLAT I ON (Cont inue d)

FRONT DOOR GLASS RUN CHANNEL FRONT SECONDARY


DOOR
WEATHERSTRIP SEAL
DOOR
SEAL
REMOVAL
(1) Rem ove door t r im pa n el.
(2) Rem ove wa t er da m .
(3) St a r t in g a t r ea r cor n er, peel wea t h er st r ip fr om
a r ou n d door fr a m e.

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

u pper r ea r cor n er, sea t t h e wea t h er st r ip in t o t h e


Fig. 34 Door Opening Weatherstrip
ch a n n el.
• P r ess t h e wea t h er st r ip t o sea t in t o t h e fr on t @- PRESS INWARD
lower gla ss r u n ch a n n el. FIRMLY AT
(2) As a pplica ble, m ove u pwa r d a n d for wa r d INDICATED AREA
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 wa t er da m .
(4) In st a ll door t r im pa n el.

FRONT DOOR OPENING WEATHERSTRIP


REMOVAL
(1) Rem ove A-pilla r t r im pa n el. © B-PILLAR
(2) Rem ove B-pilla r u pper t r im pa n el.
(3) Rem ove cowl side t r im pa n el.
(4) Rem ove in n er scu ff pla t e.
(5) Rem ove B-pilla r lower t r im pa n el.
(6) Gr a sp sea l a n d sepa r a t e fr om door open in g.

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

Fig. 37 Power Window Regulator

REAR
MOLDING
80aa0fe3

Fig. 36 Front Door Glass Exterior Molding


INSTALLATION
(1) St a r t a t t h e for wa r d en d of t h e u pper m oldin g,
for ce t h e m oldin g on t o t h e door pa n el a n d con t in u e
r ea r wa r d u n t il it is com plet ely sea t ed on t h e fla n ge. Fig. 38 Manual Window Regulator
(2) Ma t e t h e r ea r m oldin g wit h t h e u pper m oldin g
a n d for ce t h e m oldin g edge in wa r d. (2) At t a ch t h e r egu la t or t o door in n er pa n el wit h
(3) Con t in u e pr essin g a n d m ovin g down wa r d t o bolt s (F ig. 39).
com plet e t h e in st a lla t ion . (3) In st a ll t h e win dow gla ss
(4) In st a ll t h e ou t er belt wea t h er st r ip. (4) In st a ll t h e wa t er da m .
(5) In st a ll t h e t r im pa n el.
FRONT DOOR WINDOW REGULATOR
FRONT DOOR SPACER BLOCKS—TWO-DOOR
REMOVAL VEHICLES
(1) Rem ove t h e door t r im pa n el.
(2) Rem ove t h e wa t er da m . REMOVAL
(3) Rem ove t h e win dow gla ss. (1) Upper spa cer block: dr ill-ou t t h e r ivet h ea ds
(4) Loosen t h e bolt s a t t a ch in g t h e r egu la t or t o t h e a n d r em ove t h em fr om t h e r ein for cem en t pla t e (F ig.
in n er door pa n el (F ig. 37) a n d (F ig. 38) a s a pplica ble. 40).
(5) Lift t h e r egu la t or u pwa r d t o r elea se it fr om t h e (2) Lower spa cer block: r em ove t h e scr ews fr om
key h ole slot s a n d r em ove it t h r ou gh t h e a ccess h ole t h e door fa ce (F ig. 41).
in t h e door in n er pa n el. (3) As a pplica ble, r em ove t h e spa cer block fr om t h e
door win dow fr a m e or door fa ce.
INSTALLATION
(1) P osit ion t h e r egu la t or in t h e door a n d a lign INSTALLATION
wit h key h ole slot s. (1) As a pplica ble, posit ion t h e spa cer block on t h e
door win dow fr a m e or door fa ce.
XJ BODY 23 - 35
REM OVAL AN D I N STALLAT I ON (Cont inue d)

80a9f0f6

Fig. 39 Front Door Regulator


DOOR I DOOR
SPACER
£..-DOOR ))
I / , FACE
!
. FACE ,,,
' /;,
,,/
\\\
DOOR
SPACER

/ 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.

FRONT DOOR GLASS INSTALLATION


(1) P osit ion t h e gla ss in t h e door.
REMOVAL (2) In st a ll t h e bolt s a t t a ch in g t h e gla ss t o t h e r eg-
(1) Rem ove t h e door t r im pa n el. u la t or Tigh t en t h e bolt s t o 4 N·m (36 in -lbs) t or qu e.
(2) Rem ove t h e wa t er da m . (3) In st a ll in n er a n d ou t er belt wea t h er st r ip.
(3) Rem ove in n er a n d ou t er belt wea t h er st r ip. (4) At t a ch t h e door wa t er da m t o t h e door in n er
pa n el wit h a dh esive/sea la n t .
23 - 36 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

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.

REAR DOOR TRIM PANEL


REMOVAL
(1) Roll win dow down .
(2) Rem ove win dow cr a n k, if equ ipped (F ig. 43).
(3) Rem ove t h e scr ews a t t a ch in g t h e t r im pa n el t o
t h e door in n er pa n el (F ig. 44) a n d (F ig. 45).
(4) Sepa r a t e t h e t r im pa n el fa st en er s fr om door
in n er pa n el wit h a pr y t ool (u se specia l t ool C-4829)
(F ig. 46).
(5) Lift t h e t r im pa n el u p a n d ou t wa r d t o sepa r a t e PUSH-IN
FASTENER --_.;;~II
fr om t h e in n er belt sea l. 80aff4e4
(6) Move t h e door t r im pa n el ou t wa r d a n d discon - Fig. 45 Rear Door Trim Panel—Power Window
n ect t h e h a n dle-t o-la t ch r ods (F ig. 47).
(7) Discon n ect t h e power win dows wir e h a r n ess
con n ect or s, if equ ipped.
(8) Rem ove t h e t r im pa n el fr om door.

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)

INSIDE HANDLE (4) Sepa r a t e t h e wa t er da m fr om t h e door in n er


~ T O LATCH ROD pa n el.

~ \ INSIDE HANDLE INSTALLATION


I ACTUATOR (1) Rou t e t h e la t ch r ods a n d wir e h a r n esses
t h r ou gh t h e wa t er da m .
(2) P osit ion t h e wa t er da m on t h e door, a pply a dh e-
sive a s n ecessa r y a n d pr ess in t o pla ce.
(3) In st a ll door t r im pa n el.
LOCKTO \
LATCH ROD \ REAR DOOR
CLIP REMOVAL
(1) Rem ove door r est r a in t (ch eck) r et a in in g pin .
\__~-------- 80aa4b68 (2) F or veh icles equ ipped wit h power win dows a n d
power door locks, r em ove t r im pa n el a n d wa t er da m .
Fig. 47 Latch Rods Discon n ect a ll com pon en t s a n d r ou t e wir e h a r n ess
ou t of door.
INSTALLATION
(3) Rem ove bolt s a t t a ch in g h in ge t o door fa ce.
(1) Repla ce a n y br oken or da m a ged pu sh -in fa st en -
(4) Sepa r a t e door fr om veh icle.
er s.
(2) Con n ect t h e power win dow wir e h a r n ess con -
INSTALLATION
n ect or s, if equ ipped.
(1) P osit ion door in body open in g.
(3) Move t h e door t r im pa n el ou t wa r d a n d con n ect
(2) Align door h in ges, pla t es a n d sh im s a n d in st a ll
t h e h a n dle-t o-la t ch r ods.
bolt s. Tigh t en bolt s t o 3 N·m (2 ft . lbs.) t or qu e.
(4) P osit ion t h e t r im pa n el on t h e in n er belt sea l
(3) In st a ll door r est r a in t (ch eck).
a n d pu sh down t o sea t .
(4) If a pplica ble, r ou t e a n d con n ect wir e h a r n ess
(5) Align t h e loca t in g pin s a n d pu sh -in fa st en er s
con n ect or s.
(F ig. 48). P r ess in wa r d t o secu r e.
(5) If n ecessa r y, in st a ll door wa t er da m a n d t r im
(6) In st a ll t h e scr ews a t t a ch in g t h e t r im pa n el t o
pa n el.
t h e door in n er pa n el.
(7) In st a ll t h e win dow cr a n k, if equ ipped.
REAR DOOR RESTRAINT
REMOVAL
(1) Rem ove t h e door t r im pa n el.
(2) Rem ove t h e door r est r a in t (ch eck) r et a in in g pin
fr om t h e br a cket wit h a pu n ch .
(3) Rem ove t h e n u t s a n d r em ove t h e r est r a in t via
t h e a ccess open in g in t h e door in n er pa n el (F ig. 49).
RETAINING
PIN

80ab5cdf

Fig. 48 Push-In Fasteners


REAR DOOR WATERDAM
REMOVAL
(1) Rem ove door t r im pa n el. ACCESS
(2) P eel t h e wa t er da m fr om t h e door. OPENING J9223-284
(3) Rou t e t h e la t ch r ods a n d wir e h a r n esses
t h r ou gh t h e wa t er da m . Fig. 49 Door Restraint (Check)
23 - 38 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION OUTSIDE
(1) P osit ion t h e door r est r a in t in t h e door by wa y HANDLE
of t h e open in g a n d in st a ll t h e n u t s. Tigh t en t h e n u t s
t o 10 N·m (7 ft -lbs) t or qu e.
(2) P osit ion t h e door r est r a in t in br a cket wit h t h e
h oles a lign ed a n d in ser t t h e r et a in in g pin .

REAR DOOR HINGE


REMOVAL
(1) Rem ove door r est r a in (ch eck) pin . OUTSIDE
HANDLE
(2) Rem ove door h in ge bolt s a n d sh im s.
TO LATCH
(3) Ret a in bolt s a n d sh im s for cor r ect in st a lla t ion . ROD
INSTALLATION 80aa4b69

(1) P osit ion h in ge pla t es a n d sh im s on door fa ce.


(2) Align door h in ges a n d sh im s wit h bolt h oles Fig. 51 Latch Rod
a n d in st a ll h in ges. Tigh t en bolt s t o 3 N·m (2 ft . lbs.). (2) Con n ect t h e la t ch -t o-h a n dle r od t o t h e h a n dle
(3) Adju st /a lign la t ch st r iker a n d la t ch a s n eces- la t ch r elea se lever a r m .
sa r y. (3) In st a ll n u t s a t t a ch in g t h e door h a n dle t o t h e
(4) In st a ll door r est r a in (ch eck) r et a in in g pin . door.
(4) In st a ll t h e la t ch .
REAR DOOR OUTSIDE HANDLE (5) In st a ll t h e wa t er da m .
(6) In st a ll t h e t r im pa n el.
REMOVAL
(1) Rem ove t h e door t r im pa n el. REAR DOOR LATCH
(2) Roll t h e win dow t o t h e fu ll u p posit ion .
(3) P eel ba ck t h e wa t er da m t o a ccess t h e fa st en er s REMOVAL
for t h e ou t side h a n dle. (1) Rem ove a ccess plu g.
(4) Rem ove t h e la t ch . (2) Rem ove door t r im pa n el.
(5) Rem ove t h e a ccess h ole cover. (3) Rem ove wa t er da m .
(6) Rem ove t h e n u t s a t t a ch in g t h e door h a n dle t o (4) Rem ove scr ews a t t a ch in g door la t ch t o door
t h e door (F ig. 50). (F ig. 52).
(7) Discon n ect t h e h a n dle-t o-la t ch r od fr om t h e (5) Discon n ect a ll r ods fr om door la t ch .
h a n dle la t ch r elea se lever a r m (F ig. 51). (6) Rem ove door la t ch fr om door.

LATCH
REAR ROD
DOOR LATCH
ADJUSTMENT
Fig. 50 Rear Door Outside Handle
SCREW
INSTALLATION B0524e45

(1) P osit ion t h e h a n dle a t t h e door pa n el.


Fig. 52 Rear Door Latch
XJ BODY 23 - 39
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION REAR DOOR INNER BELT WEATHERSTRIP
(1) P osit ion door la t ch in door.
(2) Con n ect a ll r ods t o door la t ch . REMOVAL
(3) In st a ll scr ews a t t a ch in g door la t ch t o door. (1) Roll win dow down .
Tigh t en scr ews t o 11 N·m (8 ft . lbs.) t or qu e. (2) Rem ove door t r im pa n el.
(4) In st a ll wa t er da m . (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
(5) In st a ll door t r im pa n el. a n d lift fr om t h e door (F ig. 54).
(6) In st a ll a ccess plu g.
OUTER
REAR DOOR LATCH STRIKER BELT WEATHERSTRIP

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

STRIKER Fig. 54 Rear Door Inner/Outer Belt Weatherstrip

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.

REAR DOOR GLASS EXTERIOR MOLDING


REMOVAL
(1) Open t h e win dow.
(2) Rem ove t h e ou t er belt m oldin g.
(3) P r y a n d pu ll t h e m oldin g sect ion s fr om t h e ENDS
door pa n el fla n ge (F ig. 55). VIEWIN MEET
DIRECTION OF AT
ARROWZ CENTERLINE
80aa0fd7

Fig. 56 Door Opening Weatherstrip


INSTALLATION
(1) Wh en in st a llin g a door open in g wea t h er st r ip
sea l, st a r t a t t h e door sill cen t er lin e.
OUTER
(2) Move u pwa r d a n d a r ou n d edge of door open in g.
DOOR
PANEL
Sea t sea l on fla n ge.
(3) Move u pwa r d a n d a r ou n d t h e per im et er of t h e
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. 57).
(4) In st a ll u pper door open in g t r im .
80aa0fe5
(5) In st a ll in n er scu ff pla t e.
(6) In st a ll B-pilla r lower t r im pa n el.
Fig. 55 Rear Glass Exterior Molding
(7) In st a ll B-pilla r u pper t r im pa n el.
INSTALLATION
(1) St a r t in g a t t h e for wa r d en d of t h e u pper m old- REAR DOOR WINDOW REGULATOR
in g, for ce t h e m oldin g on t o t h e door pa n el fla n ge a n d
con t in u e r ea r wa r d u n t il it is com plet ely sea t ed on REMOVAL
t h e fla n ge. (1) Rem ove t h e door t r im pa n el.
(2) Ma t e t h e r ea r m oldin g wit h t h e u pper m oldin g (2) Rem ove t h e wa t er da m .
a n d for ce t h e m oldin g edge in wa r d. (3) Rem ove t h e bolt a t t a ch in g t h e win dow gla ss t o
(3) Con t in u e pr essin g a n d m ovin g down wa r d t o t h e r egu la t or a n d su ppor t t h e gla ss (F ig. 58).
com plet e t h e in st a lla t ion . (4) Rem ove t h e lower bolt s a t t a ch in g t h e r egu la t or
(4) In st a ll t h e ou t er belt m oldin g. t o t h e in n er door pa n el (F ig. 59).
(5) Rem ove t h e n u t s a t t a ch in g t h e r egu la t or m ot or
REAR DOOR WEATHERSTRIP t o t h e in n er door pa n el, if equ ipped.
(6) Loosen t h e u pper bolt t h a t a t t a ch es t h e r egu la -
REMOVAL t or t o t h e in n er door pa n el.
(1) Rem ove B-pilla r u pper t r im . (7) Discon n ect t h e wir e h a r n ess con n ect or fr om t h e
(2) Rem ove in n er scu ff pla t e. r egu la t or dr ive m ot or, if equ ipped.
(3) Rem ove B-pilla r lower t r im . (8) Rem ove t h e r egu la t or a n d dr ive m ot or, if
(4) Rem ove u pper door open in g t r im . equ ipped.
XJ BODY 23 - 41
REM OVAL AN D I N STALLAT I ON (Cont inue d)

@- PRESS INWARD
FIRMLY AT
INDICATED AREA

B-PILLAR

Fig. 59 Rear Door Window


REAR DOOR WINDOW GLASS
J9223-271
REMOVAL
Fig. 57 Door Opening Weatherstrip (1) Lower t h e win dow gla ss.
(2) Rem ove t h e t r im pa n el.
RETAINER (3) Rem ove t h e wa t er da m .
(WITH TABS) (4) Rem ove in n er a n d ou t er belt lin e wea t h er st r ip.
(5) Rem ove t h e win dow wea t h er st r ip fr om t h e
door.
(6) Rem ove t h e division ba r /st a t ion a r y gla ss (F ig.
60).
(7) Rem ove t h e win dow gla ss scr ew, bu sh in g a n d
"" r et a in er fr om t h e r egu la t or.

REGULATOR
'18
SCREW AND
BUSHING
(8) Rem ove t h e win dow gla ss fr om door.

WINDOW
GLASS J9223-501

Fig. 58 Regulator To Glass Screw Removal/


Installation DIVISION
BAR
INSTALLATION
(1) P osit ion win dow r egu la t or a n d, if equ ipped,
LOWER
dr ive m ot or wit h in t h e door pa n els. SCREW
(2) In st a ll t h e fa st en er s a t t a ch in g t h e r egu la t or t o
t h e door in n er pa n el.
(3) Con n ect t h e r egu la t or wir e h a r n ess con n ect or. 80ac2bd7
(4) P osit ion t h e win dow gla ss a t t h e r egu la t or a n d
in st a ll t h e r et a in er, bu sh in g a n d bolt . Fig. 60 Division Bar/Stationary Glass
(5) In st a ll t h e wa t er da m .
INSTALLATION
(6) In st a ll t h e t r im pa n el.
(1) In st a ll t h e gla ss in t h e door, a n d in st a ll t h e
r et a in er, bu sh in g a n d scr ew.
(2) Tigh t en t h e gla ss a t t a ch in g scr ew 6 N·m (53 in -
lbs) t or qu e.
(3) In st a ll t h e division ba r /st a t ion a r y gla ss in t h e
door.
23 - 42 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) In st a ll t h e gla ss r u n ch a n n el wea t h er st r ip.
(5) In st a ll t h e in n er a n d ou t er belt lin e wea t h er- WHEELHOUSE LINER
st r ip.
(6) In st a ll t h e wa t er da m .
(7) In st a ll t h e t r im pa n el.

BODY SIDE MOLDING


REMOVAL
(1) Loosen t h e body side m oldin g (F ig. 61) wit h a
h ea t gu n .
(2) Lift edge of m oldin g wit h a pu t t y kn ife a n d
peel m oldin g fr om body pa n el. Apply h ea t t o a n y
loca t ion wh er e t h e m oldin g r em a in s a dh er ed t o a BODY
pa n el. 80aafb64
(3) Rem ove t h e a dh esive fr om t h e body pa n el wit h
Mopa r Su per Clea n solven t or equ iva len t . Fig. 62 Fender Flare
(4) If t h e or igin a l m oldin g will be in st a lled, a lso
INSTALLATION
r em ove a ll a dh esive fr om it .
(1) P osit ion t h e fen der fla r e a n d r et a in er on t h e
fen der.
(2) In st a ll t h e n u t s a t t a ch in g t h e fen der fla r e a n d
r et a in er t o t h e wh eelh ou se lin er.
(3) In st a ll t h e scr ew a t t a ch in g t h e lower pa r t of
fla r e t o t h e bot t om of t h e fen der.

QUARTER WINDOW APPLIQUE


REMOVAL
(1) Rem ove t h e lift ga t e pilla r t r im .
(2) Rem ove n u t s fr om in side veh icle (F ig. 63).
(3) Usin g a t r im sick or equ iva len t , ca r efu lly pr y
t h e a ppliqu e t h e fr om pa n el.

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)

VEHICLE DRIP CROSS RAIL CROSS RAIL


ROOF MOLDING ADJUSTMENT
CLIP RELEASE BUTTON

J9223-97

Fig. 64 Luggage Rack


(6) In st a ll a n d t igh t en slide r a il scr ews.

AIR EXHAUST GRILLE

Fig. 63 Quarter Window Applique and Drip Molding REMOVAL


(1) Rem ove t h e scr ew t h a t a t t a ch es t h e gr ille t o
(2) Apply sea la n t t o t h e in n er side of t h e m oldin g door t h e open in g pa n el (F ig. 65).
t o sea l t h e r oof fla n ge. (2) P r y t h e bot t om edge of t h e gr ille fr om t h e door
open in g pa n el.
LUGGAGE RACK (3) P u ll down wa r d a n d r em ove t h e gr ille fr om
exh a u st por t in t h e door open in g pa n el.
REMOVAL
(1) Rem ove slide r a il scr ews (F ig. 64).
(2) Rem ove lu gga ge r a ck fr om r oof.
DOOR
OPENING
NOTE: Skid strips are attached to roof panel with PANEL
adhesive.

(3) Loosen ea ch skid st r ip wit h a h ea t gu n .


(4) Lift on e edge of ea ch skid st r ip wit h a pu t t y
kn ife a n d peel it fr om r oof pa n el.
(5) Rem ove or igin a l a dh esive fr om r oof wit h a n
a dh esive r em ova l solu t ion .
(6) If or igin a l skid st r ips a r e in st a lled, r em ove a ll
or igin a l a dh esive fr om m .

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)

A-PILLAR TRIM (2) Rem ove t h e n u t beh in d t h e fu se pa n el a ccess


door (Righ t side on ly) (F ig. 67).
REMOVAL (3) Rem ove t h e fa st en er s a t t a ch in g t h e lower A-pil-
(1) Rem ove fr on t a n d r ea r a ssist h a n dles, if la r cowl t r im t o t h e A-pilla r lower cowl.
equ ipped. (4) Sepa r a t e t h e lower A-pilla r cowl t r im fr om t h e
(2) Rem ove t h e in n er scu ff pla t e. A-pilla r lower cowl.
(3) Rem ove t h e lower A-pilla r cowl t r im .
COWL
(4) Usin g a sm a ll fla t bla de, pr y t h e t r im plu gs
PANEL
fr om t h e A-pilla r t r im .
(5) Rem ove 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 (F ig. 66).
(6) Sepa r a t e t h e A-pilla r t r im fr om t h e A-pilla r.

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.

LOWER A-PILLAR COWL TRIM Fig. 67 Lower A-Pillar Cowl Trim

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

Fig. 66 Trim Panels—2-Door Vehicles


XJ BODY 23 - 45
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) In st a ll t h e scr ews a t t a ch in g t h e lower A-pilla r ASSIST HANDLE
cowl t r im t o t h e A-pilla r lower cowl.
(3) In st a ll t h e n u t beh in d t h e fu se pa n el a ccess REMOVAL
door (Righ t side on ly). (1) Usin g a t r im st ick or equ iva len t , open t h e en d
(4) In st a ll t h e in n er scu ff pla t e. cover s t o a ccess t h e scr ews.
(2) Rem ove t h e scr ews (F ig. 66).
FRONT INNER SCUFF PLATE (3) Sepa r a t e t h e a ssist h a n dle fr om t h e t r im .

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.

INSTALLATION C-PILLAR TRIM


(1) P osit ion t h e scu ff pla t e on t h e door sill.
(2) In st a ll t h e scr ews a t t a ch in g t h e door sill scu ff REMOVAL
pla t e t o t h e door sill. (1) Rem ove the in n er scu ff pla t e.
(2) Rem ove the u pper door open in g t r im .
(3) Rem ove the u pper qu a r t er pa n el t r im .
(4) Rem ove the qu a r t er pa n el t r im ext en sion .
23 - 46 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

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

Fig. 69 B-Pillar Trim—4-Door Vehicles


(5) Rem ove t h e scr ews a t t a ch in g t h e C-pilla r t r im QUARTER PANEL TRIM AND WHEELHOUSE
t o t h e C-pilla r (F ig. 69).
COVER
(6) Sepa r a t e t h e C-pilla r t r im fr om t h e C-pilla r.

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

Fig. 70 Spare Tire


(5) In st a ll t h e scr ews a t t a ch in g 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.
(6) In st a ll lift ga t e scu ff pla t e.
(7) In st a ll qu a r t er pa n el t r im ext en sion .
(8) In st a ll t h e in n er scu ff pla t e.

LIFTGATE PILLAR TRIM


REMOVAL
(1) Rem ove t h e lift ga t e open in g u pper t r im .
(2) Rem ove t h e lift ga t e pilla r t r im scr ews (F ig. 71).
(3) Rem ove t h e scr ews a t t a ch in g t h e lower qu a r t er
pa n el t r im t o t h e lift ga t e pilla r.
(4) P u ll t h e t r im pa n el ou t wa r d t o det a ch t h e
spr in g st eel clips a t t a ch in g t h e t r im pa n el t o t h e pil-
la r (2-dr veh icles).
(5) Rem ove lift ga t e pilla r t r im . Fig. 71 Liftgate Pillar Trim

INSTALLATION LIFTGATE OPENING UPPER TRIM


(1) P osit ion t h e lift ga t e pilla r t r im on t h e lift ga t e
pilla r.
REMOVAL
(1) Rem ove t h e scr ews a t t a ch in g t h e lift ga t e open -
(2) P r ess t h e t r im pa n el in t o pla ce t o en ga ge t h e
in g u pper t r im t o t h e r oof pa n el (F ig. 72).
spr in g st eel clips a t t a ch in g t h e t r im pa n el t o t h e pil-
(2) P u ll down wa r d t o disen ga ge st eel clips a t t a ch -
la r (2-dr veh icles).
in g t h e lift ga t e open in g u pper t r im t o t h e r oof pa n el.
(3) In st a ll t h e scr ews a t t a ch in g t h e lower qu a r t er
(3) Sepa r a t e t r im fr om veh icle.
pa n el t r im t o t h e lift ga t e pilla r.
(4) In st a ll t h e lift ga t e pilla r t r im scr ews.
(5) In st a ll t h e lift ga t e open in g u pper t r im .
INSTALLATION
St eel clips a r e u sed for m a n u fa ct u r in g pu r poses
a n d a r e n ot r equ ir ed for ser vice.
23 - 48 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION
(1) P osit ion t h e scu ff pla t e on t h e veh icle.
(2) Cen t er st r iker in open in g.
(3) In st a ll 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 .

FRONT SHOULDER BELT/BUCKLE


CAUTION: Inspect the front shoulder belts and
buckles. Replace any belt that is either cut, frayed,
torn or damaged in any way. Replace the shoulder
belt if the retractor is damaged or inoperative.

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

Fig. 74 Anchor Bolt


INSTALLATION
(1) P osit ion t h e sh ou lder belt r et r a ct or in t h e
sh ield a n d in st a ll t h e lower a n ch or bolt wit h a Tor x
bit . Tigh t en bolt t o 43 N·m (32 ft . lbs.) t or qu e.
(2) P osit ion t h e su ppor t /gu ide wa sh er a n d sh ou lder
belt u pper a n ch or pla t e on t h e t r im pa n el. In st a ll t h e
u pper a n ch or bolt wit h a Tor x bit .
80aa4b93 (3) Rou t e belt t h r ou gh t r im pa n el.
(4) Tigh t en t h e u pper a n d lower a n ch or bolt s t o 43
Fig. 73 Liftgate Scuff Plate N·m (32 ft . lbs.) t or qu e.
XJ BODY 23 - 49
REM OVAL AN D I N STALLAT I ON (Cont inue d)

TRIM PANEL REAR SHOULDER/LAP BELT/BUCKLE


WARNING: Inspect rear shoulder/lap belts and
buckles. Replace any belt that is either cut, frayed,
torn or damaged in any way. Replace shoulder belt
if retractor is damaged or inoperative.

REMOVAL
(1) 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.

Fig. 75 Front Shoulder Belt—2-Door Vehicles

RETRACTOR

ADJUSTER

80b01c3a

80b01c3c Fig. 77 Rear Seat Shoulder/Lap Belts and Buckles

Fig. 76 Front Shoulder Belt—4-Door Vehicles


INSTALLATION
(1) P osit ion sh ou lder belt bu ckle a n d la p belt /
(5) In st a ll t h e door sill in n er scu ff pla t e/t r im pa n el bu ckle a n ch or pla t es on floor pa n el.
a n d in st a ll t h e ca p over t h e u pper a n ch or bolt . (2) In st a ll a n ch or bolt s. Tigh t en bolt s t o 43 N·m
(6) In st a ll t h e sh ou lder belt bu ckle a n d a n ch or (32 ft . lbs.) t or qu e.
bolt . Con n ect t h e wir e h a r n ess con n ect or s. Tigh t en (3) In st a ll r et r a ct or su ppor t on r ea r qu a r t er r a il.
t h e bu ckle a n ch or bolt t o 43 N·m (32 ft . lbs.) t or qu e. Tigh t en scr ew.
(4) Rou t e sh ou lder belt t h r ou gh qu a r t er t r im pa n el
slot .
23 - 50 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(5) P osit ion sh ou lder belt a t r oof r a il a n d in st a ll FRONT CARPET/MAT
u pper a n ch or bolt . Tigh t en bolt t o 43 N·m (32 ft . lbs.)
t or qu e. REMOVAL
(6) In st a ll qu a r t er t r im pa n el. (1) Rem ove t h e door sill in n er scu ff pla t es.
(7) In st a ll sh ou lder belt lower a n ch or bolt . Tigh t en (2) Rem ove t h e fr on t a n d r ea r sea t s (a s a pplica -
bolt t o 43 N·m (32 ft . lbs.) t or qu e. ble).
(8) Ret u r n r ea r sea t cu sh ion t o n or m a l posit ion (3) Rem ove floor con sole.
a n d en ga ge la t ch . (4) As n ecessa r y, r em ove t h e t r im pa n els a n d
m oldin gs.
FULL FLOOR CONSOLE (5) Rem ove a ll ot h er in t er fer in g com pon en t s.
(6) Rem ove t h e ca r pet a n d m a t fr om t h e floor
REMOVAL pa n el (F ig. 79).
(1) Rem ove t h e t r a n sm ission sh ift lever h a n dle/
kn ob: CARPET
AND MAT
• Au t om a t ic t r a n sm ission s, pu ll t h e h a n dle
st r a igh t u pwa r d t o r em ove it .
• In ser t a t h in -bla de t ool u n der t h e edge of t h e
t r a n sm ission sh ift in dica t or bezel a n d pr y u p t o
r em ove.
• Ma n u a l t r a n sm ission s, loosen t h e lockn u t a n d
u n -t h r ea d t h e sh ift kn ob fr om t h e sh a ft .
• P u ll t h e sh ift boot u p t o r em ove.
(2) In ser t a t h in -bla de t ool u n der t h e edge of t h e
t r a n sfer ca se sh ift in dica t or bezel or cover pla t e a n d
pr y u p t o r em ove.
(3) Open t h e con sole lid.
(4) Rem ove t h e scr ews a t t a ch in g t h e con sole t o t h e J9123-128
floor a n d m ou n t in g br a cket (F ig. 78).
(5) Discon n ect t h e wir e h a r n ess con n ect or. Fig. 79 Front Carpet and Mat
(6) Sepa r a t e t h e con sole fr om t h e floor.
INSTALLATION
TRANSFER (1) P osit ion t h e ca r pet a n d m a t on t h e floor pa n el.
CASE (2) In st a ll a ll t h e com pon en t s t h a t wer e r em oved
SHIFT f t o fa cilit a t e ca r pet /m a t r em ova l.
BEZEL (3) In st a ll t h e t r im pa n els a n d m oldin gs.
(4) In st a ll t h e door sill in n er scu ff pla t es.
(5) In st a ll floor con sole.
(6) In st a ll t h e fr on t a n d r ea r sea t s (a s a pplica ble).

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.

NOTE: Verify that the mirror support bracket is cor-


rectly aligned, because the adhesive will cure rap-
idly.

(7) Allow t h e a dh esive t o cu r e for 8-10 m in u t es.


Rem ove a n y excess a dh esive wit h a n a lcoh ol-da m p-
en ed clot h .
SUPPORT (8) Allow t h e a dh esive t o cu r e for a n a ddit ion a l
BUTTON 8-10 m in u t es befor e in st a llin g t h e m ir r or.
MIRROR

80ad2f1f

Fig. 81 Rearview Mirror


23 - 52 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

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

Fig. 84 Headliner Trim Moldings


To r em ove a h ea dlin er, a ll of t h e u pper t r im m old-
in gs m u st be r em oved fr om t h e per im et er of t h e

('
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.

\----__:r---,,~I SUPPORT (1) Rem ove t h e u pper t r im m oldin gs fr om t h e


CLIP per im et er of t h e h ea dlin er (F ig. 86).
(2) E n su r e t h a t a ll t h e r et a in er clips a n d scr ews
a r e disen ga ged befor e r em ovin g t h e h ea dlin er.
(3) Disen ga ge t a bs a t t a ch in g h ea dlin er /spea ker
SUNVISOR 80b8994d st r u ct u r e t o r oof r a il, if equ ipped (F ig. 85).
(4) Disen ga ge r ea r spea ker h a r n ess con n ect or, if
Fig. 83 Sunvisor w/Vanity Lamp equ ipped.
INSTALLATION
(1) In st a ll t h e su ppor t br a cket a n d t h e r et a in in g INSTALLATION
scr ew. (1) E n ga ge t a bs a t t a ch in g h ea dlin er /spea ker st r u c-
(2) Con n ect va n it y la m p con n ect or, if equ ipped. t u r e t o r oof r a il, if equ ipped. (F ig. 85)
(3) P osit ion t h e su n visor in t h e su ppor t clip a n d (2) On veh icles wit h ou t h ea dlin er spea ker s, en su r e
a lign t h e a r m su ppor t br a cket h oles wit h t h e h ea d- t h a t t h e r et a in er clips on u pper lift ga t e open in g t r im
lin er h oles. a n d r a ils a r e in st a lled. (F ig. 87)
(4) In st a ll t h e scr ews t h a t a t t a ch t h e su n visor a r m (3) E n ga ge r ea r spea ker h a r n ess con n ect or.
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.
XJ BODY 23 - 53
REM OVAL AN D I N STALLAT I ON (Cont inue d)

CLIP

I
~---~
RETAINER
HEADLINER REAR
80ae0eb6 80ae0eb4

Fig. 85 Headliner Fig. 87 Headliner Retainer Clip and Retainer Rail


ROOF RAIL (5) Rem ove t h e t r im pa n el fr om t h e lift ga t e.
PUSH NUT

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)

LIFTGATE (3) Rem ove t h e bolt s a t t a ch in g t h e h in ge t o t h e


h ea der pa n el (F ig. 89).
REMOVAL (4) Rem ove t h e bolt s a t t a ch in g t h e h in ge t o t h e
lift ga t e.
WARNING: DO NOT DISCONNECT SUPPORT ROD
CYLINDERS WITH LIFTGATE CLOSED. SUPPORT
ROD PISTONS ARE OPERATED BY HIGH PRES-
SURE GAS. THIS COULD CAUSE DAMAGE AND/OR
PERSONAL INJURY IF THEY ARE REMOVED WHILE
PISTONS ARE COMPRESSED.

(1) Rem ove cen t er h igh m ou n t ed st op la m p


(CH MSL).
(2) Open a n d su ppor t lift ga t e.
(3) Rem ove lift ga t e t r im pa n el.
(4) Discon n ect a n d plu g ba cklit e wa sh er flu id su p-
ply lin e.
(5) Rem ove scr ews t h a t a t t a ch r ea r wiper a n d lift -
ga t e power lock wir e h a r n ess con n ect or s t o lift ga t e
80b89835
a n d discon n ect con n ect or s.
(6) Usin g a ccess h ole cr ea t ed by r em ova l of
Fig. 89 Liftgate Hinge
CH MSL, r ou t e ba cklit e wa sh er flu id su pply lin e a n d
r ea r wiper a n d lift ga t e power lock wir e h a r n ess/ INSTALLATION
gr om m et s t h r ou gh a ccess h ole a n d sepa r a t e fr om lift - (1) P osit ion t h e h in ge on t h e lift ga t e.
ga t e. (2) In st a ll t h e bolt s a t t a ch in g t h e h in ge t o t h e lift -
(7) Rem ove r et a in er clips t h a t secu r e su ppor t r ods ga t e. Tigh t en t o 26 N·m (19 ft . lbs.) t or qu e.
t o ba ll st u ds. (3) In st a ll t h e bolt s a t t a ch in g t h e h in ge t o t h e
(8) Rem ove su ppor t r ods fr om ba ll st u ds. h ea der pa n el. Tigh t en t o 26 N·m (19 ft . lbs.) t or qu e.
(9) Rem ove bolt s a t t a ch in g h in ges t o lift ga t e. (4) In st a ll t h e lift ga t e open in g u pper t r im .
(10) Rem ove lift ga t e fr om veh icle. (5) Rem ove t h e su ppor t a n d close t h e lift ga t e.

INSTALLATION LIFTGATE SUPPORT ROD CYLINDER


(1) P osit ion a n d su ppor t lift ga t e a t open in g in body
a n d in st a ll bolt s a t t a ch in g h in ges t o lift ga t e. Tigh t en REMOVAL
bolt s t o 26 N·m (19 ft . lbs.) t or qu e.
(2) Con n ect lift ga t e su ppor t r ods t o ba ll st u ds a n d WARNING: DO NOT REMOVE A SUPPORT ROD
in st a ll r et a in er clips. CYLINDER WITH THE LIFTGATE CLOSED. EACH
(3) Rou t e ba cklit e wa sh er flu id su pply lin e a n d SUPPORT ROD PISTON IS OPERATED BY HIGH
r ea r wiper a n d lift ga t e power lock wir e h a r n esses/ PRESSURE GAS. IT CAN CAUSE DAMAGE AND/OR
gr om m et s t h r ou gh a ccess h ole. PERSONAL INJURY IF IT IS REMOVED WITH THE
(4) Con n ect con n ect or s a n d in st a ll scr ews t h a t PISTON COMPRESSED. DO NOT ATTEMPT TO DIS-
a t t a ch r ea r wiper a n d lift ga t e power lock wir e h a r- ASSEMBLE OR REPAIR A SUPPORT ROD CYLIN-
n ess con n ect or s t o lift ga t e. DER.
(5) Un plu g a n d con n ect ba cklit e wa sh er flu id su p-
ply lin e. (1) Open t h e lift ga t e.
(6) In st a ll lift ga t e t r im pa n el. (2) Su ppor t t h e lift ga t e in t h e open posit ion .
(7) Rem ove su ppor t s a n d close lift ga t e. (3) Rem ove t h e clip a t t a ch in g t h e su ppor t r od t o
(8) In st a ll (CH MSL). t h e ba ll st u d.
(4) Discon n ect t h e su ppor t r od fr om t h e ba ll st u d.
LIFTGATE HINGE (5) Rem ove t h e bolt s a t t a ch in g t h e su ppor t r od t o
t h e lift ga t e (F ig. 90).
REMOVAL (6) Sepa r a t e t h e su ppor t r od fr om t h e lift ga t e.
It is n ot n ecessa r y t o r em ove t h e lift ga t e t o r epla ce
on e or bot h h in ges. INSTALLATION
(1) Open a n d su ppor t t h e lift ga t e. (1) P osit ion t h e su ppor t r od on t h e lift ga t e.
(2) Rem ove t h e lift ga t e open in g u pper t r im . (2) In st a ll t h e bolt s a t t a ch in g t h e su ppor t r od t o
t h e lift ga t e.
XJ BODY 23 - 55
REM OVAL AN D I N STALLAT I ON (Cont inue d)
POWER ACTUATOR

~~·
ACTUATOR TO
LIFTGATE
LOCK ROD
SUPPORT ROD
CYLINDER OUTSIDE
HANDLE
TO LATCH
ROD
LIFTGATE
WASHER 80aa0feb LATCH 80aa0fed

Fig. 90 Liftgate Support Rod Fig. 91 Liftgate Outside Handle


(3) Con n ect t h e su ppor t r od t o t h e ba ll st u d.
CLIP
(4) Secu r e t h e su ppor t r od t o t h e ba ll st u d wit h
t h e r et a in er clip.
(5) Rem ove t h e su ppor t fr om t h e lift ga t e.

LIFTGATE SUPPORT ROD BALL STUD


REMOVAL
(1) Open t h e lift ga t e.
(2) Su ppor t t h e lift ga t e in t h e open posit ion .
(3) Rem ove t h e r et a in er clip a t t a ch in g t h e su ppor t
r od t o t h e ba ll st u d.
(4) Discon n ect t h e su ppor t r od fr om t h e ba ll st u d.
(5) Rem ove t h e ba ll st u d. LOCK OUTSIDE
CYLINDER HANDLE 80aa0fef
INSTALLATION
(1) In st a ll t h e r epla cem en t ba ll st u d. Fig. 92 Liftgate Lock Cylinder
(2) Con n ect t h e su ppor t r od t o t h e ba ll st u d. (6) In st a ll lift ga t e t r im pa n el.
(3) Secu r e t h e su ppor t r od t o t h e ba ll st u d wit h
t h e clip. LIFTGATE LOCK CYLINDER
(4) Rem ove t h e su ppor t fr om t h e lift ga t e. F or ser vice pr ocedu r es, r efer t o t h e Lift ga t e Ou t -
side H a n dle Rem ova l/In st a lla t ion pr ocedu r es.
LIFTGATE OUTSIDE HANDLE
LIFTGATE LATCH
REMOVAL
(1) Rem ove lift ga t e t r im pa n el. REMOVAL
(2) Discon n ect lift ga t e a ct u a t or lin ka ges. (1) Ra ise lift ga t e.
(3) Discon n ect lift ga t e ou t side h a n dle t o la t ch r od. (2) Rem ove lift ga t e t r im pa n el.
(4) Rem ove n u t a t t a ch in g ou t side h a n dle t o lift ga t e (3) Rem ove scr ews a t t a ch in g la t ch t o lift ga t e (F ig.
(F ig. 91). 93).
(5) Sepa r a t e ou t side h a n dle fr om lift ga t e. (4) Discon n ect r od fr om la t ch .
(6) If n ecessa r y, r em ove lock cylin der (F ig. 92). (5) Discon n ect power lock con n ect or fr om h a n dle, if
equ ipped.
INSTALLATION (6) Rem ove la t ch fr om lift ga t e.
(1) If n ecessa r y, in st a ll lock cylin der.
(2) P osit ion ou t side h a n dle on lift ga t e. INSTALLATION
(3) In st a ll n u t a t t a ch in g ou t side h a n dle t o lift ga t e. (1) P osit ion la t ch in lift ga t e.
(4) Con n ect lift ga t e ou t side h a n dle t o la t ch r od.
(5) Con n ect lift ga t e a ct u a t or lin ka ges.
23 - 56 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
POWER ACTUATOR LIFTGATE LIFTGATE WEATHERSTRIP
LOCK
REMOVAL
(1) P u ll t h e sea l a wa y fr om t h e fla n ge a r ou n d t h e
per im et er of lift ga t e open in g a n d r em ove it .
(2) Clea n t h e fla n ge a s n ecessa r y.

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.

Fig. 94 Liftgagte Striker


INSTALLATION
(1) P osit ion st r iker on veh icle.
(2) In st a ll n u t s. Tigh t en n u t s t o 54 N·m (40 ft .
lbs.) t or qu e.

Fig. 95 Liftgate Weatherstrip Installation


XJ BODY 23 - 57

ADJ U ST M EN T S t h e la t ch st r iker ou t wa r d if t h e door ch a r a ct er lin e is


in boa r d of t h e body ch a r a ct er lin e.
HOOD (3) In spect a lign m en t . If cor r ect , t igh t en st r iker
Th e h ood bolt h oles a r e elon ga t ed for for e a n d a ft wit h 28 N·m (20 ft . lbs.) t or qu e.
a n d side-t o-side a dju st m en t .
(1) If h ood is low t o t h e cowl pa n el, in ser t sh im s UP AND DOWN—MINOR ADJUSTMENT
bet ween t h e h in ge a n d h ood a t t h e r ea r h in ge bolt s. (1) Loosen t h e la t ch st r iker.
(2) Adju st t h e h ood bu m per (F ig. 96) in or ou t t o (2) Ta p t h e la t ch st r iker down wa r d if t h e door
pr ovide pr oper h ood-t o-fen der h eigh t a lign m en t . ch a r a ct er lin e is h igh er t h a n t h e body ch a r a ct er lin e
(3) Adju st t h e h ood st r iker s (F ig. 97) wit h sh im s or t a p t h e la t ch st r iker u pwa r d if t h e door ch a r a ct er
a s n ecessa r y. Tigh t en t h e scr ews t o 22 N·m (16 ft -lbs) lin e is lower t h a n t h e body ch a r a ct er lin e.
t or qu e a ft er a dju st m en t . (3) In spect a lign m en t . If cor r ect , t igh t en st r iker
(4) Align ea ch la t ch a n d st r iker so t h a t t h e st r iker wit h 28 N·m (20 ft . lbs.) t or qu e.
en t er s la t ch squ a r ely.
ALIGNMENT MAJOR—ADJUSTMENT
HOOD LATCH STRIKER Adju st m en t for a lign m en t of t h e door is m a de by
---- REINFORCEMENT
in st a llin g sh im s bet ween h in ge a n d door fa ce (F ig.
PANEL
98).

_ _ _ _ _ _ _ HOOD BUMPER
7

J9223-75 ~ ADJUSTMENT
SHIMS

RADIATOR- /
Fig. 96 Hood Bumper
SCREW
0
SUPPORT~
CROSSMEMBER '

80b8994e

Fig. 98 Door Adjustment Shims


(1) If n ot loosen ed, loosen t h e door h in ge bolt s.
(2) Add or r em ove sh im s a s n ecessa r y t o obt a in
t h e best door fit .
(3) Tigh t en door h in ge bolt s t o 3 N·m (2 ft -lbs)
t or qu e a ft er a dju st m en t is com plet ed.
(4) Apply gen er a l pu r pose sea la n t a r ou n d t h e door
Fig. 97 Hood Latch Striker h in ges/door fa ce m a t in g a r ea .

DOOR DOOR LATCH ADJUSTMENT


(1) Loca t e a ccess h ole (F ig. 99).
IN AND OUT—MINOR ADJUSTMENT (2) In ser t a 5/32-in ch h ex-wr en ch t h r ou gh h ole a n d
(1) Loosen t h e la t ch st r iker. in t o a dju st m en t scr ew. Loosen scr ew.
(2) Ta p t h e la t ch st r iker in wa r d if t h e door ch a r a c- (3) Oper a t e ou t side h a n dle bu t t on sever a l t im es t o
t er lin e is ou t boa r d of t h e body ch a r a ct er lin e or t a p r elea se a n y r est r ict ion beca u se of m is-a lign m en t .
23 - 58 BODY XJ
ADJ U ST M EN T S (Cont inue d)
(4) Tigh t en a dju st m en t scr ew t o 3 N·m (30 in -lbs) LIFTGATE
t or qu e. Th e posit ion of lift ga t e ca n be a dju st ed u pwa r d or
(5) Test h a n dle bu t t on a n d lock cylin der for pr oper down wa r d by u se of slot s in t h e h in ge. An in wa r d or
oper a t ion . ou t wa r d a dju st m en t is a ch ieved by u se of slot s in t h e
body. If a n in wa r d or ou t wa r d a dju st m en t is n eeded,
ACCESS '1
u se 3M" F a st a n d F ir m or equ iva len t on t h e h in ge
~ i"' DOOR t o body m a t in g su r fa ce a s a sea la n t .

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

COMPONENT SERVICE INTERVAL LUBRICANT


Door Latches As Required Multi-Purpose Grease NLGI
GC-LB (Water Resistant) (1)
Hood Latch, Release Mechanism & Safety As Required Multi-Purpose Grease NLGI
Latch (When Performing Other GC-LB 2 EP (2)
Underhood Service)
Hood Hinges As Required Engine Oil
Seat Track & Release Mechanism As Required Multi-Purpose Grease NLGI
GC-LB 2 EP (2)
Liftgate Hinge As Required Multi-Purpose Grease NLGI
GC-LB 2 EP (2)
Liftgate Support Arms As Required Engine Oil
Liftgate Latches As Required White Spray Lubricant (3)
Liftgate Release Handle (Pivot & Slide Contact As Required Multi-Purpose Grease NLGI
Surfaces) GC-LB 2 EP (2)
Window System Components As Required White Spray Lubricant (3)
Lock Cylinders Twice A Year Lock Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease NLGI
GC-LB 2 EP (1)
1 = Mopar Wheel Bering Grease (High Temp)
2 = Mopar Multi-Mileage Lubricant
3 = Mopar Spray White Lube
4 = Mopar Lock Cylinder Lubricant
XJ BODY 23 - 59
SPECI FI CAT I ON S (Cont inue d)

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

RIGHT SIDE SHOWN


80b698e8
XJ BODY 23 - 67
SPECI FI CAT I ON S (Cont inue d)
D—PILLAR

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

LEFT SIDE ONLY

'\\

,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

RIGHT SIDE SHOWN


80b69905
XJ BODY 23 - 83
SPECI FI CAT I ON S (Cont inue d)
REAR WHEELHOUSE

W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS

ga@//_ _ _~~
W4 -WELDING OF 4 PARTS 11 \

RIGHT SIDE SHOWN 80b69906


23 - 84 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
REAR INNER WHEELHOUSE

(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

RIGHT SIDE SHOWN


80b69907
XJ BODY 23 - 85
SPECI FI CAT I ON S (Cont inue d)
BODY SIDE

W2

W2

W2

W2

W2 -WELDIN~::----
W3 - WELDINg gF 2 PARTS
W2 W4 - WELDING OF
F43 PARTS
PARTS

RIGHT SIDE SH OWN 80b69908


23 - 86 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

W3 W2

RIGHT SIDE SHOWN 80b69909


XJ BODY 23 - 87
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

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

* BOTH SIDES W3*

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)

BODY SEALING LOCATIONS


APPLICATION METHODS

HOLD GUN NOZZLE IN DIRECTION OF DO NOT HOLD GUN NOZZLE IN DIRECTION


ARROW IN ORDERTO EFFECTIVELY SEAL OF ARROW. SEALER APPLIED AS SHOWN
METAL JOINTS. IN INEFFECTIVE.

3 METAL THICKNESS
2 METAL THICKNESS
JI 3 METAL THICKNESS
JI
2 METAL THICKNESS

SEALER MUST BE APPLIED


AS ILLUSTRATED. TO LOCK
, ~ SEAL IN PLACE, FORCE
WORK SEAL ON METAL SEAL BEYOND HOLE.
SURFACE TO GET GOOD
ADHESIVE. EDGE MUST-+-
BE FEATHERED AS ~ HIDDEN 'SEALER
SHOWN. SURFACE INCORRECTLY
APPLIED

SYMBOLS
\l!) THUMBGRADEABLE SEALER

- EXTRUDABLE THERMOPLASTIC

=-::ia:+5;?:S::::::::;::::S::t1 EXPOSED THERMOPLASTIC SEALANT


zzzzz zz z HIDDEN SEALANT

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

BODY SIDE SILL

FRONT FLOOR PAN

REAR FLOOR PAN


c:)

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

REAR FLOOR PAN

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

REAR FLOOR PAN


EXTENSION

REAR FLOOR PAN

REAR FLOOR PAN


EXTENSION

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

COWL SIDE PANEL

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)

ROOF SIDE OUTER RAIL

G
(2 DOOR ONLY)

BODY LOCK PILLAR

P = PUMPABLE
G = GENERAL PURPOSE
H = HEAT EXPANDABLE 80b6fded
XJ BODY 23 - 111
SPECI FI CAT I ON S (Cont inue d)
ROOF PANEL

P = PUMPABLE ROOF PANEL

ROOF SIDE OUTER RAIL

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

FUEL FILLER HOUSING

REAR FLOOR PAN

80b6fdef
XJ BODY 23 - 113
SPECI FI CAT I ON S (Cont inue d)
LIFTGATE OPENING

T = THUMBGRADABLE
P = PUMPABLE

LIFTGATE HEADER PANEL


REAR QUARTER
OUTER PANEL

80b6fdf0
23 - 114 BODY XJ
SPECI FI CAT I ON S (Cont inue d)

STRUCTURAL ADHESIVE LOCATIONS


LEFT QUARTER PANEL

STRUCTU RAL ADHESIVE

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)

BODY GAP AND FLUSH MEASUREMENTS


ts

LOCATION GAP FLUSH


A Front Door to Windshield Pillar 6.4 +/- 2.0 1.6 +/- 2.0
B Front Door to Rear Door 6.4 +/-1.5 0.0 +/-1.5
C Front Door to Aperture at Sill 8.1 +/- 1.5 0.0 +/-1.5
D Front Door to Fender 6.4 +/-1.5 0.0 +/-1.5
E Hood to Fender 5.6 +/-1.5 0.5 +/-1.5
F Headlamp to Fender 5.6 +/-1.5 0.5 +/-1.5
G Headlamp to Grille NIA 0.74 +/-1.0
H Grille to Hood 6.0 +/-1.5 0.24 +/-1.5
I Liftgate to Roof 7.5 +/-1.5 0.5 +/-1.5
J Liftgate to Aperture 6.5 +/-1.5 0.0 +/-1.5
K Liftgate to Fascia x.x +/- 2.0 N/A
L Rear Door to Quarter Panel 6.4 +/-1.5 0.0 +/-1.5

NOTE: ALL MEASUREMENTS ARE IN MM.

80b6fdf6
23 - 118 BODY XJ
SPECI FI CAT I ON S (Cont inue d)

BODY OPENING DIMENSIONS


WINDSHIELD OPENING

80ae834e

• A. & B. Cen t er of r a diu s a t bot t om t o cen t er of


r a diu s a t t op
XJ BODY 23 - 119
SPECI FI CAT I ON S (Cont inue d)
FRONT DOOR OPENING 2–DOOR

80ae834f

• A. Cen t er of fr on t door lower r ea r r a diu s t o cen -


t er of A-pilla r r a diu s
• B. Cen t er of r a diu s a t bot t om r ea r t o cen t er of
r a diu s a t lower A-pilla r
• C. Cen t er of r a diu s a t bot t om fr on t t o cen t er of
r a diu s a t t op r ea r
23 - 120 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
FRONT DOOR OPENING 4–DOOR

80ae8351

• C. Cen t er of fr on t door lower r ea r r a diu s t o cen -


t er of A-pilla r r a diu s
• E . Cen t er of r a diu s a t bot t om r ea r t o cen t er of
r a diu s a t lower A-pilla r
• F. Cen t er of r a diu s a t bot t om fr on t t o cen t er of
r a diu s a t t op r ea r
XJ BODY 23 - 121
SPECI FI CAT I ON S (Cont inue d)
REAR DOOR OPENING

80ae8352

• A. Qu a r t er pa n el t o fr on t ou t er body side u pper


and lower sea m
• B. Cen t er of fr on t u pper door r a diu s t o cen t er of
r ea r lower door r a diu s
• C. Cen t er of fr on t lower door r a diu s t o cen t er of
r ea r u pper door r a diu s
• D. F la n ge t o r ea r door st r iker m ou n t
23 - 122 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
QUARTER WINDOW OPENING 2–DOOR

0
0

80aac308

• A. Cen t er of u pper a n d lower r ea r qu a r t er win -


dow open in g
• B. Cen t er of r a diu s fr on t lower cor n er t o cen t er
of r a diu s r ea r u pper cor n er
• C. Cen t er of r a diu s fr on t u pper cor n er t o cen t er
of r a diu s r ea r lower cor n er
XJ BODY 23 - 123
SPECI FI CAT I ON S (Cont inue d)
QUARTER WINDOW OPENING 4–DOOR

80a9tof9

• A. Cen t er of u pper a n d lower r ea r qu a r t er win -


dow open in g
• B. Cen t er of r a diu s fr on t lower cor n er t o cen t er
of r a diu s r ea r u pper cor n er
• C. Cen t er of r a diu s fr on t u pper cor n er t o cen t er
of r a diu s r ea r lower cor n er
23 - 124 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
ENGINE COMPARTMENT

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

• A. Cen t er of u pper lift ga t e open in g t o lift ga t e D ES CRIP TION TORQU E


st r iker m ou n t Rea r Door H in ge Bolt . . . . . . . . . . . 3 N·m (2 ft . lbs.)
• B. & C. Cen t er of r a diu s u pper cor n er t o cen t er Rea r Door La t ch Scr ew . . . . . . . . 11 N·m (8 ft . lbs.)
of r a diu s lower cor n er Rea r Door La t ch St r iker Scr ew . . . . . . . . . . 28 N·m
• D. Dist a n ce bet ween ou t er qu a r t er pa n el t o t a il (20 ft . lbs.)
la m p m ou n t in g pa n el t o in n er qu a r t er pa n el sea m s Rea r Sh ou lder Belt Lower An ch or Bolt . . . . 43 N·m
(32 ft . lbs.)
TORQUE SPECIFICATIONS Rea r Sea t ba ck P ivot Bolt . . . . . . 33 N·m (25 ft . lbs.)
Rea r Sea t Belt /Bu ckle An ch or Bolt . . . . . . . . 43 N·m
D ES CRIP TION TORQU E (32 ft . lbs.)
Bu cket Sea t t o F loor P a n Bolt . . 27 N·m (20 ft . lbs.) Rea r Sh ou lder Belt Upper An ch or Bolt . . . . 43 N·m
Bu cket Sea t t o F loor P a n Nu t . . 40 N·m (30 ft . lbs.) (32 ft . lbs.)
F r on t Door H in ge Bolt s . . . . . . . . . 3 N·m (2 ft . lbs.)
F r on t Door La t ch Scr ew . . . . . . . . 11 N·m (8 ft . lbs.)
F r on t Door La t ch St r iker Scr ew . . . . . . . . . . 28 N·m
(20 ft . lbs.)
F r on t Sea t Belt An ch or Bolt . . . . 43 N·m (32 ft . lbs.)
F r on t Ret r a ct or An ch or Bolt . . . . 43 N·m (32 ft . lbs.)
F r on t Sea t Belt Bu ckle An ch or Bolt . . . . . . . 43 N·m
(32 ft . lbs.)
GOP t o Su ppor t Br a cket Nu t . . . . 4 N·m (38 in . lbs.)
GOP t o F en der Nu t . . . . . . . . . . . 4 N·m (38 in . lbs.)
Lift ga t e H in ge t o Body a n d/or Lift ga t e
Bolt . . . . . . . . . . . . . . . . . . . . 26 N·m (19 ft . lbs.)
Lift ga t e La t ch Scr ew . . . . . . . . . . 13 N·m (9 ft . lbs.)
Lift ga t e La t ch St r iker Nu t . . . . . 54 N·m (40 ft . lbs.)
23 - 126 BODY XJ

SPECI AL T OOLS
BODY

Remover, Moldings C-4829


XJ HEATING AND AIR CONDITIONING 24 - 1

HEATING AND AIR CONDITIONING


CON T EN T S

page page

GENERAL INFORMATION HEATER PERFORMANCE . . . . . . . . . . . . . . . . 13


HEATER AND AIR CONDITIONER CONTROL . . 2 HIGH PRESSURE CUT-OFF SWITCH . . . . . . . 20
HEATER AND AIR CONDITIONER . . . . . . . . . . . 2 LOW PRESSURE CYCLING
SERVICE WARNINGS AND PRECAUTIONS . . . . 3 CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION AND OPERATION REFRIGERANT SYSTEM LEAKS . . . . . . . . . . . 20
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . 4 VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . 5 SERVICE PROCEDURES
BLOWER MOTOR RESISTOR . . . . . . . . . . . . . . 5 REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . . 21
BLOWER MOTOR SWITCH . . . . . . . . . . . . . . . . 5 REFRIGERANT RECOVERY . . . . . . . . . . . . . . 21
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 4 REFRIGERANT SYSTEM CHARGE . . . . . . . . . 21
COMPRESSOR CLUTCH RELAY . . . . . . . . . . . . 6 REFRIGERANT SYSTEM EVACUATE . . . . . . . . 21
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . . . . 6 REMOVAL AND INSTALLATION
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . 5 ACCUMULATOR . . . . . . . . . . . . . . . .. . . . . . . 32
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . 6 BLOWER MOTOR RELAY . . . . . . . . .. . . . . . . 37
EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . 6 BLOWER MOTOR RESISTOR . . . . . .. . . . . . . 38
FIXED ORIFICE TUBE . . . . . . . . . . . . . . . . . . . . 6 BLOWER MOTOR . . . . . . . . . . . . . . .. . . . . . . 35
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . 6 COMPRESSOR CLUTCH RELAY . . . .. . . . . . . 29
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . . 7 COMPRESSOR CLUTCH . . . . . . . . . .. . . . . . . 26
HIGH PRESSURE RELIEF VALVE . . . . . . . . . . . 7 COMPRESSOR . . . . . . . . . . . . . . . . .. . . . . . . 25
LOW PRESSURE CYCLING CLUTCH SWITCH . 7 CONDENSER . . . . . . . . . . . . . . . . . . .. . . . . . . 32
REFRIGERANT LINE COUPLER . . . . . . . . . . . . 8 DUCTS AND OUTLETS . . . . . . . . . . .. . . . . . . 44
REFRIGERANT LINE . . . . . . . . . . . . . . . . . . . . . 7 EVAPORATOR COIL . . . . . . . . . . . . . .. . . . . . . 43
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . . . . 8 FIXED ORIFICE TUBE . . . . . . . . . . . .. . . . . . . 31
REFRIGERANT SYSTEM SERVICE HEATER CORE . . . . . . . . . . . . . . . . .. . . . . . . 44
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 8 HEATER-A/C CONTROL . . . . . . . . . . .. . . . . . . 35
REFRIGERANT SYSTEM SERVICE PORT . . . . . 8 HEATER-A/C HOUSING DOOR . . . . .. . . . . . . 42
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . 7 HEATER-A/C HOUSING . . . . . . . . . . .. . . . . . . 39
VACUUM CHECK VALVE . . . . . . . . . . . . . . . . . . 9 HIGH PRESSURE CUT-OFF SWITCH . . . . . . . 23
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . 9 KICK COVER . . . . . . . . . . . . . . . . . . .. . . . . . . 37
DIAGNOSIS AND TESTING LIQUID LINE . . . . . . . . . . . . . . . . . . .. . . . . . . 29
A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 9 LOW PRESSURE CYCLING
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . 15 CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . 31
BLOWER MOTOR RESISTOR . . . . . . . . . . . . . 18 MODE DOOR VACUUM ACTUATOR . . . . . . . . . 38
BLOWER MOTOR SWITCH . . . . . . . . . . . . . . . 18 REFRIGERANT LINE COUPLER . . . . . . . . . . . 22
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . 15 SUCTION AND DISCHARGE LINE . . . . . . . . . . 23
COMPRESSOR CLUTCH COIL . . . . . . . . . . . . 19 TEMPERATURE CONTROL CABLE . . . . . . . . . 36
COMPRESSOR CLUTCH RELAY . . . . . . . . . . . 19 VACUUM CHECK VALVE . . . . . . . . . . . . . . . . . 34
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 19 VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . 34
FLOOR/PANEL
HEATER COREDOOR BLEND-AIR DOOR AIR
RECIRCULATING
DOOR ONLYA/C
FLOOR/DE- EVAPORATOR A/C
FROST ONLY
DOOR

24 - 2 HEATING AND AIR CONDITIONING XJ

GEN ERAL I N FORM AT I ON u se en gin e va cu u m t o con t r ol t h e m ode door s t h r ou gh


va cu u m a ct u a t or m ot or s.
HEATER AND AIR CONDITIONER On a ir con dit ion ed veh icles, t h e ou t side a ir in t a ke
All veh icles a r e equ ipped wit h a com m on h ea t er- ca n be sh u t off by select in g t h e Recir cu la t ion Mode
A/C h ou sin g a ssem bly (F ig. 1). Th e syst em com bin es wit h t h e m ode con t r ol kn ob. Th is will open a va cu u m
a ir con dit ion in g, h ea t in g, a n d ven t ila t in g ca pa bilit ies a ct u a t ed r ecir cu la t in g a ir door a n d r ecir cu la t e t h e a ir
in a sin gle u n it h ou sin g m ou n t ed u n der t h e in st r u - t h a t is a lr ea dy in side t h e veh icle.
m en t pa n el. On h ea t er-on ly syst em s, t h e eva por a t or Th e opt ion a l a ir con dit ion er for a ll m odels is
coil a n d r ecir cu la t in g a ir door a r e om it t ed fr om t h e design ed for t h e u se of n on -CF C, R-134a r efr iger a n t .
h ou sin g. Th e a ir con dit ion in g syst em h a s a n eva por a t or t o cool
a n d deh u m idify t h e in com in g a ir pr ior t o blen din g it
wit h t h e h ea t ed a ir. Th is syst em u ses a fixed or ifice
t u be in t h e liqu id lin e n ea r t h e con den ser ou t let t u be
t o m et er r efr iger a n t flow t o t h e eva por a t or coil. To
m a in t a in m in im u m eva por a t or t em per a t u r e, a fixed
pr essu r e set t in g swit ch on t h e a ccu m u la t or cycles t h e
com pr essor clu t ch .

NOTE: This group covers both Left-Hand Drive


(LHD) and Right-Hand Drive (RHD) versions of this
model. Whenever required and feasible, the RHD
Fig. 1 Common Blend-Air Heater-Air Conditioner versions of affected vehicle components have been
System - Typical constructed as mirror-image of the LHD versions.
Ou t side fr esh a ir en t er s t h e veh icle t h r ou gh t h e While most of the illustrations used in this group
cowl t op open in g a t t h e ba se of t h e win dsh ield, a n d represent only the LHD version, the diagnostic and
pa sses t h r ou gh a plen u m ch a m ber t o t h e h ea t er-A/C service procedures outlined can generally be
syst em blower h ou sin g. Air flow velocit y ca n t h en be applied to either version. Exceptions to this rule
a dju st ed wit h t h e blower m ot or speed select or swit ch have been clearly identified as LHD or RHD, if a
on t h e h ea t er-A/C con t r ol pa n el. Th e a ir in t a ke open - special illustration or procedure is required.
in gs m u st be kept fr ee of sn ow, ice, lea ves, a n d ot h er
obst r u ct ion s for t h e h ea t er-A/C syst em t o r eceive a
su fficien t volu m e of ou t side a ir. HEATER AND AIR CONDITIONER CONTROL
Th e h ea t er a n d opt ion a l a ir con dit ion er a r e blen d- Bot h t h e h ea t er-on ly a n d h ea t er-A/C syst em s u se a
a ir t ype syst em s. In a blen d-a ir syst em , a blen d-a ir com bin a t ion of m ech a n ica l, elect r ica l, a n d va cu u m
door con t r ols t h e a m ou n t of u n con dit ion ed a ir (or con t r ols. Th ese con t r ols pr ovide t h e veh icle oper a t or
cooled a ir fr om t h e eva por a t or on m odels wit h a ir wit h a n u m ber of set t in g opt ion s t o h elp con t r ol t h e
con dit ion in g) is a llowed t o flow t h r ou gh , or a r ou n d, clim a t e a n d com for t wit h in t h e veh icle. Refer t o t h e
t h e h ea t er cor e. A t em per a t u r e con t r ol lever on t h e own er ’s m a n u a l for m or e in for m a t ion on t h e su g-
h ea t er-A/C con t r ol pa n el det er m in es t h e disch a r ge gest ed oper a t ion a n d u se of t h ese con t r ols.
a ir t em per a t u r e by m ovin g a ca ble, wh ich oper a t es Th e h ea t er-on ly or h ea t er-A/C con t r ol pa n el is
t h e blen d-a ir door. Th is a llows a n a lm ost im m edia t e loca t ed t o t h e r igh t of t h e in st r u m en t clu st er on t h e
m a n u a l con t r ol of t h e ou t pu t a ir t em per a t u r e of t h e in st r u m en t pa n el. Th e con t r ol pa n el con t a in s a r ot a t -
syst em . in g-t ype t em per a t u r e con t r ol kn ob, a r ot a t in g-t ype
Th e m ode con t r ol kn ob on t h e h ea t er-A/C con t r ol m ode con t r ol swit ch kn ob, a n d a r ot a t in g-t ype blower
pa n el is u sed t o dir ect t h e con dit ion ed a ir t o t h e m ot or swit ch kn ob.
select ed syst em ou t let s. Bot h m ode con t r ol swit ch es Th e h ea t er-on ly or h ea t er-A/C con t r ol pa n el ca n n ot
be r epa ir ed. If fa u lt y or da m a ged, t h e en t ir e u n it
m u st be r epla ced.
XJ HEATING AND AIR CONDITIONING 24 - 3
GEN ERAL I N FORM AT I ON (Cont inue d)
SERVICE WARNINGS AND PRECAUTIONS • Do not overcharge the refrigerant system. This
will cause excessive compressor head pressure
WARNING: and can cause noise and system failure.
• THE AIR CONDITIONING SYSTEM CONTAINS
REFRIGERANT UNDER HIGH PRESSURE. SEVERE In a ddit ion t o t h e wa r n in gs a n d ca u t ion s list ed a bove,
PERSONAL INJURY MAY RESULT FROM IMPROPER t h e followin g pr eca u t ion s m u st a lso be obser ved wh en -
SERVICE PROCEDURES. REPAIRS SHOULD ONLY ever ser vicin g t h e a ir con dit ion in g syst em :
BE PERFORMED BY QUALIFIED SERVICE PERSON- • Recover t h e r efr iger a n t befor e open in g a n y fit -
NEL. t in g or con n ect ion . Open t h e fit t in gs wit h ca u t ion ,
• AVOID BREATHING THE REFRIGERANT AND even a ft er t h e syst em h a s been disch a r ged. Never
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE open or loosen a con n ect ion befor e r ecover in g t h e
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. r efr iger a n t .
WEAR EYE PROTECTION WHEN SERVICING THE • Th e r efr iger a n t syst em m u st a lwa ys be eva cu -
AIR CONDITIONING REFRIGERANT SYSTEM. SERI- a t ed befor e ch a r gin g.
OUS EYE INJURY CAN RESULT FROM DIRECT • Do n ot open t h e r efr iger a n t syst em or u n ca p a
CONTACT WITH THE REFRIGERANT. IF EYE CON- r epla cem en t com pon en t u n t il you a r e r ea dy t o ser vice
TACT OCCURS, SEEK MEDICAL ATTENTION IMME- t h e syst em . Th is will pr even t con t a m in a t ion in t h e sys-
DIATELY. t em .
• DO NOT EXPOSE THE REFRIGERANT TO • Befor e discon n ect in g a com pon en t , clea n t h e ou t -
OPEN FLAME. POISONOUS GAS IS CREATED side of t h e fit t in gs t h or ou gh ly t o pr even t con t a m in a -
WHEN REFRIGERANT IS BURNED. AN ELEC- t ion fr om en t er in g t h e r efr iger a n t syst em .
TRONIC LEAK DETECTOR IS RECOMMENDED. • Im m edia t ely a ft er discon n ect in g a com pon en t
• IF ACCIDENTAL SYSTEM DISCHARGE fr om t h e r efr iger a n t syst em , sea l t h e open fit t in gs
OCCURS, VENTILATE THE WORK AREA BEFORE wit h a ca p or plu g.
RESUMING SERVICE. LARGE AMOUNTS OF • Befor e con n ect in g a n open r efr iger a n t fit t in g,
REFRIGERANT RELEASED IN A CLOSED WORK a lwa ys in st a ll a n ew sea l or ga sket . Coa t t h e fit t in g
AREA WILL DISPLACE THE OXYGEN AND CAUSE a n d sea l wit h clea n r efr iger a n t oil befor e con n ect in g.
SUFFOCATION. • Do n ot r em ove t h e sea lin g ca ps fr om a r epla ce-
• THE EVAPORATION RATE OF R-134a REFRIG- m en t com pon en t u n t il it is t o be in st a lled.
ERANT AT AVERAGE TEMPERATURE AND ALTI- • Wh en in st a llin g a r efr iger a n t lin e, a void sh a r p
TUDE IS EXTREMELY HIGH. AS A RESULT, ben ds t h a t m a y r est r ict r efr iger a n t flow. P osit ion t h e
ANYTHING THAT COMES IN CONTACT WITH THE r efr iger a n t lin es a wa y fr om exh a u st syst em com pon en t s
REFRIGERANT WILL FREEZE. ALWAYS PROTECT or a n y sh a r p edges, wh ich m a y da m a ge t h e lin e.
THE SKIN OR DELICATE OBJECTS FROM DIRECT • Tigh t en r efr iger a n t fit t in gs on ly t o t h e specified
CONTACT WITH THE REFRIGERANT. t or qu e. Th e a lu m in u m fit t in gs u sed in t h e r efr iger a n t
• THE R-134a SERVICE EQUIPMENT OR THE syst em will n ot t oler a t e over t igh t en in g.
VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE • Wh en discon n ect in g a r efr iger a n t fit t in g, u se a
PRESSURE TESTED OR LEAK TESTED WITH COM- wr en ch on bot h h a lves of t h e fit t in g. Th is will pr e-
PRESSED AIR. SOME MIXTURES OF AIR AND ven t t wist in g of t h e r efr iger a n t lin es or t u bes.
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE • Refr iger a n t oil will a bsor b m oist u r e fr om t h e
AT ELEVATED PRESSURES. THESE MIXTURES ARE a t m osph er e if left u n ca pped. Do n ot open a con t a in er
POTENTIALLY DANGEROUS, AND MAY RESULT IN of r efr iger a n t oil u n t il you a r e r ea dy t o u se it .
FIRE OR EXPLOSION CAUSING INJURY OR PROP- Repla ce t h e ca p on t h e oil con t a in er im m edia t ely
ERTY DAMAGE. a ft er u sin g. St or e r efr iger a n t oil on ly in a clea n , a ir-
t igh t , a n d m oist u r e-fr ee con t a in er.
• Keep ser vice t ools a n d t h e wor k a r ea clea n . Con -
CAUTION: t a m in a t ion of t h e r efr iger a n t syst em t h r ou gh ca r eless
• Liquid refrigerant is corrosive to metal sur- wor k h a bit s m u st be a voided.
faces. Follow the operating instructions supplied
with the service equipment being used. COOLI N G SY ST EM REQU I REM EN T S
• Never add R-12 to a refrigerant system To m a in t a in t h e per for m a n ce level of t h e h ea t in g-
designed to use R-134a. Damage to the system will a ir con dit ion in g syst em , t h e en gin e coolin g syst em
result. m u st be pr oper ly m a in t a in ed.
• R-12 refrigerant oil must not be mixed with Th e u se of a bu g scr een is n ot r ecom m en ded. An y
R-134a refrigerant oil. They are not compatible. obst r u ct ion s in fr on t of t h e r a dia t or or con den ser will
• Do not use R-12 equipment or parts on the r edu ce t h e per for m a n ce of t h e a ir con dit ion in g a n d
R-134a system. Damage to the system will result. en gin e coolin g syst em s.
24 - 4 HEATING AND AIR CONDITIONING XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
COOLAN T PRECAU T I ON S a r e n ot r eu sa ble a n d n ew ga sket s do n ot r equ ir e
lu br ica t ion befor e in st a llin g.
WARNING: Usin g t h e pr oper t ools wh en m a kin g a r efr iger a n t
• ANTIFREEZE IS AN ETHYLENE GLYCOL plu m bin g con n ect ion is ver y im por t a n t . Im pr oper
BASED COOLANT AND IS HARMFUL IF SWAL- t ools or im pr oper u se of t h e t ools ca n da m a ge t h e
LOWED OR INHALED. IF SWALLOWED, DRINK r efr iger a n t fit t in gs. Alwa ys u se t wo wr en ch es wh en
TWO GLASSES OF WATER AND INDUCE VOMIT- loosen in g or t igh t en in g t u be fit t in gs. Use on e wr en ch
ING. IF INHALED, MOVE TO A FRESH AIR AREA. t o h old on e side of t h e con n ect ion st a t ion a r y, wh ile
SEEK MEDICAL ATTENTION IMMEDIATELY. loosen in g or t igh t en in g t h e ot h er side of t h e con n ec-
• WASH THE SKIN AND CLOTHING THOR- t ion wit h a secon d wr en ch .
OUGHLY AFTER COMING IN CONTACT WITH ETH- Th e r efr iger a n t m u st be r ecover ed com plet ely fr om
YLENE GLYCOL. t h e syst em befor e open in g a n y fit t in g or con n ect ion .
• KEEP OUT OF THE REACH OF CHILDREN Open t h e fit t in gs wit h ca u t ion , even a ft er t h e r efr ig-
AND PETS. er a n t h a s been r ecover ed. If a n y pr essu r e is n ot iced
• DO NOT OPEN A COOLING SYSTEM WHEN a s a fit t in g is loosen ed, t igh t en t h e fit t in g a n d
THE ENGINE IS AT OPERATING TEMPERATURE. r ecover t h e r efr iger a n t fr om t h e syst em a ga in .
PERSONAL INJURY MAY RESULT. Do n ot disch a r ge r efr iger a n t in t o t h e a t m osph er e.
• DO NOT STORE ENGINE COOLANT IN OPEN Use a n R-134a r efr iger a n t r ecover y/r ecyclin g device
OR UNMARKED CONTAINERS. t h a t m eet s SAE St a n da r d J 2210.
• HOT ENGINE COOLANT CAN CAUSE SEVERE Th e r efr iger a n t syst em will r em a in ch em ica lly st a -
BURNS. DO NOT OPEN THE RADIATOR DRAIN ble a s lon g a s pu r e, m oist u r e-fr ee R-134a r efr iger a n t
COCK WHEN THE COOLING SYSTEM IS HOT AND a n d r efr iger a n t oil is u sed. Dir t , m oist u r e, or a ir ca n
PRESSURIZED. ALLOW THE COOLANT TO REACH u pset t h is ch em ica l st a bilit y. Oper a t ion a l t r ou bles or
TO ROOM TEMPERATURE BEFORE STARTING ser iou s da m a ge ca n occu r if for eign m a t er ia l is
REPAIR OPERATIONS. pr esen t in t h e r efr iger a n t syst em .
Wh en it is n ecessa r y t o open t h e r efr iger a n t sys-
Th e en gin e coolin g syst em is design ed t o develop t em , h a ve ever yt h in g n eeded t o ser vice t h e syst em
in t er n a l pr essu r es of 97 t o 124 kP a (14 t o 18 psi). r ea dy. Th e r efr iger a n t syst em sh ou ld n ot be left open
Allow t h e veh icle 15 m in u t es t o cool down , or wa it t o t h e a t m osph er e a n y lon ger t h a n n ecessa r y. Ca p or
u n t il a sa fe t em per a t u r e a n d pr essu r e a r e a t t a in ed, plu g a ll lin es a n d fit t in gs a s soon a s t h ey a r e open ed
befor e open in g t h e coolin g syst em . Refer t o Gr ou p 7 - t o pr even t t h e en t r a n ce of dir t a n d m oist u r e. All lin es
Coolin g Syst em for m or e in for m a t ion . a n d com pon en t s in pa r t s st ock sh ou ld be ca pped or
sea led u n t il t h ey a r e t o be in st a lled.
REFRI GERAN T H OSES/LI N ES/T U BES
All t ools, in clu din g t h e r efr iger a n t r ecyclin g equ ip-
PRECAU T I ON S
m en t , t h e m a n ifold ga u ge set , a n d t est h oses sh ou ld
Kin ks or sh a r p ben ds in t h e r efr iger a n t plu m bin g
be kept clea n a n d dr y. All t ools a n d equ ipm en t m u st
will r edu ce t h e ca pa cit y of t h e en t ir e syst em . H igh
be design ed for R-134a r efr iger a n t .
pr essu r es a r e pr odu ced in t h e syst em wh en it is oper-
a t in g. E xt r em e ca r e m u st be exer cised t o m a ke su r e
t h a t a ll r efr iger a n t syst em con n ect ion s a r e pr essu r e DESCRI PT I ON AN D OPERAT I ON
t igh t .
A good r u le for t h e flexible h ose r efr iger a n t lin es is ACCUMULATOR
t o keep t h e r a diu s of a ll ben ds a t lea st t en t im es t h e Th e a ccu m u la t or is m ou n t ed in t h e en gin e com -
dia m et er of t h e h ose. Sh a r p ben ds will r edu ce t h e pa r t m en t bet ween t h e eva por a t or coil ou t let t u be a n d
flow of r efr iger a n t . Th e flexible h ose lin es sh ou ld be t h e com pr essor in let . Refr iger a n t en t er s t h e a ccu m u -
r ou t ed so t h ey a r e a t lea st 80 m m (3 in ch es) fr om t h e la t or ca n ist er a s a low pr essu r e va por t h r ou gh t h e
exh a u st m a n ifold. It is a good pr a ct ice t o in spect a ll in let t u be.
flexible r efr iger a n t syst em h ose lin es a t lea st on ce a An y liqu id, oil-la den r efr iger a n t fa lls t o t h e bot t om
yea r t o m a ke su r e t h ey a r e in good con dit ion a n d of t h e ca n ist er, wh ich a ct s a s a sepa r a t or. A desicca n t
pr oper ly r ou t ed. ba g is m ou n t ed in side t h e a ccu m u la t or ca n ist er t o
Th er e a r e t wo t ypes of r efr iger a n t fit t in gs: a bsor b a n y m oist u r e wh ich m a y h a ve en t er ed a n d
• All fit t in gs wit h O-r in gs n eed t o be coa t ed wit h becom e t r a pped in t h e r efr iger a n t syst em (F ig. 2).
r efr iger a n t oil befor e in st a lla t ion . Use on ly O-r in gs
a ppr oved for u se wit h R-134a r efr iger a n t . F a ilu r e t o BLOWER MOTOR
do so m a y r esu lt in a lea k. Th e blower m ot or a n d blower wh eel a r e loca t ed in
• Un ified plu m bin g con n ect ion s wit h a lu m in u m t h e pa ssen ger side en d of t h e h ea t er-A/C h ou sin g,
ga sket s ca n n ot be ser viced wit h O-r in gs. Th e ga sket s below t h e glove box. Th e blower m ot or con t r ols t h e
OIL
VAPOR
RETURN
INLET
ACCUMULATOR
RETURN
FROM
ORIFICE
TUBE
O-RING
EVAPORATOR
TER
FIL-
DOME
SEAL CLUTCH
DESICCANT
PRESSURE
ANTI-SIPHON
SWITCH
CYCLING
OUTLET
SUREFITTING
HOLE
BAG
PRESSOR
SWITCH
TOPRES-
COM-

XJ HEATING AND AIR CONDITIONING 24 - 5


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
(P DC) dir ect ly t o t h e blower m ot or. Th e r ela y is en er-
gized wh en t h e r ela y coil is pr ovided a volt a ge sign a l
by t h e ign it ion swit ch . See t h e Dia gn osis a n d Test in g
sect ion of t h is gr ou p for m or e in for m a t ion on t h e
oper a t ion of t h e blower m ot or r ela y.
Th e blower m ot or r ela y is loca t ed in a wir e h a r n ess
con n ect or t h a t is secu r ed t o t h e h ea t er-A/C h ou sin g
beh in d t h e glove box on t h e pa ssen ger side of t h e
.---ounET TO veh icle, n ext t o t h e h ea t er-A/C wir e h a r n ess con n ec-
COMPRESSOR t or in t h e pa ssen ger com pa r t m en t .
Th e blower m ot or r ela y ca n n ot be r epa ir ed a n d, if
fa u lt y or da m a ged, it m u st be r epla ced.

BLOWER MOTOR RESISTOR


Th e blower m ot or r esist or is m ou n t ed t o t h e bot -
ANTI-SIPHON
HOLE t om of t h e h ea t er-A/C h ou sin g on t h e pa ssen ger side
of t h e veh icle u n der t h e in st r u m en t pa n el. It ca n be
a ccessed for ser vice by r em ovin g t h e h ea t er-A/C
DESICCANT BAG h ou sin g kick cover.
Th e r esist or h a s m u lt iple r esist or wir es, ea ch of
wh ich r edu ce t h e cu r r en t flow t o t h e blower m ot or by
ch a n gin g t h e r esist a n ce in t h e blower m ot or gr ou n d
pa t h . Th e blower m ot or swit ch dir ect s t h e gr ou n d
pa t h t h r ou gh t h e cor r ect r esist or wir e t o obt a in t h e
select ed speed. Wh en t h e h igh est blower speed is
select ed, t h e blower m ot or swit ch con n ect s t h e blower
J9324-6 m ot or dir ect ly t o gr ou n d, bypa ssin g t h e blower m ot or
r esist or.
Fig. 2 Accumulator - Typical Th e blower m ot or r esist or ca n n ot be r epa ir ed a n d,
velocit y of a ir flowin g t h r ou gh t h e h ea t er-A/C h ou s- if fa u lt y, it m u st be r epla ced.
in g by spin n in g a squ ir r el ca ge-t ype blower wh eel
wit h in t h e h ou sin g a t t h e select ed speed. Th e blower BLOWER MOTOR SWITCH
m ot or a n d wh eel ca n be r em oved fr om t h e en gin e Th e h ea t er or h ea t er-A/C blower m ot or is con -
com pa r t m en t side of t h e h ou sin g wit h ou t h ea t er-A/C t r olled by a fou r posit ion r ot a r y-t ype blower m ot or
h ou sin g r em ova l. swit ch , m ou n t ed in t h e h ea t er-A/C con t r ol pa n el. Th e
Th e blower m ot or will on ly oper a t e wh en t h e ign i- swit ch a llows t h e select ion of on e of fou r blower
t ion swit ch is in t h e On posit ion , a n d t h e h ea t er-A/C m ot or speeds, bu t ca n on ly be t u r n ed off by select in g
m ode con t r ol swit ch kn ob is in a n y posit ion , except t h e Off posit ion wit h t h e h ea t er-A/C m ode con t r ol
Off. Th e blower m ot or r eceives a fu sed ba t t er y feed swit ch kn ob.
t h r ou gh t h e blower m ot or r ela y wh en ever t h e ign i- Th e blower m ot or swit ch dir ect s t h e blower m ot or
t ion swit ch is in t h e On posit ion . Th e blower m ot or gr ou n d pa t h t h r ou gh t h e m ode con t r ol swit ch t o t h e
ba t t er y feed cir cu it is pr ot ect ed by a fu se in t h e blower m ot or r esist or, or dir ect ly t o gr ou n d, a s
P ower Dist r ibu t ion Cen t er (P DC). Blower m ot or r equ ir ed t o a ch ieve t h e select ed blower m ot or speed.
speed is con t r olled by r egu la t in g t h e gr ou n d pa t h Th e blower m ot or swit ch ca n n ot be r epa ir ed a n d, if
t h r ou gh t h e h ea t er-A/C con t r ol blower m ot or swit ch fa u lt y or da m a ged, t h e en t ir e h ea t er-A/C con t r ol
a n d t h e blower m ot or r esist or. pa n el m u st be r epla ced.
Th e blower m ot or a n d blower m ot or wh eel ca n n ot
be r epa ir ed a n d, if fa u lt y, t h ey m u st be r epla ced. Th e COMPRESSOR
blower m ot or a n d blower wh eel a r e ser viced on ly a s a Th e a ir con dit ion in g syst em u ses a Sa n den
u n it . SD7H 15 fixed displa cem en t com pr essor on a ll m od-
els. A la bel iden t ifyin g t h e u se of R-134a r efr iger a n t
BLOWER MOTOR RELAY is loca t ed on t h e com pr essor. Th e pu r pose of t h e com -
Th e blower m ot or r ela y is a In t er n a t ion a l St a n - pr essor is t o com pr ess t h e low-pr essu r e r efr iger a n t
da r ds Or ga n iza t ion (ISO)-t ype r ela y. Th e r ela y is a va por fr om t h e eva por a t or in t o a h igh -pr essu r e, h igh -
elect r om ech a n ica l device t h a t swit ch es ba t t er y cu r- t em per a t u r e va por. Th e com pr essor is ser viced on ly
r en t fr om a fu se in t h e P ower Dist r ibu t ion Cen t er a s a n a ssem bly.
CLUTCH SNAP
PLATERING SHAFT SNAP
KEY RING PULLEY
CLUTCH
SHIMS COIL

24 - 6 HEATING AND AIR CONDITIONING XJ


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
COMPRESSOR CLUTCH t h e h igh pr essu r e cu t -off swit ch . See t h e Dia gn osis
Th e com pr essor clu t ch a ssem bly con sist s of a st a - a n d Test in g sect ion of t h is gr ou p for m or e in for m a -
t ion a r y elect r om a gn et ic coil, a h u b bea r in g a n d pu l- t ion on t h e oper a t ion of t h e com pr essor clu t ch r ela y.
ley a ssem bly, a n d a clu t ch pla t e (F ig. 3). Th e Th e com pr essor clu t ch r ela y is loca t ed in t h e P ower
elect r om a gn et ic coil a n d pu lley a r e r et a in ed on t h e Dist r ibu t ion Cen t er (P DC) in t h e en gin e com pa r t -
com pr essor wit h sn a p r in gs. Th e clu t ch pla t e is m en t . Refer t o t h e P DC la bel for r ela y iden t ifica t ion
m ou n t ed on t h e com pr essor sh a ft a n d secu r ed wit h a a n d loca t ion .
nut. Th e com pr essor clu t ch r ela y ca n n ot be r epa ir ed
a n d, if fa u lt y or da m a ged, it m u st be r epla ced.
PULLEY
CONDENSER
Th e con den ser is loca t ed in fr on t of t h e en gin e cool-
in g r a dia t or. It is a h ea t exch a n ger t h a t a llows t h e
h igh -pr essu r e r efr iger a n t ga s t o give u p it s h ea t t o
t h e a ir pa ssin g over t h e con den ser fin s. Th is ca u ses
t h e r efr iger a n t ga s t o con den se in t o a h igh -pr essu r e
liqu id r efr iger a n t .
Th e con den ser ca n n ot be r epa ir ed a n d, if fa u lt y or
da m a ged, it m u st be r epla ced.
CLUTCH SHIMS SNAP RING SNAP RING EVAPORATOR COIL
J9524-33
Th e eva por a t or coil is loca t ed in t h e h ea t er-A/C
h ou sin g, u n der t h e in st r u m en t pa n el. Refr iger a n t
Fig. 3 Compressor Clutch en t er s t h e eva por a t or a s a low-t em per a t u r e, low-
pr essu r e liqu id. As a ir pa sses over t h e fin s of t h e
Th ese com pon en t s pr ovide t h e m ea n s t o en ga ge
eva por a t or, t h e h u m idit y in t h e a ir con den ses on t h e
a n d disen ga ge t h e com pr essor fr om t h e en gin e ser-
fin s, a n d t h e h ea t fr om t h e a ir is a bsor bed by t h e
pen t in e a ccessor y dr ive belt . Wh en t h e clu t ch coil is
r efr iger a n t . H ea t a bsor pt ion ca u ses t h e r efr iger a n t t o
en er gized, it m a gn et ica lly dr a ws t h e clu t ch in t o con -
becom e a low-pr essu r e ga s befor e it lea ves t h e eva p-
t a ct wit h t h e pu lley a n d dr ives t h e com pr essor sh a ft .
or a t or.
Wh en t h e coil is n ot en er gized, t h e pu lley fr eewh eels
Th e eva por a t or coil ca n n ot be r epa ir ed a n d, if
on t h e clu t ch h u b bea r in g, wh ich is pa r t of t h e pu lley.
fa u lt y or da m a ged, it m u st be r epla ced.
Th e com pr essor clu t ch a n d coil a r e t h e on ly ser viced
pa r t s on t h e com pr essor.
FIXED ORIFICE TUBE
Th e com pr essor clu t ch is con t r olled by sever a l com -
Th e fixed or ifice t u be is in st a lled in t h e liqu id lin e
pon en t s: t h e h ea t er-A/C m ode con t r ol swit ch , t h e low
bet ween t h e ou t let t u be of t h e con den ser a n d t h e
pr essu r e cyclin g clu t ch swit ch , t h e h igh pr essu r e cu t -
in let t u be of t h e eva por a t or. Th e fixed or ifice t u be is
off swit ch , t h e com pr essor clu t ch r ela y, a n d t h e P ow-
loca t ed in t h e en d of t h e liqu id lin e or liqu id lin e
er t r a in Con t r ol Modu le (P CM). Th e P CM m a y dela y
ju m per t h a t con n ect s t o t h e con den ser ou t let t u be.
com pr essor clu t ch en ga gem en t for u p t o 30 secon ds.
Th e in let a n d ou t let en ds of t h e t u be h a ve a scr een
Refer t o Gr ou p 14 - F u el Syst em for m or e in for m a -
t o filt er t h e r efr iger a n t . O-r in gs on t h e t u be body pr e-
t ion on t h e P CM con t r ols.
ven t t h e r efr iger a n t fr om bypa ssin g t h e fixed or ifice.
Th e fixed or ifice t u be is u sed t o m et er t h e flow of liq-
COMPRESSOR CLUTCH RELAY
u id r efr iger a n t in t o t h e eva por a t or coil.
Th e com pr essor clu t ch r ela y is a In t er n a t ion a l
Th e fixed or ifice t u be ca n n ot be r epa ir ed a n d, if
St a n da r ds Or ga n iza t ion (ISO) m icr o-r ela y. Th e t er m i-
fa u lt y or plu gged, t h e liqu id lin e or liqu id lin e
n a l design a t ion s a n d fu n ct ion s a r e t h e sa m e a s a con -
ju m per con t a in in g t h e fixed or ifice t u be m u st be
ven t ion a l ISO r ela y. H owever, t h e m icr o-r ela y
r epla ced.
t er m in a l or ien t a t ion (foot pr in t ) is differ en t , cu r r en t
ca pa cit y is lower, a n d t h e r ela y ca se dim en sion s a r e
HEATER CORE
sm a ller t h a n t h ose of t h e con ven t ion a l ISO r ela y.
Th e h ea t er cor e is loca t ed in t h e h ea t er-A/C h ou s-
Th e com pr essor clu t ch r ela y is a elect r om ech a n ica l
in g, u n der t h e in st r u m en t pa n el. It is a h ea t
device t h a t swit ch es ba t t er y cu r r en t t o t h e com pr es-
exch a n ger m a de of r ows of t u bes a n d fin s. E n gin e
sor clu t ch coil wh en t h e P ower t r a in Con t r ol Modu le
coola n t is cir cu la t ed t h r ou gh h ea t er h oses t o t h e
(P CM) gr ou n ds t h e coil side of t h e r ela y. Th e P CM
h ea t er cor e a t a ll t im es. As t h e coola n t flows t h r ou gh
r espon ds t o in pu t s fr om t h e h ea t er-A/C m ode con t r ol
swit ch , t h e low pr essu r e cyclin g clu t ch swit ch , a n d
XJ HEATING AND AIR CONDITIONING 24 - 7
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
t h e h ea t er cor e, h ea t r em oved fr om t h e en gin e is Th e swit ch con t a ct s open a n d close ca u sin g t h e P CM
t r a n sfer r ed t o t h e h ea t er cor e fin s a n d t u bes. t o t u r n t h e com pr essor clu t ch on a n d off. Th is r egu -
Air dir ect ed t h r ou gh t h e h ea t er cor e picks u p t h e la t es t h e syst em pr essu r e a n d con t r ols eva por a t or
h ea t fr om t h e h ea t er cor e fin s. Th e blen d a ir door t em per a t u r e. Con t r ollin g eva por a t or t em per a t u r e
a llows con t r ol of t h e h ea t er ou t pu t a ir t em per a t u r e pr even t s con den sa t e wa t er on t h e eva por a t or fin s
by con t r ollin g h ow m u ch of t h e a ir flowin g t h r ou gh fr om fr eezin g a n d obst r u ct in g a ir con dit ion in g syst em
t h e h ea t er-A/C h ou sin g is dir ect ed t h r ou gh t h e a ir flow.
h ea t er cor e. Th e blower m ot or speed con t r ols t h e Th e low pr essu r e cyclin g clu t ch swit ch con t a ct s a r e
a m ou n t of a ir flowin g t h r ou gh t h e h ea t er-A/C h ou s- open wh en t h e su ct ion pr essu r e is a ppr oxim a t ely 141
in g. kP a (20.5 psi) or lower. Th e swit ch con t a ct s will close
Th e h ea t er cor e ca n n ot be r epa ir ed a n d, if fa u lt y or wh en t h e su ct ion pr essu r e r ises t o a ppr oxim a t ely 234
da m a ged, it m u st be r epla ced. t o 262 kP a (34 t o 38 psi) or a bove. Lower a m bien t
t em per a t u r es, below a ppr oxim a t ely -1°C (30°F ) du r-
HIGH PRESSURE CUT-OFF SWITCH in g cold wea t h er will a lso open t h e swit ch con t a ct s.
Th e h igh pr essu r e cu t -off swit ch is loca t ed on t h e Th is is du e t o t h e pr essu r e/t em per a t u r e r ela t ion sh ip
disch a r ge lin e bet ween t h e com pr essor a n d t h e con - of t h e r efr iger a n t in t h e syst em .
den ser in let . Th is swit ch is con n ect ed in ser ies wit h Th e low pr essu r e cyclin g clu t ch swit ch is a fa ct or y-
t h e low pr essu r e cyclin g clu t ch swit ch bet ween ca libr a t ed u n it . It ca n n ot be a dju st ed or r epa ir ed
gr ou n d a n d t h e P ower t r a in Con t r ol Modu le (P CM). a n d, if fa u lt y or da m a ged, it m u st be r epla ced.
Th e swit ch con t a ct s open a n d close ca u sin g t h e P CM
t o t u r n t h e com pr essor clu t ch on a n d off. Th is pr e- REFRIGERANT
ven t s com pr essor oper a t ion wh en t h e disch a r ge lin e Th e R-134a r efr iger a n t u sed in t h is a ir con dit ion -
pr essu r e a ppr oa ch es h igh levels. in g syst em is a n on -t oxic, n on -fla m m a ble, clea r, a n d
Th e h igh pr essu r e cu t -off swit ch con t a ct s a r e open color less liqu efied ga s. R-134a r efr iger a n t is n ot com -
wh en t h e disch a r ge lin e pr essu r e r ises a bove 3100 t o pa t ible wit h R-12 r efr iger a n t in a n a ir con dit ion in g
3375 kP a (450 t o 490 psi). Th e swit ch con t a ct s will syst em .
close wh en t h e disch a r ge lin e pr essu r e dr ops t o 1860 E ven a sm a ll a m ou n t of R-12 a dded t o a R-134a
t o 2275 kP a (270 t o 330 psi). r efr iger a n t syst em , will ca u se com pr essor fa ilu r e,
Th e h igh pr essu r e cu t -off swit ch is a fa ct or y-ca li- r efr iger a n t oil slu dge, or poor a ir con dit ion in g syst em
br a t ed u n it . Th e swit ch ca n n ot be a dju st ed or per for m a n ce. Th e r efr iger a n t syst em ser vice por t s
r epa ir ed a n d, if fa u lt y or da m a ged, it m u st be h a ve been design ed t o en su r e t h a t t h e syst em is n ot
r epla ced. a cciden t a lly filled wit h t h e wr on g r efr iger a n t (R-12).

HIGH PRESSURE RELIEF VALVE REFRIGERANT LINE


Th e h igh pr essu r e r elief va lve is loca t ed on t h e Th e r efr iger a n t lin es a r e u sed t o ca r r y t h e r efr ig-
com pr essor. Th e va lve is u sed t o pr even t excessive er a n t bet ween t h e va r iou s a ir con dit ion in g syst em
r efr iger a n t syst em pr essu r e. Th e va lve ven t s t h e sys- com pon en t s. A ba r r ier h ose design is u sed for t h e a ir
t em wh en a pr essu r e of 3445 t o 4135 kP a (500 t o 600 con dit ion in g syst em on t h is veh icle. Th e en ds of t h e
psi), a n d a bove, is r ea ch ed. Th is pr even t s da m a ge t o r efr iger a n t h oses a r e m a de fr om ligh t weigh t a lu m i-
t h e com pr essor a n d ot h er syst em com pon en t s du e t o n u m , a n d u se br a ze-less fit t in gs.
con den ser a ir flow bein g r est r ict ed or a n over ch a r ge Kin ks or sh a r p ben ds in t h e r efr iger a n t plu m bin g
of r efr iger a n t . Th e va lve closes wit h a m in im u m will r edu ce t h e ca pa cit y of t h e en t ir e syst em . H igh
pr essu r e of 2756 kP a (400 psi). pr essu r es a r e pr odu ced in t h e syst em wh en it is oper-
Th e h igh pr essu r e r elief va lve ven t s on ly en ou gh a t in g. E xt r em e ca r e m u st be exer cised t o m a ke su r e
r efr iger a n t t o r edu ce syst em pr essu r e, a n d t h en t h a t a ll r efr iger a n t syst em con n ect ion s a r e pr essu r e
r e-sea t s it self. Th e m a jor it y of t h e r efr iger a n t is con - t igh t .
ser ved in t h e syst em . If t h e va lve ven t s r efr iger a n t , it A good r u le for t h e flexible h ose r efr iger a n t lin es is
does n ot m ea n t h e va lve is fa u lt y. Th e va lve is pa r t of t o keep t h e r a diu s of a ll ben ds a t lea st t en t im es t h e
t h e com pr essor a ssem bly a n d m u st n ot be r em oved or dia m et er of t h e h ose. Sh a r p ben ds will r edu ce t h e
ot h er wise dist u r bed. flow of r efr iger a n t . Th e flexible h ose lin es sh ou ld be
r ou t ed so t h ey a r e a t lea st 80 m m (3 in ch es) fr om t h e
LOW PRESSURE CYCLING CLUTCH SWITCH exh a u st m a n ifold. It is a good pr a ct ice t o in spect a ll
Th e low pr essu r e cyclin g clu t ch swit ch is m ou n t ed flexible r efr iger a n t syst em h ose lin es a t lea st on ce a
on t op of t h e a ccu m u la t or. Th e swit ch is con n ect ed in yea r t o m a ke su r e t h ey a r e in good con dit ion a n d
ser ies wit h t h e h igh pr essu r e cu t -off swit ch , bet ween pr oper ly r ou t ed.
gr ou n d a n d t h e P ower t r a in Con t r ol Modu le (P CM).
LOW
LOW(BLUE
VALVE
PRESSURE
W/BLACK
GAUGE STRIP)
HOSE HIGH
HOSE
W/BLACK
ERANT
VACUUM/REFRIG-
LOWHIGH
PRESSURE
W/BLACK
STRIP)
HOSE
(RED
PRESSURE
STRIP)
GAUGE
(YEL-
VALVE

24 - 8 HEATING AND AIR CONDITIONING XJ


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e r efr iger a n t lin es a n d h oses ca n n ot be r epa ir ed
a n d, if fa u lt y or da m a ged, t h ey m u st be r epla ced.

REFRIGERANT LINE COUPLER


Spr in g-lockin g r efr iger a n t lin e cou pler s a r e u sed t o
con n ect r efr iger a n t lin es a n d ot h er com pon en t s t o t h e
r efr iger a n t syst em . Th e cou plin g is h eld t oget h er by
a ga r t er spr in g in side a cir cu la r ca ge.
Wh en t h e cou plin g h a lves a r e con n ect ed, t h e fla r ed
en d of t h e fem a le fit t in g slips beh in d t h e ga r t er
spr in g in side t h e ca ge of t h e m a le fit t in g. Th e ga r t er VALVE
spr in g a n d ca ge pr even t t h e fla r ed en d of t h e fem a le VALVE
fit t in g fr om pu llin g ou t of t h e ca ge. Secon da r y clips
a r e in st a lled over t h e cou plin g a t t h e fa ct or y for
a dded blowoff pr ot ect ion . VACUUM/
O-r in gs a r e u sed t o sea l t h e cou plin g. Th ese REFRIGERANT
O-r in gs a r e com pa t ible wit h R-134a r efr iger a n t a n d HOSE (YELLOW
W/BLACK STRIP)
m u st be r epla ced wit h O-r in gs m a de of t h e sa m e
HIGH PRESSURE HOSE
m a t er ia l. ....,...(RED W/BLACK STRIP)

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

a lkylen e glycol, syn t h et ic (SP -20 PAG), wa x-fr ee


r efr iger a n t oil. Use on ly r efr iger a n t oil of t h e sa m e M AN I FOLD GAU GE SET CON N ECT I ON S
t ype t o ser vice t h e syst em .
CAUTION: Do not use an R-12 manifold gauge set
Refr iger a n t oil will a bsor b a n y m oist u r e it com es in
on an R-134a system. The refrigerants are not com-
con t a ct wit h , even m oist u r e in t h e a ir. Th e oil con -
patible and system damage will result.
t a in er sh ou ld be kept t igh t ly ca pped u n t il it is r ea dy
t o be u sed. Th en , ca p t h e oil im m edia t ely a ft er u sin g,
t o pr even t con t a m in a t ion . LOW PRESSURE GAUGE HOSE
Th e low pr essu r e h ose (Blu e wit h Bla ck st r ipe)
REFRIGERANT SYSTEM SERVICE EQUIPMENT a t t a ch es t o t h e su ct ion ser vice por t . Th is por t is
loca t ed on t h e su ct ion lin e bet ween t h e a ccu m u la t or
WARNING: EYE PROTECTION MUST BE WORN ou t let a n d t h e com pr essor.
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE) HIGH PRESSURE GAUGE HOSE
ALL VALVES ON THE EQUIPMENT BEING USED, Th e h igh pr essu r e h ose (Red wit h Bla ck st r ipe)
BEFORE CONNECTING TO OR DISCONNECTING a t t a ch es t o t h e disch a r ge ser vice por t . Th is por t is
FROM THE REFRIGERANT SYSTEM. FAILURE TO loca t ed on t h e disch a r ge lin e bet ween t h e com pr essor
OBSERVE THESE WARNINGS MAY RESULT IN PER- a n d t h e con den ser in let .
SONAL INJURY.
RECOVERY/RECYCLING/EVACUATION/CHARGING
Wh en ser vicin g t h e a ir con dit ion in g syst em , a HOSE
r efr iger a n t ch a r gin g st a t ion a n d a r ecover y/r ecyclin g Th e cen t er m a n ifold h ose (Yellow, or Wh it e, wit h Bla ck
device for R-134a m u st be u sed. Th is device m u st st r ipe) is u sed t o r ecover, eva cu a t e, a n d ch a r ge t h e r efr ig-
m eet SAE St a n da r d J 2210. Con t a ct a n a u t om ot ive er a n t syst em . Wh en t h e low or h igh pr essu r e va lves on
ser vice equ ipm en t su pplier for r efr iger a n t ch a r gin g t h e m a n ifold ga u ge set a r e open ed, t h e r efr iger a n t in t h e
a n d r ecyclin g/r ecover in g equ ipm en t . Refer t o t h e syst em will esca pe t h r ou gh t h is h ose.
oper a t in g in st r u ct ion s pr ovided wit h t h e equ ipm en t
for pr oper oper a t ion . REFRIGERANT SYSTEM SERVICE PORT
A m a n ifold ga u ge set m a y be n eeded wit h som e Th e t wo r efr iger a n t syst em ser vice por t s a r e u sed
ch a r gin g a n d/or r ecover y/r ecyclin g devices (F ig. 4). t o ch a r ge, r ecover /r ecycle, eva cu a t e, a n d t est t h e a ir
Th e ser vice h oses on t h e ga u ge set bein g u sed sh ou ld con dit ion in g r efr iger a n t syst em . Un iqu e ser vice por t
h a ve m a n u a l (t u r n wh eel), or a u t om a t ic ba ck-flow cou pler sizes a r e u sed on t h e R-134a syst em , t o
va lves a t t h e ser vice por t con n ect or en ds. Th is will en su r e t h a t t h e r efr iger a n t syst em is n ot a cciden t a lly
pr even t r efr iger a n t fr om bein g r elea sed in t o t h e con t a m in a t ed by t h e u se of t h e wr on g r efr iger a n t
a t m osph er e. (R-12), or r efr iger a n t syst em ser vice equ ipm en t .
CLUTCH
PRESSURE
ACCUMULATOR
CYCLING
SWITCH

XJ HEATING AND AIR CONDITIONING 24 - 9


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e h igh pr essu r e ser vice por t is loca t ed on t h e t h e m oist u r e in t h e a ir t h a t con den ses on t h e eva po-
disch a r ge lin e, bet ween t h e com pr essor a n d t h e con - r a t or fin s. Con den sin g t h e m oist u r e in t h e a ir t r a n s-
den ser in let . Th e low pr essu r e ser vice por t is loca t ed fer s h ea t en er gy in t o t h e eva por a t or fin s a n d t u bin g.
on t h e su ct ion lin e, bet ween t h e a ccu m u la t or ou t let Th is r edu ces t h e a m ou n t of h ea t t h e eva por a t or ca n
a n d t h e com pr essor. Aft er ser vicin g t h e r efr iger a n t a bsor b fr om t h e a ir. H igh h u m idit y gr ea t ly r edu ces
syst em , a lwa ys r ein st a ll t h e ser vice por t ca ps. t h e a bilit y of t h e eva por a t or t o lower t h e t em per a t u r e
of t h e a ir.
VACUUM CHECK VALVE H owever, eva por a t or ca pa cit y u sed t o r edu ce t h e
A on e-wa y va cu u m ch eck va lve is in st a lled in t h e a m ou n t of m oist u r e in t h e a ir is n ot wa st ed. Wr in g-
a ccessor y va cu u m su pply lin e n ea r t h e va cu u m t a p in g som e of t h e m oist u r e ou t of t h e a ir en t er in g t h e
on t h e en gin e in t a ke m a n ifold in t h e en gin e com pa r t - veh icle a dds t o t h e com for t of t h e pa ssen ger s.
m en t . Th is ch eck va lve h elps t o m a in t a in t h e syst em Alt h ou gh , a n own er m a y expect t oo m u ch fr om t h eir
va cu u m n eeded t o r et a in t h e select ed h ea t er-A/C a ir con dit ion in g syst em on h u m id da ys. A per for-
m ode set t in gs by pr even t in g t h e en gin e fr om bleed- m a n ce t est is t h e best wa y t o det er m in e wh et h er t h e
in g down syst em va cu u m t h r ou gh t h e in t a ke m a n i- syst em is per for m in g u p t o st a n da r d. Th is t est a lso
fold du r in g ext en ded h ea vy en gin e loa d (low en gin e pr ovides va lu a ble clu es a s t o t h e possible ca u se of
va cu u m ) oper a t ion . t r ou ble wit h t h e a ir con dit ion in g syst em .
Th e va cu u m ch eck va lve ca n n ot be r epa ir ed a n d, if Review t h e Ser vice Wa r n in gs a n d P r eca u t ion s in
fa u lt y or da m a ged, it m u st be r epla ced. t h e fr on t of t h is gr ou p befor e per for m in g t h is pr oce-
du r e. Th e a ir t em per a t u r e in t h e t est r oom a n d in
VACUUM RESERVOIR t h e veh icle m u st be a m in im u m of 21°C (70°F ) for
Th e va cu u m r eser voir is m ou n t ed t o t h e fr on t t h is t est .
bu m per ba r beh in d t h e pa ssen ger side bu m per en d (1) Con n ect a t a ch om et er a n d a m a n ifold ga u ge set .
ca p. Va cu u m st or ed in t h e r eser voir is u sed t o oper- (2) Set t h e h ea t er-A/C m ode con t r ol swit ch kn ob in
a t e t h e va cu u m -con t r olled veh icle a ccessor ies du r in g t h e Recir cu la t ion Mode posit ion , t h e t em per a t u r e
per iods of low en gin e va cu u m , su ch a s wh en t h e con t r ol kn ob in t h e fu ll cool posit ion , a n d t h e blower
veh icle is clim bin g a st eep gr a de or u n der ot h er h igh m ot or swit ch kn ob in t h e h igh est speed posit ion .
en gin e loa d oper a t in g con dit ion s. (3) St a r t t h e en gin e a n d h old t h e idle a t 1,000 r pm
Th e va cu u m r eser voir ca n n ot be r epa ir ed a n d, if wit h t h e com pr essor clu t ch en ga ged.
fa u lt y or da m a ged, it m u st be r epla ced. (4) Th e en gin e sh ou ld be a t oper a t in g t em per a t u r e.
Th e door s a n d win dows m u st be open .
(5) In ser t a t h er m om et er in t h e dr iver side cen t er
DI AGN OSI S AN D T EST I N G A/C (pa n el) ou t let . Oper a t e t h e en gin e for five m in u t es.
A/C PERFORMANCE (6) Th e com pr essor clu t ch m a y cycle, depen din g
Th e a ir con dit ion in g syst em is design ed t o pr ovide u pon t h e a m bien t t em per a t u r e a n d h u m idit y. If t h e
t h e pa ssen ger com pa r t m en t wit h low t em per a t u r e clu t ch cycles, u n plu g t h e low pr essu r e cyclin g clu t ch
a n d low h u m idit y a ir. Th e eva por a t or, loca t ed in t h e swit ch wir e h a r n ess con n ect or fr om t h e swit ch
h ea t er-A/C h ou sin g on t h e da sh pa n el below t h e loca t ed on t h e a ccu m u la t or (F ig. 5). P la ce a ju m per
in st r u m en t pa n el, is cooled t o t em per a t u r es n ea r t h e wir e a cr oss t h e t er m in a ls of t h e low pr essu r e cyclin g
fr eezin g poin t . As wa r m da m p a ir pa sses over t h e clu t ch swit ch wir e h a r n ess con n ect or .
fin s in t h e eva por a t or, t h e a ir is cooled a n d t h e m ois- CLUTCH CYCLING
t u r e is r em oved a s it con den ses on t h e fin s. Du r in g PRESSURE SWITCH
per iods of h igh h ea t a n d h u m idit y, a n a ir con dit ion -
in g syst em will be m or e effect ive in t h e Recir cu la t ion
Mode. Wit h t h e syst em in t h e Recir cu la t ion Mode,
on ly a ir fr om t h e pa ssen ger com pa r t m en t pa sses
t h r ou gh t h e eva por a t or. As t h e pa ssen ger com pa r t -
m en t a ir deh u m idifies, t h e a ir con dit ion in g syst em
ACCUMULATOR
per for m a n ce levels im pr ove.
H u m idit y h a s a n im por t a n t bea r in g on t h e t em per-
a t u r e of t h e a ir deliver ed t o t h e in t er ior of t h e veh i-
cle. It is im por t a n t t o u n der st a n d t h e effect t h a t
h u m idit y h a s on t h e per for m a n ce of t h e a ir con dit ion -
in g syst em . Wh en h u m idit y is h igh , t h e eva por a t or
h a s t o per for m a dou ble du t y. It m u st lower t h e a ir J9424-26
t em per a t u r e, a n d it m u st lower t h e t em per a t u r e of
Fig. 5 Low Pressure Cycling Clutch Switch
24 - 10 HEATING AND AIR CONDITIONING XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
(7) Wit h t h e com pr essor clu t ch en ga ged, r ecor d t h e P er for m a n ce Tem per a t u r e a n d P r essu r e ch a r t (F ig.
disch a r ge a ir t em per a t u r e a n d t h e com pr essor dis- 6). If t h e disch a r ge a ir t em per a t u r e is h igh , see
ch a r ge pr essu r e. Refr iger a n t Syst em Lea ks a n d Refr iger a n t Syst em
(8) Com pa r e t h e disch a r ge a ir t em per a t u r e t o t h e Ch a r ge in t h is gr ou p.
(9) Com pa r e t h e com pr essor disch a r ge pr essu r e t o
t h e P er for m a n ce Tem per a t u r e a n d P r essu r e ch a r t . If
t h e com pr essor disch a r ge pr essu r e is h igh , see t h e
P r essu r e Dia gn osis ch a r t

Ambient 21°C 27°C 32°C 38°C 43°C


Temperature (70°F) (80°F) (90°F) (100°F) (110°F)
Air Temperature -3 to 3°C 1 to 7°C 3 to 9°C 6 to 13°C 10 to 18°C
at Center Panel
Outlet (27-38°F) (33-44°F) (37-48°F) (43-55°F) (50-64°F)
Evaporator 179-241 kPa 221-283 kPa 262-324 kPa 303-365 kPa 345-414 kPa
Inlet Pressure
at Charge Port (26-35 psi) (32-41 psi) (38-47 psi) (44-53 psi) (50-60 psi)
Compressor 1240-1655 kPa 1380-1790 kPa 1720-2070 kPa 1860-2345 kPa 2070-2690 kPa
Discharge
Pressure (180-240 psi) (200-260 psi) (250-300 psi) (270-340 psi) (300-390 psi)

Fig. 6 Performance Temperature and Pressure


XJ HEATING AND AIR CONDITIONING 24 - 11
DI AGN OSI S AN D T EST I N G (Cont inue d)

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.

HEATER PERFORMANCE Minimum Heater


System
PREPARAT I ON S Ambient Temperature Floor Outlet
Review t h e Ser vice Wa r n in gs a n d P r eca u t ion s in Temperature
t h e fr on t of t h is gr ou p befor e per for m in g t h e follow- Celsius Fahrenheit Celsius Fahrenheit
in g pr ocedu r es.
Ch eck t h e r a dia t or coola n t level, ser pen t in e dr ive 15.5° 60° 62.2° 144°
belt t en sion , a n d en gin e va cu u m lin e con n ect ion s. 21.1° 70° 63.8° 147°
Also ch eck t h e r a dia t or a ir flow a n d t h e r a dia t or fa n 26.6° 80° 65.5° 150°
oper a t ion . St a r t t h e en gin e a n d a llow it t o wa r m u p 32.2° 90° 67.2° 153°
t o n or m a l oper a t in g t em per a t u r e.
Fig. 7 Temperature Reference
WARNING: DO NOT REMOVE THE RADIATOR
PRESSURE CAP WHEN THE ENGINE IS AT OPER- r et u r n h ose is m u ch cooler t h a n t h e su pply h ose,
ATING TEMPERATURE, PERSONAL INJURY MAY loca t e a n d r epa ir t h e en gin e coola n t flow obst r u ct ion
RESULT. in t h e h ea t er syst em .

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.

(1) Discon n ect t h e va cu u m h a r n ess con n ect or


beh in d t h e glove box a n d in boa r d of t h e glove box
open in g on t h e h ea t er-A/C h ou sin g.
(2) Con n ect t h e t est set va cu u m h ose pr obe t o ea ch
por t in t h e h ea t er-A/C h ou sin g h a lf of t h e va cu u m
BLEED VALVE J9324-75
h a r n ess con n ect or, on e a t a t im e, a n d pa u se a ft er
Fig. 8 Adjust Vacuum Test Bleed Valve ea ch con n ect ion (F ig. 9). Th e t est set ga u ge sh ou ld
r et u r n t o t h e 27 kP a (8 in . H g.) set t in g sh or t ly a ft er
VACU U M CH ECK VALV E ea ch con n ect ion is m a de. If OK, r epla ce t h e fa u lt y
(1) Rem ove t h e va cu u m ch eck va lve. Th e va lve is h ea t er-A/C con t r ol. If n ot OK, go t o St ep 3.
loca t ed in t h e (bla ck) va cu u m su pply t u be a t t h e (3) Det er m in e t h e va cu u m lin e color of t h e va cu u m
h ea t -A/C syst em va cu u m t a p. cir cu it t h a t is lea kin g. To det er m in e t h e va cu u m lin e
XJ HEATING AND AIR CONDITIONING 24 - 15
DI AGN OSI S AN D T EST I N G (Cont inue d)
in g Dia gr a m s. P ossible ca u ses of a n in oper a t ive
blower m ot or in clu de:
• F a u lt y fu se
• F a u lt y blower m ot or cir cu it wir in g or wir e h a r-
n ess con n ect or s
• F a u lt y blower m ot or r esist or
• F a u lt y blower m ot or r ela y
• F a u lt y blower m ot or swit ch
• F a u lt y h ea t er-A/C m ode con t r ol swit ch
• F a u lt y blower m ot or.
P ossible ca u ses of t h e blower m ot or n ot oper a t in g
in a ll speeds in clu de:
• F a u lt y fu se
• F a u lt y blower m ot or swit ch
• F a u lt y blower m ot or r esist or
• F a u lt y blower m ot or cir cu it wir in g or wir e h a r-
n ess con n ect or s.
J9324-60
V I BRAT I ON
Fig. 9 Vacuum Circuit Test P ossible ca u ses of blower m ot or vibr a t ion in clu de:
color s, r efer t o t h e Va cu u m Cir cu it s ch a r t (F ig. 10) or • Im pr oper blower m ot or m ou n t in g
(F ig. 11). • Im pr oper blower wh eel m ou n t in g
(4) Discon n ect a n d plu g t h e va cu u m lin e fr om t h e • Blower wh eel ou t of ba la n ce or ben t
com pon en t (fit t in g, a ct u a t or, va lve, swit ch , or r eser- • Blower m ot or fa u lt y.
voir ) on t h e ot h er en d of t h e lea kin g cir cu it . In st r u -
m en t pa n el disa ssem bly or r em ova l m a y be n ecessa r y N OI SE
t o ga in a ccess t o som e com pon en t s. See t h e ser vice To ver ify t h a t t h e blower is t h e sou r ce of t h e n oise,
pr ocedu r es in t h is gr ou p. u n plu g t h e blower m ot or wir e h a r n ess con n ect or a n d
(5) Con n ect t h e t est set h ose or pr obe t o t h e open oper a t e t h e h ea t er-A/C syst em . If t h e n oise goes
en d of t h e lea kin g cir cu it . Th e t est set ga u ge sh ou ld a wa y, possible ca u ses in clu de:
r et u r n t o t h e 27 kP a (8 in . H g.) set t in g sh or t ly a ft er • F or eign m a t er ia l in t h e h ea t er-A/C h ou sin g
ea ch con n ect ion is m a de. If OK, r epla ce t h e fa u lt y • Im pr oper blower m ot or m ou n t in g
discon n ect ed com pon en t . If n ot OK, go t o St ep 6. • Im pr oper blower wh eel m ou n t in g
(6) To loca t e a lea k in a va cu u m lin e, lea ve on e • Blower m ot or fa u lt y.
en d of t h e lin e plu gged a n d con n ect t h e t est set h ose
or pr obe t o t h e ot h er en d. Ru n you r fin ger s slowly BLOWER MOTOR RELAY
a lon g t h e lin e wh ile wa t ch in g t h e t est set ga u ge. Th e
va cu u m r ea din g will flu ct u a t e wh en you r fin ger s con - WARNING: ON VEHICLES EQUIPPED WITH AIR-
t a ct t h e sou r ce of t h e lea k. To r epa ir t h e va cu u m BAGS, REFER TO GROUP 8M - PASSIVE
lin e, cu t ou t t h e lea kin g sect ion of t h e lin e. Th en , RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
in ser t t h e loose en ds of t h e lin e in t o a su it a ble len gt h STEERING WHEEL, STEERING COLUMN, OR
of 3 m m (1/8-in ch ) in side dia m et er r u bber h ose. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
BLOWER MOTOR CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
WARNING: ON VEHICLES EQUIPPED WITH AIR- INJURY.
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
RELAY T EST
STEERING WHEEL, STEERING COLUMN, OR
Th e blower m ot or r ela y is loca t ed in a wir e h a r n ess
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
con n ect or t h a t is secu r ed t o t h e h ea t er-A/C h ou sin g
SERVICE. FAILURE TO TAKE THE PROPER PRE-
beh in d t h e glove box on t h e pa ssen ger side of t h e
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
veh icle, n ext t o t h e h ea t er-A/C wir e h a r n ess con n ec-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
t or in t h e pa ssen ger com pa r t m en t . Rem ove t h e r ela y
INJURY.
fr om it s con n ect or t o per for m t h e followin g t est s:
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o (1) A r ela y in t h e de-en er gized posit ion sh ou ld
8W-42 - Air Con dit ion in g/H ea t er in Gr ou p 8W - Wir- 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
DEFROST
BI-LEVEL
VENTED
FLOOR
PANEL
Yellow
Brown
Black
Blue
OFF
Red
MIX VACUUM

24 - 16 HEATING AND AIR CONDITIONING XJ


DI AGN OSI S AN D T EST I N G (Cont inue d)

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

VACUUM CIRCUIT LEGEND


Black Red
I.D. Function Color
A Not Used N/A
Bl-LEVEL
B Defrost Actuator (Full Position) Yellow E
F
C Floor Actuator Brown
D Defrost Actuator (Mid-Position) Blue
E Vacuum Supply (Reservoir) Black
F Panel Actuator Red
G Not Used N/A

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

Red Black Red

80aac2d2

Fig. 10 Vacuum Circuits - Heater Only


Blue
BlueYellow
Yellow
Yellow
A/C-RECIRCULATION
Black
Black
Black A/C-BIBrown
FLOOR
Green
LEVEL
Green
Green VACUUM
Red
Red VENTED Yellow
Blue
Blue
A/C-OUTSIDE
Yellow
Blue
Yellow
Black
Black DEFROST
OR Brown
Brown
PANEL
Green
Green
Green
Brown
Green
MIX
Brown
OFF Red
Red
Red

XJ HEATING AND AIR CONDITIONING 24 - 17


DI AGN OSI S AN D T EST I N G (Cont inue d)

D
A

E
B

F
C

G
-
V ACUUM

VENTED
E
OFF

G F

VACUUM CIRCUIT LEGEND


I.D. Function Color
A Not Used N/A
B Defrost Actuator (Full Position) Yellow Black Red

C Floor Actuator Brown


D Defrost Actuator (Mid-Position) Blue
E Vacuum Supply (Reservoir) Black
A/C-OUTSIDE OR PANEL
F Panel Actuator Red
E
G Recirculation Actuator Green 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

Black Red Black Red

80aac2d3

Fig. 11 Vacuum Circuits - Heater-A/C


RELAY CAVITIES
RELAY TERMINALS

24 - 18 HEATING AND AIR CONDITIONING XJ


DI AGN OSI S AN D T EST I N G (Cont inue d)
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go OK, r epa ir t h e open cir cu it t o t h e ju n ct ion block fu se
t o St ep 2. If n ot OK, r epla ce t h e fa u lt y r ela y. a s r equ ir ed.
(2) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec- (5) Th e coil gr ou n d t er m in a l ca vit y (85) is con -
t r om a gn et ) sh ou ld be 75 6 5 oh m s. If OK, go t o St ep n ect ed t o gr ou n d. Th is t er m in a l su pplies t h e gr ou n d
3. If n ot OK, r epla ce t h e fa u lt y r ela y. for t h e r ela y elect r om a gn et coil. Th er e sh ou ld be con -
(3) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86. t in u it y bet ween t h e ca vit y for r ela y t er m in a l 85 a n d
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls a good gr ou n d a t a ll t im es. If n ot OK, r epa ir t h e open
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 cir cu it a s r equ ir ed.
a n d 30. If OK, see t h e Cir cu it Test in t h is gr ou p. If
n ot OK, r epla ce t h e fa u lt y r ela y. BLOWER MOTOR RESISTOR
RELAY TERMINALS RELAY CAVITIES
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
8W-42 - Air Con dit ion in g/H ea t er in Gr ou p 8W - Wir-
in g Dia gr a m s.

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-
85 J958A-2
87 CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
TERMINAL LEGEND
NUMBER IDENTIFICATION
BAG DEPLOYMENT AND POSSIBLE PERSONAL
30 COMMON FEED INJURY.
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
l - -- - - + - - -
To t est t h e blower m ot or r esist or, u n plu g t h e r esis-
87A NORMALLY CLOSED t or wir e h a r n ess con n ect or. E a ch blower m ot or swit ch
in pu t t er m in a l on t h e r esist or m u st h a ve con t in u it y
Blower Motor Relay t o t h e r esist or ou t pu t t er m in a l, wh ich is con n ect ed t o
CI RCU I T T EST t h e cir cu it goin g t o t h e blower m ot or. If t h e blower
(1) Th e r ela y com m on feed t er m in a l ca vit y (30) is m ot or r esist or con t in u it y does n ot ch eck OK, r epla ce
con n ect ed t o fu sed ba t t er y feed dir ect ly fr om a fu se t h e fa u lt y r esist or.
in t h e P ower Dist r ibu t ion Cen t er (P DC), a n d sh ou ld
be h ot a t a ll t im es. Ch eck for ba t t er y volt a ge a t t h e BLOWER MOTOR SWITCH
con n ect or ca vit y for r ela y t er m in a l 30. If OK, go t o F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
St ep 2. If n ot OK, r epa ir t h e open cir cu it t o t h e P DC 8W-42 - Air Con dit ion in g/H ea t er in Gr ou p 8W - Wir-
a s r equ ir ed. in g Dia gr a m s. Th e blower m ot or swit ch is on ly ser-
(2) Th e r ela y n or m a lly closed t er m in a l ca vit y (87A) viced a s a pa r t of t h e h ea t er-on ly or h ea t er-A/C
is n ot u sed for t h is a pplica t ion . Go t o St ep 3. con t r ol a ssem bly.
(3) Th e r ela y n or m a lly open t er m in a l ca vit y (87) is (1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
con n ect ed t o t h e blower m ot or. Wh en t h e r ela y is Rem ove t h e h ea t er-A/C con t r ol fr om t h e in st r u m en t
en er gized, t er m in a l 87 is con n ect ed t o t er m in a l 30 pa n el. Ch eck for con t in u it y bet ween t h e gr ou n d cir-
a n d pr ovides fu ll ba t t er y cu r r en t t o t h e blower m ot or cu it ca vit y of t h e con t r ol wir e h a r n ess con n ect or a n d
feed cir cu it . Th er e sh ou ld be con t in u it y bet ween t h e a good gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go
con n ect or ca vit y for t er m in a l 87 a n d t h e blower t o St ep 2. If n ot OK, r epa ir t h e open cir cu it t o gr ou n d
m ot or r ela y ou t pu t cir cu it ca vit y of t h e blower m ot or a s r equ ir ed.
wir e h a r n ess con n ect or a t a ll t im es. If OK, go t o St ep (2) Wit h t h e h ea t er-A/C con t r ol wir e h a r n ess con -
4. If n ot OK, r epa ir t h e open cir cu it t o t h e blower n ect or u n plu gged, pla ce t h e m ode con t r ol swit ch kn ob
m ot or a s r equ ir ed. in a n y posit ion except t h e Off posit ion . Ch eck for con -
(4) Th e coil ba t t er y t er m in a l ca vit y (86) is con - t in u it y bet ween t h e gr ou n d cir cu it t er m in a l a n d ea ch
n ect ed t o t h e ign it ion swit ch . Wh en t h e ign it ion of t h e blower m ot or dr iver cir cu it t er m in a ls of t h e
swit ch is pla ced in t h e On posit ion , fu sed ign it ion con t r ol a s you m ove t h e blower swit ch t o ea ch of t h e
swit ch ou t pu t is dir ect ed fr om a fu se in t h e ju n ct ion fou r speed posit ion s. Th er e sh ou ld be con t in u it y a t
block t o t h e r ela y elect r om a gn et ic coil t o en er gize t h e ea ch dr iver cir cu it t er m in a l in on ly on e blower m ot or
r ela y. Th er e sh ou ld be ba t t er y volt a ge a t t h e con n ec- swit ch speed posit ion . If OK, t est a n d r epa ir t h e
t or ca vit y for r ela y t er m in a l 86 wit h t h e ign it ion blower dr iver cir cu it s bet ween t h e con t r ol con n ect or
swit ch in t h e On posit ion . If OK, go t o St ep 5. If n ot a n d t h e blower m ot or r esist or a s r equ ir ed. If n ot OK,
r epla ce t h e fa u lt y h ea t er-A/C con t r ol u n it .
XJ HEATING AND AIR CONDITIONING 24 - 19
DI AGN OSI S AN D T EST I N G (Cont inue d)
COMPRESSOR (2) Wit h t h e h ea t er-A/C m ode con t r ol swit ch in a n y
Wh en in vest iga t in g a n a ir con dit ion in g r ela t ed A/C m ode, a n d t h e blower m ot or swit ch in t h e lowest
n oise, you m u st fir st kn ow t h e con dit ion s u n der speed posit ion , st a r t t h e en gin e a n d r u n it a t n or m a l
wh ich t h e n oise occu r s. Th ese con dit ion s in clu de: idle.
wea t h er, veh icle speed, t r a n sm ission in gea r or n eu - (3) Th e com pr essor clu t ch coil volt a ge sh ou ld r ea d
t r a l, en gin e t em per a t u r e, a n d a n y ot h er specia l con - wit h in t wo volt s of t h e ba t t er y volt a ge. If t h er e is
dit ion s. volt a ge a t t h e clu t ch coil, bu t t h e r ea din g is n ot
Noises t h a t develop du r in g a ir con dit ion in g oper a - wit h in t wo volt s of t h e ba t t er y volt a ge, t est t h e
t ion ca n oft en be m islea din g. F or exa m ple: Wh a t clu t ch coil feed cir cu it for excessive volt a ge dr op a n d
sou n ds like a fa iled fr on t bea r in g or con n ect in g r od, r epa ir a s r equ ir ed. If t h er e is n o volt a ge r ea din g a t
m a y be ca u sed by loose bolt s, n u t s, m ou n t in g br a ck- t h e clu t ch coil, u se a DRB sca n t ool a n d t h e pr oper
et s, or a loose clu t ch a ssem bly. Ver ify ser pen t in e Dia gn ost ic P r ocedu r es m a n u a l for t est in g of t h e com -
dr ive belt t en sion . Im pr oper belt t en sion ca n ca u se a pr essor clu t ch cir cu it . Th e followin g com pon en t s
m islea din g n oise wh en t h e com pr essor is en ga ged. m u st be ch ecked a n d r epa ir ed a s r equ ir ed befor e you
Th e n oise m a y n ot occu r wh en t h e com pr essor is dis- ca n com plet e t est in g of t h e clu t ch coil:
en ga ged. • F u ses in t h e ju n ct ion block a n d t h e P ower Dis-
Dr ive belt s a r e speed sen sit ive. At differ en t en gin e t r ibu t ion Cen t er (P DC)
speeds a n d depen din g u pon belt t en sion , belt s ca n • H ea t er-A/C m ode con t r ol swit ch
develop n oises t h a t a r e m ist a ken for a com pr essor • Com pr essor clu t ch r ela y
n oise. • H igh pr essu r e cu t -off swit ch
(1) Select a qu iet a r ea for t est in g. Du plica t e t h e • Low pr essu r e cyclin g clu t ch swit ch
com pla in t con dit ion s a s m u ch a s possible. Swit ch t h e • P ower t r a in Con t r ol Modu le (P CM).
com pr essor on a n d off sever a l t im es t o clea r ly iden - (4) Th e com pr essor clu t ch coil is a ccept a ble if t h e
t ify t h e com pr essor n oise. List en t o t h e com pr essor cu r r en t dr a w m ea su r ed a t t h e clu t ch coil is 2.0 t o 3.9
clu t ch wh ile en ga ged a n d disen ga ged. a m per es wit h elect r ica l syst em volt a ge a t 11.5 t o 12.5
(2) To du plica t e a h igh -a m bien t t em per a t u r e con di- volt s. Th is sh ou ld on ly be ch ecked wit h t h e wor k
t ion (h igh h ea d pr essu r e), r est r ict t h e a ir flow a r ea t em per a t u r e a t 21° C (70° F ). If syst em volt a ge
t h r ou gh t h e con den ser. In st a ll a m a n ifold ga u ge set is m or e t h a n 12.5 volt s, a dd elect r ica l loa ds by t u r n -
t o m a ke su r e t h a t t h e disch a r ge pr essu r e does n ot in g on elect r ica l a ccessor ies u n t il t h e syst em volt a ge
exceed 2070 kP a (300 psi). dr ops below 12.5 volt s.
(3) Tigh t en a ll com pr essor m ou n t in g bolt s, t h e (a ) If t h e clu t ch coil cu r r en t r ea din g is 4
clu t ch m ou n t in g n u t , t h e clu t ch coil m ou n t in g scr ew a m per es or m or e, t h e coil is sh or t ed a n d sh ou ld be
or n u t , a n d t h e ser pen t in e dr ive belt t o t h e cor r ect r epla ced.
specifica t ion s. (b) If t h e clu t ch coil cu r r en t r ea din g is zer o, t h e
(4) Ch eck t h e r efr iger a n t syst em plu m bin g for r u b- coil is open a n d sh ou ld be r epla ced.
bin g or in t er fer en ce, wh ich ca n ca u se u n u su a l n oises.
(5) Ch eck t h e r efr iger a n t syst em ch a r ge. See t h e COMPRESSOR CLUTCH RELAY
Ch a r gin g Refr iger a n t Syst em pr ocedu r e in t h is
gr ou p. RELAY T EST
(6) Ch eck t h e com pr essor n oise a s in St ep 1. F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
(7) If t h e n oise st ill exist s, loosen t h e com pr essor 8W-42 - Air Con dit ion in g/H ea t er in Gr ou p 8W - Wir-
m ou n t in g bolt s a n d t igh t en a ga in . Repea t St ep 1. in g Dia gr a m s.
(8) If t h e n oise con t in u es, r epla ce t h e com pr essor Th e com pr essor clu t ch r ela y is loca t ed in t h e P ower
a n d r epea t St ep 1. Dist r ibu t ion Cen t er (P DC). Refer t o t h e P DC la bel for
r ela y iden t ifica t ion a n d loca t ion . Rem ove t h e r ela y
COMPRESSOR CLUTCH COIL fr om t h e P DC t o per for m t h e followin g t est s:
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o (1) A r ela y in t h e de-en er gized posit ion sh ou ld
8W-42 - Air Con dit ion in g/H ea t er in Gr ou p 8W - Wir- 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
in g Dia gr a m s. Th e ba t t er y m u st be fu lly-ch a r ged n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go
befor e per for m in g t h e followin g t est s. Refer t o Gr ou p t o St ep 2. If n ot OK, r epla ce t h e fa u lt y r ela y.
8A - Ba t t er y for m or e in for m a t ion . (2) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec-
(1) Con n ect a n a m m et er (0 t o 10 a m per e sca le) in t r om a gn et ) sh ou ld be 75 6 5 oh m s. If OK, go t o St ep
ser ies wit h t h e clu t ch coil t er m in a l. Use a volt m et er 3. If n ot OK, r epla ce t h e fa u lt y r ela y.
(0 t o 20 volt sca le) wit h clip-t ype lea ds for m ea su r in g (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 volt a ge a cr oss t h e ba t t er y a n d t h e com pr essor Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls
clu t ch coil. 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
24 - 20 HEATING AND AIR CONDITIONING XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
a n d 30. If OK, see t h e Rela y Cir cu it Test pr ocedu r e (1) Ver ify t h a t t h e r efr iger a n t syst em is pr oper ly
in t h is gr ou p. If n ot OK, r epla ce t h e fa u lt y r ela y. ch a r ged.
(2) Un plu g t h e h igh pr essu r e swit ch wir e h a r n ess
con n ect or a n d t est for con t in u it y bet ween t h e swit ch
t er m in a ls. Th er e sh ou ld be con t in u it y. If OK, r efer t o
t h e wir in g dia gr a m s a n d r epa ir t h e A/C r equ est sig-
n a l cir cu it a s r equ ir ed. If n ot OK, r epla ce t h e fa u lt y
swit ch .

LOW PRESSURE CYCLING CLUTCH SWITCH


87A 87 85
TERMINAL LEGEND Befor e per for m in g dia gn osis of t h e low pr essu r e
NUMBER IDENTIFICATION cyclin g clu t ch swit ch , be cer t a in t h a t t h e swit ch is
tJ~ 30 COMMON FEED pr oper ly in st a lled on t h e a ccu m u la t or fit t in g. Th e low
l""~ 85
86
COIL GROUND
COIL BATTERY
pr essu r e cyclin g clu t ch swit ch sh ou ld be h a n d-t igh t -
en ed on t o t h e fit t in g. If t h e swit ch is t oo loose it m a y
30 86 87 NORMALLY OPEN
87A NORMALLY CLOSED n ot open t h e Sch r a der-t ype va lve in t h e a ccu m u la t or
fit t in g, wh ich will pr even t t h e swit ch fr om cor r ect ly
9514-16
Compressor Clutch Relay m on it or in g t h e r efr iger a n t syst em pr essu r e.
Also ver ify t h a t t h e r efr iger a n t syst em h a s t h e cor-
RELAY CI RCU I T T EST r ect r efr iger a n t ch a r ge. See Refr iger a n t Syst em
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o Ch a r ge in t h is gr ou p for m or e in for m a t ion .
8W-42 - Air Con dit ion in g/H ea t er in Gr ou p 8W - Wir- F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
in g Dia gr a m s. 8W-42 - Air Con dit ion in g/H ea t er in Gr ou p 8W - Wir-
(1) Th e r ela y com m on feed t er m in a l ca vit y (30) is in g Dia gr a m s.
con n ect ed t o fu sed ba t t er y feed. Th er e sh ou ld be ba t - (1) Un plu g t h e low pr essu r e cyclin g clu t ch swit ch
t er y volt a ge a t t h e ca vit y for r ela y t er m in a l 30 a t a ll wir e h a r n ess con n ect or fr om t h e swit ch on t h e a ccu -
t im es. If OK, go t o St ep 2. If n ot OK, r epa ir t h e open m u la t or, a n d in st a ll a ju m per wir e bet ween t h e t wo
cir cu it t o t h e fu se in t h e P DC a s r equ ir ed. con n ect or ca vit ies.
(2) Th e r ela y n or m a lly closed t er m in a l (87A) is n ot (2) Con n ect a m a n ifold ga u ge set t o t h e r efr iger a n t
u sed in t h is a pplica t ion . Go t o St ep 3. syst em ser vice por t s.
(3) Th e r ela y n or m a lly open t er m in a l ca vit y (87) is (3) P la ce t h e h ea t er-A/C m ode con t r ol swit ch kn ob
con n ect ed t o t h e com pr essor clu t ch coil. Th er e sh ou ld in a n y A/C posit ion a n d st a r t t h e en gin e.
be con t in u it y bet ween t h is ca vit y a n d t h e A/C com - (4) Ch eck t h e con t in u it y bet ween t h e t wo t er m i-
pr essor clu t ch r ela y ou t pu t cir cu it ca vit y of t h e com - n a ls of t h e low pr essu r e swit ch . Th er e sh ou ld be con -
pr essor clu t ch coil wir e h a r n ess con n ect or. If OK, go t in u it y wit h a su ct ion pr essu r e r ea din g of 296 kP a
t o St ep 4. If n ot OK, r epa ir t h e open cir cu it a s (43 psi) or a bove, a n d n o con t in u it y wit h a su ct ion
r equ ir ed. pr essu r e r ea din g of 172 kP a (25 psi) or below. If OK,
(4) Th e r ela y coil ba t t er y t er m in a l (86) is con - t est a n d r epa ir t h e A/C r equ est sign a l cir cu it a s
n ect ed t o t h e fu sed ign it ion swit ch ou t pu t (r u n /st a r t ) r equ ir ed. If n ot OK, r epla ce t h e fa u lt y swit ch .
cir cu it . Th er e sh ou ld be ba t t er y volt a ge a t t h e ca vit y
for r ela y t er m in a l 86 wit h t h e ign it ion swit ch in t h e REFRIGERANT SYSTEM LEAKS
On posit ion . If OK, go t o St ep 5. If n ot OK, r epa ir t h e
open cir cu it t o t h e fu se in t h e ju n ct ion block a s WARNING: REVIEW THE WARNINGS AND CAU-
r equ ir ed. TIONS IN THE FRONT OF THIS GROUP BEFORE
(5) Th e coil gr ou n d t er m in a l ca vit y (85) is swit ch ed LEAK TESTING THE SYSTEM.
t o gr ou n d t h r ou gh t h e P ower t r a in Con t r ol Modu le
(P CM). Th er e sh ou ld be con t in u it y bet ween t h is ca v- If t h e a ir con dit ion in g syst em is n ot coolin g pr op-
it y a n d t h e A/C com pr essor clu t ch r ela y con t r ol cir- er ly, det er m in e if t h e r efr iger a n t syst em is fu lly-
cu it ca vit y of t h e P CM wir e h a r n ess con n ect or C ch a r ged. See A/C P er for m a n ce in t h is gr ou p. If t h e
(gr a y) a t a ll t im es. If n ot OK, r epa ir t h e open cir cu it r efr iger a n t syst em is low or em pt y, a lea k a t a lin e,
a s r equ ir ed. fit t in g, or com pon en t sea l is likely. F it t in gs, lin es, or
com pon en t s t h a t a ppea r t o be oily in dica t e a possible
HIGH PRESSURE CUT-OFF SWITCH r efr iger a n t lea k. To det ect a lea k in t h e r efr iger a n t
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o syst em , per for m on e of t h e followin g pr ocedu r es:
8W-42 - Air Con dit ion in g/H ea t er in Gr ou p 8W - Wir-
in g Dia gr a m s.
XJ HEATING AND AIR CONDITIONING 24 - 21
DI AGN OSI S AN D T EST I N G (Cont inue d)
SY ST EM EM PT Y REFRIGERANT SYSTEM EVACUATE
(1) E va cu a t e t h e r efr iger a n t syst em . See Refr iger-
a n t Syst em E va cu a t e in t h is gr ou p. WARNING: REVIEW THE WARNINGS AND CAU-
(2) Con n ect a n d dispen se 0.283 kP a (0.6 lbs. or 10 TIONS IN THE FRONT OF THIS GROUP BEFORE
oz.) of R-134a r efr iger a n t in t o t h e eva cu a t ed r efr iger- EVACUATING THE SYSTEM.
a n t syst em . See Refr iger a n t Syst em Ch a r ge in t h is
gr ou p. If t h e r efr iger a n t syst em h a s been open t o t h e
(3) P osit ion t h e veh icle in a win d-fr ee wor k a r ea . a t m osph er e, it m u st be eva cu a t ed befor e t h e syst em
Th is will a id in det ect in g sm a ll lea ks. ca n be ch a r ged. Moist u r e a n d a ir m ixed wit h t h e
(4) Wit h t h e en gin e n ot r u n n in g, u se a elect r on ic r efr iger a n t will r a ise t h e com pr essor h ea d pr essu r e
R-134a lea k det ect or a n d sea r ch for lea ks. Move t h e a bove a ccept a ble oper a t in g levels. Th is will r edu ce
lea k det ect or pr obe slowly a lon g t h e bot t om side of t h e per for m a n ce of t h e a ir con dit ion er a n d da m a ge
a ll lin es a n d fit t in gs, beca u se R-134a is h ea vier t h a n t h e com pr essor. E va cu a t in g will boil t h e m oist u r e ou t
a ir. of t h e r efr iger a n t syst em a t n ea r r oom t em per a t u r e.
(5) To in spect t h e eva por a t or coil for lea ks, in ser t To eva cu a t e t h e r efr iger a n t syst em , u se t h e followin g
t h e lea k det ect or pr obe in t o t h e cen t er pa n el ou t let . pr ocedu r e:
Set t h e blower m ot or swit ch t o t h e lowest speed posi- (1) Con n ect a su it a ble ch a r gin g st a t ion a n d m a n i-
t ion , a n d t h e m ode con t r ol swit ch in t h e Recir cu la - fold ga u ge set t o t h e veh icle.
t ion Mode. (2) Open t h e low a n d h igh side va lves a n d st a r t
t h e va cu u m pu m p. Wh en t h e su ct ion ga u ge r ea ds 88
SY ST EM LOW kP a (26 in . H g.) va cu u m or gr ea t er, close a ll of t h e
(1) P osit ion t h e veh icle in a win d-fr ee wor k a r ea . va lves a n d t u r n off t h e va cu u m pu m p. If t h e syst em
Th is will a id in det ect in g sm a ll lea ks. fa ils t o r ea ch t h e specified va cu u m , t h e syst em h a s a
(2) Br in g t h e r efr iger a n t syst em u p t o oper a t in g lea k t h a t m u st be cor r ect ed. If t h e syst em m a in t a in s
t em per a t u r e a n d pr essu r e. Th is is don e by a llowin g t h e specified va cu u m for five m in u t es, r est a r t t h e
t h e en gin e t o r u n wit h t h e a ir con dit ion in g syst em on va cu u m pu m p. Th en open t h e su ct ion a n d disch a r ge
for five m in u t es. va lves a n d eva cu a t e a n a ddit ion a l t en m in u t es.
(3) Wit h t h e en gin e n ot r u n n in g, u se a elect r on ic (3) Close a ll of t h e va lves. Tu r n off a n d discon n ect
R-134a lea k det ect or a n d sea r ch for lea ks. Move t h e t h e va cu u m pu m p.
lea k det ect or pr obe slowly a lon g t h e bot t om side of (4) Th e r efr iger a n t syst em is n ow r ea dy t o be
a ll lin es a n d fit t in gs, beca u se R-134a is h ea vier t h a n ch a r ged wit h r efr iger a n t .
a ir.
(4) To in spect t h e eva por a t or coil for lea ks, in ser t REFRIGERANT SYSTEM CHARGE
t h e lea k det ect or pr obe in t o t h e cen t er pa n el ou t let .
Set t h e blower m ot or swit ch t o t h e lowest speed posi- WARNING: REVIEW THE WARNINGS AND CAU-
t ion , a n d t h e m ode con t r ol swit ch in t h e Recir cu la - TIONS IN THE FRONT OF THIS GROUP BEFORE
t ion Mode. CHARGING THE REFRIGERANT SYSTEM.

Aft er t h e syst em h a s been t est ed for lea ks a n d


SERV I CE PROCEDU RES eva cu a t ed, a r efr iger a n t ch a r ge ca n be in ject ed in t o
t h e syst em . See Refr iger a n t Ch a r ge Ca pa cit y for t h e
REFRIGERANT RECOVERY pr oper a m ou n t of t h e r efr iger a n t ch a r ge. Ch a r ge t h e
syst em u sin g a r ecover y/r ecyclin g/ch a r gin g st a t ion
WARNING: REVIEW THE WARNINGS AND CAU- a ppr oved for R-134a r efr iger a n t . Th is device m u st
TIONS IN THE FRONT OF THIS GROUP BEFORE m eet SAE St a n da r d J 2210. Refer t o t h e in st r u ct ion s
RECOVERING REFRIGERANT. pr ovided wit h t h e equ ipm en t for pr oper oper a t ion .
R-134a r efr iger a n t is a h ydr oflu or oca r bon (H F C) REFRI GERAN T CH ARGE CAPACI T Y
t h a t does n ot con t a in ch lor in e. A R-134a r efr iger a n t Th e R-134a syst em ch a r ge ca pa cit y is 0.567 kg
r ecover y/r ecyclin g st a t ion t h a t m eet s SAE St a n da r d (1.25 lbs.).
J 2210 m u st be u sed t o r ecover t h e r efr iger a n t . Refer
t o t h e oper a t in g in st r u ct ion s pr ovided wit h t h e equ ip- REFRIGERANT OIL LEVEL
m en t for pr oper oper a t ion . Wh en a n a ir con dit ion in g syst em is a ssem bled a t
t h e fa ct or y, a ll com pon en t s (except t h e com pr essor )
a r e r efr iger a n t oil fr ee. Aft er t h e syst em h a s been
ch a r ged a n d oper a t ed, t h e oil in t h e com pr essor is
disper sed t h r ou gh t h e r efr iger a n t syst em . Th e a ccu -
24 - 22 HEATING AND AIR CONDITIONING XJ
SERV I CE PROCEDU RES (Cont inue d)
m u la t or, eva por a t or, con den ser, a n d com pr essor will
r et a in a sign ifica n t a m ou n t of oil.
It is im por t a n t t o h a ve t h e cor r ect a m ou n t of oil in CD
t h e r efr iger a n t syst em . Th is will en su r e pr oper lu br i-
ca t ion of t h e com pr essor. Too lit t le oil will r esu lt in
da m a ge t o t h e com pr essor. Too m u ch oil will r edu ce
t h e coolin g ca pa cit y of t h e syst em .
It will n ot be n ecessa r y t o ch eck t h e oil level in t h e
com pr essor or t o a dd oil, u n less t h er e h a s been a n oil
loss. Th is m a y be du e t o a r u pt u r e or lea k fr om a
r efr iger a n t lin e, a com pr essor sh a ft sea l, a n eva por a -
t or, or a con den ser. If a r u pt u r e occu r s, a dd 30 m illi-
lit er s (1 flu id ou n ce) of oil t o t h e syst em a ft er t h e
r epa ir h a s been m a de. Oil loss a t a lea k poin t will be
eviden t by t h e pr esen ce of a wet , sh in y su r fa ce
a r ou n d t h e lea k.
Refr iger a n t oil m u st be a dded wh en a a ccu m u la t or,
eva por a t or, or con den ser a r e r epla ced. Refer t o t h e
Refr iger a n t Oil Ca pa cit ies ch a r t . Wh en a com pr essor
is r epla ced, t h e oil m u st be dr a in ed fr om t h e old com -
pr essor a n d m ea su r ed. Dr a in a ll t h e oil fr om t h e n ew
com pr essor, t h en fill t h e n ew com pr essor wit h t h e
sa m e a m ou n t of oil t h a t wa s dr a in ed ou t of t h e old Fig. 12 Spring Lock Coupler Disconnect
com pr essor . (4) Aft er t h e ga r t er spr in g is expa n ded, pu ll t h e
fit t in gs a pa r t wit h in t h e t ool.
I Refrigerant Oil Capacities 7 (5) Rem ove t h e t ool fr om t h e discon n ect ed cou pler.
L__

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

XJ HEATING AND AIR CONDITIONING 24 - 23


REM OVAL AN D I N STALLAT I ON (Cont inue d)
HIGH PRESSURE CUT-OFF SWITCH exh a u st m a n ifold. It is a good pr a ct ice t o in spect a ll
flexible r efr iger a n t syst em h ose lin es a t lea st on ce a
REM OVAL yea r t o m a ke su r e t h ey a r e in good con dit ion a n d
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive pr oper ly r ou t ed.
ca ble.
(2) Un plu g t h e wir e h a r n ess con n ect or fr om t h e WARNING: REVIEW THE WARNINGS AND CAU-
h igh pr essu r e cu t -off swit ch , wh ich is loca t ed in a fit - TIONS IN THE FRONT OF THIS GROUP BEFORE
t in g on t h e disch a r ge lin e bet ween t h e com pr essor PERFORMING THE FOLLOWING OPERATION.
a n d t h e con den ser in let (F ig. 13).
2 .5 L EN GI N E

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

Fig. 13 High Pressure Cut-Off Switch - Typical


(3) Un scr ew t h e h igh pr essu r e cu t -off swit ch fr om
t h e disch a r ge lin e fit t in g.
(4) Rem ove t h e h igh pr essu r e cu t -off swit ch fr om
t h e veh icle.

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.

SUCTION AND DISCHARGE LINE


Kin ks or sh a r p ben ds in t h e r efr iger a n t plu m bin g
will r edu ce t h e ca pa cit y of t h e en t ir e syst em . H igh
s,
CONDENSER
pr essu r es a r e pr odu ced in t h e syst em wh en it is oper-
// 80abfecf
a t in g. E xt r em e ca r e m u st be exer cised t o m a ke su r e
t h a t a ll r efr iger a n t syst em con n ect ion s a r e pr essu r e Fig. 14 Suction and Discharge Line Remove/Install -
t igh t . Left-Hand Drive 2.5L Engine
A good r u le for t h e flexible h ose r efr iger a n t lin es is
t o keep t h e r a diu s of a ll ben ds a t lea st t en t im es t h e (6) Rem ove t h e n u t t h a t secu r es t h e su ct ion lin e
dia m et er of t h e h ose. Sh a r p ben ds will r edu ce t h e block fit t in g t o t h e a ccu m u la t or ou t let . In st a ll plu gs
flow of r efr iger a n t . Th e flexible h ose lin es sh ou ld be in , or t a pe over a ll of t h e open r efr iger a n t fit t in gs.
r ou t ed so t h ey a r e a t lea st 80 m m (3 in ch es) fr om t h e
SCREW
CONDENSER SUCTION
FWD HEX
AND
COMPRESSOR
NUT
DISCHARGE
LINE
ACCUMULATOR HEX
ACCUMULATOR
NUT CLIP INLET
SCREW
SUCTION AND COMPRESSOR
DISCHARGE
CONDENSER
FWD
LINE

24 - 24 HEATING AND AIR CONDITIONING XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Recover t h e r efr iger a n t fr om t h e r efr iger a n t
SCREW--..,..Q SUCTION AND syst em a s descr ibed in t h is gr ou p.
DISCHARGE LINE (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) Discon n ect t h e disch a r ge lin e r efr iger a n t lin e
cou pler a t t h e con den ser in let (F ig. 16). 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.
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 SUCTION
HEX NUT AND DISCHARGE
ACCUMULATOR ---- LINE

CONDENSER
80abfedb

Fig. 15 Suction and Discharge Line Remove/Install -


Right-Hand Drive 2.5L Engine
(7) Rem ove t h e scr ew t h a t secu r es t h e su ct ion a n d HEX NUT
disch a r ge lin e m a n ifold t o t h e com pr essor. 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 - CLIP~--
t in gs.
(8) Rem ove t h e su ct ion a n d disch a r ge lin e u n it
fr om t h e veh icle.
INLET
INSTALLATION
(1) Rem ove t h e t a pe or plu gs fr om t h e su ct ion a n d
disch a r ge lin e m a n ifold a n d t h e com pr essor. In st a ll
t h e su ct ion a n d disch a r ge lin e m a n ifold t o t h e com -
pr essor. Tigh t en t h e m ou n t in g scr ew t o 28 N·m (250 80abfeda
in . lbs.).
(2) Rem ove t h e t a pe or plu gs fr om t h e su ct ion lin e Fig. 16 Suction and Discharge Line Remove/Install -
a n d t h e a ccu m u la t or ou t let block fit t in gs. In st a ll t h e Left-Hand Drive 4.0L Engine
su ct ion lin e t o t h e a ccu m u la t or ou t let a n d t igh t en t h e
(5) Rem ove t h e n u t t h a t secu r es t h e su ct ion lin e
m ou n t in g n u t t o 9 N·m (80 in . lbs.).
block fit t in g t o t h e a ccu m u la t or ou t let . In st a ll plu gs
(3) Rem ove t h e t a pe or plu gs fr om t h e disch a r ge
in , or t a pe over a ll of t h e open r efr iger a n t fit t in gs.
lin e a n d t h e con den ser in let block fit t in gs. In st a ll t h e
(6) Rem ove t h e scr ew t h a t secu r es t h e su ct ion a n d
disch a r ge lin e t o t h e con den ser in let a n d t igh t en t h e
disch a r ge lin e m a n ifold t o t h e com pr essor. In st a ll
m ou n t in g scr ew t o 12 N·m (105 in . lbs.).
plu gs in , or t a pe over a ll of t h e open r efr iger a n t fit -
(4) In st a ll t h e r a dia t or gr ille pa n el. Refer t o Gr ou p
t in gs.
23 - Body for t h e pr ocedu r es.
(7) Rem ove t h e su ct ion a n d disch a r ge lin e u n it
(5) P lu g in t h e wir e h a r n ess con n ect or t o t h e h igh
fr om t h e veh icle.
pr essu r e cu t -off swit ch .
(6) Con n ect t h e ba t t er y n ega t ive ca ble. INSTALLATION
(7) 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 (1) Rem ove t h e t a pe or plu gs fr om t h e su ct ion a n d
descr ibed in t h is gr ou p. disch a r ge lin e m a n ifold a n d t h e com pr essor. In st a ll
t h e su ct ion a n d disch a r ge lin e m a n ifold t o t h e com -
LEFT-H AN D DRI V E 4 .0 L EN GI N E
pr essor. Tigh t en t h e m ou n t in g scr ew t o 28 N·m (250
REMOVAL in . lbs.).
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (2) Rem ove t h e t a pe or plu gs fr om t h e su ct ion lin e
ca ble. a n d t h e a ccu m u la t or ou t let block fit t in gs. In st a ll t h e
su ct ion lin e t o t h e a ccu m u la t or ou t let a n d t igh t en t h e
m ou n t in g n u t t o 9 N·m (80 in . lbs.).
CONDENSER DISCHARGE LINE JUMPER
CLIP COMPRESSORFWD DISCHARGE
CLIPMANIFOLD
SUCTION
LINE BLOCK
LINE NUT SCREW ACCUMULATOR
NUT

XJ HEATING AND AIR CONDITIONING 24 - 25


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rem ove t h e t a pe or plu gs fr om t h e r efr iger a n t E n gin e a pplica t ion . Tigh t en t h e a ddit ion a l m ou n t in g
lin e cou pler s on t h e disch a r ge lin e a n d t h e con den ser h a r dwa r e a s follows:
in let . In st a ll t h e disch a r ge lin e t o t h e con den ser • Su ct ion lin e t o m a n ifold block n u t - 9 N·m (80
in let . See Refr iger a n t Lin e Cou pler in t h is gr ou p for in . lbs.)
t h e pr ocedu r es. • Disch a r ge lin e t o m a n ifold block n u t - 9 N·m (80
(4) P lu g in t h e wir e h a r n ess con n ect or t o t h e h igh in . lbs.)
pr essu r e cu t -off swit ch . • Ma n ifold block t o com pr essor scr ew - 28 N·m
(5) Con n ect t h e ba t t er y n ega t ive ca ble. (250 in . lbs.).
(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. COMPRESSOR
Th e com pr essor m a y be r em oved a n d r eposit ion ed
RI GH T-H AN D DRI V E 4 .0 L EN GI N E wit h ou t discon n ect in g t h e r efr iger a n t lin es or dis-
Th e su ct ion a n d disch a r ge lin es for t h is m odel a r e ch a r gin g t h e r efr iger a n t syst em . Disch a r gin g is n ot
in dividu a l com pon en t s a n d a r e secu r ed t o a m a n ifold n ecessa r y if ser vicin g t h e com pr essor clu t ch or clu t ch
block on t h e com pr essor wit h block fit t in gs (F ig. 17). coil, t h e en gin e, t h e cylin der h ea d, or t h e gen er a t or.
Th er e is a lso a ju m per lin e in st a lled bet ween t h e dis-
ch a r ge lin e a n d t h e con den ser in let t h a t is secu r ed WARNING: REVIEW THE WARNINGS AND CAU-
wit h r efr iger a n t lin e cou pler s a t ea ch en d. E a ch of TIONS IN THE FRONT OF THIS GROUP BEFORE
t h ese com pon en t s is a va ila ble a s a sepa r a t e ser vice PERFORMING THE FOLLOWING OPERATION.
pa r t .
Th e su ct ion a n d disch a r ge lin e com pon en t s ca n be
r em oved fr om or in st a lled on t h e veh icle in dividu a lly, REM OVAL
or a s a u n it . Ot h er wise, t h e ser vice pr ocedu r es a r e (1) Recover t h e r efr iger a n t fr om t h e r efr iger a n t
t h e sa m e a s t h ose for t h e Left -H a n d Dr ive 4.0L syst em a s descr ibed in t h is gr ou p.

~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

Fig. 19 Compressor Remove/Install - RHD 4.0L


Engines
ch a r ge lin es t o t h e com pr essor a s descr ibed in t h is
gr ou p.
(3) In st a ll 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) P lu g in t h e com pr essor clu t ch coil wir e h a r n ess
con n ect or.
(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.

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.

ENGINE 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.
80abd2a8
(2) Rem ove t h e ser pen t in e dr ive belt . Refer t o
Fig. 18 Compressor Remove/Install - All 2.5L Gr ou p 7 - Coolin g Syst em for t h e pr ocedu r es.
Engines and LHD 4.0L Engines (3) Rem ove t h e com pr essor m ou n t in g bolt s a n d lift
t h e com pr essor fr om t h e m ou n t in g br a cket . Su ppor t
(8) Rem ove t h e com pr essor fr om t h e m ou n t in g
t h e com pr essor t o wor k on t h e clu t ch .
br a cket .
(4) In ser t t h e t wo pin s of t h e spa n n er wr en ch
I N STALLAT I ON (Specia l Tool C-4489) in t o t h e h oles of t h e clu t ch
pla t e. H old t h e clu t ch pla t e st a t ion a r y a n d r em ove
NOTE: If a replacement compressor is being t h e h ex n u t (F ig. 20).
installed, be certain to check the oil level. See (5) Rem ove t h e clu t ch pla t e wit h a pu ller (Specia l
Refrigerant Oil Level in this group. Tool C-6461) (F ig. 21).
(6) Rem ove t h e com pr essor sh a ft key a n d t h e
(1) In st a ll t h e com pr essor t o t h e m ou n t in g br a cket . clu t ch sh im s.
Tigh t en t h e fou r m ou n t in g bolt s a s follows: (7) Rem ove t h e ext er n a l fr on t h ou sin g sn a p r in g
• All 2.5L en gin es a n d LH D 4.0L en gin es - 27 N·m wit h sn a p r in g plier s (F ig. 22).
(20 ft . lbs.) (8) In st a ll t h e lip of t h e r ot or pu ller (Specia l Tool
• RH D 4.0L en gin es - 57 N·m (42 ft . lbs.). C-6141-1) in t o t h e sn a p r in g gr oove exposed in t h e
(2) Rem ove t h e t a pe or plu gs fr om a ll of t h e open pr eviou s st ep, a n d in st a ll t h e sh a ft pr ot ect or (Specia l
r efr iger a n t fit t in gs, a n d in st a ll t h e su ct ion a n d dis- Tool C-6141-2) (F ig. 23).
CLUTCH
PULLEY
CLUTCHPULLER
PLATE SPANNER SNAP
CLUTCH
RING
PLATE
PLIERS PULLER JAW SHAFT PROTECTOR

XJ HEATING AND AIR CONDITIONING


PULLER JAW 24PULLER
- 27
REM OVAL AN D I N STALLAT I ON (Cont inue d)

J9524-25 J9524-28

Fig. 20 Clutch Nut Remove Fig. 23 Shaft Protector and Puller


pu ller cen t er bolt clockwise u n t il t h e r ot or pu lley is
fr ee.

J9524-26

Fig. 21 Clutch Plate Remove


J9524-29

Fig. 24 Install Puller Plate


(10) Rem ove t h e scr ew a n d r et a in er fr om t h e
clu t ch coil lea d wir e h a r n ess on t h e com pr essor fr on t
h ou sin g (F ig. 25).
(11) Rem ove t h e sn a p r in g fr om t h e com pr essor
h u b a n d r em ove t h e clu t ch field coil (F ig. 26). Slide
t h e clu t ch field coil off of t h e com pr essor h u b.

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

24 - 28 HEATING AND AIR CONDITIONING XJ


CLUTCH PLATE DRIVER

REM OVAL AN D I N STALLAT I ON (Cont inue d)

COIL SNAP RING PLIERS

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.

(6) In st a ll t h e com pr essor sh a ft key a n d t h e or igi-


n a l clu t ch sh im s on t h e com pr essor sh a ft .
(7) In st a ll t h e clu t ch pla t e wit h t h e dr iver (Specia l
Tool C-6463) (F ig. 28). In st a ll t h e sh a ft h ex n u t a n d
t igh t en t o 14.4 N·m (10.5 ft . lbs.).

Fig. 26 Clutch Field Coil Snap Ring Remove


Ch eck t h e clu t ch pu lley bea r in g for r ou gh n ess or
excessive lea ka ge of gr ea se. Repla ce t h e bea r in g, if
r equ ir ed.

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.

CAUTION: If the snap ring is not fully seated in the


groove it will vibrate out, resulting in a clutch fail-
FEELER GAUGE POWER
RIGHT
FENDER
DISTRIBUTION
CENTER BATTERY

XJ HEATING AND AIR CONDITIONING 24 - 29


REM OVAL AN D I N STALLAT I ON (Cont inue d)

J8924-28

Fig. 29 Check Clutch Air Gap


NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install- Fig. 30 Power Distribution Center
ing a new clutch onto a compressor that previously (8) Test t h e r ela y oper a t ion .
did not have a clutch, use 0.040, 0.020, and 0.005
shims from the clutch hardware package that is LIQUID LINE
provided with the new clutch. Kin ks or sh a r p ben ds in t h e r efr iger a n t plu m bin g
will r edu ce t h e ca pa cit y of t h e en t ir e syst em . H igh
(9) Rever se t h e r em a in in g r em ova l pr ocedu r es t o pr essu r es a r e pr odu ced in t h e syst em wh en it is oper-
com plet e t h e in st a lla t ion . a t in g. E xt r em e ca r e m u st be exer cised t o m a ke su r e
t h a t a ll r efr iger a n t syst em con n ect ion s a r e pr essu r e
CLU T CH BREAK -I N t igh t .
Aft er a n ew com pr essor clu t ch h a s been in st a lled, A good r u le for t h e flexible h ose r efr iger a n t lin es is
cycle t h e com pr essor clu t ch a ppr oxim a t ely t wen t y t o keep t h e r a diu s of a ll ben ds a t lea st t en t im es t h e
t im es (five secon ds on , t h en five secon ds off). Du r in g dia m et er of t h e h ose. Sh a r p ben ds will r edu ce t h e
t h is pr ocedu r e, set t h e h ea t er-A/C con t r ol t o t h e flow of r efr iger a n t . Th e flexible h ose lin es sh ou ld be
Recir cu la t ion Mode, t h e blower m ot or swit ch in t h e r ou t ed so t h ey a r e a t lea st 80 m m (3 in ch es) fr om t h e
h igh est speed posit ion , a n d t h e en gin e speed a t 1500 exh a u st m a n ifold. It is a good pr a ct ice t o in spect a ll
t o 2000 r pm . Th is pr ocedu r e (bu r n ish in g) will sea t flexible r efr iger a n t syst em h ose lin es a t lea st on ce a
t h e opposin g fr ict ion su r fa ces a n d pr ovide a h igh er yea r t o m a ke su r e t h ey a r e in good con dit ion a n d
com pr essor clu t ch t or qu e ca pa bilit y. pr oper ly r ou t ed.
COMPRESSOR CLUTCH RELAY WARNING: REVIEW THE WARNINGS AND CAU-
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive TIONS IN THE FRONT OF THIS GROUP BEFORE
ca ble. PERFORMING THE FOLLOWING OPERATION.
(2) Rem ove t h e cover fr om t h e P ower Dist r ibu t ion
Cen t er (P DC) (F ig. 30).
(3) Refer t o t h e la bel on t h e P DC for com pr essor 2 .5 L EN GI N E
clu t ch r ela y iden t ifica t ion a n d loca t ion .
(4) Un plu g t h e com pr essor clu t ch r ela y fr om t h e REMOVAL
P DC. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(5) In st a ll t h e com pr essor clu t ch r ela y by a lign in g ca ble.
t h e r ela y t er m in a ls wit h t h e ca vit ies in t h e P DC a n d (2) Recover t h e r efr iger a n t fr om t h e r efr iger a n t
pu sh in g t h e r ela y fir m ly in t o pla ce. syst em a s descr ibed in t h is gr ou p.
(6) In st a ll t h e P DC cover. (3) Discon n ect t h e liqu id lin e r efr iger a n t lin e cou -
(7) Con n ect t h e ba t t er y n ega t ive ca ble. pler s a t t h e eva por a t or in let a n d, on Righ t -H a n d
24 - 30 HEATING AND AIR CONDITIONING XJ
REM OVAL
SCREW
ANCLIPD
EVAPORATOR INLET
CLIP
STUD
I N STALLAT
CONDENSERLIQUID
EVAPORATOR
LIQUID
LINE
SCREW
LINE
I ONWITH
JUMPER
ORIFICE
INLET
CLIP
FWD TUBE
(Cont
LIQUID
inue
WITH ORIFICE
LINE
LIQUID
FWD
CONDENSER
JUMPER
CLIP
LINE
TUBE
d)
Dr ive m odels on ly, t h e liqu id lin e ju m per (F ig. 31) or (4) On Left -H a n d Dr ive m odels on ly, r em ove t h e
(F ig. 32). See Refr iger a n t Lin e Cou pler in t h is gr ou p 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
for t h e pr ocedu r es. In st a ll plu gs in , or t a pe over a ll of liqu id lin e ju m per. 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. t h e open r efr iger a n t fit t in gs.
(5) Rem ove t h e liqu id lin e fr om t h e veh icle.
(6) 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.
(7) 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 liqu id lin e ju m per block fit t in g
a t t h e con den ser ou t let . 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.
(8) Rem ove t h e liqu id lin e ju m per fr om t h e veh icle.

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

ti/ (Left -H a n d Dr ive) (F ig. 33), or a t t h e eva por a t or in let


a n d t h e liqu id lin e ju m per (Righ t -H a n d Dr ive) (F ig.
34). 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. 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.
(4) Rem ove t h e liqu id lin e fr om t h e veh icle.
(5) On Righ t -H a n d Dr ive m odels on ly, discon n ect
LIQUID LINE
t h e liqu id lin e ju m per r efr iger a n t lin e cou pler a t t h e
con den ser ou t let . In st a ll plu gs in , or t a pe over a ll of
SCREW JUMPER WITH 80abfedc
t h e open r efr iger a n t fit t in gs.
ORIFICE TUBE
(6) On Righ t -H a n d Dr ive m odels on ly, r em ove t h e
Fig. 32 Liquid Line Remove/Install - Right-Hand liqu id lin e ju m per fr om t h e veh icle.
Drive 2.5L Engine
EVAPORATOR
OUTLETINLET
TUBE CLIP
STUD
CLIP
CLIP CONDENSER
LIQUID
EVAPORATOR
LIQUID
CLIP
LINE
CLIP
CLIP
WITH
LINE
INLET
JUMPER
ORIFICE
TUBE
FWD OUTLET
TUBE
WITH
CONDENSER
LIQUID
FWDTUBE
LINE

XJ HEATING AND AIR CONDITIONING 24 - 31


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) 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 (Left -H a n d
Dr
LOW
ive);
WIRE
or, onSWITCH
PRESSURE
HARNESS
t h eTORliqu id lin e, t h e eva por aACCUMULATOR
CLUTCHCYCLING
FWD
CONNEC-
t or in let ,
a n d 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 t o t h e eva por a t or in let a n d t h e
con den ser ou t let or t h e liqu id lin e ju m per. See
INLf _,~ ~ Refr iger a n t Lin e Cou pler in t h is gr ou p for t h e pr oce-
du r es.
(3) Con n ect t h e ba t t er y n ega t ive ca ble.
(4) 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.
CLIP ' LIQUID LINE
WITH ORIFICE TUBE
FIXED ORIFICE TUBE
Th e fixed or ifice t u be is loca t ed in t h e liqu id lin e
(Left -H a n d Dr ive 4.0L en gin e) or t h e liqu id lin e
ju m per (a ll except Left -H a n d Dr ive 4.0L en gin e) n ea r
t h e con den ser. Th e or ifice h a s filt er scr een s on t h e
in let a n d ou t let en ds of t h e t u be body. If t h e fixed or i-
fice t u be is fa u lt y or plu gged, t h e liqu id lin e u n it
m u st be r epla ced. See t h e ser vice pr ocedu r es for t h e
liqu id lin e in t h is gr ou p.
OUTLET LOW PRESSURE CYCLING CLUTCH SWITCH
TUBE
80abfee0 (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. 33 Liquid Line Remove/Install - Left-Hand Drive (2) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
4.0L Engine low pr essu r e cyclin g clu t ch swit ch on t h e t op of t h e
a ccu m u la t or (F ig. 35).

CLIP

/
LOW
PRESSURE
CYCLING
CLUTCH
SWITCH
~ LIQUID LINE
JUMPER WITH
ORIFICE TUBE
80abfede

Fig. 34 Liquid Line Remove/Install - Right-Hand


Drive 4.0L Engine
INSTALLATION 80abd2a4

(1) On Righ t -H a n d Dr ive m odels on ly, r em ove t h e


Fig. 35 Low Pressure Cycling Clutch Switch
t a pe or plu gs fr om t h e r efr iger a n t lin e cou pler s on
Remove/Install
t h e liqu id lin e ju m per a n d t h e con den ser ou t let .
In st a ll t h e liqu id lin e ju m per t o t h e con den ser ou t let . (3) Un scr ew t h e low pr essu r e cyclin g clu t ch swit ch
See Refr iger a n t Lin e Cou pler in t h is gr ou p for t h e fr om t h e fit t in g on t h e t op of t h e a ccu m u la t or.
pr ocedu r es.
SCREW
LOW
BAND
FWDEVAPORATOR
PRESSURE
CYCLING CLUTCH
SWITCH
CLIP NUT ACCUMULATOR
BRACKET
STUDS

24 - 32 HEATING AND AIR CONDITIONING XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Th e LOW PRESSURE CLUTCH
swit ch sh ou ld be h a n d-t igh t en ed on t o t h e a ccu m u la - CYCLING SWITCH
t or fit t in g.

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

LOW PRESSURE CYCLING CLUTCH SWITCH


Fig. 37 Accumulator Remove/Install - Right-Hand
Drive
I N STALLAT I ON
(1) In st a ll t h e a ccu m u la t or in t o t h e r et a in in g
ba n d.
(2) Rem ove t h e t a pe or plu gs fr om a ccu m u la t or
in let a n d eva por a t or ou t let t u be fit t in gs, a n d in st a ll
t h e a ccu m u la t or r efr iger a n t lin e cou pler t o t h e eva p-
or a t or ou t let t u be. 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.
(3) In st a ll t h e su ct ion lin e t o t h e a ccu m u la t or a s
descr ibed in t h is gr ou p.
(4) Tigh t en t h e a ccu m u la t or r et a in in g ba n d scr ew
t o 5 N·m (45 in . lbs.).
(5) P lu g t h e wir e h a r n ess con n ect or in t o t h e low
pr essu r e cyclin g clu t ch swit ch .
(6) Con n ect t h e ba t t er y n ega t ive ca ble.
(7) 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
NUTS BRACKET descr ibed in t h is gr ou p.
80abd2a5

NOTE: If the accumulator is replaced, add 120 ml (4


Fig. 36 Accumulator Remove/Install - Left-Hand oz.) of refrigerant oil to the refrigerant system.
Drive
(5) Discon n ect t h e su ct ion lin e fr om t h e a ccu m u la -
t or a s descr ibed in t h is gr ou p. CONDENSER
(6) Discon n ect t h e a ccu m u la t or in let t u be r efr iger-
a n t lin e cou pler fr om t h e eva por a t or ou t let t u be. See 2 .5 L EN GI N E
Refr iger a n t Lin e Cou pler in t h is gr ou p for t h e pr oce-
REMOVAL
du r es. 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.
WARNING: REVIEW THE WARNINGS AND CAU-
(7) Slide t h e a ccu m u la t or ou t of t h e r et a in in g ba n d
TIONS IN THE FRONT OF THIS GROUP BEFORE
a n d r em ove t h e a ccu m u la t or fr om t h e veh icle.
PERFORMING THE FOLLOWING OPERATION.
XJ HEATING AND AIR CONDITIONING 24 - 33
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CAUTION: Before removing the condenser, note the (2) 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-
location of each of the radiator and condenser air cle a s a u n it . Refer t o Gr ou p 7 - Coolin g Syst em for
seals. These seals are used to direct air through the t h e pr ocedu r es.
condenser and radiator. The air seals must be rein- (3) Rem ove t h e t a pe or plu gs fr om t h e liqu id lin e
stalled in their proper locations in order for the air ju m per a n d con den ser ou t let block fit t in gs. In st a ll
conditioning and engine cooling systems to per- t h e liqu id lin e ju m per t o t h e con den ser ou t let .
form as designed.
SCREW
CONDENSER RADIATOR Tigh t en t h e m ou n t in g scr ew t o 12 N·m (105 in . lbs.).
(4) Rem ove t h e t a pe or plu gs fr om t h e disch a r ge
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive lin e a n d con den ser in let block fit t in gs. In st a ll t h e dis-
ca ble. ch a r ge lin e t o t h e con den ser in let . Tigh t en t h e
(2) Recover t h e r efr iger a n t fr om t h e r efr iger a n t m ou n t in g scr ew t o 12 N·m (105 in . lbs.).
syst em a s descr ibed in t h is gr ou p. (5) In st a ll t h e r a dia t or gr ille pa n el. Refer t o Gr ou p
(3) Rem ove t h e r a dia t or gr ille pa n el. Refer t o 23 - Body for t h e pr ocedu r es.
Gr ou p 23 - Body for t h e pr ocedu r es. (6) Con n ect t h e ba t t er y n ega t ive ca ble.
(4) Rea ch t h r ou gh t h e gr ille open in g t o r em ove t h e (7) 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
scr ew fr om t h e disch a r ge lin e block fit t in g a t t h e con - descr ibed in t h is gr ou p.
den ser in let a n d r em ove t h e disch a r ge lin e fr om t h e
con den ser. In st a ll plu gs in , or t a pe over, a ll of t h e NOTE: If the condenser is replaced, add 30 ml (1
open r efr iger a n t fit t in gs. oz.) of refrigerant oil to the refrigerant system.
(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 fr om t h e liqu id lin e ju m per block fit t in g a t t h e
con den ser ou t let a n d r em ove t h e liqu id lin e ju m per 4 .0 L EN GI N E
fr om t h e con den ser. In st a ll plu gs in , or t a pe over, a ll
REMOVAL
of t h e open r efr iger a n t fit t in gs.
(6) Rem ove t h e r a dia t or a n d t h e con den ser fr om
WARNING: REVIEW THE WARNINGS AND CAU-
t h e veh icle a s a u n it . Refer t o Gr ou p 7 - Coolin g Sys-
TIONS IN THE FRONT OF THIS GROUP BEFORE
t em for t h e pr ocedu r es.
PERFORMING THE FOLLOWING OPERATION.
(7) Rem ove t h e fou r scr ews t h a t secu r e t h e con -
den ser t o t h e r a dia t or (F ig. 38).
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
CONDENSER condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.

(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) Discon n ect t h e disch a r ge lin e (Left -H a n d
Dr ive) or disch a r ge lin e ju m per (Righ t -H a n d Dr ive)
r efr iger a n t lin e cou pler a t t h e con den ser in let . See
Refr iger a n t Lin e Cou pler in t h is gr ou p for t h e pr oce-
du r es. 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.
80abfee1
(4) Discon n ect t h e liqu id lin e (Left -H a n d Dr ive) or
liqu id lin e ju m per (Righ t -H a n d Dr ive) r efr iger a n t
Fig. 38 Condenser Remove/Install - 2.5L Engine
lin e cou pler a t t h e con den ser ou t let . See Refr iger a n t
(8) Rem ove t h e con den ser fr om t h e r a dia t or. Lin e Cou pler in t h is gr ou p for t h e pr ocedu r es. 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 -
INSTALLATION t in gs.
(1) In st a ll t h e con den ser t o t h e r a dia t or. Tigh t en (5) Rem ove t h e r a dia t or a n d t h e con den ser fr om
t h e m ou n t in g scr ews t o 28 N·m (250 in . lbs.). t h e veh icle a s a u n it . Refer t o Gr ou p 7 - Coolin g Sys-
t em for t h e pr ocedu r es.
24 - 34 HEATING AND AIR CONDITIONING
CONDENSER
UPPER BRACKET LOWER CROSSMEMBER
NUT RADIATOR
GROMMET XJ
VACUUM SUPPLY
LINETO SPEED
TROL
TO SERVO
VACUUM
CON- TO
RESERVOIR
HEATER-A/C
CONTROLS
VACUUMTO CHECK
ENGINE
MANIFOLD
VALVE
INTAKE
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(6) Rem ove t h e fou r n u t s t h a t secu r e t h e u pper VACUUM CHECK VALVE
br a cket s t o t h e r a dia t or a n d t h e con den ser (F ig. 39). (1) Un plu g t h e h ea t er-A/C va cu u m su pply lin e a t
t h e va cu u m ch eck va lve (F ig. 40).
UPPER VACUUM RESER-
VOIR VACUUM
VACUUM LINE RESERVOIR SCREWS
BRACKET / 11 CHECK VALVE
f_ I'~
VACUUM
SUPPLY 11\~
LINE~

~ ~ 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

(7) 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. 41 Vacuum Reservoir Remove/Install
(3) Rem ove t h e t wo scr ews t h a t secu r e t h e r eser-
NOTE: If the condenser is replaced, add 30 ml (1 voir t o t h e fr on t bu m per.
oz.) of refrigerant oil to the refrigerant system.
XJ HEATING AND AIR CONDITIONING 24 - 35
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) Rem ove t h e va cu u m r eser voir fr om beh in d t h e ou t let t u be a n d t igh t en t h e a ccu m u la t or r et a in in g
fr on t bu m per. ba n d INSTRUMENT
scr ew.
CENTER PANEL
BEZEL
(5) Rever se t h e r em ova l pr ocedu r es t o in st a ll. (5) Con n ect t h e ba t t er y n ega t ive ca ble.
(6) If t h e veh icle is equ ipped wit h a ir con dit ion in g,
BLOWER MOTOR
BLOWER MOTOR MOUNTING SCREWS WIRE HARNESS CONNEC-
TOR eva 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.
REM OVAL
(1) If t h e veh icle is equ ipped wit h a ir con dit ion in g, HEATER-A/C CONTROL
r ecover 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. WARNING: ON VEHICLES EQUIPPED WITH AIR-
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive BAGS, REFER TO GROUP 8M - PASSIVE
ca ble. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
(3) If t h e veh icle is equ ipped wit h a ir con dit ion in g, STEERING WHEEL, STEERING COLUMN, OR
loosen t h e a ccu m u la t or r et a in in g ba n d scr ew, discon - INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
n ect t h e a ccu m u la t or in let t u be fr om t h e eva por a t or SERVICE. FAILURE TO TAKE THE PROPER PRE-
ou t let t u be a n d m ove t h e a ccu m u la t or fa r en ou gh t o CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
a ccess a n d r em ove t h e blower m ot or. BAG DEPLOYMENT AND POSSIBLE PERSONAL
(4) Un plu g t h e blower m ot or wir e h a r n ess con n ec- INJURY.
t or (F ig. 42).
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) Open t h e glove box a n d r em ove t h e glove box
st op bu m per s t o r oll down t h e glove box a s descr ibed
in Gr ou p 8E - In st r u m en t P a n el Syst em s.
(3) Rea ch t h r ou gh t h e glove box open in g a n d
u n plu g t h e va cu u m h a r n ess con n ect or.
(4) Usin g a t r im st ick or a n ot h er su it a ble wide-
bla ded fla t t ool, gen t ly pr y t h e in st r u m en t pa n el cen -
t er bezel a wa y fr om t h e in st r u m en t pa n el t o r elea se
t h e six sn a p clip r et a in er s (F ig. 43).
I INSTRUMENT PANEL

k1
! lul
80abd276

Fig. 42 Blower Motor Remove/Install


(5) Rem ove t h e t h r ee scr ews t h a t secu r e t h e
blower m ot or a n d wh eel a ssem bly t o t h e h ea t er-A/C
h ou sin g.
(6) Rot a t e a n d t ilt t h e blower m ot or u n it a s n eeded
for clea r a n ce t o r em ove t h e blower m ot or a n d wh eel
fr om t h e h ea t er-A/C h ou sin g.

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.
/

VACUUM REM OVAL


HARNESS (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
TEMPERATURE WIRE HARNESS (2) Discon n ect t h e t em per a t u r e con t r ol ca ble fr om
CONTROL CONNECTOR t h e h ea t er-A/C con t r ols. See H ea t er-A/C Con t r ols in
CABLE 80abd27a t h is gr ou p for t h e pr ocedu r es.
(3) Loca t e t h e t em per a t u r e con t r ol ca ble h ou sin g
Fig. 45 Heater-A/C Control Connections fla g r et a in er r ecept a cle on t h e bot t om of t h e h ea t er-
(10) Relea se t h e t em per a t u r e con t r ol ca ble h ou sin g A/C h ou sin g t owa r ds t h e pa ssen ger side of t h e floor
fla g r et a in er la t ch on t h e r ecept a cle on t h e ba ck of pa n t r a n sm ission t u n n el (F ig. 46). Loca t e t h e fla g
t h e h ea t er-A/C con t r ol a n d disen ga ge t h e fla g r et a in er la t ch r elea se win dow on t h e side of t h e
r et a in er fr om t h e r ecept a cle. r ecept a cle. Wh ile depr essin g t h e la t ch t h r ou gh t h e
(11) Rot a t e t h e h ea t er-A/C con t r ol a ssem bly t o la t ch r elea se win dow, u se a t r im st ick or a n ot h er
a lign t h e ca ble cor e wit h t h e slot on t h e en d of t h e su it a ble wide fla t -bla ded t ool t o gen t ly pr y t h e fla g
t em per a t u r e con t r ol lever a n d r em ove t h e ca ble en d r et a in er ou t of t h e r ecept a cle.
fr om t h e lever. (4) Rem ove t h e scr ew t h a t secu r es t h e blen d-a ir
(12) Rea ch in g t h r ou gh t h e glove box open in g, ca r e- door cr a n k a r m t o t h e blen d-a ir door pivot sh a ft .
fu lly gu ide t h e h ea t er-A/C con t r ol h a lf of t h e va cu u m
h a r n ess a r ou n d a n y obst a cles wh ile r em ovin g t h e
FLOOR
TENSION
DUCTBAND SCREW TEMPERATURE
BLEND-AIR
CABLE
CABLE
END
BOTTOM
FLAG
DOOR
FWD
RETAINER
CONTROL
A/C
PUSH
OFCRANK
HOUSING
HEATER-
ARM
NUT

XJ HEATING AND AIR


BLOWER MOTOR
RELAY CONDITIONING
VACUUM HARNESS HARNESS 24
HEATER-A/C -WIRE
37
CONNEC-
HOUS-
TOR
ING

REM OVAL AN D I N STALLAT I ON (Cont inue d)

BOTTOM OF (3) Rea ch t h r ou gh t h e glove box open in g t o loca t e


HEATER-A/C t h e blower m ot or r ela y (F ig. 47).
)Ho~~- 11 ,
HEATER-A/C
TEMPERATURE \\- WIRE
CONTROL CABLE i HARNESS
1/"FLAG RETAINER \\ CONNECTOR
1~~-

CABL~I

---.-;.......,_--.)..--; PUSH NUT

END-AIR DOOR
I
n~· CRANK ARM
tJ SCREW 80abd27c

Fig. 46 Temperature Control Cable Remove/Install


80abd27e
(5) P u ll t h e blen d-a ir door cr a n k a r m down fr om
t h e h ea t er-A/C h ou sin g t o r em ove it fr om t h e blen d- Fig. 47 Blower Motor Relay Remove/Install
a ir door pivot sh a ft . (4) Un plu g t h e blower m ot or r ela y fr om it s wir e
(6) Rem ove t h e blen d-a ir door cr a n k a r m a n d t em - h a r n ess con n ect or.
per a t u r e con t r ol ca ble fr om t h e veh icle a s a u n it . (5) In st a ll t h e blower m ot or r ela y by a lign in g t h e
(7) Rem ove t h e pu sh n u t t h a t secu r es t h e t em per- r ela y t er m in a ls wit h t h e ca vit ies in t h e wir e h a r n ess
a t u r e con t r ol ca ble en d t o t h e pin on t h e en d of t h e con n ect or a n d pu sh in g t h e r ela y fir m ly in t o pla ce.
blen d-a ir door cr a n k a r m . (6) Roll u p t h e glove box a n d r ein st a ll t h e glove
(8) Rem ove t h e t em per a t u r e con t r ol ca ble fr om t h e box st op bu m per s.
blen d-a ir door cr a n k a r m . (7) Con n ect t h e ba t t er y n ega t ive ca ble.
(8) Test t h e r ela y oper a t ion .
I N STALLAT I ON
(1) In st a ll t h e blen d-a ir door cr a n k a r m on t o t h e
KICK COVER
blen d-a ir door pivot sh a ft . Be cer t a in t h a t t h e t en sion
ba n d on t h e bot t om of t h e h ea t er-A/C h ou sin g is WARNING: ON VEHICLES EQUIPPED WITH AIR-
pr oper ly posit ion ed a ga in st t h e ca m for m a t ion on t h e BAGS, REFER TO GROUP 8M - PASSIVE
blen d-a ir door cr a n k a r m . RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
(2) In st a ll a n d t igh t en t h e scr ew t h a t secu r es t h e STEERING WHEEL, STEERING COLUMN, OR
blen d-a ir door cr a n k a r m t o t h e blen d-a ir door pivot INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
sh a ft . Tigh t en t h e m ou n t in g scr ew t o 1 N·m (10 in . SERVICE. FAILURE TO TAKE THE PROPER PRE-
lbs.). CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(3) In st a ll t h e t em per a t u r e con t r ol ca ble en d over BAG DEPLOYMENT AND POSSIBLE PERSONAL
t h e pin on t h e en d of t h e blen d-a ir door cr a n k a r m INJURY.
a n d secu r e it wit h a pu sh n u t .
(4) 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 bot t om of t h e REM OVAL
h ea t er-A/C h ou sin g. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(5) Con n ect t h e t em per a t u r e con t r ol ca ble t o t h e ca ble.
h ea t er-A/C con t r ols a n d r ein st a ll t h e h ea t er-A/C con - (2) Loosen t h e t wo u pper scr ews t h a t secu r e t h e
t r ols t o t h e in st r u m en t pa n el. See H ea t er-A/C Con - kick cover t o t h e h ea t er-A/C h ou sin g u n der t h e pa s-
t r ols in t h is gr ou p for t h e pr ocedu r es. sen ger side of t h e in st r u m en t pa n el on t h e pa ssen ger
(6) Con n ect t h e ba t t er y n ega t ive ca ble. side of t h e in st r u m en t pa n el (F ig. 48).
(3) Rem ove t h e t wo lower scr ews t h a t secu r e t h e
BLOWER MOTOR RELAY kick cover t o t h e h ea t er-A/C h ou sin g.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (4) P u ll t h e kick cover down t owa r ds t h e floor t o
ca ble. disen ga ge t h e slot t ed u pper m ou n t in g t a bs fr om
(2) Open t h e glove box a n d r em ove t h e glove box u n der t h e u pper scr ews.
st op bu m per s t o r oll down t h e glove box a s descr ibed (5) Rem ove t h e kick cover fr om t h e veh icle.
in Gr ou p 8E - In st r u m en t P a n el Syst em s.
HEATER-A/C HOUS-
ING MOUNTING SCREWS KICK COVER BLOWER
MOTOR
RESISTOR SCREWS CONNECTOR
HEATER-A/C
WIRE
LOCK
CONNECTOR
HARNESS
HOUSING

24 - 38 HEATING AND AIR CONDITIONING XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

Fig. 48 Kick Cover Remove/Install Fig. 49 Blower Motor Resistor Remove/Install


I N STALLAT I ON MODE DOOR VACUUM ACTUATOR
(1) P osit ion t h e slot t ed u pper m ou n t in g t a bs of t h e
kick cover u n der t h e u pper m ou n t in g scr ews on t h e WARNING: ON VEHICLES EQUIPPED WITH AIR-
h ea t er-A/C h ou sin g. Tigh t en t h e scr ews t o 2.2 N·m BAGS, REFER TO GROUP 8M - PASSIVE
(20 in . lbs.). RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
(2) In st a ll t h e t wo lower kick cover m ou n t in g STEERING WHEEL, STEERING COLUMN, OR
scr ews t o t h e h ea t er-A/C h ou sin g. Tigh t en t h e scr ews INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
t o 2.2 N·m (20 in . lbs.). SERVICE. FAILURE TO TAKE THE PROPER PRE-
(3) Con n ect t h e ba t t er y n ega t ive ca ble. CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
BLOWER MOTOR RESISTOR INJURY.

WARNING: ON VEHICLES EQUIPPED WITH AIR-


BAGS, REFER TO GROUP 8M - PASSIVE DEFROST DOOR ACT U AT OR
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
STEERING WHEEL, STEERING COLUMN, OR ca ble.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (2) Rem ove t h e in st r u m en t pa n el a ssem bly a s
SERVICE. FAILURE TO TAKE THE PROPER PRE- descr ibed in Gr ou p 8E - In st r u m en t P a n el Syst em s.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (3) Un plu g t h e t wo va cu u m h a r n ess con n ect or s
BAG DEPLOYMENT AND POSSIBLE PERSONAL fr om t h e defr ost door a ct u a t or (F ig. 50).
INJURY. (4) In ser t a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool in t o t h e la t ch h ole on t h e h ea t er-A/C
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive h ou sin g a ct u a t or m ou n t t o r elea se t h e a ct u a t or la t ch
ca ble. a n d pu ll fir m ly ou t wa r ds on t h e a ct u a t or t o r em ove
(2) Rem ove t h e kick cover fr om t h e h ea t er-A/C t h e a ct u a t or fr om t h e m ou n t (F ig. 51).
h ou sin g a s descr ibed in t h is gr ou p. (5) Move t h e va cu u m a ct u a t or a s r equ ir ed t o dis-
(3) P u ll ou t on t h e blower m ot or r esist or wir e h a r- en ga ge t h e h ole on t h e en d of t h e a ct u a t or lin k fr om
n ess con n ect or lock t o r elea se t h e con n ect or la t ch t h e h ooked pin on t h e en d of t h e defr ost door cr a n k
(F ig. 49). arm.
(4) Depr ess t h e la t ch on t h e blower m ot or r esist or (6) Rem ove t h e defr ost door va cu u m a ct u a t or fr om
wir e h a r n ess con n ect or a n d u n plu g it fr om t h e r esis- t h e veh icle.
t or. (7) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
(5) Rem ove t h e t wo scr ews t h a t secu r e t h e r esist or
t o t h e h ea t er-A/C h ou sin g. FLOOR DOOR ACT U AT OR
(6) Rem ove t h e r esist or fr om t h e h ou sin g. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(7) Rever se t h e r em ova l pr ocedu r es t o in st a ll. ca ble.
Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in lbs.). (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.
XJ HEATING AND AIR CONDITIONING 24 - 39
REM OVAL AN D I N STALLAT I ON (Cont inue d)
t h e h ooked pin on t h e en d of t h e floor door cr a n k
arm.
(6) Rem ove t h e floor door va cu u m a ct u a t or fr om
t h e veh icle.
(7) Rever se t h e r em ova l pr ocedu r es t o in st a ll.

PAN EL/DEM I ST DOOR ACT U AT OR


(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.
(3) Rem ove t h e defr ost door a ct u a t or a s descr ibed
in t h is gr ou p.
(4) Un plu g t h e va cu u m h a r n ess con n ect or fr om t h e
ACTUATOR LATCH TRIM STICK
ACTUATOR MOUNT LATCH
HOLE
pa n el/dem ist door a ct u a t or (F ig. 50).
(5) In ser t a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool in t o t h e la t ch h ole on t h e h ea t er-A/C
h ou sin g a ct u a t or m ou n t t o r elea se t h e a ct u a t or la t ch
a n d pu ll fir m ly ou t wa r ds on t h e a ct u a t or t o r em ove
t h e a ct u a t or fr om t h e m ou n t (F ig. 51).
(6) Move t h e va cu u m a ct u a t or a s r equ ir ed t o dis-
en ga ge t h e h ole on t h e en d of t h e a ct u a t or lin k fr om
Fig. 50 Defrost, Floor, and Panel/Demist Door t h e h ooked pin on t h e en d of t h e pa n el/dem ist door
Vacuum Actuators cr a n k a r m .
(7) Rem ove t h e pa n el/dem ist door va cu u m a ct u a t or
fr om t h e veh icle.
(8) Rever se t h e r em ova l pr ocedu r es t o in st a ll.

RECI RCU LAT I ON AI R DOOR ACT U AT OR


A r ecir cu la t ion a ir door a n d va cu u m a ct u a t or a r e
u sed on ly on m odels wit h t h e opt ion a l a ir con dit ion -
in g syst em .
(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 kick cover fr om t h e h ea t er-A/C
h ou sin g a s descr ibed in t h is gr ou p.
(3) Un plu g t h e va cu u m h a r n ess con n ect or fr om t h e
r ecir cu la t ion a ir door a ct u a t or (F ig. 52).
(4) In ser t a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool in t o t h e la t ch h ole on t h e h ea t er-A/C
h ou sin g a ct u a t or m ou n t t o r elea se t h e a ct u a t or la t ch
a n d pu ll fir m ly ou t wa r ds on t h e a ct u a t or t o r em ove
t h e a ct u a t or fr om t h e m ou n t (F ig. 51).
(5) Move t h e va cu u m a ct u a t or a s r equ ir ed t o dis-
en ga ge t h e h ole on t h e en d of t h e a ct u a t or lin k fr om
BOabd285 t h e h ooked pin on t h e en d of t h e r ecir cu la t ion a ir
door lever.
Fig. 51 Vacuum Actuator Remove/Install - Typical (6) Rem ove t h e r ecir cu la t ion a ir door va cu u m
(3) Un plu g t h e va cu u m h a r n ess con n ect or fr om t h e a ct u a t or fr om t h e veh icle.
floor door a ct u a t or (F ig. 50). (7) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
(4) In ser t a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool in t o t h e la t ch h ole on t h e h ea t er-A/C HEATER-A/C HOUSING
h ou sin g a ct u a t or m ou n t t o r elea se t h e a ct u a t or la t ch Th e h ea t er-A/C h ou sin g a ssem bly m u st be r em oved
a n d pu ll fir m ly ou t wa r ds on t h e a ct u a t or t o r em ove fr om t h e veh icle a n d t h e t wo h a lves of t h e h ou sin g
t h e a ct u a t or fr om t h e m ou n t (F ig. 51). sepa r a t ed for ser vice a ccess of t h e h ea t er cor e, eva p-
(5) Move t h e va cu u m a ct u a t or a s r equ ir ed t o dis- or a t or coil, blen d-a ir door, a n d ea ch of t h e va r iou s
en ga ge t h e h ole on t h e en d of t h e a ct u a t or lin k fr om m ode con t r ol door s.
24 - 40 HEATING AND AIR CONDITIONING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
HEATER-A/C
RIGHTHOUSING
FRONT FENDER STUD NUT STUD
11 ,
HEATER-A/C
WIRE
HARNESS
CONNECTOR
1~~-

80abd27e

Fig. 53 Heater-A/C Unit Connector


(9) If t h e veh icle is equ ipped wit h a ir con dit ion in g,
r em ove a n d r eloca t e t h e a ccu m u la t or a n d it s m ou n t -
in g br a cket .
(10) Rem ove t h e five h ea t er-A/C h ou sin g m ou n t in g
n u t s fr om t h e st u ds on t h e en gin e com pa r t m en t side
Fig. 52 Recirculation Air Door Vacuum Actuator of t h e da sh pa n el (F ig. 54). Rem ove or r eposit ion t h e
WARNING: ON VEHICLES EQUIPPED WITH AIR- eva por a t ion ca n ist er for a ccess, if r equ ir ed.
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY HEATER-A/C
STEERING WHEEL, STEERING COLUMN, OR HOUSING ----a-:_.....u1111m111, ~ ~ ~ ~ ~ i l ' i -
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
RIGHT FRONT
SERVICE. FAILURE TO TAKE THE PROPER PRE- FENDER
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL /~-~
INJURY.

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

(3) Un plu g t h e h ea t er-A/C u n it wir e h a r n ess con - 80abd234

n ect or, wh ich is fa st en ed t o t h e h ea t er-A/C h ou sin g


n ext t o t h e blower m ot or r ela y (F ig. 53). Fig. 54 Heater-A/C Housing Remove/Install
(4) If t h e veh icle is n ot equ ipped wit h a ir con di- (11) P u ll t h e h ea t er-A/C h ou sin g r ea r wa r d fa r
t ion in g, go t o St ep 6. If t h e veh icle is equ ipped wit h en ou gh for t h e m ou n t in g st u ds a n d t h e eva por a t or
a ir con dit ion in g, r ecover t h e r efr iger a n t fr om t h e dr a in t u be t o clea r t h e da sh pa n el h oles.
r efr iger a n t syst em a s descr ibed in t h is gr ou p. (12) Rem ove t h e h ea t er-A/C h ou sin g fr om t h e veh i-
(5) Discon n ect t h e r efr iger a n t lin es fr om t h e eva p- cle.
or a t or t u bes. 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. DI SASSEM BLY
(6) Dr a in t h e coolin g syst em . Refer t o Gr ou p 7 - (1) Rem ove t h e h ea t er-A/C h ou sin g fr om t h e veh i-
Coolin g Syst em for t h e pr ocedu r es. cle a n d pla ce it on a wor k ben ch .
(7) Discon n ect t h e h ea t er h oses fr om t h e h ea t er (2) Un plu g t h e va cu u m h a r n ess con n ect or s fr om
cor e t u bes. t h e floor door a ct u a t or a n d, if t h e u n it is so equ ipped,
(8) Un plu g t h e h ea t er-A/C syst em va cu u m su pply t h e r ecir cu la t ion a ir door a ct u a t or.
lin e fr om t h e t ee fit t in g n ea r t h e h ea t er cor e t u bes.
RECIRCULATION
BLOWER MOTORAIR
RING
PIVOTS
BLEND-AIR
DOOR DOOR PIVOT EVAPORATOR RUBBER
COIL TUBE
SEAL

XJ HEATING AND AIR CONDITIONING 24 - 41


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Disen ga ge t h e va cu u m h a r n ess fr om a n y r ou t -
in g clipsBLOWER
loca t ed on t h e lower h a EVAPORATOR
MOTOR
GASKETS
lf ofVACUUM
t h e TUBE
HEATER
hCLIPS
ea tCLAMP
SUPPLY
CORE
er-A/C
TUBES
LINE
h ou sin g.
(4) Disen ga ge t h e h ea t er-A/C u n it wir e h a r n ess
a n d blower m ot or r ela y wir e h a r n ess con n ect or
pu sh -in r et a in er s fr om t h eir m ou n t in g h oles on t h e
h ea t er-A/C h ou sin g.
(5) Rem ove t h e blower m ot or a n d blower wh eel
u n it fr om t h e h ea t er-A/C h ou sin g a s descr ibed in t h is
gr ou p.
(6) P u ll t h e va cu u m su pply lin e a n d con n ect or
t h r ou gh t h e foa m ga sket on t h e h ea t er-A/C h ou sin g
h ea t er cor e a n d eva por a t or coil t u be m ou n t in g fla n ge
,(la)~
(F ig. 55). RECIRCULATION AIR
GASKETS DOOR PIVOTS 80abd29c

Fig. 56 Heater-A/C Housing Assembly


(2) In st a ll t h e 14 scr ews a n d t wo sn a p clips t h a t
secu r e t h e u pper a n d lower h ea t er-A/C h ou sin g
h a lves t oget h er.
(3) In st a ll t h e blower m ot or a n d wh eel u n it t o t h e
h ea t er-A/C h ou sin g.
(4) In st a ll t h e blower m ot or h ou sin g fla n ge a n d
h ea t er cor e a n d eva por a t or coil t u be m ou n t in g fla n ge
foa m ga sket s.
(5) In ser t t h e va cu u m su pply lin e a n d con n ect or
t h r ou gh t h e foa m ga sket on t h e h ea t er-A/C h ou sin g
Fig. 55 Heater-A/C Housing Disassembly h ea t er cor e a n d eva por a t or coil t u be m ou n t in g fla n ge.
(7) Ca r efu lly r em ove t h e blower m ot or h ou sin g (6) If t h e u n it is equ ipped wit h a ir con dit ion in g,
foa m fla n ge ga sket fr om a r ou n d t h e blower m ot or r ein st a ll t h e eva por a t or coil t u be cla m p.
open in g in t h e h ea t er-A/C h ou sin g. If t h e ga sket is (7) E n ga ge t h e h ea t er-A/C u n it wir e h a r n ess a n d
defor m ed or da m a ged, it m u st be r epla ced. blower m ot or r ela y wir e h a r n ess con n ect or pu sh -in
(8) If t h e u n it is equ ipped wit h a ir con dit ion in g, r et a in er s t o t h eir m ou n t in g h oles on t h e h ea t er-A/C
r em ove t h e scr ew t h a t secu r es t h e cla m p t o t h e eva p- h ou sin g.
or a t or coil t u bes a n d r em ove t h e cla m p. (8) Rein st a ll t h e va cu u m h a r n ess t o t h e r ou t in g
(9) Ca r efu lly r em ove t h e foa m ga sket fr om t h e clips a n d plu g in t h e va cu u m h a r n ess con n ect or a t
h ea t er-A/C h ou sin g h ea t er cor e a n d eva por a t or coil t h e floor door a ct u a t or a n d, if t h e u n it is so equ ipped,
t u be m ou n t in g fla n ge. If t h e ga sket is defor m ed or t h e r ecir cu la t ion a ir door a ct u a t or.
da m a ged, it m u st be r epla ced. (9) In st a ll t h e h ea t er-A/C h ou sin g in t h e veh icle.
(10) Use a scr ewdr iver t o pr y off t h e t wo sn a p clips
I N STALLAT I ON
t h a t h elp secu r e t h e u pper a n d lower h ea t er-A/C
(1) P osit ion t h e h ea t er-A/C h ou sin g t o t h e da sh
h ou sin g h a lves t oget h er.
pa n el. Be cer t a in t h a t t h e eva por a t or dr a in t u be a n d
(11) Rem ove t h e 14 scr ews t h a t h elp secu r e t h e
t h e h ou sin g m ou n t in g st u ds a r e in ser t ed in t o t h eir
u pper a n d lower h ea t er-A/C h ou sin g h a lves t oget h er.
cor r ect m ou n t in g h oles.
(12) Ca r efu lly sepa r a t e t h e u pper h ea t er-A/C h ou s-
(2) In st a ll t h e five n u t s t o t h e m ou n t in g st u ds on
in g h a lf fr om t h e lower h a lf.
t h e en gin e com pa r t m en t side of t h e da sh pa n el.
ASSEM BLY Tigh t en t h e m ou n t in g n u t s t o 6.2 N·m (55 in . lbs.).
(1) Assem ble t h e u pper h ea t er-A/C h ou sin g h a lf t o (3) Rein st a ll t h e eva por a t ion ca n ist er if it wa s
t h e lower h a lf. Be cer t a in t h a t ea ch of t h e door pivot r eposit ion ed du r in g t h e r em ova l pr ocedu r e.
sh a ft en ds is pr oper ly en ga ged in it s pivot h ole, t h a t (4) If t h e veh icle is equ ipped wit h a ir con dit ion in g,
t h e blower m ot or r in g is pr oper ly in st a lled a n d, if t h e r ein st a ll t h e a ccu m u la t or a n d it s m ou n t in g br a cket .
u n it is so equ ipped, t h a t t h e eva por a t or coil t u be r u b- (5) Con n ect t h e h ea t er-A/C syst em va cu u m su pply
ber sea l is pr oper ly posit ion ed (F ig. 56). lin e t o t h e t ee fit t in g n ea r t h e h ea t er cor e t u bes.
(6) Con n ect t h e h ea t er h oses t o t h e h ea t er cor e
t u bes.
24 - 42 HEATING AND AIR CONDITIONING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(7) If t h e veh icle is equ ipped wit h a ir con dit ion in g,
u n plu g or r em ove t h e t a pe fr om t h e r efr iger a n t fit - FLAT BLADE PRYCRANK
TOOL ARM LATCH LATCH
DOOR HOLE
SHAFT
PIVOT
t in gs, a n d con n ect t h e r efr iger a n t lin es t o t h e eva po-
r a t or t u bes.
(8) In st a ll 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.
(9) Con n ect t h e ba t t er y n ega t ive ca ble.
(10) F ill t h e coolin g syst em . Refer t o Gr ou p 7 -
Coolin g Syst em for t h e pr ocedu r es.
(11) If t h e veh icle is equ ipped wit h a ir con dit ion -
in g, eva cu a t e a n d ch a r ge t h e r efr iger a n t syst em a s HEATER
descr ibed in t h is gr ou p. CORE
(12) St a r t t h e veh icle a n d ch eck for pr oper oper a -
t ion of t h e h ea t in g a n d a ir con dit ion in g syst em s. EVAPORATOR
1
,, -------------- f COIL ao~bd2a1
HEATER-A/C HOUSING DOOR
Fig. 57 Blend-Air Door
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- FLAT BLADE
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- PRY TOOL
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

BLEN D-AI R DOOR


(1) Rem ove a n d disa ssem ble t h e h ea t er-A/C h ou s-
in g a s descr ibed in t h is gr ou p.

NOTE: If the temperature control cable was not 80abfef2


removed with the blend-air door crank arm as a unit
during the instrument panel assembly removal pro- Fig. 58 Mode Door Crank Arm Remove/Install -
cedures, the crank arm must be removed from the Typical
blend-air door pivot shaft before the blend-air door
(4) Rea ch in side t h e u pper h a lf of t h e h ea t er-A/C
can be removed from the heater-A/C housing. See
h ou sin g a n d ca r efu lly flex t h e pa n el/defr ost door (F ig.
Temperature Control Cable in this group for the pro-
59) en ou gh so t h a t t h e door pivot clea r s t h e pivot
cedures.
h ole in t h e h ou sin g.
(2) Lift t h e blen d-a ir door pivot sh a ft ou t of t h e (5) Rem ove t h e pa n el/dem ist door fr om t h e h ea t er-
pivot h ole in t h e bot t om of t h e lower h a lf of t h e h ea t - A/C h ou sin g.
er-A/C h ou sin g (F ig. 57). (6) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
(3) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
DEFROST DOOR AN D CRAN K ARM
PAN EL/DEM I ST DOOR AN D CRAN K ARM (1) Rem ove a n d disa ssem ble t h e h ea t er-A/C h ou s-
(1) Rem ove a n d disa ssem ble t h e h ea t er-A/C h ou s- in g a s descr ibed in t h is gr ou p.
in g a s descr ibed in t h is gr ou p. (2) Rem ove t h e pa n el/dem ist door a n d cr a n k a r m
(2) Rem ove t h e defr ost a n d pa n el/dem ist door va c- a s descr ibed in t h is gr ou p.
u u m a ct u a t or s a s descr ibed in t h is gr ou p. (3) In ser t a scr ewdr iver in t o t h e la t ch h ole (F ig.
(3) In ser t a scr ewdr iver in t o t h e la t ch h ole (F ig. 58) of t h e defr ost door pivot sh a ft t o r elea se t h e la t ch
58) of t h e pa n el/dem ist door pivot sh a ft t o r elea se t h e of t h e defr ost door cr a n k a r m , a n d pu ll t h e cr a n k
la t ch of t h e pa n el/dem ist door cr a n k a r m , a n d pu ll a r m ou t of t h e pivot sh a ft fr om t h e ou t side of t h e
t h e cr a n k a r m ou t of t h e pivot sh a ft fr om t h e ou t side u pper h a lf of t h e h ea t er-A/C h ou sin g.
of t h e u pper h a lf of t h e h ea t er-A/C h ou sin g. (4) Rea ch in side t h e u pper h a lf of t h e h ea t er-A/C
h ou sin g a n d ca r efu lly flex t h e defr ost door (F ig. 59)
XJ HEATING AND AIR CONDITIONING 24 - 43
REM OVAL AN D I N STALLAT I ON (Cont inue d) RECIRCULATION AIR DOOR
PIVOT SHAFT LOWER HEATER-A/C HOUS-
LEVER
ING

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.

RECI RCU LAT I ON AI R DOOR


A r ecir cu la t ion a ir door a n d va cu u m a ct u a t or a r e
u sed on ly on m odels wit h t h e opt ion a l a ir con dit ion -
in g syst em .
(1) Rem ove a n d disa ssem ble t h e h ea t er-A/C h ou s-
in g a s descr ibed in t h is gr ou p.
(2) Rem ove t h e r ecir cu la t ion a ir door va cu u m
a ct u a t or a s descr ibed in t h is gr ou p.
(3) Rea ch in side t h e lower h a lf of t h e h ea t er-A/C
h ou sin g a n d lift t h e bot t om edge of t h e r ecir cu la t ion
DEFROSTD~ a ir door u pwa r ds (F ig. 61).

Fig. 59 Panel/Demist and Defrost Doors


en ou gh so t h a t t h e door pivot clea r s t h e pivot h ole in
t h e h ou sin g.
(5) Rem ove t h e defr ost door fr om t h e h ea t er-A/C
h ou sin g.
(6) Rever se t h e r em ova l pr ocedu r es t o in st a ll.

FLOOR DOOR AN D CRAN K ARM


(1) Rem ove a n d disa ssem ble t h e h ea t er-A/C h ou s-
in g a s descr ibed in t h is gr ou p.
(2) Rem ove t h e floor door va cu u m a ct u a t or a s
descr ibed in t h is gr ou p.
(3) In ser t a scr ewdr iver in t o t h e la t ch h ole (F ig. PIVOT
58) of t h e floor door pivot sh a ft t o r elea se t h e la t ch of SHAFT 80abd299
t h e floor door cr a n k a r m , a n d pu ll t h e cr a n k a r m ou t
of t h e pivot sh a ft fr om t h e ou t side of t h e lower h a lf of Fig. 61 Recirculation Air Door
t h e h ea t er-A/C h ou sin g. (4) Gu ide t h e r ecir cu la t ion a ir door lever t h r ou gh
(4) Rea ch in side t h e lower h a lf of t h e h ea t er-A/C t h e a ir in t a ke gr ille of t h e h ea t er-A/C h ou sin g wh ile
h ou sin g a n d ca r efu lly flex t h e floor door (F ig. 60) r em ovin g t h e door fr om t h e h ou sin g.
en ou gh so t h a t t h e door pivot clea r s t h e pivot h ole in (5) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
t h e h ou sin g.
EVAPORATOR COIL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Rem ove a n d disa ssem ble t h e h ea t er-A/C h ou s-


in g a s descr ibed in t h is gr ou p.
(2) Lift t h e eva por a t or coil u n it ou t of t h e lower
CRANK ARM PIVOT SHAFT 80abd298
h a lf of t h e h ea t er-A/C h ou sin g (F ig. 62).
Fig. 60 Floor Door (3) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Be
cer t a in t h a t t h e eva por a t or foa m in su la t or wr a p a n d
r u bber t u be sea l a r e r ein st a lled.
FOAM
TOR
INSULA-
WRAP CONDENSATE
EVAPORATOR
DRAIN TUBE
COIL TUBE SEAL LOWER HEATER-A/C HOUS-
HEATER
ING CORE

24 - 44 HEATING AND AIR CONDITIONING XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d) DEMISTER OUTLETS
PANEL OUTLET BARRELS

EVAPORATOR HEATER CORE


COIL

LOWER HEATER-A/C
HOUSING
80abd29b

CONDENSATE Fig. 63 Heater Core


DRAIN TUBE 80abd29a BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 62 Evaporator Coil
NOTE: If the evaporator is replaced, add 60 ml (2
oz.) of refrigerant oil to the refrigerant system. PAN EL OU T LET DU CT S
Th e pa n el ou t let du ct s a r e in t egr a l t o t h e in st r u -
m en t pa n el a ssem bly. Refer t o Gr ou p 8E - In st r u -
HEATER CORE m en t P a n el Syst em s for t h e in st r u m en t pa n el
a ssem bly ser vice pr ocedu r es.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE PAN EL OU T LET BARRELS
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (1) Use a t r im st ick or a n ot h er su it a ble wide-
STEERING WHEEL, STEERING COLUMN, OR bla ded fla t t ool t o gen t ly pr y t h e pa n el ou t let ba r r el
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR ou t of t h e pa n el ou t let h ou sin g (F ig. 64). Th e ba r r el
SERVICE. FAILURE TO TAKE THE PROPER PRE- is r et a in ed by a ligh t sn a p fit .
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- DEMISTER
BAG DEPLOYMENT AND POSSIBLE PERSONAL OUTLETS
INJURY.

(1) Rem ove a n d disa ssem ble t h e h ea t er-A/C h ou s-


in g a s descr ibed in t h is gr ou p.
(2) Lift t h e h ea t er cor e ou t of t h e lower h a lf of t h e
h ea t er-A/C h ou sin g (F ig. 63).
(3) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Be
cer t a in t h a t t h e h ea t er cor e foa m in su la t or is r ein -
st a lled.

DUCTS AND OUTLETS


WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE 80abd29e

RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY


Fig. 64 Panel Outlet Barrels
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (2) To in st a ll, posit ion t h e ba r r el in t h e pa n el ou t -
SERVICE. FAILURE TO TAKE THE PROPER PRE- let h ou sin g a n d pr ess fir m ly u n t il t h e ba r r el sn a ps
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- in t o pla ce.
DEMISTER
DEMISTER
HOSE DUCT SCREWS

XJ HEATING AND AIR CONDITIONING 24 - 45


HOSE
SCREW DEFROST INSTRUMENT
DUCT/DEMISTER
HOSE
FWDADAPTER
PANEL CONSOLE REAR DUCT FLOOR
FLOOR
DUCT
CONSOLE
AND ADAPTER SCREW

REM OVAL AN D I N STALLAT I ON (Cont inue d)


DEM I ST ER OU T LET S
Th e side win dow dem ist er ou t let s a r e in t egr a l t o
t h e in st r u m en t pa n el en d ca ps. Refer t o Gr ou p 8E -
In st r u m en t P a n el Syst em s for t h e in st r u m en t pa n el
en d ca p ser vice pr ocedu r es.

DEFROST DU CT /DEM I ST ER ADAPT ER


(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 dem ist er h oses fr om t h e defr ost
du ct /dem ist er a da pt er (F ig. 65).

Fig. 66 Demister Duct Remove/Install


(6) 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 m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).

CON SOLE REAR DU CT


(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 floor con sole fr om t h e floor pa n
t r a n sm ission t u n n el (F ig. 67). Refer t o Gr ou p 23 -
80abd29f
Body for t h e pr ocedu r es.

Fig. 65 Defrost Duct/Demister Adapter


(3) Rem ove t h e t h r ee scr ews t h a t secu r e t h e
defr ost du ct /dem ist er a da pt er t o t h e in st r u m en t
pa n el.
(4) Rem ove t h e defr ost du ct /dem ist er a da pt er fr om
t h e in st r u m en t pa n el.
(5) 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 m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).

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

EMISSION CONTROL SYSTEMS


CON T EN T S

page page

EVAPORATIVE EMISSION CONTROLS . . . . . . . 11 ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . 1

ON -BOARD DI AGN OST I CS

INDEX
page page

GENERAL INFORMATION LOAD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . 10


SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . 1 MALFUNCTION INDICATOR LAMP (MIL) . . . . . . 1
DESCRIPTION AND OPERATION MONITORED SYSTEMS . . . . . . . . . . . . . . . . . . 7
CIRCUIT ACTUATION TEST MODE . . . . . . . . . . 2 NON-MONITORED CIRCUITS . . . . . . . . . . . . . . 9
COMPONENT MONITORS . . . . . . . . . . . . . . . . . 9 STATE DISPLAY TEST MODE . . . . . . . . . . . . . . 2
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . 2 TRIP DEFINITION . . . . . . . . . . . . . . . . . . . . . . . 9
HIGH AND LOW LIMITS . . . . . . . . . . . . . . . . . . 10

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-

25 - 2 EMISSION CONTROL SYSTEMS XJ


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
St a t e Displa y In pu t s a n d Ou t pu t s or St a t e Displa y
I 16-WAY Sen sor s.
DATA LINK

! CONNECTOR CIRCUIT ACTUATION TEST MODE


Th e Cir cu it Act u a t ion Test Mode ch ecks for pr oper
oper a t ion of ou t pu t cir cu it s or devices t h e P ower t r a in
Con t r ol Modu le (P CM) m a y n ot in t er n a lly r ecogn ize.
Th e P CM a t t em pt s t o a ct iva t e t h ese ou t pu t s a n d
a llow a n obser ver t o ver ify pr oper oper a t ion . Most of
t h e t est s pr ovide a n a u dible or visu a l in dica t ion of
device oper a t ion (click of r ela y con t a ct s, fu el spr a y,
et c.). E xcept for in t er m it t en t con dit ion s, if a device
fu n ct ion s pr oper ly du r in g t est in g, a ssu m e t h e device,
it s a ssocia t ed wir in g, a n d dr iver cir cu it wor k cor-
r ect ly. Con n ect t h e DRB sca n t ool t o t h e da t a lin k
con n ect or a n d a ccess t h e Act u a t or s scr een .

80aac28e DIAGNOSTIC TROUBLE CODES


A Dia gn ost ic Tr ou ble Code (DTC) in dica t es t h e
Fig. 1 Data Link (Diagnostic) Connector Location P CM h a s r ecogn ized a n a bn or m a l con dit ion in t h e
det ect ed, t h e P CM sen ds a m essa ge t o t h e in st r u - syst em .
m en t clu st er t o illu m in a t e t h e la m p. Th e P CM illu - Th e t ech n icia n ca n r et r ieve a n d displa y DTC’s in
m in a t es t h e MIL on ly for DTC’s t h a t a ffect veh icle t h r ee differ en t wa ys:
em ission s. Th er e a r e som e m on it or s t h a t m a y t a ke • Th e pr efer r ed a n d m ost a ccu r a t e m et h od of
t wo con secu t ive t r ips, wit h a det ect ed fa u lt , befor e r et r ievin g a DTC is by u sin g t h e DRB sca n t ool. Th e
t h e MIL is illu m in a t ed. Th e MIL st a ys on con t in u - sca n t ool su pplies det a iled dia gn ost ic in for m a t ion
ou sly wh en t h e P CM h a s en t er ed a Lim p-In m ode or wh ich ca n be u sed t o m or e a ccu r a t ely dia gn ose
iden t ified a fa iled em ission com pon en t . Refer t o t h e ca u ses for a DTC.
Dia gn ost ic Tr ou ble Code ch a r t s in t h is gr ou p for • Th e secon d m et h od is by obser vin g t h e t wo-digit
em ission r ela t ed codes. n u m ber displa yed a t t h e Ma lfu n ct ion In dica t or La m p
Also, t h e MIL eit h er fla sh es or illu m in a t es con t in - (MIL). Th e MIL is displa yed on t h e in st r u m en t pa n el
u ou sly wh en t h e P CM det ect s a ct ive en gin e m isfir e. a s t h e Ch eck E n gin e la m p. Th is m et h od is t o be u sed
Refer t o Misfir e Mon it or in g in t h is sect ion . a s a “qu ick-t est ” on ly. Alwa ys u se t h e DRB sca n t ool
Addit ion a lly, t h e P CM m a y r eset (t u r n off) t h e MIL for det a iled in for m a t ion .
wh en on e of t h e followin g occu r : • Th e t h ir d m et h od is by obser vin g t h e t wo-digit
• P CM does n ot det ect t h e m a lfu n ct ion for 3 con - n u m ber displa yed a t t h e veh icle odom et er. Th is
secu t ive t r ips (except m isfir e a n d F u el syst em Mon i- m et h od, sim ila r t o t h e MIL la m p, is a lso t o be u sed
t or s). a s a “qu ick-t est ” on ly.
• P CM does n ot det ect a m a lfu n ct ion wh ile per- Re m e m be r th a t D TC’s a re th e re s u lts o f a s y s -
for m in g t h r ee su ccessive en gin e m isfir e or fu el sys- te m o r c irc u it fa ilu re , bu t d o n o t d ire c tly id e n -
t em t est s. Th e P CM per for m s t h ese t est s wh ile t h e tify th e fa ile d c o m p o n e n t o r c o m p o n e n ts .
en gin e is oper a t in g wit h in 6 375 RP M of a n d wit h in
NOTE: For a list of DTC’s, refer to the charts in this
10 % of t h e loa d of t h e oper a t in g con dit ion a t wh ich
section.
t h e m a lfu n ct ion wa s fir st det ect ed.

STATE DISPLAY TEST MODE BU LB CH ECK


Th e swit ch in pu t s t o t h e P ower t r a in Con t r ol Mod- E a ch t im e t h e ign it ion key is t u r n ed t o t h e ON
u le (P CM) h a ve t wo r ecogn ized st a t es; H IGH a n d posit ion , t h e m a lfu n ct ion in dica t or (ch eck en gin e)
LOW. F or t h is r ea son , t h e P CM ca n n ot r ecogn ize t h e la m p on t h e in st r u m en t pa n el sh ou ld illu m in a t e for
differ en ce bet ween a select ed swit ch posit ion ver su s a ppr oxim a t ely 2 secon ds t h en go ou t . Th is is don e for
a n open cir cu it , a sh or t cir cu it , or a defect ive swit ch . a bu lb ch eck.
If t h e St a t e Displa y scr een sh ows t h e ch a n ge fr om
H IGH t o LOW or LOW t o H IGH , a ssu m e t h e en t ir e OBTAI N I N G DT C’S U SI N G DRB SCAN T OOL
swit ch cir cu it t o t h e P CM fu n ct ion s pr oper ly. Con n ect (1) Con n ect t h e DRB sca n t ool t o t h e da t a lin k
t h e DRB sca n t ool t o t h e da t a lin k con n ect or a n d (dia gn ost ic) con n ect or. Th is con n ect or is loca t ed in
a ccess t h e st a t e displa y scr een . Th en a ccess eit h er
XJ EMISSION CONTROL SYSTEMS 25 - 3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
t h e pa ssen ger com pa r t m en t ; a t t h e lower edge of An exa m ple of a fla sh ed DTC is a s follows:
in st r u m en t pa n el; n ea r t h e st eer in g colu m n . • La m p fla sh es 4 t im es, pa u ses, a n d t h en fla sh es
(2) Tu r n t h e ign it ion swit ch on a n d a ccess t h e 6 m or e t im es. Th is in dica t es a DTC code n u m ber 46.
“Rea d F a u lt ” scr een . • La m p fla sh es 5 t im es, pa u ses, a n d fla sh es 5
(3) Recor d a ll t h e DTC’s a n d “fr eeze fr a m e” in for- m or e t im es. Th is in dica t es a DTC code n u m ber 55. A
m a t ion sh own on t h e DRB sca n t ool. DTC 55 will a lwa ys be t h e la st code t o be displa yed.
(4) To er a se DTC’s, u se t h e “E r a se Tr ou ble Code” Th is in dica t es t h e en d of a ll st or ed codes.
da t a scr een on t h e DRB sca n t ool. D o n o t e ra s e a n y
D TC’s u n til p ro ble m s h a v e be e n in v e s tig a te d OBTAI N I N G DT C’S U SI N G V EH I CLE
a n d re p a irs h a v e be e n p e rfo rm e d . ODOM ET ER
(1) Cycle t h e ign it ion key On - Off - On - Off - On
OBTAI N I N G DT C’S U SI N G M I L LAM P wit h in 5 secon ds.
(1) Cycle t h e ign it ion key On - Off - On - Off - On (2) Aft er a sh or t pa u se, t h e m ilea ge sh own on t h e
wit h in 5 secon ds. veh icles digit a l odom et er will be t em por a r ily delet ed.
(2) Cou n t t h e n u m ber of t im es t h e MIL (ch eck Aft er t h is occu r s, r ea d t h e DTC n u m ber displa yed on
en gin e la m p) on t h e in st r u m en t pa n el fla sh es on a n d t h e odom et er. E a ch t wo–digit n u m ber will be dis-
off. Th e n u m ber of fla sh es r epr esen t s t h e t r ou ble pla yed wit h a sligh t dela y bet ween n u m ber s.
code. Th er e is a sligh t pa u se bet ween t h e fla sh es r ep- (3) A DTC n u m ber 55 will a lwa ys be t h e la st code
r esen t in g t h e fir st a n d secon d digit s of t h e code. t o be displa yed. Th is in dica t es t h e en d of a ll st or ed
Lon ger pa u ses sepa r a t e in dividu a l t wo digit t r ou ble codes. Aft er code 55 h a s been displa yed, t h e odom et er
codes. will r et u r n t o it s n or m a l m ode.

DI AGN OST I C T ROU BLE CODE DESCRI PT I ON S

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

MONITORED SYSTEMS M I L 2 1 —OX Y GEN SEN SOR (O2 S) M ON I T OR


Th er e a r e n ew elect r on ic cir cu it m on it or s t h a t E ffect ive con t r ol of exh a u st em ission s is a ch ieved
ch eck fu el, em ission , en gin e a n d ign it ion per for- by a n oxygen feedba ck syst em . Th e m ost im por t a n t
m a n ce. Th ese m on it or s u se in for m a t ion fr om va r iou s elem en t of t h e feedba ck syst em is t h e O2S. Th e O2S
sen sor cir cu it s t o in dica t e t h e over a ll oper a t ion of t h e is loca t ed in t h e exh a u st pa t h . On ce it r ea ch es oper-
fu el, en gin e, ign it ion a n d em ission syst em s a n d t h u s a t in g t em per a t u r e 300° t o 350°C (572° t o 662°F ), t h e
t h e em ission s per for m a n ce of t h e veh icle. sen sor gen er a t es a volt a ge t h a t is in ver sely pr opor-
Th e fu el, en gin e, ign it ion a n d em ission syst em s t ion a l t o t h e a m ou n t of oxygen in t h e exh a u st . Th e
m on it or s do n ot in dica t e a specific com pon en t pr ob- in for m a t ion obt a in ed by t h e sen sor is u sed t o ca lcu -
lem . Th ey do in dica t e t h a t t h er e is a n im plied pr ob- la t e t h e fu el in ject or pu lse widt h . Th is m a in t a in s a
lem wit h in on e of t h e syst em s a n d t h a t a specific 14.7 t o 1 Air F u el (A/F ) r a t io. At t h is m ixt u r e r a t io,
pr oblem m u st be dia gn osed. t h e ca t a lyst wor ks best t o r em ove h ydr oca r bon s (H C),
If a n y of t h ese m on it or s det ect a pr oblem a ffect in g ca r bon m on oxide (CO) a n d n it r ogen oxide (NOx) fr om
veh icle em ission s, t h e Ma lfu n ct ion In dica t or (Ch eck t h e exh a u st .
E n gin e) La m p will be illu m in a t ed. Th ese m on it or s Th e O2S is a lso t h e m a in sen sin g elem en t for t h e
gen er a t e Dia gn ost ic Tr ou ble Codes t h a t ca n be dis- Ca t a lyst a n d F u el Mon it or s.
pla yed wit h t h e ch eck en gin e la m p or a sca n t ool. Th e O2S ca n fa il in a n y or a ll of t h e followin g
Th e followin g is a list of t h e syst em m on it or s: m a n n er s:
• Misfir e Mon it or • slow r espon se r a t e
• F u el Syst em Mon it or • r edu ced ou t pu t volt a ge
• Oxygen Sen sor Mon it or • dyn a m ic sh ift
• Oxygen Sen sor H ea t er Mon it or • sh or t ed or open cir cu it s
• Ca t a lyst Mon it or Respon se r a t e is t h e t im e r equ ir ed for t h e sen sor t o
All t h ese syst em m on it or s r equ ir e t wo con secu t ive swit ch fr om lea n t o r ich on ce it is exposed t o a r ich er
t r ips wit h t h e m a lfu n ct ion pr esen t t o set a fa u lt . t h a n opt im u m A/F m ixt u r e or vice ver sa . As t h e sen -
F ollowin g is a descr ipt ion of ea ch syst em m on it or, sor st a r t s m a lfu n ct ion in g, it cou ld t a ke lon ger t o
a n d it s DTC. det ect t h e ch a n ges in t h e oxygen con t en t of t h e
Re fe r to th e a p p ro p ria te P o w e rtra in D ia g n o s - exh a u st ga s.
tic s P ro c e d u re s m a n u a l fo r d ia g n o s tic p ro c e - Th e ou t pu t volt a ge of t h e O2S r a n ges fr om 0 t o 1
d u re s . volt . A good sen sor ca n ea sily gen er a t e a n y ou t pu t
25 - 8 EMISSION CONTROL SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
volt a ge in t h is r a n ge a s it is exposed t o differ en t con - Th e P CM is pr ogr a m m ed t o m a in t a in t h e opt im u m
cen t r a t ion s of oxygen . To det ect a sh ift in t h e A/F a ir /fu el r a t io of 14.7 t o 1. Th is is don e by m a kin g
m ixt u r e (lea n or r ich ), t h e ou t pu t volt a ge h a s t o sh or t t er m cor r ect ion s in t h e fu el in ject or pu lse widt h
ch a n ge beyon d a t h r esh old va lu e. A m a lfu n ct ion in g ba sed on t h e O2S sen sor ou t pu t . Th e pr ogr a m m ed
sen sor cou ld h a ve difficu lt y ch a n gin g beyon d t h e m em or y a ct s a s a self ca libr a t ion t ool t h a t t h e en gin e
t h r esh old va lu e. con t r oller u ses t o com pen sa t e for va r ia t ion s in en gin e
specifica t ion s, sen sor t oler a n ces a n d en gin e fa t igu e
M I L 2 1 —OX Y GEN SEN SOR H EAT ER M ON I T OR over t h e life spa n of t h e en gin e. By m on it or in g t h e
If t h er e is a n oxygen sen sor (O2S) sh or t ed t o volt - a ct u a l fu el-a ir r a t io wit h t h e O2S sen sor (sh or t t er m )
a ge DTC, a s well a s a O2S h ea t er DTC, t h e O2S a n d m u lt iplyin g t h a t wit h t h e pr ogr a m lon g-t er m
fa u lt MUST be r epa ir ed fir st . Befor e ch eckin g t h e (a da pt ive) m em or y a n d com pa r in g t h a t t o t h e lim it ,
O2S fa u lt , ver ify t h a t t h e h ea t er cir cu it is oper a t in g it ca n be det er m in ed wh et h er it will pa ss a n em is-
cor r ect ly. sion s t est . If a m a lfu n ct ion occu r s su ch t h a t t h e P CM
E ffect ive con t r ol of exh a u st em ission s is a ch ieved ca n n ot m a in t a in t h e opt im u m A/F r a t io, t h en t h e
by a n oxygen feedba ck syst em . Th e m ost im por t a n t MIL will be illu m in a t ed.
elem en t of t h e feedba ck syst em is t h e O2S. Th e O2S
is loca t ed in t h e exh a u st pa t h . On ce it r ea ch es oper- M I L 6 4 —CATALY ST M ON I T OR
a t in g t em per a t u r e 300° t o 350°C (572 ° t o 662°F ), t h e To com ply wit h clea n a ir r egu la t ion s, veh icles a r e
sen sor gen er a t es a volt a ge t h a t is in ver sely pr opor- equ ipped wit h ca t a lyt ic con ver t er s. Th ese con ver t er s
t ion a l t o t h e a m ou n t of oxygen in t h e exh a u st . Th e r edu ce t h e em ission of h ydr oca r bon s, oxides of n it r o-
in for m a t ion obt a in ed by t h e sen sor is u sed t o ca lcu - gen a n d ca r bon m on oxide.
la t e t h e fu el in ject or pu lse widt h . Th is m a in t a in s a Nor m a l veh icle m iles or en gin e m isfir e ca n ca u se a
14.7 t o 1 Air F u el (A/F ) r a t io. At t h is m ixt u r e r a t io, ca t a lyst t o deca y. A m elt down of t h e cer a m ic cor e ca n
t h e ca t a lyst wor ks best t o r em ove h ydr oca r bon s (H C), ca u se a r edu ct ion of t h e exh a u st pa ssa ge. Th is ca n
ca r bon m on oxide (CO) a n d n it r ogen oxide (NOx) fr om in cr ea se veh icle em ission s a n d det er ior a t e en gin e
t h e exh a u st . per for m a n ce, dr ivea bilit y a n d fu el econ om y.
Th e volt a ge r ea din gs t a ken fr om t h e O2S sen sor Th e ca t a lyst m on it or u ses du a l oxygen sen sor s
a r e ver y t em per a t u r e sen sit ive. Th e r ea din gs a r e n ot (O2S’s) t o m on it or t h e efficien cy of t h e con ver t er. Th e
a ccu r a t e below 300°C. H ea t in g of t h e O2S sen sor is du a l O2S’s sen sor st r a t egy is ba sed on t h e fa ct t h a t
don e t o a llow t h e en gin e con t r oller t o sh ift t o closed a s a ca t a lyst det er ior a t es, it s oxygen st or a ge ca pa cit y
loop con t r ol a s soon a s possible. Th e h ea t in g elem en t a n d it s efficien cy a r e bot h r edu ced. By m on it or in g
u sed t o h ea t t h e O2S sen sor m u st be t est ed t o en su r e t h e oxygen st or a ge ca pa cit y of a ca t a lyst , it s effi-
t h a t it is h ea t in g t h e sen sor pr oper ly. cien cy ca n be in dir ect ly ca lcu la t ed. Th e u pst r ea m
Th e O2S sen sor cir cu it is m on it or ed for a dr op in O2S is u sed t o det ect t h e a m ou n t of oxygen in t h e
volt a ge. Th e sen sor ou t pu t is u sed t o t est t h e h ea t er exh a u st ga s befor e t h e ga s en t er s t h e ca t a lyt ic con -
by isola t in g t h e effect of t h e h ea t er elem en t on t h e ver t er. Th e P CM ca lcu la t es t h e A/F m ixt u r e fr om t h e
O2S sen sor ou t pu t volt a ge fr om t h e ot h er effect s. ou t pu t of t h e O2S. A low volt a ge in dica t es h igh oxy-
gen con t en t (lea n m ixt u r e). A h igh volt a ge in dica t es a
M I L 4 3 —M I SFI RE M ON I T OR low con t en t of oxygen (r ich m ixt u r e).
E xcessive en gin e m isfir e r esu lt s in in cr ea sed ca t a - Wh en t h e u pst r ea m O2S det ect s a lea n con dit ion ,
lyst t em per a t u r e a n d ca u ses a n in cr ea se in H C em is- t h er e is a n a bu n da n ce of oxygen in t h e exh a u st ga s.
sion s. Sever e m isfir es cou ld ca u se ca t a lyst da m a ge. A fu n ct ion in g con ver t er wou ld st or e t h is oxygen so it
To pr even t ca t a lyt ic con ver t or da m a ge, t h e P CM ca n u se it for t h e oxida t ion of H C a n d CO. As t h e
m on it or s en gin e m isfir e. con ver t er a bsor bs t h e oxygen , t h er e will be a la ck of
Th e P ower t r a in Con t r ol Modu le (P CM) m on it or s oxygen down st r ea m of t h e con ver t er. Th e ou t pu t of
for m isfir e du r in g m ost en gin e oper a t in g con dit ion s t h e down st r ea m O2S will in dica t e lim it ed a ct ivit y in
(posit ive t or qu e) by lookin g a t ch a n ges in t h e cr a n k- t h is con dit ion .
sh a ft speed. If a m isfir e occu r s t h e speed of t h e As t h e con ver t er loses t h e a bilit y t o st or e oxygen ,
cr a n ksh a ft will va r y m or e t h a n n or m a l. t h e con dit ion ca n be det ect ed fr om t h e beh a vior of
t h e down st r ea m O2S. Wh en t h e efficien cy dr ops, n o
M I L 5 1 /5 2 —FU EL SY ST EM M ON I T OR ch em ica l r ea ct ion t a kes pla ce. Th is m ea n s t h e con -
To com ply wit h clea n a ir r egu la t ion s, veh icles a r e cen t r a t ion of oxygen will be t h e sa m e down st r ea m a s
equ ipped wit h ca t a lyt ic con ver t er s. Th ese con ver t er s u pst r ea m . Th e ou t pu t volt a ge of t h e down st r ea m
r edu ce t h e em ission of h ydr oca r bon s, oxides of n it r o- O2S copies t h e volt a ge of t h e u pst r ea m sen sor. Th e
gen a n d ca r bon m on oxide. Th e ca t a lyst wor ks best on ly differ en ce is a t im e la g (seen by t h e P CM)
wh en t h e Air F u el (A/F ) r a t io is a t or n ea r t h e opt i- bet ween t h e swit ch in g of t h e O2S’s.
m u m of 14.7 t o 1.
XJ EMISSION CONTROL SYSTEMS 25 - 9
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
To m on it or t h e syst em , t h e n u m ber of lea n -t o-r ich COMPONENT MONITORS
swit ch es of u pst r ea m a n d down st r ea m O2S’s is Th er e a r e sever a l com pon en t s t h a t will a ffect veh i-
cou n t ed. Th e r a t io of down st r ea m swit ch es t o cle em ission s if t h ey m a lfu n ct ion . If on e of t h ese com -
u pst r ea m swit ch es is u sed t o det er m in e wh et h er t h e pon en t s m a lfu n ct ion s t h e Ma lfu n ct ion In dica t or
ca t a lyst is oper a t in g pr oper ly. An effect ive ca t a lyst La m p (Ch eck E n gin e) will illu m in a t e.
will h a ve fewer down st r ea m swit ch es t h a n it h a s Som e of t h e com pon en t m on it or s a r e ch eckin g for
u pst r ea m swit ch es i.e., a r a t io closer t o zer o. F or a pr oper oper a t ion of t h e pa r t . E lect r ica lly oper a t ed
t ot a lly in effect ive ca t a lyst , t h is r a t io will be on e-t o- com pon en t s n ow h a ve in pu t (r a t ion a lit y) a n d ou t pu t
on e, in dica t in g t h a t n o oxida t ion occu r s in t h e device. (fu n ct ion a lit y) ch ecks. P r eviou sly, a com pon en t like
Th e syst em m u st be m on it or ed so t h a t wh en ca t a - t h e Th r ot t le P osit ion sen sor (TP S) wa s ch ecked by
lyst efficien cy det er ior a t es a n d exh a u st em ission s t h e P CM for a n open or sh or t ed cir cu it . If on e of
in cr ea se t o over t h e lega l lim it , t h e MIL (ch eck t h ese con dit ion s occu r r ed, a DTC wa s set . Now t h er e
en gin e la m p) will be illu m in a t ed. is a ch eck t o en su r e t h a t t h e com pon en t is wor kin g.
Th is is don e by wa t ch in g for a TP S in dica t ion of a
TRIP DEFINITION gr ea t er or lesser t h r ot t le open in g t h a n MAP a n d
Th e t er m “Tr ip” h a s differ en t m ea n in gs depen din g en gin e r pm in dica t e. In t h e ca se of t h e TP S, if en gin e
on wh a t t h e cir cu m st a n ces a r e. If t h e MIL (Ma lfu n c- va cu u m is h igh a n d en gin e r pm is 1600 or gr ea t er
t ion In dica t or La m p) is OF F, a Tr ip is defin ed a s a n d t h e TP S in dica t es a la r ge t h r ot t le open in g, a
wh en t h e Oxygen Sen sor Mon it or a n d t h e Ca t a lyst DTC will be set . Th e sa m e a pplies t o low va cu u m if
Mon it or h a ve been com plet ed in t h e sa m e dr ive cycle. t h e TP S in dica t es a sm a ll t h r ot t le open in g.
Wh en a n y E m ission DTC is set , t h e MIL on t h e All open /sh or t cir cu it ch ecks or a n y com pon en t t h a t
da sh is t u r n ed ON. Wh en t h e MIL is ON, it t a kes 3 h a s a n a ssocia t ed lim p in will set a fa u lt a ft er 1 t r ip
good t r ips t o t u r n t h e MIL OF F. In t h is ca se, it wit h t h e m a lfu n ct ion pr esen t . Com pon en t s wit h ou t
depen ds on wh a t t ype of DTC is set t o kn ow wh a t a a n a ssocia t ed lim p in will t a ke t wo t r ips t o illu m i-
“Tr ip” is. n a t e t h e MIL.
F or t h e F u el Mon it or or Mis-F ir e Mon it or (con t in - Refer t o t h e Dia gn ost ic Tr ou ble Codes Descr ipt ion
u ou s m on it or ), t h e veh icle m u st be oper a t ed in t h e Ch a r t s in t h is sect ion a n d t h e a ppr opr ia t e P ower-
“Sim ila r Con dit ion Win dow” for a specified a m ou n t of t r a in Dia gn ost ic P r ocedu r e Ma n u a l for dia gn ost ic
t im e t o be con sider ed a Good Tr ip. pr ocedu r es.
If a Non -Con t iu ou s OBDII Mon it or, su ch a s:
• Oxygen Sen sor NON-MONITORED CIRCUITS
• Ca t a lyst Mon it or Th e P CM does n ot m on it or t h e followin g cir cu it s,
• P u r ge F low Mon it or syst em s a n d con dit ion s t h a t cou ld h a ve m a lfu n ct ion s
• Lea k Det ect ion P u m p Mon it or (if equ ipped) ca u sin g dr ivea bilit y pr oblem s. Th e P CM m igh t n ot
• E GR Mon it or (if equ ipped) st or e dia gn ost ic t r ou ble codes for t h ese con dit ion s.
• Oxygen Sen sor H ea t er Mon it or H owever, pr oblem s wit h t h ese syst em s m a y ca u se t h e
fa ils t wice in a r ow a n d t u r n s ON t h e MIL, r e-r u n - P CM t o st or e dia gn ost ic t r ou ble codes for ot h er sys-
n in g t h a t m on it or wh ich pr eviou sly fa iled, on t h e t em s or com pon en t s. F or exa m ple, a fu el pr essu r e
n ext st a r t -u p a n d pa ssin g t h e m on it or is con sider ed pr oblem will n ot r egist er a fa u lt dir ect ly, bu t cou ld
t o be a Good Tr ip. ca u se a r ich /lea n con dit ion or m isfir e. Th is cou ld
If a n y ot h er E m ission DTC is set (n ot a n OBDII ca u se t h e P CM t o st or e a n oxygen sen sor or m isfir e
Mon it or ), a Good Tr ip is con sider ed t o be wh en t h e dia gn ost ic t r ou ble code
Oxygen Sen sor Mon it or a n d Ca t a lyst Mon it or h a ve
been com plet ed; or 2 Min u t es of en gin e r u n t im e if FU EL PRESSU RE
t h e Oxygen Sen sor Mon it or or Ca t a lyst Mon it or h a ve Th e fu el pr essu r e r egu la t or con t r ols fu el syst em
been st opped fr om r u n n in g. pr essu r e. Th e P CM ca n n ot det ect a clogged fu el
It ca n t a ke u p t o 2 F a ilu r es in a r ow t o t u r n on t h e pu m p in let filt er, clogged in -lin e fu el filt er, or a
MIL. Aft er t h e MIL is ON, it t a kes 3 Good Tr ips t o pin ch ed fu el su pply or r et u r n lin e. H owever, t h ese
t u r n t h e MIL OF F. Aft er t h e MIL is OF F, t h e P CM cou ld r esu lt in a r ich or lea n con dit ion ca u sin g t h e
will self-er a se t h e DTC a ft er 40 Wa r m -u p cycles. A P CM t o st or e a n oxygen sen sor or fu el syst em dia g-
Wa r m -u p cycle is cou n t ed wh en t h e E CT (E n gin e n ost ic t r ou ble code.
Coola n t Tem per a t u r e Sen sor ) h a s cr ossed 160°F a n d
h a s r isen by a t lea st 40°F sin ce t h e en gin e h a s been SECON DARY I GN I T I ON CI RCU I T
st a r t ed. Th e P CM ca n n ot det ect a n in oper a t ive ign it ion coil,
fou led or wor n spa r k plu gs, ign it ion cr oss fir in g, or
open spa r k plu g ca bles.
25 - 10 EMISSION CONTROL SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
CY LI N DER COM PRESSI ON syst em devices. H owever, t h ese cou ld ca u se t h e P CM
Th e P CM ca n n ot det ect u n even , low, or h igh en gin e t o st or e a MAP sen sor dia gn ost ic t r ou ble code a n d
cylin der com pr ession . ca u se a h igh idle con dit ion .

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

XJ EMISSION CONTROL SYSTEMS 25 - 11

EVAPORAT I V E EM I SSI ON CON T ROLS

INDEX
page page

DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING


CRANKCASE VENTILATION SYSTEM . . . . . . . 12 VACUUM SCHEMATICS . . . . . . . . . . . . . . . . . . 13
DUTY CYCLE EVAP CANISTER PURGE REMOVAL AND INSTALLATION
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DUTY CYCLE EVAP CANISTER PURGE
EVAP CANISTER . . . . . . . . . . . . . . . . . . . . . . . 11 SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EVAPORATION (EVAP) CONTROL SYSTEM . . 11 EVAP CANISTER . . . . . . . . . . . . . . . . . . . . . . . 13
ROLLOVER VALVE . . . . . . . . . . . . . . . . . . . . . . 11 ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . 14
VEHICLE EMISSION CONTROL INFORMATION SPECIFICATIONS
(VECI) LABEL . . . . . . . . . . . . . . . . . . . . . . . . 13 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 14

DESCRI PT I ON AN D OPERAT I ON ROLLOVER l


FUEL VALVE ::j_
EVAPORATION (EVAP) CONTROL SYSTEM SUPPLY
TUBE
Th e fu n ct ion of t h e E VAP con t r ol syst em is t o pr e-
ven t t h e em ission s of ga solin e va por s fr om t h e fu el RETAINER
CLAMP
t a n k in t o t h e a t m osph er e. Wh en fu el eva por a t es in
t h e fu el t a n k, t h e va por s pa ss t h r ou gh ven t h oses or
t u bes t o a ca r bon filled E VAP ca n ist er. Th ey a r e t em -
por a r ily h eld in t h e ca n ist er u n t il t h ey ca n be dr a wn
in t o t h e in t a ke m a n ifold wh en t h e en gin e is r u n n in g.
All en gin es u se a du t y cycle pu r ge syst em . Th e
P CM con t r ols va por flow by oper a t in g t h e du t y cycle
E VAP pu r ge solen oid. Refer t o Du t y Cycle E VAP
Ca n ist er P u r ge Solen oid for a ddit ion a l in for m a t ion .
Th e E VAP ca n ist er is a fea t u r e on a ll m odels for
I
t h e st or a ge of fu el va por s fr om t h e fu el t a n k.
FUEL FIL TERI
FUEL PRESSURE
NOTE: The hoses used in this system are specially REGULATOR 80aac284
manufactured. If replacement becomes necessary, it
is important to use only fuel resistant hose. Fig. 1 Rollover Valve Location
On RH D m odels, t h e ca n ist er is loca t ed in t h e left
ROLLOVER VALVE side of t h e en gin e com pa r t m en t n ea r t h e h ea t er
blower m ot or (F ig. 3). Th e E VAP ca n ist er is filled
Th e fu el t a n k is equ ipped wit h a r ollover va lve.
wit h gr a n u les of a n a ct iva t ed ca r bon m ixt u r e. F u el
Th e va lve is loca t ed on t h e t op of t h e fu el t a n k (F ig.
va por s en t er in g t h e E VAP ca n ist er a r e a bsor bed by
1). Th e va lve will pr even t fu el flow t h r ou gh t h e fu el
t h e ch a r coa l gr a n u les.
t a n k ven t (E VAP ) h oses in t h e even t of a n a cciden t a l
F u el t a n k pr essu r e ven t s in t o t h e E VAP ca n ist er.
veh icle r ollover. Th e E VAP ca n ist er dr a ws fu el va por s
F u el va por s a r e t em por a r ily h eld in t h e ca n ist er u n t il
fr om t h e fu el t a n k t h r ou gh t h is va lve.
t h ey ca n be dr a wn in t o t h e in t a ke m a n ifold. Th e du t y
Th e va lve ca n n ot be ser viced sepa r a t ely. If r epla ce-
cycle E VAP ca n ist er pu r ge solen oid a llows t h e E VAP
m en t is n ecessa r y, t h e fu el t a n k m u st be r epla ced.
ca n ist er t o be pu r ged a t pr edet er m in ed t im es a n d a t
Refer t o F u el Ta n k Rem ova l/In st a lla t ion in Gr ou p 14,
cer t a in en gin e oper a t in g con dit ion s.
F u el Syst em .

EVAP CANISTER DUTY CYCLE EVAP CANISTER PURGE SOLENOID


Th e Du t y Cycle E VAP Ca n ist er P u r ge Solen oid r eg-
A m a in t en a n ce fr ee, E VAP ca n ist er is u sed on a ll
u la t es t h e r a t e of va por flow fr om t h e E VAP ca n ist er
veh icles. On con ven t ion a l left h a n d dr ive (LH D) m od-
t o t h e in t a ke m a n ifold. Th e P ower t r a in Con t r ol Mod-
els, t h e E VAP ca n ist er is loca t ed in t h e en gin e com -
u le (P CM) oper a t es t h e solen oid.
pa r t m en t on t h e pa ssen ger side fr a m e r a il (F ig. 2).
MOUNTING
STRAP
FWD MOUNTING
STRAP
MOUNTING STRAP
EVAP
BOLTEVAP
MOUNTING
STRAP
CANISTER
FWDCANISTER
BOLT MOUNTING
PURGE
FIXED
AIR BOLT
ORIFICE
FITTING
SOLE-
NOID
AIR
COVER
FILTER
INLET
ELECTRICAL
CONNECTOR
TING
FIT- VACUUM
HARNESS

25 - 12 EMISSION CONTROL SYSTEMS XJ


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
it . Th e solen oid will n ot oper a t e pr oper ly u n less it is
in st a lled cor r ect ly.

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.

Fig. 3 EVAP Canister Location—RHD Models


Du r in g t h e cold st a r t wa r m -u p per iod a n d t h e h ot
st a r t t im e dela y, t h e P CM does n ot en er gize t h e sole-
n oid. Wh en de-en er gized, n o va por s a r e pu r ged. Th e
P CM de-en er gizes t h e solen oid du r in g open loop oper-
a t ion . FIXED
Th e en gin e en t er s closed loop oper a t ion a ft er it ORIFICE
r ea ch es a specified t em per a t u r e a n d t h e t im e dela y FITTING
en ds. Du r in g closed loop oper a t ion , t h e P CM cycles
(en er gizes a n d de-en er gizes) t h e solen oid 5 or 10
t im es per secon d, depen din g u pon oper a t in g con di-
t ion s. Th e P CM va r ies t h e va por flow r a t e by ch a n g- AIR FILTER
in g solen oid pu lse widt h . P u lse widt h is t h e a m ou n t COVER
of t im e t h a t t h e solen oid is en er gized. Th e P CM
8056d9f4
a dju st s solen oid pu lse widt h ba sed on en gin e oper a t -
in g con dit ion .
Fig. 5 CCV System—2.5L Engine—Typical
On veh icles equ ipped wit h Left H a n d Dr ive (LH 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 On 4.0L 6 cylin der en gin es, a m olded va cu u m t u be
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 con n ect s m a n ifold va cu u m t o t op of cylin der h ea d
ca n ist er (F ig. 4). On veh icles equ ipped wit h Righ t (va lve) cover a t da sh pa n el en d. Th e va cu u m fit t in g
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 con t a in s a fixed or ifice of a ca libr a t ed size. It m et er s
loca t ed in t h e left -r ea r side of en gin e com pa r t m en t . t h e a m ou n t of cr a n kca se va por s dr a wn ou t of t h e
Th e t op of t h e solen oid h a s t h e wor d UP or TOP on en gin e.
AIR INLET TING
FIT- FWD
FIXED ORIFICE
FITTING
AIR COVER
FILTER FWD VECI LABEL
MOUNTING
STRAP EVAPSTRAP
MOUNTING
CANISTER
BOLT

XJ EMISSION CONTROL SYSTEMS 25 - 13


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

YECI
LABEL

J9325-27

Fig. 7 VECI Label Location—Typical


DI AGN OSI S AN D T EST I N G
VACUUM SCHEMATICS
A va cu u m sch em a t ic for em ission r ela t ed it em s ca n
be fou n d on t h e Veh icle E m ission Con t r ol In for m a -
Fig. 6 CCV System—4.0L Engine—Typical t ion (VE CI) La bel. Refer t o VE CI La bel in t h is gr ou p
On 2.5L 4 cylin der en gin es, a fit t in g on dr iver s for la bel loca t ion .
side of cylin der h ea d (va lve) cover con t a in s t h e
m et er ed or ifice. It is con n ect ed t o m a n ifold va cu u m .
A fr esh a ir su pply h ose fr om t h e a ir clea n er is con - REM OVAL AN D I N STALLAT I ON
n ect ed t o fr on t of cylin der h ea d cover on 4.0L
en gin es. It is con n ect ed t o r ea r of cover on 2.5L EVAP CANISTER
en gin es. On veh icle equ ipped wit h Left H a n d Dr ive (LH D),
Wh en t h e en gin e is oper a t in g, fr esh a ir en t er s t h e t h e E VAP ca n ist er is loca t ed in en gin e com pa r t m en t
en gin e a n d m ixes wit h cr a n kca se va por s. Ma n ifold on r igh t side fr a m e r a il (F ig. 8). On veh icles equ ipped
va cu u m dr a ws t h e va por /a ir m ixt u r e t h r ou gh t h e wit h Righ t H a n d Dr ive (RH D), t h e ca n ist er is loca t ed
fixed or ifice a n d in t o t h e in t a ke m a n ifold. Th e va por s on left side of en gin e com pa r t m en t n ea r h ea t er
a r e t h en con su m ed du r in g com bu st ion . blower m ot or (F ig. 9).

VEHICLE EMISSION CONTROL INFORMATION


(VECI) LABEL
All veh icles a r e equ ipped wit h a com bin ed VE CI
la bel. Th is la bel is loca t ed in t h e en gin e com pa r t -
m en t (F ig. 7) a n d con t a in s t h e followin g:
• E n gin e fa m ily a n d displa cem en t
• E va por a t ive fa m ily
• E m ission con t r ol syst em sch em a t ic
• Cer t ifica t ion a pplica t ion
• E n gin e t im in g specifica t ion s (if a dju st a ble)
• Idle speeds (if a dju st a ble)
• Spa r k plu g a n d ga p
Th e la bel a lso con t a in s a n en gin e va cu u m sch e-
m a t ic. Th er e a r e u n iqu e la bels for veh icles bu ilt for
sa le in t h e st a t e of Ca lifor n ia a n d t h e cou n t r y of
Ca n a da . Ca n a dia n la bels a r e wr it t en in bot h t h e Fig. 8 EVAP Canister Location—LHD Models
E n glish a n d F r en ch la n gu a ges. Th ese la bels a r e per- REM OVAL
m a n en t ly a t t a ch ed a n d ca n n ot be r em oved wit h ou t (1) Discon n ect va cu u m lin es a t E VAP ca n ist er.
defa cin g in for m a t ion a n d dest r oyin g la bel. Not e loca t ion of lin es befor e r em ova l.
MOUNTING
STRAP MOUNTING STRAP
BOLT
EVAP
FWDCANISTER

25 - 14 EMISSION CONTROL SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

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

DIFFERENTIAL AND DRIVELINE


CON T EN T S

page page

194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 47 PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . 1


8 1/4 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . 83 TUBE AND 181 FBI AXLE . . . . . . . . . . . . . . . . 15

PROPELLER SH AFT S

INDEX
page page

GENERAL INFORMATION REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . 6


LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DISASSEMBLY AND ASSEMBLY
PROPELLER SHAFT JOINT ANGLE . . . . . . . . . . 2 DOUBLE CARDAN JOINT . . . . . . . . . . . . . . . . . 9
PROPELLER SHAFT JOINTS . . . . . . . . . . . . . . . 2 SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . 7
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . 1 CLEANING AND INSPECTION
DIAGNOSIS AND TESTING PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . 12
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 ADJUSTMENTS
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 ADJUSTMENT AT AXLE WITH
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE PROCEDURES FRONT AXLE ANGLE ADJUSTMENT . . . . . . . . 13
DRIVELINE ANGLE MEASUREMENT SPECIFICATIONS
PREPARATION . . . . . . . . . . . . . . . . . . . . . . .. 5 PROPELLER SHAFTS AND U–JOINTS . . . . . . 14
PROPELLER SHAFT ANGLE MEASUREMENT .. 5 SPECIAL TOOLS
REMOVAL AND INSTALLATION PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . 14
FRONT PROPELLER SHAFT . . . . . . . . . . . . . .. 6

GEN ERAL I N FORM AT I ON Tu bu la r pr opeller sh a ft s a r e ba la n ced by t h e m a n -


u fa ct u r er wit h weigh t s spot welded t o t h e t u be.
PROPELLER SHAFTS Th e pr opeller sh a ft is design ed a n d bu ilt wit h t h e
Th e pr opeller sh a ft (F ig. 1) t r a n sm it s power fr om yoke lu gs in lin e wit h ea ch ot h er. Th is is ca lled ph a s-
on e poin t t o a n ot h er in a sm oot h a n d con t in u ou s in g. Th is design pr odu ces t h e sm oot h est r u n n in g con -
a ct ion . Th e sh a ft is design ed t o sen d t or qu e t h r ou gh dit ion . An ou t of ph a se sh a ft ca n ca u se a vibr a t ion .
a n a n gle fr om t h e t r a n sm ission (t r a n sfer ca se on B e fo re u n d e rc o a tin g a v e h ic le , th e p ro p e lle r
4WD veh icles) t o t h e a xle. s h a ft a n d th e U -jo in ts s h o u ld be c o v e re d . Th is
Th e pr opeller sh a ft m u st oper a t e t h r ou gh con - w ill p re v e n t th e u n d e rc o a tin g fro m c a u s in g a n
st a n t ly ch a n gin g r ela t ive a n gles bet ween t h e t r a n s- u n ba la n c e d c o n d itio n .
m ission a n d a xle. It m u st a lso be ca pa ble of ch a n gin g
len gt h wh ile t r a n sm it t in g t or qu e. Th e a xle r ides su s- CAUTION: Use exact replacement parts for attach-
pen ded by spr in gs in a floa t in g m ot ion . Th is m ea n s ing the propeller shafts. This will ensure safe oper-
t h e pr opeller sh a ft m u st be a ble t o con t r a ct , expa n d ation. The specified torque must always be applied
a n d ch a n ge oper a t in g a n gles wh en goin g over va r iou s when tightening the fasteners.
r oa d su r fa ces. Th is is a ccom plish ed t h r ou gh u n iver-
sa l join t s, wh ich per m it t h e pr opeller sh a ft t o oper a t e
LUBRICATION
a t differ en t a n gles. Th e slip join t s (or yokes) per m it
Th e slip yoke on t h e fr on t pr opeller sh a ft is
con t r a ct ion or expa n sion .
equ ipped wit h a lu br ica t ion fit t in g. Use a m u lt i-pu r -
REAR AXLE REAR PROPELLER
STRAPSHAFT
BOOT STRAP TRANSFER CASE
FRONT LER
PROPEL-
SHAFT
FRONT
AXLE

3-2 DIFFERENTIAL AND DRIVELINE XJ


GEN ERAL I N FORM AT I ON (Cont inue d)

REAR
AXLE

TRANSFER
CASE

FRONT
PROPELLER
SHAFT

FRONT
AXLE

STRAP
80a53ac2

Fig. 1 Front & Rear Propeller Shafts—4WD


pose NLGI Gr a de 2 E P lu br ica n t . Th e fa ct or y • An gles t h a t a r e equ a l or opposit e wit h in 1
in st a lled u n iver sa l join t s a r e lu br ica t ed for t h e life of degr ee of ea ch ot h er.
t h e veh icle a n d do n ot n eed lu br ica t ion . All u n iver sa l • H a ve a 3 degr ee m a xim u m oper a t in g a n gle.
join t s sh ou ld be in spect ed for lea ka ge a n d da m a ge • H a ve a t lea st a 1/2 degr ee con t in u ou s oper a t in g
ea ch t im e t h e veh icle is ser viced. If sea l lea ka ge or (pr opeller sh a ft ) a n gle.
da m a ge exist s, t h e u n iver sa l join t sh ou ld be r epla ced. E n gin e speed (r pm ) is t h e m a in fa ct or in det er m in -
Refer t o Gr ou p 0, Lu br ica t ion a n d Ma in t en a n ce, for in g t h e m a xim u m a llowa ble oper a t in g a n gle. As a
a ddit ion a l in for m a t ion . gu ide t o t h e m a xim u m n or m a l oper a t in g a n gles r efer
t o (F ig. 2).
PROPELLER SHAFT JOINT ANGLE
Wh en t wo sh a ft s com e t oget h er a t a com m on join t , PROPELLER SHAFT MAX. NORMAL
t h e ben d t h a t is for m ed is ca lled t h e oper a t in g a n gle. R.P.M. OPERATING ANGLES
Th e la r ger t h e a n gle, t h e la r ger t h e a m ou n t of a ccel- 5000 3°
er a t ion a n d deceler a t ion of t h e join t . Th is speedin g 4500 3°
u p a n d slowin g down of t h e join t m u st be ca n celled 4000 4°
t o pr odu ce a sm oot h power flow. Th is is don e t h r ou gh 3500 5°
t h e ph a sin g of a pr opeller sh a ft a n d en su r in g t h a t 3000 5°
t h e pr oper pr opeller sh a ft join t wor kin g a n gles a r e 2500 7°
m a in t a in ed. 2000 8°
A pr opeller sh a ft is pr oper ly ph a sed wh en t h e yoke 1500 11°
en ds a r e in t h e sa m e pla n e, or in lin e. A t wist ed
sh a ft will m a ke t h e yokes ou t of ph a se a n d ca u se a
Fig. 2 Maximum Angles And Engine Speed
n ot icea ble vibr a t ion .
Wh en t a kin g pr opeller sh a ft join t a n gle m ea su r e- PROPELLER SHAFT JOINTS
m en t s, or ch eckin g t h e ph a sin g, of t wo piece sh a ft s, Two differ en t t ypes of pr opeller sh a ft join t s a r e
con sider ea ch sh a ft sepa r a t ely. u sed:
Idea lly t h e dr ivelin e syst em sh ou ld h a ve; • Sin gle ca r da n u n iver sa l join t (F ig. 3).
NEEDLE
RETAINING
1.BEARING
2.
3.
4.
5. LINK
SOCKET
SCOKET
THRUST
NEEDLE
BEARING
SPIDER
YOKE
YOKE
SEAL
CLIP
CAP
BEARINGS
WASHER
BEARING
SPRING
BALL RETAINER 6.
8.
9.
10.
7. SOCKET
SEAL
REAR
BEARING
SPIDER
YOKE
BALL
CAP 11. FRONT
12.
13.
14.
15. NEEDLE
THRUST
DRIVE
RETAINING
SHAFT
SPIDER
WASHER
CLIP
YOKE

XJ DIFFERENTIAL AND DRIVELINE 3-3


GEN ERAL I N FORM AT I ON (Cont inue d)
• Dou ble ca r da n (CV) u n iver sa l join t (F ig. 4). DI AGN OSI S AN D T EST I N G
Non e of t h e u n iver sa l join t s a r e ser vicible. If on e
becom es wor n or da m a ged, t h e com plet e u n iver sa l VIBRATION
join t a ssem bly m u st be r epla ced. Tir es t h a t a r e ou t -of-r ou n d, or wh eels t h a t a r e
BEARING u n ba la n ced, will ca u se a low fr equ en cy vibr a t ion .
CAP Refer t o Gr ou p 22, Tir es a n d Wh eels, for a ddit ion a l
SEAL
in for m a t ion .
Br a ke dr u m s t h a t a r e u n ba la n ced will ca u se a
h a r sh , low fr equ en cy vibr a t ion . Refer t o Gr ou p 5,
Br a kes, for a ddit ion a l in for m a t ion .
SPIDER Dr ivelin e vibr a t ion ca n a lso r esu lt fr om loose or
da m a ged en gin e m ou n t s. Refer t o Gr ou p 9, E n gin es,
for a ddit ion a l in for m a t ion .
P r opeller sh a ft vibr a t ion in cr ea ses a s t h e veh icle
speed is in cr ea sed. A vibr a t ion t h a t occu r s wit h in a
specific speed r a n ge is n ot u su a lly ca u sed by a pr o-
peller sh a ft bein g u n ba la n ced. Defect ive u n iver sa l
join t s, or a n in cor r ect pr opeller sh a ft a n gle, a r e u su -
a lly t h e ca u se of su ch a vibr a t ion .

UNBALANCE

~
YOKE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
RETAINING vibrations.
CLIP J9216-4

Fig. 3 Single Cardan Universal Joint

l. LINK YOKE 6. SEAL 11. FRONT SPIDER


2. SOCKET SPRING 7. BEARING CAP 12. NEEDLE BEARINGS
3. SOCKET BALL RETAINER 8. REAR SPIDER 13. THRUST WASHER
4. THRUST WASHER 9. SOCKET YOKE 14. DRIVE SHAFT YOKE
5. NEEDLE BEARINGS 10. SOCKET BALL 15. RETAINING CLIP
J9216-21

Fig. 4 Double Cardan (CV) Universal Joint


CLAMP SCREWDRIVER

3-4 DIFFERENTIAL AND DRIVELINE XJ


DI AGN OSI S AN D T EST I N G (Cont inue d)
DRI V ELI N E V I BRAT I ON

Drive Condition Possible Cause Correction


PROPELLER SHAFT a. Undercoating or other foreign a. Clean exterior of shaft and wash
material on shaft. with solvent.
b. Loose U-joint clamp screws. b. Tighten screws properly.
c. Loose or bent U-joint yoke or c. Install replacement yoke.
excessive runout.
d. Incorrect drive line angularity. d. Correct angularity.
e. Rear spring center bolt not in e. Loosen spring U-bolts and seat
seat. center bolts.
f. Worn U-joint bearings. f. Replace U-joint.
g. Propeller shaft damaged (bent g. Install replacement propeller
tube) or out of balance. shaft.
h. Broken rear spring. h. Replace rear spring.
i. Excessive runout or unbalanced i. Reindex propeller shaft 180°, test
condition. and correct as necessary.
j. Excessive drive pinion gear shaft j. Reindex propeller shaft 180° and
yoke runout. evaluate.
UNIVERSAL JOINT NOISE a. U-joint clamp screws loose. a. Tighten screws with specified
torque.
b. Lack of lubrication. Replace U-joint.

If pr opeller sh a ft is su spect ed of bein g u n ba la n ced,


it ca n be ver ified wit h t h e followin g pr ocedu r e:
(1) Ra ise t h e veh icle.
(2) Clea n a ll t h e for eign m a t er ia l fr om t h e pr opel-
ler sh a ft a n d t h e u n iver sa l join t s.
(3) In spect t h e pr opeller sh a ft for m issin g ba la n ce
weigh t s, br oken welds, a n d ben t a r ea s. If th e p ro -
p e lle r s h a ft is be n t, it m u s t be re p la c e d .
(4) In spect t h e u n iver sa l join t s t o en su r e t h a t t h ey
a r e n ot wor n , a r e pr oper ly in st a lled, a n d a r e cor-
r ect ly a lign ed wit h t h e sh a ft .
(5) Ch eck t h e u n iver sa l join t cla m p scr ews t or qu e. SCREWDRIVER
(6) Rem ove t h e wh eels a n d t ir es. In st a ll t h e wh eel
lu g n u t s t o r et a in t h e br a ke dr u m s or r ot or s.
(7) Ma r k a n d n u m ber t h e sh a ft six in ch es fr om t h e
\ RF487
yoke en d a t fou r posit ion s 90° a pa r t .
(8) Ru n a n d a cceler a t e t h e veh icle u n t il vibr a t ion Fig. 5 Clamp Screw At Position 1
occu r s. Not e t h e in t en sit y a n d speed t h e vibr a t ion (14) In cr ea se dist a n ce bet ween t h e cla m p scr ews
occu r r ed. St op t h e en gin e. a n d r epea t t h e t est u n t il t h e a m ou n t of vibr a t ion is
(9) In st a ll a scr ew cla m p a t posit ion 1 (F ig. 5). a t t h e lowest level. Ben d t h e sla ck en d of t h e cla m ps
(10) St a r t t h e en gin e a n d r e-ch eck for vibr a t ion . If so t h e scr ews will n ot loosen .
t h er e is lit t le or n o ch a n ge in vibr a t ion , m ove t h e (15) If t h e vibr a t ion r em a in s u n a ccept a ble, a pply
cla m p t o on e of t h e ot h er t h r ee posit ion s. Repea t t h e t h e sa m e st eps t o t h e fr on t en d of t h e pr opeller sh a ft .
vibr a t ion t est . (16) In st a ll t h e wh eel a n d t ir es. Lower t h e veh icle.
(11) If t h er e is n o differ en ce in vibr a t ion a t t h e
ot h er posit ion s, t h e sou r ce of t h e vibr a t ion m a y n ot RUNOUT
be pr opeller sh a ft . (1) Rem ove dir t , r u st , pa in t , a n d u n der coa t in g
(12) If t h e vibr a t ion decr ea sed, in st a ll a secon d fr om t h e pr opeller sh a ft su r fa ce wh er e t h e dia l in di-
cla m p (F ig. 6) a n d r epea t t h e t est . ca t or will con t a ct t h e sh a ft .
(13) If t h e a ddit ion a l cla m p ca u ses a n a ddit ion a l (2) Th e dia l in dica t or m u st be in st a lled per pen dic-
vibr a t ion , sepa r a t e t h e cla m ps (1/4 in ch a bove a n d u la r t o t h e sh a ft su r fa ce.
below t h e m a r k). Repea t t h e vibr a t ion t est (F ig. 7).
⁄ INCH
12 SLIP YOKE BEARING CAP SPECIAL TOOL(J-23498A)
7663

XJ DIFFERENTIAL AND DRIVELINE 3-5


DI AGN OSI S AN D T EST I N G (Cont inue d)
SERV I CE PROCEDU RES
DRIVELINE ANGLE MEASUREMENT PREPARATION
Befor e m ea su r in g u n iver sa l join t a n gles, t h e fol-
lowin g m u st be don e;
• In fla t e a ll t ir es t o cor r ect pr essu r e.
• Ch eck t h e a n gles in t h e sa m e loa ded or
u n loa ded con dit ion a s wh en t h e vibr a t ion occu r r ed.
P r opeller sh a ft a n gles ch a n ge a ccor din g t o t h e
a m ou n t of loa d in t h e veh icle.
• Ch eck t h e con dit ion of a ll su spen sion com po-
n en t s a n d ver ify a ll fa st en er s a r e t or qu ed t o specifi-
ca t ion s.
• Ch eck t h e con dit ion of t h e en gin e a n d t r a n sm is-
sion m ou n t s a n d ver ify a ll fa st en er s a r e t or qu ed t o
specifica t ion s.
Fig. 6 Two Clamp Screws At The Same Position
PROPELLER SHAFT ANGLE MEASUREMENT
To a ccu r a t ely ch eck dr ivelin e a lign m en t , r a ise a n d
su ppor t t h e veh icle a t t h e a xles a s level a s possible.
Allow t h e wh eels a n d pr opeller sh a ft t o t u r n . Rem ove
a n y ext er n a l bea r in g sn a p r in gs (if equ ipped) fr om
u n iver sa l join t so t h a t t h e in clin om et er ba se sit s fla t .
(1) Rot a t e t h e sh a ft u n t il t r a n sm ission /t r a n sfer
ca se ou t pu t yoke bea r in g ca p is fa cin g down wa r d.
Alw a y s m a k e m e a s u re m e n ts fro m fro n t to
re a r.
(2) P la ce In clin om et er on yoke bea r in g ca p (A) pa r-
a llel t o t h e sh a ft (F ig. 8). Cen t er bu bble in sigh t gla ss
a n d r ecor d m ea su r em en t .
Th is m e a s u re m e n t w ill g iv e y o u th e tra n s m is -
s io n o r Ou tp u t Yo k e An g le (A).

Fig. 7 Clamp Screws Separated


(3) Mea su r e r u n ou t a t t h e cen t er a n d en ds of t h e
sh a ft su fficien t ly fa r a wa y fr om weld a r ea s t o en su r e
t h a t t h e effect s of t h e weld pr ocess will n ot en t er in t o
t h e m ea su r em en t s.
(4) Refer t o Ru n ou t Specifica t ion s ch a r t .
(5) Repla ce t h e pr opeller sh a ft if t h e r u n ou t
exceeds t h e lim it .
RU N OU T SPECI FI CAT I ON S

Front of shaft 0.010 in. (0.25 mm)


Center of shaft 0.015 in. (0.38 mm)
Rear of shaft 0.010 in. (0.25 mm)
NOTE: Measure front/rear runout approximately 3
inches (76 mm) from the weld seam at each end of
the shaft tube for tube lengths over 30 inches. Under
30 inches the max. runout is 0.20 inch for full length
of the tube.
J9216-13

Fig. 8 Front (Output) Angle Measurement (A)


(3) Rot a t e pr opeller sh a ft 90 degr ees a n d pla ce
In clin om et er on yoke bea r in g ca p pa r a llel t o t h e
SPECIAL TOOL(J-23498A)
7663 PINION
SHAFTSPECIAL
YOKE
YOKE BEARING
BEARING
TOOL
(J23498–A)
CAP
CAP7663

3-6 DIFFERENTIAL AND DRIVELINE XJ


SERV I CE PROCEDU RES (Cont inue d)
sh a ft (F ig. 9). Cen t er bu bble in sigh t gla ss a n d r ecor d (6) Su bt r a ct sm a ller figu r e fr om la r ger (C m in u s
m ea su r em en t . Th is m ea su r em en t ca n a lso be t a ken B) t o obt a in a xle In pu t Oper a t in g An gle.
a t t h e r ea r en d of t h e sh a ft . Refer t o r u les given below a n d t h e exa m ple in for
Th is m e a s u re m e n t w ill g iv e y o u th e p ro p e lle r a ddit ion a l in for m a t ion .
s h a ft a n g le (C). • Good ca n cella t ion of U–join t oper a t in g a n gles
(wit h in 1°).
• Oper a t in g a n gles less t h a n 3°.
• At lea st 1/2 of on e degr ee con t in u ou s oper a t in g
(pr opeller sh a ft ) a n gle.

REM OVAL AN D I N STALLAT I ON


FRONT PROPELLER SHAFT
SHAFT YOKE REM OVAL
BEARING CAP
(1) H oist a n d su ppor t veh icle on sa fet y st a n ds.
(2) Scr ibe a lign m en t m a r ks on t h e yokes a t t h e
t r a n sfer ca se. P la ce m a r ks a t t h e pin ion sh a ft a n d a t
SPECIAL TOOL ea ch en d of t h e pr opeller sh a ft . Th ese m a r ks will be
i.----- 7663 u sed for in st a lla t ion r efer en ce (F ig. 12).
(J23498-A) (3) Rem ove t h e u n iver sa l join t st r a p bolt s a t t h e
pin ion sh a ft yoke.
0 (4) Discon n ect t h e pr opeller sh a ft a t t h e t r a n sfer
J9216-9
ca se a n d r em ove t h e pr opeller sh a ft .
Fig. 9 Propeller Shaft Angle Measurement (C)
I N STALLAT I ON
(4) Su bt r a ct sm a ller figu r e fr om la r ger (C m in u s (1) P osit ion t h e pr opeller sh a ft wit h t h e yoke r ef-
A) t o obt a in t r a n sm ission ou t pu t oper a t in g a n gle. er en ce m a r ks a lign ed (F ig. 13). In st a ll t h e pr opeller
(5) Rot a t e pr opeller sh a ft 90 degr ees a n d pla ce sh a ft .
In clin om et er on pin ion yoke bea r in g ca p pa r a llel t o Re p la c e m e n t u n iv e rs a l jo in t s tra p s a n d bo lts
t h e sh a ft (F ig. 10). Cen t er bu bble in sigh t gla ss a n d m u s t be in s ta lle d .
r ecor d m ea su r em en t . (2) Tigh t en t h e u n iver sa l join t st r a p/cla m p bolt s a t
Th is m e a s u re m e n t w ill g iv e y o u th e p in io n t h e a xle yoke t o 19 N·m (14 ft . lbs.) t or qu e.
s h a ft o r in p u t y o k e a n g le (B ). (3) Tigh t en t h e fla n ge t o t r a n sfer ca se bolt s t o 27
N·m (20 ft . lbs.) t or qu e.
(4) Lower t h e veh icle.

REAR PROPELLER SHAFT


REM OVAL
(1) Sh ift t h e t r a n sm ission a n d t r a n sfer ca se in t o
Neu t r a l.
(2) H oist a n d su ppor t veh icle on sa fet y st a n ds.
(3) Scr ibe a lign m en t m a r ks a t t h e pin ion sh a ft a n d
a t ea ch en d of t h e pr opeller sh a ft . Th ese m a r ks will
be u sed for in st a lla t ion r efer en ce.
(4) Rem ove t h e u n iver sa l join t st r a p bolt s a t t h e
pin ion sh a ft yoke.
(5) P r y open cla m p h oldin g t h e du st boot t o pr opel-
ler sh a ft yoke (F ig. 14).
SPECIAL/;·.· (6) Slide t h e slip yoke off of t h e t r a n sm ission /
t r a n sfer ca se ou t pu t sh a ft a n d r em ove t h e pr opeller
TOOL sh a ft (F ig. 15).
7663
(J-23498A) J9216-12

Fig. 10 Rear (Input) Angle Measurement (B)


FRONT
YOKEAXLE
Output
CLAMP
Yoke
Transmission
BOOT (C)
(A) PROPELLER
Output
Prop.
Output
3.0° Angle
Shaft
Operating
SHAFT
Yoke(A)
==4.9°
3.0°
Angle−3.0°
CV-JOINT
4.9°
1.9°
or Horizontal
TRANSFER
Level
SLINGER
4.9° CASE
Angle
BOOTAmount
Trans.
(C)
Axle Output
Input
of U-Joint
Operating
Operating
(B)
(C)
or
Axle
Cancellation
REFERENCE
3.2°
Axle
Prop.
Input
Angle
Angle
Angle
Input
Shaft
Operating
−1.7°
1.9°
0.2°
(B)
Yoke
MARKS
= 4.9°
=Angle
3.2°
Input
−3.2°
1.7°
Yoke
4.9°

XJ DIFFERENTIAL AND DRIVELINE 3-7


REM OVAL AN D I N STALLAT I ON (Cont inue d)

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

Trans. Output Operating Angle 1. 9°


Axle Input Operating Angle -1 .7°
Amount of U-J6int Cancellation 0.2°
J9316-3

Fig. 11 Universal Joint Angle Example


FRONT REFERENCE MARKS
AXLE ------,
PROPELLER
BOOT SHAFT

<1 .
YOKE ' ' ""

CLAMP

SLINGER
80a53482 J9316-2

Fig. 12 Front Propeller Shaft Fig. 13 Reference Marks on Yokes


I N STALLAT I ON (4) Lower t h e veh icle.
(1) Slide t h e slip yoke on t h e t r a n sm ission /t r a n sfer
ca se ou t pu t sh a ft . Align t h e in st a lla t ion r efer en ce DI SASSEM BLY AN D ASSEM BLY
m a r ks a t t h e a xle yoke a n d in st a ll t h e pr opeller sh a ft
(F ig. 15). SINGLE CARDAN UNIVERSAL JOINT
Re p la c e m e n t u n iv e rs a l jo in t s tra p s a n d bo lts
m u s t be in s ta lle d . DI SASSEM BLY
(2) Tigh t en t h e u n iver sa l join t st r a p/cla m p bolt s a t In dividu a l com pon en t s of ca r da n u n iver sa l join t s
t h e a xle yoke t o 19 N·m (14 ft . lbs.) t or qu e. a r e n ot ser vicea ble. If wor n or lea kin g, t h ey m u st be
(3) Cr im p cla m p t o h old du st boot t o pr opeller r epla ced a s a n a ssem bly.
sh a ft yoke (F ig. 16). (1) Rem ove t h e pr opeller sh a ft .
SPECIAL
BOOT
OUTPUT
SLINGER
C-4975–A
SHAFT
TOOL TRANSFER
CLAMPSLINGER
CASE
YOKE
BOOT
CLAMP
BOOTPROPELLER
SHAFT
CLAMP
AWL AXLE YOKE SNAP RING SOCKET PRESS

3-8 DIFFERENTIAL AND DRIVELINE XJ


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

SNAP RING

Fig. 14 Dust Boot Clamp

Fig. 17 Remove Snap Ring


(4) Set t h e yoke in a n a r bor pr ess or vise wit h a
socket wh ose in side dia m et er is la r ge en ou gh t o
BOOT
r eceive t h e bea r in g ca p posit ion ed ben ea t h t h e yoke.
(5) P osit ion t h e yoke wit h t h e gr ea se fit t in g, if
equ ipped, poin t in g u p.
(6) P la ce a socket wit h a n ou t side dia m et er
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 pr ess t h e ca p t h r ou gh t h e yoke t o
~, '~- 0 r elea se t h e lower bea r in g ca p (F ig. 18).

~-~------
CLAMP
PRESS

Fig. 15 Rear Propeller Shaft


SPECIAL TOOL
C-4975-A

SLINGER

80a50357 J9316-21'

Fig. 16 Crimping Dust Boot Clamp—Typical Fig. 18 Press Out Bearing


(2) Usin g a soft dr ift , t a p t h e ou t side of t h e bea r- (7) If t h e bea r in g ca p will n ot pu ll ou t of t h e yoke
in g ca p a ssem bly t o loosen sn a p r in g. by h a n d a ft er pr essin g, t a p t h e yoke ea r n ea r t h e
(3) Rem ove sn a p r in gs fr om bot h sides of yoke bea r in g ca p t o dislodge t h e ca p.
(F ig. 17).
BEARING
CROSS
CAP BEARING CAP CROSS TRUNNION YOKE

XJ DIFFERENTIAL AND DRIVELINE 3-9


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(8) To r em ove t h e opposit e bea r in g ca p, t u r n t h e CROSS
yoke over a n d st r a igh t en t h e cr oss in t h e open h ole.
Th en , ca r efu lly pr ess t h e en d of t h e cr oss u n t il t h e
r em a in in g bea r in g ca p ca n be r em oved (F ig. 19).

CAUTION: If the cross or bearing cap are not


straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.

CROSS

J9316-22

Fig. 20 Install Cross In Yoke

80a9539c

Fig. 19 Press Out Remaining Bearing


ASSEM BLY
(1) Apply ext r em e pr essu r e (E P ) N.L.G.I. Gr a de 1
or 2 gr ea se t o in side of yoke bor es t o a id in in st a lla -
t ion .
(2) P osit ion t h e cr oss in t h e yoke wit h it s lu be fit -
t in g, if equ ipped, poin t in g u p (F ig. 20).
(3) P la ce a bea r in g ca p over t h e t r u n n ion a n d
a lign t h e ca p wit h t h e yoke bor e (F ig. 21). Keep t h e
n eedle bea r in gs u pr igh t in t h e bea r in g a ssem bly. A
n eedle bea r in g lyin g a t t h e bot t om of t h e ca p will
pr even t pr oper a ssem bly.
(4) P r ess t h e bea r in g ca p in t o t h e yoke bor e
en ou gh t o in st a ll a sn a p r in g. Fig. 21 Install Bearing On Trunnion
(5) In st a ll a sn a p r in g.
(6) Repea t St ep 3 a n d St ep 4 t o in st a ll t h e oppo- DOUBLE CARDAN JOINT
sit e bea r in g ca p. If t h e join t is st iff or bin din g, st r ike
t h e yoke wit h a soft h a m m er t o sea t t h e n eedle bea r- DI SASSEM BLY
in gs. In dividu a l com pon en t s of ca r da n u n iver sa l join t s
(7) Add gr ea se t o lu be fit t in g, if equ ipped. a r e n ot ser vicea ble. If wor n or lea kin g, t h ey m u st be
(8) In st a ll t h e pr opeller sh a ft . r epla ced a s a n a ssem bly.
(1) Rem ove t h e pr opeller sh a ft .
(2) Usin g a soft dr ift , t a p t h e ou t side of t h e bea r-
in g ca p a ssem bly t o loosen sn a p r in g.
3 - 10 DIFFERENTIAL AND DRIVELINE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(3) Rem ove a ll t h e bea r in g ca p sn a p r in gs (F ig. (6) Gr a sp t h e pr ot r u din g bea r in g by vise ja ws. Ta p
22). t h e lin k yoke wit h a m a llet a n d dr ift t o dislodge t h e
bea r in g ca p fr om t h e yoke (F ig. 24).

J9316-5

Fig. 22 Remove Snap Rings J9316-7

(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

Fig. 25 Remove Centering Kit


(8) P r ess t h e r em a in in g bea r in g ca ps ou t t h e ot h er
en d of t h e lin k yoke a s descr ibed a bove t o com plet e
J9316-6 t h e disa ssem bly.

Fig. 23 Press Out Bearing


XJ DIFFERENTIAL AND DRIVELINE 3 - 11
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
ASSEM BLY (4) P r ess t h e bea r in g ca p in t o t h e yoke bor e
D u rin g a s s e m bly, e n s u re th a t th e a lig n m e n t en ou gh t o in st a ll a sn a p r in g (F ig. 28).
m a rk s o n th e lin k y o k e a n d p ro p e lle r s h a ft (5) In st a ll a sn a p r in g.
y o k e a re a lig n e d .
(1) Apply ext r em e pr essu r e (E P ) N.L.G.I. Gr a de 1
or 2 gr ea se t o in side of yoke bor es t o a id in in st a lla -
t ion .
(2) F it a cr oss in t o t h e pr opeller sh a ft yoke (F ig.
26).

Fig. 28 Press In Bearing Cap


(6) F lip t h e pr opeller sh a ft yoke a n d in st a ll t h e
J9316-9
bea r in g ca p on t o t h e opposit e t r u n n ion . In st a ll a
Fig. 26 Install Cross In Yoke sn a p r in g (F ig. 29).

(3) P la ce a bea r in g ca p over t h e t r u n n ion a n d


a lign t h e ca p wit h t h e yoke bor e (F ig. 27). Keep t h e
n eedle bea r in gs u pr igh t in t h e bea r in g a ssem bly. A
n eedle bea r in g lyin g a t t h e bot t om of t h e ca p will
pr even t pr oper a ssem bly.

J9316-12

Fig. 29 Press In Bearing Cap


(7) F it t h e lin k yoke on t h e r em a in in g t wo t r u n -
n ion s a n d pr ess bot h bea r in g ca ps in t o pla ce (F ig.
30).
Fig. 27 Install Bearing Cap (8) In st a ll sn a p r in gs.
3 - 12 DIFFERENTIAL AND DRIVELINE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

J9316-13 J9316-15

Fig. 30 Install Link Yoke Fig. 32 Install Remaining Cross


(9) In st a ll t h e cen t er in g kit a ssem bly in side t h e
lin k yoke m a kin g su r e t h e spr in g is pr oper ly posi-
t ion ed (F ig. 31).

J9316-16

Fig. 33 Press In Bearing Cap


J9316-14 CLEAN I N G AN D I N SPECT I ON
Fig. 31 Install Centering Kit PROPELLER SHAFT
(10) P la ce t wo bea r in g ca ps on opposit e t r u n n ion s (1) Clea n a ll u n iver sa l join t bor es wit h clea n in g
of t h e r em a in in g cr oss. F it t h e open t r u n n ion s in t o solven t a n d a wir e br u sh .
t h e lin k yoke bor es a n d t h e bea r in g ca ps in t o t h e (2) In spect t h e yokes for dist or t ion , cr a cks, a n d
cen t er in g kit (F ig. 32). wor n bea r in g ca p bor es.
(11) P r ess t h e r em a in in g t wo bea r in g ca ps in t o
pla ce a n d in st a ll sn a p r in gs (F ig. 33). ADJ U ST M EN T S
(12) Ta p t h e sn a p r in gs t o a llow t h em t o sea t in t o
t h e gr ooves (F ig. 34). ADJUSTMENT AT AXLE WITH LEAF SPRINGS
(13) Ch eck for pr oper a ssem bly. F lex t h e join t
Adju st t h e pin ion sh a ft a n gle a t t h e spr in gs wit h
beyon d cen t er, it sh ou ld sn a p over-cen t er in bot h
t a per ed sh im s (F ig. 36). In st a ll t a per ed sh im s
dir ect ion s wh en cor r ect ly a ssem bled (F ig. 35).
bet ween t h e spr in gs a n d a xle pa d t o cor r ect t h e
(14) In st a ll t h e pr opeller sh a ft .
WEDGESUSPENSION ARM SHIM

XJ DIFFERENTIAL AND DRIVELINE 3 - 13


ADJ U ST M EN T S (Cont inue d)

Fig. 36 Angle Adjustment at Leaf Springs

J9316-17

Fig. 34 Seat Snap Rings In Groove

SHIM

SUSPENSION
ARM

J8916-22

Fig. 37 Front Axle Angle Adjustment

J9316-18

Fig. 35 Check Assembly


a n gle. Refer t o Gr ou p 2, Su spen sion , for a ddit ion a l
in for m a t ion .

FRONT AXLE ANGLE ADJUSTMENT


Adju st t h e pin ion gea r a n gle a t t h e lower su spen -
sion a r m s wit h sh im s (F ig. 37). Addin g sh im s will
decr ea se t h e pin ion gea r sh a ft a n gle bu t will in cr ea se
t h e ca st er a n gle. Th e pin ion gea r sh a ft a n gle h a s pr i-
or it y over t h e ca st er a n gle. Refer t o Gr ou p 2, Su spen -
sion , for a ddit ion a l in for m a t ion .
3 - 14 DIFFERENTIAL AND DRIVELINE XJ

SPECI FI CAT I ON S SPECI AL T OOLS


PROPELLER SHAFTS AND U–JOINTS PROPELLER SHAFT

D ES CRIP TION TORQU E


Bolt s, Tr a n sfer Ca se Yoke . . . . . . 27 N·m (20 ft . lbs.)
Bolt s, Axle Yoke . . . . . . . . . . . . . 19 N·m (14 ft . lbs.)
Bolt s, Axle Yoke . . . . . . . . . . . . . 19 N·m (14 ft . lbs.)

Inclinometer—7663
XJ DIFFERENTIAL AND DRIVELINE 3 - 15

T U BE AN D 1 8 1 FBI AX LE

INDEX
page page

GENERAL INFORMATION HUB BEARING AND AXLE SHAFT . . . . . . . . . . 24


181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 30
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . 15 PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION AND OPERATION RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 16 STEERING KNUCKLE AND BALL STUDS . . . . 25
DIAGNOSIS AND TESTING TUBE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . 21
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . 17 DISASSEMBLY AND ASSEMBLY
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . 17 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 34
FRONT AXLES . . . . . . . . . . . . . . . . . . . . . . . . . 18 STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 34
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CLEANING AND INSPECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . 16 AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . 35
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . 17 CARDAN U-JOINT . . . . . . . . . . . . . . . . . . . . . . 35
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ADJUSTMENTS
SERVICE PROCEDURES DIFFERENTIAL BEARING PRELOAD AND
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . 20 GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL AND INSTALLATION GEAR CONTACT PATTERN ANALYSIS . . . . . . 41
AXLE BUSHING REPLACEMENT ... . . . . . . . . 26 PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . 35
AXLE SHAFT OIL SEAL . . . . . . . ... . . . . . . . . 29 SPECIFICATIONS
AXLE SHAFT—CARDAN U-JOINT .. . . . . . . . . 22 181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DIFFERENTIAL SIDE BEARINGS ... . . . . . . . . 28 181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DIFFERENTIAL . . . . . . . . . . . . . ... . . . . . . . . 26 SPECIAL TOOLS
DRIVE AXLE ASSEMBLY . . . . . . ... . . . . . . . . 20 181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 43

GEN ERAL I N FORM AT I ON Th e 181 F BI a xle h a s t h e a ssem bly pa r t n u m ber


a n d gea r r a t io list ed on a t a g. Th e t a g is a t t a ch ed t o
181 FBI AXLE t h e h ou sin g cover by a cover bolt . Bu ild da t e iden t i-
Th e 181 F r on t Bea m -design Ir on (F BI) a xle con - fica t ion codes a r e st a m ped on t h e cover side of t h e
sist s of a ca st ir on differ en t ia l h ou sin g wit h a xle a xle sh a ft t u be.
sh a ft t u bes ext en din g fr om eit h er side. Th e t u bes a r e Th e differ en t ia l ca se is a on e–piece design . Th e dif-
pr essed in t o t h e differ en t ia l h ou sin g a n d welded. fer en t ia l pin ion m a t e sh a ft is r et a in ed wit h a r oll
Th e in t egr a l t ype h ou sin g, h ypoid gea r design h a s pin . Differ en t ia l bea r in g pr eloa d a n d r in g gea r ba ck-
t h e cen t er lin e of t h e pin ion set a bove t h e cen t er lin e la sh is a dju st ed by t h e u se of sh im s (select t h ick-
of t h e r in g gea r. n ess). Th e sh im s a r e loca t ed bet ween t h e differ en t ia l
Th e a xle h a s a fit t in g for a ven t h ose u sed t o bea r in g con es a n d ca se. P in ion bea r in g pr eloa d is set
r elieve in t er n a l pr essu r e ca u sed by lu br ica n t va por- a n d m a in t a in ed by t h e u se of sh im s (select t h ick-
iza t ion a n d in t er n a l expa n sion . n ess).
Th e a xles a r e equ ipped wit h sem i–floa t in g a xle
sh a ft s, m ea n in g t h a t loa ds a r e su ppor t ed by t h e h u b LUBRICANT SPECIFICATIONS
bea r in gs. Th e a xle sh a ft s a r e r et a in ed by n u t s a t t h e A m u lt i–pu r pose, h ypoid gea r lu br ica n t wh ich con -
h u b bea r in gs. Th e h u b bea r in gs a r e bolt ed t o t h e for m s t o t h e followin g specifica t ion s sh ou ld be u sed.
st eer in g kn u ckle a t t h e ou t boa r d en d of t h e a xle t u be Mopa r t H ypoid Gea r Lu br ica n t con for m s t o a ll of
yoke. Th e h u b bea r in gs a r e ser viced a s a n a ssem bly. t h ese specifica t ion s.
F or veh icles wit h ABS br a kes, t h e ABS wh eel • Th e lu br ica n t sh ou ld h a ve MIL–L–2105C a n d
speed sen sor s a r e a t t a ch ed t o t h e kn u ckle a ssem - AP I GL 5 qu a lit y specifica t ion s.
blies. Th e t on e r in gs for t h e ABS syst em a r e pr essed • Lu br ica n t is a t h er m a lly st a ble SAE 80W–90
on t o t h e a xle sh a ft . D o n o t d a m a g e AB S to n e gea r lu br ica n t .
w h e e l o r th e s e n s o r w h e n re m o v in g a x le s h a fts . • Lu br ica n t for a xles in t en ded for h ea vy-du t y or
Th e st a m ped st eel cover pr ovides a m ea n s for t r a iler t ow u se is SAE 75W–140 SYNTH E TIC gea r
in spect ion a n d ser vicin g t h e differ en t ia l. lu br ica n t .
INPINION
WHEEL
STRAIGHT
ROTATES
GEARS
PINION
AHEADAT
ROTATE
GEAR
100%
DRIVING
OF
CASE
WITH
SPEED
EACH
SIDE
CASEGEAR PINION GEARS
PINION
ROTATE
100%
SHAFT
ON
AXLE
DIFFERENTIAL
CASE SPEED
OUTER WHEEL 110% CASE INNER WHEEL 90% CASE
SPEED SPEED

3 - 16 DIFFERENTIAL AND DRIVELINE XJ


GEN ERAL I N FORM AT I ON (Cont inue d)
Th e 181 F BI a xle lu br ica n t ca pa cit y is 1.48 L (3.13 2). In t h is in st a n ce, t h e in pu t t or qu e a pplied t o t h e
pt s.). pin ion gea r s is n ot divided equ a lly. Th e pin ion gea r s
n ow r ot a t e a r ou n d t h e pin ion m a t e sh a ft in opposit e
CAUTION: If axle is submerged in water, lubricant dir ect ion s. Th is a llows t h e side gea r a n d a xle sh a ft
must be replaced immediately to avoid possible a t t a ch ed t o t h e ou t side wh eel t o r ot a t e a t a fa st er
premature axle failure. speed.
AXLE (j;

DESCRI PT I ON AN D OPERAT I ON OUTER WHEEL


I 100% DIFFERENTIAL INNER WHEEL
I
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.
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.

PINION GEARS ROTATE GEAR NOISE


WITH CASE J9303-13 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 -
Fig. 1 Differential Operation—Straight Ahead Driving a ged gea r s.
Wh en t u r n in g cor n er s, t h e ou t side wh eel m u st Gea r n oise u su a lly h a ppen s a t a specific speed
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 r a n ge. Th e r a n ge is 30 t o 40 m ph , or a bove 50 m ph .
com plet e a t u r n . Th e differ en ce m u st be com pen sa t ed Th e n oise ca n a lso occu r du r in g a specific t ype of
for t o pr even t t h e t ir es fr om scu ffin g a n d skiddin g dr ivin g con dit ion . Th ese con dit ion s a r e a cceler a t ion ,
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 deceler a t ion , coa st , or con st a n t loa d.
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.
XJ DIFFERENTIAL AND DRIVELINE 3 - 17
DI AGN OSI S AN D T EST I N G (Cont inue 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 pin ion gea r sh a ft bor e will a lso ca u se low speed
speed r a n ge wh er e t h e n oise is t h e gr ea t est . Sh ift kn ock.
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: VIBRATION
• Ch eck for in su fficien t lu br ica n t . Vibr a t ion a t t h e r ea r of t h e veh icle is u su a lly
• In cor r ect r in g gea r ba ckla sh . ca u sed by a :
• Gea r da m a ge. • Da m a ged dr ive sh a ft .
Differ en t ia l side a n d pin ion gea r s ca n be ch ecked • Missin g dr ive sh a ft ba la n ce weigh t (s).
by t u r n in g t h e veh icle. Th ey u su a lly do n ot ca u se • Wor n or ou t –of–ba la n ce wh eels.
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 • Loose wh eel lu g n u t 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- • Wor n U–join t (s).
cle t u r n s. A wor n pin ion gea r m a t e sh a ft ca n a lso • Loose/br oken spr in gs.
ca u se a sn a ppin g or a kn ockin g n oise. • Da m a ged a xle sh a ft bea r in g(s).
• Loose pin ion gea r n u t .
BEARING NOISE • E xcessive pin ion yoke r u n ou t .
Th e a xle sh a ft , differ en t ia l a n d pin ion gea r bea r- • Ben t a xle sh a ft (s).
in gs ca n a ll pr odu ce n oise wh en wor n or da m a ged. Ch eck for loose or da m a ged fr on t –en d com pon en t s
Bea r in g n oise ca n be eit h er a wh in in g, or a gr owlin g or en gin e/t r a n sm ission m ou n t s. Th ese com pon en t s
sou 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
P in ion gea r bea r in gs h a ve a con st a n t –pit ch n oise. vibr a t ion . Do n ot over look en gin e a ccessor ies, br a ck-
Th is n oise ch a n ges on ly wit h veh icle speed. P in ion et s a n d dr ive belt s.
bea r in g n oise will be h igh er beca u se it r ot a t es a t a All dr ivelin e com pon en t s sh ou ld be exa m in ed
fa st er r a t e. Dr ive t h e veh icle a n d loa d t h e differ en - befor e st a r t in g a n y r epa ir.
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 Refer t o Gr ou p 22, Wh eels a n d Tir es, for a ddit ion a l
is t h e sou r ce of t h e n oise. If t h e bea r in g n oise is vibr a t ion in for m a t ion .
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
sou r ce. DRIVELINE SNAP
Wor n or da m a ged differ en t ia l bea r in gs u su a lly pr o- A sn a p or clu n k n oise wh en t h e veh icle is sh ift ed
du ce a low pit ch n oise. Differ en t ia l bea r in g n oise is in t o gea r (or t h e clu t ch en ga ged), ca n be ca u sed by:
sim ila r t o pin ion bea r in g n oise. Th e pit ch of differ en - • H igh en gin e idle speed.
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 • Loose en gin e/t r a n sm ission /t r a n sfer ca se m ou n t s.
wit h veh icle speed. • Wor n U–join t s.
Axle sh a ft bea r in gs pr odu ce n oise a n d vibr a t ion • Loose spr in g m ou n t s.
wh en wor n or da m a ged. Th e n oise gen er a lly ch a n ges • Loose pin ion gea r n u t a n d yoke.
wh en t h e bea r in gs a r e loa ded. Roa d t est t h e veh icle. • E xcessive r in g gea r ba ckla sh .
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 . • E xcessive side gea r /ca se clea r a n ce.
Th is will loa d t h e bea r in gs a n d ch a n ge t h e n oise Th e sou r ce of a sn a p or a clu n k n oise ca n be det er-
level. Wh er e a xle bea r in g da m a ge is sligh t , t h e n oise m in ed wit h t h e a ssist a n ce of a h elper. Ra ise t h e veh i-
is u su a lly n ot n ot icea ble a t speeds a bove 30 m ph . 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
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
LOW SPEED KNOCK for t h e n oise, a m ech a n ics st et h oscope is h elpfu l in
Low speed kn ock is gen er a lly ca u sed by a wor n isola t in g t h e sou r ce of a n oise.
U–join t or by wor n side–gea r t h r u st wa sh er s. A wor n
3 - 18 DIFFERENTIAL AND DRIVELINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
FRONT AXLES

DI AGN OSI S

CONDITION POSSIBLE CAUSES CORRECTION


WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Faulty or brinelled bearings must
be replaced.
AXLE SHAFT NOISE 1. Misaligned axle shaft tube. 1. Inspect axle shaft tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Replace bent or sprung axle
shaft.
3. End play in drive pinion bearings. 3. Refer to Drive Pinion Bearing
Pre-Load Adjustment.
4. Excessive gear backlash between 4. Check adjustment of ring gear
ring gear and pinion gear. backlash and pinion gear. Correct as
necessary.
5. Improper adjustment of drive 5. Adjust drive pinion shaft bearings.
pinion gear shaft bearings.
6. Loose drive pinion gearshaft yoke 6. Tighten drive pinion gearshaft
nut. yoke nut with specified torque.
7. Improper wheel bearing 7. Readjust as necessary.
adjustment.
8. Scuffed gear tooth contact 8. If necessary, replace scuffed
surfaces. gears.
AXLE SHAFT BROKE 1. Misaligned axle shaft tube. 1. Replace broken axle shaft after
correcting axle shaft tube alignment.
2. Vehicle overloaded. 2. Replace broken axle shaft. Avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken axle shaft after
inspecting for other possible casues.
Avoid erratic use of clutch.
4. Grabbing clutch. 4. Replace broken axle shaft.
Inspect clutch and make necessary
repairs or adjustments.
DIFFERENTIAL CASE CRACKED 1. Improper adjustment of differential 1. Replace cracked case; examine
bearings. gears and bearings for possible
damage. At reassembly, adjust
differential bearings properly.
2. Excessive ring gear backlash. 2. Replace cracked case; examine
gears and bearings for possible
damage. At reassembly, adjust ring
gear backlash properly.
3. Vehicle overloaded. 3. Replace cracked case; examine
gears and bearings for possible
damage. Avoid excessive weight on
vehicle.
4. Erratic clutch operation. 4. Replace cracked case. After
inspecting for other possible causes,
examine gears and bearings for
possible damage. Avoid erratic use
of clutch.
XJ DIFFERENTIAL AND DRIVELINE 3 - 19
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


DIFFERENTIAL GEARS SCORED 1. Insufficient lubrication. 1. Replace scored gears. Scoring
marks on the drive face of gear
teeth or in the bore are caused by
instantaneous fusing of the mating
surfaces. Scored gears should be
replaced. Fill rear differential housing
to required capacity with proper
lubricant. Refer to Specifications.
2. Improper grade of lubricant. 2. Replace scored gears. Inspect all
gears and bearings for possible
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
3. Excessive spinning of one 3. Replace scored gears. Inspect all
wheel/tire. gears, pinion bores and shaft for
damage. Service as necessary.
LOSS OF LUBRICANT 1. Lubricant level too high. 1. Drain excess lubricant by
removing fill plug and allow lubricant
to level at lower edge of fill plug
hole.
2. Worn axle shaft seals. Replace worn seals.
3. Cracked differential housing. 3. Repair or replace housing as
necessary.
4. Worn drive pinion gear shaft seal. 4. Replace worn drive pinion gear
shaft seal.
5. Scored and worn yoke. 5. Replace worn or scored yoke and
seal.
6. Axle cover not properly sealed. 6. Remove cover and clean flange
and reseal.
AXLE OVERHEATING 1. Lubricant level too low. 1. Refill differential housing.
2. Incorrect grade of lubricant. 2. Drain, flush and refill with correct
amount of the correct lubricant.
3. Bearings adjusted too tight. 3. Readjust bearings.
4. Excessive gear wear. 4. Inspect gears for excessive wear
or scoring. Replace as necessary.
5. Insufficient ring gear backlash. 5. Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (RING GEAR 1. Overloading. 1. Replace gears. Examine other
AND PINION) gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for possible
damage. Avoid erratic clutch
operation.
3. Ice-spotted pavements. 3. Replace gears. Examine the
remaining parts for possible
damage. Replace parts as required.
4. Improper adjustments. 4. Replace gears. Examine other
parts for possible damage. Ensure
ring gear backlash is correct.
SEALING
BEAD
NESSSURFACE
6.35MM
THICK-
(1/4”) CONTOUR OF BEAD

3 - 20 DIFFERENTIAL AND DRIVELINE XJ


DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


AXLE NOISE 1. Insufficient lubricant. 1. Refill axle with correct amount of
proper lubricant. Also inspect for
leaks and correct as necessary.
2. Improper ring gear and drive 2. Check ring gear and pinion gear
pinion gear adjustment. teeth contact pattern.
3. Unmatched ring gear and drive 3. Remove unmatched ring gear and
pinion gear. drive pinion gear. Replace with
matched gear and drive pinion gear
set.
4. Worn teeth on ring gear or drive 4. Check teeth on ring gear and
pinion gear. drive pinion gear for correct contact.
If necessary, replace with new
matched set.
5. Loose drive pinion gear shaft 5. Adjust drive pinion gearshaft
bearings. bearing preload torque.
6. Loose differential bearings. 6. Adjust differential bearing preload
torque.
7. Misaligned or sprung ring gear. 7. Measure ring gear runout.
8. Loose differential bearing cap 8. Tighten with specified torque.
bolts.

SERV I CE PROCEDU RES CONTOUR OF BEAD

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

3 - 22 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) P osit ion t h e u pper a n d lower su spen sion a r m s BEARING
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 CAP
h old su spen sion a r m s t o t h e a xle br a cket s.
(5) Con n ect t h e t r a ck ba r t o t h e a xle br a cket .
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
a xle br a cket .
(6) In st a ll t h e sh ock a bsor ber s a n d t igh t en t h e
bolt s t o 23 N·m (17 ft . lbs.) t or qu e.
(7) In st a ll t h e st a bilizer ba r lin ks t o t h e a xle
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.
(8) 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
kn u ckles. Refer t o Gr ou p 2, Su spen sion , for pr oper ~~RING
pr ocedu r es.
(9) In st a ll t h e st eer in g da m per t o t h e a xle 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.
BEARING
(10) In st a ll t h e br a ke r ot or s a n d ca liper s. Refer t o SNAP CAP
Gr ou p 5, Br a kes, for t h e pr oper pr ocedu r es. RINGS
(11) Con n ect t h e wh eel speed sen sor wir in g h a r-
J8902-15
n ess t o t h e veh icle wir in g h a r n ess, if n ecessa r y.
(12) In st a ll t h e wh eel a n d t ir e a ssem blies. Fig. 4 Axle Shaft Outer U–Joint
(13) Rem ove t h e lift in g device fr om t h e a xle a n d
lower t h e veh icle. LARGE-
DIAMETER
(14) Tigh t en t h e u pper su spen sion a r m n u t s t o 75 SOCKET
N·m (55 ft . lbs.) t or qu e. Tigh t en t h e lower su spen sion WRENCH
a r m n u t s t o 115 N·m (85 ft . lbs.) t or qu e.
(15) Tigh t en t h e t r a ck ba r bolt a t t h e a xle br a cket
t o 100 N·m (74 ft . lbs.) t or qu e.
(16) Ch eck t h e fr on t wh eel a lign m en t .

AXLE SHAFT—CARDAN U-JOINT


Sin gle ca r da n U–join t com pon en t s a r e n ot ser vice-
a ble. If defect ive, t h ey m u st be r epla ced a s a u n it . If
t h e bea r in gs, sea ls, spider, or bea r in g ca ps a r e da m -
a ged or wor n , r epla ce t h e com plet e U–join t . SMALL-
DIAMETER
SOCKET
REM OVAL WRENCH

CAUTION: Clamp only the narrow forged portion of


the yoke in the vise. Also, to avoid distorting the
yoke, do not over tighten the vise jaws.
J8902-16
(1) Rem ove a xle sh a ft .
(2) Rem ove t h e bea r in g ca p r et a in in g sn a p r in gs Fig. 5 Yoke Bearing Cap Removal
(F ig. 4).
(6) Com pr ess t h e vise ja ws t o for ce t h e bea r in g ca p
It c a n be h e lp fu l to s a tu ra te th e be a rin g c a p s
in t o t h e la r ger socket (r eceiver ).
w ith p e n e tra tin g o il p rio r to re m o v a l.
(7) Relea se t h e vise ja ws. Rem ove t h e socket s a n d
(3) Loca t e a socket wh er e t h e in side dia m et er is
bea r in g ca p t h a t wa s pa r t ia lly for ced ou t of t h e yoke.
la r ger in dia m et er t h a n t h e bea r in g ca p. P la ce t h e
(8) Repea t t h e a bove pr ocedu r e for t h e r em a in in g
socket (r eceiver ) a ga in st t h e yoke a n d a r ou n d t h e
bea r in g ca p.
per im et er of t h e bea r in g ca p t o be r em oved.
(9) Rem ove t h e r em a in in g bea r in g ca p, bea r in gs,
(4) Loca t e a socket wh er e t h e ou t side dia m et er is
sea ls a n d spider fr om t h e pr opeller sh a ft yoke.
sm a ller in dia m et er t h a n t h e bea r in g ca p. P la ce t h e
socket (dr iver ) a ga in st t h e opposit e bea r in g ca p.
(5) P osit ion t h e yoke wit h t h e socket s in a vise
(F ig. 5).
SPECIAL SPECIAL
TOOL C-452
TOOL C-3281
YOKE SPECIAL TOOL C-3972–A
SPECIAL
AXLE
PINION
TOOL
HOUSING
C-4171
YOKE

XJ DIFFERENTIAL AND DRIVELINE 3 - 23


REM OVAL AN D I N STALLAT I ON (Cont inue d)
I N STALLAT I ON I N STALLAT I ON
(1) P a ck t h e bea r in g ca ps 1/3 fu ll of wh eel bea r in g (1) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
lu br ica n t . Apply ext r em e pr essu r e (E P ), lit h iu m –ba se lip of pin ion sea l. In st a ll sea l wit h In st a ller C-3972-A
lu br ica n t t o a id in in st a lla t ion . a n d H a n dle C-4171 (F ig. 7).
(2) P osit ion t h e spider in t h e yoke. In ser t t h e sea ls
a n d bea r in gs. Ta p t h e bea r in g ca ps in t o t h e yoke
bor es fa r en ou gh t o h old t h e spider in posit ion . SPECIAL
(3) P la ce t h e socket (dr iver ) a ga in st on e bea r in g SPECIAL TOOL TOOL
ca p. P osit ion t h e yoke wit h t h e socket wr en ch in a C-4171 C-3972-A
vise.
(4) Com pr ess t h e vise t o for ce t h e bea r in g ca ps
in t o t h e yoke. F or ce t h e ca ps en ou gh t o in st a ll t h e
r et a in in g clips.
(5) In st a ll t h e bea r in g ca p r et a in in g clips.
(6) In st a ll a xle sh a ft .

PINION SHAFT SEAL


REM OVAL
(1) Ra ise a n d su ppor t t h e veh icle. 80a7e2be

(2) Rem ove wh eel a n d t ir e a ssem blies.


(3) Rem ove br a ke r ot or s a n d ca liper s. Refer t o
Fig. 7 Pinion Seal Installation
Gr ou p 5, Br a kes, for pr oper pr ocedu r es. (2) In st a ll yoke on t h e pin ion gea r wit h In st a ller
(4) Ma r k t h e pr opeller sh a ft a n d pin ion yoke for W-162–D, Cu p 8109, a n d H older 6958 (F ig. 8).
in st a lla t ion r efer en ce.
(5) Rem ove t h e pr opeller sh a ft fr om t h e yoke. PINION
(6) Rot a t e t h e pin ion gea r t h r ee or fou r t im es. YOKE
(7) Mea su r e t h e a m ou n t of t or qu e n ecessa r y t o
r ot a t e t h e pin ion gea r wit h a (in . lbs.) dia l-t ype
t or qu e wr en ch . Recor d t h e t or qu e r ea din g for in st a l-
la t ion r efer en ce.
(8) Usin g H older 6958 t o h old t h e pin ion yoke,
r em ove t h e pin ion n u t a n d wa sh er.
(9) Use Rem over C-452 a n d Wr en ch C-3281 t o
r em ove t h e pin ion yoke (F ig. 6).

AXLE
HOUSING
80a7e2bf

Fig. 8 Pinion Yoke Installation


CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to the pinion bearings may
result.

(3) In st a ll t h e pin ion wa sh er a n d a n ew n u t on t h e


pin ion gea r. Tig h te n th e n u t o n ly e n o u g h to
re m o v e th e s h a ft e n d p la y.
J9102-31 (4) Tigh t en pin ion n u t t o 217 N·m (160 ft . lbs.).
(5) Rot a t e t h e pin ion sh a ft u sin g a (in . lbs.) t or qu e
Fig. 6 Pinion Yoke Removal wr en ch . Rot a t in g t or qu e sh ou ld be equ a l t o t h e r ea d-
in g r ecor ded du r in g r em ova l, plu s a n a ddit ion a l 0.56
(10) Use a su it a ble pr y t ool or a slide h a m m er
N·m (5 in . lbs.) (F ig. 9).
m ou n t ed scr ew t o r em ove t h e pin ion sh a ft sea l.
(6) If t h e r ot a t in g t or qu e is low, u se H older 6958 t o
h old t h e pin ion yoke, a n d t igh t en t h e pin ion sh a ft
TONE WHEELPINION
(ABS) YOKE
INCH POUND
BOLT WRENCH
TORQUE STEERING
KNUCKLE HUB
BRAKE
AND
SHIELD
ASSEMBLY
BEARING WASHER
NUT COTTER
RETAINER
PIN

3 - 24 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(10) In st a ll wh eel a n d t ir e a ssem blies.
(11) Lower t h e veh icle.

HUB BEARING AND AXLE SHAFT


If t h e a xle sh a ft a n d h u b bea r in g a r e bein g
r em oved in or der t o ser vice a n ot h er com pon en t , t h e
a xle sh a ft a n d h u b bea r in g ca n be r em oved a s a n
a ssem bly.

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

Fig. 10 Hub, Knuckle and Axle Shaft


HUB BEARING
HUB BEARING AXLE SHAFT KNUCKLE
KNUCKLE
AXLE SHAFT
AXLE AXLE
STEERING
YOKE
KNUCKLE LOWER BALL
UPPERSTUD
STUD
BALL

XJ DIFFERENTIAL AND DRIVELINE 3 - 25


REM OVAL AN D I N STALLAT I ON (Cont inue d)
in st a lla t ion of u pper a n d lower ba ll st u ds r equ ir e t h e
u se of Tool Kit 6289.

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

Fig. 12 Hub Bearing and Axle Assembly STEERING


KNUCKLE J9302-16
(3) In st a ll t h e h u b bea r in g a n d a xle sh a ft a ssem -
bly, or a xle sh a ft , in t o t h e h ou sin g a n d differ en t ia l Fig. 13 Steering Knuckle Removal/Installation
side gea r s. Avoid da m a gin g t h e a xle sh a ft oil sea ls in
t h e a xle h ou sin g. U PPER BALL ST U D REPLACEM EN T
(4) In st a ll t h e h u b bea r in g, if n ecessa r y. (1) P osit ion t ools a s sh own t o r em ove a n d in st a ll
(5) In st a ll t h e h u b t o kn u ckle bolt s a n d t igh t en t o ba ll st u d (F ig. 14).
102 N·m (75 ft . lbs.) t or qu e.
LOWER BALL ST U D REPLACEM EN T
(6) In st a ll t h e h u b wa sh er a n d n u t , if n ecessa r y.
(1) P osit ion t ools a s sh own t o r em ove a n d in st a ll
Tigh t en t h e h u b n u t t o 237 N·m (175 ft . lbs.) t or qu e.
ba ll st u d (F ig. 15).
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 (F ig.
10). K N U CK LE I N STALLAT I ON
(7) In st a ll ABS wh eel speed sen sor, if n ecessa r y. (1) P osit ion t h e st eer in g kn u ckle on t h e ba ll st u ds.
Refer t o Gr ou p 5, Br a kes, for pr oper pr ocedu r es. (2) In st a ll a n d t igh t en t h e bot t om r et a in in g n u t t o
(8) In st a ll t h e br a ke r ot or a n d ca liper. Refer t o 109 N·m (80 ft . lbs.) t or qu e. In st a ll n ew cot t er pin .
Gr ou p 5, Br a kes, for pr oper pr ocedu r es. (3) In st a ll a n d t igh t en t h e t op r et a in in g n u t t o 101
(9) In st a ll t h e wh eel a n d t ir e a ssem bly. N·m (75 ft . lbs.) t or qu e. In st a ll n ew cot t er pin .
(10) Rem ove su ppor t a n d lower t h e veh icle. (4) In st a ll t h e h u b bea r in g a n d a xle sh a ft .
(5) Con n ect t h e t ie-r od or dr a g lin k en d t o t h e
STEERING KNUCKLE AND BALL STUDS st eer in g kn u ckle a r m . Refer t o Gr ou p 2, Su spen sion ,
Ba ll st u d ser vice pr ocedu r es below r equ ir e r em ova l for pr oper pr ocedu r es.
of t h e h u b bea r in g a n d a xle sh a ft . Rem ova l a n d
REMOVAL INSTALLATION

3 - 26 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

4212F
4212F

6289-12

REMOVAL INSTALLATION

80a7e2a7

Fig. 14 Upper Ball Stud Remove/Install


AXLE BUSHING REPLACEMENT CAUTION: Do not spread over 0.50 mm (0.020 in). If
Refer t o Gr ou p 2, Su spen sion , for t h e pr oper a xle the housing is over-spread, it could be distorted or
bu sh in g pr ocedu r es. damaged.

DIFFERENTIAL (9) Spr ea d t h e h ou sin g en ou gh t o r em ove t h e dif-


fer en t ia l ca se fr om t h e h ou sin g. Mea su r e t h e dis-
REM OVAL t a n ce wit h t h e dia l in dica t or (F ig. 19).
(1) Ra ise a n d su ppor t veh icle. (10) Rem ove t h e dia l in dica t or.
(2) Rem ove t h e lu br ica n t fill h ole plu g fr om t h e (11) Wh ile h oldin g t h e differ en t ia l ca se in posit ion ,
differ en t ia l h ou sin g cover. r em ove t h e differ en t ia l bea r in g ca p bolt s a n d ca ps.
(3) Rem ove t h e differ en t ia l h ou sin g cover a n d (12) Rem ove t h e differ en t ia l fr om t h e h ou sin g.
a llow flu id t o dr a in . E n su r e t h a t t h e differ en t ia l bea r in g cu ps r em a in in
(4) Rem ove h u b bea r in gs a n d a xle sh a ft s. posit ion on t h e differ en t ia l bea r in gs (F ig. 20).
(5) Not e t h e in st a lla t ion r efer en ce let t er s st a m ped (13) Ma r k or t a g t h e differ en t ia l bea r in g cu ps t o
on t h e bea r in g ca ps a n d h ou sin g m a ch in ed sea lin g in dica t e wh ich side of t h e differ en t ia l t h ey wer e
su r fa ce (F ig. 16). r em oved fr om .
(6) Loosen t h e differ en t ia l bea r in g ca p bolt s. (14) Rem ove spr ea der fr om h ou sin g.
(7) P osit ion Spr ea der W–129–B, u t ilizin g som e
it em s fr om Ada pt er Kit 6987, wit h t h e t ool dowel I N STALLAT I ON
pin s sea t ed in t h e loca t in g h oles (F ig. 17). In st a ll t h e If r epla cem en t differ en t ia l bea r in gs or differ en t ia l
h olddown cla m ps a n d t igh t en t h e t ool t u r n bu ckle fin - ca se a r e bein g in st a lled, differ en t ia l side bea r in g
ger –t igh t . sh im r equ ir em en t s m a y ch a n ge. Refer t o t h e Differ-
(8) In st a ll a Gu ide P in C-3288-B a t t h e left side of en t ia l Bea r in g P r eloa d a n d Gea r Ba ckla sh pr oce-
t h e differ en t ia l h ou sin g. At t a ch Dia l In dica t or C-3339 du r es in t h is sect ion t o det er m in e t h e pr oper sh im
t o gu ide pin . Loa d t h e lever a da pt er a ga in st t h e select ion .
opposit e side of t h e h ou sin g (F ig. 18) a n d zer o t h e (1) P osit ion Spr ea der W-129-B, u t ilizin g som e
in dica t or. it em s fr om Ada pt er Kit 6987, wit h t h e t ool dowel
INSTALLATION
ENCE LETTERS
REFER- REMOVALINSTALLATION
SPECIAL
SPECIAL
ENCE
TOOL
TOOL
LETTERS
REFER-
6289–3
4212F
6289–1 AXLE HOUSING TURNBUCKLE
INSTALLATION SPECIAL
SPECIAL
SPECIALTOOL
SAFETY
SPECIALTOOL
HOLD
TOOL
TOOL
W-129–B
DOWEL
6289–12
6289–4
DOWN
4212F

XJ DIFFERENTIAL AND DRIVELINE 3 - 27


REM OVAL AN D I N STALLAT I ON (Cont inue d)

SPECIAL
SPECIAL TOOL
14"---TOOL 6289-4
'---~b---' 6289-1

SPECIAL
TOOL
4212F

REMOVAL INSTALLATION
80a7e2a8

Fig. 15 Lower Ball Stud Remove/Install

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

3 - 28 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
DIAL INDICATOR DIFFERENTIAL
~LEVER CASE
.,,,,s;;,>~~~~- ADAPTER

(C) (C) A 80a534c8

Fig. 18 Install Dial Indicator Fig. 20 Differential Case Removal


SPECIAL
TOOL
C-3339

SAFETY
HOLD
DOWN

TURNBUCKLE

80a534c5

Fig. 19 Spread Axle Housing Fig. 21 Install Axle Housing Spreader


(3) Spr ea d t h e h ou sin g en ou gh t o in st a ll t h e ca se DIFFERENTIAL SIDE BEARINGS
in t h e h ou sin g. Mea su r e t h e dist a n ce wit h t h e dia l
in dica t or (F ig. 19). REM OVAL
(4) Rem ove t h e dia l in dica t or. (1) Rem ove differ en t ia l ca se fr om a xle h ou sin g.
(5) In st a ll differ en t ia l ca se in t h e h ou sin g. E n su r e (2) Rem ove t h e bea r in gs fr om t h e differ en t ia l ca se
t h a t t h e differ en t ia l bea r in g cu ps r em a in in posit ion wit h P u ller /P r ess C-293-PA, C-293-39 Ada pt er
on t h e differ en t ia l bea r in gs. Ta p t h e differ en t ia l ca se Blocks, a n d P lu g SP -3289 (F ig. 23).
t o en su r e t h e bea r in gs cu ps a r e fu lly sea t ed in t h e
h ou sin g. I N STALLAT I ON
(6) In st a ll t h e bea r in g ca ps a t t h eir or igin a l loca - If r epla cem en t differ en t ia l side bea r in gs or differ-
t ion s (F ig. 22). en t ia l ca se a r e bein g in st a lled, differ en t ia l side bea r-
(7) Loosely in st a ll differ en t ia l bea r in g ca p bolt s. in g sh im r equ ir em en t s m a y ch a n ge. Refer t o t h e
(8) Rem ove a xle h ou sin g spr ea der. Differ en t ia l Bea r in g P r eloa d a n d Gea r Ba ckla sh pr o-
(9) Tigh t en t h e bea r in g ca p bolt s t o 61 N·m (45 ft . cedu r es in t h is sect ion t o det er m in e t h e pr oper sh im
lbs.) t or qu e. select ion .
(10) In st a ll t h e h u b bea r in gs a n d a xle sh a ft s.
INSTALLATION
SPECIAL
SPECIAL
ENCE
C-293–PA
DIFFERENTIAL
TOOL
LETTERS
SP-3289
REFER-
TOOL BEARING INSTALLATION
ENCE
SPECIAL
LETTERS
C-293–39
REFER-
TOOL SPECIAL C-3716–A
TOOL SPECIAL TOOL C-4171

XJ DIFFERENTIAL AND DRIVELINE 3 - 29


REM OVAL AN D I N STALLAT I ON (Cont inue d)

J9003-92

Fig. 22 Differential Bearing Cap Reference Letters

J9302-21

Fig. 24 Differential Side Bearing Installation


AXLE SHAFT OIL SEAL
REM OVAL
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove differ en t ia l a ssem bly.
(3) Rem ove t h e in n er a xle sh a ft sea ls wit h a pr y
SPECIAL ba y.
TOOL
SP-3289 I N STALLAT I ON
(1) Rem ove a n y sea ler r em a in in g fr om or igin a l
sea ls.
(2) Rem ove sea ler fr om a xle t u be t o h ou sin g ju n c-
t ion , if n ecessa r y.
(3) In st a ll oil sea ls wit h Discs 8110 a n d Tu r n -
bu ckle 6797 (F ig. 25). Tigh t en t ool u n t il disc bot t om s
in h ou sin g.
(4) In st a ll differ en t ia l a ssem bly.

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

3 - 30 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
TURNBUCKLE TORQUE
6797 /WRENCH

=========~:;;:::~/ RING GEAR


BOLT

RING
GEAR

J9202-77

Fig. 25 Axle Seal Installation Fig. 27 Ring Gear Bolt Installation


PINION GEAR
Th e r in g a n d pin ion gea r s a r e ser viced a s a
m a t ch ed set . Do n ot r epla ce t h e pin ion gea r wit h ou t
r epla cin g t h e r in g gea r.

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

CAUTION: Do not reuse the bolts that held the ring


gear to the differential case. The bolts can fracture
causing extensive damage.

(1) In ver t t h e differ en t ia l ca se a n d st a r t t wo r in g


gea r bolt s. Th is will pr ovide ca se-t o-r in g gea r bolt
h ole a lign m en t .
(2) In ver t t h e differ en t ia l ca se in t h e vise.
(3) In st a ll n ew r in g gea r bolt s a n d a lt er n a t ely
t igh t en t o 95–122 N·m (70–90 ft . lbs.) t or qu e (F ig.
27).
(4) In st a ll differ en t ia l in a xle h ou sin g a n d ver ify J9102-31
gea r m esh a n d con t a ct pa t t er n .
Fig. 28 Pinion Yoke Removal
REMOVER RAWHIDE
HANDLE
HAM-
MER DRIVER HANDLE

XJ DIFFERENTIAL AND DRIVELINE 3 - 31


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(6) Rem ove t h e pin ion gea r a n d pr eloa d sh im s (9) Rem ove t h e dept h sh im s fr om r ea r pin ion bea r-
fr om h ou sin g (F ig. 29). Ca t ch t h e pin ion wit h you r in g cu p bor e in a xle h ou sin g. Recor d t h e t h ickn ess of
h a n d t o pr even t it fr om fa llin g a n d bein g da m a ged. t h e dept h sh im s.

NOTE: The pinion depth shims can be very thin.


Verify that all shims have been removed before pro-
ceeding.

J9302-25

Fig. 29 Remove Pinion Gear


J9302-23
(7) Rem ove t h e fr on t pin ion bea r in g cu p, bea r in g,
oil slin ger, if equ ipped, a n d pin ion sea l wit h Rem over
Fig. 31 Rear Bearing Cup Removal
D-147 a n d H a n dle C–4171 (F ig. 30).
(10) Rem ove t h e r ea r pin ion bea r in g fr om t h e pin -
ion wit h P u ller /P r ess C–293-PA a n d Ada pt er s
C-293-39 (F ig. 32).
P la c e 4 a d a p te r blo c k s s o th e y d o n o t d a m a g e
th e be a rin g c a g e .

I N STALLAT I ON

NOTE: Pinion depth shims are placed between the


rear pinion bearing cup and axle housing to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pin-
ion depth shim should not require replacement.
Refer to Pinion Gear Depth to select the proper
thickness shim before installing pinion gear.

(1) P la ce pr oper t h ickn ess dept h sh im in r ea r pin -


ion bea r in g cu p bor e in t h e a xle h ou sin g.
(2) 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 r ea r pin ion bea r in g
cu p. In st a ll t h e bea r in g cu p wit h In st a ller D-146 a n d
J9302-22 H a n dle C–4171 (F ig. 33). Ver ify cu p is cor r ect ly
sea t ed.
Fig. 30 Front Bearing Cup Removal (3) Apply Mopa r t Door E a se, or equ iva len t , st ick
(8) Rem ove t h e r ea r pin ion bea r in g cu p fr om a xle lu br ica n t t o ou t side su r fa ce of fr on t pin ion bea r in g
h ou sin g (F ig. 31). Use Rem over D-149 a n d H a n dle cu p. In st a ll t h e bea r in g cu p wit h In st a ller D-144 a n d
C–4171. H a n dle C–4171 (F ig. 34).
DRIVE
GEAR
HANDLE
ADAPTERS
PINION
SHAFT SPECIAL C-293–PA
TOOL INSTALLER VISE INSTALLER SPECIAL
HANDLE
C-3972–A
TOOLSPECIALC-4171
TOOL

3 - 32 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

SPECIAL INSTALLER HANDLE


TOOL
C-293-PA

Fig. 34 Pinion Outer Bearing Cup Installation

SPECIAL
SPECIAL TOOL TOOL
C-4171 C-3972-A
Fig. 32 Inner Bearing Removal
INSTALLER

80a7e2be

Fig. 35 Pinion Seal Installation


(8) In st a ll pin ion gea r in h ou sin g.
(9) In st a ll yoke wit h In st a ller W-162-B, Cu p 8109,
a n d H older 6958 (F ig. 38).
(10) In st a ll t h e pin ion wa sh er a n d a n ew n u t on
t h e pin ion gea r. Tigh t en t h e n u t t o 217 N·m (160 ft .
lbs.).

CAUTION: Never loosen pinion gear nut to


decrease pinion gear bearing rotating torque and
HANDLE J9402-66
never exceed specified preload rotating torque.

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

XJ DIFFERENTIAL AND DRIVELINE 3 - 33


REM OVAL AN D I N STALLAT I ON (Cont inue d)

PINION
YOKE

INSTALLATION
TOOL

DRIVE
PINION GEAR
SHAFT
REAR BEARING AXLE
HOUSING
80a7e2bf

Fig. 38 Pinion Yoke Installation


(14) If t h e m a xim u m t igh t en in g t or qu e is r ea ch ed
pr ior t o a ch ievin g t h e desir ed r ot a t in g t or qu e, r em ove
DRIVE t h e pin ion yoke a n d decr ea se t h e t h ickn ess of t h e
PINION GEAR J9302-68
pr eloa d sh im pa ck. Decr ea sin g t h e sh im pa ck t h ick-
n ess 0.025 m m (0.001 in .) will in cr ea se t h e r ot a t in g
Fig. 36 Rear Pinion Bearing Installation
t or qu e a ppr oxim a t ely 0.9 N·m (8 in . lbs.).
(13) Tigh t en pin ion sh a ft n u t in 6.8 N·m (5 ft . lbs.) (15) In st a ll differ en t ia l a ssem bly.
in cr em en t s u n t il t h e m a xim u m t igh t en in g or desir ed
r ot a t in g t or qu e is r ea ch ed.

WASHER

PINION
OIL SEAL

PINION PRELOAD
SPACER - - - - - - - FRONT
BEARING
CONE

J9203-63

Fig. 37 Pinion Preload Shims–Typical


in. MATE
lbs. TORQUE
LOCKPIN
SHAFT WRENCH PINION YOKEDRIFT THRUST
WASHER
PINION GEAR
MATE SIDE GEAR

3 - 34 DIFFERENTIAL AND DRIVELINE XJ

(3) Rem ove t h e pin ion gea r m a t e sh a ft fr om t h e


differ en t ia l ca se a n d t h e pin ion m a t e gea r s.
(4) Rot a t e differ en t ia l side gea r s a n d r em ove t h e
pin ion m a t e gea r s a n d t h r u st wa sh er s (F ig. 41).
THRUST
WASHER
in. lbs.
TORQUE
WRENCH

Fig. 39 Check Pinion Gear Rotating Torque


DI SASSEM BLY AN D ASSEM BLY PINION
MATE GEAR SIDE GEAR J9203-61
STANDARD DIFFERENTIAL
Fig. 41 Pinion Mate Gear Removal
DI SASSEM BLY (5) Rem ove t h e differ en t ia l side gea r s a n d t h r u st
(1) Rem ove t h e r in g gea r. wa sh er s.
(2) Usin g a su it a ble r oll pin pu n ch , dr ive ou t t h e
r oll pin h oldin g pin ion gea r m a t e sh a ft in t h e differ- ASSEM BLY
en t ia l ca se (F ig. 40). (1) In st a ll t h e differ en t ia l side gea r s a n d t h r u st
wa sh er s.
(2) In st a ll t h e pin ion m a t e gea r s a n d t h r u st wa sh -
er s.
(3) In st a ll t h e pin ion gea r m a t e sh a ft . Align t h e
r oll pin h oles in sh a ft a n d t h e differ en t ia l ca se.
(4) In st a ll t h e r oll pin t o h old t h e pin ion m a t e
sh a ft in t h e differ en t ia l ca se (F ig. 42).
(5) In st a ll t h e r in g gea r.
(6) Lu br ica t e a ll differ en t ia l com pon en t s wit h
h ypoid gea r lu br ica n t .

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

XJ DIFFERENTIAL AND DRIVELINE 3 - 35


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
CLEAN I N G AN D I N SPECT I ON
CARDAN U-JOINT
Clea n a ll t h e U–join t yoke bor es wit h clea n in g sol-
ven t a n d a wir e br u sh . E n su r e t h a t a ll t h e r u st a n d
for eign m a t t er a r e r em oved fr om t h e bor es.
In spect t h e yokes for dist or t ion , cr a cks a n d wor n
bea r in g ca p bor es.
Repla ce t h e com plet e U–join t if a n y of t h e com po-
n en t s a r e defect ive.

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

3 - 36 DIFFERENTIAL AND DRIVELINE XJ


ADJ U ST M EN T S (Cont inue d)
pin ion is 92.08 m m (3.625 in .). Th e st a n da r d dept h Not e wh er e Old a n d New P in ion Ma r kin g colu m n s
pr ovides t h e best gea r t oot h con t a ct pa t t er n . Refer t o in t er sect . In t er sect in g figu r e r epr esen t s plu s or
Ba ckla sh a n d Con t a ct P a t t er n An a lysis pa r a gr a ph in m in u s t h e a m ou n t n eeded.
t h is sect ion for a ddit ion a l in for m a t ion . Not e t h e et ch ed n u m ber on t h e fa ce of t h e dr ive
pin ion gea r (–1, –2, 0, +1, +2, et c.). Th e n u m ber s r ep-
DRIVE PINION
PRODUCTION GEAR DEPTH 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 -
NUMBERS VARIANCE 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
r equ ir ed t h ickn ess of t h e dept h sh im s. If t h e n u m 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 of
t h e dept h sh im . If t h e n u m ber is 0 n o ch a n ge is n ec-
essa r y.

PI N I ON DEPT H M EASU REM EN T AN D


ADJ U ST M EN T
Mea su r em en t s a r e t a ken wit h pin ion bea r in g cu ps
a n d pin ion bea r in gs in st a lled in t h e a xle h ou sin g
wit h ou t a n y sh im s pla ced beh in d t h e r ea r pin ion
bea r in g cu p. Ta ke m ea su r em en t s wit h P in ion Ga u ge
GEAR MATCHING NUMBER Set 6774 a n d Dia l In dica t or C-3339 (F ig. 46).
(SAME AS RING GEAR NUMBER) J9003-100 (1) Assem ble P in ion H eigh t Block 6739, P in ion
Block 6733, a n d r ea r pin ion bea r in g on t o Scr ew 6741
Fig. 44 Pinion Gear ID Numbers (F ig. 46).
Com pen sa t ion for pin ion dept h va r ia n ce is (2) In ser t a ssem bled h eigh t ga u ge com pon en t s,
a ch ieved wit h select sh im s. Th e sh im s a r e pla ced r ea r bea r in g a n d scr ew in t o a xle h ou sin g t h r ou gh
beh in d t h e r ea r pin ion bea r in g cu p (F ig. 45). pin ion bea r in g cu ps (F ig. 47).
(3) In st a ll fr on t pin ion bea r in g a n d Con e-n u t 6740
h a n d t igh t (F ig. 46).
(4) P la ce Ar bor Disc 6732 on Ar bor D-115-3 in posi-
t ion in a xle h ou sin g side bea r in g cr a dles (F ig. 48).
In st a ll differ en t ia l bea r in g ca ps on Ar bor Discs a n d
t igh t en ca p bolt s t o 41 N·m (30 ft . lbs.).

DRIVE NOTE: Arbor Discs 6732 has different step diame-


PINION GEAR ters to fit other axles. Choose proper step for axle
DEPTH
SHIM being serviced.

(5) Assem ble Dia l In dica t or C-3339 in t o Scoot er


Block D-115-2 a n d secu r e set scr ew.
(6) P la ce Scoot er Block/Dia l In dica t or in posit ion
in a xle h ou sin g so dia l pr obe a n d scoot er block a r e
flu sh a ga in st t h e r ea r wa r d su r fa ce of t h e pin ion
h eigh t block (F ig. 46). H old scoot er block in pla ce a n d
zer o t h e dia l in dica t or fa ce t o t h e poin t er. Tigh t en
dia l in dica t or fa ce lock scr ew.
DIFFERENTIAL (7) Wit h scoot er block st ill in posit ion a ga in st t h e
BEARING pin ion h eigh t block, slowly slide t h e dia l in dica t or
SHIM
J9402-5 pr obe over t h e edge of t h e pin ion h eigh t block.
(8) Slide t h e dia l in dica t or pr obe a cr oss t h e ga p
Fig. 45 Shim Locations bet ween t h e pin ion h eigh t block a n d t h e a r bor ba r
If a n ew gea r set is bein g in st a lled, n ot e t h e dept h wit h t h e scoot er block a ga in st t h e pin ion h eigh t block
va r ia n ce et ch ed in t o bot h t h e or igin a l a n d r epla ce- (F ig. 49). Wh en t h e dia l pr obe con t a ct s t h e a r bor ba r,
m en t pin ion gea r. Add or su bt r a ct t h e t h ickn ess of t h e dia l poin t er will t u r n clockwise. Br in g dia l
t h e or igin a l dept h sh im s t o com pen sa t e for t h e differ- poin t er ba ck t o zer o a ga in st t h e a r bor ba r, do n ot
en ce in t h e dept h va r ia n ces. Refer t o t h e Dept h Va r i- t u r n dia l fa ce. Con t in u e m ovin g t h e dia l pr obe t o t h e
a n ce ch a r t . cr est of t h e a r bor ba r a n d r ecor d t h e h igh est r ea din g.
If t h e dia l in dica t or ca n n ot a ch ieve t h e zer o r ea din g,
PINION
DIAL SCOOTER
INDICATOR
HEIGHT
PINION
ARBORSCREW
ARBOR
BLOCK
CONE
DISC ARBOR
PINIONDISC
HEIGHT
BLOCK PINION HEIGHT
BLOCKPINION BLOCK PINION BLOCK
ARBOR

XJ DIFFERENTIAL AND DRIVELINE 3 - 37


ADJ U ST M EN T S (Cont inue d)
PI N I ON GEAR DEPT H VARI AN CE

Original Pinion Replacement Pinion Gear Depth Variance


Gear Depth
Variance −4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008

DIAL INDICATOR PINION BLOCK

t
PINION HEIGHT
PINION BLOCK BLOCK

SCOOTER BLOCK
Fig. 47 Pinion Height Block—Typical

ARBOR DISC ARBOR DISC

J9403-45

Fig. 46 Pinion Gear Depth Gauge Tools—Typical


t h e r ea r bea r in g cu p or t h e pin ion dept h ga u ge set is
n ot in st a lled cor r ect ly.
(9) Select a sh im equ a l t o t h e dia l in dica t or r ea d-
in g plu s t h e dr ive pin ion gea r dept h va r ia n ce n u m ber
et ch ed in t h e fa ce of t h e pin ion gea r (F ig. 44). F or
exa m ple, if t h e dept h va r ia n ce is –2, a dd +0.002 in .
t o t h e dia l in dica t or r ea din g.

NOTE: If an oil slinger is used behind the inner pin-


ion bearing, deduct the thickness of the slinger
from the dial indicator reading and use that total for Fig. 48 Gauge Tools In Housing—Typical
shim selection.
ARBOR DIAL INDICATOR
SCOOTER BLOCK DIFFERENTIAL
DIFFERENTIAL CASE
BEARING
AXLE
SHIM
HOUSING DRIVE PINION
DEPTH
BEARING
GEAR
SHIM
CAP

3 - 38 DIFFERENTIAL AND DRIVELINE XJ


ADJ U ST M EN T S (Cont inue d)

DRIVE
PINION GEAR
DEPTH
SHIM

Fig. 49 Pinion Gear Depth Measurement—Typical


DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
J9402-5
I N T RODU CT I ON
Differ en t ia l side bea r in g pr eloa d a n d gea r ba ckla sh
Fig. 50 Axle Adjustment Shim Locations
is a ch ieved by select ive sh im s posit ion ed beh in d t h e
differ en t ia l side bea r in g con es. Th e pr oper sh im (3) In st a ll r in g gea r on differ en t ia l ca se a n d
t h ickn ess ca n be det er m in ed u sin g slip-fit du m m y t igh t en bolt s t o specifica t ion .
bea r in gs D-348 in pla ce of t h e differ en t ia l side bea r- (4) In st a ll du m m y side bea r in gs D-348 on differ en -
in gs a n d a dia l in dica t or C-3339. Befor e pr oceedin g t ia l ca se.
wit h t h e differ en t ia l bea r in g pr eloa d a n d gea r ba ck- (5) In st a ll differ en t ia l ca se in a xle h ou sin g.
la sh m ea su r em en t s, m ea su r e t h e pin ion gea r dept h (6) In st a ll t h e m a r ked bea r in g ca ps in t h eir cor r ect
a n d pr epa r e t h e pin ion gea r for in st a lla t ion . E st a b- posit ion s. In st a ll a n d sn u g t h e bolt s (F ig. 51).
lish in g pr oper pin ion gea r dept h is essen t ia l t o est a b-
lish in g gea r ba ckla sh a n d t oot h con t a ct pa t t er n s.
Aft er t h e over a ll sh im t h ickn ess t o t a ke u p differ en -
t ia l side pla y is m ea su r ed, t h e pin ion gea r is
in st a lled, a n d t h e gea r ba ckla sh sh im t h ickn ess is
m ea su r ed. Th e over a ll sh im t h ickn ess is t h e t ot a l of
t h e dia l in dica t or r ea din g a n d t h e pr eloa d specifica -
t ion a dded t oget h er. Th e gea r ba ckla sh m ea su r em en t
det er m in es t h e t h ickn ess of t h e sh im u sed on t h e
r in g gea r side of t h e differ en t ia l ca se. Su bt r a ct t h e
gea r ba ckla sh sh im t h ickn ess fr om t h e t ot a l over a ll
sh im t h ickn ess a n d select t h a t a m ou n t for t h e pin ion
gea r side of t h e differ en t ia l (F ig. 50). Differ en t ia l
sh im m ea su r em en t s a r e per for m ed wit h a xle
spr ea der W-129-B r em oved.

SH I M SELECT I ON Fig. 51 Tighten Bolts Holding Bearing Caps


NOTE: It is difficult to salvage the differential side (7) Usin g a dea d-blow t ype m a llet , sea t t h e differ-
bearings during the removal procedure. Install en t ia l du m m y bea r in gs t o ea ch side of t h e a xle h ou s-
replacement bearings if necessary. in g (F ig. 52) a n d (F ig. 53).
(8) Th r ea d gu ide st u d C-3288-B in t o r ea r cover
(1) Rem ove differ en t ia l side bea r in gs fr om differ- bolt h ole below r in g gea r (F ig. 54).
en t ia l ca se. (9) At t a ch a dia l in dica t or C-3339 t o gu ide st u d.
(2) Rem ove fa ct or y in st a lled sh im s fr om differ en - P osit ion t h e dia l in dica t or plu n ger on a fla t su r fa ce
t ia l ca se. bet ween t h e r in g gea r bolt h ea ds (F ig. 54).
DIFFERENTIAL
CASE MALLET AXLE HOUSING
AXLE HOUSING
MALLET SPECIAL
ZERO
SPECIAL
SPECIAL
C-3288–B
DIAL
TOOL
TOOL
TOOL
INDICATOR
C-3339
C-3339FACE DIFFEREN-
SPECIAL
TIAL CASE
TOOL
FORCE
C-3288–B
TODIFFERENTIAL
PINION
AXLE
GEAR
HOUSING
CASE
SIDE

XJ DIFFERENTIAL AND DRIVELINE 3 - 39


ADJ U ST M EN T S (Cont inue d)

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

Fig. 53 Seat Ring Gear Side Differential Dummy SPECIAL


Side Bearing TOOL-~~~~ff
(10) P u sh a n d h old differ en t ia l ca se t o pin ion gea r C-3288-B
side of a xle h ou sin g (F ig. 55).
80a7e2fe
(11) Zer o dia l in dica t or fa ce t o poin t er (F ig. 55).
(12) P u sh a n d h old differ en t ia l ca se t o r in g gea r Fig. 55 Hold Differential Case and Zero Dial
side of t h e a xle h ou sin g (F ig. 56). Indicator
(13) Recor d dia l in dica t or r ea din g (F ig. 56).
(20) P osit ion t h e dia l in dica t or plu n ger on a fla t
(14) Add 0.008 in . (0.2 m m ) t o t h e zer o en d pla y
su r fa ce bet ween t h e r in g gea r bolt h ea ds. (F ig. 54).
t ot a l. Th is n ew t ot a l r epr esen t s t h e t h ickn ess of
(21) P u sh a n d h old differ en t ia l ca se t owa r d pin ion
sh im s t o com pr ess, or pr eloa d t h e n ew bea r in gs wh en
gea r (F ig. 57).
t h e differ en t ia l is in st a lled.
(22) Zer o dia l in dica t or fa ce t o poin t er (F ig. 57).
(15) Rot a t e dia l in dica t or ou t of t h e wa y on t h e
(23) P u sh a n d h old differ en t ia l ca se t o r in g gea r
gu ide st u d.
side of t h e a xle h ou sin g (F ig. 58).
(16) Rem ove differ en t ia l ca se a n d du m m y bea r in gs
(24) Recor d dia l in dica t or r ea din g (F ig. 58).
fr om a xle h ou sin g.
(25) Su bt r a ct 0.002 in . (0.05 m m ) fr om t h e dia l
(17) In st a ll t h e pin ion gea r in a xle h ou sin g. In st a ll
in dica t or r ea din g t o com pen sa t e for ba ckla sh bet ween
t h e pin ion yoke a n d est a blish t h e cor r ect pin ion
r in g a n d pin ion gea r s. Th is t ot a l is t h e t h ickn ess
r ot a t in g t or qu e.
sh im r equ ir ed t o a ch ieve pr oper ba ckla sh .
(18) In st a ll differ en t ia l ca se a n d du m m y bea r in gs
(26) Su bt r a ct t h e ba ckla sh sh im t h ickn ess fr om
D-348 in a xle h ou sin g (wit h ou t sh im s), in st a ll bea r-
t h e t ot a l pr eloa d sh im t h ickn ess. Th e r em a in der is
in g ca ps a n d t igh t en bolt s sn u g.
(19) Sea t r in g gea r side du m m y bea r in g (F ig. 53).
AXLE HOUSING
DIFFERENTIAL
DIFFERENTIAL
AXLE
AXLE HOUSING
HOUSING
CASECASE ZERO
FORCE
DIAL
READ
READ
TO
DIFFERENTIAL
PINION
INDICATOR
RING
PINION
DIAL
DIAL
GEAR
GEAR
INDICATOR
INDICATOR
GEAR
FACE
CASE
SIDE DIAL CATOR
INDI-
FORCE
FORCEDIFFERENTIAL
DIFFEREN-
CASETIAL
TO CASE
PINIONTOGEAR
RING
GEARSIDE
SIDE

3 - 40 DIFFERENTIAL AND DRIVELINE XJ


ADJ U ST M EN T S (Cont inue d)
t h e sh im t h ickn ess r equ ir ed on t h e pin ion side of t h e
a xle h ou sin g.
(27) Rot a t e dia l in dica t or ou t of t h e wa y on gu ide
st u d.
(28) Rem ove differ en t ia l ca se a n d du m m y bea r in gs
fr om a xle h ou sin g.
(29) In st a ll side bea r in g sh im s on differ en t ia l ca se
h u bs.
(30) In st a ll side bea r in gs a n d cu ps on differ en t ia l
ca se.
(31) In st a ll spr ea der W-129-B, u t ilizin g som e it em s
fr om Ada pt er Set 6987, on a xle h ou sin g a n d spr ea d
a xle open in g en ou gh t o r eceive differ en t ia l ca se.
(32) In st a ll differ en t ia l ca se in a xle h ou sin g.
(33) Rem ove spr ea der fr om a xle h ou sin g.
(34) Rot a t e t h e differ en t ia l ca se sever a l t im es t o
Fig. 56 Hold Differential Case and Read Dial sea t t h e side bea r in gs.
Indicator (35) P osit ion t h e in dica t or plu n ger a ga in st a r in g
gea r t oot h (F ig. 59).
c FORCE DIFFERENTIAL
(36) P u sh a n d h old r in g gea r u pwa r d wh ile n ot
CASE TO PINION
GEAR SIDE
a llowin g t h e pin ion gea r t o r ot a t e.
(37) Zer o dia l in dica t or fa ce t o poin t er.
(38) P u sh a n d h old r in g gea r down wa r d wh ile n ot
a llowin g t h e pin ion gea r t o r ot a t e. Dia l in dica t or
r ea din g sh ou ld be bet ween 0.12 m m (0.005 in .) a n d
0.20 m m (0.008 in .). If ba ckla sh is n ot wit h in specifi-
ca t ion s t r a n sfer t h e n ecessa r y a m ou n t of sh im t h ick-
n ess fr om on e side of t h e a xle h ou sin g t o t h e ot h er
(F ig. 60).
(39) Ver ify differ en t ia l ca se a n d r in g gea r r u n ou t
by m ea su r in g r in g t o pin ion gea r ba ckla sh a t sever a l
loca t ion s a r ou n d t h e r in g gea r. Rea din gs sh ou ld n ot
va r y m or e t h a n 0.05 m m (0.002 in .). If r ea din gs va r y
80a534d7
m or e t h a n specified, t h e r in g gea r or t h e differ en t ia l
ca se is defect ive.
Fig. 57 Hold Differential Case and Zero Dial
Aft er t h e pr oper ba ckla sh is a ch ieved, per for m
Indicator
Gea r Con t a ct P a t t er n An a lysis pr ocedu r e.
READ DIAL FORCE DIFFERENTIAL
INDICATOR CASE TO RING
\l}

'GEAR SIDE

-------

80a534d8

Fig. 58 Hold Differential Case and Read Dial


Indicator Fig. 59 Ring Gear Backlash Measurement
FOR
FORMORE
LESS BACKLASH
BACKLASH INCREASE
FOR MORE
SHIM BACKLASH
THIS SIDE
DECREASE SHIM
INCREASE SHIM
THISTHIS
DIE DECREASE SHIM THIS
SIDEFOR
FORLESS
MORE
BACKLASH
BACK- SIDE FOR LESS BACK-
LASH LASH

XJ DIFFERENTIAL AND DRIVELINE 3 - 41


ADJ U ST M EN T S (Cont inue d)

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

3 - 42 DIFFERENTIAL AND DRIVELINE XJ


ADJ U ST M EN T S (Cont inue d)

DRIVE SIDE COAST SIDE


OF RING OF RING
GEAR TEETH GEAR TEETH

DESIRABLE CONTACT PATTERN.


PATTERN SHOULD BE CENTERED
ON THE DRIVE SIDE OF TOOTH.
PATTERN SHOULD BE CENTERED ON
THE COAST SIDE OF TOOTH,
BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP OF
THE TOOTH.

RING GEAR BACKLASH CORRECl


THINNER PINION GEAR DEPTH
SHIM REQUIRED.

RING GEAR BACKLASH CORRECT.


THICKER PINION GEAR DEPTH
SHIM REQUIRED.

PINION GEAR DEPTH SHIM


CORRECT. DECREASE RING
GEAR BACKLASH.

PINION GEAR DEPTH SHIM


CORRECT. INCREASE RING
GEAR BACKLASH.

J9003-24

Fig. 61 Gear Tooth Contact Patterns


XJ DIFFERENTIAL AND DRIVELINE 3 - 43

SPECI FI CAT I ON S
181 FBI AXLE

Axle Type . . . . . . . . . . . . . . . . . . . . . . . . . . . H ypoid


Lu br ica n t . . . . . . . . SAE Th er m a lly St a ble 80W–90
Lu be Ca pa cit y . . . . . . . . . . . . . . . . . . 1.2 L (2.5 pt s.)
Axle Ra t io . . . . . . . . 3.07, 3.31, 3.54, 3.55, 3.73, 4.10
Differ en t ia l Side Gea r Clea r a n ce . . . . 0.12–0.20 m m
(0.005–0.008 in .)
Rin g Gea r Dia m et er . . . . . . . . . 18.09 cm (7.125 in .) Plug—SP-3289
Ba ckla sh . . . . . . . . . . . 0–0.15 m m (0.005–0.008 in .)
P in ion St d. Dept h . . . . . . . . . . . 92.1 m m (3.625 in .)
P in ion Bea r in g Rot a t in g Tor qu e
Or igin a l Bea r in gs . . . . . . . . 1–2 N·m (10–20 in . lbs.)
New Bea r in gs . . . . . . . . . 1.5–4 N·m (15–35 in . lbs.)
181 FBI AXLE

D ES CRIP TION TORQU E


F ill Ho le P lu g . . . . . . . . . . . . . . 34 N·m (25 ft . lbs.)
D iff. Co v e r B o lt . . . . . . . . . . . . 41 N·m (30 ft . lbs.) Adapter—C-293-39
B e a rin g Ca p B o lt . . . . . . . . . . . 61 N·m (45 ft . lbs.)
Rin g Ge a r B o lt . . . . . . 95–122 N·m (70–90 ft . lbs.)
Ax le N u t . . . . . . . . . . . . . . . . 237 N·m (175 ft . lbs.)
Hu b B rg . B o lt . . . . . . . . . . . . . 102 N·m (75 ft . lbs.)
Lo w e r B a ll S tu d . . . . . . . . . . . 108 N·m (80 ft . lbs.)
U p p e r B a ll S tu d . . . . . . . . . . . 101 N·m (75 ft . lbs.)

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

Dial Indicator—C-3339 Remover—D-149

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

Tool Set, Pinion Depth—6774


3 - 46 DIFFERENTIAL AND DRIVELINE XJ
SPECI AL T OOLS (Cont inue d)

1-1/8 HEX TURNBUCKLE 1-1/4 HEX TURNBUCKLE

Adapter Kit—6987 Installer—W-262

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

GENERAL INFORMATION DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 60


194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 47 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 67
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . 47 PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 63
DESCRIPTION AND OPERATION PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . 55
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 48 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TRAC-LOK OPERATION . . . . . . . . . . . . . . . . . . 48 RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
BEARING NOISE . . . . . . . . . . . . . .. . . . . . . . . 49 STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 67
DRIVELINE SNAP . . . . . . . . . . . . .. . . . . . . . . 50 TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . 68
GEAR NOISE . . . . . . . . . . . . . . . . .. . . . . . . . . 49 CLEANING AND INSPECTION
GENERAL INFORMATION . . . . . . .. . . . . . . . . 49 AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . 72
LOW SPEED KNOCK . . . . . . . . . . .. . . . . . . . . 50 TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
TRAC–LOK DIFFERENTIAL NOISE . . . . . . . . . 50 ADJUSTMENTS
TRAC–LOK TEST . . . . . . . . . . . . . .. . . . . . . . . 53 DIFFERENTIAL BEARING PRELOAD AND
VIBRATION . . . . . . . . . . . . . . . . . .. . . . . . . . . 50 GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 74
SERVICE PROCEDURES GEAR CONTACT PATTERN ANALYSIS . . . . . . 76
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . 53 PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . 72
REMOVAL AND INSTALLATION SPECIFICATIONS
AXLE SHAFT SEAL AND BEARING ... . . . . . . 59 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 78
AXLE SHAFT . . . . . . . . . . . . . . . . .... . . . . . . 58 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 78
COLLAPSIBLE SPACER . . . . . . . . .... . . . . . . 56 SPECIAL TOOLS
DIFFERENTIAL SIDE BEARINGS . .... . . . . . . 62 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 78

GEN ERAL I N FORM AT I ON Th e 194 RBI a xle h a s t h e a ssem bly pa r t n u m ber


a n d gea r r a t io list ed on a t a g. Th e t a g is a t t a ch ed t o
194 RBI AXLE t h e differ en t ia l h ou sin g by a cover bolt . Bu ild da t e
Th e 194 Rea r Bea m -design Ir on (RBI) a xle h ou sin g iden t ifica t ion codes a r e st a m ped on t h e cover side of
h a s a n ir on cen t er ca st in g (differ en t ia l h ou sin g) wit h a n a xle sh a ft t u be.
a xle sh a ft t u bes ext en din g fr om eit h er side. Th e Th e differ en t ia l ca se is a on e-piece design . Th e dif-
t u bes a r e pr essed in t o a n d welded t o t h e differ en t ia l fer en t ia l pin ion m a t e sh a ft is r et a in ed wit h a
h ou sin g t o for m a on e-piece a xle h ou sin g. t h r ea ded pin . Differ en t ia l bea r in g pr eloa d a n d r in g
Th e in t egr a l t ype, h ypoid gea r design , h ou sin g h a s gea r ba ckla sh is a dju st ed by t h e u se of select ive
t h e cen t er lin e of t h e pin ion set below t h e cen t er lin e spa cer sh im s. P in ion bea r in g pr eloa d is set a n d
of t h e r in g gea r. m a in t a in ed by t h e u se of a colla psible spa cer (F ig. 1).
Th e a xle h a s a ven t h ose t o r elieve in t er n a l pr es-
su r e ca u sed by lu br ica n t va por iza t ion a n d in t er n a l LUBRICANT SPECIFICATIONS
expa n sion . A m u lt i-pu r pose, h ypoid gea r lu br ica n t wh ich con -
Th e a xles a r e equ ipped wit h sem i–floa t in g a xle for m s t o t h e followin g specifica t ion s sh ou ld be u sed.
sh a ft s, m ea n in g t h a t loa ds a r e su ppor t ed by t h e a xle Mopa r t H ypoid Gea r Lu br ica n t con for m s t o a ll of
sh a ft a n d bea r in gs. Th e a xle sh a ft s a r e r et a in ed by t h ese specifica t ion s.
C–clips in t h e differ en t ia l side gea r s. • Th e lu br ica n t sh ou ld h a ve MIL–L–2105C a n d
Th e cover pr ovides a m ea n s for ser vicin g t h e differ- AP I GL 5 qu a lit y specifica t ion s.
en t ia l wit h ou t r em ovin g t h e a xle. • Lu br ica n t is a t h er m a lly st a ble SAE 80W–90
F or veh icles equ ipped wit h ABS br a kes, t h e a xles gea r lu br ica n t .
h a ve a t on e r in g pr essed on t o t h e a xle sh a ft . Use • Lu br ica n t for a xles in t en ded for h ea vy-du t y or
ca r e wh en r em ovin g a xle sh a ft s t o en su r e t h a t t h e t r a iler t ow u se is SAE 75W–140 SYNTH E TIC gea r
t on e wh eel or t h e wh eel speed sen sor a r e n ot da m - lu br ica n t .
a ged. Tr a c-lok differ en t ia ls r equ ir e t h e a ddit ion of 4 oz.
of fr ict ion m odifier t o t h e a xle lu br ica n t . Th e 194 RBI
DIFFERENTIAL
SHIM-RING
COLLAPSIBLE
GEAR
BEARING
SIDE
SPACER PINION GEAR
BEARING
DIFFERENTIAL
PINION
RING
DEPTH
GEAR
GEAR
SHIM-
SIDE
SHIM PINION GEARS
INPINION
WHEEL
PINION
STRAIGHT
ROTATE
100%
ROTATES
SHAFT
GEARS
PINION
ON
AHEAD
AXLE
DIFFERENTIAL
CASE
AT
ROTATE
GEAR
100%
DRIVING
SPEED
OF
CASE
WITH
SPEED
EACH
SIDE
CASEGEAR
OUTER WHEEL 110% CASE INNER WHEEL 90% CASE
SPEED SPEED

3 - 48 DIFFERENTIAL AND DRIVELINE XJ


GEN ERAL I N FORM AT I ON (Cont inue d)
IN STRAIGHT AHEAD DRIVING
COLLAPSIBLE EACH WHEEL ROTATES AT 100%
SPACER OF CASE SPEED

DIFFERENTIAL
BEARING
SHIM-RING
GEAR SIDE

PINION GEARS ROTATE


WITH CASE J9303-13
80a5037a

Fig. 1 Shim Locations Fig. 2 Differential Operation—Straight Ahead Driving

a xle lu br ica n t ca pa cit y is 1.66L (3.50 pt s.) t ot a l, 2). In t h is in st a n ce, t h e in pu t t or qu e a pplied t o t h e


in clu din g t h e fr ict ion m odifier if n ecessa r y. pin ion gea r s is n ot divided equ a lly. Th e pin ion gea r s
n ow r ot a t e a r ou n d t h e pin ion m a t e sh a ft in opposit e
CAUTION: If axle is submerged in water, lubricant dir ect ion s. Th is a llows t h e side gea r a n d a xle sh a ft
must be replaced immediately to avoid possible a t t a ch ed t o t h e ou t side wh eel t o r ot a t e a t a fa st er
premature axle failure. speed.
AXLE (j;

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

XJ DIFFERENTIAL AND DRIVELINE 3 - 49


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
• Over loa din g (excessive en gin e t or qu e) or exceed-
in g veh icle weigh t ca pa cit y.
RING DRIVE • In cor r ect clea r a n ce or ba ckla sh a dju st m en t .
GEAR PINION 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.

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)

CONDITION POSSIBLE CAUSES CORRECTION


WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Faulty or brinelled bearings must
be replaced.
AXLE SHAFT NOISE 1. Misaligned axle shaft tube. 1. Inspect axle shaft tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Replace bent or sprung axle
shaft.
3. End play in drive pinion bearings. 3. Refer to Drive Pinion Bearing
Pre-Load Adjustment.
4. Excessive gear backlash between 4. Check adjustment of ring gear
ring gear and pinion gear. backlash and pinion gear. Correct as
necessary.
5. Improper adjustment of drive 5. Adjust drive pinion shaft bearings.
pinion gear shaft bearings.
6. Loose drive pinion gearshaft yoke 6. Tighten drive pinion gearshaft
nut. yoke nut with specified torque.
7. Improper wheel bearing 7. Readjust as necessary.
adjustment.
8. Scuffed gear tooth contact 8. If necessary, replace scuffed
surfaces. gears.
AXLE SHAFT BROKE 1. Misaligned axle shaft tube. 1. Replace broken axle shaft after
correcting axle shaft tube alignment.
2. Vehicle overloaded. 2. Replace broken axle shaft. Avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken axle shaft after
inspecting for other possible casues.
Avoid erratic use of clutch.
4. Grabbing clutch. 4. Replace broken axle shaft.
Inspect clutch and make necessary
repairs or adjustments.
DIFFERENTIAL CASE CRACKED 1. Improper adjustment of differential 1. Replace cracked case; examine
bearings. gears and bearings for possible
damage. At reassembly, adjust
differential bearings properly.
2. Excessive ring gear backlash. 2. Replace cracked case; examine
gears and bearings for possible
damage. At reassembly, adjust ring
gear backlash properly.
3. Vehicle overloaded. 3. Replace cracked case; examine
gears and bearings for possible
damage. Avoid excessive weight on
vehicle.
4. Erratic clutch operation. 4. Replace cracked case. After
inspecting for other possible causes,
examine gears and bearings for
possible damage. Avoid erratic use
of clutch.
3 - 52 DIFFERENTIAL AND DRIVELINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


DIFFERENTIAL GEARS SCORED 1. Insufficient lubrication. 1. Replace scored gears. Scoring
marks on the drive face of gear
teeth or in the bore are caused by
instantaneous fusing of the mating
surfaces. Scored gears should be
replaced. Fill rear differential housing
to required capacity with proper
lubricant. Refer to Specifications.
2. Improper grade of lubricant. 2. Replace scored gears. Inspect all
gears and bearings for possible
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
3. Excessive spinning of one 3. Replace scored gears. Inspect all
wheel/tire. gears, pinion bores and shaft for
damage. Service as necessary.
LOSS OF LUBRICANT 1. Lubricant level too high. 1. Drain excess lubricant by
removing fill plug and allow lubricant
to level at lower edge of fill plug
hole.
2. Worn axle shaft seals. Replace worn seals.
3. Cracked differential housing. 3. Repair or replace housing as
necessary.
4. Worn drive pinion gear shaft seal. 4. Replace worn drive pinion gear
shaft seal.
5. Scored and worn yoke. 5. Replace worn or scored yoke and
seal.
6. Axle cover not properly sealed. 6. Remove cover and clean flange
and reseal.
AXLE OVERHEATING 1. Lubricant level too low. 1. Refill differential housing.
2. Incorrect grade of lubricant. 2. Drain, flush and refill with correct
amount of the correct lubricant.
3. Bearings adjusted too tight. 3. Readjust bearings.
4. Excessive gear wear. 4. Inspect gears for excessive wear
or scoring. Replace as necessary.
5. Insufficient ring gear backlash. 5. Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (RING GEAR 1. Overloading. 1. Replace gears. Examine other
AND PINION) gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for possible
damage. Avoid erratic clutch
operation.
3. Ice-spotted pavements. 3. Replace gears. Examine the
remaining parts for possible
damage. Replace parts as required.
4. Improper adjustments. 4. Replace gears. Examine other
parts for possible damage. Ensure
ring gear backlash is correct.
SPECIAL
6790
IN WITH
CENTER
HOLE
TOOL
BOLT TORQUE WRENCH

XJ DIFFERENTIAL AND DRIVELINE 3 - 53


DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


AXLE NOISE 1. Insufficient lubricant. 1. Refill axle with correct amount of
proper lubricant. Also inspect for
leaks and correct as necessary.
2. Improper ring gear and drive 2. Check ring gear and pinion gear
pinion gear adjustment. teeth contact pattern.
3. Unmatched ring gear and drive 3. Remove unmatched ring gear and
pinion gear. drive pinion gear. Replace with
matched gear and drive pinion gear
set.
4. Worn teeth on ring gear or drive 4. Check teeth on ring gear and
pinion gear. drive pinion gear for correct contact.
If necessary, replace with new
matched set.
5. Loose drive pinion gear shaft 5. Adjust drive pinion gearshaft
bearings. bearing preload torque.
6. Loose differential bearings. 6. Adjust differential bearing preload
torque.
7. Misaligned or sprung ring gear. 7. Measure ring gear runout.
8. Loose differential bearing cap 8. Tighten with specified torque.
bolts.

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

3 - 54 DIFFERENTIAL AND DRIVELINE XJ


SERV I CE PROCEDU RES (Cont inue d)
(7) Rem ove wh eel speed sen sor s, if n ecessa r y.
Refer t o Gr ou p 5, Br a kes, for pr oper pr ocedu r es.
(8) Discon n ect t h e br a ke h ose a t t h e a xle ju n ct ion
block. Do n ot discon n ect t h e br a ke h ydr a u lic lin es a t
t h e wh eel cylin der s. Refer t o Gr ou p 5, Br a kes, for
pr oper pr ocedu r es.
(9) Discon n ect t h e ven t h ose fr om t h e a xle sh a ft
t u be.
(10) Ma r k t h e pr opeller sh a ft a n d yokes for in st a l-
la t ion a lign m en t r efer en ce.
(11) Rem ove pr opeller sh a ft .
(12) Discon n ect st a bilizer ba r lin ks.
(13) Discon n ect sh ock a bsor ber s fr om a xle.
AXLE HOUSING (14) Rem ove t h e U-bolt s wh ich h old t h e a xle t o t h e
COVER 80a534a8
spr in g br a cket s.
(15) Sepa r a t e t h e a xle fr om t h e veh icle.
Fig. 6 Apply Sealant
I N STALLAT I ON
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. NOTE: The weight of the vehicle must be sup-
(7) In st a ll t h e cover a n d a n y iden t ifica t ion t a g. ported by the springs before suspension arms and
Tigh t en t h e cover bolt s t o 41 N·m (30 ft . lbs.) t or qu e. track bar fasteners can be tightened. If the springs
(8) F or Tr a c–lok differ en t ia ls, a qu a n t it y of are not at their normal ride position, vehicle ride
Mopa r t Tr a c–lok lu br ica n t (fr ict ion m odifier ), or height and handling could be affected.
equ iva len t , m u st be a dded a ft er r epa ir ser vice or a
lu br ica n t ch a n ge. Refer t o t h e Lu br ica n t Specifica - (1) Ra ise t h e a xle wit h lift in g device a n d a lign t h e
t ion s sect ion of t h is gr ou p for t h e qu a n t it y n ecessa r y. spr in g cen t er in g bolt s wit h t h e m a t in g h oles in t h e
(9) F ill differ en t ia l wit h Mopa r t H ypoid Gea r a xle spr in g per ch .
Lu br ica n t , or equ iva len t , t o bot t om of t h e fill plu g (2) In st a ll t h e U-bolt s wh ich h old t h e a xle t o t h e
h ole. Refer t o t h e Lu br ica n t Specifica t ion s sect ion of spr in g br a cket s. Tigh t en n u t s t o 70 N·m (52 ft . lbs.).
t h is gr ou p for t h e qu a n t it y n ecessa r y. (3) In st a ll sh ock a bsor ber s a n d t igh t en n u t s t o 60
N·m (44 ft . lbs.) t or qu e.
CAUTION: Overfilling the differential can result in (4) In st a ll st a bilizer ba r lin ks a n d t igh t en n u t s t o
lubricant foaming and overheating. 74 N·m (55 ft . lbs.) t or qu e.
(5) In st a ll t h e wh eel speed sen sor s, if n ecessa r y.
(10) In st a ll t h e fill h ole plu g a n d lower t h e veh icle.
Refer t o Gr ou p 5, Br a kes, for pr oper pr ocedu r es.
(11) Tr a c–lok differ en t ia l equ ipped veh icles sh ou ld
(6) Con n ect pa r kin g br a ke ca ble t o br a cket s a n d
be r oa d t est ed by m a kin g 10 t o 12 slow figu r e-eigh t
lever.
t u r n s. Th is m a n eu ver will pu m p t h e lu br ica n t
(7) In st a ll t h e br a ke dr u m s. Refer t o Gr ou p 5,
t h r ou gh t h e clu t ch discs t o elim in a t e a possible ch a t -
Br a kes, for pr oper pr ocedu r es.
t er n oise com pla in t .
(8) Con n ect t h e br a ke h ose t o t h e a xle ju n ct ion
block. Refer t o Gr ou p 5, Br a kes, for pr oper pr oce-
REM OVAL AN D I N STALLAT I ON du r es.
(9) In st a ll a xle ven t h ose.
REAR AXLE (10) Align pr opeller sh a ft a n d pin ion yoke r efer-
en ce m a r ks. In st a ll U-join t st r a ps a n d bolt s. Tigh t en
REM OVAL t o 19 N·m (14 ft . lbs.) t or qu e.
(1) Ra ise a n d su ppor t t h e veh icle. (11) In st a ll t h e wh eels a n d t ir es.
(2) P osit ion a su it a ble lift in g device u n der t h e (12) Add gea r lu br ica n t , if n ecessa r y. Refer t o
a xle. Lu br ica n t Specifica t ion s in t h is sect ion for lu br ica n t
(3) Secu r e a xle t o device. r equ ir em en t s.
(4) Rem ove t h e wh eels a n d t ir es. (13) Rem ove lift in g device fr om a xle a n d lower t h e
(5) Rem ove t h e br a ke dr u m s fr om t h e a xle. Refer veh icle.
t o Gr ou p 5, Br a kes, for pr oper pr ocedu r es.
(6) Discon n ect pa r kin g br a ke ca bles fr om br a cket s
a n d lever.
SPECIAL SPECIAL
TOOL C-452
TOOL C-3281
YOKE SPECIAL TOOL C-3972–A
SPECIAL
AXLE
PINION
TOOL
HOUSING
C-4171
YOKE

XJ DIFFERENTIAL AND DRIVELINE 3 - 55


REM OVAL AN D I N STALLAT I ON (Cont inue d)
PINION SHAFT SEAL
REM OVAL SPECIAL
(1) Ra ise a n d su ppor t t h e veh icle. SPECIAL TOOL TOOL
(2) Rem ove wh eel a n d t ir e a ssem blies. C-4171 C-3972-A
(3) Rem ove t h e br a ke dr u m s. Refer t o Gr ou p 5,
Br a kes, for pr oper pr ocedu r es.
(4) Ma r k t h e pr opeller sh a ft a n d pin ion yoke for
in st a lla t ion a lign m en t r efer en ce.
(5) Rem ove t h e pr opeller sh a ft fr om t h e yoke.
(6) Rot a t e t h e pin ion gea r t h r ee or fou r t im es.
(7) Mea su r e t h e a m ou n t of t or qu e n ecessa r y t o
r ot a t e t h e pin ion gea r wit h a (in . lbs.) dia l-t ype
t or qu e wr en ch . Recor d t h e t or qu e r ea din g for in st a l-
la t ion r efer en ce. 80a7e2be
(8) Usin g H older 6958 t o h old t h e pin ion yoke,
r em ove t h e pin ion n u t a n d wa sh er. Fig. 8 Pinion Seal Installation
(9) Use Rem over C-452 a n d Wr en ch C-3281 t o
r em ove t h e pin ion yoke (F ig. 7). PINION
YOKE

AXLE
HOUSING
80a8710c

J9102-31 Fig. 9 Pinion Yoke Installation


CAUTION: Never loosen pinion gear nut to
Fig. 7 Pinion Yoke Removal decrease pinion gear bearing rotating torque and
(10) Use a su it a ble pr y t ool or slide h a m m er never exceed specified preload torque. If preload
m ou n t ed scr ew t o r em ove t h e pin ion gea r sea l. torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
I N STALLAT I ON sequence will then have to be repeated.
(1) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
lip of pin ion sea l. In st a ll sea l wit h In st a ller C-3972-A (5) Rot a t e t h e pin ion sh a ft u sin g a (in . lbs.) t or qu e
a n d H a n dle C-4171 (F ig. 8). wr en ch . Rot a t in g t or qu e sh ou ld be equ a l t o t h e r ea d-
(2) In st a ll yoke on t h e pin ion gea r wit h Scr ew in g r ecor ded du r in g r em ova l plu s a n a ddit ion a l 0.56
8112, Cu p 8109, a n d H older 6958 (F ig. 9). N·m (5 in . lbs.) (F ig. 10).
(6) If t h e r ot a t in g t or qu e is low, u se H older 6958 t o
CAUTION: Do not exceed the minimum tightening h old t h e pin ion yoke (F ig. 11), a n d t igh t en t h e pin ion
torque when installing the pinion yoke at this point. sh a ft n u t in 6.8 N·m (5 ft . lbs.) in cr em en t s u n t il t h e
Damage to the collapsible spacer or bearings may pr oper r ot a t in g t or qu e is a ch ieved.
result.
CAUTION: If the maximum tightening torque is
(3) In st a ll t h e yoke wa sh er a n d a n ew n u t on t h e reached prior to reaching the required rotating
pin ion gea r a n d t igh t en t h e pin ion n u t u n t il t h er e is torque, the collapsible spacer may have been dam-
zer o bea r in g en d-pla y. aged. Replace the collapsible spacer.
(4) Tigh t en t h e n u t t o 271 N·m (200 ft . lbs.).
3/4 DRIVE
PINION YOKE
WRENCH
TORQUE
INCH SPECIAL
POUND TOOL
6958
WRENCH
TORQUE 1 in. PIPE SPECIAL SPECIAL
TOOL C-452
TOOL C-3281
YOKE

3 - 56 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rem ove r ea r br a ke dr u m s. Refer t o Gr ou p 5,
Br a kes, for pr oper pr ocedu r es.
(4) Ma r k t h e pr opeller sh a ft a n d pin ion yoke for
in st a lla t ion r efer en ce.
(5) Rem ove t h e pr opeller sh a ft fr om t h e yoke.
(6) Rot a t e t h e pin ion gea r t h r ee or fou r t im es.
(7) Mea su r e t h e a m ou n t of t or qu e n ecessa r y t o
r ot a t e t h e pin ion gea r wit h a (in . lbs.) dia l-t ype
t or qu e wr en ch . Recor d t h e t or qu e r ea din g for in st a l-
la t ion r efer en ce.
(8) Usin g H older 6958 t o h old t h e pin ion yoke,
r em ove t h e pin ion n u t a n d wa sh er.
(9) Use Rem over C-452 a n d Wr en ch C-3281 t o
r em ove t h e pin ion yoke (F ig. 12).
(10) 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 pin ion sh a ft sea l.
(11) Rem ove t h e fr on t pin ion bea r in g u sin g a pa ir
of su it a ble pick t ools t o pu ll t h e bea r in g st r a igh t off
t h e pin ion gea r sh a ft . It m a y be n ecessa r y t o ligh t ly
t a p t h e en d of t h e pin ion gea r wit h a r a wh ide or r u b-
ber m a llet if t h e bea r in g becom es bou n d on t h e pin -
ion sh a ft .
Fig. 10 Check Pinion Rotation Torque (12) Rem ove t h e colla psible spa cer .

3/4 DRIVE
TORQUE SPECIAL TOOL
WRENCH 80a4d33b C-452 J9102-31

Fig. 11 Tightening Pinion Shaft Nut–Typical Fig. 12 Pinion Yoke Removal


(7) Align t h e in st a lla t ion r efer en ce m a r ks on t h e REM OVAL W/PI N I ON REM OV ED
pr opeller sh a ft a n d yoke a n d in st a ll t h e pr opeller (1) Ra ise a n d su ppor t t h e veh icle.
sh a ft . (2) Rem ove wh eel a n d t ir e a ssem blies.
(8) Add gea r lu br ica n t t o t h e differ en t ia l h ou sin g, (3) Rem ove r ea r br a ke dr u m s. Refer t o Gr ou p 5,
if n ecessa r y. Refer t o t h e Lu br ica n t Specifica t ion s for Br a kes, for pr oper pr ocedu r es.
gea r lu br ica n t r equ ir em en t s. (4) Ma r k t h e pr opeller sh a ft a n d pin ion yoke for
(9) In st a ll t h e br a ke dr u m s. Refer t o Gr ou p 5, in st a lla t ion r efer en ce.
Br a kes, for pr oper pr ocedu r es. (5) Rem ove t h e pr opeller sh a ft fr om t h e yoke.
(10) In st a ll wh eel a n d t ir e a ssem blies. (6) Rot a t e t h e pin ion gea r t h r ee or fou r t im es.
(11) Lower t h e veh icle. (7) Mea su r e t h e a m ou n t of t or qu e n ecessa r y t o
r ot a t e t h e pin ion gea r wit h a (in . lbs.) dia l-t ype
COLLAPSIBLE SPACER t or qu e wr en ch . Recor d t h e t or qu e r ea din g for in st a l-
la t ion r efer en ce.
REM OVAL W/PI N I ON I N STALLED
(8) Rem ove differ en t ia l a ssem bly fr om a xle h ou s-
(1) Ra ise a n d su ppor t t h e veh icle.
in g.
(2) Rem ove wh eel a n d t ir e a ssem blies.
RAWHIDE HAM-
MER OIL
REAR
SLINGER
BEAR-
ING SPECIAL
C-3972–A
TOOL
IBLE
COLLAPS-
SPECIAL
SHOULDER
SPACER
PINION
C-4171
GEAR
TOOL

XJ DIFFERENTIAL AND DRIVELINE 3 - 57


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(9) Usin g H older 6958 t o h old yoke, r em ove t h e
pin ion yoke n u t a n d wa sh er.
(10) Usin g Rem over C–452 a n d Wr en ch C–3281,
r em ove t h e pin ion yoke fr om pin ion sh a ft (F ig. 12).
(11) Rem ove t h e pin ion gea r fr om h ou sin g (F ig.
13). 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.
(12) Rem ove colla psible spa cer fr om pin ion sh a ft .
RAWHIDE
HAMMER

REAR
BEARING

OIL
r------ PINION
GEAR
SLINGER

J9302-66

Fig. 14 Collapsible Preload Spacer

SPECIAL
SPECIAL TOOL TOOL
C-4171 C-3972-A
J9302-25

Fig. 13 Remove Pinion Gear


I N STALLAT I ON
(1) In st a ll a n ew colla psible pr eloa d spa cer on pin -
ion sh a ft (F ig. 14).
(2) If pin ion gea r wa s r em oved, in st a ll pin ion gea r
in h ou sin g.
(3) In st a ll pin ion fr on t bea r in g, if n ecessa r y.
(4) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
80a7e2be
lip of pin ion sea l. In st a ll sea l wit h In st a ller C-3972-A
a n d H a n dle C–4171 (F ig. 15). Fig. 15 Pinion Seal Installation
(5) In st a ll yoke wit h Scr ew 8112, Cu p 8109, a n d
CAUTION: Never loosen pinion gear nut to
H older 6958 (F ig. 16).
decrease pinion gear bearing rotating torque and
(6) If t h e or igin a l pin ion bea r in gs a r e bein g u sed,
never exceed specified preload torque. If preload
in st a ll differ en t ia l a ssem bly a n d a xle sh a ft s, if n eces-
torque or rotating torque is exceeded a new col-
sa r y.
lapsible spacer must be installed. The torque
NOTE: If new pinion bearings were installed, do not sequence will then have to be repeated.
install the differential assembly and axle shafts until
(9) Usin g yoke h older 6958 a n d a t or qu e wr en ch
after the pinion bearing preload and rotating torque
set a t 474 N·m (350 ft . lbs.), cr u sh colla psible spa cer
are set.
u n t il bea r in g en d pla y is t a ken u p (F ig. 17).
(7) In st a ll t h e yoke wa sh er a n d a n ew n u t on t h e
NOTE: If more than 474 N·m (350 ft. lbs.) of torque
pin ion gea r. Tigh t en t h e pin ion n u t u n t il t h er e is zer o
is necessary to remove the bearing end play, the
bea r in g en d-pla y.
collapsible spacer is defective and must be
(8) Tigh t en t h e n u t t o 271 N·m (200 ft . lbs.).
replaced.
3/4 DRIVE WRENCH
TORQUE SPECIAL TOOL
6958 AXLE
PINION
1HOUSING
in. PIPE
YOKE PINION YOKE
INCH POUND WRENCH
TORQUE

3 - 58 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

PINION
YOKE

AXLE
HOUSING
80a8710c

Fig. 16 Pinion Yoke Installation


(10) Slowly t igh t en t h e n u t in 6.8 N·m (5 ft . lbs.)
in cr em en t s u n t il t h e r ot a t in g t or qu e is a ch ieved.
Mea su r e t h e r ot a t in g t or qu e fr equ en t ly t o a void over
cr u sh in g t h e colla psible spa cer (F ig. 18).
Fig. 18 Check Pinion Gear Rotation Torque
AXLE SHAFT
REM OVAL
(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.
(2) Rem ove wh eel a n d t ir e a ssem bly.
(3) Rem ove br a ke dr u m . Refer t o Gr ou p 5, Br a kes,
for pr oper pr ocedu r e.
(4) Clea n a ll for eign m a t er ia l fr om h ou sin g cover
a r ea .
(5) Loosen h ou sin g cover bolt s. Dr a in lu br ica n t
3/4 DRIVE 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-
TORQUE in g cover.
WRENCH 80a4d33b
(6) Rot a t e differ en t ia l ca se so t h a t pin ion m a t e
gea r sh a ft lock scr ew is a ccessible. Rem ove lock
Fig. 17 Tightening Pinion Nut–Typical
scr ew a n d pin ion m a t e gea r sh a ft fr om differ en t ia l
(11) Ch eck r ot a t in g t or qu e wit h a (in . lbs.) t or qu e ca se (F ig. 19).
wr en ch (F ig. 18). Th e t or qu e n ecessa r y t o r ot a t e t h e (7) P u sh a xle sh a ft in wa r d a n d r em ove a xle sh a ft
pin ion gea r sh ou ld be: C–clip lock fr om t h e a xle sh a ft (F ig. 20).
• Or igin a l Bea r in gs — Th e r ea din g r ecor ded du r- (8) Rem ove a xle sh a ft . Use ca r e t o pr even t da m a ge
in g r em ova l, plu s a n a ddit ion a l 0.56 N·m (5 in . lbs.). t o a xle sh a ft bea r in g a n d sea l, wh ich will r em a in in
• New Bea r in gs — 2 t o 5 N·m (15 t o 35 in . lbs.). a xle sh a ft t u be. Also, exer cise ca r e n ot t o da m a ge t h e
(12) In st a ll differ en t ia l a ssem bly a n d a xle sh a ft s, wh eel speed sen sor on veh icles equ ipped wit h ABS
if n ecessa r y. br a kes.
(13) Align m a r ks m a de pr eviou sly on yoke a n d (9) In spect a xle sh a ft sea l for lea ka ge or da m a ge.
pr opeller sh a ft a n d in st a ll pr opeller sh a ft . (10) In spect r oller bea r in g con t a ct su r fa ce on a xle
(14) In st a ll r ea r br a ke dr u m s. Refer t o Gr ou p 5, sh a ft for sign s of br in ellin g, ga llin g a n d pit t in g. If
Br a kes, for pr oper pr ocedu r es. a n y of t h ese con dit ion s exist , t h e a xle sh a ft a n d/or
(15) Add gea r lu br ica n t , if n ecessa r y. Refer t o bea r in g a n d sea l m u st be r epla ced.
Lu br ica n t Specifica t ion s of t h is sect ion for lu br ica n t
r equ ir em en t s.
(16) In st a ll wh eel a n d t ir e a ssem blies.
(17) Lower veh icle.
SIDE GEAR AXLEPINION
SHAFT
LOCK
SCREW
C-CLIPLOCK
GEAR MATE SHAFT AXLE SHAFT
TUBE FOOT ADAPTER
THREADED
GUIDE
PLATE
GUIDE
ROD
NUT

XJ DIFFERENTIAL AND DRIVELINE 3 - 59


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(6) In st a ll br a ke dr u m . Refer t o Gr ou p 5, Br a kes,
for pr oper pr ocedu r es.
(7) In st a ll wh eel a n d t ir e.
(8) Lower veh icle.

AXLE SHAFT SEAL AND BEARING


REM OVAL
(1) Rem ove t h e a xle sh a ft .
(2) Rem ove t h e a xle sh a ft sea l fr om t h e en d of t h e
a xle sh a ft t u be wit h a sm a ll pr y ba r.

NOTE: The seal and bearing can be removed at the


same time with the bearing removal tool.
J9302-47 (3) Rem ove t h e a xle sh a ft bea r in g fr om t h e a xle
t u be wit h Bea r in g Rem ova l Tool Set 6310 u sin g
Fig. 19 Mate Shaft Lock Screw Ada pt er F oot 6310-5 (F ig. 21).
AXLE SHAFT
TUBE

~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

3 - 60 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

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

(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. Fig. 24 Install Axle Housing Spreader
(3) Rem ove t h e differ en t ia l h ou sin g cover a n d opposit e side of t h e h ou sin g (F ig. 25) a n d zer o t h e
a llow flu id t o dr a in . in dica t or.
(4) Rem ove a xle sh a ft s.
(5) Not e t h e in st a lla t ion r efer en ce let t er s st a m ped CAUTION: Do not spread over 0.38 mm (0.015 in). If
on t h e bea r in g ca ps a n d h ou sin g m a ch in ed sea lin g the housing is over–spread, it could be distorted or
su r fa ce (F ig. 23). damaged.

(9) Spr ea d t h e h ou sin g en ou gh t o r em ove t h e dif-


fer en t ia l ca se fr om t h e h ou sin g. Mea su r e t h e dis-
t a n ce wit h t h e dia l in dica t or (F ig. 26).
DIAL INDICATOR
~LEVER
ADAPTER

Fig. 23 Bearing Cap Identification


(6) Loosen t h e differ en t ia l bea r in g ca p bolt s.
(7) P osit ion Spr ea der W–129–B, u t ilizin g som e
it em s fr om Ada pt er set 6987, wit h t h e t ool dowel pin s Fig. 25 Install Dial Indicator
sea t ed in t h e loca t in g h oles (F ig. 24). In st a ll t h e h old-
down cla m ps a n d t igh t en t h e t ool t u r n bu ckle fin ger- (10) Rem ove t h e dia l in dica t or.
–t igh t . (11) Wh ile h oldin g t h e differ en t ia l ca se in posit ion ,
(8) In st a ll a P ilot St u d C-3288-B a t t h e left side of r em ove t h e differ en t ia l bea r in g ca p bolt s a n d ca ps.
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 pilot st u d. Loa d t h e in dica t or plu n ger a ga in st t h e
AXLE
SPECIAL
HOUSING
C-3339
BEARING
TOOL CUPS DIFFERENTIAL
SPECIALTOOL
W-129–B
CASE AXLE HOUSING TURNBUCKLE SAFETY
SPECIALTOOL
HOLD
W-129–B
DOWEL
DOWN

XJ DIFFERENTIAL AND DRIVELINE 3 - 61


REM OVAL AN D I N STALLAT I ON (Cont inue d)
sh im r equ ir em en t s m a y ch a n ge. Refer t o t h e Differ-
en t ia l Bea r in g P r eloa d a n d Gea r Ba ckla sh pr oce-
du r es in t h is sect ion t o det er m in e t h e pr oper sh im
select ion .
(1) P osit ion Spr ea der W–129–B, u t ilizin g som e
it em s fr om Ada pt er set 6987, wit h t h e t ool dowel pin s
sea t ed in t h e loca t in g h oles (F ig. 28). In st a ll t h e h old-
down cla m ps a n d t igh t en t h e t ool t u r n bu ckle fin ger-
–t igh t .

DOWEL

SAFETY
HOLD
DOWN

Fig. 26 Spread Axle Housing


(12) Rem ove t h e differ en t ia l fr om t h e h ou sin g.
E n su r e t h a t t h e differ en t ia l bea r in g cu ps r em a in in SPECIAL
TURNBUCKLE
posit ion on t h e differ en t ia l bea r in gs (F ig. 27). TOOL
W-129-B
DIFFERENTIAL
CASE
0
80a534c5

Fig. 28 Install Axle Housing Spreader


(2) In st a ll a P ilot St u d C-3288-B a t t h e left side of
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 pilot st u d. Loa d t h e in dica t or plu n ger a ga in st t h e
opposit e side of t h e h ou sin g (F ig. 25) a n d zer o t h e
in dica t or.

CAUTION: Do not spread over 0.38 mm (0.015 in). If


the housing is over–spread, it could be distorted or
(C) (C) A 80a534c8 damaged.

Fig. 27 Differential Case Removal (3) Spr ea d t h e h ou sin g en ou gh t o in st a ll t h e ca se


in t h e h ou sin g. Mea su r e t h e dist a n ce wit h t h e dia l
(13) Ma r k or t a g t h e differ en t ia l bea r in g cu ps t o
in dica t or (F ig. 26).
in dica t e wh ich side of t h e differ en t ia l t h ey wer e
(4) Rem ove t h e dia l in dica t or.
r em oved fr om .
(5) In st a ll differ en t ia l ca se in t h e h ou sin g. E n su r e
(14) Ret r ieve differ en t ia l ca se pr eloa d sh im s fr om
t h a t t h e differ en t ia l bea r in g cu ps r em a in in posit ion
a xle h ou sin g. Ma r k or t a g t h e differ en t ia l ca se pr e-
on t h e differ en t ia l bea r in gs a n d t h a t t h e pr eloa d
loa d sh im s t o in dica t e wh ich side of t h e differ en t ia l
sh im s r em a in bet ween t h e fa ce of t h e bea r in g cu p
t h ey wer e r em oved fr om .
a n d t h e h ou sin g. Ta p t h e differ en t ia l ca se t o en su r e
(15) Rem ove spr ea der fr om h ou sin g.
t h e bea r in gs cu ps a n d sh im s a r e fu lly sea t ed in t h e
I N STALLAT I ON h ou sin g.
If r epla cem en t differ en t ia l bea r in gs or differ en t ia l (6) In st a ll t h e bea r in g ca ps a t t h eir or igin a l loca -
ca se a r e bein g in st a lled, differ en t ia l side bea r in g t ion s (F ig. 29).
(7) Loosely in st a ll differ en t ia l bea r in g ca p bolt s.
INSTALLATION
ENCE LETTERS
REFER- INSTALLATION
ENCE LETTERS
REFER- SPECIAL
SPECIALC-293–PA
DIFFERENTIAL
TOOL
TOOL
SP-3289
TOOL
BEARING
C-3716–A
BEARING SPECIAL
HANDLE
DIFFERENTIAL
TOOL C-4171
C-293–39

3 - 62 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

SPECIAL
TOOL
J9003-92 SP-3289

Fig. 29 Differential Bearing Cap Reference Letters


(8) Rem ove a xle h ou sin g spr ea der.
(9) Tigh t en t h e bea r in g ca p bolt s t o 77 N·m (57 ft .
lbs.) t or qu e.
(10) In st a ll t h e a xle sh a ft s.

DIFFERENTIAL SIDE BEARINGS


REM OVAL
(1) Rem ove differ en t ia l fr om a xle h ou sin g.
(2) Rem ove t h e bea r in gs fr om t h e differ en t ia l ca se 80a7e2a9

wit h P u ller /P r ess C-293-PA, C-293-39 Blocks, a n d


P lu g SP -3289 (F ig. 30). Fig. 30 Differential Bearing Removal

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

CAUTION: Do not reuse the bolts that held the ring


gear to the differential case. The bolts can fracture Fig. 31 Install Differential Side Bearings
causing extensive damage. (1) In ver t t h e differ en t ia l ca se a n d st a r t t wo r in g
gea r bolt s. Th is will pr ovide ca se-t o-r in g gea r bolt
h ole a lign m en t .
(2) In ver t t h e differ en t ia l ca se in t h e vise.
RAWHIDE
RING GEAR
CASE
HAM-
MER CASE
TORQUE
RINGRING
GEAR
WRENCH
GEAR
BOLT SPECIAL SPECIAL
TOOL C-452
TOOL C-3281
YOKE RAWHIDE HAM-
MER

XJ DIFFERENTIAL AND DRIVELINE 3 - 63


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) Usin g H older 6958 t o h old yoke, r em ove t h e
pin ion yoke n u t a n d wa sh er.
(5) Usin g Rem over C–452 a n d Wr en ch C–3281,
r em ove t h e pin ion yoke fr om pin ion sh a ft (F ig. 34).
SPECIAL TOOL
C-3281

Fig. 32 Ring Gear Removal


(3) In st a ll n ew r in g gea r bolt s a n d a lt er n a t ely
t igh t en t o 95–122 N·m (70–90 ft . lbs.) t or qu e (F ig. J9102-31
27).
(4) In st a ll differ en t ia l in a xle h ou sin g a n d ver ify Fig. 34 Pinion Yoke Removal
gea r m esh a n d con t a ct pa t t er n .
(6) Rem ove t h e pin ion gea r fr om h ou sin g (F ig. 35).

/~~~~
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

Fig. 33 Ring Gear Bolt Installation


J9302-25
PINION GEAR
Th e r in g a n d pin ion gea r s a r e ser viced in a Fig. 35 Remove Pinion Gear
m a t ch ed set . Do n ot r epla ce t h e pin ion gea r wit h ou t
(7) Use a su it a ble pr y t ool or a slide h a m m er
r epla cin g t h e r in g gea r.
m ou n t ed scr ew t o r em ove t h e pin ion sh a ft sea l.
REM OVAL (8) Rem ove oil slin ger, if equ ipped, a n d fr on t pin -
(1) Rem ove differ en t ia l fr om t h e a xle h ou sin g. ion bea r in g.
(2) Ma r k pin ion yoke a n d pr opeller sh a ft for (9) Rem ove t h e fr on t pin ion bea r in g cu p wit h
in st a lla t ion a lign m en t . Rem over C-4345 a n d H a n dle C–4171 (F ig. 36).
(3) Discon n ect pr opeller sh a ft fr om pin ion yoke. (10) Rem ove t h e r ea r bea r in g cu p fr om h ou sin g
Usin g su it a ble wir e, t ie pr opeller sh a ft t o u n der body. (F ig. 37). Use Rem over D-149 a n d H a n dle C–4171.
DRIVER
REMOVER HANDLE
HANDLE DRIVE
OIL
GEAR
REAR
ADAPTERS
SLINGER
PINION
SHAFT
BEAR-
INGSPECIAL C-293–PA
TOOL IBLE
COLLAPS-
SHOULDER
SPACER
PINION
GEAR
VISE

3 - 64 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

REAR
BEARING

1 - - - - - - - PINION
OIL GEAR
SLINGER

J9302-22
J9302-66

Fig. 36 Front Bearing Cup Removal Fig. 38 Collapsible Spacer


SPECIAL
TOOL
C-293-PA

J9302-23

Fig. 37 Rear Bearing Cup Removal


(11) Rem ove t h e colla psible pr eloa d spa cer (F ig. Fig. 39 Rear Bearing Removal
38).
I N STALLAT I ON
(12) Rem ove t h e r ea r bea r in g fr om t h e pin ion wit h
(1) Apply Mopa r t Door E a se, or equ iva len t , st ick
P u ller /P r ess C-293-PA a n d Ada pt er s C-293-40 (F ig.
lu br ica n t t o ou t side su r fa ce of bea r in g cu p.
39).
(2) In st a ll t h e pin ion r ea r bea r in g cu p wit h
P la c e 4 a d a p te r blo c k s s o th e y d o n o t d a m a g e
In st a ller D-146 a n d Dr iver H a n dle C–4171 (F ig. 40).
th e be a rin g c a g e .
E n su r e cu p is cor r ect ly sea t ed.
(13) Rem ove t h e dept h sh im s fr om t h e pin ion gea r
(3) Apply Mopa r t Door E a se, or equ iva len t , st ick
sh a ft . Recor d t h e t h ickn ess of t h e dept h sh im s.
lu br ica n t t o ou t side su r fa ce of bea r in g cu p.
HANDLE
INSTALLER HANDLE
INSTALLER DRIVE PINION
DRIVE
REAR
GEAR
PINION
BEARING
SHAFT
GEAR PRESS SPECIAL
C-3972–A
INSTALLATION
TOOLSPECIALC-4171
TOOL
TOOL

XJ DIFFERENTIAL AND DRIVELINE 3 - 65


REM OVAL AN D I N STALLAT I ON (Cont inue d)

INSTALLER

SPECIAL
SPECIAL TOOL TOOL
C-4171 C-3972-A

80a7e2be

Fig. 42 Pinion Seal Installation


proper thickness shim before installing rear pinion
bearing.
HANDLE J9402-66
(7) P la ce t h e pr oper t h ickn ess dept h sh im on t h e
pin ion gea r.
Fig. 40 Pinion Rear Bearing Cup Installation (8) In st a ll t h e r ea r bea r in g a n d slin ger, if
(4) In st a ll t h e pin ion fr on t bea r in g cu p wit h equ ipped, on t h e pin ion gea r wit h In st a ller W-262
In st a ller D–130 a n d H a n dle C–4171 (F ig. 41). (F ig. 43).

INSTALLER HANDLE

INSTALLATION
TOOL

DRIVE
PINION GEAR
SHAFT
REAR BEARING

Fig. 41 Pinion Front Bearing Cup Installation


(5) In st a ll pin ion fr on t bea r in g, a n d oil slin ger, if
equ ipped.
(6) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
J9003-67
lip of pin ion sea l. In st a ll sea l wit h In st a ller C-3972-A
a n d H a n dle C–4171 (F ig. 42).
Fig. 43 Shaft Rear Bearing Installation
NOTE: Pinion depth shims are placed between the (9) In st a ll a n ew colla psible pr eloa d spa cer on pin -
rear pinion bearing cone and pinion gear to achieve ion sh a ft a n d in st a ll pin ion gea r in h ou sin g (F ig. 44).
proper ring and pinion gear mesh. If the factory (10) In st a ll pin ion gea r in h ou sin g.
installed ring and pinion gears are reused, the pin- (11) In st a ll yoke wit h In st a ller Scr ew 8112, Cu p
ion depth shim should not require replacement. If 8109, a n d h older 6958 (F ig. 45).
required, refer to Pinion Gear Depth to select the
OIL
REAR
SLINGER
BEAR-
ING AXLE
IBLE
COLLAPS-
SHOULDER
PINION
SPACER
PINION
HOUSING
GEAR
YOKE 3/4 DRIVE
PINION YOKE
WRENCH
TORQUE
INCH SPECIAL
POUND TOOL
6958
WRENCH
TORQUE 1 in. PIPE

3 - 66 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
NOTE: If the spacer requires more than 474 N·m
(350 ft. lbs.) torque to crush, the collapsible spacer
is defective and must be replaced.

(15) Slowly t igh t en t h e n u t in 6.8 N·m (5 ft . lbs.)


in cr em en t s u n t il t h e r ot a t in g t or qu e is a ch ieved.
Mea su r e t h e r ot a t in g t or qu e fr equ en t ly t o a void over
cr u sh in g t h e colla psible spa cer (F ig. 47).

REAR
BEARING
/SHOUIDER
OIL
l------- PINION
GEAR
SLINGER

J9302-66
3/4 DRIVE
TORQUE
Fig. 44 Collapsible Preload Spacer WRENCH 80a4d33b

PINION Fig. 46 Tightening Pinion Nut–Typical


YOKE
(16) Ch eck bea r in g r ot a t in g t or qu e wit h a (in . lbs.)
t or qu e wr en ch (F ig. 47). Th e t or qu e n ecessa r y t o
r ot a t e t h e pin ion gea r sh ou ld be:
• Or igin a l Bea r in gs — 1 t o 3 N·m (10 t o 20 in .
lbs.).
• New Bea r in gs — 2 t o 5 N·m (15 t o 35 in . lbs.).

AXLE
HOUSING
80a8710c

Fig. 45 Pinion Yoke Installation


(12) In st a ll t h e yoke wa sh er a n d a n ew n u t on t h e
pin ion gea r a n d t igh t en t h e pin ion n u t u n t il t h er e is
zer o bea r in g en d-pla y.
(13) Tigh t en t h e n u t t o 271 N·m (200 ft . lbs.).

CAUTION: Never loosen pinion gear nut to


decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.

(14) Usin g yoke h older 6958 a n d a t or qu e wr en ch


set a t 474 N·m (350 ft . lbs.), cr u sh colla psible spa cer Fig. 47 Check Pinion Gear Rotating Torque
u n t il bea r in g en d pla y is t a ken u p (F ig. 46).
(17) In st a ll differ en t ia l in h ou sin g.
SEALING
BEAD
NESSSURFACE
6.35MM
THICK-
(1/4”) CONTOUR OF BEAD THRUST
WASHER
PINION GEAR
MATE SIDE GEAR
PINION
LOCK
SCREW
GEAR MATE SHAFT

XJ DIFFERENTIAL AND DRIVELINE 3 - 67


REM OVAL AN D I N STALLAT I ON (Cont inue d)
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).
CONTOUR OF BEAD

Fig. 49 Pinion Gear Mate Shaft Lock Screw


THRUST
WASHER

Fig. 48 Typical Housing Cover With Sealant


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.

CAUTION: Overfilling the differential can result in


lubricant foaming and overheating. PINION
MATE GEAR SIDE GEAR J9203-61
(3) Refill t h e differ en t ia l h ou sin g wit h gea r lu br i-
ca n t . Refer t o t h e Lu br ica n t Specifica t ion s sect ion of Fig. 50 Pinion Mate Gear Removal
t h is gr ou p for t h e gea r lu br ica n t r equ ir em en t s. ASSEM BLY
(4) In st a ll t h e fill h ole plu g. (1) In st a ll t h e differ en t ia l side gea r s a n d t h r u st
wa sh er s.
DI SASSEM BLY AN D ASSEM BLY (2) In st a ll t h e pin ion m a t e gea r s a n d t h r u st wa sh -
er s.
STANDARD DIFFERENTIAL (3) In st a ll t h e pin ion gea r m a t e sh a ft .
(4) Align t h e h ole in t h e pin ion gea r m a t e sh a ft
DI SASSEM BLY wit h t h e h ole in t h e differ en t ia l ca se a n d in st a ll t h e
(1) Rem ove pin ion gea r m a t e sh a ft lock scr ew (F ig. pin ion gea r m a t e sh a ft lock scr ew.
49). (5) Lu br ica t e a ll differ en t ia l com pon en t s wit h
(2) Rem ove pin ion gea r m a t e sh a ft . h ypoid gea r lu br ica n t .
(3) Rot a t e t h e differ en t ia l side gea r s a n d r em ove
t h e pin ion m a t e gea r s a n d t h r u st wa sh er s (F ig. 50).
(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 SIDE
DIFFERENTIAL
GEAR
THRUST
PINION
VISE
WASHER PINION
SHAFT
MATESPECIAL
LOCK
SHAFT
SCREW
TOOL
6965

3 - 68 DIFFERENTIAL AND DRIVELINE XJ


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 51 Trac–lok Differential Components


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. 51). 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 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

Fig. 52 Differential Case Holding Tool


DRIFT
PINION MATE GEAR PINION
LOCK
SCREW
PINION
GEARSIDE
MATE
SHAFT
GEAR
MATE
SHAFT THREADED
THREADED
SPECIAL
DISC DIFFERENTIAL
ADAPTER
C-6960–3
TOOL
RODC–6960–1
C-6960–3
C-6960–4
DISCCASE LOWER
SOCKET
SLOT
SCREWDRIVER
SIDE
IN ADAPTER
GEAR

XJ DIFFERENTIAL AND DRIVELINE 3 - 69


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(4) Rem ove t h e pin ion gea r m a t e sh a ft lock scr ew
(F ig. 53).

Fig. 53 Mate Shaft Lock Screw


DIFFERENTIAL
(5) Rem ove t h e pin ion gea r m a t e sh a ft . If n eces- CASE 80a83886
sa r y, u se a dr ift a n d h a m m er (F ig. 54).
Fig. 55 Step Plate Tool Installation

PINION
MATE GEAR THREADED
ADAPTER
DISC
C-6960-1

80a773e1

Fig. 54 Mate Shaft Removal


(6) In st a ll a n d lu br ica t e St ep P la t e C-6960-3 (F ig.
55).
DISC
(7) Assem ble Th r ea ded Ada pt er C-6960-1 in t o t op
C-6960-3
side gea r. Th r ea d F or cin g Scr ew C-6960-4 in t o
a da pt er u n t il it becom es cen t er ed in a da pt er pla t e. 80a8387f

(8) P osit ion a sm a ll scr ew dr iver in slot of


Th r ea ded Ada pt er C-6960-1 (F ig. 56) t o pr even t Fig. 56 Threaded Adapter Installation
a da pt er fr om t u r n in g.
TORQUE
THRUST
WRENCH
DIFFERENTIAL
WASHER TOOLCASEASSEM-
BLED FEELER GAUGE PINION
SIDE GEAR
GEARSAND
RETAINER
DISC
CLUTCH
PACK DIFFERENTIAL
TOOLCASE

3 - 70 DIFFERENTIAL AND DRIVELINE XJ


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(9) Tigh t en for cin g scr ew t ool 122 N·m (90 ft . lbs.)
m a xim u m t o com pr ess Belleville spr in gs in clu t ch
pa cks (F ig. 57).

TORQUE
WRENCH

Fig. 59 Pinion Gear Removal


(15) Rem ove F or cin g Scr ew C-6960-4, St ep P la t e
C-6960-3, a n d Th r ea ded Ada pt er C-6960-1.
Fig. 57 Tighten Belleville Spring Compressor Tool (16) Rem ove t op side gea r, clu t ch pa ck r et a in er,
(10) Usin g a n a ppr opr ia t e size feeler ga u ge, a n d clu t ch pa ck. Keep pla t es in cor r ect or der du r in g
r em ove t h r u st wa sh er s fr om beh in d t h e pin ion gea r s r em ova l (F ig. 60).
(F ig. 58). DIFFERENTIAL
CASE

THRUST SIDE GEAR


WASHER AND CLUTCH
DISC PACK

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

XJ DIFFERENTIAL AND DRIVELINE 3 - 71


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
Lu br ica t e ea ch com pon en t wit h gea r lu br ica n t (4) P osit ion t h e differ en t ia l ca se on Side Gea r
befor e a ssem bly. H oldin g Tool 6965.
(1) Assem ble t h e clu t ch discs in t o pa cks a n d (5) In st a ll lu br ica t ed St ep P la t e C-6960-3 in lower
secu r e disc pa cks wit h r et a in in g clips (F ig. 61). side gea r (F ig. 63).
CLUTCH PACK
UPPER SIDE
GEAR AND CLUTCH
DISC PACK

.
SPECIAL

/
RETAINER
J8903-50
TOOL
C-6960-3

80a83887

Fig. 61 Clutch Disc Pack


Fig. 63 Upper Side Gear & Clutch Disc Pack
(2) P osit ion a ssem bled clu t ch disc pa cks on t h e Installation
side gea r h u bs.
(3) In st a ll clu t ch pa ck a n d side gea r in t h e r in g (6) In st a ll t h e u pper side gea r a n d clu t ch disc pa ck
gea r side of t h e differ en t ia l ca se (F ig. 62). B e s u re (F ig. 63).
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 (7) H old a ssem bly in posit ion . In ser t Th r ea ded
a n d a re s e a te d in th e c a s e p o c k e ts . Ada pt er C-6960-1 in t o t op side gea r.
(8) In ser t F or cin g Scr ew C-6960-4.
(9) Tigh t en for cin g scr ew t ool t o sligh t ly com pr ess
clu t ch discs.
(10) P la ce pin ion gea r s in posit ion in side gea r s
LOWER a n d ver ify t h a t t h e pin ion m a t e sh a ft h ole is a lign ed.
SIDE GEAR (11) Rot a t e ca se wit h Tu r n in g Ba r C-6960-2 u n t il
AND CLUTCH t h e pin ion m a t e sh a ft h oles in pin ion gea r s a lign
DISC PACK wit h h oles in ca se. It m a y be n ecessa r y t o sligh t ly
t igh t en 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.
(12) Tigh t en for cin g scr ew t o 122 N·m (90 ft . lbs.)
m a xim u m t o com pr ess t h e Belleville spr in gs.
(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
pin ion gea r s a n d a lign wa sh er s wit h a sm a ll scr ew
dr iver. In ser t m a t e sh a ft in t o ea ch pin ion gea r t o ver-
ify a lign m en t .
(14) Rem ove F or cin g Scr ew C-6960-4, St ep P la t e
C-6960-3, a n d Th r ea ded Ada pt er C-6960-1.
(15) In st a ll pin ion gea r m a t e sh a ft a n d a lign h oles
in sh a ft a n d ca se.
(16) In st a ll t h e pin ion m a t e sh a ft lock scr ew fin ger
80a7739c t igh t t o h old sh a ft du r in g differ en t ia l in st a lla t ion .
If re p la c e m e n t g e a rs a n d th ru s t w a s h e rs w e re
Fig. 62 Clutch Discs & Lower Side Gear Installation in s ta lle d , it is n o t n e c e s s a ry to m e a s u re th e
DIFFERENTIAL
PRODUCTION
GEAR
(SAME
SHIM-RING
AS
MATCHING
COLLAPSIBLE
RING
GEAR
BEARING
BERS
NUM-
GEAR
SIDE
NUMBER
SPACER
NUM-
BER) PINION GEAR
BEARING
DIFFERENTIAL
PINION
RING
DRIVE
GEAR
DEPTH
GEAR
GEAR
SHIM-
VARIANCE
SIDE
SHIM
PINION
DEPTH

3 - 72 DIFFERENTIAL AND DRIVELINE XJ


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
g e a r ba c k la s h . Co rre c t fit is d u e to c lo s e ADJ U ST M EN T S
m a c h in in g to le ra n c e s d u rin g m a n u fa c tu re .
(17) Lu br ica t e a ll differ en t ia l com pon en t s wit h PINION GEAR DEPTH
h ypoid gea r lu br ica n t .
GEN ERAL I N FORM AT I ON
Rin g a n d pin ion gea r s a r e su pplied a s m a t ch ed
CLEAN I N G AN D I N SPECT I ON 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
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.
AXLE COMPONENTS 64). A plu s (+) n u m ber, m in u s (–) n u m ber or zer o (0)
Wa sh differ en t ia l com pon en t s wit h clea n in g solven t 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 -
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 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
th e d iffe re n tia l c o m p o n e n ts . dept h va r ies fr om t h e st a n da r d dept h set t in g of a
Wa sh bea r in gs wit h solven t a n d t owel dr y, or dr y pin ion et ch ed wit h a (0). Th e st a n da r d set t in g fr om
wit h com pr essed a ir. DO NOT spin bea r in gs wit h 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
com pr essed a ir. Cu p a n d be a rin g m u s t be pin ion is 96.850 m m (3.813 in .). Th e st a n da r d dept h
re p la c e d a s m a tc h e d s e ts o n ly. pr ovides t h e best t eet h con t a ct pa t t er n . Refer t o
Clea n a xle sh a ft t u bes a n d oil ch a n n els in h ou sin g. Ba ckla 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
In spect for ; t h is sect ion for a ddit ion a l in for m a t ion .
• Sm oot h a ppea r a n ce wit h n o br oken /den t ed su r-
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- DRIVE PINION
PRODUCTION GEAR DEPTH
fa ces. VARIANCE
NUMBERS
• 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. GEAR MATCHING NUMBER
• P in ion yoke for cr a cks, wor n splin es, pit t ed (SAME AS RING GEAR NUMBER) J9003-100
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. Fig. 64 Pinion Gear ID Numbers
• P r eloa d sh im s for da m a ge a n d dist or t ion . In st a ll Com pen sa t ion for pin ion dept h va r ia n ce is
n ew sh im s, if n ecessa r y. a ch ieved wit h select sh im s. Th e sh im s a r e pla ced
u n der t h e in n er pin ion bea r in g con e (F ig. 65).
TRAC-LOK
Clea n a ll com pon en t s in clea n in g solven t . Dr y com -
pon en t s wit h com pr essed a ir. In spect clu t ch pa ck
pla t es for wea r, scor in g or da m a ge. Repla ce bot h
clu t ch pa cks if a n y on e com pon en t in eit h er pa ck is
da m a ged. In spect side a n d pin ion gea r s. Repla ce a n y
gea r t h a t is wor n , cr a cked, ch ipped or da m a ged. DIFFERENTIAL
BEARING
In spect differ en t ia l ca se a n d pin ion sh a ft . Repla ce if
SHIM-RING
wor n or da m a ged. GEAR SIDE
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
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.
RING GEAR
80a5037a

Fig. 65 Shim Locations


PINION
DIAL SCOOTER
INDICATOR
HEIGHT
PINION
ARBORSCREW
ARBOR
BLOCK
CONE
DISC

XJ DIFFERENTIAL AND DRIVELINE 3 - 73


ADJ U ST M EN T S (Cont inue d)

PI N I ON GEAR DEPT H VARI AN CE

Original Pinion Replacement Pinion Gear Depth Variance


Gear Depth
Variance −4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008

If a n ew gea r set is bein g in st a lled, n ot e t h e dept h DIAL INDICATOR


va r ia n ce et ch ed in t o 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
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-
a n ce ch a r t s.
Not e wh er e Old a n d New P in ion Ma r kin g colu m n s
in t er sect . In t er sect in g figu r e r epr esen t s plu s or
m in u s a m ou n t n eeded.
Not e t h e et ch ed n u m ber on t h e fa ce of t h e dr ive
pin ion gea r (–1, –2, 0, +1, +2, et c.). Th e n u m ber s r ep-
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 -
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
r equ ir ed t h ickn ess of t h e dept h sh im (s). If t h e n u m -
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
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
n ecessa r y. Refer t o t h e P in ion Gea r Dept h Va r ia n ce SCOOTER BLOCK
Ch a r t .
ARBOR DISC
PI N I ON DEPT H M EASU REM EN T AN D
ADJ U ST M EN T J9403-45
Mea su r em en t s a r e t a ken wit h pin ion cu ps a n d pin -
ion bea r in gs in st a lled in h ou sin g. Ta ke m ea su r e- Fig. 66 Pinion Gear Depth Gauge Tools—Typical
m en t s wit h a P in ion Ga u ge Set , P in ion Block 6735,
t igh t en ca p bolt s. Refer t o t h e Tor qu e Specifica t ion s
Ar bor Discs 6732, a n d Dia l In dica t or C-3339 (F ig.
in t h is sect ion .
66).
(1) Assem ble P in ion H eigh t Block 6739, P in ion NOTE: Arbor Discs 6732 have different step diame-
Block 6735, a n d r ea r pin ion bea r in g on t o Scr ew 6741 ters to fit other axle sizes. Pick correct size step for
(F ig. 66). axle being serviced.
(2) In ser t a ssem bled h eigh t ga u ge com pon en t s,
r ea r bea r in g a n d scr ew in t o a xle h ou sin g t h r ou gh (5) Assem ble Dia l In dica t or C-3339 in t o Scoot er
pin ion bea r in g cu ps (F ig. 67). Block D-115-2 a n d secu r e set scr ew.
(3) In st a ll fr on t pin ion bea r in g a n d Con e 6740 (6) P la ce Scoot er Block/Dia l In dica t or in posit ion
h a n d t igh t (F ig. 66). in a xle h ou sin g so dia l pr obe a n d scoot er block a r e
(4) P la ce Ar bor Disc 6732 on Ar bor D-115-3 in posi- flu sh a ga in st t h e su r fa ce of t h e pin ion h eigh t block.
t ion in a xle h ou sin g side bea r in g cr a dles (F ig. 68). H old scoot er block in pla ce a n d zer o t h e dia l in dica -
In st a ll differ en t ia l bea r in g ca ps on Ar bor Discs a n d t or fa ce t o t h e poin t er. Tigh t en dia l in dica t or fa ce
lock scr ew.
ARBOR
PINIONDISC
HEIGHT
BLOCK PINION HEIGHT
BLOCKPINION BLOCK PINION BLOCK
ARBOR ARBOR DIAL INDICATOR
SCOOTER BLOCK

3 - 74 DIFFERENTIAL AND DRIVELINE XJ


ADJ U ST M EN T S (Cont inue d)
ple, if t h e dept h va r ia n ce is –2, a dd +0.002 in . t o t h e
dia l in dica t or r ea din g.

t
PINION HEIGHT
BLOCK

Fig. 67 Pinion Height Block—Typical

Fig. 69 Pinion Gear Depth Measurement—Typical


(10) Rem ove t h e pin ion dept h ga u ge com pon en t s
fr om t h e a xle h ou sin g

DIFFERENTIAL BEARING PRELOAD AND GEAR


BACKLASH
Differ en t ia l side bea r in g pr eloa d a n d gea r ba ckla sh
is a ch ieved by select ive sh im s in ser t ed bet ween t h e
bea r in g cu p a n d t h e a xle h ou sin g. Th e pr oper sh im
t h ickn ess ca n be det er m in ed u sin g slip-fit du m m y
bea r in gs D-348 in pla ce of t h e differ en t ia l side bea r-
in gs a n d a dia l in dica t or C-3339. Befor e pr oceedin g
wit h t h e differ en t ia l bea r in g pr eloa d a n d gea r ba ck-
la sh m ea su r em en t s, m ea su r e t h e pin ion gea r dept h
a n d pr epa r e t h e pin ion gea r for in st a lla t ion . E st a b-
Fig. 68 Gauge Tools In Housing—Typical lish in g pr oper pin ion gea r dept h is essen t ia l t o est a b-
(7) Wit h scoot er block st ill in posit ion a ga in st t h e lish in g gea r ba ckla sh a n d t oot h con t a ct pa t t er n s.
pin ion h eigh t block, slowly slide t h e dia l in dica t or Aft er t h e over a ll sh im t h ickn ess t o t a ke u p differ en -
pr obe over t h e edge of t h e pin ion h eigh t block. t ia l side pla y is m ea su r ed, t h e pin ion gea r is
Obser ve h ow m a n y r evolu t ion s cou n t er clockwise t h e in st a lled, a n d t h e gea r ba ckla sh sh im t h ickn ess is
dia l poin t er t r a vels (a ppr oxim a t ely 0.125 in .) t o t h e m ea su r ed. Th e over a ll sh im t h ickn ess is t h e t ot a l of
ou t -st op of t h e dia l in dica t or. t h e dia l in dica t or r ea din g, st a r t in g poin t sh im t h ick-
(8) Slide t h e dia l in dica t or pr obe a cr oss t h e ga p n ess, a n d t h e pr eloa d specifica t ion a dded t oget h er.
bet ween t h e pin ion h eigh t block a n d t h e a r bor ba r Th e gea r ba ckla sh m ea su r em en t det er m in es t h e
wit h t h e scoot er block a ga in st t h e pin ion h eigh t block t h ickn ess of t h e sh im u sed on t h e r in g gea r side of
(F ig. 69). Wh en t h e dia l pr obe con t a ct s t h e a r bor ba r, t h e differ en t ia l ca se. Su bt r a ct t h e gea r ba ckla sh sh im
t h e dia l poin t er will t u r n clockwise. Br in g dia l t h ickn ess fr om t h e t ot a l over a ll sh im t h ickn ess a n d
poin t er ba ck t o zer o a ga in st t h e a r bor ba r, do n ot select t h a t a m ou n t for t h e pin ion gea r side of t h e dif-
t u r n dia l fa ce. Con t in u e m ovin g t h e dia l pr obe t o t h e fer en t ia l (F ig. 70).
cr est of t h e a r bor ba r a n d r ecor d t h e h igh est r ea din g.
If t h e dia l in dica t or ca n n ot a ch ieve t h e zer o r ea din g, SH I M SELECT I ON
t h e r ea r bea r in g cu p or t h e pin ion dept h ga u ge set is
n ot in st a lled cor r ect ly. NOTE: It is difficult to salvage the differential side
(9) Select a sh im equ a l t o t h e dia l in dica t or r ea d- bearings during the removal procedure. Install
in g plu s t h e dr ive pin ion gea r dept h va r ia n ce n u m ber replacement bearings if necessary.
et ch ed in t h e fa ce of t h e pin ion gea r (F ig. 64) u sin g
(1) Rem ove side bea r in gs fr om differ en t ia l ca se.
t h e opposit e sign on t h e va r ia n ce n u m ber. F or exa m -
DIFFERENTIAL
SHIM-RING
COLLAPSIBLE
SPECIAL
GEAR
BEARING
DIFFERENTIAL
TOOL
SIDE
SPACER
D-348 CASE PINION GEAR
SPECIAL
BEARING
DIFFERENTIAL
PINION
RING
DEPTH
AXLE
GEAR
HOUSING
TOOL
GEAR
SHIM-
SIDE
SHIM
8107 SPECIAL TOOL C-3339 DIFFEREN-
SPECIAL
TIAL CASE
TOOL C-3288–BAXLE HOUSING

XJ DIFFERENTIAL AND DRIVELINE 3 - 75


ADJ U ST M EN T S (Cont inue d)

COLLAPSIBLE
SPACER

DIFFERENTIAL
BEARING
SHIM-RING
GEAR SIDE

80a5037a

Fig. 70 Axle Adjustment Shim Locations


(2) In st a ll r in g gea r, if n ecessa r y, on differ en t ia l
ca se a n d t igh t en bolt s t o specifica t ion .
(3) In st a ll du m m y side bea r in gs D-348 on differ en -
t ia l ca se. 80a7e2cf

(4) In st a ll differ en t ia l ca se in a xle h ou sin g.


(5) In ser t Du m m y Sh im s 8107 (0.118 in . (3.0 m m )) Fig. 72 Differential Side play Measurement
st a r t in g poin t sh im s bet ween t h e du m m y bea r in g (9) P u sh fir m ly a n d h old differ en t ia l ca se t o pin ion
a n d t h e a xle h ou sin g (F ig. 71). gea r side of a xle h ou sin g.
(10) Zer o dia l in dica t or fa ce t o poin t er.
(11) P u sh fir m ly a n d h old differ en t ia l ca se t o r in g
gea r side of t h e a xle h ou sin g.
(12) Recor d dia l in dica t or r ea din g.
(13) Add t h e dia l in dica t or r ea din g t o t h e st a r t in g
poin t sh im t h ickn ess t o det er m in e t ot a l sh im t h ick-
n ess t o a ch ieve zer o differ en t ia l en d pla y.
(14) Add 0.008 in . (0.2 m m ) t o t h e zer o en d pla y
t ot a l. Th is n ew t ot a l r epr esen t s t h e t h ickn ess of
sh im s t o com pr ess, or pr eloa d t h e n ew bea r in gs wh en
t h e differ en t ia l is in st a lled.
(15) Rot a t e dia l in dica t or ou t of t h e wa y on gu ide
st u d.
(16) Rem ove differ en t ia l ca se, du m m y bea r in gs,
a n d st a r t in g poin t sh im s fr om a xle h ou sin g.
(17) In st a ll pin ion gea r in a xle h ou sin g. In st a ll t h e
yoke a n d est a blish t h e cor r ect pin ion r ot a t in g t or qu e.
(18) In st a ll differ en t ia l ca se a n d du m m y bea r in gs
in a xle h ou sin g (wit h ou t sh im s) a n d t igh t en r et a in in g
AXLE
--DIFFERENTIAL HOUSING
ca p bolt s.
CASE (19) P osit ion t h e dia l in dica t or plu n ger on a fla t
80a95398
su r fa ce bet ween t h e r in g gea r bolt h ea ds (F ig. 72).
Fig. 71 Insert Starting Point Shims (20) P u sh a n d h old differ en t ia l ca se t owa r d pin ion
gea r.
(6) In st a ll t h e m a r ked bea r in g ca ps in t h eir cor r ect (21) Zer o dia l in dica t or fa ce t o poin t er.
posit ion s. In st a ll a n d t igh t en t h e bolt s. (22) P u sh a n d h old differ en t ia l ca se t o r in g gea r
(7) Th r ea d gu ide st u d C-3288-B in t o r ea r cover side of t h e a xle h ou sin g.
bolt h ole below r in g gea r (F ig. 72). (23) Recor d dia l in dica t or r ea din g.
(8) At t a ch dia l in dica t or C-3339 t o gu ide st u d. (24) Su bt r a ct 0.002 in . (0.05 m m ) fr om t h e dia l
P osit ion t h e dia l in dica t or plu n ger on a fla t su r fa ce in dica t or r ea din g t o com pen sa t e for ba ckla sh bet ween
on a r in g gea r bolt h ea d (F ig. 72).
DIAL CATOR
INDI- FOR
FORMORE
LESS BACKLASH
BACKLASH INCREASE
FOR MORE
SHIM BACKLASH
THIS SIDE
DECREASE SHIM
INCREASE SHIM
THISTHIS
DIE DECREASE SHIM THIS
SIDEFOR
FORLESS
MORE
BACKLASH
BACK- SIDE FOR LESS BACK-
LASH LASH

3 - 76 DIFFERENTIAL AND DRIVELINE XJ


ADJ U ST M EN T S (Cont inue d)
r in g a n d pin ion gea r s. Th is t ot a l is t h e t h ickn ess of
sh im r equ ir ed t o a ch ieve pr oper ba ckla sh .
(25) Su bt r a ct t h e ba ckla sh sh im t h ickn ess fr om
t h e t ot a l pr eloa d sh im t h ickn ess. Th e r em a in der is
t h e sh im t h ickn ess r equ ir ed on t h e pin ion side of t h e
a xle h ou sin g.
(26) Rot a t e dia l in dica t or ou t of t h e wa y on gu ide
st u d.
(27) Rem ove differ en t ia l ca se a n d du m m y bea r in gs
fr om a xle h ou sin g.
(28) In st a ll n ew side bea r in g con es a n d cu ps on
differ en t ia l ca se.
(29) In st a ll spr ea der W-129-B, u t ilizin g som e com -
pon en t s of Ada pt er Set 6987, on a xle h ou sin g a n d
spr ea d a xle open in g en ou gh t o r eceive differ en t ia l
ca se.
(30) P la ce side bea r in g sh im s in a xle h ou sin g
Fig. 73 Ring Gear Backlash Measurement
a ga in st a xle t u bes.
(31) In st a ll differ en t ia l ca se in a xle h ou sin g. -r- - - - F O R MORE BACKLASH-----,
(32) Rot a t e t h e differ en t ia l ca se sever a l t im es t o
sea t t h e side bea r in gs.
DECRtsE SHIM INCREASE LM
(33) P osit ion t h e in dica t or plu n ger a ga in st a r in g THIS SIDE FOR THIS SIDE FOR
gea r t oot h (F ig. 73). MORE BACKLASH MORE BACKLASH
(34) P u sh a n d h old r in g gea r u pwa r d wh ile n ot 0

a llowin g t h e pin ion gea r t o r ot a t e.


(35) Zer o dia l in dica t or fa ce t o poin t er.
(36) P u sh a n d h old r in g gea r down wa r d wh ile n ot
a llowin g t h e pin ion gea r t o r ot a t e. Dia l in dica t or
r ea din g sh ou ld be bet ween 0.12 m m (0.005 in .) a n d
0.20 m m (0.008 in .). If ba ckla sh is n ot wit h in specifi-
ca t ion s t r a n sfer t h e n ecessa r y a m ou n t of sh im t h ick-
n ess fr om on e side of t h e differ en t ia l h ou sin g t o t h e
ot h er (F ig. 74).
(37) Ver ify differ en t ia l ca se a n d r in g gea r r u n ou t INCREASE SHIM DECREASE SHIM
by m ea su r in g r in g t o pin ion gea r ba ckla sh a t sever a l THIS SIDE FOR / THIS SIDE FOR
loca t ion s a r ou n d t h e r in g gea r. Rea din gs sh ou ld n ot LESS iCl<lASH ./ LESS BACKLASH
va r y m or e t h a n 0.05 m m (0.002 in .). If r ea din gs va r y
m or e t h a n specified, t h e r in g gea r or t h e differ en t ia l FOR LESS BACKLASH------'t
ca se is defect ive. J9302-28
Aft er t h e pr oper ba ckla sh is a ch ieved, per for m t h e
Gea r Con t a ct P a t t er n An a lysis pr ocedu r e. Fig. 74 Backlash Shim Adjustment
(3) Usin g a boxed en d wr en ch on a r in g gea r bolt ,
GEAR CONTACT PATTERN ANALYSIS Rot a t e t h e differ en t ia l ca se on e com plet e r evolu t ion
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 in bot h dir ect ion s wh ile a loa d is bein g a pplied fr om
will sh ow if t h e pin ion gea r dept h is cor r ect in t h e sh op t owel.
a xle h ou sin g. It will a lso sh ow if t h e r in g gea r ba ck- 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
la sh h a s been a dju st ed cor r ect ly. Th e ba ckla sh ca n be degr ee of con t a ct a ga in st t h e pin ion gea r t eet h will
a dju st ed wit h in specifica t ion s t o a ch ieve desir ed 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
t oot h con t a ct pa t t er n s. 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
(1) Apply a t h in coa t of h ydr a t ed fer r ic oxide, or 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
equ iva len t , t o t h e dr ive a n d coa st side of t h e r in g (F ig. 61) a n d a dju st pin ion dept h a n d gea r ba ckla sh
gea r t eet h . a s n ecessa r y.
(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 .
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

XJ DIFFERENTIAL AND DRIVELINE 3 - 77


ADJ U ST M EN T S (Cont inue d)

DRIVE SIDE COAST SIDE


OF RING OF RING
GEAR TEETH GEAR TEETH

DESIRABLE CONTACT PATTERN.


PATTERN SHOULD BE CENTERED
ON THE DRIVE SIDE OF TOOTH.
PATTERN SHOULD BE CENTERED ON
THE COAST SIDE OF TOOTH,
BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP OF
THE TOOTH.

RING GEAR BACKLASH CORRECl


THINNER PINION GEAR DEPTH
SHIM REQUIRED.

RING GEAR BACKLASH CORRECT.


THICKER PINION GEAR DEPTH
SHIM REQUIRED.

PINION GEAR DEPTH SHIM


CORRECT. DECREASE RING
GEAR BACKLASH.

PINION GEAR DEPTH SHIM


CORRECT. INCREASE RING
GEAR BACKLASH.

J9003-24

Fig. 75 Gear Tooth Contact Patterns


3 - 78 DIFFERENTIAL AND DRIVELINE XJ

SPECI FI CAT I ON S
194 RBI AXLE

D ES CRIP TION S P ECIF ICATION


Axle Type . . . . . . . . . . . . . . . Sem i–F loa t in g H ypoid
Lu br ica n t . . . . . . . . SAE Th er m a lly St a ble 80W–90
Lu br ica n t Tr a iler Tow . . . . . . . . Syn t h et ic 75W–140
Lu be Ca pa cit y . . . . . . . . . . . . . . . . 1.66 L (3.50 pt s.)
Axle Ra t ios . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.11
Differ en t ia l Bea r in g P r eloa d . . . . 0.1 m m (0.004 in .) Adapter—C-293-39
Differ en t ia l Side Gea r
Clea r a n ce . . . . . . . . . . . . 0–0.15 m m (0–0.006 in .)
Rin g Gea r Dia m et er . . . . . . . . . . 19.2 cm (7.562 in .)
Rin g Gea r Ba ckla sh . . . 0–0.15 m m (0.005–0.008 in .)
P in ion St d. Dept h . . . . . . . . . . 92.08 m m (3.625 in .)
P in ion Bea r in g P r eloa d-Or igin a l
Bea r in gs . . . . . . . . . . . . . 1–2 N·m (10–20 in . lbs.)
P in ion Bea r in g P r eloa d-New
Bea r in gs . . . . . . . . . . . 1.5–4 N·m (15–35 in . lbs.)
194 RBI AXLE Adapter—C-293-40

D ES CRIP TION TORQU E


Bolt , Diff. Cover . . . . . . . . . . . . . 41 N·m (30 ft . lbs.)
Bolot , Bea r in g Ca p . . . . . . . . . . . 77 N·m (57 ft . lbs.)
Nu t , P in ion . . . . . . . 271–474 N·m (200–350 ft . lbs.)
Scr ew, P in ion Ma t e
Sh a ft Lock . . . . . . . . . . . . . 16.25 N·m (12 ft . lbs.)
Bolt , Rin g Gea r . . . . . . . 95–122 N·m (70–90 ft . lbs.)
Bolt , RWAL/ABS Sen sor . . . . . . . 8 N·m (70 in . lbs.)

SPECI AL T OOLS Plug—SP-3289

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

Disc, Axle Arbor—6732

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

Tool Set, Pinion Depth—6774 Starting Point Shim—8107

Trac-lok Tool Set—6960 Spreader—W-129-B

1-1/8 HEX TURNBUCKLE 1-1/4 HEX TURNBUCKLE

Holder—6965
Adapter Kit—6987

Puller—7794-A Guide Pin—C-3288-B


3 - 82 DIFFERENTIAL AND DRIVELINE XJ
SPECI AL T OOLS (Cont inue d)

Bearing Remover Tool Set—6310

Hub Puller—6790

Dial Indicator—C-3339
XJ DIFFERENTIAL AND DRIVELINE 3 - 83

8 1 /4 REAR AX LE

INDEX
page page

GENERAL INFORMATION DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 95


8 1/4 AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 96
AXLE IDENTIFICATION . . . . . . . . . . . . . . . . . . 83 PINION SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 93
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . 83 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DESCRIPTION AND OPERATION RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 84 DISASSEMBLY AND ASSEMBLY
TRAC-LOK OPERATION . . . . . . . . . . . . . . . . . . 85 STANDARD DIFFERENTIAL . . . . . . . . . . . . . . 100
DIAGNOSIS AND TESTING TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . 101
BEARING NOISE . . . . . . . . . . . . . .. . . . . . . . . 86 CLEANING AND INSPECTION
DRIVELINE SNAP . . . . . . . . . . . . .. . . . . . . . . 86 8 1/4 AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . 104
GEAR NOISE . . . . . . . . . . . . . . . . .. . . . . . . . . 86 TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
GENERAL INFORMATION . . . . . . .. . . . . . . . . 85 ADJUSTMENTS
LOW SPEED KNOCK . . . . . . . . . . .. . . . . . . . . 86 8 1/4 AXLE PINION GEAR DEPTH . . . . . . . . . 105
TRAC–LOK DIFFERENTIAL NOISE . . . . . . . . . 87 DIFFERENTIAL BEARING PRELOAD AND
TRAC–LOK TEST . . . . . . . . . . . . . .. . . . . . . . . 90 GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . 107
VIBRATION . . . . . . . . . . . . . . . . . .. . . . . . . . . 86 GEAR CONTACT PATTERN ANALYSIS . . . . . . 108
SERVICE PROCEDURES SIDE GEAR CLEARANCE . . . . . . . . . . . . . . . 108
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . 90 SPECIFICATIONS
REMOVAL AND INSTALLATION 8 1/4 INCH AXLE . . . . . . . . . . . . . . . . . . . . . . 110
AXLE SEAL AND BEARING . . . . . . . . . . . . . . . 92 8 1/4 INCH AXLE . . . . . . . . . . . . . . . . . . . . . . 110
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 91 SPECIAL TOOLS
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . 95 8 1/4 AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . 111

GEN ERAL I N FORM AT I ON P in ion bea r in g pr eloa d is set a n d m a in t a in ed by t h e


u se of a colla psible spa cer.
8 1/4 AXLES Axles equ ipped wit h a Tr a c-Loky differ en t ia l a r e
Th e 8 1/4 in ch a xle h ou sin gs con sist of a ca st ir on opt ion a l. A Tr a c-Lok differ en t ia l h a s a on e-piece dif-
cen t er sect ion wit h a xle sh a ft t u bes ext en din g fr om fer en t ia l ca se, a n d t h e sa m e in t er n a l com pon en t s a s
eit h er side. Th e t u bes a r e pr essed in t o a n d welded t o a st a n da r d differ en t ia l, plu s t wo clu t ch disc pa cks.
t h e differ en t ia l h ou sin g t o for m a on e-piece a xle
h ou sin g (F ig. 1). AXLE IDENTIFICATION
Th e a xles h a ve a ven t h ose t o r elieve in t er n a l pr es- Th e a xle differ en t ia l cover ca n be u sed for iden t ifi-
su r e ca u sed by lu br ica n t va por iza t ion a n d in t er n a l ca t ion of t h e a xle (F ig. 2). A t a g is a lso a t t a ch ed t o
expa n sion . t h e cover .
Th e a xles a r e equ ipped wit h sem i-floa t in g a xle
sh a ft s, m ea n in g veh icle loa ds a r e su ppor t ed by t h e LUBRICANT SPECIFICATIONS
a xle sh a ft a n d bea r in gs. Th e a xle sh a ft s a r e r et a in ed Mu lt i-pu r pose, h ypoid gea r lu br ica n t sh ou ld be
by C-clips in t h e differ en t ia l side gea r s. u sed for r ea r a xles wit h a st a n da r d differ en t ia l. Th e
Th e r em ova ble, st a m ped st eel cover pr ovides a lu br ica n t sh ou ld h a ve a MIL-L-2105C a n d AP I GL 5
m ea n s for in spect ion a n d ser vice wit h ou t r em ovin g qu a lit y specifica t ion s.
t h e com plet e a xle fr om t h e veh icle. Tr a c-Lok differ en t ia ls r equ ir e t h e a ddit ion of 5 oz.
Th e 8 1/4 a xle h a ve t h e a ssem bly pa r t n u m ber a n d of fr ict ion m odifier t o t h e a xle lu br ica n t a ft er ser vice.
gea r r a t io list ed on t a g. Th e t a g is a t t a ch ed t o t h e Th e 8 1/4 a xle lu br ica n t ca pa cit y is 2.27 L (4.8 pt s.)
differ en t ia l h ou sin g by a cover bolt . t ot a l, in clu din g t h e fr ict ion m odifier, if n ecessa r y.
Th e differ en t ia l ca se is a on e-piece design . Th e dif-
fer en t ia l pin ion m a t e sh a ft is r et a in ed wit h a NOTE: If the rear axle is submerged in water, the
t h r ea ded pin . Differ en t ia l bea r in g pr eloa d a n d r in g lubricant must be replaced immediately. Avoid the
gea r ba ckla sh a r e set a n d m a in t a in ed by t h r ea ded possibility of premature axle failure resulting from
a dju st er s a t t h e ou t side of t h e differ en t ia l h ou sin g. water contamination of the lubricant.
DIFFERENTIAL
PUSH-IN
1. DIFFERENTIAL
2.
3.
4.
5.
6.
7.
8.
9.
10.PINION
BEARING
PINION
FILL
GEAR
COVER
GEAR
CUP
PRELOAD
PLUGDEPTH
SHAFT
CASE
BEARING
HOUSING
SHAFT
COLLAPSIBLE
REAR
SHIMS
FRONT
BEARING
BEARING
SPACER IDENTIFICATION TAG
11.
15.
14.
16.
17.
18.
19.
20.
12.
13. SEAL
ADJUSTER
THRUST
YOKE
LOCK
NUT
BEARING
SIDE
C-LOCK
WASHER
GEAR
WASHER
CAP 21.
22.
23.
24.
25.
26.
27.
28. THRUST
PINION
SHAFT
MAT
RING
COVER
PLUG SHAFT
GEAR
LOCK
GEARS
WAHSERS
BOLT
BOLT

3 - 84 DIFFERENTIAL AND DRIVELINE XJ

~1. DIFFERENTIAL CASE 11. SEAL 21. PINION GEARS


2. DIFFERENTIAL BEARING 12. YOKE 22. THRUST WASHERS
3. BEARING CUP 13. WASHER 23. SHAFT LOCK BOLT
4. PINION GEAR SHAFT 14. NUT 24. MATE SHAFT
5. PINION GEAR DEPTH SHIMS 15. LOCK 25. RING GEAR BOLT
6. BEARING CUP 16. ADJUSTER 26. COVER
7. PINION GEAR SHAFT REAR BEARING 17. BEARING CAP 27. PLUG
8. BEARING PRELOAD COLLAPSIBLE SPACER 18. THRUST WASHER 28. RING GEAR
9. DIFFERENTIAL HOUSING 19. SIDE GEAR
10. PINION GEAR SHAFT FRONT BEARING 20. C-LOCK )9203-14

Fig. 1 8 1/4 Axle

DIFFERENTIAL IDENTIFICATION DESCRI PT I ON AN D OPERAT I ON


COVER TAG
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:
• 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)
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
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
t h e sh a ft s.
PUSH-IN 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 -
FILL PLUG J9203-11 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
occu r s beca u se in pu t t or qu e a pplied t o t h e gea r s is
Fig. 2 Differential Cover 8 1/4 Inch Axle divided a n d dist r ibu t ed equ a lly bet ween t h e t wo side
gea r s. As a r esu lt , t h e pin ion gea r s r evolve wit h t h e
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).
PINION GEARS
INPINION
WHEEL
PINION
STRAIGHT
ROTATE
100%
ROTATES
SHAFT
GEARS
PINION
ON
AHEAD
AXLE
DIFFERENTIAL
CASE
AT
ROTATE
GEAR
100%
DRIVING
SPEED
OF
CASE
WITH
SPEED
EACH
SIDE
CASEGEAR CLUTCH
CASE
PACK RING GEAR SIDE GEAR PINION
DRIVE
CLUTCH
MATEPINION
GEAR
SHAFT
PACK
OUTER WHEEL 110% CASE INNER WHEEL 90% CASE
SPEED SPEED

XJ DIFFERENTIAL AND DRIVELINE 3 - 85


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
IN STRAIGHT AHEAD DRIVING In oper a t ion , t h e Tr a c-lok clu t ch es a r e en ga ged by
EACH WHEEL ROTATES AT 100% t wo con cu r r en t for ces. Th e fir st bein g t h e pr eloa d
OF CASE SPEED
for ce exer t ed t h r ou gh Belleville spr in g wa sh er s
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
for ces gen er a t ed by t h e side gea r s a s t or qu e is
a pplied t h r ou gh t h e r in g gea r (F ig. 4).

DRIVE
PINION

PINION GEARS ROTATE


WITH CASE J9303-13

Fig. 3 Differential Operation—Straight Ahead Driving


Wh en t u r n in g cor n er s, t h e ou t side wh eel m u st
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
com plet e a t u r n . Th e differ en ce m u st be com pen sa t ed
for t o pr even t t h e t ir es fr om scu ffin g a n d skiddin 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
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.
2). In t h is in st a n ce, t h e in pu t t or qu e a pplied t o t h e
pin ion gea r s is n ot divided equ a lly. Th e pin ion gea r s
n ow r ot a t e a r ou n d t h e pin ion m a t e sh a ft in opposit e
dir ect ion s. Th is a llows t h e side gea r a n d a xle sh a ft
a t t a ch ed t o t h e ou t side wh eel t o r ot a t e a t a fa st er
speed.
AXLE (j;

OUTER WHEEL
I 100% DIFFERENTIAL INNER WHEEL
I
110% CASE SPEED CASE SPEED 90% CASE SPEED
J9303-15

Fig. 5 Trac-lok Limited Slip Differential Operation


Th e Tr a c-lok design pr ovides t h e differ en t ia l a ct ion
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
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-
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 .
Tr a c-lok differ en t ia ls r esist wh eel spin on bu m py
r oa ds a n d pr ovide m or e pu llin g power wh en on e
PINION GEARS ROTATE
ON PINION SHAFT J9303-14 wh eel looses t r a ct ion . P u llin g power is pr ovided con -
t in u ou sly u n t il bot h wh eels loose t r a ct ion . If bot h
Fig. 4 Differential Operation—On Turns wh eels slip du e t o u n equ a l t r a ct ion , Tr a c-lok oper a -
t ion is n or m a l. In ext r em e ca ses of differ en ces of
TRAC-LOK OPERATION 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 .
In a con ven t ion a l differ en t ia l, if on e wh eel spin s,
t h e opposit e wh eel will gen er a t e on ly a s m u ch t or qu e
a s t h e spin n in g wh eel. DI AGN OSI S AN D T EST I N G
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
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 GENERAL INFORMATION
con t a in m u lt iple discs. Th e clu t ch es will h a ve r a dia l Axle bea r in g pr oblem con dit ion s a r e u su a lly ca u sed
gr ooves on t h e pla t es, a n d con cen t r ic gr ooves on t h e by:
discs or bon ded fiber m a t er ia l t h a t is sm oot h in • In su fficien t or in cor r ect lu br ica n t .
a ppea r a n ce. • F or eign m a t t er /wa t er con t a m in a t ion .
3 - 86 DIFFERENTIAL AND DRIVELINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
• In cor r ect bea r in g pr eloa d t or qu e a dju st m en t . 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 ba ckla sh . wit h veh icle speed.
Axle gea r pr oblem con dit ion s a r e u su a lly t h e r esu lt Axle sh a ft bea r in gs pr odu ce n oise a n d vibr a t ion
of: wh en wor n or da m a ged. Th e n oise gen er a lly ch a n ges
• In su fficien t lu br ica t ion . wh en t h e bea r in gs a r e loa ded. Roa d t est t h e veh icle.
• In cor r ect or con t a m in a t ed lu br ica n t . 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 .
• Over loa din g (excessive en gin e t or qu e) or exceed- Th is will loa d t h e bea r in gs a n d ch a n ge t h e n oise
in g veh icle weigh t ca pa cit y. level. Wh er e a xle bea r in g da m a ge is sligh t , t h e n oise
• In cor r ect clea r a n ce or ba ckla sh a dju st m en t . is u su a lly n ot n ot icea ble a t speeds a bove 30 m ph .
Axle com pon en t br ea ka ge is m ost oft en t h e r esu lt
of: LOW SPEED KNOCK
• Sever e over loa din g. Low speed kn ock is gen er a lly ca u sed by a wor n
• In su fficien t lu br ica n t . U–join t or by wor n side–gea r t h r u st wa sh er s. A wor n
• In cor r ect lu br ica n t . pin ion gea r sh a ft bor e will a lso ca u se low speed
• Im pr oper ly t igh t en ed com pon en t s. kn ock.

GEAR NOISE VIBRATION


Axle gea r n oise ca n be ca u sed by in su fficien t lu br i- Vibr a t ion a t t h e r ea r of t h e veh icle is u su a lly
ca n t , in cor r ect ba ckla sh , t oot h con t a ct , or wor n /da m - ca u sed by a :
a ged gea r s. • Da m a ged dr ive sh a ft .
Gea r n oise u su a lly h a ppen s a t a specific speed • Missin g dr ive sh a ft ba la n ce weigh t (s).
r a n ge. Th e r a n ge is 30 t o 40 m ph , or a bove 50 m ph . • Wor n or ou t –of–ba la n ce wh eels.
Th e n oise ca n a lso occu r du r in g a specific t ype of • Loose wh eel lu g n u t s.
dr ivin g con dit ion . Th ese con dit ion s a r e a cceler a t ion , • Wor n U–join t (s).
deceler a t ion , coa st , or con st a n t loa d. • Loose/br oken spr in gs.
Wh en r oa d t est in g, a cceler a t e t h e veh icle t o t h e • Da m a ged a xle sh a ft bea r in g(s).
speed r a n ge wh er e t h e n oise is t h e gr ea t est . Sh ift • Loose pin ion gea r n u t .
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. • E xcessive pin ion yoke r u n ou t .
If t h e n oise st ops or ch a n ges gr ea t ly: • Ben t a xle sh a ft (s).
• Ch eck for in su fficien t lu br ica n t . Ch eck for loose or da m a ged fr on t –en d com pon en t s
• In cor r ect r in g gea r ba ckla sh . or en gin e/t r a n sm ission m ou n t s. Th ese com pon en t s
• Gea r da m a ge. 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
Differ en t ia l side a n d pin ion gea r s ca n be ch ecked vibr a t ion . Do n ot over look en gin e a ccessor ies, br a ck-
by t u r n in g t h e veh icle. Th ey u su a lly do n ot ca u se et s a n d dr ive belt s.
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 All dr ivelin e com pon en t s sh ou ld be exa m in ed
a r e u n loa ded. Th e side gea r s a r e loa ded du r in g veh i- befor e st a r t in g a n y r epa ir.
cle t u r n s. A wor n pin ion gea r m a t e sh a ft ca n a lso Refer t o Gr ou p 22, Wh eels a n d Tir es, for a ddit ion a l
ca u se a sn a ppin g or a kn ockin g n oise. vibr a t ion in for m a t ion .

BEARING NOISE DRIVELINE SNAP


Th e a xle sh a ft , differ en t ia l a n d pin ion gea r bea r- A sn a p or clu n k n oise wh en t h e veh icle is sh ift ed
in gs ca n a ll pr odu ce n oise wh en wor n or da m a ged. in t o gea r (or t h e clu t ch en ga ged), ca n be ca u sed by:
Bea r in g n oise ca n be eit h er a wh in in g, or a gr owlin g • H igh en gin e idle speed.
sou n d. • Loose en gin e/t r a n sm ission /t r a n sfer ca se m ou n t s.
P in ion gea r bea r in gs h a ve a con st a n t –pit ch n oise. • Wor n U–join t s.
Th is n oise ch a n ges on ly wit h veh icle speed. P in ion • Loose spr in g m ou n t s.
bea r in g n oise will be h igh er beca u se it r ot a t es a t a • Loose pin ion gea r n u t a n d yoke.
fa st er r a t e. Dr ive t h e veh icle a n d loa d t h e differ en - • E xcessive r in g gea r ba ckla sh .
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 • E xcessive side gea r /ca se clea r a n ce.
is t h e sou r ce of t h e n oise. If t h e bea r in g n oise is Th e sou r ce of a sn a p or a clu n k n oise ca n be det er-
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 m in ed wit h t h e a ssist a n ce of a h elper. Ra ise t h e veh i-
sou r ce. 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
Wor n or da m a ged differ en t ia l bea r in gs u su a lly pr o- 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
du ce a low pit ch n oise. Differ en t ia l bea r in g n oise is for t h e n oise, a m ech a n ics st et h oscope is h elpfu l in
sim ila r t o pin ion bea r in g n oise. Th e pit ch of differ en - isola t in g t h e sou r ce of a n oise.
XJ DIFFERENTIAL AND DRIVELINE 3 - 87
DI AGN OSI S AN D T EST I N G (Cont inue d)
TRAC–LOK DIFFERENTIAL NOISE 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
Th e m ost com m on pr oblem is a ch a t t er n oise wh en m a ke 10 t o 12 slow, figu r e-eigh t t u r n s. Th is m a n eu -
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 ver will pu m p lu br ica n t t h r ou gh t h e clu t ch es. Th is
r epa ir, dr a in , flu sh a n d r efill t h e a xle wit h t h e spec- will cor r ect t h e con dit ion in m ost in st a n ces. If t h e
ified lu br ica n t . Refer t o Lu br ica n t ch a n ge in t h is ch a t t er per sist s, clu t ch da m a ge cou ld h a ve occu r r ed.
Gr ou p.
A con t a in er of Mopa r t Tr a c-lok Lu br ica n t (fr ict ion
m odifier ) sh ou ld be a dded a ft er r epa ir ser vice or du r-
in g a lu br ica n t ch a n ge.
3 - 88 DIFFERENTIAL AND DRIVELINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Faulty or brinelled bearings must
be replaced.
AXLE SHAFT NOISE 1. Misaligned axle shaft tube. 1. Inspect axle shaft tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Replace bent or sprung axle
shaft.
3. End play in drive pinion bearings. 3. Refer to Drive Pinion Bearing
Pre-Load Adjustment.
4. Excessive gear backlash between 4. Check adjustment of ring gear
ring gear and pinion gear. backlash and pinion gear. Correct as
necessary.
5. Improper adjustment of drive 5. Adjust drive pinion shaft bearings.
pinion gear shaft bearings.
6. Loose drive pinion gearshaft yoke 6. Tighten drive pinion gearshaft
nut. yoke nut with specified torque.
7. Improper wheel bearing 7. Readjust as necessary.
adjustment.
8. Scuffed gear tooth contact 8. If necessary, replace scuffed
surfaces. gears.
AXLE SHAFT BROKE 1. Misaligned axle shaft tube. 1. Replace broken axle shaft after
correcting axle shaft tube alignment.
2. Vehicle overloaded. 2. Replace broken axle shaft. Avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken axle shaft after
inspecting for other possible casues.
Avoid erratic use of clutch.
4. Grabbing clutch. 4. Replace broken axle shaft.
Inspect clutch and make necessary
repairs or adjustments.
DIFFERENTIAL CASE CRACKED 1. Improper adjustment of differential 1. Replace cracked case; examine
bearings. gears and bearings for possible
damage. At reassembly, adjust
differential bearings properly.
2. Excessive ring gear backlash. 2. Replace cracked case; examine
gears and bearings for possible
damage. At reassembly, adjust ring
gear backlash properly.
3. Vehicle overloaded. 3. Replace cracked case; examine
gears and bearings for possible
damage. Avoid excessive weight on
vehicle.
4. Erratic clutch operation. 4. Replace cracked case. After
inspecting for other possible causes,
examine gears and bearings for
possible damage. Avoid erratic use
of clutch.
XJ DIFFERENTIAL AND DRIVELINE 3 - 89
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


DIFFERENTIAL GEARS SCORED 1. Insufficient lubrication. 1. Replace scored gears. Scoring
marks on the drive face of gear
teeth or in the bore are caused by
instantaneous fusing of the mating
surfaces. Scored gears should be
replaced. Fill rear differential housing
to required capacity with proper
lubricant. Refer to Specifications.
2. Improper grade of lubricant. 2. Replace scored gears. Inspect all
gears and bearings for possible
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
3. Excessive spinning of one 3. Replace scored gears. Inspect all
wheel/tire. gears, pinion bores and shaft for
damage. Service as necessary.
LOSS OF LUBRICANT 1. Lubricant level too high. 1. Drain excess lubricant by
removing fill plug and allow lubricant
to level at lower edge of fill plug
hole.
LOSS OF LUBRICANT 2. Worn axle shaft seals. Replace worn seals.
3. Cracked differential housing. 3. Repair or replace housing as
necessary.
4. Worn drive pinion gear shaft seal. 4. Replace worn drive pinion gear
shaft seal.
5. Scored and worn yoke. 5. Replace worn or scored yoke and
seal.
6. Axle cover not properly sealed. 6. Remove cover and clean flange
and reseal.
AXLE OVERHEATING 1. Lubricant level too low. 1. Refill differential housing.
2. Incorrect grade of lubricant. 2. Drain, flush and refill with correct
amount of the correct lubricant.
3. Bearings adjusted too tight. 3. Readjust bearings.
4. Excessive gear wear. 4. Inspect gears for excessive wear
or scoring. Replace as necessary.
5. Insufficient ring gear backlash. 5. Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (RING GEAR 1. Overloading. 1. Replace gears. Examine other
AND PINION) gears and bearings for possible
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for possible
damage. Avoid erratic clutch
operation.
3. Ice-spotted pavements. 3. Replace gears. Examine the
remaining parts for possible
damage. Replace parts as required.
4. Improper adjustments. 4. Replace gears. Examine other
parts for possible damage. Ensure
ring gear backlash is correct.
SPECIAL
6790
IN WITH
CENTER
HOLE
TOOL
BOLT TORQUE WRENCH

3 - 90 DIFFERENTIAL AND DRIVELINE XJ


DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


AXLE NOISE 1. Insufficient lubricant. 1. Refill axle with correct amount of
proper lubricant. Also inspect for
leaks and correct as necessary.
2. Improper ring gear and drive 2. Check ring gear and pinion gear
pinion gear adjustment. teeth contact pattern.
3. Unmatched ring gear and drive 3. Remove unmatched ring gear and
pinion gear. drive pinion gear. Replace with
matched gear and drive pinion gear
set.
4. Worn teeth on ring gear or drive 4. Check teeth on ring gear and
pinion gear. drive pinion gear for correct contact.
If necessary, replace with new
matched set.
5. Loose drive pinion gear shaft 5. Adjust drive pinion gearshaft
bearings. bearing preload torque.
6. Loose differential bearings. 6. Adjust differential bearing preload
torque.
7. Misaligned or sprung ring gear. 7. Measure ring gear runout.
8. Loose differential bearing cap 8. Tighten with specified torque.
bolts.

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

XJ DIFFERENTIAL AND DRIVELINE 3 - 91


SERV I CE PROCEDU RES (Cont inue d)
(7) Discon n ect t h e pa r kin g br a ke ca bles a n d ca ble
br a cket s.
(8) Discon n ect t h e ven t h ose fr om t h e a xle sh a ft
t u be.
(9) Ma r k t h e pr opeller sh a ft a n d yoke for in st a lla -
t ion a lign m en t r efer en ce.
(10) Rem ove pr opeller sh a ft .
(11) Discon n ect sh ock a bsor ber s fr om a xle.
(12) Rem ove t h e st a bilizer lin ks.
(13) Rem ove t h e spr in g cla m ps a n d spr in g br a ck-
et s. Refer t o Gr ou p 2, Su spen sion , for pr oper pr oce-
du r es.
(14) Sepa r a t e t h e a xle fr om t h e veh icle.
AXLE HOUSING
I N STALLAT I ON
COVER 80a534a8
(1) Ra ise t h e a xle wit h lift in g device a n d a lign t o
Fig. 7 Apply Sealant t h e lea f spr in g cen t er in g bolt s.
(2) In st a ll t h e spr in g cla m ps a n d spr in g br a cket s.
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
Refer t o Gr ou p 2, Su spen sion , for pr oper pr ocedu r es.
a fte r a p p ly in g th e s e a la n t.
(3) In st a ll sh ock a bsor ber s a n d t igh t en n u t s t o 60
(7) In st a ll t h e cover a n d a n y iden t ifica t ion t a g.
N·m (44 ft . lbs.) t or qu e.
Tigh t en t h e cover bolt s t o 41 N·m (30 ft . lbs.) t or qu e.
(4) In st a ll t h e st a bilizer lin ks. Tigh t en swa y ba r
(8) F or Tr a c–lok differ en t ia ls, a qu a n t it y of
lin ks t o 74 N·m (55 ft . lbs.).
Mopa r t Tr a c–lok lu br ica n t (fr ict ion m odifier ), or
(5) Con n ect t h e pa r kin g br a ke ca bles a n d ca ble
equ iva len t , m u st be a dded a ft er r epa ir ser vice or a
br a cket s.
lu br ica n t ch a n ge. Refer t o t h e Lu br ica n t Specifica -
(6) In st a ll t h e br a ke dr u m s. Refer t o Gr ou p 5,
t ion s sect ion of t h is gr ou p for t h e qu a n t it y n ecessa r y.
Br a kes, for pr oper pr ocedu r es.
(9) F ill differ en t ia l wit h Mopa r t H ypoid Gea r
(7) Con n ect t h e br a ke h ose t o t h e a xle ju n ct ion
Lu br ica n t , or equ iva len t , t o bot t om of t h e fill plu g
block. Refer t o Gr ou p 5, Br a kes, for pr oper pr oce-
h ole. Refer t o t h e Lu br ica n t Specifica t ion s sect ion of
du r es.
t h is gr ou p for t h e qu a n t it y n ecessa r y.
(8) In st a ll a xle ven t h ose.
CAUTION: Overfilling the differential can result in (9) Align pr opeller sh a ft a n d pin ion yoke r efer en ce
lubricant foaming and overheating. m a r ks. In st a ll u n iver sa l join t st r a ps a n d bolt s.
Tigh t en t o 19 N·m (14 ft . lbs.) t or qu e.
(10) In st a ll t h e fill h ole plu g a n d lower t h e veh icle. (10) In st a ll t h e wh eels a n d t ir es.
(11) Tr a c–lok differ en t ia l equ ipped veh icles sh ou ld (11) Add gea r lu br ica n t , if n ecessa r y. Refer t o
be r oa d t est ed by m a kin g 10 t o 12 slow figu r e-eigh t Lu br ica n t Specifica t ion s in t h is sect ion for lu br ica n t
t u r n s. Th is m a n eu ver will pu m p t h e lu br ica n t r equ ir em en t s.
t h r ou gh t h e clu t ch discs t o elim in a t e a possible ch a t - (12) Rem ove lift in g device fr om a xle a n d lower t h e
t er n oise com pla in t . veh icle.

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

3 - 92 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
scr ew a n d pin ion m a t e gea r sh a ft fr om differ en t ia l (2) In ser t C–clip lock in en d of a xle sh a ft . P u sh
ca se (F ig. 8). a xle sh a ft ou t wa r d t o sea t C–clip lock in side gea r.
(3) In ser t pin ion m a t e sh a ft in t o differ en t ia l ca se
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.
(4) Align h ole in sh a ft wit h h ole in t h e differ en t ia l
ca se a n d in st a ll lock scr ew wit h Loct it et on t h e
t h r ea ds. Tigh t en lock scr ew t o 11 N·m (8 ft . lbs.)
t or qu e.
(5) In st a ll cover a n d a dd flu id. Refer t o Lu br ica n t
Ch a n ge pr ocedu r e in t h is sect ion for pr ocedu r e a n d
lu br ica n t r equ ir em en t s.
(6) In st a ll br a ke dr u m . Refer t o Gr ou p 5, Br a kes,
for pr oper pr ocedu r es.
(7) In st a ll wh eel a n d t ir e.
(8) Lower veh icle.

AXLE SEAL AND BEARING


REM OVAL
Fig. 8 Mate Shaft Lock Screw (1) Rem ove a xle sh a ft .
(7) P u sh a xle sh a ft in wa r d a n d r em ove a xle sh a ft (2) Rem ove a xle sh a ft sea l fr om t h e en d of t h e a xle
C–clip lock fr om t h e a xle sh a ft (F ig. 9). t u be wit h a sm a ll pr y ba r (F ig. 10).

NOTE: The seal and bearing can be removed at the


same time with the bearing removal tool.

(3) Rem ove t h e a xle sh a ft bea r in g fr om t h e a xle


t u be wit h Bea r in g Rem ova l Tool Set 6310, u sin g
Ada pt er F oot 6310-9 (F ig. 11).

J9003-45

Fig. 9 Axle Shaft C–Clip Lock


(8) Rem ove a xle sh a ft . Use ca r e t o pr even t da m a ge
t o a xle sh a ft bea r in g a n d sea l, wh ich will r em a in in
a xle sh a ft t u be.
(9) In spect a xle sh a ft sea l for lea ka ge or da m a ge.
(10) In spect r oller bea r in g con t a ct su r fa ce on a xle
sh a ft for sign s of br in ellin g, ga llin g a n d pit t in g. If
a n y of t h ese con dit ion s exist , t h e a xle sh a ft a n d/or Fig. 10 Axle Seal Removal
bea r in g a n d sea l m u st be r epla ced. I N STALLAT I ON

I N STALLAT I ON NOTE: Do not install the original axle shaft seal.


(1) Lu br ica t e bea r in g bor e a n d sea l lip wit h gea r Always install a new seal.
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. (1) Wipe t h e a xle t u be bor e clea n . Rem ove a n y old
sea ler or bu r r s fr om t h e t u be.
NOTE: Use care to prevent shaft splines from dam- (2) In st a ll t h e a xle sh a ft bea r in g wit h In st a ller
aging axle shaft seal lip. C-4198 a n d H a n dle C-4171 (F ig. 12). E n su r e t h a t t h e
bea r in g pa r t n u m ber is a ga in st t h e in st a ller. Ver ify
AXLE SHAFT
TUBE
AXLE TUBE FOOT INSTALLER
ADAPTER
THREADED
GUIDE
HANDLE
PLATE
GUIDE
ROD
NUT TOOL C452 PINION YOKE

XJ DIFFERENTIAL AND DRIVELINE 3 - 93


REM OVAL AN D I N STALLAT I ON (Cont inue d)
AXLE SHAFT (3) Discon n ect t h e pr opeller sh a ft fr om t h e pin ion
TUBE yoke. Secu r e t h e pr opeller sh a ft in a n u pr igh t posi-
t ion t o pr even t da m a ge t o t h e r ea r u n iver sa l join t .
(4) Rem ove t h e wh eel a n d t ir e a ssem blies.
(5) Rem ove t h e br a ke dr u m s t o pr even t a n y dr a g.
Th e dr a g m a y ca u se a fa lse bea r in g pr eloa d t or qu e
m ea su r em en t .
(6) Rot a t e t h e pin ion yoke t h r ee or fou r t im es.
(7) Mea su r e t h e a m ou n t of t or qu e n ecessa r y t o
r ot a t e t h e pin ion gea r wit h a (in . lbs.) dia l-t ype
t or qu e wr en ch . Recor d t h e t or qu e r ea din g for in st a l-
la t ion r efer en ce.
(8) H old t h e yoke wit h Wr en ch 6719. Rem ove t h e
pin ion sh a ft n u t a n d wa sh er.
GUIDE (9) Rem ove t h e yoke wit h Rem over C-452 (F ig. 13).

THREADED
ROD

J9003-5l

Fig. 11 Axle Shaft Bearing Removal Tool


t h a t t h e bea r in g in in st a lled st r a igh t a n d t h e t ool
fu lly con t a ct s t h e a xle t u be wh en sea t in g t h e bea r in g.
(3) In st a ll a n ew a xle sea l wit h In st a ller C-4076-B
a n d H a n dle C-4735-1. Wh en t h e t ool con t a ct s t h e TOOL
a xle t u be, t h e sea l is in st a lled t o t h e cor r ect dept h . C452
(4) Coa t t h e lip of t h e sea l wit h a xle lu br ica n t for
pr ot ect ion pr ior t o in st a llin g t h e a xle sh a ft . J9403-18
(5) In st a ll t h e a xle sh a ft .
Fig. 13 Yoke Removal
(10) Rem ove t h e pin ion sh a ft sea l wit h su it a ble
pr y t ool or slide-h a m m er m ou n t ed scr ew.

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.

NOTE: The outer perimeter of the seal is pre-coated


J9403-57 with a special sealant. An additional application of
sealant is not required.
Fig. 12 Axle Shaft Seal and Bearing Installation
(4) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
PINION SEAL lip of pin ion sea l.
(5) In st a ll t h e n ew pin ion sh a ft sea l wit h In st a ller
REM OVAL C-4076-B a n d H a n dle C-4735-1 (F ig. 14).
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Scr ibe a m a r k on t h e u n iver sa l join t , pin ion NOTE: The seal is correctly installed when the seal
yoke, a n d pin ion sh a ft for r efer en ce. flange contacts the face of the differential housing
flange.
SPECIAL C-4735
TOOLSPECIAL TOOL C-4076-A DIFFERENTIAL HOUSING DIFFERENTIALYOKE
HOUSING
PINION
HOLDER
YOKE
INCH
TORQUE
POUND
WRENCH
WRENCH
TORQUE

3 - 94 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

Fig. 14 8 1/4 Axle Pinion Seal Installation


(6) P osit ion t h e pin ion yoke on t h e en d of t h e sh a ft
wit h t h e r efer en ce m a r ks a lign ed.
(7) Sea t yoke on pin ion sh a ft wit h In st a ller C-3718
a n d Wr en ch 6719.
(8) Rem ove t h e t ools a n d in st a ll t h e pin ion yoke
Fig. 15 Tightening Pinion Shaft Nut
wa sh er. Th e con vex side of t h e wa sh er m u st fa ce ou t -
wa r d.

CAUTION: Do not exceed the minimum tightening


torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer or bear-
ings may result.

(9) H old pin ion yoke wit h Yoke H older 6719 a n d


t igh t en sh a ft n u t t o 285 N·m (210 ft . lbs.) (F ig. 15).
Rot a t e pin ion sh a ft sever a l r evolu t ion s t o en su r e t h e
bea r in g r oller s a r e sea t ed.
(10) Rot a t e t h e pin ion sh a ft u sin g a n (in . lbs.)
t or qu e wr en ch . Rot a t in g t or qu e sh ou ld be equ a l t o
t h e r ea din g r ecor ded du r in g r em ova l, plu s a n a ddi-
t ion a l 0.56 N·m (5 in . lbs.) (F ig. 16).

CAUTION: Never loosen pinion gear nut to


decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.

(11) If t h e r ot a t in g t or qu e is low, u se Yoke H older Fig. 16 Check Pinion Rotation Torque


6719 t o h old t h e pin ion yoke (F ig. 15) a n d t igh t en t h e (12) Th e sea l r epla cem en t is u n a ccept a ble if t h e
pin ion sh a ft n u t in 6.8 N·m (5 ft . lbs.) in cr em en t s fin a l pin ion n u t t or qu e is less t h a n 285 N·m (210 ft .
u n t il pr oper r ot a t in g t or qu e is a ch ieved. lbs.).
(13) In st a ll t h e pr opeller sh a ft wit h t h e in st a lla -
NOTE: The bearing rotating torque should be con- t ion r efer en ce m a r ks a lign ed.
stant during a complete revolution of the pinion. If (14) Tigh t en t h e u n iver sa l join t yoke cla m p scr ews
the rotating torque varies, this indicates a binding t o 19 N·m (14 ft . lbs.).
condition. (15) In st a ll t h e br a ke dr u m s.
DIFFERENTIAL
REFERENCE
INSTALLATION
HOUSING
MARKS BACKING PLATE C-4164
TOOL INSTALLATION
REFERENCE
AXLE
MARKS
TUBE DIFFERENTIAL
REFERENCE
INSTALLATION
HOUSING
MARKS INSTALLATION
REFERENCE MARKS
BEARING BEARING
CAP CAP

XJ DIFFERENTIAL AND DRIVELINE 3 - 95


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(16) In st a ll wh eel a n d t ir e a ssem blies a n d lower (5) H old t h e differ en t ia l ca se wh ile r em ovin g bea r-
t h e veh icle. in g ca ps a n d a dju st er s.
(17) Ch eck t h e differ en t ia l h ou sin g lu br ica n t level. (6) Rem ove t h e differ en t ia l ca se.

DIFFERENTIAL NOTE: Each differential bearing cup and threaded


adjuster must be kept with their respective bearing.
REM OVAL
(1) Rem ove t h e a xle sh a ft s. I N STALLAT I ON
(1) Apply a coa t in g of h ypoid gea r lu br ica n t t o t h e
NOTE: Side play resulting from bearing races being differ en t ia l bea r in gs, bea r in g cu ps, a n d t h r ea ded
loose on case hubs requires replacement of the dif- a dju st er s. A da b of gr ea se ca n be u sed t o keep t h e
ferential case. a dju st er s in posit ion . Ca r efu lly posit ion t h e a ssem -
bled differ en t ia l ca se in t h e h ou sin g.
(2) Ma r k t h e differ en t ia l h ou sin g a n d t h e differ en - (2) Obser ve t h e r efer en ce m a r ks a n d in st a ll t h e
t ia l bea r in g ca ps for in st a lla t ion r efer en ce (F ig. 17). differ en t ia l bea r in g ca ps a t t h eir or igin a l loca t ion s
(F ig. 19).

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.

DIFFERENTIAL SIDE BEARINGS


REM OVAL
(1) Rem ove differ en t ia l ca se fr om a xle h ou sin g.
(2) Rem ove t h e bea r in gs fr om t h e differ en t ia l ca se
wit h P u ller /P r ess C-293-PA a n d Ada pt er s C-293-48
a n d P lu g SP -3289 (F ig. 20).
BACKING
PLATE I N STALLAT I ON
(1) In st a ll differ en t ia l side bea r in gs. Use In st a ller
C-4340 wit h h a n dle C-4171 (F ig. 21).
(2) In st a ll differ en t ia l ca se in a xle h ou sin g.
Fig. 18 Threaded Adjuster Tool
SPECIAL
SPECIAL
DIFFERENTIAL
C-293–PA
SP-3289
TOOL
TOOL
BEARING
BEARING
TOOLC-4340 SPECIAL
HANDLE
DIFFEREN-
TOOL
C-4171
C-293–48
TIAL RAWHIDE HAM-
MER CASE RING GEAR

3 - 96 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
RING GEAR
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 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. 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

Fig. 20 Differential Bearing Removal


Fig. 22 Ring Gear Removal
I N STALLAT I ON

CAUTION: Do not reuse the bolts that held the ring


gear to the differential case. The bolts can fracture
causing extensive damage.

(1) In ver t t h e differ en t ia l ca se.


(2) P osit ion r in g gea r on t h e differ en t ia l ca se a n d
st a r t t wo r in g gea r bolt s. Th is will pr ovide ca se-t o-
r in g gea r bolt h ole a lign m en t .
(3) In ver t t h e differ en t ia l ca se in t h e vise.
(4) In st a ll n ew r in g gea r bolt s a n d a lt er n a t ely
t igh t en t o 102 N·m (75 ft . lbs.) t or qu e (F ig. 23).
(5) In st a ll differ en t ia l in a xle h ou sin g a n d ver ify
gea r m esh a n d con t a ct pa t t er n .

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.

Fig. 21 Install Differential Side Bearings REM OVAL


(1) Rem ove differ en t ia l fr om t h e a xle h ou sin 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 .
RING
TOOL
GEAR
CASE
C452 TORQUE
RING
PINION
GEAR
WRENCH
YOKE
BOLT REMOVER RAWHIDE
HANDLE
HAM-
MER

XJ DIFFERENTIAL AND DRIVELINE 3 - 97


REM OVAL AN D I N STALLAT I ON (Cont inue d)
TORQUE
/WRENCH

========~;::::;/ RING GEAR


BOLT

RING
GEAR

J9202-77

Fig. 23 Ring Gear Bolt Installation Fig. 25 Remove Pinion Gear


(3) Discon n ect pr opeller sh a ft fr om pin ion yoke. (10) Rem ove t h e fr on t pin ion bea r in g cu p wit h
Usin g su it a ble wir e, t ie pr opeller sh a ft t o u n der body. Rem over C-4345 a n d H a n dle C–4171 (F ig. 26).
(4) Usin g Yoke H older 6719 t o h old yoke a n d
r em ove t h e pin ion yoke n u t a n d wa sh er.
(5) Usin g Rem over C–452, r em ove t h e pin ion yoke
fr om pin ion sh a ft (F ig. 24).

PINION
YOKE

TOOL
C452

J9403-18

Fig. 24 Pinion Yoke Removal J9302-22

(6) P a r t ia lly in st a ll pin ion n u t on t o pin ion t o pr o-


t ect t h e t h r ea ds. Fig. 26 Front Bearing Cup Removal
(7) Rem ove t h e pin ion gea r fr om h ou sin g (F ig. 25).
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.
(8) Rem ove t h e pin ion sh a ft sea l wit h su it a ble pr y
t ool or slide-h a m m er m ou n t ed scr ew.
(9) Rem ove oil slin ger, if equ ipped, a n d fr on t pin -
ion bea r in g.
OIL
DRIVER
REAR
SLINGER
BEAR-
ING IBLE
COLLAPS-
SHOULDER
SPACER
PINION
HANDLE
GEAR DRIVE
GEAR
HANDLE
ADAPTERS
PINION
SHAFT SPECIAL C-293–PA
TOOL INSTALLER VISE

3 - 98 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(11) Rem ove t h e r ea r bea r in g cu p fr om h ou sin g SPECIAL
(F ig. 27). Use Rem over C-4307 a n d H a n dle C–4171. TOOL
C-293-PA

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

Fig. 28 Collapsible Spacer


(13) Rem ove t h e r ea r bea r in g fr om t h e pin ion (F ig.
29) wit h P u ller /P r ess C-293-PA a n d Ada pt er s C-293-
47. HANDLE J9402-66
P la c e 4 a d a p te r blo c k s s o th e y d o n o t d a m a g e
th e be a rin g c a g e . Fig. 30 Pinion Rear Bearing Cup Installation
SPECIAL INSTALLER
C-4735
TOOLSPECIAL TOOL C-4076-A DIFFERENTIAL
HANDLEHOUSING DRIVE
OIL
REAR
PINION
SLINGER
DRIVE
REAR
BEAR-
GEAR
ING
PINION
BEARING
SHAFT
GEAR PRESS INSTALLATION
IBLE
COLLAPS-
SHOULDER
SPACER
PINION
GEAR
TOOL

XJ DIFFERENTIAL AND DRIVELINE 3 - 99


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) Apply Mopa r t Door E a se, or equ iva len t , st ick (9) In st a ll t h e r ea r bea r in g a n d slin ger, if
lu br ica n t t o ou t side su r fa ce of bea r in g cu p. equ ipped, on t h e pin ion gea r (F ig. 33) wit h In st a ller
(5) In st a ll t h e pin ion fr on t bea r in g cu p (F ig. 31) 6448.
wit h In st a ller D–130 a n d H a n dle C–4171.

INSTALLER HANDLE

INSTALLATION
TOOL

DRIVE
PINION GEAR
SHAFT
REAR BEARING

Fig. 31 Pinion Front Bearing Cup Installation


(6) In st a ll pin ion fr on t bea r in g, a n d oil slin ger, if
equ ipped.
J9003-67
(7) Apply a ligh t coa t in g of gea r lu br ica n t on t h e
lip of pin ion sea l. In st a ll sea l wit h In st a ller
C-4076–B a n d H a n dle C-4735-1 (F ig. 32). Fig. 33 Shaft Rear Bearing Installation
(10) In st a ll a n ew colla psible pr eloa d spa cer on
pin ion sh a ft a n d in st a ll pin ion gea r in h ou sin g (F ig.
34).
(11) In st a ll pin ion gea r in h ou sin g.

REAR
Fig. 32 Pinion Seal Installation BEARING

NOTE: Pinion depth shims are placed between the


rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If the factory
OIL
installed ring and pinion gears are reused, the pin- SLINGER
ion depth shim should not require replacement. If
required, refer to Pinion Gear Depth to select the
proper thickness shim before installing rear pinion
J9302-66
bearing.

(8) P la ce t h e pr oper t h ickn ess dept h sh im on t h e Fig. 34 Collapsible Preload Spacer


pin ion gea r. (12) In st a ll yoke wit h In st a ller C-3718 a n d Yoke
H older 6719.
PINION YOKE
INCH POUND WRENCH
TORQUE THRUST
WASHER
PINION GEAR
MATE SIDE GEAR
PINION
LOCK
SCREW
GEAR MATE SHAFT

3 - 100 DIFFERENTIAL AND DRIVELINE XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(13) In st a ll t h e yoke wa sh er a n d a n ew n u t on t h e DI SASSEM BLY AN D ASSEM BLY
pin ion gea r a n d t igh t en t h e pin ion n u t u n t il t h er e is
zer o bea r in g en d-pla y. It will n ot be possible a t t h is STANDARD DIFFERENTIAL
poin t t o a ch ieve zer o bea r in g en d-pla y if a n ew col-
la psible spa cer wa s in st a lled. DI SASSEM BLY
(14) Tigh t en t h e n u t t o 285 N·m (210 ft . lbs.). (1) Rem ove pin ion gea r m a t e sh a ft lock scr ew (F ig.
49).
CAUTION: Never loosen pinion gear nut to (2) Rem ove pin ion gea r m a t e sh a ft .
decrease pinion gear bearing rotating torque and (3) Rot a t e t h e differ en t ia l side gea r s a n d r em ove
never exceed specified preload torque. If preload t h e pin ion m a t e gea r s a n d t h r u st wa sh er s (F ig. 50).
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.

(15) Usin g Yoke H older 6719, cr u sh colla psible


spa cer u n t il bea r in g en d pla y is t a ken u p.
(16) Slowly t igh t en t h e n u t in 6.8 N·m (5 ft . lbs.)
in cr em en t s u n t il t h e desir ed r ot a t in g t or qu e is
a ch ieved. Mea su r e t h e r ot a t in g t or qu e fr equ en t ly t o
a void over cr u sh in g t h e colla psible spa cer (F ig. 35).
(17) Ch eck bea r in g r ot a t in g t or qu e wit h a n in ch
pou n d t or qu e wr en ch (F ig. 35). Th e t or qu e n ecessa r y
t o r ot a t e t h e pin ion gea r sh ou ld be:
• Or igin a l Bea r in gs — 1 t o 3 N·m (10 t o 20 in .
lbs.).
• New Bea r in gs — 2 t o 5 N·m (15 t o 35 in . lbs.).

Fig. 36 Pinion Gear Mate Shaft Lock Screw


THRUST
WASHER

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

XJ DIFFERENTIAL AND DRIVELINE 3 - 101


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

Fig. 38 Trac–lok Differential Components


ASSEM BLY
(1) In st a ll t h e differ en t ia l side gea r s a n d t h r u st
wa sh er s.
(2) In st a ll t h e pin ion m a t e gea r s a n d t h r u st wa sh -
er s.
(3) In st a ll t h e pin ion gea r m a t e sh a ft .
(4) Align t h e h ole in t h e pin ion gea r m a t e sh a ft
wit h t h e h ole in t h e differ en t ia l ca se a n d in st a ll t h e
pin ion gea r m a t e sh a ft lock scr ew.
(5) Lu br ica t e a ll differ en t ia l com pon en t s wit h
h ypoid gea r lu br ica n t .

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

3 - 102 DIFFERENTIAL AND DRIVELINE XJ


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

J9302-47

Fig. 40 Mate Shaft Lock Screw

PINION DIFFERENTIAL
MATE GEAR CASE 80a982ec

Fig. 42 Step Plate Tool Installation

THREADED
ADAPTER
DISC
8140-1

80a773e1

Fig. 41 Mate Shaft Removal


(8) P osit ion a sm a ll scr ew dr iver in slot of
Th r ea ded Ada pt er 8140-1 (F ig. 43) t o pr even t a da pt er
fr om t u r n in g.
(9) Tigh t en for cin g scr ew t ool 122 N·m (90 ft . lbs.)
m a xim u m t o com pr ess Belleville spr in gs in clu t ch
pa cks (F ig. 44).
(10) Usin g a n a ppr opr ia t e size feeler ga u ge, DISC
r em ove t h r u st wa sh er s fr om beh in d t h e pin ion gea r s 8140-2
(F ig. 45).
80a982ed
(11) In ser t Tu r n in g Ba r 6960-2 in ca se (F ig. 46).
(12) Loosen t h e F or cin g Scr ew 6960-4 in sm a ll
Fig. 43 Threaded Adapter Installation
in cr em en t s u n t il t h e clu t ch pa ck t en sion is r elieved
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 (16) Rem ove t op side gea r, clu t ch pa ck r et a in er,
Ba r 6960-2. a n d clu t ch pa ck. Keep pla t es in cor r ect or der du r in g
(13) Rot a t e differ en t ia l ca se u n t il t h e pin ion gea r s r em ova l (F ig. 47).
ca n be r em oved. (17) Rem ove differ en t ia l ca se fr om Side Gea r H old-
(14) Rem ove pin ion gea r s fr om differ en t ia l ca se. in g Tool 8138. Rem ove side gea r, clu t ch pa ck r et a in er,
(15) Rem ove F or cin g Scr ew 6960-4, St ep P la t e a n d clu t ch pa ck. Keep pla t es in cor r ect or der du r in g
8140–2, a n d Th r ea ded Ada pt er 8140–1. r em ova l.
TORQUE
THRUST
WRENCH
DIFFERENTIAL
WASHER TOOLCASEASSEM-
BLED FEELER GAUGE PINION
SIDE GEAR
GEARSAND
RETAINER
DISC
CLUTCH
PACK DIFFERENTIAL
TOOLCASE

XJ DIFFERENTIAL AND DRIVELINE 3 - 103


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

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

3 - 104 DIFFERENTIAL AND DRIVELINE XJ


DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

CLUTCH PACK
UPPER SIDE
GEAR AND CLUTCH
DISC PACK

.
SPECIAL

/
RETAINER
J8903-50
TOOL
8140-2

80a982ee

Fig. 48 Clutch Disc Pack


Fig. 50 Upper Side Gear & Clutch Disc Pack
Installation
(15) In st a ll pin ion gea r m a t e sh a ft a n d a lign h oles
in sh a ft a n d ca se.
LOWER (16) In st a ll t h e pin ion m a t e sh a ft lock scr ew fin ger
SIDE GEAR t igh t t o h old sh a ft du r in g differ en t ia l in st a lla t ion .
AND CLUTCH (17) Lu br ica t e a ll differ en t ia l com pon en t s wit h
DISC PACK h ypoid gea r lu br ica n t .

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

XJ DIFFERENTIAL AND DRIVELINE 3 - 105


CLEAN I N G AN D I N SPECT I ON (Cont inue d)
• Rin g a n d pin ion gea r for wor n a n d ch ipped DRIVE PINION
t eet h . PRODUCTION GEAR DEPTH
NUMBERS VARIANCE
• 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 in ion dept h 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.
• Th e differ en t ia l ca se. Repla ce t h e ca se if cr a cked
or da m a ged.
• Th e a xle sh a ft C-clip locks for cr a cks a n d exces-
sive wea r. Repla ce t h em if n ecessa r y.
• E a ch t h r ea ded a dju st er t o det er m in e if it r ot a t es
GEAR MATCHING NUMBER
fr eely. If a n a dju st er bin ds, r epa ir t h e da m a ged (SAME AS RING GEAR NUMBER) J9003-100
t h r ea ds or r epla ce t h e a dju st er.
P olish ea ch a xle sh a ft sea lin g su r fa ce wit h No. 600 Fig. 51 Pinion Gear ID Numbers
cr ocu s clot h . Th is ca n r em ove sligh t su r fa ce da m a ge.
Do n ot r edu ce t h e dia m et er of t h e a xle sh a ft sea l con - Com pen sa t ion for pin ion dept h va r ia n ce is
t a ct su r fa ce. Wh en polish in g, t h e cr ocu s clot h sh ou ld a ch ieved wit h select sh im s. Th e sh im s a r e pla ced
be m oved a r ou n d t h e cir cu m fer en ce of t h e sh a ft (n ot u n der t h e r ea r pin ion bea r in g con e (F ig. 52).
in -lin e wit h t h e sh a ft ).
AXLE
HOUSING
TRAC-LOK
Clea n a ll com pon en t s in clea n in g solven t . Dr y com -
pon en t s wit h com pr essed a ir. In spect clu t ch pa ck
pla t es for wea r, scor in g or da m a ge. Repla ce bot h
clu t ch pa cks if a n y on e com pon en t in eit h er pa ck is
da m a ged. In spect side a n d pin ion gea r s. Repla ce a n y
gea r t h a t is wor n , cr a cked, ch ipped or da m a ged.
In spect differ en t ia l ca se a n d pin ion sh a ft . Repla ce if
wor n or da m a ged.

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

3 - 106 DIFFERENTIAL AND DRIVELINE XJ


ADJ U ST M EN T S (Cont inue d)
PI N I ON GEAR DEPT H VARI AN CE

Original Pinion Replacement Pinion Gear Depth Variance


Gear Depth
Variance −4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008

PI N I ON DEPT H M EASU REM EN T AN D (13) Lu br ica t e t h e pin ion gea r fr on t a n d r ea r bea r-


ADJ U ST M EN T in gs wit h gea r lu br ica n t .
(1) In st a ll fr on t pin ion bea r in g cu p. Use In st a ller (14) Re-t igh t en t h e com pr ession n u t t ool t o 1-3
D-130 a n d H a n dle C-4171. N·m (15-25 in . lbs.) t or qu e.
(2) In st a ll r ea r pin ion bea r in g cu p. Use In st a ller (15) Rot a t e t h e pin ion gea r sever a l com plet e r evo-
C-4308 a n d H a n dle C-4171. lu t ion s t o a lign t h e bea r in g r oller s.
(3) Use P in ion Gea r Adju st m en t Ga u ge Set (16) In st a ll Ga u ge Block (F ig. 54).
C-3715-B (F ig. 53).
(4) P osit ion Spa cer SP -6030 over Sh a ft SP -5385.
(5) P osit ion pin ion r ea r bea r in g on sh a ft .
(6) P osit ion t ools (wit h bea r in g) in t h e h ou sin g.
(7) In st a ll Sleeve SP -5382.
(8) In st a ll pin ion fr on t bea r in g.
(9) In st a ll Spa cer SP -6022.
(10) In st a ll Sleeve SP -3194-B, Wa sh er SP -534, a n d
Nu t SP -3193.
SPECIAL TOOL SET
C-3715-B
SP-6029
SP-6030 GAUGE
SP-3194-B BLOCK

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

XJ DIFFERENTIAL AND DRIVELINE 3 - 107


ADJ U ST M EN T S (Cont inue d)
• Ma in t a in t h e t or qu e wh ile a dju st in g t h e bea r in g
pr eloa d a n d r in g gea r ba ckla sh .
• E xcessive a dju st er t or qu e will in t r odu ce a h igh
bea r in g loa d a n d ca u se pr em a t u r e bea r in g fa ilu r e.
In su fficien t a dju st er t or qu e ca n r esu lt in excessive
differ en t ia l ca se fr ee-pla y a n d r in g gea r n oise.
• In su fficien t a dju st er t or qu e will n ot su ppor t t h e
r in g gea r cor r ect ly a n d ca n ca u se excessive differ en -
t ia l ca se fr ee-pla y a n d r in g gea r n oise.

NOTE: The differential bearing cups will not always


immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
• Maintain the gear teeth engaged (meshed) as
marked.
Fig. 55 Crossbore Arbor • The bearings must be seated by rapidly rotat-
ing the pinion gear a half turn back and forth.
• Do this five to ten times each time the
threaded adjusters are adjusted.

(1) Use Wr en ch C-4164 t o a dju st ea ch t h r ea ded


a dju st er in wa r d u n t il t h e differ en t ia l bea r in g fr ee-
pla y is elim in a t ed (F ig. 57). Allow som e r in g gea r
BEARING
ba ckla sh (a ppr oxim a t ely 0.01 in ch /0.25 m m ) bet ween

@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.

NOTE: Depth shims are available in 0.001-inch


increments from 0.020 inch to 0.038 inch.
Fig. 57 Threaded Adjuster Tool
(26) Rem ove t h e t ools fr om t h e differ en t ia l h ou s- (2) In st a ll dia l in dica t or a n d posit ion t h e plu n ger
in g. a ga in st t h e dr ive side of a r in g gea r t oot h (F ig. 58).
Mea su r e t h e ba ckla sh a t 4 posit ion s (90 degr ees
DIFFERENTIAL BEARING PRELOAD AND GEAR a pa r t ) a r ou n d t h e r in g gea r. Loca t e a n d m a r k t h e
BACKLASH a r ea of m in im u m ba ckla sh .
Th e followin g m u st be con sider ed wh en a dju st in g (3) Rot a t e t h e r in g gea r t o t h e posit ion of t h e lea st
bea r in g pr eloa d a n d gea r ba ckla sh : ba ckla sh . Ma r k t h e gea r so t h a t a ll fu t u r e ba ckla sh
• Th e m a xim u m r in g gea r ba ckla sh va r ia t ion is m ea su r em en t s will be t a ken wit h t h e sa m e gea r
0.003 in ch (0.076 m m ). t eet h m esh ed.
• Ma r k t h e gea r s so t h e sa m e t eet h a r e m esh ed (4) Loosen t h e r igh t -side, t igh t en t h e left -side
du r in g a ll ba ckla sh m ea su r em en t s. t h r ea ded a dju st er. Obt a in ba ckla sh of 0.003 t o 0.004
in ch (0.076 t o 0.102 m m ) wit h ea ch a dju st er t igh t -
EXCITER
RING DIAL INDICATOR
RING GEAR

3 - 108 DIFFERENTIAL AND DRIVELINE XJ


ADJ U ST M EN T S (Cont inue d)
(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.
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
degr ee of con t a ct a ga in st t h e pin ion gea r t eet h will
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
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
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
(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. 58 Ring Gear Backlash Measurement SIDE GEAR CLEARANCE


Wh en m ea su r in g side gea r clea r a n ce, ch eck ea ch
en ed t o 14 N·m (10 ft . lbs.). Sea t t h e bea r in g cu ps
gea r in depen den t ly. If it n ecessa r y t o r epla ce a side
wit h t h e pr ocedu r e descr ibed a bove.
gea r, r epla ce bot h gea r s a s a m a t ch ed set .
(5) Tigh t en t h e differ en t ia l bea r in g ca p bolt s 95
(1) In st a ll t h e a xle sh a ft s a n d C-clip locks a n d pin -
N·m (70 ft . lbs.).
ion m a t e sh a ft .
(6) Tigh t en t h e r igh t -side t h r ea ded a dju st er t o 102
(2) Mea su r e ea ch side gea r clea r a n ce. In ser t a
N·m (75 ft . lbs.). Sea t t h e bea r in g cu ps wit h t h e pr o-
m a t ch ed pa ir of feeler ga u ge bla des bet ween t h e gea r
cedu r e descr ibed a bove. Con t in u e t o t igh t en t h e
a n d differ en t ia l h ou sin g on opposit e sides of t h e h u b
r igh t -side a dju st er a n d sea t bea r in g cu ps u n t il t h e
(F ig. 60).
t or qu e r em a in s con st a n t a t 102 N·m (75 ft . lbs.)
(3) If side gea r clea r a n ces is n o m or e t h a n 0.005
(7) Mea su r e t h e r in g gea r ba ckla sh . Th e r a n ge of
in ch . Det er m in e if t h e sh a ft is con t a ct in g t h e pin ion
ba ckla sh is 0.006 t o 0.008 in ch (0.15 t o 0.203 m m ).
gea r m a t e sh a ft . D o n o t re m o v e th e fe e le r
(8) Con t in u e in cr ea sin g t h e t or qu e a t t h e r igh t -
g a u g e s , in s p e c t th e a x le s h a ft w ith th e fe e le r
side t h r ea ded a dju st er u n t il t h e specified ba ckla sh is
g a u g e in s e rte d be h in d th e s id e g e a r. If t h e en d of
obt a in ed.
t h e a xle sh a ft is n ot con t a ct in g t h e pin ion gea r m a t e
NOTE: The left-side threaded adjuster torque sh a ft , t h e side gea r clea r a n ce is a ccept a ble.
should have approximately 102 N·m (75 ft. lbs.). If (4) If clea r a n ce is m or e t h a n 0.005 in ch (a xle sh a ft
the torque is considerably less, the complete n ot con t a ct in g m a t e sh a ft ), r ecor d t h e side gea r clea r-
adjustment procedure must be repeated. a n ce. Rem ove t h e t h r u st wa sh er a n d m ea su r e it s
t h ickn ess wit h a m icr om et er. Add t h e wa sh er t h ick-
(9) Tigh t en t h e left -side t h r ea ded a dju st er u n t il n ess t o t h e r ecor ded side gea r clea r a n ce. Th e su m of
102 N·m (75 ft . lbs.) t or qu e is in dica t ed. Sea t t h e gea r clea r a n ce a n d wa sh er t h ickn ess will det er m in e
bea r in g r oller s wit h t h e pr ocedu r e descr ibed a bove. r equ ir ed t h ickn ess of r epla cem en t t h r u st wa sh er
Do t h is u n t il t h e t or qu e r em a in s con st a n t . (F ig. 61).
(10) In st a ll t h e t h r ea ded a dju st er locks a n d In som e ca ses, t h e en d of t h e a xle sh a ft will m ove
t igh t en t h e lock scr ews t o 10 N·m (90 in . lbs.). a n d con t a ct t h e m a t e sh a ft wh en t h e feeler ga u ge is
Aft er t h e pr oper ba ckla sh is a ch ieved, per for m t h e in ser t ed. Th e C-clip lock is pr even t in g t h e side gea r
Gea r Con t a ct An a lysis pr ocedu r e. fr om slidin g on t h e a xle sh a ft .
(5) If t h er e is n o side gea r clea r a n ce, r em ove t h e
GEAR CONTACT PATTERN ANALYSIS C-clip lock fr om t h e a xle sh a ft . Use a m icr om et er t o
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 m ea su r e t h e t h r u st wa sh er t h ickn ess. Recor d t h e
will sh ow if t h e pin ion gea r dept h is cor r ect in t h e t h ickn ess a n d r e-in st a ll t h e t h r u st wa sh er. Assem ble
a xle h ou sin g. It will a lso sh ow if t h e r in g gea r ba ck- t h e differ en t ia l ca se wit h ou t t h e C-clip lock in st a lled
la sh h a s been a dju st ed cor r ect ly. Th e ba ckla sh ca n be a n d r e-m ea su r e t h e side gea r clea r a n ce.
a dju st ed wit h in specifica t ion s t o a ch ieve desir ed (6) Com pa r e bot h clea r a n ce m ea su r em en t s. If t h e
t oot h con t a ct pa t t er n s. differ en ce is less t h a n 0.012 in ch (0.305 m m ), a dd
(1) Apply a t h in coa t of h ydr a t ed fer r ic oxide, or clea r a n ce r ecor ded wh en t h e C-clip lock wa s in st a lled
equ iva len t , t o t h e dr ive a n d coa st side of t h e r in g t o t h r u st wa sh er t h ickn ess m ea su r ed. Th e su m will
gea r t eet h .
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

XJ DIFFERENTIAL AND DRIVELINE 3 - 109


ADJ U ST M EN T S (Cont inue d)

DRIVE SIDE COAST SIDE


OF RING OF RING
GEAR TEETH GEAR TEETH

DESIRABLE CONTACT PATTERN.


PATTERN SHOULD BE CENTERED
ON THE DRIVE SIDE OF TOOTH.
PATTERN SHOULD BE CENTERED ON
THE COAST SIDE OF TOOTH,
BUT MAY BE SLIGHTLY TOWARD
THE TOE. THERE SHOULD ALWAYS
BE SOME CLEARANCE BETWEEN
CONTACT PATTERN AND TOP OF
THE TOOTH.

RING GEAR BACKLASH CORRECl


THINNER PINION GEAR DEPTH
SHIM REQUIRED.

RING GEAR BACKLASH CORRECT.


THICKER PINION GEAR DEPTH
SHIM REQUIRED.

PINION GEAR DEPTH SHIM


CORRECT. DECREASE RING
GEAR BACKLASH.

PINION GEAR DEPTH SHIM


CORRECT. INCREASE RING
GEAR BACKLASH.

J9003-24

Fig. 59 Gear Tooth Contact Patterns


REPLACEMENT
NEW
SIDE SIDE
WASHER GEAR
THICKNESS
GEARCLEARANCE
WASHER
CLEARANCE
THICKNESS
THRUST
TOTAL SIDEGEAR
+0.033
−0.037
0.007
0.040
0.003
FEELER GAUGE
BLADES

3 - 110 DIFFERENTIAL AND DRIVELINE XJ


ADJ U ST M EN T S (Cont inue d)
SPECI FI CAT I ON S
8 1/4 INCH AXLE

Axle Type . . . . . . . . . . . . . . . . Sem i-floa t in g, h ypoid


Lu br ica n t . . . . . . . . . . . . . . . . . . . . . . . SAE 80W-90
Lu be Ca pa cit y . . . . . . . . . . . . . . . . . 2.27 L (4.8 pt s.)
Tr a c-Lok Addit ive . . . . . . . . . . . . . . . . 148 m l (5 oz.)
Axle Ra t io . . . . . . . . . . . . . . . . . . . . . 3.21, 3.55, 3.90
D iffe re n tia l
Ca se Clea r a n ce . . . . . . . . . . . . . 0.12 m m (0.005 in .)
Ca se F la n ge Ru n ou t . . . . . . . . 0.076 m m (0.003 in .)
/
I Rin g Ge a r
Dia m et er . . . . . . . . . . . . . . . . . . . 20.95 cm (8.25 in .)
Ba ckla sh . . . . . . . . . . 0.12-0.20 m m (0.005-0.008 in .)
Fig. 60 Side Gear Clearance Measurement Ru n ou t . . . . . . . . . . . . . . . . . . . 0.127 m m (0.005 in .)
P in io n B e a rin g
SIDE GEAR CLEARANCE 0.007 P r eloa d . . . . . . . . . . . . . . . . . 1-2 N·m (10-20 in .lbs.)
THRUST WASHER THICKNESS + 0.033
TOTAL 0.040 8 1/4 INCH AXLE
L----------- 0.040
REPLACEMENT WASHER THICKNESS - 0.037 D ES CRIP TION TORQU E
NEW SIDE GEAR CLEARANCE 0.003
J9203-31 Diff. Cover Bolt . . . . . . . . . . . . . . 41 N·m (30 ft . lbs.)
Bea r in g Ca p Bolt . . . . . . . . . . 136 N·m (100 ft . lbs.)
Fig. 61 Side Gear Calculations P in ion Nu t –Min im u m . . . . . . . 285 N·m (210 ft . lbs.)
Rin g Gea r Bolt . . . . . . . . . . . . . . 95 N·m (70 ft . lbs.)
det er m in e t h e r equ ir ed t h ickn ess of t h e r epla cem en t
Ba ckin g P la t e Bolt . . . . . . . . . . . 64 N·m (48 ft . lbs.)
t h r u st wa sh er.
(7) If clea r a n ce is 0.012 in ch (0.305 m m ) or RWAL/ABS Sen sor Bolt . . . . . . . 24 N·m (18. ft . lbs.)
gr ea t er, bot h side gea r s m u st be r epla ced (m a t ch ed
set ) a n d t h e clea r a n ce m ea su r em en t s r epea t ed.
(8) If clea r a n ce (a bove) con t in u es t o be 0.012 in ch
(0.305 m m ) or gr ea t er, t h e ca se m u st be r epla ced.
XJ DIFFERENTIAL AND DRIVELINE 3 - 111

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

Adjustment Rod—C-4164 Adapters—C-293-47

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

ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . 30 BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 1

BASE BRAK E SY ST EM

INDEX
page page

GENERAL INFORMATION REMOVAL AND INSTALLATION


BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE WARNINGS & CAUTIONS . . . . . . . . . 2 BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . 20
DESCRIPTION AND OPERATION COMBINATION VALVE . . . . . . . . . . . . . . . . . . . 14
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . 5 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . 16
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . 18
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 3 DISC BRAKE SHOES . . . . . . . . . . . . . . . . . . . . 17
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . 3 DRUM BRAKE SHOES . . . . . . . . . . . . . . . . . . . 19
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 3 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . 15
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 4 PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . 21
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . 2 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . 15
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 3 REAR PARKING BRAKE CABLES . . . . . . . . . . 21
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . 2 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 13
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 2 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . 5 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . 23
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . 10 MASTER CYLINDER RESERVOIR . . . . . . . . . . 22
BRAKE FLUID CONTAMINATION . . . . . . . . . . . 11 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . 24
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . 10 CLEANING AND INSPECTION
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 9 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . 9 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . 25
MASTER CYLINDER/POWER BOOSTER . . . . . . 8 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . 26
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . 8 ADJUSTMENTS
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 8 PARKING BRAKE CABLE TENSIONER . . . . . . 28
SERVICE PROCEDURES REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . 26
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . 11 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 26
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . 12 SPECIFICATIONS
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 11 BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . 29
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . 28
DISC ROTOR MACHINING . . . . . . . . . . . . . . . . 12 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 29
MASTER CYLINDER BLEEDING . . . . . . . . . . . 11 SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 29
5-2 BRAKES XJ

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.

SERVICE WARNINGS & CAUTIONS


WARNING: FACTORY INSTALLED BRAKE LININGS DESCRI PT I ON AN D OPERAT I ON
DO NOT CONTAIN ASBESTOS FIBERS. DUST AND
DIRT ACCUMULATING ON BRAKE PARTS DURING BRAKE PEDAL
NORMAL USE MAY CONTAIN ASBESTOS FIBERS A su spen ded-t ype br a ke peda l is u sed, t h e peda l
FROM AFTER MARKET BRAKE LININGS. BREATH- pivot s on a sh a ft m ou n t ed in t h e peda l su ppor t
ING EXCESSIVE CONCENTRATIONS OF ASBESTOS br a cket . Th e br a cket is a t t a ch ed t o t h e da sh pa n el
FIBERS CAN CAUSE SERIOUS BODILY HARM. a n d st eer in g su ppor t br a cket . Th e u n it is ser viced a s
EXERCISE CARE WHEN SERVICING BRAKE a n a ssem bly, except for t h e peda l pa d.
PARTS. DO NOT CLEAN BRAKE PARTS WITH COM-
PRESSED AIR OR BY DRY BRUSHING. USE A VAC- STOP LAMP SWITCH
UUM CLEANER SPECIFICALLY DESIGNED FOR Th e plu n ger t ype st op la m p swit ch is m ou n t ed on a
THE REMOVAL OF ASBESTOS FIBERS FROM br a cket a t t a ch ed t o t h e br a ke peda l su ppor t . Th e
BRAKE COMPONENTS. IF A SUITABLE VACUUM swit ch ca n be a dju st ed wh en n ecessa r y.
CLEANER IS NOT AVAILABLE, CLEANING SHOULD
BE DONE WITH A WATER DAMPENED CLOTH. DO RED BRAKE WARNING LAMP
NOT SAND, OR GRIND BRAKE LINING UNLESS A r ed wa r n in g la m p is u sed for t h e ser vice br a ke
EQUIPMENT USED IS DESIGNED TO CONTAIN THE por t ion of t h e h ydr a u lic syst em . Th e la m p is loca t ed
DUST RESIDUE. DISPOSE OF ALL RESIDUE CON- in t h e in st r u m en t clu st er.
TAINING ASBESTOS FIBERS IN SEALED BAGS OR Th e r ed wa r n in g ligh t a ler t s t h e dr iver if a pr es-
CONTAINERS TO MINIMIZE EXPOSURE TO YOUR- su r e differ en t ia l exist s bet ween t h e fr on t a n d r ea r
SELF AND OTHERS. FOLLOW PRACTICES PRE- h ydr a u lic syst em s. Th e ligh t a lso a ler t s t h e dr iver
SCRIBED BY THE OCCUPATIONAL SAFETY AND wh en t h e pa r kin g br a kes a r e a pplied.
HEALTH ADMINISTRATION AND THE ENVIRONMEN-
TAL PROTECTION AGENCY FOR THE HANDLING, POWER BRAKE BOOSTER
PROCESSING, AND DISPOSITION OF DUST OR Th e boost er a ssem bly con sist s of a h ou sin g divided
DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. in t o sepa r a t e ch a m ber s by t wo in t er n a l dia ph r a gm s.
Th e ou t er edge of ea ch dia ph r a gm is a t t a ch ed t o t h e
boost er h ou sin g. Th e dia ph r a gm s a r e con n ect ed t o
CAUTION: Never use gasoline, kerosene, alcohol, t h e boost er pr im a r y pu sh r od.
motor oil, transmission fluid, or any fluid containing Two pu sh r ods a r e u sed in t h e boost er. Th e pr i-
mineral oil to clean the system components. These m a r y pu sh r od con n ect s t h e boost er t o t h e br a ke
fluids damage rubber cups and seals. Use only peda l. Th e secon da r y pu sh r od con n ect s t h e boost er
fresh brake fluid or Mopar brake cleaner to clean or t o t h e m a st er cylin der t o st r oke t h e cylin der pist on s.
XJ BRAKES 5-3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e a t m osph er ic in let va lve is open ed a n d closed va lve on ly con t r ols (m et er s) flu id flow du r in g h igh
by t h e pr im a r y pu sh r od. Boost er va cu u m su pply is effor t br a ke st ops.
t h r ou gh a h ose a t t a ch ed t o a n in t a ke m a n ifold fit t in g
a t on e en d a n d t o t h e boost er ch eck va lve a t t h e FRONT DISC BRAKES
ot h er. Th e va cu u m ch eck va lve in t h e boost er h ou sin g Th e ca liper s a r e a sin gle pist on t ype. Th e ca liper s
is a on e-wa y device t h a t pr even t s va cu u m lea k ba ck. a r e fr ee t o slide la t er a lly, t h is a llows con t in u ou s com -
P ower a ssist is gen er a t ed by u t ilizin g t h e pr essu r e pen sa t ion for lin in g wea r.
differ en t ia l bet ween n or m a l a t m osph er ic pr essu r e Wh en t h e br a kes a r e a pplied flu id pr essu r e is
a n d a va cu u m . Th e va cu u m n eeded for boost er oper- exer t ed a ga in st t h e ca liper pist on . Th e flu id pr essu r e
a t ion is t a ken dir ect ly fr om t h e en gin e in t a ke m a n i- is exer t ed equ a lly a n d in a ll dir ect ion s. Th is m ea n s
fold. Th e en t r y poin t for a t m osph er ic pr essu r e is pr essu r e exer t ed a ga in st t h e ca liper pist on a n d
t h r ou gh a filt er a n d in let va lve a t t h e r ea r of t h e wit h in t h e ca liper bor e will be equ a l (F ig. 2).
h ou sin g (F ig. 1). F lu id pr essu r e a pplied t o t h e pist on is t r a n sm it t ed
Th e ch a m ber a r ea s for wa r d of t h e boost er dia - dir ect ly t o t h e in boa r d br a ke sh oe. Th is for ces t h e
ph r a gm s a r e exposed t o va cu u m fr om t h e in t a ke sh oe lin in g a ga in st t h e in n er su r fa ce of t h e disc
m a n ifold. Th e ch a m ber a r ea s t o t h e r ea r of t h e dia - br a ke r ot or. At t h e sa m e t im e, flu id pr essu r e wit h in
ph r a gm s, a r e exposed t o n or m a l a t m osph er ic pr es- t h e pist on bor e for ces t h e ca liper t o slide in wa r d on
su r e of 101.3 kilopa sca ls (14.7 pou n ds/squ a r e in .). t h e m ou n t in g bolt s. Th is a ct ion br in gs t h e ou t boa r d
Br a ke peda l a pplica t ion ca u ses t h e pr im a r y pu sh br a ke sh oe lin in g in t o con t a ct wit h t h e ou t er su r fa ce
r od t o open t h e a t m osph er ic in let va lve. Th is exposes of t h e disc br a ke r ot or.
t h e a r ea beh in d t h e dia ph r a gm s t o a t m osph er ic pr es- In su m m a r y, flu id pr essu r e a ct in g sim u lt a n eou sly
su r e. Th e r esu lt in g pr essu r e differ en t ia l pr ovides t h e on bot h pist on a n d ca liper, pr odu ces a st r on g cla m p-
ext r a a pply pr essu r e for power a ssist . in g a ct ion . Wh en su fficien t for ce is a pplied, fr ict ion
will st op t h e r ot or s fr om t u r n in g a n d br in g t h e veh i-
MASTER CYLINDER cle t o a st op.
Th e m a st er cylin der h a s a r em ova ble n ylon r eser- Applica t ion a n d r elea se of t h e br a ke peda l gen er-
voir. Th e cylin der body is m a de of a lu m in u m a n d a t es on ly a ver y sligh t m ovem en t of t h e ca liper a n d
con t a in s a pr im a r y a n d secon da r y pist on a ssem bly. pist on . Upon r elea se of t h e peda l, t h e ca liper a n d pis-
Th e cylin der body in clu din g t h e pist on a ssem blies t on r et u r n t o a r est posit ion . Th e br a ke sh oes do n ot
a r e n ot ser vicea ble. If dia gn osis in dica t es a n in t er n a l r et r a ct a n a ppr ecia ble dist a n ce fr om t h e r ot or. In
pr oblem wit h t h e cylin der body, it m u st be r epla ced fa ct , clea r a n ce is u su a lly a t , or close t o zer o. Th e r ea -
a s a n a ssem bly. Th e r eser voir a n d gr om m et s a r e t h e son s for t h is a r e t o keep r oa d debr is fr om get t in g
on ly r epla cea ble pa r t s on t h e m a st er cylin der. bet ween t h e r ot or a n d lin in g a n d in wipin g t h e r ot or
su r fa ce clea r ea ch r evolu t ion .
COMBINATION VALVE Th e ca liper pist on sea l con t r ols t h e a m ou n t of pis-
Th e com bin a t ion va lve con t a in s a pr essu r e differ- t on ext en sion n eeded t o com pen sa t e for n or m a l lin in g
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 - wea r.
in g va lve. Th e va lve is n ot r epa ir a ble. It m u st be Du r in g br a ke a pplica t ion , t h e sea l is deflect ed ou t -
r epla ced if dia gn osis in dica t es t h is is n ecessa r y. wa r d by flu id pr essu r e a n d pist on m ovem en t (F ig. 3).
Th e pr essu r e differ en t ia l swit ch is con n ect ed t o t h e Wh en t h e br a kes (a n d flu id pr essu r e) a r e r elea sed,
br a ke wa r n in g ligh t . Th e swit ch is a ct u a t ed by m ove- t h e sea l r ela xes a n d r et r a ct s t h e pist on .
m en t of t h e swit ch va lve. Th e swit ch m on it or s flu id Th e a m ou n t of pist on r et r a ct ion is det er m in ed by
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 br a ke lin in g wea r. Gen er a lly t h e a m ou n t is ju st
cir cu it s. en ou gh t o m a in t a in con t a ct bet ween t h e pist on a n d
A decr ea se or loss of flu id pr essu r e in eit h er in boa r d br a ke sh oe.
h ydr a u lic cir cu it will ca u se t h e swit ch va lve t o sh u t -
t le t o t h e low pr essu r e side. Movem en t of t h e va lve REAR DRUM BRAKE
pu sh es t h e swit ch plu n ger u pwa r d. Th is a ct ion closes Th e br a ke syst em s u se a lea din g sh oe (pr im a r y)
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 a n d t r a ilin g sh oe (secon da r y) (F ig. 4). Wh en t h e
cir cu it t o t h e r ed wa r n in g ligh t . Th e swit ch va lve will br a ke peda l is depr essed h ydr a u lic pr essu r e pu sh es
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 t h e r ea r br a ke wh eel cylin der pist on s ou t wa r d. Th e
m a de. wh eel cylin der pu sh r ods t h en pu sh t h e br a ke sh oes
Th e r ea r pr opor t ion in g va lve is u sed t o ba la n ce ou t wa r d a ga in st t h e br a ke dr u m . Wh en t h e br a ke
fr on t -r ea r br a ke a ct ion . Th e va lve a llows n or m a l peda l is r elea sed r et u r n spr in gs a t t a ch ed t o t h e
flu id flow du r in g m oder a t e effor t br a ke st ops. Th e br a ke sh oes pu ll t h e sh oes ba ck t o t h er e or igin a l
posit ion .
MASTER
MOUNTING
VACUUM
CHECK VALVE
CYLINDER
STUD ROD
SECONDARY
(2) FRONT
(TO CYLINDER)
MASTER
SPRING
PHRAGM
PUSH
DIA- REAR PHRAGM
DIA- BOOSTER
MOUNTING
HOUSING
STUDS (4) INLET ASSEMBLY
ATMOSPHERIC
VALVE
SEAL PRIMARY
ROD AIR
(TO PEDAL)
FILTER
BRAKE
PUSH

5-4 BRAKES XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

VACUUM FRONT REAR


CHECK DIAPHRAGM DIAPHRAGM HOUSING
VALVE

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

Fig. 1 Power Brake Booster–Typical


PARKING BRAKE in t o, or welded t o t h e lever. A clip is u sed t o secu r e
P a r kin g br a ke a dju st m en t is con t r olled by a ca ble t h e pin in t h e br a ke sh oe. Th e pin a llows ea ch lever
t en sion er m ech a n ism . Th e ca ble t en sion er, on ce t o pivot in depen den t ly of t h e br a ke sh oe.
a dju st ed a t t h e fa ct or y, sh ou ld n ot n eed fu r t h er To a pply t h e pa r kin g br a kes, t h e h a n d lever is
a dju st m en t u n der n or m a l cir cu m st a n ces. Adju st m en t pu lled u pwa r d. Th is pu lls t h e r ea r br a ke sh oe a ct u -
m a y be r equ ir ed if a n ew t en sion er, or ca bles a r e a t in g lever s for wa r d, by m ea n s t en sion er a n d ca bles.
in st a lled, or discon n ect ed. As t h e a ct u a t in g lever is pu lled for wa r d, t h e pa r kin g
br a ke st r u t (wh ich is con n ect ed t o bot h sh oes), exer t s
PARK I N G BRAK E OPERAT I ON a lin ea r for ce a ga in st t h e pr im a r y br a ke sh oe. Th is
A h a n d oper a t ed lever in t h e pa ssen ger com pa r t - a ct ion pr esses t h e pr im a r y sh oe in t o con t a ct wit h t h e
m en t is t h e m a in a pplica t ion device. Th e fr on t ca ble dr u m . On ce t h e pr im a r y sh oe con t a ct s t h e dr u m ,
is con n ect ed bet ween t h e h a n d lever a n d t h e t en - for ce is exer t ed t h r ou gh t h e st r u t . Th is for ce is t r a n s-
sion er. Th e t en sion er r od is a t t a ch ed t o t h e equ a lizer fer r ed t h r ou gh t h e st r u t t o t h e secon da r y br a ke sh oe
wh ich is t h e con n ect in g poin t for t h e r ea r ca bles (F ig. ca u sin g it t o pivot in t o t h e dr u m a s well.
5). A gea r t ype r a t ch et in g m ech a n ism is u sed t o h old
Th e r ea r ca bles a r e con n ect ed t o t h e a ct u a t in g t h e lever in a n a pplied posit ion . P a r kin g br a ke
lever on ea ch secon da r y br a ke sh oe. Th e lever s a r e r elea se is a ccom plish ed by t h e h a n d lever r elea se
a t t a ch ed t o t h e br a ke sh oes by a pin eit h er pr essed bu t t on .
PISTON
BRAKE
OUTBOARD
CALIPER
PISTON
SUREPRES-
SEAL
SHOE
OFF CALIPER
HOUSING
CYLINDER BORE
INBOARD
DUST
SHOEBOOTSEAL PISTON
PISTON
PRESSURE
BRAKE
SEAL
PISTON
BORE
ON

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.

PRELI M I N ARY BRAK E CH ECK


(1) Ch eck con dit ion of t ir es a n d wh eels. Da m a ged
PISTON wh eels a n d wor n , da m a ged, or u n der in fla t ed t ir es
BORE ca n ca u se pu ll, sh u dder, vibr a t ion , a n d a con dit ion
sim ila r t o gr a b.
(2) If com pla in t wa s ba sed on n oise wh en br a kin g,
ch eck su spen sion com pon en t s. J ou n ce fr on t a n d r ea r
of veh icle a n d list en for n oise t h a t m igh t be ca u sed
by loose, wor n or da m a ged su spen sion or st eer in g
com pon en t s.
(3) In spect br a ke flu id level a n d con dit ion . Not e
t h a t t h e fr on t disc br a ke r eser voir flu id level will
OUTBOARD INBOARD decr ea se in pr opor t ion t o n or m a l lin in g wea r. Als o
SHOE SHOE n o te th a t bra k e flu id te n d s to d a rk e n o v e r tim e .
J9405-102
Th is is n o rm a l a n d s h o u ld n o t be m is ta k e n fo r
c o n ta m in a tio n .
Fig. 2 Brake Caliper Operation (a ) If flu id level is a bn or m a lly low, look for evi-
den ce of lea ks a t ca liper s, wh eel cylin der s, br a ke
PISTON CYLINDER BORE CALIPER
HOUSING lin es, a n d m a st er cylin der.
(b) If flu id a ppea r s con t a m in a t ed, dr a in ou t a
sa m ple. Syst em will h a ve t o be flu sh ed if flu id is
sepa r a t ed in t o la yer s, or con t a in s a su bst a n ce
ot h er t h a n br a ke flu id. Th e syst em sea ls a n d cu ps
will a lso h a ve t o be r epla ced a ft er flu sh in g. Use
clea n br a ke flu id t o flu sh t h e syst em .
(4) Ch eck pa r kin g br a ke oper a t ion . Ver ify fr ee
m ovem en t a n d fu ll r elea se of ca bles a n d peda l. Also
n ot e if veh icle wa s bein g oper a t ed wit h pa r kin g
br a ke pa r t ia lly a pplied.
Fig. 3 Lining Wear Compensation By Piston Seal (5) Ch eck br a ke peda l oper a t ion . Ver ify t h a t peda l
A pa r kin g br a ke swit ch is m ou n t ed on t h e pa r kin g does n ot bin d a n d h a s a dequ a t e fr ee pla y. If peda l
br a ke lever a n d is a ct u a t ed by m ovem en t of t h e la cks fr ee pla y, ch eck peda l a n d power boost er for
lever. Th e swit ch , wh ich is in cir cu it wit h t h e r ed bein g loose or for bin d con dit ion . Do n ot r oa d t est
wa r n in g ligh t in t h e da sh , will illu m in a t e t h e wa r n - u n t il con dit ion is cor r ect ed.
in g ligh t wh en ever t h e pa r kin g br a kes a r e a pplied. (6) If com pon en t s ch ecked a ppea r OK, r oa d t est
t h e veh icle.
BRAKE HOSES AND LINES
ROAD T EST I N G
F lexible r u bber h ose is u sed a t bot h fr on t br a kes
(1) If com pla in t in volved low br a ke peda l, pu m p
a n d a t t h e r ea r a xle ju n ct ion block. Dou ble wa lled
peda l a n d n ot e if it com es ba ck u p t o n or m a l h eigh t .
st eel t u bin g is u sed t o con n ect t h e m a st er cylin der t o
(2) Ch eck br a ke peda l r espon se wit h t r a n sm ission
t h e m a jor h ydr a u lic br a kin g com pon en t s a n d t h en t o
in Neu t r a l a n d en gin e r u n n in g. P eda l sh ou ld r em a in
t h e flexible r u bber h oses.
fir m u n der con st a n t foot pr essu r e.
(3) Du r in g r oa d t est , m a ke n or m a l a n d fir m br a ke
DI AGN OSI S AN D T EST I N G st ops in 25-40 m ph r a n ge. Not e fa u lt y br a ke oper a -
t ion su ch a s low peda l, h a r d peda l, fa de, peda l pu lsa -
BASE BRAKE SYSTEM t ion , pu ll, gr a b, dr a g, n oise, et c.
Ba se br a ke com pon en t s con sist of t h e br a ke sh oes,
ca liper s, wh eel cylin der s, br a ke dr u m s, r ot or s, br a ke
ADJUSTER
RIGHT
REAR
REAR
ASSEMBLY
CABLE
LEVER
SHOE
ADJUSTER
CABLES
GUIDE
BRAKE
HOLDDOWN
SPRINGS
CABLE
RETURN
ANDTENSIONER
RETAINERS
EQUALIZER
SPRINGROD
SHOE
ADJUSTER
LEVERSPRING
GUIDE
PLATE LEADING
PIN TRAILING
FRONT
PARK
SHOE
CABLE
SHOE
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

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

Fig. 4 Brake Components


r ot or s, dr u m s, or r ea r br a kes ou t of a dju st m en t a r e
t h e m ost likely ca u ses.

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.

HARD PEDAL OR HIGH PEDAL EFFORT


A h a r d peda l or h igh peda l effor t m a y be du e t o
lin in g t h a t is wa t er soa ked, con t a m in a t ed, gla zed, or
TENSIONER ROD 80aac290
ba dly wor n . Th e power boost er or ch eck va lve cou ld
a lso be fa u lt y.
Fig. 5 Parking Brake Components
PEDAL PULSATION
PEDAL FALLS AWAY P eda l pu lsa t ion is ca u sed by com pon en t s t h a t a r e
A br a ke peda l t h a t fa lls a wa y u n der st ea dy foot loose, or beyon d t oler a n ce lim it s.
pr essu r e is gen er a lly t h e r esu lt of a syst em lea k. Th e Th e pr im a r y ca u se of pu lsa t ion a r e disc br a ke
lea k poin t cou ld be a t a br a ke lin e, fit t in g, h ose, or r ot or s wit h excessive la t er a l r u n ou t or t h ickn ess va r i-
ca liper /wh eel cylin der. In t er n a l lea ka ge in t h e m a st er a t ion , or ou t of r ou n d br a ke dr u m s. Ot h er ca u ses a r e
cylin der ca u sed by wor n or da m a ged pist on cu ps, loose wh eel bea r in gs or ca liper s a n d wor n , da m a ged
m a y a lso be t h e pr oblem ca u se. t ir es.
If lea ka ge is sever e, flu id will be eviden t a t or
a r ou n d t h e lea kin g com pon en t . H owever, in t er n a l NOTE: Some pedal pulsation may be felt during
lea ka ge in t h e m a st er cylin der m a y n ot be ph ysica lly ABS activation.
eviden t .

LOW PEDAL BRAKE DRAG


If a low peda l is exper ien ced, pu m p t h e peda l sev- Br a ke dr a g occu r s wh en t h e lin in g is in con st a n t
er a l t im es. If t h e peda l com es ba ck u p wor n lin in gs, con t a ct wit h t h e r ot or or dr u m . Dr a g ca n occu r a t on e
wh eel, a ll wh eels, fr on t s on ly, or r ea r s on ly.
XJ BRAKES 5-7
DI AGN OSI S AN D T EST I N G (Cont inue d)
Dr a g is a pr odu ct of in com plet e br a ke sh oe r elea se. As t h e dr a ggin g br a ke over h ea t s, efficien cy is so
Dr a g ca n be m in or or sever e en ou gh t o over h ea t t h e r edu ced t h a t fa de occu r s. Sin ce t h e opposit e br a ke
lin in gs, r ot or s a n d dr u m s. u n it is st ill fu n ct ion in g n or m a lly, it s br a kin g effect is
Min or dr a g will u su a lly ca u se sligh t su r fa ce ch a r- m a gn ified. Th is ca u ses pu ll t o swit ch dir ect ion in
r in g of t h e lin in g. It ca n a lso gen er a t e h a r d spot s in fa vor of t h e n or m a lly fu n ct ion in g br a ke u n it .
r ot or s a n d dr u m s fr om t h e over h ea t -cool down pr o- An a ddit ion a l poin t wh en dia gn osin g a ch a n ge in
cess. In m ost ca ses, t h e r ot or s, dr u m s, wh eels a n d pu ll con dit ion con cer n s br a ke cool down . Rem em ber
t ir es a r e qu it e wa r m t o t h e t ou ch a ft er t h e veh icle is t h a t pu ll will r et u r n t o t h e or igin a l dir ect ion , if t h e
st opped. dr a ggin g br a ke u n it is a llowed t o cool down (a n d is
Sever e dr a g ca n ch a r t h e br a ke lin in g a ll t h e wa y n ot ser iou sly da m a ged).
t h r ou gh . It ca n a lso dist or t a n d scor e r ot or s a n d
dr u m s t o t h e poin t of r epla cem en t . Th e wh eels, t ir es REAR BRAKE GRAB OR PULL
a n d br a ke com pon en t s will be ext r em ely h ot . In Rea r gr a b or pu ll is u su a lly ca u sed by im pr oper ly
sever e ca ses, t h e lin in g m a y gen er a t e sm oke a s it a dju st ed or seized pa r kin g br a ke ca bles, con t a m i-
ch a r s fr om over h ea t in g. n a t ed lin in g, ben t or bin din g sh oes a n d su ppor t
Com m on ca u ses of br a ke dr a g a r e: pla t es, or im pr oper ly a ssem bled com pon en t s. Th is is
• Seized or im pr oper ly a dju st ed pa r kin g br a ke pa r t icu la r ly t r u e wh en on ly on e r ea r wh eel is
ca bles. in volved. H owever, wh en bot h r ea r wh eels a r e
• Loose/wor n wh eel bea r in g. a ffect ed, t h e m a st er cylin der, pr opor t ion in g va lve, or
• Seized ca liper or wh eel cylin der pist on . RWAL va lve cou ld be a t fa u lt .
• Ca liper bin din g on cor r oded bu sh in gs or r u st ed
slide su r fa ces. BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
• Loose ca liper m ou n t in g. WATER PUDDLES
• Dr u m br a ke sh oes bin din g on wor n /da m a ged Th is con dit ion is gen er a lly ca u sed by wa t er soa ked
su ppor t pla t es. lin in g. If t h e lin in g is on ly wet , it ca n be dr ied by
• Misa ssem bled com pon en t s. dr ivin g wit h t h e br a kes ver y ligh t ly a pplied for a
If br a ke dr a g occu r s a t a ll wh eels, t h e pr oblem m ile or t wo. H owever, if t h e lin in g is bot h soa ked a n d
m a y be r ela t ed t o a blocked m a st er cylin der r et u r n dir t con t a m in a t ed, clea n in g a n d/or r epla cem en t will
por t , or fa u lt y power boost er (bin ds-does n ot r elea se). be n ecessa r y.

BRAKE FADE BRAKE SQUEAK/SQUEAL


Br a ke fa de is u su a lly a pr odu ct of over h ea t in g Br a ke squ ea k or squ ea l m a y be du e t o lin in gs t h a t
ca u sed by br a ke dr a g. H owever, br a ke over h ea t in g a r e wet or con t a m in a t ed wit h br a ke flu id, gr ea se, or
a n d r esu lt in g fa de ca n a lso be ca u sed by r idin g t h e oil. Gla zed lin in gs a n d r ot or s wit h h a r d spot s ca n
br a ke peda l, m a kin g r epea t ed h igh deceler a t ion st ops a lso con t r ibu t e t o squ ea k. Dir t a n d for eign m a t er ia l
in a sh or t t im e spa n , or con st a n t br a kin g on st eep em bedded in t h e br a ke lin in g will a lso ca u se squ ea k/
m ou n t a in r oa ds. Refer t o t h e Br a ke Dr a g in for m a t ion squ ea l.
in t h is sect ion for ca u ses. A ver y lou d squ ea k or squ ea l is fr equ en t ly a sign of
sever ely wor n br a ke lin in g. If t h e lin in g h a s wor n
BRAKE PULL t h r ou gh t o t h e br a ke sh oes in spot s, m et a l-t o-m et a l
F r on t br a ke pu ll con dit ion cou ld r esu lt fr om : con t a ct occu r s. If t h e con dit ion is a llowed t o con t in u e,
• Con t a m in a t ed lin in g in on e ca liper r ot or s a n d dr u m s ca n becom e so scor ed t h a t r epla ce-
• Seized ca liper pist on m en t is n ecessa r y.
• Bin din g ca liper
• Loose ca liper BRAKE CHATTER
• Ru st y a da pt er /ca liper slide su r fa ces Br a ke ch a t t er is u su a lly ca u sed by loose or wor n
• Im pr oper br a ke sh oes com pon en t s, or gla zed/bu r n t lin in g. Rot or s wit h h a r d
• Da m a ged r ot or spot s ca n a lso con t r ibu t e t o ch a t t er. Addit ion a l ca u ses
A wor n , da m a ged wh eel bea r in g or su spen sion of ch a t t er a r e ou t -of-t oler a n ce r ot or s, br a ke lin in g n ot
com pon en t a r e fu r t h er ca u ses of pu ll. A da m a ged secu r ely a t t a ch ed t o t h e sh oes, loose wh eel bea r in gs
fr on t t ir e (br u ised, ply sepa r a t ion ) ca n a lso ca u se a n d con t a m in a t ed br a ke lin in g.
pu ll.
A com m on a n d fr equ en t ly m isdia gn osed pu ll con di- THUMP/CLUNK NOISE
t ion is wh er e dir ect ion of pu ll ch a n ges a ft er a few Th u m pin g or clu n k n oises du r in g br a kin g a r e fr e-
st ops. Th e ca u se is a com bin a t ion of br a ke dr a g fol- qu en t ly n o t ca u sed by br a ke com pon en t s. In m a n y
lowed by fa de a t on e of t h e br a ke u n it s. ca ses, su ch n oises a r e ca u sed by loose or da m a ged
st eer in g, su spen sion , or en gin e com pon en t s. H owever,
TERMINAL PINS
PLUNGERPOSITIONS
TEST

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.

BRAKE LINING CONTAMINATION


Br a ke lin in g con t a m in a t ion is m ost ly a pr odu ct of
lea kin g ca liper s or wh eel cylin der s, wor n sea ls, dr iv-
in g t h r ou gh deep wa t er pu ddles, or lin in g t h a t h a s
becom e cover ed wit h gr ea se a n d gr it du r in g r epa ir.
Con t a m in a t ed lin in g sh ou ld be r epla ced t o a void fu r-
t h er br a ke pr oblem s.

WHEEL AND TIRE PROBLEMS


Som e con dit ion s a t t r ibu t ed t o br a ke com pon en t s J9405-88
m a y a ct u a lly be ca u sed by a wh eel or t ir e pr oblem .
A da m a ged wh eel ca n ca u se sh u dder, vibr a t ion a n d Fig. 6 Stop Lamp Switch Terminal Identification
pu ll. A wor n or da m a ged t ir e ca n a lso ca u se pu ll.
(c) If con t in u it y exist s, swit ch is OK. Repla ce
Sever ely wor n t ir es wit h ver y lit t le t r ea d left ca n
swit ch if m et er in dica t es la ck of con t in u it y (swit ch
pr odu ce a gr a b-like con dit ion a s t h e t ir e loses a n d
is open ).
r ecover s t r a ct ion . F la t -spot t ed t ir es ca n ca u se vibr a -
t ion a n d gen er a t e sh u dder du r in g br a ke oper a t ion . A
t ir e wit h in t er n a l da m a ge su ch a s a sever e br u ise,
RED BRAKE WARNING LAMP
Th e r ed br a ke wa r n in g ligh t will illu m in a t e u n der
cu t , or ply sepa r a t ion ca n ca u se pu ll a n d vibr a t ion .
t h e followin g con dit ion s:
STOP LAMP SWITCH • 2-3 secon ds a t st a r t -u p a s pa r t of n or m a l bu lb
ch eck.
St op la m p swit ch oper a t ion ca n be t est ed wit h a n
• Wh en pa r kin g br a kes a r e a pplied.
oh m m et er. Th e oh m m et er is u sed t o ch eck con t in u it y
• Low br a ke peda l ca u sed by lea k in fr on t /r ea r
bet ween t h e pin t er m in a ls a t differ en t plu n ger posi-
br a ke h ydr a u lic cir cu it .
t ion s (F ig. 6).
If t h e r ed ligh t r em a in s on a ft er st a r t -u p, fir st ver-
NOTE: The switch wire harness must be discon- ify t h a t t h e pa r kin g br a kes a r e fu lly r elea sed. Th en
nected before testing switch continuity. ch eck peda l a ct ion a n d flu id level. A r ed ligh t plu s
low peda l in dica t es t h e pr essu r e differ en t ia l swit ch
a n d va lve h a ve been a ct u a t ed du e t o a syst em lea k.
SWI T CH CI RCU I T I DEN T I FI CAT I ON On m odels wit h ABS br a kes, t h e a m ber wa r n in g
• Ter m in a ls 1 a n d 2 a r e for br a ke sen sor cir cu it . ligh t on ly illu m in a t es wh en a n ABS m a lfu n ct ion h a s
• Ter m in a ls 5 a n d 6 a r e for t h e st op la m p cir cu it . occu r r ed. Th e ABS ligh t oper a t es in depen den t ly of
• Ter m in a ls 3 a n d 4 a r e for t h e speed con t r ol cir- t h e r ed wa r n in g ligh t .
cu it . F or a ddit ion in for m a t ion r efer t o Gr ou p 8W.

SWI T CH CON T I N U I T Y T EST MASTER CYLINDER/POWER BOOSTER


(1) Ch eck con t in u it y bet ween t er m in a l pin s 5 a n d (1) St a r t en gin e a n d ch eck boost er va cu u m h ose
6 a s follows: con n ect ion s. A h issin g n oise in dica t es va cu u m lea k.
(a ) P u ll plu n ger a ll t h e wa y ou t t o fu lly ext en ded Cor r ect a n y va cu u m lea k befor e pr oceedin g.
posit ion . (2) St op en gin e a n d sh ift t r a n sm ission in t o Neu -
(b) At t a ch t est lea ds t o pin s 5 a n d 6 a n d n ot e t r a l.
oh m m et er r ea din g. (3) P u m p br a ke peda l u n t il a ll va cu u m r eser ve in
(c) If con t in u it y exist s, pr oceed t o n ext t est . boost er is deplet ed.
Repla ce swit ch if m et er in dica t es la ck of con t in u it y (4) P r ess a n d h old br a ke peda l u n der ligh t foot
(sh or t ed or open ). pr essu r e. Th e peda l sh ou ld h old fir m , if t h e peda l
(2) Ch eck con t in u it y bet ween t er m in a l pin s 1 a n d fa lls a wa y m a st er cylin der is fa u lt y (in t er n a l lea k-
2 a n d pin s 3 a n d 4 a s follows: a ge).
(a ) P u sh swit ch plu n ger in wa r d t o fu lly (5) St a r t en gin e a n d n ot e peda l a ct ion it sh ou ld
r et r a ct ed posit ion . fa ll a wa y sligh t ly u n der ligh t foot pr essu r e t h en h old
(b) At t a ch t est lea ds t o pin s 1 a n d 2 a n d n ot e fir m . If n o peda l a ct ion is discer n ible, power boost er,
oh m m et er r ea din g.
TEE
VACUUM
FITTING
GAUGE
SHORT CONNECTING
CLAMPTOOL
HOSE INTAKE
CHECK
CHECK
MANI-
FOLD
VALVE
VALVE
HOSE BOOSTER CHECK
VALVE
VALVE
SEAL APPLY TEST VACUUM HERE

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.

POWER BOOST ER VACU U M T EST


(1) Con n ect va cu u m ga u ge t o boost er ch eck va lve
wit h sh or t len gt h of h ose a n d T-fit t in g (F ig. 7).
(2) St a r t a n d r u n en gin e a t cu r b idle speed for on e
m in u t e.
(3) Obser ve t h e va cu u m su pply. If va cu u m su pply
8031e866
is n ot a dequ a t e, r epa ir va cu u m su pply.
(4) Cla m p h ose sh u t bet ween va cu u m sou r ce a n d
Fig. 8 Vacuum Check Valve And Seal
ch eck va lve.
(5) St op en gin e a n d obser ve va cu u m ga u ge. COMBINATION VALVE
(6) If va cu u m dr ops m or e t h a n on e in ch H G (33
m illiba r s) wit h in 15 secon ds, boost er dia ph r a gm or PRESSU RE DI FFEREN T I AL SWI T CH
ch eck va lve is fa u lt y. (1) H a ve h elper sit in dr iver s sea t t o a pply br a ke
peda l a n d obser ve r ed br a ke wa r n in g ligh t .
CHECK (2) Ra ise veh icle on h oist .
VALVE (3) Con n ect bleed h ose t o a r ea r wh eel cylin der
a n d im m er se h ose en d in con t a in er pa r t ia lly filled
wit h br a ke flu id.
(4) H a ve h elper pr ess a n d h old br a ke peda l t o floor
a n d obser ve wa r n in g ligh t .
(a ) If wa r n in g ligh t illu m in a t es, swit ch is oper a t -
in g cor r ect ly.
(b) If ligh t fa ils t o illu m in a t e, ch eck cir cu it fu se,
bu lb, a n d wir in g. Th e pa r kin g br a ke swit ch ca n be
u sed t o a id in iden t ifyin g wh et h er or n ot t h e br a ke
ligh t bu lb a n d fu se is fu n ct ion a l. Repa ir or r epla ce
pa r t s a s n ecessa r y a n d t est differ en t ia l pr essu r e
swit ch oper a t ion a ga in .
(5) If wa r n in g ligh t st ill does n ot illu m in a t e,
swit ch is fa u lt y. Repla ce com bin a t ion va lve a ssem bly,
bleed br a ke syst em a n d ver ify pr oper swit ch a n d
VACUUM va lve oper a t ion .
GAUGE
J9005-81
REAR PROPORT I ON I N G VALV E
Th e va lve con t r ols flu id flow. If flu id en t er s t h e
Fig. 7 Typical Booster Vacuum Test Connections va lve a n d does n ot exit t h e va lve t h e com bin a t ion
va lve m u st be r epla ced.
POWER BOOST ER CH ECK VALV E T EST
(1) Discon n ect va cu u m h ose fr om ch eck va lve.
DISC BRAKE ROTOR
(2) Rem ove ch eck va lve a n d va lve sea l fr om
Th e r ot or br a kin g su r fa ces sh ou ld n ot be r efin ish ed
boost er.
u n less n ecessa r y.
(3) Use a h a n d oper a t ed va cu u m pu m p for t est .
Ligh t su r fa ce r u st a n d sca le ca n be r em oved wit h a
(4) Apply 15-20 in ch es va cu u m a t la r ge en d of
la t h e equ ipped wit h du a l sa n din g discs. Th e r ot or
ch eck va lve (F ig. 8).
su r fa ces ca n be r est or ed by m a ch in in g in a disc br a ke
la t h e if su r fa ce scor in g a n d wea r a r e ligh t .
DIAL INDICATOR ROTOR TAKE MINIMUM
MEASUREMENTS
AROUND
MICROMETER
ROTOR
OF 6

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.

NOTE: Be sure wheel bearing has zero end play


before checking rotor runout. Fig. 10 Measuring Rotor Thickness
BRAKE DRUM
Ma xim u m a llowa ble r ot or r u n ou t is 0.102 m m
Th e m a xim u m a llowa ble dia m et er of t h e dr u m
(0.004 in .).
br a kin g su r fa ce is st a m ped or ca st in t o t h e dr u m
ou t er edge. Gen er a lly, a dr u m ca n be m a ch in ed t o a
m a xim u m of 1.52 m m (0.060 in .) over size. Alwa ys
r epla ce t h e dr u m if m a ch in in g wou ld ca u se dr u m
dia m et er t o exceed t h e size lim it in dica t ed on t h e
dr u m .

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.

SERV I CE PROCEDU RES


BRAKE FLUID LEVEL 80aa0fe0

Alwa ys clea n t h e m a st er cylin der r eser voir a n d ca p


befor e a ddin g flu id. Th is will pr even t dir t fr om fa ll- Fig. 12 Master Cylinder Bleeding
in g in t h e r eser voir a n d con t a m in a t in g t h e br a ke
BRAKE BLEEDING
flu id.
Use Mopa r br a ke flu id, or a n equ iva len t qu a lit y
Th e r eser voir h a s a ADD a n d a F ULL m a r k on t h e
flu id m eet in g SAE J 1703-F a n d DOT 3 st a n da r ds
side (F ig. 11) fill t o t h e F ULL m a r k.
on ly. Use fr esh , clea n flu id fr om a sea led con t a in er a t
a ll t im es.
MASTER CYLINDER BLEEDING
Do n ot pu m p t h e br a ke peda l a t a n y t im e wh ile
A n ew m a st er cylin der sh ou ld be bled befor e in st a l-
bleedin g. Air in t h e syst em will be com pr essed in t o
la t ion on t h e veh icle. Requ ir ed bleedin g t ools in clu de
sm a ll bu bbles t h a t a r e dist r ibu t ed t h r ou gh ou t t h e
bleed t u bes a n d a wood dowel t o st r oke t h e pist on s.
h ydr a u lic syst em . Th is will m a ke a ddit ion a l bleedin g
Bleed t u bes ca n be fa br ica t ed fr om br a ke lin e.
oper a t ion s n ecessa r y.
BLEEDI N G PROCEDU RE Do n ot a llow t h e m a st er cylin der t o r u n ou t of flu id
(1) Mou n t m a st er cylin der in vise. du r in g bleed oper a t ion s. An em pt y cylin der will a llow
FLUID
TAINER
TIALLY
WITH
BLEED
FILLED
FLUID
CON-
PAR-HOSE

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.

BRAKE DRUM MACHINING


FLUID
Th e br a ke dr u m s ca n be m a ch in ed on a dr u m la t h e
CONTAINER
PARTIALLY wh en n ecessa r y. In it ia l m a ch in in g cu t s sh ou ld be lim -
FILLED WITH it ed t o 0.12 - 0.20 m m (0.005 - 0.008 in .) a t a t im e a s
FLUID h ea vier feed r a t es ca n pr odu ce t a per a n d su r fa ce
va r ia t ion . F in a l fin ish cu t s of 0.025 t o 0.038 m m
(0.001 t o 0.0015 in .) a r e r ecom m en ded a n d will gen -
J8905-18 er a lly pr ovide t h e best su r fa ce fin ish .
Be su r e t h e dr u m is secu r ely m ou n t ed in t h e la t h e
Fig. 13 Bleed Hose Setup befor e m a ch in in g oper a t ion s. A da m per st r a p sh ou ld
(4) Open u p bleeder, t h en h a ve a h elper pr ess a lwa ys be u sed a r ou n d t h e dr u m t o r edu ce vibr a t ion
down t h e br a ke peda l. On ce t h e peda l is down close a n d a void ch a t t er m a r ks.
t h e bleeder. Repea t bleedin g u n t il flu id st r ea m is Th e m a xim u m a llowa ble dia m et er of t h e dr u m
clea r a n d fr ee of bu bbles. Th en m ove t o t h e n ext br a kin g su r fa ce is st a m ped or ca st in t o t h e dr u m
wh eel. ou t er edge. Alwa ys r epla ce t h e dr u m if m a ch in in g
wou ld ca u se dr u m dia m et er t o exceed t h e size lim it
PRESSU RE BLEEDI N G in dica t ed on t h e dr u m .
If pr essu r e bleedin g equ ipm en t will be u sed, t h e
fr on t br a ke m et er in g va lve will h a ve t o be h eld open BRAKE LINE
t o bleed t h e fr on t br a kes. Th e va lve st em is loca t ed Mopa r pr efor m ed m et a l br a ke lin e is r ecom m en ded
a n d pr efer r ed for a ll r epa ir s. H owever, dou ble-wa ll
BRAKING
BRAKING
DISC
GRINDER
DISC CUTTING
TOOLS DAMPER

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 .

Fig. 14 Rotor Refinishing

[ 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

Fig. 18 Booster Push Rod


(4) In st a ll boost er pu sh r od on peda l pin a n d
in st a ll n ew r et a in er clip.
80aafb2f
(5) In st a ll kn ee blocker.

Fig. 17 Stop Lamp Switch COMBINATION VALVE


I N STALLAT I ON NOTE: The combination valve is not repairable. The
(1) P u ll swit ch plu n ger a ll t h e wa y ou t t o fu lly valve is serviced as an assembly only.
ext en ded posit ion .
(2) Con n ect h a r n ess wir es t o swit ch .
(3) P r ess a n d h old br a ke peda l in a pplied posit ion . REM OVAL
(4) In st a ll swit ch a s follows: Align t a b on swit ch (1) Rem ove a ir clea n er cover a n d h ose for a ccess t o
wit h n ot ch in swit ch br a cket . Th en in ser t swit ch in va lve.
br a cket a n d t u r n it clockwise a bou t 30° t o lock it in (2) Un sn a p con n ect or lock t a bs a n d discon n ect dif-
pla ce. fer en t ia l pr essu r e swit ch wir e a t com bin a t ion va lve
(5) Relea se br a ke peda l. Th en pu ll peda l fu lly r ea r- (F ig. 19). Do n ot pu ll swit ch wir e t o discon n ect .
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 SWITCH
TERMINAL
m a ke r a t ch et in g sou n d a s it self a dju st s.

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

NOTE: Bleed master cylinder on bench before


installation. 80ab88a7

Fig. 21 Booster Push Rod


BOOSTER CALIPER
OUTBOARD
BRAKESHOE
BOSS C-CLAMP

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.

DISC BRAKE CALIPER


REM OVAL
(1) Ra ise a n d su ppor t veh icle.
(2) Rem ove fr on t wh eel a n d t ir e a ssem bly.
(3) Dr a in sm a ll a m ou n t of flu id fr om m a st er cylin -
der br a ke r eser voir wit h su ct ion gu n .
(4) Bot t om ca liper pist on in bor e wit h C-cla m p.
80ab88a8
P osit ion cla m p scr ew on ou t boa r d br a ke sh oe a n d
cla m p fr a m e on r ea r of ca liper (F ig. 23). D o n o t
Fig. 22 Booster Mounting
a llo w c la m p s c re w to be a r d ire c tly o n o u tbo a rd
(10) In en gin e com pa r t m en t , slide boost er st u ds s h o e re ta in e r s p rin g . U s e w o o d o r m e ta l s p a c e r
ou t of da sh pa n el, t ilt boost er u pwa r d, a n d r em ove be tw e e n s h o e a n d c la m p s c re w.
boost er fr om en gin e com pa r t m en t .
(11) Rem ove da sh sea l fr om boost er.

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.

NOTE: Lubricate the pedal pin and bushing with


Mopar multi-mileage grease before installation.
J9305-42
(5) Tigh t en boost er m ou n t in g n u t s t o 39 N·m (29
ft . lbs.). Fig. 23 Bottoming Caliper Piston With C-Clamp
(6) In st a ll t h e kn ee blocker. (5) Rem ove br a ke h ose m ou n t in g bolt a n d disca r d
(7) If or igin a l m a st er cylin der is bein g in st a lled, wa sh er s (F ig. 24).
ch eck con dit ion of sea l a t r ea r of m a st er cylin der. (6) Rem ove ca liper m ou n t in g bolt s (F ig. 25).
Repla ce sea l if cu t , or t or n . (7) Tilt t op of ca liper ou t wa r d wit h pr y t ool if n ec-
(8) Clea n cylin der m ou n t in g su r fa ce of br a ke essa r y (F ig. 26) a n d r em ove ca liper .
boost er. Use sh op t owel wet t ed wit h br a ke clea n er for (8) Rem ove ca liper fr om veh icle.
t h is pu r pose. Dir t , gr ea se, or sim ila r m a t er ia ls will
pr even t pr oper cylin der sea t in g a n d cou ld r esu lt in I N STALLAT I ON
va cu u m lea k. (1) Clea n br a ke sh oe m ou n t in g ledges wit h wir e
(9) Align a n d in st a ll m a st er cylin der on boost er br u sh a n d a pply ligh t coa t of Mopa r m u lt i-m ilea ge
st u ds. 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 gr ea se t o su r fa ces (F ig. 27).
(155 in . lbs.). (2) Con n ect br a ke h ose t o ca liper wit h n e w
(10) Con n ect va cu u m h ose t o boost er ch eck va lve. wa sh er on bot h sides of h ose fit t in g. Do n ot t igh t en
(11) Con n ect a n d secu r e br a ke lin es t o com bin a t ion fit t in g bolt com plet ely a t t h is t im e.
va lve a n d m a st er cylin der. St a r t a ll br a ke lin e fit - (3) In st a ll ca liper by posit ion n ot ch es a t lower en d
t in gs by h a n d t o a void cr oss t h r ea din g. of br a ke sh oes on bot t om m ou n t in g ledge. Th en
(12) In st a ll com bin a t ion va lve on boost er st u ds. r ot a t e ca liper over r ot or a n d sea t n ot ch es a t u pper
Tigh t en br a cket m ou n t in g n u t s t o 17.5 N·m (155 in . en d of sh oes on t op m ou n t in g ledge (F ig. 28).
lbs.).
CALIPERS CALIPER MOUNTER
CALIPER
FITTING
BOLT
WASHERS
(2) TILT
OUTBOARD
MOUNTING
BUSHINGS
REMOVE
CALIPER
LEDGES
TO
CALIPER
MOUNTING
BOLTS

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

Fig. 26 Caliper Removal

CALIPERS

8031e88f

Fig. 24 Brake Hose And Bolt

Fig. 27 Caliper Lubrication Points


(6) In st a ll wh eel a n d t ir e a ssem bly.
(7) Rem ove su ppor t a n d lower veh icle.
J9105-31 (8) P u m p br a ke peda l u n t il ca liper pist on s a n d
br a ke sh oes a r e sea t ed.
Fig. 25 Caliper Mounting Bolts (9) F ill m a st er cylin der a n d bleed br a ke syst em .
(4) Coa t ca liper m ou n t in g bolt s wit h silicon e DISC BRAKE SHOES
gr ea se. Th en in st a ll a n d t igh t en bolt s t o 15 N·m (11
ft . lbs.). REM OVAL
(1) Ra ise a n d su ppor t veh icle.
CAUTION: If new caliper bolts are being installed,
(2) Rem ove wh eel a n d t ir e a ssem bly.
or if the original reason for repair was a drag/pull
(3) Rem ove ca liper.
condition, check caliper bolt length before proceed-
(4) P r essin g on e en d of ou t boa r d sh oe in wa r d t o
ing. Bolts must not have a shank length greater
disen ga ge sh oe lu g. Th en r ot a t e sh oe u pwa r d u n t il
than 67.6 mm (2.66 in.) (Fig. 29).
r et a in er spr in g clea r s ca liper. P r ess opposit e en d of
(5) Tigh t en br a ke h ose fit t in g bolt t o 31 N·m (23 ft . sh oe in wa r d t o disen ga ge sh oe lu g a n d r ot a t e sh oe u p
lbs.). a n d ou t of ca liper (F ig. 30).
(5) Gr a sp en ds of in boa r d sh oe a n d t ilt sh oe ou t -
CAUTION: Insure the brake hose is not twisted or wa r d t o r elea se spr in gs fr om ca liper pist on (F ig. 31)
kinked and clear of all steering and suspension a n d r em ove sh oe fr om ca liper.
components.
CALIPER BOLT
CORRECT
22 mmSHANK
THREADLENGTH
(0.866
BOTTOM
67
2.637
TOP
in.)
LENGTH:
mmLEDGE
in.(6(60.60.0236
mm)
in.)
BRAKESHOE
LEDGE
BRAKESHOE
OUTER
TAB
SEATED
ON
NOTCH
SURFACE
LEDGE
IN OUTBOARD
BRAKESHOE
LOCATING
LUG CALIPER
PISTON SHOE
SHOESPRING
SPRINGS INBOARD
LOCATING
CALIPER
BRAKE-
SHOE
LUG

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

Fig. 30 Outboard Brake Shoe Removal

1/
BOTTOM
LEDGE
J9005-35

Fig. 28 Caliper Installation

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

Fig. 33 Drum Brake Components—Typical


ANCHOR
SHOE
PINSURFACES
CONTACT SUPPORT
PLATE AIRCRAFT TYPE CLAMP
HOSE CABLE
RETAINER
CABLE
ASSEMBLY

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

Fig. 34 Shoe Contact Surfaces


(9) In st a ll br a ke sh oes on su ppor t pla t e. Secu r e
sh oes wit h n ew h old-down spr in gs, pin s a n d r et a in -
er s.
(10) In st a ll pa r kin g br a ke st r u t a n d spr in g.
(11) In st a ll gu ide pla t e a n d a dju st er ca ble on
a n ch or pin .
(12) In st a ll pr im a r y a n d secon da r y r et u r n spr in gs.
(13) In st a ll a dju st er ca ble gu ide on secon da r y
sh oe.
(14) Lu br ica t e a n d a ssem ble a dju st er scr ew.
(15) In st a ll a dju st er scr ew, spr in g a n d lever a n d
con n ect t o a dju st er ca ble.
(16) Adju st sh oes t o dr u m . Fig. 35 Parking Brake Cable Removal
(17) In st a ll wh eel/t ir e a ssem blies a n d lower veh i- (5) Discon n ect br a ke lin e a t wh eel cylin der.
cle. (6) Rem ove wh eel cylin der fr om su ppor t pla t e.
(18) Ver ify fir m br a ke peda l befor e m ovin g veh icle. (7) Rem ove a xle sh a ft , r efer t o Gr ou p 3 for pr oce-
du r es.
WHEEL CYLINDER (8) Rem ove bolt s a t t a ch in g su ppor t pla t e t o a xle
a n d r em ove su ppor t pla t e.
REM OVAL
(1) Rem ove wh eel a n d t ir e a ssem bly. I N STALLAT I ON
(2) Rem ove br a ke dr u m . (1) Apply bea d of silicon e sea ler a r ou n d a xle
(3) Discon n ect wh eel cylin der br a ke lin e. m ou n t in g su r fa ce of su ppor t pla t e.
(4) Rem ove br a ke sh oe r et u r n spr in gs a n d m ove (2) In st a ll su ppor t pla t e on a xle fla n ge. Tigh t en
sh oes ou t of en ga gem en t wit h cylin der pu sh r ods. a t t a ch in g bolt s t o 47-81 N·m (35-60 ft . lbs.).
(5) Rem ove cylin der a t t a ch in g bolt s a n d r em ove (3) Apply bea d of silicon e sea ler a r ou n d wh eel cyl-
cylin der fr om su ppor t pla t e. in der m ou n t in g su r fa ce a n d in st a ll wh eel cylin der.
(4) In st a ll br a ke lin e in wh eel cylin der.
I N STALLAT I ON (5) In st a ll pa r kin g br a ke ca ble in su ppor t pla t e.
(1) Apply bea d of silicon e sea ler a r ou n d cylin der (6) In st a ll a xle sh a ft , r efer t o Gr ou p 3 for pr oce-
m ou n t in g su r fa ce of su ppor t pla t e. du r e.
(2) In st a ll cylin der m ou n t in g bolt s a n d t igh t en t o (7) Con n ect pa r kin g br a ke ca ble t o lever on sec-
cor r ect t or qu e. on da r y sh oe a n d in st a ll br a ke sh oes on su ppor t pla t e.
(3) Con n ect br a ke lin e t o cylin der. (8) Adju st br a ke sh oes t o dr u m wit h br a ke ga u ge.
(4) In st a ll br a ke sh oe r et u r n spr in g. (9) In st a ll br a ke dr u m a n d wh eel a n d t ir e a ssem -
(5) In st a ll br a ke dr u m . bly.
(6) In st a ll wh eel a n d t ir e a ssem bly. (10) Bleed br a ke syst em .
(7) Bleed br a ke syst em .
WORM
HOSEREAR
CLAMP
DRIVE
CABLES TENSIONER
EQUALIZER
ROD
CABLE
RETAINER REAR
CABLE
FRONT CABLE REAR CABLES TENSIONER
EQUALIZER
ROD FRONT CABLE

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).

TENSIONER ROD 80aac290

Fig. 36 Parking Brake Cables

TENSIONER ROD 80aac290

Fig. 38 Parking Brake Equalizer


(4) Lower veh icle.
(5) Disen ga ge fr on t ca ble fr om t h e ca ble lever.
(6) Com pr ess ca ble r et a in er wit h wor m dr ive h ose
cla m p a n d r em ove t h e ca ble fr om t h e pa r kin g br a ke
lever ba se.
(7) Discon n ect pa r kin g br a ke la m p swit ch wir e
(F ig. 39).
(8) Rem ove pa r kin g br a ke lever a ssem bly m ou n t -
in g bolt s (F ig. 39).
(9) Rem ove lever a ssem bly.
(10) Rem ove pa r kin g br a ke la m p swit ch .

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

PARKING BRAKE SWITCH 80aafb0a


J9505-77

Fig. 39 Parking Brake Lever Assembly Fig. 40 Reservoir Retaining Pins


(3) In ser t fr on t ca ble t h r ou gh t h e pa r kin g br a ke
lever ba se. In su r e t h e ca ble r et a in er is sea t ed in t o
t h e ba se.
(4) At t a ch t h e fr on t ca ble t o t h e ca ble lever (F ig.
39).
(5) Con n ect pa r kin g br a ke la m p swit ch wir e.
(6) Ra ise veh icle.
(7) In st a ll a dju st in g n u t t o t h e t en sion er r od a n d
a dju st pa r kin g br a kes.
(8) Lower veh icle.
(9) Ver ify cor r ect pa r kin g br a ke oper a t ion .

DI SASSEM BLY AN D ASSEM BLY


}9505-47
MASTER CYLINDER RESERVOIR
Fig. 41 Loosening Reservoir
REM OVAL
(1) Rem ove r eser voir ca p a n d em pt y flu id in t o
dr a in con t a in er.
(2) Rem ove pin s t h a t r et a in r eser voir t o m a st er
cylin der. Use h a m m er a n d pin pu n ch t o r em ove pin s
(F ig. 40).
(3) Cla m p cylin der body in vise wit h br a ss pr ot ec-
t ive ja ws.
(4) Loosen r eser voir fr om gr om m et s wit h pr y t ool
(F ig. 41).
(5) Rem ove r eser voir by r ockin g it t o on e side a n d
J9505-48
pu llin g fr ee of gr om m et s (F ig. 42).
(6) Rem ove old gr om m et s fr om cylin der body (F ig. Fig. 42 Reservoir Removal
43).
(1) Lu br ica t e n ew gr om m et s wit h clea n br a ke flu id
I N STALLAT I ON a n d In st a ll n ew gr om m et s in cylin der body (F ig. 44).
Use fin ger pr essu r e t o in st a ll a n d sea t gr om m et s.
CAUTION: Do not use any type of tool to install (2) St a r t r eser voir in gr om m et s. Th en r ock r eser-
the grommets. Tools may cut, or tear the grommets voir ba ck a n d for t h wh ile pr essin g down wa r d t o sea t
creating a leak problem after installation. Install the it in gr om m et s.
grommets using finger pressure only. (3) In st a ll pin s t h a t r et a in r eser voir t o cylin der
body.
GROMMETS WORK NEW
PLACE USING
GROMMETS
FINGER
CYLINDER
MASTER
SURE
BODY
PRES-
ONLY
INTO CALIPER
SHOPOR
PISTON
TOWELS
CLOTHS AIR GUN CALIPER
PADDING
MATERIAL

XJ BRAKES 5 - 23
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)

J9505-49

Fig. 43 Grommet Removal

Fig. 45 Padding Caliper Interior

Fig. 44 Grommet Installation


(4) F ill a n d bleed m a st er cylin der on ben ch befor e
in st a lla t ion in veh icle.

DISC BRAKE CALIPER


DI SASSEM BLY
(1) Rem ove br a ke sh oes fr om ca liper.
(2) Dr a in br a ke flu id ou t of ca liper.
(3) P a d in t er ior of ca liper wit h m in im u m , 2.54 cm
(1 in .) t h ickn ess of sh op t owels or r a gs (F ig. 45). Tow- Fig. 46 Caliper Piston Removal
els a r e n eeded t o pr ot ect ca liper pist on du r in g
r em ova l. (5) Rem ove ca liper pist on du st boot wit h su it a ble
(4) Rem ove ca liper pist on wit h s h o rt bu rs ts of t ool (F ig. 47) a n d disca r d boot .
low pr essu r e com pr essed a ir. Dir ect a ir t h r ou gh flu id (6) Rem ove ca liper pist on sea l wit h wood or pla st ic
in let por t a n d ea se pist on ou t of bor e (F ig. 46). t ool (F ig. 48) a n d disca r d sea l. Do n ot u se m et a l t ools
a s t h ey will scr a t ch pist on bor e.
CAUTION: Do not blow the piston out of the bore (7) Rem ove ca liper m ou n t in g bolt bu sh in gs a n d
with sustained air pressure. This could result in a boot s (F ig. 49).
cracked piston. Use only enough air pressure to
ease the piston out. ASSEM BLY
(1) Coa t ca liper pist on bor e, n ew pist on sea l a n d
pist on wit h clea n br a ke flu id.
WARNING: NEVER ATTEMPT TO CATCH THE PIS- (2) Lu br ica t e ca liper bu sh in gs a n d in t er ior of
TON AS IT LEAVES THE BORE. THIS MAY RESULT bu sh in g boot s wit h silicon e gr ea se.
IN PERSONAL INJURY. (3) In st a ll bu sh in g boot s in ca liper, t h en in ser t
bu sh in g in t o boot a n d pu sh bu sh in g in t o pla ce (F ig.
50).
CALIPER
REMOVE
WOOD
CIL
SEAL
ILAR
OR
SLIDE
TOOL
WITH
COLLAPSE
WITH
PEN-
SIM-
SCREWDRIVER
BUSH-
PUNCH
ING BOOT
OR BOOT DUST
PISTON
BOOT SEAL
GROOVE
BUSHING
PISTON
SEAL TIONBOOT
PIS- DUST BOOT
PISTON SEAL

5 - 24 BRAKES XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
BOOT

COLLAPSE BOOT
WITH PUNCH
OR SCREWDRIVER

Fig. 50 Bushings And Boots Installation


Fig. 47 Caliper Piston Dust Boot Removal

Fig. 51 Piston Seal Installation


Fig. 48 Piston Seal Removal
PISTON

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.

CAUTION: Do not use gasoline, kerosene, thinner,


or similar solvents. These products may leave a
residue that could damage the piston and seal.

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.

CAUTION: If the caliper piston is replaced, install


the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
Fig. 54 Piston Dust Boot Installation piston tolerances are different.

SPRING Th e bor e ca n be lig h tly polish ed wit h a br a ke


h on e t o r em ove ver y m in or su r fa ce im per fect ion s
BOOT (F ig. 56). Th e ca liper sh ou ld be r epla ced if t h e bor e is
sever ely cor r oded, r u st ed, scor ed, or if polish in g
wou ld in cr ea se bor e dia m et er m or e t h a n 0.025 m m
(0.001 in ch ).

REAR DRUM BRAKE


CUP
EXPANDERS
CLEAN I N G
BLEED SCREW Clea n t h e in dividu a l br a ke com pon en t s, in clu din g
t h e su ppor t pla t e a n d wh eel cylin der ext er ior, wit h a
Fig. 55 Wheel Cylinder Components–Typical wa t er da m pen ed clot h or wit h br a ke clea n er. Do n ot
u se a n y ot h er clea n in g a gen t s. Rem ove ligh t r u st a n d
SPECIAL HONE
PISTON BORE CALIPER ANCHOR
SHOE
PINSURFACES
CONTACT SUPPORT
PLATE

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.

CLEAN I N G REAR DRUM BRAKE


Clea n t h e cylin der a n d pist on s wit h clea n br a ke Th e r ea r dr u m br a kes a r e equ ipped wit h a self-a d-
flu id or br a ke clea n er on ly. Do n ot u se a n y ot h er ju st in g m ech a n ism . Un der n or m a l cir cu m st a n ces, t h e
clea n in g a gen t s. on ly t im e a dju st m en t is r equ ir ed is wh en t h e sh oes
Dr y t h e cylin der a n d pist on s wit h com pr essed a ir. a r e r epla ced, r em oved for a ccess t o ot h er pa r t s, or
Do n ot u se r a gs or sh op t owels t o dr y t h e cylin der wh en on e or bot h dr u m s a r e r epla ced.
com pon en t s. Lin t fr om clot h m a t er ia l will a dh er e t o Adju st m en t ca n be m a de wit h a st a n da r d br a ke
t h e cylin der bor es a n d pist on s. ga u ge or wit h a dju st in g t ool. Adju st m en t is per-
for m ed wit h t h e com plet e br a ke a ssem bly in st a lled
I N SPECT I ON on t h e ba ckin g pla t e.
In spect t h e cylin der bor e. Ligh t discolor a t ion a n d
da r k st a in s in t h e bor e a r e n or m a l a n d will n ot ADJ U ST M EN T WI T H BRAK E GAU GE
im pa ir cylin der oper a t ion . (1) Be su r e pa r kin g br a kes a r e fu lly r elea sed.
BRAKE
BRAKE
GAUGE
DRUM BRAKE SHOESBRAKEGAUGE ADJUSTER
ADJUSTING
SPRING
TOOL STAR WHEEL
SCREWDRIVER LEVER BRAKE
SHOEWEB

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

Fig. 58 Adjusting Gauge On Drum


(5) Rever se ga u ge a n d in st a ll it on br a ke sh oes.
P osit ion ga u ge legs a t sh oe cen t er s a s sh own (F ig.
59). If ga u ge does n ot fit (t oo loose/t oo t igh t ), a dju st
sh oes.

Fig. 60 Brake Adjustment


(6) Rot a t e a dju st er scr ew st a r wh eel (m ove t ool
h a n dle u pwa r d) u n t il sligh t dr a g ca n be felt wh en
wh eel is r ot a t ed.
(7) P u sh a n d h old a dju st er lever a wa y fr om st a r
wh eel wit h t h in scr ewdr iver.
(8) Ba ck off a dju st er scr ew st a r wh eel u n t il br a ke
J9005-27 dr a g is elim in a t ed.
(9) Repea t a dju st m en t a t opposit e wh eel. Be su r e
Fig. 59 Adjusting Gauge On Brake Shoes a dju st m en t is equ a l a t bot h wh eels.
(6) P u ll sh oe a dju st er lever a wa y fr om a dju st er (10) In st a ll su ppor t pla t e a ccess h ole plu gs.
scr ew st a r wh eel. (11) Adju st pa r kin g br a ke ca ble a n d lower veh icle.
(7) Tu r n a dju st er scr ew st a r wh eel (by h a n d) t o (12) In st a ll br a ke dr u m s a n d wh eels a n d lower
expa n d or r et r a ct br a ke sh oes. Con t in u e a dju st m en t veh icle.
u n t il ga u ge ou t side legs a r e ligh t dr a g-fit on sh oes. (13) Dr ive veh icle a n d m a ke on e for wa r d st op fol-
(8) In st a ll br a ke dr u m s a n d wh eels a n d lower lowed by on e r ever se st op. Repea t pr ocedu r e 8-10
veh icle. 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
(9) Dr ive veh icle a n d m a ke on e for wa r d st op fol- a dju st m en t .
lowed by on e r ever se st op. Repea t pr ocedu r e 8-10
TENSIONER
ROD
BRACKET
TO EQUALIZER (1/4
6.5 MM
in.) TENSIONER
ROD

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.)

PARKING BRAKE CABLE TENSIONER


NOTE: Parking brake adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec-
ROD
essary, perform the following procedure for proper TO
parking brake operation. EQUALIZER

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.

NOTE: Do not loosen/tighten equalizer adjusting


nut for any reason after completing adjustment.
XJ BRAKES 5 - 29
SPECI FI CAT I ON S (Cont inue d)
BRAKE COMPONENTS SPCI AL T OOLS

D is c B ra k e Ca lip e r BASE BRAKES


Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slidin g
D is c B ra k e Ro to r
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Ven t ila t ed
Ma x. Ru n ou t . . . . . . . . . . . . . 0.12 m m (0.005 in .)
Ma x. Th ickn ess Va r ia t ion . . 0.013 m m (0.0005 in .)
B ra k e D ru m
Size . . . . . . . . . . . . . . . . . . . . . . . . . 9 in . or 10 in .
B ra k e B o o s te r
Type . . . . . . . . . . . . . . . . . . . . . . Du a l Dia ph r a gm
TORQUE CHART Installer Caliper Dust Boot C-4842
D ES CRIP TION TORQU E
B ra k e P e d a l
P ivot Bolt /Nu t . . . . . . . . . . . . . 35 N·m (26 ft . lbs.)
B ra k e B o o s te r
Mou n t in g Nu t s . . . . . . . . . . . . 39 N·m (29 ft . lbs.)
Ma s te r Cy lin d e r
Mou n t in g Nu t s . . . . . . . . . . 17.5 N·m (155 in . lbs.)
Br a ke Lin es . . . . . . . . . . . . . 19 N·m (170 in . lbs.)
Co m bin a tio n Va lv e
Mou n t in g Nu t s . . . . . . . . . . 17.5 N·m (155 in . lbs.)
Br a ke Lin es . . . . . . . . . . . . . 19 N·m (170 in . lbs.)
Ca lip e r
Mou n t in g Bolt s . . . . . . . . . . . . 15 N·m (11 ft . lbs.)
Br a ke H ose Bolt . . . . . . . . . . . 31 N·m (23 ft . lbs.)
Wh e e l Cy lin d e r Handle C-4171
Mou n t in g Bolt s . . . . . . . . . . . . . 10 N·m (7 ft . lbs.)
Br a ke Lin e . . . . . . . . . . . . . . . 16 N·m (12 ft . lbs.)
P a rk in g B ra k e
Lever Scr ews . . . . . . . . . . 10-14 N·m (7-10 ft . lbs.)
Lever Br a cket Scr ews . . . 10-14 N·m (7-10 ft . lbs.)
Ca ble Ret a in er Nu t . . . . . . . . 1.5 N·m (14 in . lbs.)
HCU/CAB
MASTER
ASSEMBLY
CYLIN-
DER
LEFT
RIGHT
POWER
BRAKE
BOOSTER HCU/CAB NESS
HAR- LEFT
ACCELERATION
RIGHT REAR
SWITCH
HYDRAULIC BRAKE WIRES TO
FRONT
FRONT REAR WHEEL
WHEEL
WHEEL LINES TO WHEELS WHEEL WHEEL SPEED
SENSORS

5 - 30 BRAKES XJ

AN T I LOCK BRAK ES

INDEX
page page

GENERAL INFORMATION SERVICE PROCEDURES


ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . 30 BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . 33
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . 33 ACCELERATION SWITCH . . . . . . . . . . . . . . . . 36
ACCELERATION SWITCH . . . . . . . . . . . . . . . . 32 FRONT WHEEL SPEED SENSOR . . . . . . . . . . 34
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . 30 HYDRAULIC CONTROL UNIT/
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . 32 CONTROLLER ANTILOCK BRAKES . . . . . . . 33
CONTROLLER ANTILOCK BRAKES . . . . . . . . . 31 REAR WHEEL SPEED SENSOR . . . . . . . . . . . 34
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . 31 DISASSEMBLY AND ASSEMBLY
WHEEL SPEED SENSORS AND HYDRAULIC CONTROL UNIT/
TONE WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 32 CONTROLLER ANTILOCK BRAKE . . . . . . . . 36
DIAGNOSIS AND TESTING SPECIFICATIONS
ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . 33 T0RQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 37

GEN ERAL I N FORM AT I ON


ANTILOCK BRAKE SYSTEM
Th e a n t ilock br a ke syst em (ABS) is a n elect r on i-
MASTER
POWER BRAKE

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

Th e h ydr a u lic syst em is a t h r ee ch a n n el design . BRAKE LINES : :


Th e fr on t wh eel br a kes a r e con t r olled in dividu a lly TOWHEELS I I
I I
a n d t h e r ea r wh eel br a kes in t a n dem (F ig. 1). Th e I I

ABS elect r ica l syst em is sepa r a t e fr om ot h er elect r 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.

ANTILOCK BRAKES CAB


Th e ABS br a ke syst em per for m s sever a l self-t est s
ever y t im e t h e ign it ion swit ch is t u r n ed on a n d t h e
veh icle is dr iven . Th e CAB m on it or s t h e syst em s
in pu t a n d ou t pu t cir cu it s t o ver ify t h e syst em is oper-
a t in g cor r ect ly. If t h e on boa r d dia gn ost ic syst em
sen ses t h a t a cir cu it is m a lfu n ct ion in g t h e syst em
will set a t r ou ble code in it s m em or y.

NOTE: The MDS or DRB III scan tool is used to


diagnose the ABS system. For additional informa-
tion refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diag-
nostic Manual.
80aafb2b

Fig. 5 CAB Harness Connector Release


MOTOR
HCU HCU/CABFWD
BRACKET
CAB WHEEL SPEED
FRONT WHEEL
SENSOR
PIGTAIL
SPEED SEN-
SOR TONESTEERING
WHEEL
KNUCKLE

5 - 34 BRAKES XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

WHEEL SPEED STEERING


SENSOR PIGTAIL KNUCKLE

HCU/CAB
MOTOR BRACKET

80aafb1e

Fig. 6 HCU/CAB Mounting


I N STALLAT I ON
(1) In st a ll H CU/CAB on t h e m ou n t in g st u ds. FRONT WHEEL
SPEED SENSOR
(2) In st a ll m ou n t in g n u t s a n d bolt . Tigh t en t o 11.5
8031 e865
N·m (102 in . lbs.).
(3) In st a ll br a ke lin es t o t h e H CU a n d t igh t en t o
19 N·m (170 in . lbs.). Fig. 7 Front Wheel Speed Sensor
(4) In st a ll wir in g h a r n ess con n ect or t o t h e CAB (3) P osit ion sen sor on st eer in g kn u ckle. Sea t sen -
a n d pu sh down on t h e r elea se t o secu r e t h e con n ec- sor loca t in g t a b in h ole in kn u ckle a n d in st a ll sen sor
t or. a t t a ch in g bolt fin ger t igh t .
(5) In st a ll n ega t ive ba t t er y ca ble t o t h e ba t t er y. (4) Tigh t en sen sor a t t a ch in g bolt t o 4.7 N·m (42 in .
(6) Bleed ABS br a ke syst em . lbs.).
(5) If or igin a l sen sor h a s been in st a lled, ch eck sen -
FRONT WHEEL SPEED SENSOR sor a ir ga p. Air ga p sh ou ld be 0.36 t o 1.5 m m (0.014
t o 0.059 in .). If ga p is in cor r ect , sen sor is eit h er loose,
REM OVAL or da m a ged.
(1) Ra ise veh icle a n d t u r n wh eel ou t wa r d for ea s- (6) Secu r e sen sor wir e t o st eer in g kn u ckle a n d
ier a ccess t o sen sor. body br a cket s.
(2) Rem ove sen sor wir e fr om m ou n t in g br a cket s. (7) Rou t e sen sor wir e for wa r d a n d beh in d sh ock
(3) Clea n sen sor a n d su r r ou n din g a r ea wit h sh op a bsor ber. Th en a t t a ch sen sor wir e t o spr in g sea t
t owel befor e r em ova l. br a cket wit h gr om m et s on sen sor wir e.
(4) Rem ove bolt a t t a ch in g sen sor t o st eer in g (8) Rou t e sen sor wir e t o ou t er sill br a cket . Rem ove
kn u ckle a n d r em ove sen sor (F ig. 7). a ll t wist s or kin ks fr om wir e.
(5) Rem ove sen sor wir e fr om br a cket s on body a n d (9) At t a ch sen sor wir e t o sill br a cket wit h gr om -
st eer in g kn u ckle. m et . Be su r e wir e is fr ee of t wist s a n d kin ks.
(6) Un sea t sen sor wir e gr om m et in wh eel h ou se (10) Ver ify sen sor wir e r ou t in g. Wir e sh ou ld loop
pa n el. for wa r d a n d a bove sill br a cket . Loose en d of wir e
(7) In en gin e com pa r t m en t , discon n ect sen sor wir e sh ou ld be below sill br a cket a n d t owa r ds br a ke h ose.
con n ect or a t h a r n ess plu g. Th en r em ove sen sor a n d (11) Sea t sen sor wir e gr om m et in body pa n el a n d
wir e. clip wir e t o br a ke lin e a t gr om m et loca t ion .
(12) Con n ect sen sor wir e t o h a r n ess in en gin e com -
I N STALLAT I ON pa r t m en t .
(1) If o rig in a l sen sor will be in st a lled, wipe a ll
t r a ces of old spa cer m a t er ia l off sen sor picku p fa ce. REAR WHEEL SPEED SENSOR
Use a dr y sh op t owel for t h is pu r pose.
(2) Apply Mopa r Lock N’ Sea l or Loct it e t 242 t o REM OVAL
bolt t h a t secu r es sen sor in st eer in g kn u ckle. Use n ew (1) Ra ise a n d fold r ea r sea t for wa r d for a ccess t o
sen sor bolt if or igin a l bolt is wor n or da m a ged. r ea r sen sor con n ect or s (F ig. 8).
(2) Discon n ect sen sor s a t r ea r h a r n ess con n ect or s.
REAR
SENSOR
CROSSMEMBER
FLOORPAN
NESS
HAR-
SEATFWD TO
ACCELERATION
L.R. SENSOR
SENSOR
WHEEL TO R.R. SENSOR
WHEELWHEEL
MOUNTING
SENSOR
TONEWHEEL
BRACKET
SENSOR
SPEED REAR
SENSOR BRASS
FEELER
WHEEL
SPEED
TONE
SENSOR
AIR
ATTACHED
GAUGE
SENSOR
RING
GAP SPACER
FACE
TO

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

Fig. 8 Acceleration Switch And Rear Sensor


Connections
J9205-17
(4) Ra ise veh icle.
(5) Discon n ect sen sor wir es a t r ea r a xle con n ec- Fig. 10 Setting Air Gap On Original Rear Sensor
t or s.
(6) If n e w sen sor wa s in st a lled, pu sh ca r dboa r d
(6) Rem ove wh eel a n d t ir e a ssem bly.
spa cer on sen sor fa ce a ga in st t on e r in g (F ig. 11).
(7) Rem ove br a ke dr u m .
Th en t igh t en sen sor bolt t o 13 N·m (115 in . lbs.). Cor-
(8) Rem ove clips secu r in g sen sor wir es t o br a ke
r ect a ir ga p will be est a blish ed a s t on e r in g r ot a t es
lin es, r ea r a xle a n d, br a ke h ose.
a n d peels spa cer off sen sor fa ce.
(9) Un sea t sen sor wir e su ppor t pla t e gr om m et .
(10) Rem ove bolt a t t a ch in g sen sor t o br a cket a n d
r em ove sen sor (F ig. 9).

AIR GAP
REAR SPACER
SENSOR ATTACHED TO
SENSOR FACE

J9205-35

Fig. 11 New Rear Sensor


(7) Rou t e sen sor wir es t o r ea r sea t a r ea .
Fig. 9 Rear Wheel Speed Sensor (8) F eed sen sor wir es t h r ou gh floor pa n a ccess h ole
a n d sea t sen sor gr om m et s in floor pa n .
REAR
CROSSMEMBER
FWD SEAT ACCELERATION SWITCH SWITCHBRACKET CAB SWITCH
NUMBER
PART MOUNTING
ARROW
FRONT
SCREWS
PROPER
OF SWITCH
MOUNTING
INDICATES
FOR

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.

Fig. 12 Acceleration Switch Mounting


I N STALLAT I ON

CAUTION: The mercury switch (inside the acceler-


ation switch), will not function properly if the switch
is mispositioned. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig.
13).

(1) P osit ion swit ch in m ou n t in g br a cket .


(2) In st a ll swit ch m ou n t in g bolt s a n d t igh t en t o 3
N·m (27.5 in . lbs.). Fig. 14 CAB Mounting Screws
(3) Con n ect h a r n ess t o swit ch . Be su r e h a r n ess ASSEM BLY
con n ect or is fir m ly sea t ed. (1) In st a ll t h e CAB on t o t h e H CU.
(4) Move sea t ba ck t o n or m a l posit ion . (2) In st a ll t h e CAB m ou n t in g scr ews a n d t igh t en
t o 1.8 N·m (16 in . lbs.).
(3) In st a ll pu m p m ot or con n ect or t o t h e CAB.
XJ BRAKES 5 - 37

SPECI FI CAT I ON S
T0RQUE CHART

D ES CRIP TION TORQU E


Ac c e le ra tio n S e n s o r
Sen sor Bolt . . . . . . . . . . . . . . 3 N·m (27.5 in . lbs.)
Br a cket Bolt . . . . . . . . . . . . 1.7 N·m (15.5 in . lbs.)
Hy d ra u lic Co n tro l U n it/Co n tro lle r An tilo c k
B ra k e s
Mou n t in g Nu t s . . . . . . . . . . 11.5 N·m (102 in . lbs.)
Br a ke Lin es . . . . . . . . . . . . . 19 N·m (170 in . lbs.)
Co n tro lle r An tilo c k B ra k e s
Mou n t in g Scr ews . . . . . . . . . . 1.8 N·m (16 in . lbs.)
Wh e e l S p e e d S e n s o rs
F r on t Mou n t in g Bolt . . . . . . . 4.7 N·m (42 in . lbs.)
Rea r Mou n t in g Bolt . . . . . . . 13 N·m (115 in . lbs.)
XJ CLUTCH 6-1

CLUTCH
CON T EN T S

page page

GENERAL INFORMATION IMPROPER CLUTCH RELEASE OR


CLUTCH COMPONENTS . . . . . . . . . . . ....... 1 ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . 3
CLUTCH HYDRAULIC FLUID . . . . . . . . ....... 2 MISALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . 5
CLUTCH LUBRICATION . . . . . . . . . . . . ....... 2 SERVICE PROCEDURES
INSTALLATION METHODS AND PARTS CLUTCH COMPONENT LUBRICATION . . . . . . . 5
USAGE . . . . . . . . . . . . . . . . . . . . . . . ....... 2 CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . 10
SAFETY PRECAUTIONS . . . . . . . . . . . ....... 1 CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . 5
DESCRIPTION AND OPERATION FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH OPERATION . . . . . . . . . . . . . ....... 2 REMOVAL AND INSTALLATION
DIAGNOSIS AND TESTING CLUTCH COVER AND DISC . . . . . . . . . . . . . . . 11
CLUTCH CONTAMINATION . . . . . . . . . . . . . . . . 3 CLUTCH HOUSING REPLACEMENT—AX15 . . 12
CLUTCH RUNOUT . . . . . . . . . . . . . . . . . . . . . . . 3 CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . 14
DIAGNOSTIC CHARTS . . . . . . . . . . . . . . . . . . . 5 PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . 14
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 3 RELEASE BEARING . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

GEN ERAL I N FORM AT I ON con n ect ed t o t h e clu t ch r elea se for k. Th e m a st er cyl-


in der is m ou n t ed on t h e dr iver side of t h e da sh pa n el
CLUTCH COMPONENTS a dja cen t t o t h e br a ke m a st er cylin der a n d boost er
Th e clu t ch m ech a n ism con sist s of a sin gle, dr y-t ype a ssem bly. Th is posit ion in g is sim ila r for bot h left a n d
disc a n d a dia ph r a gm st yle clu t ch cover. A h ydr a u lic r igh t h a n d dr ive m odels.
lin ka ge is u sed t o oper a t e t h e clu t ch r elea se bea r in g
a n d for k. SAFETY PRECAUTIONS
A n eedle-t ype pilot bea r in g in t h e cr a n ksh a ft
fla n ge su ppor t s t h e t r a n sm ission in pu t sh a ft . A WARNING: EXERCISE CARE WHEN SERVICING
sleeve t ype r elea se bea r in g is u sed t o en ga ge a n d dis- CLUTCH COMPONENTS. FACTORY INSTALLED
en ga ge t h e clu t ch cover pr essu r e pla t e. CLUTCH DISCS DO NOT CONTAIN ASBESTOS
Th e r elea se bea r in g is oper a t ed by a r elea se for k in FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
t h e clu t ch h ou sin g. Th e for k pivot s on a ba ll st u d CONTAIN ASBESTOS FIBERS FROM AFTERMAR-
m ou n t ed in t h e h ou sin g. Th e r elea se for k is a ct u a t ed KET COMPONENTS. BREATHING EXCESSIVE CON-
by a h ydr a u lic sla ve cylin der m ou n t ed in t h e h ou s- CENTRATIONS OF THESE FIBERS CAN CAUSE
in g. Th e sla ve cylin der is oper a t ed by a clu t ch m a st er SERIOUS BODILY HARM. WEAR A RESPIRATOR
cylin der m ou n t ed on t h e da sh pa n el. Th e cylin der DURING SERVICE AND NEVER CLEAN CLUTCH
pu sh r od is con n ect ed t o t h e clu t ch peda l. COMPONENTS WITH COMPRESSED AIR OR WITH
Th e clu t ch disc h a s cu sh ion spr in gs in t h e disc A DRY BRUSH. EITHER CLEAN THE COMPONENTS
h u b. Th e clu t ch disc fa cin g is r ivet ed t o t h e h u b. Th e WITH A WATER DAMPENED RAGS OR USE A VAC-
fa cin g is m a de fr om a n on -a sbest os m a t er ia l. Th e UUM CLEANER SPECIFICALLY DESIGNED FOR
clu t ch cover pr essu r e pla t e is a dia ph r a gm t ype wit h REMOVING ASBESTOS FIBERS AND DUST. DO NOT
a on e-piece spr in g a n d m u lt iple r elea se fin ger s. Th e CREATE DUST BY SANDING A CLUTCH DISC.
pr essu r e pla t e r elea se fin ger s a r e pr eset du r in g m a n - REPLACE THE DISC IF THE FRICTION MATERIAL IS
u fa ct u r e a n d a r e n ot a dju st a ble. DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
H Y DRAU LI C LI N K AGE COM PON EN T S IN SEALED BAGS OR CONTAINERS. THIS WILL
Th e h ydr a u lic lin ka ge con sist s of a clu t ch m a st er HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
cylin der wit h in t egr a l r eser voir, a clu t ch sla ve cylin - OTHERS. FOLLOW ALL RECOMMENDED SAFETY
der a n d a n in t er con n ect in g flu id lin e. PRACTICES PRESCRIBED BY THE OCCUPATIONAL
Th e clu t ch m a st er cylin der pu sh r od is con n ect ed SAFETY AND HEALTH ADMINISTRATION (OSHA)
t o t h e clu t ch peda l. Th e sla ve cylin der pu sh r od is AND THE ENVIRONMENTAL SAFETY AGENCY
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.
6-2 CLUTCH XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
CLUTCH HYDRAULIC FLUID A cocked pilot bea r in g is a n ot h er ca u se of clu t ch
Th e clu t ch h ydr a u lic lin ka ge cylin der s a n d lin es n oise, dr a g, h a r d sh ift in g, a n d r a pid bea r in g wea r.
a r e pr efilled wit h flu id a t t h e fa ct or y. Alwa ys u se a n a lign m en t t ool t o in st a ll a n ew bea r-
Th e h ydr a u lic syst em sh ou ld n ot r equ ir e a ddit ion a l in g. Th is pr a ct ice h elps a void cockin g t h e bea r in g
flu id u n der n or m a l cir cu m st a n ces. In fa ct , t h e r eser- du r in g in st a lla t ion .
voir flu id level will a ct u a lly in cr ea se a s n or m a l clu t ch
wea r occu r s. F or t h is r ea son , it is im por t a n t t o a void
DESCRI PT I ON AN D OPERAT I ON
over fillin g, or r em ovin g flu id fr om t h e r eser voir. Th is
a ct ion will ca u se clu t ch r elea se pr oblem s.
CLUTCH OPERATION
If in spect ion or dia gn osis in dica t es a ddit ion a l flu id
Lever a ge, cla m pin g for ce, a n d fr ict ion a r e wh a t
m a y be n eeded, u se Mopa r t br a ke flu id, or a n equ iv-
m a ke t h e clu t ch wor k. Th e disc ser ves a s t h e fr ict ion
a len t , m eet in g SAE J 1703 a n d DOT 3 st a n da r ds. Do
elem en t a n d a dia ph r a gm spr in g a n d pr essu r e pla t e
n ot u se a n y ot h er t ype of flu id.
pr ovide t h e cla m pin g for ce. Th e clu t ch peda l, h ydr a u -
lic lin ka ge, r elea se lever a n d bea r in g pr ovide t h e
CLUTCH LUBRICATION
lever a ge.
P r oper clu t ch com pon en t lu br ica t ion is im por t a n t
Th e clu t ch cover a ssem bly cla m ps t h e disc a ga in st
t o sa t isfa ct or y oper a t ion . Usin g t h e cor r ect lu br ica n t
t h e flywh eel. Th e a ssem bly con sist s of t h e cover, dia -
a n d a voidin g over lu br ica t ion a r e a lso equ a lly im por-
ph r a gm spr in g, pr essu r e pla t e, a n d fu lcr u m com po-
tant.
n en t s. Th e pr essu r e pla t e cla m ps t h e clu t ch disc
Du r in g ser vice, a pply r ecom m en ded lu br ica n t spa r-
a ga in st t h e flywh eel a n d t h e spr in g pr ovides t h e
in gly. Do n ot over lu br ica t e a s t h is cou ld r esu lt in
cla m pin g for ce.
clu t ch disc a n d pr essu r e pla t e con t a m in a t ion .
Th e clu t ch disc fr ict ion m a t er ia l is r ivet ed t o t h e
Clu t ch a n d t r a n sm ission com pon en t s r equ ir in g
disc h u b. Th e h u b bor e is splin ed for in st a lla t ion on
lu br ica t ion a r e:
t h e t r a n sm ission in pu t sh a ft . Th e h u b splin es con -
• pilot bea r in g.
n ect t h e disc t o t h e t r a n sm ission .
• r elea se lever pivot ba ll st u d.
Th e clu t ch lin ka ge u ses h ydr a u lic pr essu r e t o oper-
• r elea se lever pivot su r fa ces.
a t e t h e clu t ch . Th e clu t ch m a st er cylin der pu sh r od is
• r elea se bea r in g bor e.
con n ect ed t o t h e clu t ch peda l a n d t h e sla ve cylin der
• clu t ch peda l pivot bor e a n d bu sh in gs.
pu sh r od is con n ect ed t o t h e r elea se lever in t h e
• t r a n sm ission in pu t sh a ft splin es a n d pilot h u b.
clu t ch h ou sin g.
• r elea se bea r in g slide su r fa ce of fr on t bea r in g
Depr essin g t h e clu t ch peda l develops flu id pr essu r e
r et a in er.
in t h e clu t ch m a st er cylin der. Th is pr essu r e is t r a n s-
D o n o t a p p ly g re a s e to a n y p a rt o f th e c lu tc h
m it t ed t o t h e sla ve cylin der t h r ou gh a con n ect in g
c o v e r o r d is c .
lin e. In t u r n , t h e sla ve cylin der oper a t es t h e clu t ch
Use Mopa r t m u lt i-m ilea ge gr ea se or a silicon e
r elea se lever.
gr ea se for t h e clu t ch peda l bu sh in gs a n d pivot sh a ft .
Th e clu t ch r elea se bea r in g is m ou n t ed on t h e
Use Mopa r t h igh t em per a t u r e bea r in g gr ea se or
t r a n sm ission fr on t bea r in g r et a in er. Th e bea r in g is
equ iva len t for t h e pilot bea r in g, r elea se bea r in g bor e,
a t t a ch ed t o t h e r elea se lever, wh ich m oves t h e bea r-
t r a n sm ission in pu t sh a ft a n d r elea se for k com po-
in g in t o con t a ct wit h t h e clu t ch cover dia ph r a gm
n en t s. Apply r ecom m en ded a m ou n t s on ly a n d do n ot
spr in g.
over lu br ica t e.
Sla ve cylin der for ce ca u ses t h e r elea se lever t o
m ove t h e r elea se bea r in g in t o con t a ct wit h t h e dia -
INSTALLATION METHODS AND PARTS USAGE
ph r a gm spr in g. As a ddit ion a l for ce is a pplied, t h e
Dist or t ion of clu t ch com pon en t s du r in g in st a lla t ion
bea r in g pr esses t h e dia ph r a gm spr in g fin ger s in wa r d
a n d t h e u se of n on -st a n da r d com pon en t s a r e com m on
on t h e fu lcr u m s. Th is a ct ion m oves t h e pr essu r e
ca u ses of clu t ch m a lfu n ct ion .
pla t e r ea r wa r d r elievin g cla m p for ce on t h e disc. Th e
Im pr oper clu t ch cover bolt t igh t en in g ca n dist or t
clu t ch disc is disen ga ged a n d fr eewh eelin g a t t h is
t h e cover. Th e u su a l r esu lt is clu t ch gr a b, ch a t t er
poin t .
a n d r a pid wea r.
Th e pr ocess of clu t ch r e-en ga gem en t is sim ply t h e
An im pr oper ly sea t ed flywh eel a n d/or clu t ch h ou s-
r ever se of wh a t occu r s du r in g disen ga gem en t . Relea s-
in g a r e a ddit ion a l ca u ses of clu t ch fa ilu r e. Im pr oper
in g peda l pr essu r e r em oves clu t ch lin ka ge pr essu r e.
sea t in g will pr odu ce m isa lign m en t a n d a ddit ion a l
Th e r elea se bea r in g m oves a wa y fr om t h e dia ph r a gm
clu t ch pr oblem s.
spr in g wh ich a llows t h e pr essu r e pla t e t o exer t
Th e u se of n on -st a n da r d or low qu a lit y pa r t s will
cla m pin g for ce on t h e clu t ch disc.
a lso lea d t o pr oblem s a n d wea r. Use r ecom m en ded
fa ct or y pa r t s on ly.
XJ CLUTCH 6-3

DI AGN OSI S AN D T EST I N G n en t s. A visu a l in spect ion of t h e r elea se com pon en t s


will u su a lly r evea l t h e pr oblem pa r t .
GENERAL INFORMATION Relea se pr oblem s ca n r esu lt in h a r d sh ift in g a n d
P r oblem dia gn osis will gen er a lly r equ ir e a r oa d n oise. It em s t o look for a r e: lea ks a t t h e clu t ch cylin -
t est t o det er m in e t h e t ype of fa u lt . Com pon en t der s a n d in t er con n ect in g lin e; loose sla ve cylin der
in spect ion will t h en det er m in e t h e pr oblem ca u se bolt s; wor n /loose r elea se for k a n d pivot st u d; da m -
a ft er r oa d t est in g. a ged r elea se bea r in g; a n d a wor n clu t ch disc, or pr es-
Dr ive t h e veh icle a t n or m a l speeds du r in g t h e r oa d su r e pla t e.
t est . Sh ift t h e t r a n sm ission t h r ou gh a ll gea r r a n ges Nor m a l con den sa t ion in veh icles t h a t a r e st or ed or
a n d obser ve clu t ch a ct ion . ou t of ser vice for lon g per iods of t im e ca n gen er a t e
If ch a t t er, gr a b, slip, or im pr oper r elea se is exper i- en ou gh cor r osion t o m a ke t h e disc st ick t o t h e flywh eel,
en ced, r em ove a n d in spect t h e clu t ch com pon en t s. or pr essu r e pla t e. If t h is con dit ion is exper ien ced, cor-
H owever, if t h e pr oblem is n oise or h a r d sh ift in g, fu r- r ect ion on ly r equ ir es t h a t t h e disc be loosen ed m a n u -
t h er dia gn osis m a y be n eeded. Th e t r a n sm ission or a lly t h r ou gh t h e in spect ion pla t e open in g.
a n ot h er dr ivelin e com pon en t m a y a ct u a lly be a t E n ga gem en t pr oblem s u su a lly r esu lt in slip, ch a t -
fa u lt . Ca r efu l obser va t ion du r in g t h e t est will h elp t er /sh u dder, a n d n oisy oper a t ion . Th e pr im a r y ca u ses
n a r r ow t h e pr oblem a r ea . a r e clu t ch disc con t a m in a t ion ; clu t ch disc wea r ; m is-
a lign m en t , or dist or t ion ; flywh eel da m a ge; or a com -
CLUTCH CONTAMINATION bin a t ion of t h e for egoin g. A visu a l in spect ion is
F lu id con t a m in a t ion is a fr equ en t ca u se of clu t ch r equ ir ed t o det er m in e t h e pa r t a ct u a lly ca u sin g t h e
m a lfu n ct ion s. Oil, gr ea se, wa t er, or ot h er flu ids on pr oblem .
t h e clu t ch con t a ct su r fa ces will ca u se fa u lt y oper a -
t ion . Th e u su a l r esu lt is ch a t t er, slip a n d gr a b. CLUTCH RUNOUT
Du r in g in spect ion , n ot e if a n y com pon en t s a r e con -
t a m in a t ed. Look for eviden ce of oil, gr ea se, clu t ch CLU T CH DI SC
h ydr a u lic flu id, or wa t er /r oa d spla sh on clu t ch com - Ch eck t h e clu t ch disc befor e in st a lla t ion . Axia l
pon en t s. (fa ce) r u n ou t of a n ew disc sh ou ld n ot exceed 0.5 m m
Oil con t a m in a t ion in dica t es a lea k a t eit h er t h e (0.020 in .). Mea su r e r u n ou t a bou t 6 m m (1/4 in .) fr om
r ea r m a in sea l or t r a n sm ission in pu t sh a ft . Oil lea ks t h e ou t er edge of t h e disc fa cin g. Obt a in a n ot h er disc
pr odu ce a r esidu e of oil on t h e h ou sin g in t er ior a n d if r u n ou t is excessive.
on t h e clu t ch cover a n d flywh eel. H ea t bu ildu p
CLU T CH COV ER
ca u sed by slippa ge bet ween t h e clu t ch cover, disc,
Ch eck con dit ion of t h e clu t ch cover befor e in st a lla -
a n d flywh eel ca n som et im es ba ke t h e oil r esidu e on t o
t ion . A wa r ped cover or dia ph r a gm spr in g will ca u se
t h e com pon en t s. Th e gla ze-like r esidu e r a n ges in
gr a b a n d in com plet e r elea se or en ga gem en t . Be ca r e-
color fr om a m ber t o bla ck.
fu l wh en h a n dlin g t h e cover a n d disc. Im pa ct ca n dis-
Roa d spla sh con t a m in a t ion m ea n s dir t /wa t er is
t or t t h e cover, dia ph r a gm spr in g, r elea se fin ger s a n d
en t er in g t h e clu t ch h ou sin g. Th is m a y be du e t o loose
t h e h u b of t h e clu t ch disc.
bolt s, h ou sin g cr a cks, or t h r ou gh t h e sla ve cylin der
Use a n a lign m en t t ool wh en posit ion in g t h e disc on
open in g. Dr ivin g t h r ou gh deep wa t er pu ddles ca n
t h e flywh eel. Th e t ool pr even t s a cciden t a l m isa lign -
for ce wa t er /r oa d spla sh in t o t h e h ou sin g t h r ou gh
m en t wh ich cou ld r esu lt in cover dist or t ion a n d disc
su ch open in gs.
da m a ge.
Clu t ch flu id lea ks a r e fr om loose or da m a ged
A fr equ en t ca u se of clu t ch cover dist or t ion is
clu t ch lin ka ge flu id lin es or con n ect ion s. H owever,
im pr oper bolt t igh t en in g. To a void wa r pin g t h e cover,
m ost clu t ch flu id lea ks will u su a lly be n ot ed a n d cor-
t h e bolt s m u st be t igh t en ed in a dia gon a l pa t t er n a n d
r ect ed befor e sever e con t a m in a t ion occu r s.
on ly 2–3 t h r ea ds a t a t im e t o t h e specified t or qu e.
Gr ea se con t a m in a t ion is u su a lly a pr odu ct of exces-
sive lu br ica t ion du r in g clu t ch ser vice. Apply on ly a FLY WH EEL
sm a ll a m ou n t of gr ea se t o t h e in pu t sh a ft splin es, F lywh eel r u n ou t sh ou ld n ot exceed 0.08 m m (0.003
bea r in g r et a in er, pilot bea r in g, r elea se for k a n d pivot in .). Mea su r e r u n ou t a t t h e ou t er edge of t h e fly-
st u d. E xcess gr ea se ca n be t h r own off du r in g oper a - wh eel fa ce wit h a dia l in dica t or. Mou n t t h e in dica t or
t ion a n d con t a m in a t e t h e disc. on a st u d in st a lled in pla ce of on e of t h e flywh eel
bolt s.
IMPROPER CLUTCH RELEASE OR ENGAGEMENT Com m on ca u ses of r u n ou t a r e:
Clu t ch r elea se or en ga gem en t pr oblem s a r e ca u sed • h ea t wa r pa ge.
by wea r, or da m a ge t o on e or m or e clu t ch com po- • im pr oper m a ch in in g.
6-4 CLUTCH XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

9 Inspect release bearing slide surface of trans.


front bearing retainer. Surface should be smooth,
free of nicks, scores. Replace retainer if
necessary. Lubricate slide surface before
installing release bearing.
10 Do not replace release bearing unless actually
faulty. Replace bearing only if seized, noisy, or
damaged.
11 Check clutch cover diaphragm spring and release
fingers. Replace cover if spring or fingers are
bent, warped, broken, cracked. Do not tamper
with factory spring setting as clutch problems will
result.
12 Check condition of clutch cover. Replace clutch
cover if plate surface is deeply scored. warped,
worn, or cracked. Be sure cover is correct size
and properly aligned on disc and flywheel.
13 Inspect clutch housing. Be sure bolts are tight.
Replace housing if damaged.
14 Verify that housing alignment dowels are in
position before installing housing.
15 Clean engine block surface before installing
clutch housing. Dirt, grime can produce
misalignment.
1 Check clutch housing bolts. Tighten if loose. Be
sure housing is fully seated on engine block. 16 Make sure side of clutch disc marked “flywheel
side” is toward flywheel.
2 Check flywheel. Scuff sand face to remove glaze.
Clean surface with wax and grease remover. 17 Check rear main seal if clutch disc and cover were
Replace flywheel if severely scored, worn or oil covered. Replace seal if necessary.
cracked. Secure flywheel with new bolts (if 18 Check crankshaft flange (if flywheel is removed).
removed). Do not reuse old bolts. Use Mopar Be sure flance is clean and flywheel bolt threads
Lock N’Seal on bolts. are in good condition.
3 Tighten clutch cover bolts 2-3 threads at a time, 19 Check pilot bearing. Replace bearing if damaged.
alternately and evenly (in a star pattern) to Lube with Mopar high temp. bearing grease
specified torque. Failure to do so could wrap the before installation.
cover.
20 Check transmission input shaft. Disc must slide
4 Check release fork. Replace fork if bent or worn. freely on shaft splines. Lightly grease splines
Make sure pivot and bearing contact surfaces are before installation. Replace shaft if splines or pilot
lubricated. bearing hub are damaged.
5 Check release fork pivot (in housing). Be sure 21 Check flywheel bolt torque. If bolts are loose,
pivot is suecure and ball end is lubricated. replace them. Use Mopar Lock N’Seal to secure
6 Transmission input shaft bearing will cause noise, new bolts.
chatter, or improper release if damaged. Check 22 Check clutch disc facing. Replace disc if facing is
condition before installing transmission. charred, scored, flaking off, or worn. Also check
7 Check slave cylinder. Replace it if leaking. Be runout of new disc. Runout should not exceed 0.5
sure cylinder is properly secured in housing and mm (0.02 in.).
cylinder piston is seated in release fork.
8 Check input shaft seal if clutch cover and disc J9506-2
were oil covered. Replace seal if worn, or cut.
Clutch Components
XJ CLUTCH 6-5
DI AGN OSI S AN D T EST I N G (Cont inue d)
• in cor r ect bolt t igh t en in g. SERV I CE PROCEDU RES
• im pr oper sea t in g on cr a n ksh a ft fla n ge sh ou lder.
• for eign m a t er ia l on cr a n ksh a ft fla n ge. CLUTCH COMPONENT LUBRICATION
F lywh eel m a ch in in g is n ot r ecom m en ded. Th e fly- P r oper clu t ch com pon en t lu br ica t ion is im por t a n t
wh eel clu t ch su r fa ce is m a ch in ed t o a u n iqu e con t ou r t o sa t isfa ct or y oper a t ion . Usin g t h e cor r ect lu br ica n t
a n d m a ch in in g will n ega t e t h is fea t u r e. H owever, a n d n ot over lu br ica t in g a r e equ a lly im por t a n t . Apply
m in or flywh eel scor in g ca n be clea n ed u p by h a n d r ecom m en ded lu br ica n t spa r in gly t o a void disc a n d
wit h 180 gr it em er y, or wit h su r fa ce gr in din g equ ip- pr essu r e pla t e con t a m in a t ion .
m en t . Rem ove on ly en ou gh m a t er ia l t o r edu ce scor- Clu t ch a n d t r a n sm ission com pon en t s r equ ir in g
in g (a ppr oxim a t ely 0.001 - 0.003 in .). H ea vy st ock lu br ica t ion a r e:
r em ova l is n o t re c o m m e n d e d . Repla ce t h e flywh eel • P ilot bea r in g.
if scor in g is sever e a n d deeper t h a n 0.076 m m (0.003 • Relea se lever pivot ba ll st u d.
in .). E xcessive st ock r em ova l ca n r esu lt in flywh eel • Relea se lever con t a ct su r fa ces.
cr a ckin g or wa r pa ge a ft er in st a lla t ion ; it ca n a lso • Relea se bea r in g bor e.
wea ken t h e flywh eel a n d in t er fer e wit h pr oper clu t ch • Clu t ch disc h u b splin es.
r elea se. • Clu t ch peda l pivot sh a ft bor e.
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 • Clu t ch peda l bu sh in gs.
flywh eel. Dir t a n d gr ea se on t h e fla n ge su r fa ce m a y • In pu t sh a ft splin es.
cock t h e flywh eel ca u sin g excessive r u n ou t . Use n ew • In pu t sh a ft pilot h u b.
bolt s wh en r em ou n t in g a flywh eel a n d secu r e t h e • Tr a n sm ission fr on t bea r in g r et a in er slide su r-
bolt s wit h Mopa r t Lock An d Sea l. Tigh t en flywh eel fa ce.
bolt s t o specified t or qu e on ly. Over t igh t en in g ca n dis-
t or t t h e flywh eel h u b ca u sin g r u n ou t . NOTE: Never apply grease to any part of the clutch
cover, or disc.
MISALIGNMENT
Clu t ch h ou sin g a lign m en t is im por t a n t t o pr oper
clu t ch oper a t ion . Th e h ou sin g m a in t a in s a lign m en t RECOM M EN DED LU BRI CAN T S
bet ween t h e cr a n ksh a ft a n d t r a n sm ission in pu t Use Mopa r t m u lt i-pu r pose gr ea se for t h e clu t ch
sh a ft . Misa lign m en t ca n ca u se clu t ch n oise, h a r d peda l bu sh in gs a n d pivot sh a ft . Use Mopa r t h igh
sh ift in g, in com plet e r elea se a n d ch a t t er. It ca n a lso t em per a t u r e gr ea se (or equ iva len t ) for a ll ot h er lu br i-
r esu lt in pr em a t u r e wea r of t h e pilot bea r in g, cover ca t ion r equ ir em en t s. Apply r ecom m en ded a m ou n t s
r elea se fin ger s a n d clu t ch disc. In sever e ca ses, m is- a n d do n ot over lu br ica t e.
a lign m en t ca n a lso ca u se pr em a t u r e wea r of t h e
t r a n sm ission in pu t sh a ft a n d fr on t bea r in g. CLUTCH LINKAGE FLUID
H ou sin g m isa lign m en t is gen er a lly ca u sed by Th e in t egr a l clu t ch m a st er cylin der r eser voir, sla ve
in cor r ect sea t in g on t h e en gin e or t r a n sm ission , loose cylin der a n d flu id lin es a r e pr e-filled wit h flu id pr ior
h ou sin g bolt s, m issin g a lign m en t dowels, or h ou sin g t o a ssem bly oper a t ion s.
da m a ge. Tigh t en a ll t h e clu t ch h ou sin g bolt s t o Th e h ydr a u lic syst em sh ou ld n ot r equ ir e a ddit ion a l
pr oper t or qu e befor e in st a llin g a n y st r u t s. Also be 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-
su r e a lign m en t dowels a r e in pla ce a n d sea t ed in t h e 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
block a n d h ou sin g befor e bolt t igh t en in g. In fr e- 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-
qu en t ly, m isa lign m en t m a y a lso be ca u sed by h ou sin g 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
m ou n t in g su r fa ces t h a t a r e n ot com plet ely pa r a llel. th e re s e rv o ir. Th is w ill c a u s e c lu tc h re le a s e
Misa lign m en t ca n be cor r ect ed wit h sh im s. p ro ble m s .
If in spect ion or dia gn osis in dica t es a ddit ion a l flu id
DIAGNOSTIC CHARTS m a y be n eeded, u se Mopa r t br a ke flu id, or a n equ iv-
Th e dia gn osis ch a r t s descr ibe com m on clu t ch pr ob- a len t m eet in g st a n da r ds SAE J 1703 a n d DOT 3. Do
lem s, ca u ses a n d cor r ect ion . F a u lt con dit ion s a r e n ot u se a n y ot h er t ype of flu id.
list ed a t t h e t op of ea ch ch a r t . Con dit ion s, ca u ses a n d
cor r ect ive a ct ion a r e ou t lin ed in t h e in dica t ed col-
u m n s.
6-6 CLUTCH XJ
SERV I CE PROCEDU RES (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


DISC FACING WORN OUT 1. Normal wear. Driver frequently 1. Replace clutch disc. Also replace
rides (slips) clutch. Results in rapid cover if spring is weak or pressure
war overheating. Insufficient clutch plate surface is damaged.
cover diaphragm spring tension.
CLUTCH DISC FACING 1. Leak at rear main seal or at 1. Replace leaking seals. Apply less
CONTAMINATED WITH OIL, transmission input shaft seal. grease to input shaft splines.
GREASE, OR CLUTCH FLUID Excessive amount of grease Replace clutch disc (do not clean
applied to input shaft splines. Road and reuse). Clean clutch cover
splash, water entering housing. and reuse only if cover is in good
Slave cylinder leaking. condition. Replace slave cylinder if
leaking.
CLUTCH IS RUNNING PARTIALLY 1. Release bearing sticking-binding. 1. Verify that bearing is actually
DISENGAGED Does not return to normal running binding, the replace bearing and
position. transmission front bearing retainer
if sleeve surface is damaged.
FLYWHEEL HEIGHT INCORRECT 1. Flywheel surface improperly 1. Replace flywheel.
machined. Too much stock
removed or surface is tapered.
WRONG DISC OR PRESSURE 1. Incorrect parts order or model 1. Replace with correct parts.
PLATE INSTALLED number. Compare old and new parts before
installation.
CLUTCH DISC, COVER AND/OR 1. Rough handling (impact) bent 1. Install new disc or cover as
DIAPHRAGM SPRING, SARPED, cover, spring, or disc. Incorrect bolt needed. Follow installation/
DISTORTED tightening sequence and method tightening instructions.
caused warped cover.
FACING ON FLYWHEEL SIDE OF 1. Flywheel surface scored and 1. Reduce scores and nicks by
DISC TORN, GOUGED, WORN nicked. sanding or surface grinding.
Replace flywheel if scores-nicks
are deeper than .002-.004 inch.
CLUTCH DISC FACING BURN 1. Frequent operation under high 1. Scuff sand flywheel. Replace
(CHARRED). FLYWHEEL AND loads or hard acceleration clutch cover and disc. Alert driver
COVER PRESSURE PLATE conditions. Driver frequently rides to problem cause.
SURFACES HEAVILY GLAZED (slips) clutch. Results in rapid wear
and overheating of disc and cover.
XJ CLUTCH 6-7
SERV I CE PROCEDU RES (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


CLUTCH DISC WARPED 1. New disc not checked for axial 1. Replace disc. Be sure runout of
runout before installation. new disc is less than .5 mm (.020
in.).
CLUTCH DISC BINDS ON INPUT 1. Clutch disc hub splines damaged 1. Clean, smooth and lubricate disc
SHAFT SPLINES during installation. Input shaft and shaft splines. Replace disc
splines rough, damaged. and/or input shaft if splines are
Corrosion, rust formations on severely damaged.
splines of disc and input shaft.
CLUTCH DISC RUSTED TO 1. Occurs in vehicles stored, or not 1. Remove clutch cover and disc.
FLYWHEEL AND/OR PRESSURE driven for extended periods of Sand rusted surfaces clean with
PLATE time. Also occurs after steam 180 grit paper. Replace disc cover,
cleaning if vehicle is not used for and flywheel if corrosion is severe.
extended period.
CLUTCH DISC FACING STICKS TO 1. Vacuum may form in pockets over 1. Drill 1/16 inch diameter hole
FLYWHEEL rivet heads in clutch disc. Occurs through rivets and scuff sand disc
as clutch cools down after use. facing with 180 grit paper.
CLUTCH DISC TOO THICK 1. Wrong disc installed. 1. Replace disc.
PILOT BEARING SEIZED, LOOSE, 1. Bearing cocked during installation. 1. Lubricate and install new bearing.
OR ROLLERS ARE WORN Bearing defective. Bearing not Check and correct any
lubricated. Clutch misalignment. misalignment.
CLUTCH WILL NOT DISENGAGE 1. Low clutch fluid level. 1. Top off reservoir and check for
PROPERLY leaks.
2. Clutch cover loose. 2. Tighten bolts.
5. Clutch cover diaphragm spring 5. Replace cover.
bent or warped during transmission
installation.
6. Clutch disc installed backwards. 6. Remove and reinstall disc
correctly. Be sure disc side
marked “to flywheel” is actually
toward flywheel.
7. Release fork bent or fork pivot is 7. Replace fork and pivot if worn or
loose or damaged. damaged.
8. Clutch master or slave cylinder 8. Replace master and slave cylinder
fault. as assembly.
6-8 CLUTCH XJ
SERV I CE PROCEDU RES (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


CLUTCH DISC FACING COVERED 1. Oil leak at rear main or input shaft 1. Correct leak and replace disc (do
WITH OIL, GREASE, OR CLUTCH seal. not clean and reuse the disc).
FLUID
2. Too much grease applied to 2. Apply lighter grease coating to
splines or disc and input shaft. splines and replace disc (do not
clean and reuse the disc).
CLUTCH DISC AND/OR COVER 1. Incorrect or substandard parts. 1. Replace disc and/or cover with
WARPED, OR DISC FACINGS correct parts.
EXHIBIT UNUSUAL WRONG TYPE
CLUTCH MASTER OR SLAVE 1. Master or slave cylinder 1. Replace both cylinders as
CYLINDER PLUNGER DRAGGING- components worn or corroded. assembly (and reservoir).
BINDING
NO FAULT FOUND WITH CLUTCH 1. Problem actually related to 1. Further diagnosis required. Check
COMPONENTS suspension or driveline component. engine/transmission mounts,
propeller shafts and U-joints, tires,
suspension attaching parts and
other driveline components as
needed.
2. Engine related problem. 2. Check EFI and ignition systems.
PARTIAL ENGAGEMENT OF 1. Clutch pressure plate position 1. Replace clutch cover and disc.
CLUTCH DISC (ONE SIDE setting incorrect or modified.
WORN-OPPOSITE SIDE GLAZED 2. Clutch cover, spring, or release 2. Replace clutch cover and disc.
AND LIGHTLY WORN) fingers bent, distorted (rough
handling, improper assembly).
3. Clutch disc damaged or distorted. 3. Replace disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, or cover and/or
clutch housing. Correct as
necessary.
XJ CLUTCH 6-9
SERV I CE PROCEDU RES (Cont inue d)

CONDITION POSSIBLE CAUSE CORRECTION


Clutch components damaged or worn 1. Incorrect or sub-standard clutch 1. Replace with parts of correct type
out prematurely. parts. and quality.
Pilot bearing damaged. 1. Bearing cocked during installation. 1. Replace bearing. Be sure it is
Bearing not lubricated prior to properly seated and lubricated
installation. Bearing defect. before installing clutch.
2. Clutch misalignment. 2. Check and correct misalignment
caused by excessive runout of
flywheel, disc, cover or clutch
housing. Replace input shaft if
bearing hub is damaged.
Loose components. 1. Attaching bolts loose at flywheel, 1. Tighten bolts to specified torque.
cover, or clutch housing. Replace any clutch bolts that are
damaged.
Components appear overheated. 1. Frequent high load, full throttle 1. Replace parts as needed. Alert
Hub of disc cracked or torsion operation. driver to condition causes.
damper springs are distorted or
broken.
Contact surface of release bearing 1. Clutch cover incorrect, or release 1. Replace clutch cover and bearing.
damaged. fingers are bent or distorted
causing damage.
2. Release bearing defect. 2. Replace bearing.
3. Release bearing misaligned. 3. Check and correct runout of clutch
components. Check front bearing
retainer sleeve surface. Replace if
damaged.
Release bearing is noisy. 1. Release bearing defect. 1. Replace bearing.
Clutch pedal squeak. 1. Pivot pin loose. Pedal bushings 1. Tighten pivot pin. Replace
worn out or cracked. bushings if worn or damaged.
Lubricate pin and bushings with
silicone base lubricator chassis
grease.
CLUTCH
CYLINDER
CLUTCH MASTER
MASTER
RESER-
VOIR
RESERVOIR
RESERVOIR
CYLINDER CAP FLUIDFLUID
LEVEL
LINE
TORINDICA-
RING

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.

CAUTION: Do not use an oxy/acetylene torch to


remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace- J9506-19
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the Fig. 3 Typical Method Of Marking Clutch Cover
gear teeth resulting in rapid wear and damage after Position
installation. (4) Rem ove cover bolt s a n d r em ove cover a n d disc
(F ig. 4).
(5) Th e h ea t ed gea r m u st be in st a lled even ly t o
a void m isa lign m en t or dist or t ion . A sh op pr ess a n d I N STALLAT I ON
su it a ble pr ess pla t es sh ou ld be u sed t o in st a ll t h e (1) Ligh t ly scu ff sa n d flywh eel fa ce wit h 180 gr it
gea r if a t a ll possible. em er y clot h . Th en clea n su r fa ce wit h a wa x a n d
(6) Be su r e t o wea r eye a n d h a n d pr ot ect ion . H ea t gr ea se r em over.
r esist en t gloves a n d sa fet y goggles a r e n eeded for (2) Lu br ica t e pilot bea r in g wit h Mopa r t h igh t em -
per son a l sa fet y. Also u se m et a l t on gs, vise gr ips, or per a t u r e bea r in g gr ea se.
sim ila r t ools t o posit ion t h e gea r a s n ecessa r y for (3) Ch eck n ew clu t ch for r u n ou t a n d fr ee oper a t ion
in st a lla t ion . on in pu t sh a ft splin es.
(7) Allow t h e flywh eel a n d r in g gea r t o cool down (4) P osit ion clu t ch disc on flywh eel. Be su r e side of
befor e in st a lla t ion . Set t h e a ssem bly on a wor kben ch disc m a r ked flywh eel side is posit ion ed a ga in st fly-
a n d let it cool in n or m a l sh op a ir. wh eel (F ig. 4). If disc is n ot m a r ked, be su r e fla t side
of disc h u b is t owa r d flywh eel.
CAUTION: Do not use water, or compressed air to
(5) In spect con dit ion of pr essu r e pla t e su r fa ce of
cool the flywheel. The rapid cooling produced by
clu t ch cover (F ig. 4). Repla ce cover if t h is su r fa ce is
water or compressed air can distort, or crack the
wor n , h ea t ch ecked, cr a cked, or scor ed.
gear and flywheel.
(6) In ser t clu t ch a lign m en t t ool in clu t ch disc (F ig.
5).
(7) In ser t a lign m en t t ool in pilot bea r in g a n d posi-
REM OVAL AN D I N STALLAT I ON t ion disc on flywh eel. Be su r e disc h u b is posit ion ed
cor r ect ly. Side of h u b m a r ked F lywh eel Side sh ou ld
CLUTCH COVER AND DISC fa ce flywh eel (F ig. 4). If disc is n ot m a r ked, pla ce fla t
side of disc a ga in st flywh eel.
REM OVAL (8) P osit ion clu t ch cover over disc a n d on flywh eel
(1) Rem ove t r a n sm ission . Refer t o Gr ou p 21, (F ig. 5).
Tr a n sm ission a n d Tr a n sfer Ca se, for pr oper pr oce- (9) In st a ll clu t ch cover bolt s fin ger t igh t .
du r es. (10) Tigh t en cover bolt s even ly a n d in r ot a t ion a
(2) If or igin a l clu t ch cover will be r ein st a lled, m a r k few t h r ea ds a t a t im e. Cover bolt s m u st be t igh t en ed
posit ion of cover on flywh eel for a ssem bly r efer en ce even ly a n d t o specified t or qu e t o a void dist or t in g
(F ig. 3). Use pa in t or a scr iber for t h is pu r pose. cover. Tigh t en in g t or qu es a r e 31 N·m (23 ft . lbs.) on
(3) Loosen cover bolt s even ly a n d in r ot a t ion t o 2.5L en gin es a n d 54 N·m (40 ft . lbs.) on 4.0L en gin es.
r elieve spr in g t en sion equ a lly. Th is is n ecessa r y t o
a void wa r pin g cover.
DISC “FLYWHEEL
STAMPED
INSPECT
ON
SURFACE
THIS
THIS
SIDE”
FACE
SUR- CLUTCH
CLUTCH
HOUSING
COVER ENGINE
FLYWHEEL
(4.0L) BRACKET
TRANSFER CASE TUBE
VENT CLUTCH
CLUTCH DISC
COVER
TORQUE
ALIGNMENT
AND TOOL
DISC
ITEM

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.

ENGINE (4.0L) ITEM TORQUE


A 50-64 N•m (37-47 ft. lbs.)
B 41-61 N•m (30-45 ft. lbs.)
C 30-41 N•m (22-30 ft. lbs.)
D 7-9 N•m (5-7 ft. lbs.)
TRANSFER
CASE

BRACKET
J9506-4

Fig. 6 Manual Transmission Mounting—4.0L


HOUSING
BOLTS
TRANSMISSION
(38 N·m/28
ft.—TO-
lbs.) CLUTCH
HOUSINGFWD ENGINE
TRANSMISSION
(2.5L)
COVER BRACKETPIVOT 23RELEASE
N·m
CLUTCH
IN. LBS.)
(200
HOUSING
SPRING
BEARING
CONED
SLEEVE
WASHER
AND RELEASE CLUTCH
FORK
TORQUE
HOUSING
ITEM

XJ CLUTCH 6 - 13
REM OVAL AN D I N STALLAT I ON (Cont inue d)

CLUTCH
HOUSING

J9506-5

Fig. 7 Manual Transmission Mounting—2.5L


bea r in g r et a in er slide su r fa ce wit h ligh t coa t of sa m e
gr ea se.
(5) In st a ll r elea se for k, bea r in g, a n d boot in h ou s-
in g. Be su r e r elea se for k boot is pr oper ly sea t ed in
h ou sin g.
(6) 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.

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

Fig. 8 Clutch Housing Attachment


(4) Lu br ica t e r elea se bea r in g bor e, r elea se for k
con t a ct su r fa ces, a n d r elea se for k pivot st u d wit h RELEASE RN1232
FORK
Mopa r t h igh t em per a t u r e bea r in g gr ea se. Also lu br i-
ca t e t r a n sm ission in pu t sh a ft splin es, pilot h u b a n d Fig. 9 Release Bearing And Release Fork Mounting
KEEP INSTALLATION
ING BEARINGMUST
BEARING
PILOT
ALIGNMENT
STRAIGHT
TRANSMISSION
BEARING
TODAMAGE
AVOID
FACE
SEAL
DUR-
TOOL

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)

Fig. 11 Slave Cylinder Attachment


Fig. 13 Clutch Master Cylinder Location—Right
Hand Drive Models
(11) Con n ect clu t ch peda l posit ion swit ch wir es.

SPECI FI CAT I ON S
TORQUE

D ES CRIP TION TORQU E


Bolt s, clu t ch cover 2.5 L . . . . . . . 31 N·m (23 ft . lbs)
Bolt s, clu t ch cover 4.0 L . . . . . . . 52 N·m (38 ft . lbs)
Bolt /Nu t , clu t ch cyl. m ou n t . . . . 23 N·m (200 in . lbs)
Fig. 12 Clutch Master Cylinder And Push Rod Bolt , clu t ch h ou sin g M12 . . . . . . . 75 N·m (55 ft . lbs)
Attachment—Left Hand Drive Models Bolt , clu t ch h ou sin g 3/8 . . . . . . . . 37 N·m (27 ft . lbs)
Bolt , clu t ch h ou sin g 7/16 . . . . . . . 58 N·m (43 ft . lbs)
Bolt , clu t ch h ou sin g/t r a n s. . . . . . . 38 N·m (28 ft . lbs)
Bolt , du st sh ield M8 . . . . . . . . . . . 8 N·m (72 in . lbs)
(5) In st a ll a n d t igh t en clu t ch m a st er cylin der Bolt , du st sh ield lower . . . . . . . . . 50 N·m (37 ft . lbs)
a t t a ch in g n u t s t o 23-34 N·m (200-300 in . lbs.) t or qu e. Bolt , X-m em ber /fr a m e . . . . . . . . . 41 N·m (30 ft . lbs)
(6) Ra ise veh icle. Bolt , X-m em ber /r ea r su ppor t . . . 45 N·m (33 ft . lbs.)
(7) In ser t sla ve cylin der pu sh r od t h r ou gh clu t ch Bolt s, flywh eel 4.0 L . . . . . . . . 142 N·m (105 ft . lbs)
h ou sin g open in g a n d in t o r elea se lever. Be su r e ca p Bolt s, flywh eel 2.5 L . . 68 N·m (50 ft . lbs) +1/4 t u r n
on en d of r od is secu r ely en ga ged in lever. Ch eck t h is Bolt , st a r t er m ot or . . . . . . . . . . . . 45 N·m (33 ft . lbs)
befor e in st a llin g cylin der a t t a ch in g n u t s.
Bolt s, U-join t s . . . . . . . . . . . . . 19 N·m (170 in . lbs.)
(8) In st a ll a n d t igh t en sla ve cylin der a t t a ch in g
n u t s t o 23-34 N·m (200-300 in . lbs.) t or qu e.
(9) Secu r e clu t ch flu id lin e in body clips.
(10) Lower veh icle.
XJ COOLING SYSTEM 7-1

COOLING SYSTEM
CON T EN T S

page page

GENERAL INFORMATION RADIATOR COOLANT FLOW CHECK . . . . . . . 19


ACCESSORY DRIVE BELT TENSION . . . . . . . . . 3 TESTING COOLING SYSTEM FOR LEAKS . . . 19
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . 20
COOLING SYSTEM COMPONENTS . . . . . . . . . . 2 SERVICE PROCEDURES
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 ADDING ADDITIONAL COOLANT—ROUTINE . . 22
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . 1 COOLANT LEVEL CHECK—ROUTINE . . . . . . . 22
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 3 COOLANT LEVEL CHECK—SERVICE . . . . . . . 22
RADIATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COOLANT SERVICE . . . . . . . . . . . . . . . . . . . . 22
SYSTEM COOLANT ROUTING . . . . . . . . . . . . . 2 DRAINING AND FILLING COOLING SYSTEM . . 23
WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . 2 REVERSE FLUSHING . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
ACCESSORY DRIVE BELT TENSION . . . . . . . . . 4 AUXILIARY ELECTRIC COOLING FAN . . . . . . . 34
AUTOMATIC TRANSMISSION OIL COOLER . . . 3 COOLANT RESERVE TANK . . . . . . . . . . . . . . . 25
AUXILIARY ELECTRIC COOLING FAN . . . . . . . . 8 COOLING SYSTEM FANS . . . . . . . . . . . . . . . . 37
COOLANT PERFORMANCE . . . . . . . . . . . . . . . . 5 ENGINE ACCESSORY DRIVE BELTS . . . . . . . . 34
COOLANT RESERVE/OVERFLOW SYSTEM . . . 3 ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . 34
COOLANT SELECTION-ADDITIVES . . . . . . . . . . 5 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
COOLING SYSTEM FANS . . . . . . . . . . . . . . . . . 4 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 29
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . 6 TRANSMISSION OIL COOLERS . . . . . . . . . . . . 24
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 4 VISCOUS FAN DRIVE REMOVAL/
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 38
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 25
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . 7 CLEANING AND INSPECTION
WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . 6 COOLING SYSTEM CLEANING . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING COOLING SYSTEM HOSES . . . . . . . . . . . . . . . 38
AUXILIARY ELECTRIC COOLING FAN . . . . . . . 21 FAN BLADE INSPECTION . . . . . . . . . . . . . . . . 38
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . 12 RADIATOR CLEANING . . . . . . . . . . . . . . . . . . . 38
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 RADIATOR PRESSURE CAP . . . . . . . . . . . . . . 38
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIFICATIONS
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . 9 BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . 38
LOW COOLANT LEVEL-AERATION . . . . . . . . . 22 COOLING SYSTEM CAPACITIES . . . . . . . . . . . 38
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . 8 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 39
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . 10 SPECIAL TOOLS
PRESSURE TESTING RADIATOR CAPS . . . . . 22 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
RADIATOR CAP-TO-FILLER NECK SEAL—
PRESSURE RELIEF CHECK . . . . . . . . . . . . . 21

GEN ERAL I N FORM AT I ON COOLING SYSTEM


Th e coolin g syst em r egu la t es en gin e oper a t in g t em -
ENGINE ACCESSORY DRIVE BELTS per a t u r e. It a llows t h e en gin e t o r ea ch n or m a l oper-
a t in g t em per a t u r e a s qu ickly a s possible, m a in t a in s
CAUTION: When installing a serpentine accessory n or m a l oper a t in g t em per a t u r e a n d pr even t s over-
drive belt, the belt MUST be routed correctly. If not, h ea t in g.
the engine may overheat due to water pump rotat- Th e coolin g syst em a lso pr ovides a m ea n s of h ea t -
ing in wrong direction. Refer to the appropriate in g t h e pa ssen ger com pa r t m en t a n d coolin g t h e a u t o-
engine Belt Schematic in this group for the correct m a t ic t r a n sm ission flu id (if equ ipped). Th e coolin g
belt routing. Or, refer to the Belt Routing Label syst em is pr essu r ized a n d u ses a cen t r ifu ga l wa t er
located in the engine compartment. pu m p t o cir cu la t e coola n t t h r ou gh ou t t h e syst em .
HEATER CORE RADIATOR
TO WATER
RADIATOR
UPPER
PUMPHOSE WATER PUMP TO
PULLEY
COOLANT RECOVERY
BOTTLE RADIATOR LOWER
HOSE

7-2 COOLING SYSTEM XJ


GEN ERAL I N FORM AT I ON (Cont inue d)
An opt ion a l fa ct or y in st a lled h ea vy du t y coolin g WATER PUMPS
pa cka ge is a va ila ble on m ost m odels. Th e pa cka ge A qu ick t est t o det er m in e if t h e pu m p is wor kin g is
con sist s of a r a dia t or t h a t h a s a n in cr ea sed n u m ber t o ch eck if t h e h ea t er wa r m s pr oper ly. A defect ive
of coolin g fin s. Veh icles equ ipped wit h a 4.0L 6- cyl- wa t er pu m p will n ot be a ble t o cir cu la t e h ea t ed cool-
in der en gin e a n d h ea vy du t y coolin g a n d/or a ir con - 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.
dit ion in g a lso h a ve a n a u xilia r y elect r ic coolin g fa n .
COOLANT
COOLING SYSTEM COMPONENTS Th e coolin g syst em is design ed a r ou n d t h e coola n t .
Th e coolin g syst em con sist s of: Coola n t flows t h r ou gh t h e en gin e wa t er ja cket s
• A r a dia t or a bsor bin g h ea t pr odu ced du r in g en gin e oper a t ion .
• Coolin g fa n (m ech a n ica l a n d/or elect r ica l) Th e coola n t ca r r ies h ea t t o t h e r a dia t or a n d h ea t er
• Th er m a l viscou s fa n dr ive cor e. H er e it is t r a n sfer r ed t o t h e a m bien t a ir pa ss-
• F a n sh r ou d in g t h r ou gh t h e r a dia t or a n d h ea t er cor e fin s. Th e
• Ra dia t or pr essu r e ca p coola n t a lso r em oves h ea t fr om t h e a u t om a t ic t r a n s-
• Th er m ost a t m ission flu id in veh icles equ ipped wit h a n a u t om a t ic
• Coola n t r eser ve/over flow syst em t r a n sm ission .
• Tr a n sm ission oil cooler (if equ ipped wit h a n
a u t om a t ic t r a n sm ission ) RADIATORS
• Coola n t 2.5L 4–cylin der en gin e r a dia t or s a r e t h e down flow
• Wa t er pu m p t ype, 4.0L 6-cylin der en gin e r a dia t or s a r e t h e cr oss
• H oses a n d h ose cla m ps flow t ype. P la st ic t a n ks a r e u sed on a ll r a dia t or s.

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

Fig. 1 Coolant Flow—2.5L 4-Cylinder Engine—Typical


TO COOLANT
HEATER
OVERFLOW
CORE
RADIATORWATER
RESERVE/
TANK
THERMOSTAT
HOUSING
PUMP

XJ COOLING SYSTEM 7-3


GEN ERAL I N FORM AT I ON (Cont inue d)
ENGINE BLOCK HEATER
An opt ion a l en gin e block h ea t er is a va ila ble for a ll
m odels. Th e h ea t er is equ ipped wit h a power cor d.
Th e cor d is a t t a ch ed t o a n en gin e com pa r t m en t com -
pon en t wit h t ie-st r a ps. Th e h ea t er wa r m s t h e en gin e
pr ovidin g ea sier en gin e st a r t in g a n d fa st er wa r m -u p
in low t em per a t u r es. Th e h ea t er is m ou n t ed in a cor e
h ole of t h e en gin e cylin der block (in pla ce of a fr eeze
TO COOLANT plu g) wit h t h e h ea t in g elem en t im m er sed in en gin e
RESERVE/OVERFLOW coola n t . Con n ect t h e power cor d t o a gr ou n ded 110-
TANK
120 volt AC elect r ica l ou t let wit h a gr ou n ded, t h r ee-

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

7-4 COOLING SYSTEM XJ


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
As t h e en gin e cools, a va cu u m is for m ed in t h e COOlANT
coolin g syst em of bot h t h e r a dia t or a n d en gin e. Cool- RESERVE/OVERFLOW
a n t will t h en be dr a wn fr om t h e coola n t t a n k a n d TANK
r et u r n ed t o a pr oper level in t h e r a dia t or.
Th e coola n t r eser ve/over flow syst em con sist s of a
r a dia t or m ou n t ed pr essu r ized ca p, a pla st ic r eser ve/ MOUNTING
BOLTS
over flow t a n k (F ig. 3) (F ig. 4), a t u be (h ose) con n ect -
in g t h e r a dia t or a n d t a n k, a n d a n over flow t u be on
t h e side of t h e t a n k.
COOLANT
RESERVE/OVERFLOW
TANK

TUBE TO
RADIATOR

Fig. 4 Reserve/Overflow Tank—With Right Hand


Drive
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 a n y-
t h in g bu t t h e belt .

ENGINE BLOCK HEATER


An opt ion a l en gin e block h ea t er is a va ila ble for a ll
J9407-26 m odels. Th e h ea t er is equ ipped wit h a power cor d.
Th e cor d is a t t a ch ed t o a n en gin e com pa r t m en t com -
Fig. 3 Reserve/Overflow Tank—Except Right Hand pon en t wit h t ie-st r a ps. Th e h ea t er wa r m s t h e en gin e
Drive pr ovidin g ea sier en gin e st a r t in g a n d fa st er wa r m -u p
in low t em per a t u r es. Th e h ea t er is m ou n t ed in a cor e
COOLING SYSTEM FANS h ole of t h e en gin e cylin der block (in pla ce of a fr eeze
Also r efer t o eit h er t h e Viscou s F a n Dr ive a n d/or
plu g) wit h t h e h ea t in g elem en t im m er sed in en gin e
t h e Au xilia r y E lect r ic Coolin g F a n .
coola n t . Con n ect t h e power cor d t o a gr ou n ded 110-
All m odels a r e equ ipped wit h a m ech a n ica l t em per-
120 volt AC elect r ica l ou t let wit h a gr ou n ded, t h r ee-
a t u r e con t r olled fa n . Th is t h er m a l viscou s fa n dr ive
wir e ext en sion cor d.
is a t or qu e-a n d-t em per a t u r e-sen sit ive clu t ch u n it . It
a u t om a t ica lly in cr ea ses or decr ea ses fa n speed t o WARNING: DO NOT OPERATE ENGINE UNLESS
pr ovide pr oper en gin e coolin g. Veh icles wit h a 4.0L BLOCK HEATER CORD HAS BEEN DISCONNECTED
6-cylin der en gin e m a y a lso h a ve a n a u xilia r y elect r i- FROM POWER SOURCE AND SECURED IN PLACE.
ca l coolin g fa n ; wh en equ ipped a ir con dit ion in g
a n d/or h ea vy du t y coolin g. BLOCK H E ATE R SP E CIF ICATIONS
• 2.5L 4-Cylin der E n gin e: 115 Volt s 400 Wa t t s
ACCESSORY DRIVE BELT TENSION • 4.0L 6-Cylin der E n gin e: 120 Volt s 600 Wa t t s
Bot h t h e 2.5l a n d 4.0l en gin es u se on e a ccessor y
dr ive belt . Cor r ect dr ive belt t en sion is r equ ir ed t o THERMOSTAT
en su r e opt im u m per for m a n ce of t h e belt dr iven A pellet -t ype t h er m ost a t con t r ols t h e oper a t in g
en gin e a ccessor ies. Th er e a r e differ en t t ypes of t em per a t u r e of t h e en gin e by con t r ollin g t h e a m ou n t
a dju st m en t ga u ges for ch eckin g eit h er a ser pen t in e of coola n t flow t o t h e r a dia t or. On a ll en gin es t h e
or a con ven t ion a l “V-t ype” belt . Refer t o t h e in st r u c- t h er m ost a t is closed below 195°F (90°C). Above t h is
t ion s su pplied wit h t h e ga u ge. Ma ke su r e t o u se a t em per a t u r e, coola n t is a llowed t o flow t o t h e r a dia -
ga u ge design ed specifica lly for ser pen t in e st yle belt s. t or. Th is pr ovides qu ick en gin e wa r m -u p a n d over a ll
P la ce ga u ge in t h e m iddle of t h e sect ion of belt bein g t em per a t u r e con t r ol.
XJ COOLING SYSTEM 7-5
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
An a r r ow plu s t h e wor d U P is st a m ped on t h e a n d wa t er is -32 deg. C (-26 deg. F ). 5 deg. C h igh er
fr on t fla n ge n ext t o t h e a ir bleed. Th e wor ds TO t h a n et h ylen e-glycol’s fr eeze poin t . Th e boilin g poin t
RAD a r e st a m ped on on e a r m of t h e t h er m ost a t . (pr ot ect ion a ga in st su m m er boil-over ) of pr opylen e-
Th ey in dica t e t h e pr oper in st a lled posit ion . glycol is 125 deg. C (257 deg. F ) a t 96.5 kP a (14 psi),
Th e sa m e t h er m ost a t is u sed for win t er a n d su m - com pa r ed t o 128 deg. C (263 deg. F ) for et h ylen e-gly-
m er sea son s. An en gin e sh ou ld n ot be oper a t ed wit h - col. Use of pr opylen e-glycol ca n r esu lt in boil-over or
ou t a t h er m ost a t , except for ser vicin g or t est in g. fr eeze-u p in Ch r ysler veh icles, wh ich a r e design ed for
Oper a t in g wit h ou t a t h er m ost a t ca u ses ot h er pr ob- et h ylen e-glycol. P r opylen e glycol a lso h a s poor er h ea t
lem s. Th ese a r e: lon ger en gin e wa r m -u p t im e, u n r e- t r a n sfer ch a r a ct er ist ics t h a n et h ylen e glycol. Th is
lia ble wa r m -u p per for m a n ce, in cr ea sed exh a u st ca n in cr ea se cylin der h ea d t em per a t u r es u n der cer-
em ission s a n d cr a n kca se con den sa t ion . Th is con den - t a in con dit ion s.
sa t ion ca n r esu lt in slu dge for m a t ion .
Propylene-glycol/Ethylene-glycol Mixtures—Should Not Be
CAUTION: Do not operate an engine without a Used in Chrysler Vehicles
thermostat, except for servicing or testing. P r opylen e-glycol/et h ylen e-glycol Mixt u r es ca n
ca u se t h e dest a biliza t ion of va r iou s cor r osion in h ibi-
t or s, ca u sin g da m a ge t o t h e va r iou s coolin g syst em
COOLANT PERFORMANCE com pon en t s. Also, on ce et h ylen e-glycol a n d pr opy-
len e-glycol ba sed coola n t s a r e m ixed in t h e veh icle,
ET H Y LEN E-GLY COL M I X T U RES con ven t ion a l m et h ods of det er m in in g fr eeze poin t will
Th e r equ ir ed et h ylen e-glycol (a n t ifr eeze) a n d wa t er n ot be a ccu r a t e. Bot h t h e r efr a ct ive in dex a n d spe-
m ixt u r e depen ds u pon t h e clim a t e a n d veh icle oper- cific gr a vit y differ bet ween et h ylen e glycol a n d pr opy-
a t in g con dit ion s. Th e r ecom m en ded m ixt u r e of 50/50 len e glycol.
et h ylen e-glycol a n d wa t er will pr ovide pr ot ect ion
a ga in st fr eezin g t o -37 deg. C (-35 deg. F ). Th e a n t i- CAUTION: Richer antifreeze mixtures cannot be
fr eeze con cen t r a t ion m u s t a lw a y s be a m in im u m of measured with normal field equipment and can
44 per cen t , yea r-r ou n d in a ll clim a t es. If p e rc e n ta g e cause problems associated with 100 percent ethyl-
is lo w e r th a n 44 p e rc e n t, e n g in e p a rts m a y be ene-glycol.
e ro d e d by c a v ita tio n , a n d c o o lin g s y s te m c o m -
p o n e n ts m a y be s e v e re ly d a m a g e d by c o rro s io n .
Ma xim u m pr ot ect ion a ga in st fr eezin g is pr ovided COOLANT SELECTION-ADDITIVES
wit h a 68 per cen t a n t ifr eeze con cen t r a t ion , wh ich Coola n t sh ou ld be m a in t a in ed a t t h e specified level
pr even t s fr eezin g down t o -67.7 deg. C (-90 deg. F ). A wit h a m ixt u r e of et h ylen e glycol-ba sed a n t ifr eeze
h igh er per cen t a ge will fr eeze a t a wa r m er t em per a - a n d low m in er a l con t en t wa t er. On ly u se a n a n t i-
t u r e. Also, a h igh er per cen t a ge of a n t ifr eeze ca n fr eeze con t a in in g ALUGARD 340-2 y.
ca u se t h e en gin e t o over h ea t beca u se t h e specific
h ea t of a n t ifr eeze is lower t h a n t h a t of wa t er. CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
100 Percent Ethylene-Glycol—Should Not Be Used in
Chrysler Vehicles
Use of 100 per cen t et h ylen e-glycol will ca u se for- RADIATOR PRESSURE CAP
m a t ion of a ddit ive deposit s in t h e syst em , a s t h e cor- All r a dia t or s a r e equ ipped wit h a pr essu r e ca p.
r osion in h ibit ive a ddit ives in et h ylen e-glycol r equ ir e Th is ca p r elea ses pr essu r e a t som e poin t wit h in a
t h e pr esen ce of wa t er t o dissolve. Th e deposit s a ct a s r a n ge of 83-110 kP a (12-16 psi). Th e pr essu r e r elief
in su la t ion , ca u sin g t em per a t u r es t o r ise t o a s h igh a s poin t (in pou n ds) is en gr a ved on t op of t h e ca p (F ig.
149 deg. C (300) deg. F ). Th is t em per a t u r e is h ot 5).
en ou gh t o m elt pla st ic a n d soft en solder. Th e Th e coolin g syst em will oper a t e a t pr essu r es
in cr ea sed t em per a t u r e ca n r esu lt in en gin e det on a - sligh t ly a bove a t m osph er ic pr essu r e. Th is r esu lt s in a
t ion . In a ddit ion , 100 per cen t et h ylen e-glycol fr eezes h igh er coola n t boilin g poin t a llowin g in cr ea sed r a di-
a t 22 deg. C (-8 deg. F ). a t or coolin g ca pa cit y. Th e ca p con t a in s a spr in g-
loa ded pr essu r e r elief va lve t h a t open s wh en syst em
Propylene-glycol Formulations—Should Not Be Used in pr essu r e r ea ch es r elea se r a n ge of 83-110 kP a (12-16
Chrysler Vehicles psi).
P ro p y le n e -g ly c o l fo rm u la tio n s d o n o t m e e t A ven t va lve in t h e cen t er of ca p a llows a sm a ll
Ch ry s le r c o o la n t s p e c ific a tio n s . It ’s over a ll effec- coola n t flow t h r ou gh ca p wh en coola n t is below boil-
t ive t em per a t u r e r a n ge is sm a ller t h a n t h a t of et h yl- in g t em per a t u r e. Th e va lve is com plet ely closed wh en
en e-glycol. Th e fr eeze poin t of 50/50 pr opylen e-glycol boilin g poin t is r ea ch ed. As t h e coola n t cools, it con -
VACUUM VENT VALVE (SHOWN
CROSS-SECTIONAL
ING POSITION)
IN SEAL-
TOP VIEW
VIEWPRESSURE
PRESSURE
FILLER
RATING
NECK
VALVE
SEAL ROTATION DIRECTION
FRONT
VIEWED
VIEW
AS R STAMPED INTO IMPELLER
ROTATION DIRECTION
BACK
VIEWED
VIEW
AS

7-6 COOLING SYSTEM XJ


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)

TOP VIEW cous fan drive assembly. REVERSE is stamped or


imprinted on the cover of the viscous fan drive and
inner side of the fan. The letter R is stamped into
the back of the water pump impeller (Fig. 6).

FRONT VIEW BACK VIEW

ROTATION DWEIRE~TION ROTA~f~lJJl~TION


AS VIE

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.

CAUTION: All engines are equipped with a reverse


(counter-clockwise) rotating water pump and vis-
CLAMP NUMBER/
LETTER HOSE
TYPICAL
LOCA-
TENSION
TION CLAMP
HOSE
CONSTANT
TOOL
6094
CLAMP TYPICAL HOSE HOSECLAMP THERMOSTATIC
VISCOUS
SPRING
FAN DRIVE MOUNTING HUB

XJ COOLING SYSTEM 7-7


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
CAUTION: A number or letter is stamped into the Or din a r y wor m gea r t ype h ose cla m ps (wh en
tongue of constant tension clamps (Fig. 8). If equ ipped) ca n be r em oved wit h a st r a igh t scr ew-
replacement is necessary, use only an original dr iver or a h ex socket . To p re v e n t d a m a g e to
equipment clamp with matching number or letter. h o s e s o r c la m p s , th e h o s e c la m p s s h o u ld be
tig h te n e d to 4 N ·m (34 in . lbs .) to rqu e . D o n o t
o v e r tig h te n h o s e c la m p s .

VISCOUS FAN DRIVE


NOTE: Also refer to Cooling System Fans.

Th e t h er m a l viscou s fa n dr ive is a silicon e-flu id-


filled cou plin g u sed t o con n ect t h e fa n bla des t o
eit h er t h e en gin e or t h e wa t er pu m p sh a ft . Th e cou -
plin g a llows t h e fa n t o be dr iven in a n or m a l m a n n er.
Th is is don e a t low en gin e speeds wh ile lim it in g t h e
t op speed of t h e fa n t o a pr edet er m in ed m a xim u m
level a t h igh er en gin e speeds.
A t h er m ost a t ic bim et a llic spr in g coil is loca t ed on
J9207-36 t h e fr on t fa ce of t h e viscou s fa n dr ive u n it . A t ypica l
viscou s u n it is sh own in (F ig. 9). Th is spr in g coil
Fig. 7 Hose Clamp Tool—Typical r ea ct s t o t h e t em per a t u r e of t h e r a dia t or disch a r ge
TYPICAL a ir. It en ga ges t h e viscou s fa n dr ive for h igh er fa n
CONSTANT speed if t h e a ir t em per a t u r e fr om t h e r a dia t or r ises
TENSION HOSE
CLAMP
a bove a cer t a in poin t . Un t il a ddit ion a l en gin e coolin g
is n ecessa r y, t h e fa n will r em a in a t a r edu ced r pm
r ega r dless of en gin e speed.

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

7-8 COOLING SYSTEM XJ


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.

CAUTION: If the viscous fan drive is replaced


because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.

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.

NOT NORMAL CRACKS


REPLACE BELT J9007-4.4

Fig. 11 Serpentine Belt Wear Patterns

SERPEN T I N E BELT DI AGN OSI S CH ART

CONDITION POSSIBLE CAUSES CORRECTION


RIB CHUNKING (One or more ribs has 1. Foreign objects imbedded in pulley 1. Remove foreign objects from pulley
separated from belt body) grooves. grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
2. Abrasive environment 2. Clean pulley(s). Replace belt if
necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove tips 4. Replace pulley. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of insufficient 1. Adjust tension
tension
2. Belt or pulley exposed to substance 2. Replace belt and clean pulleys
that has reduced friction (belt dressing,
oil, ethylene glycol)
3. Driven component bearing failure 3. Replace faulty component or bearing
(seizure)
4. Belt glazed or hardened from heat 4. Replace belt.
and excessive slippage
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt
groove
2. Pulley groove tip has worn away 2. Replace belt
rubber to tensile member
7 - 10 COOLING SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


9GROOVE JUMPING” 1. Belt tension either too low or too 1. Adjust belt tension
(Belt does not maintain correct high
position on pulley) 2. Pulley(s) not within design 2. Replace pulley(s)
tolerance
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BELT BROKEN 1. Excessive tension 1. Replace belt and adjust tension to
(Note: Identify and correct problem specification
before new belt is installed) 2. Tensile member damaged during 2. Replace belt
belt installation
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component and
belt
NOISE 1. Belt slippage 1. Adjust belt
(Objectional squeal, squeak, or 2. Bearing noise 2. Locate and repair
rumble is heard or felt while drive belt 3. Belt misalignment 3. Align belt/pulley(s)
is in operation) 4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced 5. Locate defective driven component
vibration and repair
6. System resonant frequency 6. Vary belt tension within
induced vibration specifications.
TENSION SHEETING FABRIC 1. Tension sheeting contacting 1. Correct rubbing condition
FAILURE stationary object
(Woven fabric on outside,
2. Excessive heat causing woven 2. Replace belt
circumference of belt has cracked or
fabric to age
separated from body of belt)
3. Tension sheeting splice has 3. Replace belt
fractured
CORD EDGE FAILURE 1. Excessive tension 1. Adjust belt tension
(Tensile member exposed at edges of 2. Belt contacting stationary object 2. Replace belt
belt or separated from belt body) 3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between 4. Replace belt and adjust tension to
tensile member and rubber matrix specifications

PRELIMINARY CHECKS TRAILER TOWING:


Con su lt Tr a iler Towin g sect ion of own er s m a n u a l.
EN GI N E COOLI N G SY ST EM OV ERH EAT I N G Do n ot exceed lim it s.
E st a blish wh a t dr ivin g con dit ion s ca u sed t h e com -
pla in t . Abn or m a l loa ds on t h e coolin g syst em su ch a s AIR CONDITIONING; ADD-ON OR AFTER MARKET:
t h e followin g m a y be t h e ca u se: A m a xim u m coolin g pa cka ge sh ou ld h a ve been
or der ed wit h veh icle if a dd-on or a ft er m a r ket A/C is
PROLONGED IDLE, VERY HIGH AMBIENT TEMPERATURE, in st a lled. If n ot , m a xim u m coolin g syst em com po-
SLIGHT TAIL WIND AT IDLE, SLOW TRAFFIC, TRAFFIC
n en t s sh ou ld be in st a lled for m odel in volved per
JAMS, HIGH SPEED OR STEEP GRADES.
m a n u fa ct u r er ’s specifica t ion s.
Dr ivin g t ech n iqu es t h a t a void over h ea t in g a r e:
• Idle wit h A/C off wh en t em per a t u r e ga u ge is a t RECENT SERVICE OR ACCIDENT REPAIR:
en d of n or m a l r a n ge.
Det er m in e if a n y r ecen t ser vice h a s been per-
• In cr ea sin g en gin e speed for m or e a ir flow is r ec- for m ed on veh icle t h a t m a y effect coolin g syst em .
om m en ded. Th is m a y be:
XJ COOLING SYSTEM 7 - 11
DI AGN OSI S AN D T EST I N G (Cont inue d)
• E n gin e a dju st m en t s (in cor r ect t im in g) NOTE: If investigation reveals none of the previous
• Slippin g en gin e a ccessor y dr ive belt (s) items as a cause for an engine overheating com-
• Br a kes (possibly dr a ggin g) plaint, refer to following Cooling System Diagnosis
• Ch a n ged pa r t s. In cor r ect wa t er pu m p or pu m p charts.
r ot a t in g in wr on g dir ect ion du e t o belt n ot cor r ect ly
r ou t ed Th ese ch a r t s a r e t o be u sed a s a qu ick-r efer en ce
• Recon dit ion ed r a dia t or or coolin g syst em r efill- on ly. Refer t o t h e gr ou p t ext for in for m a t ion .
in g (possibly u n der filled or a ir t r a pped in syst em ).
7 - 12 COOLING SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
COOLING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to On-Board Diagnostics in
LOW (DTC) number 17 been set indicating the service manual text. Replace
a stuck open engine thermostat? thermostat if necessary. If a
Diagnostic Trouble Code (DTC)
number 17 has not been set, the
problem may be with the temperature
gauge.
2. Is the temperature gauge (if 2. Check the engine temperature
equipped) connected to the sensor connector in the engine
temperature gauge coolant sensor on compartment. Refer to Group 8E.
the engine? Repair as necessary.
3. Is the temperature gauge (if 3. Check gauge operation. Refer to
equipped) operating OK? Group 8E. Repair as necessary.
4. Coolant level low in cold ambient 4. Check coolant level in the coolant
temperatures accompanied with poor reserve/overflow tank and the
heater performance. radiator. Inspect system for leaks.
Repair leaks as necessary. Refer to
the Coolant section of the manual text
for WARNINGS and precautions
before removing the radiator cap.
5. Improper operation of internal 5. Inspect heater and repair as
heater doors or heater controls. necessary. Refer to Group 24,
Heating and Air Conditioning for
procedures.
TEMPERATURE GAUGE READS 1. Trailer is being towed, a steep hill is1. This may be a temporary condition
HIGH OR ENGINE COOLANT being climbed, vehicle is operated in and repair is not necessary. Turn off
WARNING LAMP ILLUMINATES. slow moving traffic, or engine is being the air conditioning and attempt to
COOLANT MAY OR MAY NOT BE idled with very high ambient (outside) drive the vehicle without any of the
LOST OR LEAKING FROM temperatures and the air conditioning previous conditions. Observe the
COOLING SYSTEM is on. Higher altitudes could aggravate temperature gauge. The gauge
these conditions. should return to the normal range. If
the gauge does not return to normal
range, determine the cause for
overheating and repair. Refer to
POSSIBLE CAUSES (numbers 2
through 20).
2. Is temperature gauge (if equipped) 2. Check gauge. Refer to Group 8E.
reading correctly? Repair as necessary.
3. Is temperature warning lamp (if 3. Check warning lamp operation.
equipped) illuminating unnecessarily? Refer to Group 8E. Repair as
necessary.
4. Coolant low in coolant reserve/ 4. Check for coolant leaks and repair
overflow tank and radiator. as necessary. Refer to Testing
Cooling System For Leaks in this
group.
5. Pressure cap not installed tightly. If 5. Tighten cap.
cap is loose, boiling point of coolant
will be lowered. Also refer to the
following step 6.
6. Poor seals at radiator cap. 6. (a) Check condition of cap and cap
seals. Refer to Radiator Cap. Replace
cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.

COOLING SYSTEM DIAGNOSIS


XJ COOLING SYSTEM 7 - 13
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


TEMPERATURE GAUGE READS 7. Coolant level low in radiator but not
7. (a) Check condition of radiator cap
HIGH OR ENGINE COOLANT in coolant reserve/overflow tank. This and cap seals. Refer to Radiator Cap
WARNING LAMP ILLUMINATES. means the radiator is not drawing in this group. Replace cap if necessary.
COOLANT MAY OR MAY NOT BE coolant from the coolant reserve/ (b) Check condition of radiator filler
LOST OR LEAKING FROM COOLING overflow tank as the engine cools. neck. If neck is bent or damaged,
SYTEM (Continued) As the engine cools, a vacuum is replace radiator.
formed in the cooling system of the (c) Check the condition of the hose
engine and radiator. If radiator cap from the radiator to the coolant tank. It
seals are defective, or cooling system should fit tight at both ends without any
has leaks, a vacuum can not be kinks or tears. Replace hose if
formed. necessary.
(d) Check coolant reserve/overflow
tank and tank hose for blockage.
Repair as necessary.
8. Freeze point of antifreeze not 8. Check antifreeze. Refer to Coolant
correct. Mixture may be too rich. section of this group. Adjust antifreeze-
to-water ratio as required.
9. Coolant not flowing through system. 9. Check for coolant flow at radiator
filler neck with some coolant removed,
engine warm and thermostat open.
Coolant should be observed flowing
through radiator. If flow is not
observed, determine reason for lack of
flow and repair as necessary.
10. Radiator or A/C condenser fins are 10. Clean insects or debris. Refer to
dirty or clogged. Radiator Cleaning in this group.
11. Radiator core is corroded or 11. Have radiator re-cored or replaced.
plugged.
12. Aftermarket A/C installed without 12. Install proper radiator.
proper radiator.
13. Fuel or ignition system problems. 13. Refer to Fuel and Ignition System
groups for diagnosis. Also refer to the
appropriate Powertrain Diagnostic
Procedures service manual for
operation of the DRB scan tool.
14. Dragging brakes. 14. Check and correct as necessary.
Refer to Group 5, Brakes in this
manual text.
15. Bug screen is being used reducing 15. Remove bug screen.
airflow.
16. Thermostat partially or completely 16. Check thermostat operation and
shut. This is more prevalent on high replace as necessary. Refer to
mileage vehicles. Thermostats in this group.
17. Thermal viscous fan drive not 17. Check fan drive operation and
operating properly. replace if necessary. Refer to Viscous
Fan Drive in this group.
18. Electric cooling fan not operating 18. Check electric fan operation and
properly (XJ models with 4.0L engine repair as necessary. Refer to Auxiliary
equipped with heavy duty cooling Electric Cooling Fan-XJ Models with
and/or air conditioning). 4.0L 6-cylinder engine in the manual
text.

COOLING SYSTEM DIAGNOSIS (CONT.)


7 - 14 COOLING SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


TEMPERATURE GAUGE READS 19. Cylinder head gasket leaking 19. Check for cylinder head gasket
HIGH OR ENGINE COOLANT leaks. Refer to Testing Cooling System
WARNING LAMP ILLUMINATES. for Leaks in this group. For repair refer
COOLANT MAY OR MAY NOT BE to Group 9, Engines.
LOST OR LEAKING FROM COOLING
SYSTEM (Continued)
20. Heater core leaking. 20. Check heater core for leaks. Refer
to Group 24, Heating and Air
Conditioning. Repair as necessary.
TEMPERATURE GUAGE READING IS 1. On XJ models equipped with a 4.0L 1. A normal condition. No correction is
INCONSISTENT (FLUCTUATES, 6-cylinder engine, heavy duty cooling necessary. If gauge cycling is going
CCLES OR IS ERRACTIC) and/or air conditioning, the gauge may into the hot zone, check electric fan
cycle up and down. This is due to the operation and repair as necessary.
cycling of the electric radiator fan. Refer to Auxiliary Electric Cooling
Fan-XJ Models with 4.0L 6-cylinder
engine in the manual text.
2. During cold weather operation, with 2. A normal condition. No correction is
the heater blower in the high position, necessary.
the gauge reading may drop slightly.
3. Temperature gauge or engine 3. Check operation of gauge and repair
mounted gauge sensor defective or if necessary. Refer to Group 8E,
shorted. Also, corroded or loose wiring Instrument Panel and Gauges.
in this circuit.
4. Gauge reading rises when vehicle is 4. A normal condition. No correction is
brought to a stop after heavy use necessary. Gauge reading should
(engine still running). return to normal range after vehicle is
driven.
5. Gauge reading high after restarting a 5. A normal condition. No correction is
warmed-up (hot) engine. necessary. The gauge should return to
normal range after a few minutes of
engine operation.
6. Coolant level low in radiator (air will 6. Check and correct coolant leaks.
build up in the cooling system causing Refer to Testing Cooling Sytem for
the thermostat to open late). Leaks in this group.
7. Cylinder head gasket leaking 7. (a) Check for cylinder head gasket
allowing exhaust gas to enter cooling leaks with a commercially available
system causing thermostat to open late. Block Leak Tester. Repair as
necessary.
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from
exhaust system. Repair as necessary.
8. Water pump impeller loose on shaft. 8. Check water pump and replace as
necessary. Refer to Water Pumps in
this group.
9. Loose accessory drive belt (water 9. Refer to Engine Accessory Drive
pump slipping). Belts in this group. Check and correct
as necessary.
10. Air leak on the suction side of water 10. Locate leak and repair as
pump allows air to build up in cooling necessary.
system causing thermostat to open late.

COOLING SYSTEM DIAGNOSIS (CONT.)


XJ COOLING SYSTEM 7 - 15
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


PRESSURE CAP IS BLOWING OFF 1. Pressure relief valve in radiator cap 1. Check condition of radiator cap and
STEAM AND/OR COOLANT TO is defective. cap seals. Refer to Radiator Caps in
COOLANT TANK. TEMPERATURE this group. Replace cap as necessary.
GAUGE READING MAY BE ABOVE
NORMAL BUT NOT HIGH. COOLANT
LEVEL MAY BE HIGH IN COOLANT
RESERVE/OVERFLOW TANK
COOLANT LOSS TO THE GROUND 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
WITHOUT PRESSURE CAP system hoses, water pump or engine. necessary. Refer to Testing Cooling
BLOWOFF. GAUGE IS READING System for Leaks in this group.
HIGH OR HOT
DETONATION OR PREIGNITION 1. Engine overheating. 1. Check reason for overheating and
(NOT CAUSED BY IGNITION repair as necessary.
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH
2. Freeze point of antifreeze not 2. Check antifreeze. Refer to the
correct. Mixture is too rich or too lean. Coolant section in this group. Adjust
antifreeze-to-water ratio as required.

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.

COOLING SYSTEM DIAGNOSIS (CONT.)


7 - 16 COOLING SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


NOISY FAN 1. Fan blades loose. Replace fan blade assembly. Refer to
Cooling System Fans in this group.
2. Fan blades striking a surrounding 2. Locate point of fan blade contact
object. and repair as necessary.
3. Air obstructions at radiator or air 3. Remove obstructions and/or clean
conditioning condenser. debris or insects from radiator or A/C
condenser.
4. Electric fan motor defective (if 4. Replace electric fan motor. Refer to
equipped). Auxiliary Electric Cooling Fan-XJ
Models with 4.0L 6-Cylinder engine in
the manual text.
5. Thermal viscous fan drive has 5. Replace fan drive. Bearing is not
defective bearing. serviceable. Refer to Viscous Fan
Drive in this group.
6. A certain amount of fan noise 6. Refer to Viscous Fan Drive in this
(roaring) may be evident on models group for an explanation of normal fan
equipped with a thermal viscous fan noise.
drive. Some of this noise is normal.
INADEQUATE AIR CONDITIONER 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as
PERFORMANCE (COOLING SYSTEM restricted, obstructed or dirty (insects, necessary. Refer to Radiator Cleaning
SUSPECTED) leaves etc.). in this group.
2. Electric radiator fan not operating 2. Refer to Auxiliary Electric Cooling
when A/C is operated (if equipped with Fan-XJ Models with 4.0L 6-Cylinder
electric fan). engine in the manual text. Repair as
necessary.
3. Thermal viscous fan drive is 3. Refer to Viscous Fan Drive for
freewheeling. diagnosis. Repair as necessary.
4. Engine is overheating (heat may be 4. Correct overheating condition. Refer
transferred from radiator to A/C to text in Group 7, Cooling.
condenser. High underhood
temperatures due to engine overheating
may also transfer heat to A/C
components).
5. Some models with certain engines 5. Check for missing or damaged air
are equipped with air seals at the seals and repair as necessary.
radiator and/or A/C condenser. If these
seals are missing or damaged, not
enough air flow will be pulled through
the radiator and A/C condenser.
INADEQUATE HEATER 1. Has a diagnostic trouble code (DTC) 1. Refer to On-Board Diagnostics in
PERFORMANCE. THERMOSTAT number 17 been set? the manual text and replace thermostat
FAILED IN OPEN POSITION if necessary.
2. Coolant level low. 2. Refer to Testing Cooling System for
Leaks in the manual text. Repair as
necessary.
3. Obstructions in heater hose fittings at 3. Remove heater hoses at both ends
engine. and check for obstructions. Repair as
necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.

COOLING SYSTEM DIAGNOSIS (CONT.)


XJ COOLING SYSTEM 7 - 17
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


INADEQUATE HEATER 5. Some models with certain engines 5. Refer to Group 24, Heating and
PERFORMANCE. THERMOSTAT are equipped with a water control Air Conditioning for diagnosis. Repair
FAILED IN OPEN POSITION valve located on one of the heater as necessary.
(Continued) hoses. This valve may be defective.
6. Water pump is not pumping water 6. Refer to Water Pumps in this
to heater core. When the engine is group. Repair as necessary. If a
fully warmed up, both heater hoses slipping belt is detected, refer to
should be hot to the touch. If only Engine Accessory Drive Belts in this
one of the hoses is hot, the water group. Repair as necessary.
pump may not be operating correctly.
The accessory drive belt may also be
slipping causing poor water pump
operation.
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and
certain drive line components. One or replace or repair as necessary.
more of these shields may be
missing.
2. Is temperature gauge reading 2. Refer to the previous Temperature
above the normal range? Gauge Reads High in these
Diagnosis Charts. Repair as
necessary.
3. Is cooling fan operating correctly? 3. Refer to Cooling System Fan in
this group for diagnosis. Repair as
necessary.
4. Has undercoating been applied to 4. Clean undercoating as necessary.
any unnecessary component?
5. Engine may be running rich 5. Refer to the DRB scan tool and
causing the catalytic convertor to the appropriate Powertrain
overheat. Diagnostic Procedures service
manual. Repair as necessary.
POOR DRIVEABILITY 1. For proper driveability, good 1. Refer to On-Board Diagnostics in
(THERMOSTAT POSSIBLY STUCK vehicle emissions and for preventing this group. DTC’s may also be
OPEN) GAUGE READING MAY BE build-up of engine oil sludge, the checked using the DRB scan tool.
LOW thermostat must be operating Refer to the proper Powertrain
properly. Has a diagnostic trouble Diagnostics Procedures service
code (DTC) number 17 been set? manual for checking the thermostat
using the DRB scan tool. Replace
thermostat if necessary.
STEAM IS COMING FROM FRONT 1. During wet weather, moisture 1. Occasional steam emitting from
OF VEHICLE NEAR GRILL AREA (snow, ice or rain condensation) on this area is normal. No repair is
WHEN WEATHER IS WET, ENGINE the radiator will evaporate when the necessary.
IS WARMED UP AND RUNNING, thermostat opens. This opening
AND VEHICLE IS STATIONARY. allows heated water into the radiator.
TEMPERATURE GAUGE IS IN When the moisture contacts the hot
NORMAL RANGE radiator, steam may be emitted. This
usually occurs in cold weather with
no fan or airflow to blow it away.

COOLING SYSTEM DIAGNOSIS (CONT.)


7 - 18 COOLING SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSES CORRECTION


COOLANT COLOR 1. Coolant color is not necessarily an 1. Refer to Coolant in this group for
indication of adequate corrosion or antifreeze tests. Adjust antifreeze-to-
temperature protection. Do not rely water ratio as necessary.
on coolant color for determining
condition of coolant.
COOLANT LEVEL CHANGES IN 1. Level changes are to be expected 1. A normal condition. No repair is
COOLANT RESERVE/OVERFLOW as coolant volume fluctuates with necessary.
TANK. TEMPERATURE GAUGE IS engine temperature. If the level in the
IN NORMAL RANGE tank was between the FULL and ADD
marks at normal engine operating
temperature, the level should return
to within that range after operation at
elevated temperatures.

COOLING SYSTEM DIAGNOSIS (CONT.)


TYPICAL
PRESSURE
COOLINGTESTER
SYTEM
TYPICAL BLACK
LIGHT TOOL

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).

Fig. 13 Pressurizing System—Typical


Oper a t e t h e t est er pu m p t o a pply 124 kP a (18 psi)
pr essu r e t o t h e syst em . If t h e h oses en la r ge exces-
sively or bu lge wh ile t est in g, r epla ce a s n ecessa r y.
Obser ve t h e ga u ge poin t er a n d det er m in e t h e con di-
t ion of t h e coolin g syst em a ccor din g t o t h e followin g
cr it er ia :
• H olds St ea dy: If t h e poin t er r em a in s st ea dy for
t wo m in u t es, t h er e a r e n o ser iou s coola n t lea ks in
t h e syst em . H owever, t h er e cou ld be a n in t er n a l lea k
t h a t does n ot a ppea r wit h n or m a l syst em t est pr es-
su r e. In spect for in t er ior lea ka ge or do t h e In t er n a l
Lea ka ge Test . Do t h is if it is cer t a in t h a t coola n t is
bein g lost a n d n o lea ks ca n be det ect ed.
• Dr ops Slowly: Sh ows a sm a ll lea k or seepa ge is
occu r r in g. E xa m in e a ll con n ect ion s for seepa ge or
Fig. 12 Leak Detection Using Black Light—Typical sligh t lea ka ge wit h a fla sh ligh t . In spect t h e r a dia t or,
PRESSU RE T EST ER M ET H OD h oses, ga sket edges a n d h ea t er. Sea l a n y sm a ll lea k
Th e en gin e sh ou ld be a t t h e n or m a l oper a t in g t em - h oles wit h a Sea ler Lu br ica n t or equ iva len t . Repa ir
per a t u r e. Rech eck t h e syst em cold if t h e ca u se of lea k h oles a n d r ein spect t h e syst em wit h pr essu r e
coola n t loss is n ot loca t ed du r in g wa r m en gin e exa m - a pplied.
in a t ion . • Dr ops Qu ickly: Sh ows t h a t a ser iou s lea ka ge is
occu r r in g. E xa m in e t h e syst em for ser iou s ext er n a l
7 - 20 COOLING SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
lea ka ge. If n o lea ks a r e visible, in spect for in t er n a l Dr a in su fficien t coola n t t o a llow for t h er m ost a t
lea ka ge. La r ge r a dia t or lea k h oles sh ou ld be r epa ir ed r em ova l. Refer t o Th er m ost a t Repla cem en t . Discon -
by a r epu t a ble r a dia t or r epa ir sh op. n ect t h e wa t er pu m p dr ive belt .
Discon n ect t h e u pper r a dia t or h ose fr om t h e t h er-
I N T ERN AL LEAK AGE I N SPECT I ON m ost a t h ou sin g. Rem ove t h e h ou sin g a n d t h er m ost a t .
Rem ove t h e en gin e oil pa n dr a in plu g a n d dr a in a In st a ll t h e t h er m ost a t h ou sin g.
sm a ll a m ou n t of en gin e oil. Coola n t , bein g h ea vier Add coola n t t o t h e r a dia t or t o br in g t h e level t o
t h a n en gin e oil, will dr a in fir st . An ot h er wa y of t est - wit h in 6.3 m m (1/4 in ) of t h e t op of t h e t h er m ost a t
in g is t o oper a t e t h e en gin e a n d ch eck for wa t er glob- h ou sin g.
u les on t h e en gin e oil dipst ick. Also in spect t h e
a u t om a t ic t r a n sm ission oil dipst ick for wa t er glob- CAUTION: Avoid overheating. Do not operate the
u les. In spect t h e a u t om a t ic t r a n sm ission flu id cooler engine for an excessive period of time. Open the
for lea ka ge. Oper a t e t h e en gin e wit h ou t t h e pr essu r e draincock immediately after the test to eliminate
ca p on t h e r a dia t or u n t il t h er m ost a t open s. boil over of coolant.
At t a ch a pr essu r e t est er t o t h e filler n eck. If pr es-
su r e bu ilds u p qu ickly, a lea k exist s a s a r esu lt of a St a r t t h e en gin e a n d a cceler a t e r a pidly t h r ee t im es
fa u lt y cylin der h ea d ga sket or cr a ck in t h e en gin e. (t o a ppr oxim a t ely 3000 r pm ) wh ile obser vin g t h e
Repa ir a s n ecessa r y. coola n t . If in t er n a l en gin e com bu st ion ga ses a r e lea k-
in g in t o t h e coolin g syst em , bu bbles will a ppea r in
WARNING: DO NOT ALLOW PRESSURE TO t h e coola n t . If bu bbles do n ot a ppea r, t h er e is n o
EXCEED 124 KPA (18 PSI). TURN THE ENGINE OFF. in t er n a l com bu st ion ga s lea ka ge.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE VISCOUS FAN DRIVE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE. LEAK S
Viscou s fa n dr ive oper a t ion is n ot a ffect ed by sm a ll
If t h er e is n o im m edia t e pr essu r e in cr ea se, pu m p oil st a in s n ea r t h e dr ive bea r in g. If lea ka ge a ppea r s
t h e pr essu r e t est er u n t il t h e in dica t ed pr essu r e is excessive, r epla ce t h e fa n dr ive u n it .
wit h in t h e syst em r a n ge. Vibr a t ion of t h e ga u ge
poin t er in dica t es com pr ession or com bu st ion lea ka ge T EST I N G
in t o t h e coolin g syst em . If t h e fa n a ssem bly fr ee-wh eels wit h ou t dr a g (t h e
fa n bla des will r evolve m or e t h a n five t u r n s wh en
WARNING: DO NOT DISCONNECT THE SPARK spu n by h a n d), r epla ce t h e fa n dr ive. Th is spin t est
PLUG WIRES WHILE THE ENGINE IS OPERATING. m u st be per for m ed wh en t h e en gin e is cool.
F or t h e followin g t est , t h e coolin g syst em m u st be
in good con dit ion . It a lso will en su r e a ga in st exces-
CAUTION: Do not operate the engine with a spark sively h igh coola n t t em per a t u r e.
plug shorted for more than a minute. The catalytic
converter may be damaged. WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
Isola t e t h e com pr ession lea k by sh or t in g ea ch
spa r k plu g t o t h e cylin der block. Th e ga u ge poin t er (1) Dr ill a 3.18-m m (1/8-in ) dia m et er h ole in t h e
sh ou ld st op or decr ea se vibr a t ion wh en spa r k plu g t op cen t er of t h e fa n sh r ou d.
for lea kin g cylin der is sh or t ed. Th is h a ppen s beca u se (2) Obt a in a dia l t h er m om et er wit h a n 8 in ch st em
of t h e a bsen ce of com bu st ion pr essu r e. (or equ iva len t ). It sh ou ld h a ve a r a n ge of -18°-t o-
105°C (0°-t o-220° F ). In ser t t h er m om et er t h r ou gh t h e
COM BU ST I ON LEAK AGE T EST (WI T H OU T h ole in t h e sh r ou d. Be su r e t h a t t h er e is a dequ a t e
PRESSU RE T EST ER) clea r a n ce fr om t h e fa n bla des.
DO NOT WASTE r eu sa ble coola n t . If t h e solu t ion (3) Con n ect a t a ch om et er a n d a n en gin e ign it ion
is clea n , dr a in t h e coola n t in t o a clea n con t a in er for t im in g ligh t (t im in g ligh t is t o be u sed a s a st r obe
r eu se. ligh t ).
(4) Block t h e a ir flow t h r ou gh t h e r a dia t or. Secu r e
WARNING: DO NOT REMOVE THE CYLINDER
a sh eet of pla st ic in fr on t of t h e r a dia t or (or a ir con -
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
dit ion er con den ser ). Use t a pe a t t h e t op t o secu r e t h e
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
pla st ic a n d be su r e t h a t t h e a ir flow is blocked.
PRESSURE. SERIOUS BURNS FROM COOLANT
(5) Be su r e t h a t t h e a ir con dit ion er (if equ ipped) is
CAN OCCUR.
t u r n ed off.
VACUUM VENT VALVE (SHOWN
ING POSITION)
IN SEAL- PRESSURE
PRESSURE
FILLER
RATING
NECK
VALVE
SEAL

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.

(6) St a r t t h e en gin e a n d oper a t e a t 2400 r pm .


Wit h in t en m in u t es t h e a ir t em per a t u r e (in dica t ed on
t h e dia l t h er m om et er ) sh ou ld be u p t o 88° C (190° F ).
F a n dr ive e n g a g e m e n t sh ou ld h a ve st a r t ed t o occu r
a t bet ween 74° t o 82° C (165° t o 180° F ). E n ga ge-
m en t is dist in gu ish a ble by a defin it e in c re a s e in fa n
flow n oise (r oa r in g). Th e t im in g ligh t a lso will in di-
ca t e a n in cr ea se in t h e speed of t h e fa n .
(7) Wh en t h e a ir t em per a t u r e r ea ch es 88° C (190°
F ), r em ove t h e pla st ic sh eet . F a n dr ive d is e n g a g e -
m e n t sh ou ld h a ve st a r t ed t o occu r a t bet ween 57° t o PRESSURE
79° C (135° t o 175° F ). A defin it e d e c re a s e of fa n RATING
flow n oise (r oa r in g) sh ou ld be n ot iced. If n ot , r epla ce
t h e defect ive viscou s fa n dr ive u n it .

AUXILIARY ELECTRIC COOLING FAN


ELECT RI C COOLI N G FAN AN D RELAY
DI AGN OSI S

NOTE: Refer to Electrical Group 8W for electric


cooling fan and relay circuit schematic. VACUUM
VENT VALVE
Th e power t r a in con t r ol m odu le (P CM) will en t er a (SHOWN IN SEALING POSITION)
J9207-5
dia gn ost ic t r ou ble code (DTC) in m em or y if it det ect s
a pr oblem in t h e a u xilia r y coolin g fa n r ela y or cir cu it . Fig. 14 Radiator Pressure Cap
Refer t o Gr ou p 25, E m ission Con t r ol Syst em s for cor-
Th er e is n o n eed t o r em ove t h e r a dia t or ca p
r ect DTC r et r ieva l pr ocedu r es.
e x c e p t for t h e followin g pu r poses:
If t h e elect r ic coolin g fa n is in oper a t ive, ch eck fu se
(1) To ch eck a n d a dju st a n t ifr eeze fr eeze poin t .
#11 (20A) in ju n ct ion block a n d fu se #5 (40A m a xi-
(2) To r efill syst em wit h n ew a n t ifr eeze.
fu se) in t h e P ower Dist r ibu t ion Cen t er (P DC) wit h a
(3) F or con du ct in g ser vice pr ocedu r es.
12 volt t est la m p or DVOM. If fu ses a r e o.k., r efer t o
(4) Wh en ch eckin g for va cu u m lea ks.
Gr ou p 8W for elect r ic coolin g fa n a n d r ela y cir cu it
sch em a t ic. WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE
RADIATOR CAP-TO-FILLER NECK SEAL— REMOVING RADIATOR CAP. WITH A RAG,
PRESSURE RELIEF CHECK SQUEEZE RADIATOR UPPER HOSE TO CHECK IF
Wit h r a dia t or ca p in st a lled on filler n eck, r em ove SYSTEM IS UNDER PRESSURE. PLACE A RAG
coola n t r eser ve/ over flow t a n k h ose fr om n ipple on OVER THE CAP AND WITHOUT PUSHING DOWN,
filler n eck. Con n ect a h a n d oper a t ed va cu u m pu m p ROTATE CAP COUNTER-CLOCKWISE TO THE
t o n ipple. Oper a t e pu m p u n t il a r ea din g of 47-t o-61 FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH
kP a (14- t o-18 in . H g) a ppea r s on ga u ge. If t h e r ea d- OVERFLOW HOSE INTO COOLANT RESERVE/
in g st a ys st ea dy, or dr ops sligh t ly a n d t h en r em a in s OVERFLOW TANK. SQUEEZE RADIATOR UPPER
st ea dy, t h e pr essu r e va lve sea l is good. Repla ce r a di- HOSE TO DETERMINE WHEN PRESSURE HAS
a t or ca p if r ea din g does n ot h old. BEEN RELEASED. WHEN COOLANT AND STEAM
STOP BEING PUSHED INTO TANK AND SYSTEM
WARNING: THE WARNING WORDS -DO NOT OPEN PRESSURE DROPS, REMOVE RADIATOR CAP
HOT- ON THE RADIATOR PRESSURE CAP (Fig. 14) COMPLETELY.
ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
VENT SCALDING OR INJURY, THE RADIATOR CAP
7 - 22 COOLING SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
PRESSURE TESTING RADIATOR CAPS Low coola n t level ca n ca u se t h er m ost a t pellet t o be
Rem ove ca p fr om r a dia t or. Be su r e t h a t sea lin g su spen ded in a ir in st ea d of coola n t . Th is will ca u se
su r fa ces a r e clea n . Moist en r u bber ga sket wit h wa t er t h er m ost a t t o open la t er, wh ich in t u r n ca u ses h igh er
a n d in st a ll t h e ca p on pr essu r e t est er (t ool 7700 or coola n t t em per a t u r e. Air t r a pped in coolin g syst em
a n equ iva len t ) (F ig. 15). a lso r edu ces a m ou n t of coola n t cir cu la t in g in h ea t er
cor e r esu lt in g in low h ea t ou t pu t .

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.

SERV I CE PROCEDU RES


TYPICAL COOLANT LEVEL CHECK—ROUTINE
COOLING
SYSTEM
PRESSURE NOTE: Do not remove radiator cap for routine
TESTER coolant level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
J9507-3
Th e coola n t r eser ve/over flow syst em pr ovides a
Fig. 15 Pressure Testing Radiator Pressure qu ick visu a l m et h od for det er m in in g coola n t level
Cap—Typical wit h ou t r em ovin g r a dia t or pr essu r e ca p. Wit h en gin e
Oper a t e t h e t est er pu m p a n d obser ve t h e ga u ge cold a n d n ot r u n n in g, obser ve coola n t level in
poin t er a t it s h igh est poin t . Th e ca p r elea se pr essu r e r eser ve/over flow t a n k. Th e coola n t level sh ou ld be
sh ou ld be 83-t o-110 kP a (12-t o-16 psi). Th e ca p is sa t - bet ween ADD a n d F ULL m a r ks.
isfa ct or y wh en t h e pr essu r e h olds st ea dy. It is a lso
good if it h olds pr essu r e wit h in t h e 83-t o-110 kP a COOLANT SERVICE
(12-t o-16 psi) r a n ge for 30 secon ds or m or e. If t h e It is r ecom m en ded t h a t t h e coolin g syst em be
poin t er dr ops qu ickly, r epla ce t h e ca p. dr a in ed a n d flu sh ed a t 84,000 kilom et er s (52,500
m iles), or 3 yea r s, wh ich ever occu r s fir st . Th en ever y
CAUTION: Radiator pressure testing tools are very t wo yea r s, or 48,000 kilom et er s (30,000 m iles),
sensitive to small air leaks, which will not cause wh ich ever occu r s fir st .
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be ADDING ADDITIONAL COOLANT—ROUTINE
replaced just because it leaks slowly when tested D o n o t re m o v e ra d ia to r c a p to a d d c o o la n t to
with this tool. Add water to tool. Turn tool upside s y s te m . Wh en a ddin g coola n t t o m a in t a in cor r ect
down and recheck pressure cap to confirm that cap level, do so a t coola n t r eser ve/over flow t a n k. Use a
needs replacement. 50/50 m ixt u r e of et h ylen e-glycol a n t ifr eeze con t a in in g
Alu ga r d 340-2 y a n d low m in er a l con t en t wa t er.
CAP IN S P ECTION Rem ove r a dia t or ca p on ly for t est in g or wh en r efill-
Visu a lly in spect t h e pr essu r e va lve ga sket on t h e in g syst em a ft er ser vice. Rem ovin g ca p u n n ecessa r ily
ca p. Repla ce ca p if t h e ga sket is swollen , t or n or ca n ca u se loss of coola n t a n d a llow a ir t o en t er sys-
wor n . In spect t h e a r ea a r ou n d r a dia t or filler n eck for t em , wh ich pr odu ces cor r osion .
wh it e deposit s t h a t in dica t e a lea kin g ca p.
COOLANT LEVEL CHECK—SERVICE
LOW COOLANT LEVEL-AERATION Th e coolin g syst em is closed a n d design ed t o m a in -
If t h e coola n t level in r a dia t or dr ops below t op of t a in coola n t level t o t op of r a dia t or.
r a dia t or cor e t u bes, a ir will en t er coolin g syst em .
RADIATOR PETCOCK

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.

Wh en veh icle ser vicin g r equ ir es a coola n t level


RADIATOR
ch eck in r a dia t or, dr a in sever a l ou n ces of coola n t
fr om r a dia t or dr a in cock. Do t h is wh ile obser vin g
coola n t r eser ve/over flow syst em t a n k. Th e coola n t
level in r eser ve/over flow t a n k sh ou ld dr op sligh t ly. If
n ot , in spect for a lea k bet ween r a dia t or a n d coola n t
r eser ve/over flow syst em con n ect ion . Rem ove r a dia t or
ca p. Th e coola n t level sh ou ld be t o t op of r a dia t or. If
n ot a n d if coola n t level in r eser ve/over flow t a n k is a t
ADD m a r k, ch eck for :
• An a ir lea k in coola n t r eser ve/over flow t a n k or
it s h ose
• An a ir lea k in r a dia t or filler n eck
• Lea k in pr essu r e ca p sea l t o r a dia t or filler n eck

DRAINING AND FILLING COOLING SYSTEM Fig. 16 Radiator Petcock—4.0L (LHD/RHD)


DRAI N I N G 2 .5 L 4 -CY LI N DER EN GI N E a clea n con t a in er. Open dr a in cock a n d dr a in coola n t
fr om r a dia t or.
WARNING: DO NOT REMOVE THE CYLINDER BLOCK (4) Dr a in coola n t fr om en gin e by r em ovin g t h e
DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN- dr a in plu g a n d coola n t t em per a t u r e sen sor on left
COCK WITH SYSTEM HOT AND UNDER PRESSURE. side of block.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
REFI LLI N G COOLI N G SY ST EM
DO NOT WASTE r eu sa ble coola n t . If t h e solu t ion (1) Tigh t en t h e r a dia t or pet cock a n d t h e cylin der
is clea n , dr a in t h e coola n t in t o a clea n con t a in er for block dr a in plu g(s). If r em oved, in st a ll coola n t t em -
r eu se. per a t u r e sen sor (4.0L 6-cylin der en gin e).
DO NOT r em ove t h e r a dia t or ca p wh en dr a in in g (2) F ill syst em u sin g a 50/50 m ixt u r e of wa t er a n d
t h e coola n t fr om t h e r eser ve/over flow t a n k. Open t h e a n t ifr eeze a s descr ibed in t h e Coola n t sect ion of t h is
r a dia t or dr a in cock a n d wh en t h e t a n k is em pt y, gr ou p. F ill r a dia t or t o t op a n d in st a ll r a dia t or ca p.
r em ove t h e r a dia t or ca p. Th e coola n t does n ot h a ve Add su fficien t coola n t t o r eser ve/over flow t a n k t o
t o be r em oved fr om t h e t a n k u n less t h e syst em is r a ise level t o F ULL m a r k.
bein g r efilled wit h a fr esh m ixt u r e. (3) Wit h h ea t er con t r ol u n it in t h e H E AT posit ion ,
(1) Dr a in t h e coola n t fr om t h e r a dia t or by loosen - oper a t e en gin e wit h r a dia t or ca p in pla ce.
in g t h e pet cock. (4) Aft er en gin e h a s r ea ch ed n or m a l oper a t in g
(2) Dr a in coola n t fr om en gin e by r em ovin g dr a in t em per a t u r e, sh u t en gin e off a n d a llow it t o cool.
plu g a t left r ea r side of block. (5) Add coola n t t o r eser ve/over flow t a n k a s n eces-
sa r y. On ly a d d c o o la n t w h e n th e e n g in e is c o ld .
DRAI N I N G 4 .0 L 6 -CY LI N DER EN GI N E Co o la n t le v e l in a w a rm e n g in e w ill be h ig h e r
d u e to th e rm a l e x p a n s io n .
WARNING: DO NOT REMOVE THE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN- REVERSE FLUSHING
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR. CAUTION: The cooling system normally operates
at 97-to-124 kPa (14- to-18 psi) pressure. Exceeding
DO NOT WASTE r eu sa ble coola n t . If t h e solu t ion this pressure may damage the radiator or hoses.
is clea n , dr a in t h e coola n t in t o a clea n con t a in er for
r eu se. Rever se flu sh in g of t h e coolin g syst em is t h e for c-
(1) Rem ove r a dia t or pr essu r e ca p. in g of wa t er t h r ou gh t h e coolin g syst em . Th is is don e
(2) F or a ccess t o r a dia t or dr a in cock (F ig. 16), u sin g a ir pr essu r e in t h e opposit e dir ect ion of n or m a l
r em ove r a dia t or gr ille m ou n t in g scr ews a n d r em ove coola n t flow. It is u su a lly on ly n ecessa r y wit h ver y
gr ill. Refer t o Gr ou p 23, Body for cor r ect pr ocedu r e. dir t y syst em s wit h eviden ce of pa r t ia l plu ggin g.
(3) At t a ch on e en d of a 24 in ch lon g X 1/4 in ch ID
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
AIR
ING CONDENSER
CONDITION- HOSE
CLAMPS
MOUNTING
(2) BOLT MOUNTING BOLT
AUXILIARY AUTOMATIC TRANSMIS-
SION OIL COOLER

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.

Allow t h e r a dia t or t o fill wit h wa t er. Wh en r a dia t or AI R-T O-OI L COOLER


is filled, a pply a ir in sh or t bla st s a llowin g r a dia t or t o
REMOVAL
r efill bet ween bla st s. Con t in u e t h is r ever se flu sh in g
u n t il clea n wa t er flows ou t t h r ou gh r ea r of r a dia t or (1) Rem ove t h e gr ill m ou n t in g scr ews a n d r em ove
coolin g t u be pa ssa ges. F or m or e in for m a t ion , r efer t o t h e gr ill. Refer t o Gr ou p 23, Body for pr ocedu r es.
oper a t in g in st r u ct ion s su pplied wit h flu sh in g equ ip- (2) P la ce a dr a in pa n below t h e t r a n sm ission oil
m en t . H a ve r a dia t or clea n ed m or e ext en sively by a cooler.
r a dia t or r epa ir sh op. (3) Rem ove t h e t wo h ose cla m ps a t oil cooler in let
a n d ou t let t u bes.
REV ERSE FLU SH I N G EN GI N E (4) Rem ove t h e t wo oil cooler m ou n t in g bolt s (F ig.
Dr a in t h e coolin g syst em . Rem ove t h e t h er m ost a t 17) (F ig. 18).
h ou sin g a n d t h er m ost a t . In st a ll t h e t h er m ost a t h ou s- (5) Rem ove t h e oil cooler fr om veh icle.
in g. Discon n ect t h e r a dia t or u pper h ose fr om t h e AIR HOSE AUXILIARY AUTOMATIC
r a dia t or a n d a t t a ch t h e flu sh in g gu n t o t h e h ose. Dis- CONDITIONING: mCLAMPSn TRANSMISSION OIL
con n ect t h e r a dia t or lower h ose fr om t h e wa t er CONDENSER <········ffi (2) . . COOLER
pu m p. At t a ch a lea d a wa y h ose t o t h e wa t er pu m p Rllllilllllll········
in let fit t in g.

CAUTION: Be sure that the heater control valve is


closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.

Con n ect t h e wa t er su pply h ose a n d a ir su pply h ose


t o t h e flu sh in g gu n . Allow t h e en gin e t o fill wit h
wa t er. Wh en t h e en gin e is filled, a pply a ir in sh or t
bla st s, a llowin g t h e syst em t o fill bet ween a ir bla st s.
Con t in u e u n t il clea n wa t er flows t h r ou gh t h e lea d
a wa y h ose. F or m or e in for m a t ion , r efer t o oper a t in g
in st r u ct ion s su pplied wit h flu sh in g equ ipm en t .
Rem ove t h e lea d a wa y h ose, flu sh in g gu n , wa t er su p-
ply h ose a n d a ir su pply h ose. Rem ove t h e t h er m ost a t
h ou sin g a n d in st a ll t h er m ost a t . In st a ll t h e t h er m ost a t MOUNTING
h ou sin g wit h a r epla cem en t ga sket . Refer t o Th er m ost a t BOLT J9407-28
Repla cem en t . Con n ect t h e r a dia t or h oses. Refill t h e Fig. 17 Auxiliary Air-To-Oil Cooler—4.0L Engine
coolin g syst em wit h t h e cor r ect a n t ifr eeze/wa t er m ix-
t u r e.
AUTO. TRANS. OIL COOLER HOSECLAMPS MOUNTING
BOLTS FRONT TUBECLAMP
TOMOUNTING
RADI-
ATOR BOLTS
LOWER BRACKET RESERVE/OVER-
COOLANT
OVERFLOW
RESERVE/
MOUNTING
FLOW
TUBE
RADI-
BOLTS
TANK
CLAMP
ATANK
TOR
TO

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

Fig. 18 Auxiliary Air-To-Oil Cooler2.5L Engine


Fig. 19 Reserve/Overflow Tank—Except Right Hand
INSTALLATION Drive
(1) P osit ion a n d secu r e oil cooler t o veh icle.
Tigh t en m ou n t in g bolt s t o 8 N·m (72 in . lbs.) t or qu e.
(2) Secu r e in let a n d ou t let t u bes wit h h ose cla m ps.
Tigh t en t h e t wo cla m ps t o 2 N·m (15 in . lbs.) t or qu e.

COOLANT RESERVE TANK


REM OVAL
(1) Rem ove t h e t u be cla m p a t t h e t a n k a n d r em ove
t u be.
(2) Rem ove t h e t a n k m ou n t in g bolt s a n d r em ove
t a n k (F ig. 19) (F ig. 20).

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)

FRONT VIEW BACK VIEW THERMAL (4) FAN HUB-TO-PUMP


VISCOUS PULLEY STUDS
ROTATION DIRECTION ROTATION DIRECTION FAN DRIVE
AS VIEWED AS VIEWED

Fig. 21 Reverse Rotating Water Pump—Typical


WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
J9307-10

'
(4) FAN HUB-TO-PUMP PULLEY NUTS

Fig. 22 Fan Mounting Nuts


FAN
BLADE J9307-7

WITH THE SYSTEM HOT AND UNDER PRESSURE.


SERIOUS BURNS FROM COOLANT CAN OCCUR.

DO NOT WASTE r eu sa ble coola n t . If t h e 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-2 .5 L EN GI N E (LH D/RH D)


(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Dr a in t h e coolin g syst em . PUMP
(3) Rem ove u pper r a dia t or h ose. ASSEMBLY
(4) Loosen (bu t do n ot r em ove a t t h is t im e) t h e 2.5L
fou r fa n h u b-t o-wa t er pu m p pu lley m ou n t in g n u t s
PUMP
(F ig. 22). BRACKET 80a871e2
(5) Rem ove a ccessor y dr ive belt (r efer t o Accessor y
Dr ive Belt , Rem ova l a n d In st a lla t ion in t h is sect ion ) Fig. 23 Power Steering Pump Attachment-2.5L
(6) Un bolt fa n sh r ou d
(7) Rem ove t h e fou r fa n h u b-t o-wa t er pu m p pu lley ket . Not e t h a t on e of t h e fou r bolt s is lon ger t h a n t h e
n u t s a n d r em ove fa n a n d sh r ou d t oget h er ot h er bolt s.
(11) If pu m p is t o be r epla ced, t h e h ea t er h ose fit -
CAUTION: After removing fan blade/viscous fan t in g m u st be r em oved. Not e posit ion of fit t in g befor e
drive assembly, do not place thermal viscous fan r em ova l.
drive in horizontal position. If stored horizontally,
silicone fluid in viscous fan drive could drain into I N STALLAT I ON -2 .5 L EN GI N E (LH D/RH D)
its bearing assembly and contaminate lubricant. (1) If pu m p is bein g r epla ced, in st a ll t h e h ea t er
h ose fit t in g t o t h e pu m p. Use a sea la n t on t h e fit t in g
(8) Rem ove power st eer in g pu m p a n d br a cket (F ig. su ch a s Mopa r y Th r ea d Sea la n t Wit h Teflon . Refer
23), r efer t o Gr ou p 19 St eer in g for cor r ect pr ocedu r e. t o t h e dir ect ion s on t h e pa cka ge.
(9) Rem ove lower r a dia t or h ose fr om wa t er pu m p. (2) Clea n t h e ga sket m a t in g su r fa ces. If t h e or igi-
Rem ove h ea t er h ose fr om wa t er pu m p fit t in g. n a l pu m p is u sed, r em ove a n y deposit s or ot h er for-
(10) Rem ove t h e fou r pu m p m ou n t in g bolt s (F ig. eign m a t er ia l. In spect t h e cylin der block a n d wa t er
24) a n d r em ove pu m p fr om veh icle. Disca r d old ga s- pu m p m a t in g su r fa ces for er osion or da m a ge fr om
ca vit a t ion .
BOLTS
(4) LONG
PULLEY
SHORT
BOLT
(3) MOUNTING
LOWER
STUDS
VENT HOLE HEATER
UPPER
WATER
PUMP
HOSE
VENT
FITTING
PUMP
GAS-
HOLE
KET PUMP
WATER
PULLEY
PUMP HUB BOLTS (4)

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.

REM OVAL-4 .0 L EN GI N E (LH D/RH D)


(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Dr a in t h e coolin g syst em .
(3) Discon n ect elect r ic coolin g fa n con n ect or.
(4) Rem ove elect r ic coolin g fa n /sh r ou d a ssem bly (if
equ ipped).
(5) Un bolt viscou s fa n sh r ou d.
(6) Loosen (bu t do n ot r em ove a t t h is t im e) t h e
fou r wa t er pu m p pu lley-t o-wa t er pu m p h u b m ou n t in g
bolt s (F ig. 25) a n d t h e fou r viscou s fa n t o idler pu lley
(3) SHORT n u t s.

LONG
BOLT

J9307-12 BOLTS (4)

Fig. 24 Water Pump Remove/Install—Typical


(3) In st a ll t h e ga sket a n d wa t er pu m p. Th e sili-
con e bea d on t h e ga sket sh ou ld be fa cin g t h e wa t er
pu m p. Also, t h e ga sket is in st a lled dr y. Tigh t en
m ou n t in g bolt s t o 30 N·m (22 ft . lbs.) t or qu e. Rot a t e PUMP PULLEY J9307-49
t h e sh a ft by h a n d t o be su r e it t u r n s fr eely.
(4) Con n ect t h e r a dia t or a n d h ea t er h oses t o t h e Fig. 25 Water Pump Pulley Bolts
wa t er pu m p.
NOTE: The engine accessory drive belt must be
(5) In st a ll power st eer in g pu m p a n d br a cket . Refer
removed prior to removing the fan (if installed at
t o Gr ou p 19, St eer in g.
pump) or fan pulley.
(6) P osit ion wa t er pu m p pu lley t o wa t er pu m p
h u b. (7) Rem ove a ccessor y dr ive belt (r efer t o Accessor y
(7) In st a ll sh r ou d a n d fa n t oget h er a n d in st a ll fou r Dr ive Belt , Rem ova l a n d In st a lla t ion in t h is sect ion )
n u t s t o wa t er pu m p h u b st u ds. Tigh t en n u t s t o 27 (8) Rem ove t h e fou r viscou s fa n t o idler pu lley
N·m (20 ft . lbs.) t or qu e. n u t s a n d r em ove t h e fa n a n d sh r ou d t oget h er.
(8) In st a ll a n d t igh t en u pper fa n sh r ou d n u t s.
CAUTION: After removing fan blade/viscous fan
CAUTION: When installing the serpentine engine drive assembly, do not place thermal viscous fan
accessory drive belt, the belt MUST be routed cor- drive in horizontal position. If stored horizontally,
rectly. If not, the engine may overheat due to the silicone fluid in viscous fan drive could drain into
water pump rotating in the wrong direction. Refer to its bearing assembly and contaminate lubricant.
the Belt Removal and Installation in this group for
appropriate belt routing. You may also refer to the (9) Rem ove t h e fou r wa t er pu m p pu lley bolt s a n d
Belt Routing Label in the vehicle engine compart- r em ove t h e pu lley.
ment. (10) Rem ove power st eer in g pu m p a n d br a cket
(F ig. 26), r efer t o Gr ou p 19 St eer in g.
(9) In st a ll a n d t en sion a ccessor y dr ive belt , r efer t o (11) Rem ove lower r a dia t or h ose fr om wa t er pu m p.
Accessor y Dr ive Belt r em ova l a n d in st a lla t ion in t h is Rem ove h ea t er h ose fr om wa t er pu m p fit t in g.
gr ou p.
BOLTS
(4) LONG
PULLEY
SHORT
BOLT
(3) MOUNTING
LOWER
STUDS
VENT HOLE HEATER
UPPER
WATER
PUMP
HOSE
VENT
FITTING
PUMP
GAS-
HOLE
KET

7 - 28 COOLING SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

PUMP ASSEMBLY

-----~
PUMP BRACKET 80500555

Fig. 26 Power Steering Pump Attachment-4.0L


(12) Rem ove t h e fou r pu m p m ou n t in g bolt s (F ig. (13) If pu m p is t o be r epla ced, t h e h ea t er h ose fit -
27) a n d r em ove pu m p fr om veh icle. Disca r d old ga s- t in g m u st be r em oved. Not e posit ion of fit t in g befor e
ket . Not e t h a t on e of t h e fou r bolt s is lon ger t h a n t h e r em ova l.
ot h er bolt s.
I N STALLAT I ON -4 .0 L EN GI N E (LH D/RH D)
HEATER HOSE (1) If pu m p is bein g r epla ced, in st a ll t h e h ea t er
FITTING
h ose fit t in g t o t h e pu m p. Use a sea la n t on t h e fit t in g
su ch a s Mopa r y Th r ea d Sea la n t Wit h Teflon . Refer
UPPER t o t h e dir ect ion s on t h e pa cka ge.
VENT
HOLE (2) Clea n t h e ga sket m a t in g su r fa ces. If t h e or igi-
n a l pu m p is u sed, r em ove a n y deposit s or ot h er for-
eign m a t er ia l. In spect t h e cylin der block a n d wa t er
pu m p m a t in g su r fa ces for er osion or da m a ge fr om
ca vit a t ion .
(3) In st a ll t h e ga sket a n d wa t er pu m p. Th e sili-
con e bea d on t h e ga sket sh ou ld be fa cin g t h e wa t er
pu m p. Also, t h e ga sket is in st a lled dr y. Tigh t en
m ou n t in g bolt s t o 30 N·m (22 ft . lbs.) t or qu e. Rot a t e
t h e sh a ft by h a n d t o be su r e it t u r n s fr eely.
(4) Con n ect t h e r a dia t or a n d h ea t er h oses t o t h e
wa t er pu m p.
(3) SHORT
(5) P osit ion wa t er pu m p pu lley t o wa t er pu m p
h u b.
(6) In st a ll fou r pu m p pu lley bolt s. Tigh t en bolt s (or
n u t s) t o 27 N·m (20 ft . lbs.) t or qu e.
(7) In st a ll power st eer in g pu m p. Refer t o Gr ou p
LONG 19, St eer in g for pr oper pr ocedu r e a n d t or qu e va lu es.
BOLT
(8) In st a ll t h e viscou s fa n a n d sh r ou d t oget h er.
In st a ll t h e fou r fa n t o idler pu lley n u t s a n d t igh t en
t o 27 N·m (20 ft . lbs.).
J9307-12

Fig. 27 Water Pump Remove/Install—Typical


LONGSHORT
BOLT BOLT GASKET THERMOSTAT
HOUSING
THERMOSTAT

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.

(9) In st a ll a n d t igh t en viscou s fa n sh r ou d bolt s.


\
(10) In st a ll a n d t en sion t h e a ccessor y dr ive belt ,
r efer t o Accessor y Dr ive Belt r em ova l a n d in st a lla -
t ion in t h is gr ou p.
(11) In st a ll t h e elect r ic coolin g fa n /sh r ou d a ssy.
(12) In st a ll a n d t igh t en fa n sh r ou d bolt s a n d con -
n ect elect r ica l fa n con n ect or.
(13) F ill coolin g syst em wit h coola n t a n d ch eck for

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

WARNING: DO NOT LOOSEN THE RADIATOR Fig. 28 Thermostat Removal/Installation


DRAINCOCK WITH THE SYSTEM HOT AND PRES- (5) Clea n t h e ga sket m a t in g su r fa ces.
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR. I N STALLAT I ON
(1) In st a ll t h e r epla cem en t t h er m ost a t so t h a t t h e
DO NOT WASTE r eu sa ble coola n t . If t h e solu t ion pellet , wh ich is en cir cled by a coil spr in g, fa ces t h e
is clea n , dr a in t h e coola n t in t o a clea n con t a in er for en gin e. All t h er m ost a t s a r e m a r ked on t h e ou t er
r eu se. fla n ge t o in dica t e t h e pr oper in st a lled posit ion .
(1) Dr a in t h e coola n t fr om t h e r a dia t or u n t il t h e (a ) Obser ve t h e r ecess gr oove in t h e en gin e cyl-
level is below t h e t h er m ost a t h ou sin g. in der h ea d (F ig. 29).
(b) P osit ion t h er m ost a t in t o t h is gr oove wit h
WARNING: CONSTANT TENSION HOSE CLAMPS a r r ow a n d a ir bleed h ole on ou t er fla n ge poin t in g
ARE USED ON MOST COOLING SYSTEM HOSES. u p.
WHEN REMOVING OR INSTALLING, USE ONLY (2) In st a ll r epla cem en t ga sket a n d t h er m ost a t
TOOLS DESIGNED FOR SERVICING THIS TYPE OF h ou sin g.
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 7). SNAP-ON CLAMP TOOL (NUMBER CAUTION: Tightening the thermostat housing
HPC-20) MAY BE USED FOR LARGER CLAMPS. unevenly or with the thermostat out of its recess
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- may result in a cracked housing.
ING CONSTANT TENSION CLAMPS.
(3) Tigh t en t h e h ou sin g bolt s t o 20 N·m (15 ft . lbs.)
t or qu e.
CAUTION: A number or letter is stamped into the (4) In st a ll h oses t o t h er m ost a t h ou sin g.
tongue of constant tension clamps (Fig. 8). If (5) In st a ll elect r ica l con n ect or t o coola n t t em per a -
replacement is necessary, use only an original t u r e sen sor.
equipment clamp with matching number or letter. (6) Be su r e t h a t t h e r a dia t or dr a in cock is t igh t ly
closed. F ill t h e coolin g syst em t o t h e cor r ect level
(2) Rem ove r a dia t or u pper h ose a n d h ea t er h ose a t
wit h t h e r equ ir ed coola n t m ixt u r e. Refer t o Refillin g
t h er m ost a t h ou sin g.
Coolin g Syst em in t h is gr ou p.
(3) Discon n ect wir in g con n ect or a t en gin e coola n t
(7) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks.
t em per a t u r e sen sor.
GROOVE

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

WELL NUTS (2)

\
FAN SHROUD
MOUNTING
BOLTS (4)

E-CUP
19507-49

Fig. 30 Radiator Remove/Install—2.5L 4-Cylinder Engine


4 .0 L 6 -CY LI N DER EN GI N E
RECEIVER/DRIER
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.

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.

WARNING: CONSTANT TENSION HOSE CLAMPS


ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 7). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.

CAUTION: A number or letter is stamped into the


Fig. 31 Condenser Mounting Bolts—2.5L 4-Cylinder tongue of constant tension clamps (Fig. 8). If
Engine—Typical replacement is necessary, use only an original
equipment clamp with matching number or letter.
MOUNTING
ELECTRIC
BOLT COOLING
ELECTRIC
FAN COOLING
CONNECTOR
FAN MOUNTINGBOLT

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

Fig. 33 Auxiliary Electric Cooling Fan and Fan Shroud—Typical

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

Fig. 36 Auxiliary Cooling Fan—Remove/Install—


Typical
(3) Lift fa n st r a igh t u p a n d ou t of veh icle.

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

Fig. 38 Heater and Cord—4.0L 6-Cylinder Engine


s c h e m a tic s o n B e lt Ro u tin g La be l. Th is la bel is 8056d9fa

loca t ed in t h e en gin e com pa r t m en t .


Refer t o (F ig. 39) xxxxx (F ig. 40) xxxxxx (F ig. 41) Fig. 40 Models with 2.5L Engine—Without A/C
xxxxx (F ig. 42) for pr oper belt r ou t in g on veh icles
wit h con ven t ion a l left h a n d dr ive. Refer t o (F ig. 43)
xxxxx (F ig. 44) for pr oper belt r ou t in g on veh icles
wit h r igh t h a n d dr ive (RH D). Or, r efer t o t h e Belt
Rou t in g La bel loca t ed in t h e veh icle en gin e com pa r t -
m en t .

sos6d9fc I

Fig. 41 Models with 4.0L Engine—Without A/C—


Except RHD
(4) Rem ove belt .

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)

TENSION ADJUSTMENT BOLT THERMAL (4) FAN HUB-TO-PUMP


VISCOUS PULLEY STUDS
FAN DRIVE

UPPER ALTERNATOR NUT 80abd2b6

'
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.

COOLING SYSTEM FANS


REM OVAL
Som e en gin es h a ve t h e m ech a n ica l fa n /viscou s fa n
dr ive a ssem bly m ou n t ed dir ect ly t o t h e wa t er pu m p
h u b (F ig. 47). It m a y a lso be m ou n t ed t o a h u b/bea r-
in g a t t a ch ed t o a n a lu m in u m br a cket on t h e r igh t
fr on t side of en gin e (F ig. 48).
(1) Loosen bu t do n ot r em ove a t t h is t im e, t h e fou r
fa n h u b m ou n t in g n u t s (F ig. 47) xxxxxx (F ig. 48).
(2) Rem ove a ccessor y ser pen t in e dr ive belt . Refer
t o Belt Ser vice in t h e E n gin e Accessor y Dr ive Belt ~
sect ion of t h is gr ou p. J9307-52
PULLEY NUTS_.-@
(3) Som e m odels wit h cer t a in en gin es m a y r equ ir e
t h e r em ova l of t h e fa n sh r ou d t o r em ove t h e viscou s Fig. 48 Bracket Mounted Cooling Fan
fa n dr ive. Th e fa n sh r ou d a n d fa n bla de/viscou s fa n
flu id in viscou s fa n dr ive cou ld dr a in in t o it s bea r in g
dr ive sh ou ld be r em oved fr om t h e veh icle a s on e
a ssem bly a n d con t a m in a t e lu br ica n t .
a ssem bly.
(4) Rem ove fou r fa n h u b m ou n t in g n u t s (F ig. 47) I N STALLAT I ON
xxxxxxxxxx (F ig. 48) a n d r em ove fa n /viscou s fa n (1) Assem ble fa n bla de t o viscou s fa n dr ive.
dr ive a ssem bly fr om veh icle. Tigh t en m ou n t in g bolt s t o 27 N·m (20 ft . lbs.) t or qu e.
(5) Aft er r em ovin g fa n bla de/viscou s fa n dr ive (2) P osit ion m ou n t in g fla n ge of fa n bla de/viscou s
a ssem bly, d o n o t pla ce t h er m a l viscou s fa n dr ive in fa n dr ive a ssem bly on t o h u b. In st a ll fou r n u t s a n d
h or izon t a l posit ion . If st or ed h or izon t a lly, silicon e t igh t en t o 24 N·m (18 ft . lbs.) t or qu e. Tigh t en t h e
7 - 38 COOLING SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
fir st t wo n u t s 180 degr ees a pa r t . Th en t igh t en la st (1) Rem ove fa n bla de a n d viscou s fa n dr ive a s a n
t wo n u t s. a ssem bly fr om t h e en gin e. Refer t o pr ecedin g
Rem ova l pr ocedu r e.
CAUTION: When installing a serpentine accessory (2) Rem ove fa n bla de a ssem bly fr om viscou s fa n
drive belt, the belt MUST be routed correctly. If not, dr ive u n it (fou r bolt s).
the engine may overheat due to the water pump (3) La y fa n on a fla t su r fa ce wit h lea din g edge fa c-
rotating in the wrong direction. Refer to appropriate in g down . Wit h t ip of bla de t ou ch in g fla t su r fa ce,
Engine Accessory Drive Belt Schematic in this r epla ce fa n if clea r a n ce bet ween opposit e bla de a n d
group for correct belt routing. su r fa ce is gr ea t er t h a n 2.0 m m (.090 in ch ). Rockin g
m ot ion of opposit e bla des sh ou ld n ot exceed 2.0 m m
(3) In st a ll a ccessor y dr ive belt s. Ten sion belt s t o (.090 in ch ). Test a ll bla des in t h is m a n n er.
specifica t ion s. Refer t o t h e Specifica t ion s sect ion a t
t h e en d of t h is gr ou p. WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF NOT WITHIN SPECI-
VISCOUS FAN DRIVE REMOVAL/INSTALLATION FICATIONS.
Refer t o Coolin g Syst em F a n for r em ova l a n d
in st a lla t ion pr ocedu r es of t h e viscou s dr ive u n it . (4) In spect fa n a ssem bly for cr a cks, ben ds, loose
r ivet s or br oken welds. Repla ce fa n if a n y da m a ge is
Visc ous Fa n Drive Fluid Pum p Out fou n d.
Re quire m e nt :
Aft er in st a llin g a n e w viscou s fa n dr ive, br in g t h e CAUTION: If fan blade assembly is replaced
en gin e speed u p t o a ppr oxim a t ely 2000 r pm a n d h old because of mechanical damage, water pump and
for a ppr oxim a t ely t wo m in u t es. Th is will en su r e viscous fan drive should also be inspected. These
pr oper flu id dist r ibu t ion wit h in t h e dr ive. components could have been damaged due to
excessive vibration.
CLEAN I N G AN D I N SPECT I ON
COOLING SYSTEM HOSES
RADIATOR PRESSURE CAP
I N SPECT I ON
I N SPECT I ON In spect t h e h oses a t r egu la r in t er va ls. Repla ce
Visu a lly in spect t h e pr essu r e va lve ga sket on t h e h oses t h a t a r e cr a cked, feel br it t le wh en squ eezed or
ca p. Repla ce ca p if t h e ga sket is swollen , t or n or swell excessively wh en t h e syst em is pr essu r ized.
wor n . In spect t h e a r ea a r ou n d r a dia t or filler n eck for Th e u se of m olded r epla cem en t h oses is r ecom -
wh it e deposit s t h a t in dica t e a lea kin g ca p. m en ded. Wh en per for m in g a h ose in spect ion , in spect
t h e r a dia t or lower h ose for pr oper posit ion a n d con -
RADIATOR CLEANING dit ion of t h e spr in g.
Th e r a dia t or a n d a ir con dit ion in g fin s sh ou ld be
clea n ed wh en a n a ccu m u la t ion of bu gs, lea ves et c.
h a s occu r r ed. Clea n r a dia t or fin s a r e n ecessa r y for SPECI FI CAT I ON S
good h ea t t r a n sfer. Wit h t h e en gin e cold, a pply cold
wa t er a n d com pr essed a ir t o t h e ba ck (en gin e side) of COOLING SYSTEM CAPACITIES
t h e r a dia t or t o flu sh t h e r a dia t or a n d/or A/C con -
den ser of debr is. BELT TENSION
Belt t en sion m u st be a dju st ed. Refer t o t h e follow-
COOLING SYSTEM CLEANING in g Belt Ten sion ch a r t for specifica t ion s.
Dr a in coolin g syst em a n d r efill wit h wa t er. Ru n
en gin e wit h r a dia t or ca p in st a lled u n t il u pper r a dia -
t or h ose is h ot . St op en gin e a n d dr a in wa t er fr om
syst em . If wa t er is dir t y, fill syst em wit h wa t er, r u n
en gin e a n d dr a in syst em . Repea t u n t il wa t er dr a in s
clea n .

FAN BLADE INSPECTION


Th e fa n bla des ca n n ot be r epa ir ed. If fa n is da m -
a ged, it m u st be r epla ced. In spect fa n a s follows:
XJ COOLING SYSTEM 7 - 39
SPECI FI CAT I ON S (Cont inue d)

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

*800-900 N (180-200 lbs. force) D ES CRIP TION TORQU E


(With ** new serpentine belt) Ra d ia to r (2.5L En g in e )
*623-712 N (140-160 lbs. force) Mou n t in g Bolt s . . . . . . . . . . . . . 6 N·m (55 in . lbs.)
(With ** used serpentine belt) Th e rm o s ta t Ho u s in g
**Belt is considered new if it has been used 15 Bolt s . . . . . . . . . . . . . . . . . . . . 20 N·m (15 ft . lbs.)
minutes or less. Vis c o u s F a n D riv e As s y.-to -Wa te r P u m p
*Specifications for use with a belt tension gauge. Nu t s . . . . . . . . . . . . . . . . . . . . 27 N·m (20 ft . lbs.)
Refer to operating instructions supplied with gauge. Wa te r P u m p
Bolt s . . . . . . . . . . . . . . . . . . . . 30 N·m (22 ft . lbs.)
TORQUE SPECIFICATIONS
SPECI AL T OOLS
D ES CRIP TION TORQU E
Au to . Tra n s . Au x ilia ry Oil Co o le r COOLING
Mt g. Scr ews . . . . . . . . . . . . . . . . 2 N·m (18in . lbs.)
Au x ilia ry Ele c tric Co o lin g F a n
Mt g. Scr ews . . . . . . . . . . . . . . . 4 N·m (36 in . lbs.)
B lo c k He a te r
Mou n t in g Scr ew . . . . . . . . . . . . 4 N·m (20 in . lbs.)
Co n d e n s e r-to -Ra d ia to r
Scr ews . . . . . . . . . . . . . . . . . . . 6 N·m (55 in . lbs.)
F a n B la d e As s y.-to -Vis c o u s F a n D riv e
Bolt s . . . . . . . . . . . . . . . . . . . . 24 N·m (18 ft . lbs.)
F a n S h ro u d (2.5L En g in e )
Mou n t in g Bolt s . . . . . . . . . . . . . 2 N·m (20 in . lbs.) Hose Clamp Tool—6094
F a n S h ro u d (4.0L En g in e ) Cooling System Pressure Tester—7700–A
Scr ews . . . . . . . . . . . . . . . . . . . 4 N·m (20 in . lbs.)
Ge n e ra to r P iv o t
Bolt . . . . . . . . . . . . . . . . . . . . . 38 N·m (28 ft . lbs.)
Ge n e ra to r Re a r Ad j.
Bolt . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 ft . lbs.)
Is o la to r-to -Cro s s m e m be r
Nu t s . . . . . . . . . . . . . . . . . . . . 10 N·m (86 in . lbs.)
Is o la to r-to -Ra d ia to r
Nu t s . . . . . . . . . . . . . . . . . . . . . 5 N·m (47 in . lbs.)
Ra d ia to r (4.0L En g in e )
Mou n t in g Bolt s . . . . . . . . . . . . . . 8 N·m (6 ft . lbs.)
POSITIVE
NANCE
LOW-MAINTE-
POST TERY
BAT- PLATE GROUPS
VENT TEST
ELECTROLYTE
INDICA-
TOR
LEVEL VENTGREEN
NEGATIVE
BALL
POST

XJ BATTERY 8A - 1

BATTERY
CON T EN T S

page page

GENERAL INFORMATION IGNITION-OFF DRAW TEST . . . . . . . . . . . . . . . 9


INTRODUCTION . . . . . . . . . . . ............. 1 LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OVERVIEW . . . . . . . . . . . . . . . ............. 1 OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . . . 7
DESCRIPTION AND OPERATION VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . 10
BATTERY MOUNTING . . . . . . . ............. 3 SERVICE PROCEDURES
BATTERY SIZE AND RATINGS . ............. 2 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . 11
BATTERY . . . . . . . . . . . . . . . . . ............. 2 REMOVAL AND INSTALLATION
DIAGNOSIS AND TESTING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BATTERY . . . . . . . . . . . . . . . . . ............. 3 SPECIFICATIONS
BUILT-IN TEST INDICATOR . . . ............. 4 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HYDROMETER TEST . . . . . . . . ............. 6

GEN ERAL I N FORM AT I ON n a n ce pr ocedu r e, ba t t er y ch a r gin g in for m a t ion is


loca t ed in t h is gr ou p. Th is wa s don e beca u se t h e ba t -
OVERVIEW t er y m u st be fu lly-ch a r ged befor e a n y dia gn osis ca n
Th e ba t t er y, st a r t in g, a n d ch a r gin g syst em s oper- be per for m ed.
a t e wit h on e a n ot h er, a n d m u st be t est ed a s a com - Th e fa ct or y-in st a lled low-m a in t en a n ce ba t t er y h a s
plet e syst em . In or der for t h e veh icle t o st a r t a n d r em ova ble ba t t er y cell ca ps. Wa t er ca n be a dded t o
ch a r ge pr oper ly, a ll of t h e com pon en t s in volved in t h is ba t t er y. Th e ba t t er y is n ot sea led a n d h a s ven t
t h ese syst em s m u st per for m wit h in specifica t ion s. h oles in t h e cell ca ps (F ig. 1). Th e ch em ica l com posi-
Gr ou p 8A cover s t h e ba t t er y, Gr ou p 8B cover s t h e t ion wit h in t h e low-m a in t en a n ce ba t t er y r edu ces ba t -
st a r t in g syst em , a n d Gr ou p 8C cover s t h e ch a r gin g t er y ga ssin g a n d wa t er loss, a t n or m a l ch a r ge a n d
syst em . Refer t o Gr ou p 8W - Wir in g Dia gr a m s for disch a r ge r a t es.
com plet e cir cu it descr ipt ion s a n d dia gr a m s. We h a ve POSITIVE VENT
sepa r a t ed t h ese syst em s t o m a ke it ea sier t o loca t e
t h e in for m a t ion you a r e seekin g wit h in t h is Ser vice
POST .,--:;;.=======~==
Ma n u a l. H owever, wh en a t t em pt in g t o dia gn ose a n y
of t h ese syst em s, it is im por t a n t t h a t you keep t h eir
in t er depen den cy in m in d.
Th e dia gn ost ic pr ocedu r es u sed in t h ese gr ou ps
in clu de t h e m ost ba sic con ven t ion a l dia gn ost ic m et h -
ods, t o t h e m or e soph ist ica t ed On -Boa r d Dia gn ost ics
(OBD) bu ilt in t o t h e P ower t r a in Con t r ol Modu le
(P CM). Use of a in du ct ion m illia m per e a m m et er, volt /
oh m m et er, ba t t er y ch a r ger, ca r bon pile r h eost a t (loa d
t est er ), a n d 12-volt t est la m p m a y be r equ ir ed.
All OBD-sen sed syst em s a r e m on it or ed by t h e
P CM. E a ch m on it or ed cir cu it is a ssign ed a Dia gn os-
t ic Tr ou ble Code (DTC). Th e P CM will st or e a DTC in
elect r on ic m em or y for a n y fa ilu r e it det ect s. See t h e Fig. 1 Low-Maintenance Battery - Typical
On -Boa r d Dia gn ost ics Test in Gr ou p 8C - Ch a r gin g Ra pid loss of elect r olyt e ca n be ca u sed by a n over-
Syst em for m or e in for m a t ion . ch a r gin g con dit ion . Be cer t a in t o dia gn ose t h e ch a r g-
in g syst em befor e r et u r n in g t h e veh icle t o ser vice.
INTRODUCTION Refer t o Gr ou p 8C - Ch a r gin g Syst em for m or e in for-
Th is sect ion cover s on ly ba t t er y dia gn ost ic a n d ser- m a t ion .
vice pr ocedu r es. F or ba t t er y m a in t en a n ce pr ocedu r es, Th e fa ct or y-in st a lled ba t t er y a lso h a s a bu ilt -in
r efer t o Gr ou p 0 - Lu br ica t ion a n d Ma in t en a n ce. t est in dica t or (h ydr om et er ). Th e color visible in t h e
Wh ile ba t t er y ch a r gin g ca n be con sider ed a m a in t e- sigh t gla ss of t h e in dica t or will r evea l t h e ba t t er y
8A - 2 BATTERY XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
con dit ion . See Bu ilt -In Test In dica t or in t h is gr ou p Ch a r gin g t h e ba t t er y gr a du a lly ch a n ges t h e su l-
for m or e in for m a t ion . fa t ed lea d pla t es ba ck in t o spon ge lea d a n d lea d
It is im por t a n t t h a t t h e ba t t er y, st a r t in g, a n d oxide, a n d t h e wa t er ba ck in t o su lfu r ic a cid. Th is
ch a r gin g syst em s be t h or ou gh ly t est ed a n d in spect ed a ct ion r est or es t h e differ en ce in t h e elect r on ch a r ges
a n y t im e a ba t t er y n eeds t o be ch a r ged or r epla ced. deposit ed on t h e pla t es, a n d t h e volt a ge pot en t ia l of
Th e ca u se of a bn or m a l disch a r ge, over ch a r gin g, or t h e ba t t er y cells.
ea r ly ba t t er y fa ilu r e m u st be dia gn osed a n d cor r ect ed F or a ba t t er y t o r em a in u sefu l, it m u st be a ble t o
befor e a ba t t er y is r epla ced or r et u r n ed t o ser vice. pr odu ce h igh -a m per a ge cu r r en t over a n ext en ded
per iod. A ba t t er y m u st a lso be a ble t o a ccept a
NOTE: This group covers both Left-Hand Drive ch a r ge, so t h a t it s volt a ge pot en t ia l m a y be r est or ed.
(LHD) and Right-Hand Drive (RHD) versions of this In a ddit ion t o pr odu cin g a n d st or in g elect r ica l
model. Whenever required and feasible, the RHD en er gy, t h e ba t t er y ser ves a s a ca pa cit or, or volt a ge
versions of affected vehicle components have been st a bilizer, for a veh icle’s elect r ica l syst em . It a bsor bs
constructed as mirror-image of the LHD versions. m ost a bn or m a l or t r a n sien t volt a ges ca u sed by t h e
While most of the illustrations used in this group swit ch in g of a n y of t h e veh icle’s elect r ica l com po-
represent only the LHD version, the diagnostic and n en t s.
service procedures outlined can generally be Th e ba t t er y is ven t ed t o r elea se excess h ydr ogen
applied to either version. Exceptions to this rule ga s t h a t is cr ea t ed wh en t h e ba t t er y is bein g ch a r ged
have been clearly identified as LHD or RHD, if a or disch a r ged. H owever, even wit h t h ese ven t s, t h e
special illustration or procedure is required. h ydr ogen ga s ca n collect in or a r ou n d t h e ba t t er y. If
h ydr ogen ga s is exposed t o fla m e or spa r ks, it m a y
ign it e.
DESCRI PT I ON AN D OPERAT I ON If t h e elect r olyt e level is low, t h e ba t t er y m a y a r c
in t er n a lly a n d explode. If t h e ba t t er y is equ ipped
BATTERY wit h r em ova ble cell ca ps, a dd dist illed wa t er wh en -
Th e st or a ge ba t t er y is a device u sed t o st or e elec- ever t h e elect r olyt e level is below t h e t op of t h e
t r ica l en er gy pot en t ia l in a ch em ica l for m . Wh en a n pla t es. If t h e ba t t er y cell ca ps ca n n ot be r em oved, t h e
elect r ica l loa d is a pplied t o t h e ba t t er y t er m in a ls, a n ba t t er y m u st be r epla ced if t h e elect r olyt e level
elect r och em ica l r ea ct ion occu r s wit h in t h e ba t t er y. becom es low.
Th is r ea ct ion ca u ses t h e ba t t er y t o disch a r ge elect r i-
ca l cu r r en t . BATTERY SIZE AND RATINGS
Th e ba t t er y is m a de u p of six in dividu a l cells t h a t Th e ba t t er y Gr ou p Size n u m ber, t h e Cold Cr a n kin g
a r e con n ect ed in ser ies. E a ch cell con t a in s posit ively Am per a ge (CCA) r a t in g, a n d t h e Reser ve Ca pa cit y
ch a r ged pla t e gr ou ps m a de of lea d oxide, a n d n ega - (RC) r a t in g or Am per e-H ou r s (AH ) r a t in g ca n be
t ively ch a r ged pla t e gr ou ps m a de of spon ge lea d. fou n d on t h e or igin a l equ ipm en t ba t t er y la bel. Be
Th ese dissim ila r m et a l pla t es a r e su bm er ged in a cer t a in t h a t a r epla cem en t ba t t er y h a s t h e cor r ect
su lfu r ic a cid a n d wa t er solu t ion ca lled a n elect r olyt e. Gr ou p Size n u m ber, a s well a s CCA, a n d RC or AH
As t h e ba t t er y disch a r ges, a gr a du a l ch em ica l r a t in gs t h a t equ a l or exceed t h e or igin a l equ ipm en t
ch a n ge t a kes pla ce wit h in ea ch cell. Th e su lfu r ic a cid specifica t ion for t h e veh icle bein g ser viced.
in t h e elect r olyt e com bin es wit h t h e pla t e m a t er ia ls, See t h e Ba t t er y Cla ssifica t ion s a n d Ra t in gs ch a r t
ca u sin g bot h pla t es t o slowly ch a n ge t o lea d su lfa t e. in Specifica t ion s a t t h e ba ck of t h is gr ou p for m or e
At t h e sa m e t im e, oxygen fr om t h e posit ive pla t e in for m a t ion . Ba t t er y sizes a n d r a t in gs a r e discu ssed
m a t er ia l com bin es wit h h ydr ogen fr om t h e su lfu r ic in m or e det a il below.
a cid, ca u sin g t h e elect r olyt e t o becom e m a in ly wa t er.
GROU P SI Z E
Th e ch em ica l ch a n ges wit h in t h e ba t t er y a r e
Th e ou t side dim en sion s a n d t er m in a l pla cem en t of
ca u sed by t h e m ovem en t of excess or fr ee elect r on s
t h e ba t t er y con for m t o st a n da r ds est a blish ed by t h e
bet ween t h e posit ive a n d n ega t ive pla t e gr ou ps. Th is
Ba t t er y Cou n cil In t er n a t ion a l (BCI). E a ch ba t t er y is
m ovem en t of elect r on s pr odu ces a flow of elect r ica l
a ssign ed a BCI Gr ou p Size n u m ber t o h elp iden t ify a
cu r r en t t h r ou gh t h e loa d device a t t a ch ed t o t h e ba t -
cor r ect ly-sized r epla cem en t .
t er y t er m in a ls.
As t h e pla t e m a t er ia ls becom e m or e sim ila r ch em - COLD CRAN K I N G AM PERAGE
ica lly, a n d t h e elect r olyt e becom es less a cid, t h e volt - Th e Cold Cr a n kin g Am per a ge (CCA) r a t in g speci-
a ge pot en t ia l of ea ch cell is r edu ced. H owever, by fies h ow m u ch cu r r en t (in a m per es) t h e ba t t er y ca n
ch a r gin g t h e ba t t er y wit h a volt a ge h igh er t h a n t h a t deliver for t h ir t y secon ds a t -18° C (0° F ). Ter m in a l
of t h e ba t t er y, t h e ba t t er y disch a r gin g pr ocess is volt a ge m u st n ot fa ll below 7.2 volt s du r in g or a ft er
r ever sed. t h e t h ir t y secon d disch a r ge per iod. Th e CCA r equ ir ed
XJ BATTERY 8A - 3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
is gen er a lly h igh er a s en gin e displa cem en t in cr ea ses, See t h e Ba t t er y Ch a r gin g pr ocedu r e in t h is gr ou p for
depen din g a lso u pon t h e st a r t er cu r r en t dr a w m or e in for m a t ion .
r equ ir em en t s.
WARNING:
RESERV E CAPACI T Y • IF THE BATTERY SHOWS SIGNS OF FREEZ-
Th e Reser ve Ca pa cit y (RC) r a t in g specifies t h e ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
t im e (in m in u t es) it t a kes for ba t t er y t er m in a l volt - LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
a ge t o fa ll below 10.5 volt s, a t a disch a r ge r a t e of 25 CHARGE. THE BATTERY MAY ARC INTERNALLY
a m per es. RC is det er m in ed wit h t h e ba t t er y fu lly- AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
ch a r ged a t 26.7° C (80° F ). Th is r a t in g est im a t es h ow CLE DAMAGE MAY RESULT.
lon g t h e ba t t er y m igh t la st a ft er a ch a r gin g syst em • EXPLOSIVE HYDROGEN GAS FORMS IN AND
fa ilu r e, u n der m in im u m elect r ica l loa d. AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
AM PERE-H OU RS PERSONAL INJURY AND/OR VEHICLE DAMAGE
Th e Am per e-H ou r s (AH ) r a t in g specifies t h e cu r- MAY RESULT.
r en t (in a m per es) t h a t a ba t t er y ca n deliver st ea dily • THE BATTERY CONTAINS SULFURIC ACID,
for t wen t y h ou r s, wit h t h e volt a ge in t h e ba t t er y n ot WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
fa llin g below 10.5 volt s. Th is r a t in g is a lso som et im es TACT WITH THE SKIN, EYES, OR CLOTHING. IN
r efer r ed t o a s t h e t wen t y-h ou r disch a r ge r a t in g. THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
BATTERY MOUNTING OF THE REACH OF CHILDREN.
Th e ba t t er y is m ou n t ed t o a m olded pla st ic t r a y • IF THE BATTERY IS EQUIPPED WITH REMOV-
loca t ed in t h e r igh t fr on t cor n er of t h e en gin e com - ABLE CELL CAPS, BE CERTAIN THAT EACH OF
pa r t m en t . Two T-bolt s a r e h eld in for m a t ion s on ea ch THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
side of t h e t r a y by pu sh -on r et a in er s, a n d ext en d THE BATTERY IS RETURNED TO SERVICE. PER-
u pwa r d on ea ch side of t h e ba t t er y. A h olddown st r a p SONAL INJURY AND/OR VEHICLE DAMAGE MAY
fit s a cr oss t h e t op of t h e ba t t er y ca se a n d t h er m o- RESULT FROM LOOSE OR MISSING CELL CAPS.
gu a r d. Th e en ds of t h e T-bolt s pa ss t h r ou gh t h e h old-
down st r a p on ea ch side of t h e ba t t er y, a n d a n u t Th e con dit ion of a ba t t er y is det er m in ed by t wo cr i-
secu r es t h e h olddown st r a p t o t h e T-bolt s. On e en d of t er ia :
a su ppor t st r a p is loca t ed u n der t h e for wa r d-m ost 1. S ta te -Of-Ch a rg e - Th is ca n be det er m in ed by
h olddown st r a p n u t , a n d t h e ot h er en d is secu r ed t o viewin g t h e bu ilt -in t est in dica t or, by ch eckin g t h e
t h e u pper r a dia t or cr ossm em ber by a bolt . specific gr a vit y of t h e elect r olyt e (h ydr om et er t est ),
Th e ba t t er y t r a y is secu r ed wit h t h r ee n u t s t o or by ch eckin g t h e ba t t er y volt a ge (open -cir cu it volt -
t h r ee st u ds t h a t pr ot r u de fr om t h e wh eelh ou se in n er a ge t est ).
pa n el, for wa r d of t h e r igh t fr on t wh eel. 2. Cra n k in g Ca p a c ity - Th is ca n be det er m in ed
On som e m odels, a h ole in t h e bot t om of t h e ba t - by per for m in g a ba t t er y loa d t est , wh ich m ea su r es
t er y t r a y is fit t ed wit h a ba t t er y t em per a t u r e sen sor. t h e a bilit y of t h e ba t t er y t o su pply h igh -a m per a ge
Models wit h ou t t h e ba t t er y t em per a t u r e sen sor h a ve cu r r en t .
a plu g fit t ed t o t h is h ole. Refer t o Gr ou p 8C - Ch a r g- F ir st , det er m in e t h e ba t t er y st a t e-of-ch a r ge. Th is
in g Syst em for m or e in for m a t ion on t h e ba t t er y t em - ca n be don e in on e of t h r ee wa ys. If t h e ba t t er y h a s a
per a t u r e sen sor. bu ilt -in t est in dica t or, view t h e t est in dica t or t o
Wh en in st a llin g a ba t t er y, be cer t a in t h a t t h e h old- det er m in e t h e st a t e-of-ch a r ge. If t h e ba t t er y h a s n o
down fa st en er s a r e t igh t en ed t o t h e pr oper specifica - t est in dica t or, bu t h a s r em ova ble cell ca ps, per for m
t ion s. Im pr oper h olddown fa st en er t igh t n ess, wh et h er t h e h ydr om et er t est t o det er m in e t h e st a t e-of-ch a r ge.
t oo loose or t oo t igh t , ca n r esu lt in da m a ge t o t h e If t h e cell ca ps a r e n ot r em ova ble, or a h ydr om et er is
ba t t er y. See t h e Ba t t er y Rem ova l a n d In st a lla t ion n ot a va ila ble, per for m t h e open -cir cu it volt a ge t est t o
pr ocedu r es for t h e cor r ect h olddown fa st en er t igh t - det er m in e t h e st a t e-of-ch a r ge.
n ess specifica t ion s. Th e ba t t er y m u st be ch a r ged befor e pr oceedin g
wit h a loa d t est if:
• Th e bu ilt -in t est in dica t or h a s a bla ck or da r k
DI AGN OSI S AN D T EST I N G color visible.
• Th e t em per a t u r e cor r ect ed specific gr a vit y is
BATTERY less t h a n 1.235.
Th e ba t t er y m u st be com plet ely ch a r ged a n d t h e • Th e open -cir cu it volt a ge is less t h a n 12.4 volt s.
t op, post s, a n d t er m in a l cla m ps sh ou ld be pr oper ly A ba t t er y t h a t will n ot a ccept a ch a r ge is fa u lt y,
clea n ed befor e dia gn ost ic pr ocedu r es a r e per for m ed. a n d m u st be r epla ced. F u r t h er t est in g is n ot
8A - 4 BATTERY XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
r equ ir ed. A fu lly-ch a r ged ba t t er y m u st be loa d t est ed AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
t o det er m in e it s cr a n kin g ca pa cit y. A ba t t er y t h a t is CLE DAMAGE MAY RESULT.
fu lly-ch a r ged, bu t does n ot pa ss t h e loa d t est , is • EXPLOSIVE HYDROGEN GAS FORMS IN AND
fa u lt y a n d m u st be r epla ced. AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
NOTE: Completely discharged batteries may take PERSONAL INJURY AND/OR VEHICLE DAMAGE
several hours to accept a charge. See Charging A MAY RESULT.
Completely Discharged Battery in this group for • THE BATTERY CONTAINS SULFURIC ACID,
more information. WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
A ba t t er y is fu lly-ch a r ged wh en : THE EVENT OF CONTACT, FLUSH WITH WATER
• All cells a r e ga ssin g fr eely du r in g ch a r gin g. AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
• A gr een color is visible in t h e sigh t gla ss of t h e OF THE REACH OF CHILDREN.
bu ilt -in t est in dica t or. • IF THE BATTERY IS EQUIPPED WITH REMOV-
• Th r ee cor r ect ed specific gr a vit y t est s, t a ken a t ABLE CELL CAPS, BE CERTAIN THAT EACH OF
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- THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
cific gr a vit y. THE BATTERY IS RETURNED TO SERVICE. PER-
• Open -cir cu it volt a ge is 12.4 volt s or gr ea t er . SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
ABN ORM AL BAT T ERY DI SCH ARGI N G
An y of t h e followin g con dit ion s ca n r esu lt in a bn or- Befor e t est in g, visu a lly in spect t h e ba t t er y for a n y
m a l ba t t er y disch a r gin g: da m a ge (a cr a cked ca se or cover, loose post s, et c.)
1. Cor r oded or loose ba t t er y post s a n d t er m in a l t h a t wou ld ca u se t h e ba t t er y t o be fa u lt y. In or der t o
cla m ps. obt a in cor r ect in dica t ion s fr om t h e bu ilt -in t est in di-
2. A loose or wor n gen er a t or dr ive belt . ca t or, it is im por t a n t t h a t t h e ba t t er y be level a n d
3. E lect r ica l loa ds t h a t exceed t h e ou t pu t of t h e h a ve a clea n sigh t gla ss. Addit ion a l ligh t m a y be
ch a r gin g syst em . Th is ca n be du e t o equ ipm en t r equ ir ed t o view t h e in dica t or. D o n o t u s e o p e n
in st a lled a ft er m a n u fa ct u r e, or r epea t ed sh or t t r ip fla m e a s a s o u rc e o f a d d itio n a l lig h t.
u se. To r ea d t h e bu ilt -in t est in dica t or, look in t o t h e
4. Slow dr ivin g speeds (h ea vy t r a ffic con dit ion s) or sigh t gla ss a n d n ot e t h e color of t h e in dica t or (F ig. 3).
pr olon ged idlin g, wit h h igh -a m per a ge dr a w syst em s Refer t o t h e followin g descr ipt ion , a s t h e color in di-
in u se. ca t es:
5. A fa u lt y cir cu it or com pon en t ca u sin g excessive • Gre e n - in dica t es 75% t o 100% st a t e-of-ch a r ge.
ign it ion -off dr a w. See t h e Ign it ion -Off Dr a w Test pr o- Th e ba t t er y is a dequ a t ely ch a r ged for fu r t h er t est in g
cedu r e in t h is gr ou p for m or e in for m a t ion . or r et u r n t o u se. If t h e veh icle will n ot cr a n k for a
6. A fa u lt y or in cor r ect ch a r gin g syst em com po- m in im u m of fift een secon ds wit h a fu lly-ch a r ged ba t -
n en t . Refer t o Gr ou p 8C - Ch a r gin g Syst em for m or e t er y, per for m t h e Loa d Test pr ocedu r e a s descr ibed in
in for m a t ion . t h is gr ou p.
7. A fa u lt y or in cor r ect ba t t er y. • B la c k o r D a rk - in dica t es 0% t o 75% st a t e-of-
ch a r ge. Th e ba t t er y is in a dequ a t ely ch a r ged a n d
BUILT-IN TEST INDICATOR m u st be ch a r ged u n t il a gr een in dica t ion is visible in
A t est in dica t or (h ydr om et er ) bu ilt in t o t h e t op of t h e sigh t gla ss (12.4 volt s or m or e), befor e t h e ba t -
t h e ba t t er y ca se pr ovides visu a l in for m a t ion for ba t - t er y is t est ed fu r t h er or r et u r n ed t o ser vice. See t h e
t er y t est in g (F ig. 2). Like a h ydr om et er, t h e bu ilt -in Ba t t er y Ch a r gin g pr ocedu r e in t h is gr ou p for m or e
t est in dica t or m ea su r es t h e specific gr a vit y of t h e in for m a t ion . Also see Abn or m a l Ba t t er y Disch a r gin g
elect r olyt e. Th e t est in dica t or r evea ls t h e ba t t er y in t h is gr ou p for possible ca u ses of t h e disch a r ged
st a t e-of-ch a r ge; h owever, it will n ot r evea l t h e cr a n k- con dit ion .
in g ca pa cit y of t h e ba t t er y. A loa d t est m u st be per- • Cle a r o r B rig h t - in dica t es a low elect r olyt e
for m ed t o det er m in e t h e ba t t er y cr a n kin g ca pa cit y. level. Th e elect r olyt e level in t h e ba t t er y is below t h e
See t h e Loa d Test pr ocedu r e in t h is gr ou p for m or e t est in dica t or. A m a in t en a n ce-fr ee ba t t er y wit h n on -
in for m a t ion . r em ova ble cell ca ps m u st be r epla ced if t h e elect r o-
lyt e level is low. Wa t er m u st be a dded t o a low-
WARNING:
m a in t en a n ce ba t t er y wit h r em ova ble cell ca ps befor e
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
it is ch a r ged. See t h e Ba t t er y Ch a r gin g pr ocedu r e in
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
t h is gr ou p for m or e in for m a t ion . A low elect r olyt e
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
level m a y be ca u sed by a n over ch a r gin g con dit ion .
CHARGE. THE BATTERY MAY ARC INTERNALLY
XJ BATTERY 8A - 5
DI AGN OSI S AN D T EST I N G (Cont inue d)

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.

Befor e t est in g, visu a lly in spect t h e ba t t er y for a n y

(@ <i) (Q) da m a ge (a cr a cked ca se or cover, loose post s, et c.)


t h a t wou ld ca u se t h e ba t t er y t o be fa u lt y. Th en
r em ove t h e cell ca ps a n d ch eck t h e elect r olyt e level.
Add dist illed wa t er if t h e elect r olyt e level is below
t h e t op of t h e ba t t er y pla t es.
GREEN BLACK CLEAR Refer t o t h e in st r u ct ion s su pplied wit h t h e h ydr om -
80a72333 et er for r ecom m en da t ion s on t h e cor r ect u se of t h e
h ydr om et er. Rem ove on ly en ou gh elect r olyt e fr om t h e
Fig. 3 Built-In Test Indicator Sight Glass ba t t er y cell so t h a t t h e floa t is off t h e bot t om of t h e
HYDROMETER TEST h ydr om et er ba r r el wit h pr essu r e on t h e bu lb
Th e h ydr om et er t est r evea ls t h e ba t t er y st a t e-of- r elea sed.
ch a r ge by m ea su r in g t h e specific gr a vit y of t h e elec-
t r olyt e. Th is t est ca n n ot be per for m ed on CAUTION: Exercise care when inserting the tip of
m a in t en a n ce-fr ee ba t t er ies wit h n on -r em ova ble cell the hydrometer into a cell to avoid damaging the
ca ps. If t h e ba t t er y h a s n on -r em ova ble cell ca ps, see plate separators. Damaged plate separators can
t h e Bu ilt -In Test In dica t or or t h e Open -Cir cu it Volt - cause early battery failure.
a ge Test pr ocedu r es in t h is gr ou p.
To r ea d t h e h ydr om et er cor r ect ly, h old it wit h t h e
Specific gr a vit y is a com pa r ison of t h e den sit y of
t op su r fa ce of t h e elect r olyt e a t eye level (F ig. 4).
t h e elect r olyt e t o t h e den sit y of pu r e wa t er. P u r e
H ydr om et er floa t s a r e gen er a lly ca libr a t ed t o in di-
wa t er h a s a specific gr a vit y of 1.000, a n d su lfu r ic
ca t e t h e specific gr a vit y cor r ect ly on ly a t 26.7° C (80°
a cid h a s a specific gr a vit y of 1.835. Su lfu r ic a cid
F ). Wh en t est in g t h e specific gr a vit y a t a n y ot h er
m a kes u p a ppr oxim a t ely 35% of t h e elect r olyt e by
t em per a t u r e, a cor r ect ion fa ct or is r equ ir ed.
weigh t , or 24% by volu m e.
Th e cor r ect ion fa ct or is a ppr oxim a t ely a specific
In a fu lly-ch a r ged ba t t er y t h e elect r olyt e will h a ve
gr a vit y va lu e of 0.004, r efer r ed t o a s fou r poin t s of
a t em per a t u r e-cor r ect ed specific gr a vit y of 1.260 t o
specific gr a vit y. F or ea ch 5.5° C a bove 26.7° C (10° F
1.290. H owever, a specific gr a vit y of 1.235 or a bove is
a bove 80° F ), a dd fou r poin t s. F or ea ch 5.5° C below
sa t isfa ct or y for ba t t er y loa d t est in g a n d/or r et u r n t o
26.7° C (10° F below 80° F ), su bt r a ct fou r poin t s.
ser vice.
Alwa ys cor r ect t h e specific gr a vit y for t em per a t u r e
WARNING: va r ia t ion . Test t h e specific gr a vit y of t h e elect r olyt e
• IF THE BATTERY SHOWS SIGNS OF FREEZ- in ea ch ba t t er y cell.
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- EXAMP LE: A ba t t er y is t est ed a t -12.2° C (10° F )
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR a n d h a s a specific gr a vit y of 1.240. Det er m in e t h e
CHARGE. THE BATTERY MAY ARC INTERNALLY a ct u a l specific gr a vit y a s follows:
(1) Det er m in e t h e n u m ber of degr ees a bove or
below 26.7° C (80° F ):
HYDROMETER
FLOAT
BARREL
BULB TEMPERATURE READING
SURFACE
SPECIFIC COHESION
READING
GRAVITY

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 .

OPEN-CIRCUIT VOLTAGE TEST


A ba t t er y open -cir cu it volt a ge (n o loa d) t est will
898A-7
sh ow t h e st a t e-of-ch a r ge of a ba t t er y. Th is t est ca n be
u sed in pla ce of t h e h ydr om et er t est wh en a h ydr om - Fig. 5 Testing Open-Circuit Voltage - Typical
AMMETER
INDUCTION
POSITIVE
CLAMP
CLAMP NEGATIVE
CLAMP

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.

IGNITION-OFF DRAW TEST


Ign it ion -Off Dr a w (IOD) r efer s t o power bein g
dr a in ed fr om t h e ba t t er y wit h t h e ign it ion swit ch in
t h e Off posit ion . A n or m a l veh icle elect r ica l syst em
will dr a w fr om five t o t wen t y-five m illia m per es
(0.005 t o 0.025 a m per e) wit h t h e ign it ion swit ch in
t h e Off posit ion , a n d a ll n on -ign it ion con t r olled cir-
'-/Fnr
Ai._·.-___ cu it s in pr oper wor kin g or der. Th e t wen t y-five m illi-
¥0l..TSEL.£ClOIII a m per es a r e n eeded t o en a ble t h e m em or y fu n ct ion s
898A-10 for t h e P ower t r a in Con t r ol Modu le (P CM), digit a l
clock, elect r on ica lly t u n ed r a dio, a n d ot h er m odu les
Fig. 8 Remove Surface Charge from Battery - wh ich m a y va r y wit h t h e veh icle equ ipm en t .
Typical A veh icle t h a t h a s n ot been oper a t ed for a ppr oxi-
m a t ely t wen t y da ys, m a y disch a r ge t h e ba t t er y t o a n
in a dequ a t e level. Wh en a veh icle will n ot be u sed for
t wen t y da ys or m or e (st or ed), r em ove t h e IOD fu se
fr om t h e P ower Dist r ibu t ion Cen t er (P DC). Th is will
r edu ce ba t t er y disch a r gin g.
E xcessive IOD ca n be ca u sed by:
• E lect r ica l it em s left on
• F a u lt y or im pr oper ly a dju st ed swit ch es
• F a u lt y or sh or t ed elect r on ic m odu les a n d com po-
n en t s
• An in t er n a lly sh or t ed gen er a t or
• In t er m it t en t sh or t s in t h e wir in g.
If t h e IOD is over t wen t y-five m illia m per es, t h e
898A-11 pr oblem m u st be fou n d a n d cor r ect ed befor e r epla c-
in g a ba t t er y. In m ost ca ses, t h e ba t t er y ca n be
Fig. 9 Load 50% CCA Rating - Note Voltage - Typical ch a r ged a n d r et u r n ed t o ser vice a ft er t h e excessive
(6) Th e volt a ge dr op will va r y wit h t h e ba t t er y IOD con dit ion h a s been cor r ect ed.
t em per a t u r e a t t h e t im e of t h e loa d t est . Th e ba t t er y
t em per a t u r e ca n be est im a t ed by u sin g t h e a m bien t DI AGN OSI S
t em per a t u r e du r in g t h e pa st sever a l h ou r s. If t h e (1) Ver ify t h a t a ll elect r ica l a ccessor ies a r e off.
ba t t er y h a s been ch a r ged, boost ed, or loa ded a few Tu r n off a ll la m ps, r em ove t h e ign it ion key, a n d close
m in u t es pr ior t o t h e t est , t h e ba t t er y will be som e- a ll door s. If t h e veh icle is equ ipped wit h a illu m i-
wh a t wa r m er. See t h e Loa d Test Tem per a t u r e ch a r t n a t ed en t r y syst em or elect r on ica lly t u n ed r a dio,
for t h e pr oper loa ded volt a ge r ea din g. a llow t h e elect r on ic t im er fu n ct ion of t h ese syst em s
t o a u t om a t ica lly sh u t off (t im e ou t ). Th is m a y t a ke
Load Test Temperature u p t o t h r ee m in u t es.
(2) Det er m in e t h a t t h e u n der h ood la m p is oper a t -
Minimum Volt- Temperature in g pr oper ly, t h en u n plu g t h e la m p wir e h a r n ess con -
age °F °C n ect or or r em ove t h e la m p bu lb.
(3) Discon n ect t h e ba t t er y n ega t ive ca ble.
9.6 volts 70° and above 21° and above
(4) Set a n elect r on ic digit a l m u lt i-m et er t o it s
9.5 volts 60° 16° h igh est a m per a ge sca le. Con n ect t h e m u lt i-m et er
9.4 volts 50° 10° bet ween t h e discon n ect ed ba t t er y n ega t ive ca ble
9.3 volts 40° 4° cla m p a n d t h e ba t t er y n ega t ive t er m in a l post . Ma ke
su r e t h a t t h e door s r em a in closed so t h a t t h e illu m i-
9.1 volts 30° -1° n a t ed en t r y syst em is n ot a ct iva t ed. Th e m u lt i-m et er
8.9 volts 20° -7° a m per a ge r ea din g m a y r em a in h igh for u p t o t h r ee
8.7 volts 10° -12° m in u t es, or m a y n ot give a n y r ea din g a t a ll wh ile set
in t h e h igh est a m per a ge sca le, depen din g u pon t h e
8.5 volts 0° -18°
elect r ica l equ ipm en t on t h e veh icle. Th e m u lt i-m et er
8A - 10 BATTERY XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
lea ds m u st be secu r ely cla m ped t o t h e ba t t er y n ega - a ge dr op in t h e ba t t er y posit ive ca ble cla m p-t o-t er m i-
t ive ca ble cla m p a n d t h e ba t t er y n ega t ive t er m in a l n a l post con n ect ion a n d t h e ba t t er y posit ive ca ble.
post . If con t in u it y bet ween t h e ba t t er y n ega t ive t er-
m in a l post a n d t h e n ega t ive ca ble cla m p is lost du r- WARNING:
in g a n y pa r t of t h e IOD t est , t h e elect r on ic t im er • IF THE BATTERY SHOWS SIGNS OF FREEZ-
fu n ct ion will be a ct iva t ed a n d a ll of t h e t est s will ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
h a ve t o be r epea t ed. LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
(5) Aft er a bou t t h r ee m in u t es, t h e h igh -a m per a ge CHARGE. THE BATTERY MAY ARC INTERNALLY
IOD r ea din g on t h e m u lt i-m et er sh ou ld becom e ver y AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
low or n on exist en t , depen din g u pon t h e elect r ica l CLE DAMAGE MAY RESULT.
equ ipm en t on t h e veh icle. If t h e a m per a ge r ea din g • EXPLOSIVE HYDROGEN GAS FORMS IN AND
r em a in s h igh , r em ove ea ch fu se or cir cu it br ea ker AROUND THE BATTERY. DO NOT SMOKE, USE
(r efer t o Gr ou p 8W - Wir in g Dia gr a m s for m or e in for- FLAME, OR CREATE SPARKS NEAR THE BATTERY.
m a t ion ) u n t il t h e a m per a ge r ea din g becom es ver y PERSONAL INJURY AND/OR VEHICLE DAMAGE
low, or n on exist en t . Th is will isola t e ea ch cir cu it a n d MAY RESULT.
iden t ify t h e sou r ce of t h e h igh -a m per a ge IOD. If t h e • THE BATTERY CONTAINS SULFURIC ACID,
a m per a ge r ea din g r em a in s h igh a ft er discon n ect in g WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
ea ch fu se a n d cir cu it br ea ker, u n plu g t h e wir e h a r- TACT WITH THE SKIN, EYES, OR CLOTHING. IN
n ess con n ect or fr om t h e gen er a t or. If t h e a m per a ge THE EVENT OF CONTACT, FLUSH WITH WATER
r ea din g n ow becom es ver y low or n on exist en t , r efer AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
t o Gr ou p 8C - Ch a r gin g Syst em t o dia gn ose t h e OF THE REACH OF CHILDREN.
fa u lt y ch a r gin g syst em . Aft er t h e h igh -a m per a ge IOD • IF THE BATTERY IS EQUIPPED WITH REMOV-
h a s been cor r ect ed, swit ch t h e m u lt i-m et er t o pr o- ABLE CELL CAPS, BE CERTAIN THAT EACH OF
gr essively lower a m per a ge sca les a n d, if n ecessa r y, THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
r epea t t h e fu se a n d cir cu it br ea ker r em ova l pr ocess THE BATTERY IS RETURNED TO SERVICE. PER-
t o iden t ify a n d cor r ect t h e sou r ces of excessive IOD. SONAL INJURY AND/OR VEHICLE DAMAGE MAY
It is n ow sa fe t o select t h e lowest m illia m per e sca le RESULT FROM LOOSE OR MISSING CELL CAPS.
of t h e m u lt i-m et er t o ch eck t h e low-a m per a ge IOD.
Th e followin g oper a t ion will r equ ir e a volt m et er
CAUTION: Do not open any doors, or turn on any a ccu r a t e t o 1/10 (0.10) volt . Befor e per for m in g t h e
electrical accessories with the lowest milliampere t est s, be cer t a in t h e followin g pr ocedu r es a r e a ccom -
scale selected, or the multi-meter may be damaged. plish ed:
(6) Obser ve t h e m u lt i-m et er r ea din g. Th e low-a m - • Ba t t er y is fu lly-ch a r ged a s descr ibed in t h is
per a ge IOD sh ou ld n ot exceed t wen t y-five m illia m - gr ou p.
per es (0.025 a m per e). If t h e dr a w exceeds t wen t y-five • F u lly en ga ge t h e pa r kin g br a ke.
m illia m per es, isola t e ea ch cir cu it by r em ovin g t h e • If t h e veh icle is equ ipped wit h a n a u t om a t ic
cir cu it br ea ker s a n d fu ses. Th e m u lt i-m et er r ea din g t r a n sm ission , pla ce t h e gea r sh ift select or lever in t h e
will dr op t o wit h in t h e a ccept a ble lim it wh en t h e P a r k posit ion . If t h e veh icle is equ ipped wit h a m a n -
sou r ce of t h e excessive dr a w is discon n ect ed. Repa ir u a l t r a n sm ission , pla ce t h e gea r sh ift select or lever in
t h is cir cu it a s r equ ir ed; wh et h er a wir in g sh or t , t h e Neu t r a l posit ion a n d fu lly depr ess t h e clu t ch
in cor r ect swit ch a dju st m en t , or a com pon en t fa ilu r e peda l.
is a t fa u lt . • Un plu g t h e Au t om a t ic Sh u t Down (ASD) r ela y t o
pr even t t h e en gin e fr om st a r t in g. Th e ASD r ela y is
VOLTAGE DROP TEST loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC).
Th e volt a ge dr op t est will det er m in e if t h er e is Refer t o t h e P DC la bel for ASD r ela y iden t ifica t ion
excessive r esist a n ce in t h e ba t t er y t er m in a l con n ec- a n d loca t ion .
t ion s or t h e ba t t er y ca bles. Wh en per for m in g t h ese (1) Con n ect t h e posit ive lea d of t h e volt m et er t o
t est s, it is im por t a n t t o r em em ber t h a t t h e volt a ge 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-
dr op is givin g a n in dica t ion of t h e r esist a n ce bet ween 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
t h e t wo poin t s a t wh ich t h e volt m et er pr obes a r e ca ble cla m p (F ig. 10). Rot a t e a n d h old t h e ign it ion
a t t a ch ed. swit ch in t h e St a r t posit ion . Obser ve t h e volt m et er. If
Ex a m p le : Wh en t est in g t h e r esist a n ce of t h e ba t - volt a ge is det ect ed, cor r ect t h e poor con t a ct bet ween
t er y posit ive ca ble, t ou ch t h e volt m et er lea ds t o t h e t h e ca ble cla m p a n d t h e t er m in a l post .
ba t t er y posit ive ca ble cla m p a n d t h e ca ble con n ect or (2) Con n ect t h e posit ive lea d of t h e volt m et er t o
a t t h e st a r t er solen oid. If you pr obe t h e ba t t er y pos- t h e ba t t er y posit ive t er m in a l post . Con n ect t h e n ega -
it ive t er m in a l post a n d t h e ca ble con n ect or a t t h e t ive lea d of t h e volt m et er t o t h e ba t t er y posit ive ca ble
st a r t er solen oid, you a r e r ea din g t h e com bin ed volt - cla m p (F ig. 11). Rot a t e a n d h old t h e ign it ion swit ch
BATTERY VOLTMETER
VOLTMETER BATTERY STARTER
MOTOR VOLTMETER BATTERY

XJ BATTERY 8A - 11
DI AGN OSI S AN D T EST I N G (Cont inue d) ENGINE
GROUND BATTERY VOLTMETER

VOLTMETER-----!

80660062 Fig. 12 Test Battery Positive Cable Resistance -


Typical
Fig. 10 Test Battery Negative Connection
Resistance - Typical 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 t h e r ea din g is a bove 0.2 volt , clea n a n d
in t h e St a r t posit ion . Obser ve t h e volt m et er. If volt -
t igh t en t h e ba t t er y n ega t ive ca ble a t t a ch m en t on t h e
a ge is det ect ed, cor r ect t h e poor con t a ct bet ween t h e
en gin e block. Repea t t h e t est . If t h e r ea din g is st ill
ca ble cla m p a n d t h e t er m in a l post .
a bove 0.2 volt , r epla ce t h e fa u lt y ba t t er y n ega t ive
ca ble.
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.

REM OVAL AN D I N STALLAT I ON (4) Rem ove t h e ba t t er y h olddown s a n d r em ove t h e


ba t t er y fr om t h e veh icle (F ig. 17).
BATTERY (5) In spect t h e ba t t er y t r a y a n d h olddown s for cor-
(1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . r osion or da m a ge. Rem ove a n y cor r osion u sin g a wir e
Ma ke su r e a ll elect r ica l a ccessor ies a r e t u r n ed off. br u sh a n d a sodiu m bica r bon a t e (ba kin g soda ) a n d
(2) Loosen t h e ca ble t er m in a l cla m ps a n d discon - wa r m wa t er clea n in g solu t ion . P a in t a n y exposed
n ect bot h ba t t er y ca bles, n ega t ive ca ble fir st . If n ec- ba r e m et a l a n d r epla ce a n y da m a ged pa r t s.
essa r y, u se a pu ller t o r em ove t h e t er m in a l cla m ps (6) Slide t h e t h er m ogu a r d off of t h e ba t t er y ca se.
fr om t h e ba t t er y post s (F ig. 15). In spect t h e ba t t er y ca se for cr a cks or ot h er da m a ge
(3) In spect t h e ca ble t er m in a l cla m ps for cor r osion t h a t cou ld r esu lt in elect r olyt e lea ks. Also, ch eck t h e
a n d da m a ge. Rem ove a n y cor r osion u sin g a wir e ba t t er y t er m in a l post s for loosen ess. Ba t t er ies wit h
br u sh or a post a n d t er m in a l clea n in g t ool, a n d a da m a ged ca ses or loose post s m u st be r epla ced.
sodiu m bica r bon a t e (ba kin g soda ) a n d wa r m wa t er (7) Ch eck t h e elect r olyt e level in t h e ba t t er y. Use a
clea n in g solu t ion (F ig. 16). Repla ce a n y ca ble t h a t pu t t y kn ife or a n ot h er su it a ble wide fla t -bla ded t ool
h a s da m a ged or defor m ed t er m in a l cla m ps. t o pr y t h e cell ca ps off (F ig. 18). Do n ot u se a scr ew-
SUPPORTSTRAP
CROSS-
RADIATOR
BOLT
FWD
TERMINAL
BATTERY
MEMBER
BRUSH TRAY
TEST INDICA-
TOR NUTS WHEELHOUSE
STUD
PUSH-ON
NUTSENSOR
THERMOGUARD
HOLD
RETAINER
BATTERY
DOWN
PANEL
INNER
CABLE
T-BOLT

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

Fig. 18 Removing Cell Caps - Typical


(8) In spect t h e ba t t er y bu ilt -in t est in dica t or sigh t
gla ss for a n in dica t ion of t h e ba t t er y con dit ion . If t h e
Fig. 16 Clean Battery Cable Terminal Clamp -
ba t t er y is disch a r ged, ch a r ge a s r equ ir ed. See t h e
Typical
Bu ilt -In Test In dica t or a n d t h e Ba t t er y Ch a r gin g pr o-
BOLT---.--,H cedu r es in t h is gr ou p for m or e in for m a t ion .
(9) If t h e ba t t er y is t o be r ein st a lled, clea n t h e ou t -
side of t h e ba t t er y ca se a n d t h e t op cover wit h a
sodiu m bica r bon a t e (ba kin g soda ) a n d wa r m wa t er
clea n in g solu t ion t o r em ove a n y a cid film (F ig. 19).
Rin se t h e ba t t er y wit h clea n wa t er. E n su r e t h a t t h e
clea n in g solu t ion does n ot en t er t h e ba t t er y cells
t h r ou gh t h e ven t h oles. If t h e ba t t er y is bein g
r epla ced, see t h e Ba t t er y Ra t in gs a n d Cla ssifica t ion s
ch a r t in Specifica t ion s a t t h e ba ck of t h is gr ou p. Con -
fir m t h a t t h e r epla cem en t ba t t er y is t h e cor r ect size
a n d h a s t h e cor r ect r a t in gs for t h e veh icle.
(10) Clea n a n y cor r osion fr om t h e ba t t er y t er m in a l
post s wit h a wir e br u sh or a post a n d t er m in a l
clea n er, a n d a sodiu m bica r bon a t e (ba kin g soda ) a n d
wa r m wa t er clea n in g solu t ion (F ig. 20).
(11) Rein st a ll t h e ba t t er y t h er m ogu a r d by slidin g
it over t h e ba t t er y ca se.
(12) P osit ion t h e ba t t er y in t h e t r a y. E n su r e t h a t
T-BOLT t h e posit ive a n d n ega t ive t er m in a l post s a r e cor r ect ly
posit ion ed. Th e ca ble t er m in a l cla m ps m u st r ea ch t h e
cor r ect ba t t er y post wit h ou t st r et ch in g t h e ca bles
(F ig. 21).
(13) Loosely in st a ll t h e ba t t er y h olddown h a r d-
wa r e. E n su r e t h a t t h e ba t t er y ba se is cor r ect ly posi-
t ion ed in t h e t r a y, t h en t igh t en t h e h olddown n u t s t o
2.2 N·m (20 in . lbs.). Tigh t en t h e h olddown su ppor t
st r a p bolt t o 9 N·m (77 in . lbs.).

80aafb1c CAUTION: Be certain that the battery cables are


connected to the correct battery terminals. Reverse
Fig. 17 Battery Holddowns polarity may damage electrical components.
TEST
BATTERY
BATTERY
INDICA-
TORTEST CATOR
INDI- CLEANING
WARMTERMINAL
BAKING
BRUSH
WATER
SODA
BATTERY
BRUSH
CABLE
SOLU-
TION
AND RADIATOR
CROSSMEMBER
POSITIVE
BATTERY
FWDCABLE WHEELHOUSE
NEGATIVE
INNER
CABLEPANEL

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

Fig. 21 Battery Cables


(14) In st a ll a n d t igh t en t h e ba t t er y posit ive ca ble
RKl0B
t er m in a l cla m p. Th en in st a ll a n d t igh t en t h e ba t t er y
n ega t ive ca ble t er m in a l cla m p. Tigh t en bot h ca ble
Fig. 19 Clean Battery - Typical t er m in a l cla m p bolt s t o 8.5 N·m (75 in . lbs.).
(15) Apply a t h in coa t in g of pet r oleu m jelly or
ch a ssis gr ea se t o t h e exposed su r fa ces of t h e ba t t er y
ca ble t er m in a l cla m ps a n d t h e ba t t er y t er m in a l
post s.
TERMINAL
BRUSH

J928B-30

Fig. 20 Clean Battery Terminal Post - Typical

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

GENERAL INFORMATION CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . 6


INTRODUCTION . . . . . . . . . . . ............. 1 FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . 3
OVERVIEW . . . . . . . . . . . . . . . ............. 1 STARTER NOISE - 2.5L ENGINE . . . . . . . . . . . . 7
DESCRIPTION AND OPERATION STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
STARTER RELAY . . . . . . . . . . . ............. 2 REMOVAL AND INSTALLATION
STARTER . . . . . . . . . . . . . . . . ............. 2 STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 9
STARTING SYSTEM . . . . . . . . ............. 2 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING SPECIFICATIONS
COLD CRANKING TEST . . . . . ............. 3 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 10

GEN ERAL I N FORM AT I ON

OVERVIEW • Ign it ion swit ch


Th e ba t t er y, st a r t in g, a n d ch a r gin g syst em s oper- • Clu t ch peda l posit ion swit ch (m a n u a l t r a n sm is-
a t e wit h on e a n ot h er, a n d m u st be t est ed a s a com - sion )
plet e syst em . In or der for t h e veh icle t o st a r t a n d • P a r k/n eu t r a l posit ion swit ch (a u t om a t ic t r a n s-
ch a r ge pr oper ly, a ll of t h e com pon en t s in volved in m ission )
t h ese syst em s m u st per for m wit h in specifica t ion s. • Wir e h a r n ess a n d con n ect ion s.
Gr ou p 8A cover s t h e ba t t er y, Gr ou p 8B cover s t h e Th is gr ou p cover s dia gn osis of t h e com plet e st a r t -
st a r t in g syst em , a n d Gr ou p 8C cover s t h e ch a r gin g in g syst em , except t h e ba t t er y. H owever, t h is gr ou p
syst em . Refer t o Gr ou p 8W - Wir in g Dia gr a m s for on ly cover s ser vice pr ocedu r es for t h e st a r t er a n d
com plet e cir cu it descr ipt ion s a n d dia gr a m s. We h a ve st a r t er r ela y. Ser vice pr ocedu r es for ot h er st a r t in g
sepa r a t ed t h ese syst em s t o m a ke it ea sier t o loca t e syst em com pon en t s ca n be loca t ed a s follows:
t h e in for m a t ion you a r e seekin g wit h in t h is Ser vice • Ba t t er y - r efer t o Gr ou p 8A - Ba t t er y for t h e
Ma n u a l. H owever, wh en a t t em pt in g t o dia gn ose a n y dia gn ost ic a n d ser vice pr ocedu r es
of t h ese syst em s, it is im por t a n t t h a t you keep t h eir • Ign it ion swit ch - r efer t o Gr ou p 8D - Ign it ion
in t er depen den cy in m in d. Syst em s for t h e ser vice pr ocedu r es
Th e dia gn ost ic pr ocedu r es u sed in t h ese gr ou ps • Clu t ch peda l posit ion swit ch - r efer t o Gr ou p 6 -
in clu de t h e m ost ba sic con ven t ion a l dia gn ost ic m et h - Clu t ch for t h e ser vice pr ocedu r es
ods, t o t h e m or e soph ist ica t ed On -Boa r d Dia gn ost ics • P a r k/n eu t r a l posit ion swit ch - r efer t o Gr ou p 21
(OBD) bu ilt in t o t h e P ower t r a in Con t r ol Modu le - Tr a n sm ission for t h e ser vice pr ocedu r es
(P CM). Use of a in du ct ion m illia m per e a m m et er, volt / • Wir e h a r n ess a n d con n ect ion s - r efer t o Gr ou p
oh m m et er, ba t t er y ch a r ger, ca r bon pile r h eost a t (loa d 8W - Wir in g Dia gr a m s for t h e ser vice pr ocedu r es.
t est er ), a n d 12-volt t est la m p m a y be r equ ir ed.
All OBD-sen sed syst em s a r e m on it or ed by t h e NOTE: This group covers both Left-Hand Drive
P CM. E a ch m on it or ed cir cu it is a ssign ed a Dia gn os- (LHD) and Right-Hand Drive (RHD) versions of this
t ic Tr ou ble Code (DTC). Th e P CM will st or e a DTC in model. Whenever required and feasible, the RHD
elect r on ic m em or y for a n y fa ilu r e it det ect s. See t h e versions of affected vehicle components have been
On -Boa r d Dia gn ost ics Test in Gr ou p 8C - Ch a r gin g constructed as mirror-image of the LHD versions.
Syst em for m or e in for m a t ion . While most of the illustrations used in this group
represent only the LHD version, the diagnostic and
INTRODUCTION service procedures outlined can generally be
Th e st a r t in g syst em con sist s of: applied to either version. Exceptions to this rule
• Ba t t er y have been clearly identified as LHD or RHD, if a
• St a r t er r ela y special illustration or procedure is required.
• St a r t er wit h a n in t egr a l solen oid
8B - 2 STARTING SYSTEMS XJ

DESCRI PT I ON AN D OPERAT I ON t a ct disc t o open t h e st a r t er feed cir cu it , a n d t h e sh ift


lever t o disen ga ge t h e over r u n n in g clu t ch a n d pin ion
STARTING SYSTEM gea r fr om t h e st a r t er r in g gea r.
Th e st a r t in g syst em com pon en t s for m t wo sepa r a t e
cir cu it s. A h igh -a m per a ge feed cir cu it t h a t feeds t h e STARTER
st a r t er bet ween 150 a n d 350 a m per es, a n d a low-a m - Th e st a r t er m ot or in cor por a t es sever a l fea t u r es t o
per a ge con t r ol cir cu it t h a t oper a t es on less t h a n 20 cr ea t e a r elia ble, efficien t , com pa ct , a n d ligh t weigh t
a m per es. u n it . A pla n et a r y gea r syst em (in t er m edia t e t r a n s-
If t h e veh icle is equ ipped wit h a n a u t om a t ic t r a n s- m ission ) is u sed bet ween t h e elect r ic m ot or a n d t h e
m ission , ba t t er y volt a ge is su pplied t h r ou gh t h e low- pin ion gea r. Th is fea t u r e m a kes it possible t o r edu ce
a m per a ge con t r ol cir cu it t o t h e coil ba t t er y t er m in a l t h e dim en sion s of t h e st a r t er. At t h e sa m e t im e, it
of t h e st a r t er r ela y wh en t h e ign it ion swit ch is a llows h igh er a r m a t u r e r ot a t ion a l speed a n d deliver s
t u r n ed t o t h e St a r t posit ion . Th e pa r k/n eu t r a l posi- in cr ea sed t or qu e t h r ou gh t h e pin ion gea r t o t h e
t ion swit ch is in st a lled in ser ies bet ween t h e st a r t er st a r t er r in g gea r on t h e a u t om a t ic t r a n sm ission
r ela y coil gr ou n d t er m in a l a n d gr ou n d. Th is n or m a lly t or qu e con ver t er or t or qu e con ver t er dr ive pla t e, or
open swit ch pr even t s t h e st a r t er r ela y fr om bein g on t h e m a n u a l t r a n sm ission flywh eel.
en er gized u n less t h e a u t om a t ic t r a n sm ission gea r Th e u se of a per m a n en t m a gn et field a lso r edu ces
select or is in t h e Neu t r a l or P a r k posit ion s. t h e size a n d weigh t of t h e st a r t er. Th e per m a n en t
If t h e veh icle is equ ipped wit h a m a n u a l t r a n sm is- m a gn et field con sist s of fou r h igh -st r en gt h per m a -
sion , it h a s a clu t ch peda l posit ion swit ch in st a lled in n en t m a gn et s. Th e m a gn et s a r e a lign ed a ccor din g t o
ser ies bet ween t h e ign it ion swit ch a n d t h e coil ba t - t h eir pola r it y, a n d a r e per m a n en t ly m ou n t ed in t h e
t er y t er m in a l of t h e st a r t er r ela y. Th is n or m a lly open st a r t er field fr a m e.
swit ch pr even t s t h e st a r t er r ela y fr om bein g en er- Th e st a r t er m ot or s for a ll en gin es a r e a ct iva t ed by
gized u n less t h e clu t ch peda l is depr essed, pr even t in g a solen oid m ou n t ed t o t h e over r u n n in g clu t ch h ou s-
st a r t er oper a t ion wh ile t h e clu t ch disc a n d t h e fly- in g. H owever, t h e st a r t er m ot or a n d solen oid a r e ser-
wh eel a r e en ga ged. Th e st a r t er r ela y coil gr ou n d t er- viced on ly a s a com plet e a ssem bly. If eit h er
m in a l is a lwa ys gr ou n ded on veh icles wit h a m a n u a l com pon en t is fa u lt y or da m a ged, t h e en t ir e st a r t er
t r a n sm ission . a ssem bly m u st be r epla ced.
Wh en t h e st a r t er r ela y coil is en er gized, t h e n or-
m a lly open r ela y con t a ct s close. Th e r ela y con t a ct s CAUTION:
con n ect t h e r ela y com m on feed t er m in a l t o t h e r ela y • Permanent magnet starters are highly sensi-
n or m a lly open t er m in a l. Th e closed r ela y con t a ct s tive to hammering, shocks, and external pressure.
en er gize t h e st a r t er solen oid coil win din gs. The permanent magnets may be damaged and the
Th e en er gized solen oid pu ll-in coil pu lls in t h e sole- starter rendered unserviceable, if subjected to any
n oid plu n ger. Th e solen oid plu n ger pu lls t h e sh ift of these conditions.
lever in t h e st a r t er. Th is en ga ges t h e st a r t er over r u n - • The starter motor must not be clamped in a
n in g clu t ch a n d pin ion gea r wit h t h e st a r t er r in g vise by the starter field frame. Doing so may dam-
gea r on t h e m a n u a l t r a n sm ission flywh eel, or on t h e age the permanent magnets. The starter should
a u t om a t ic t r a n sm ission t or qu e con ver t er dr ive pla t e. only be clamped by the mounting flange.
As t h e solen oid plu n ger r ea ch es t h e en d of it s • Do not connect the starter motor incorrectly
t r a vel, t h e solen oid con t a ct disc com plet es t h e h igh - when testing. Reverse polarity may damage the per-
a m per a ge st a r t er feed cir cu it a n d en er gizes t h e sole- manent magnets and render the starter unservice-
n oid plu n ger h old-in coil. Cu r r en t n ow flows bet ween able.
t h e solen oid ba t t er y t er m in a l a n d t h e st a r t er m ot or,
en er gizin g t h e st a r t er.
STARTER RELAY
On ce t h e en gin e st a r t s, t h e over r u n n in g clu t ch pr o-
Th e st a r t er r ela y is a In t er n a t ion a l St a n da r ds
t ect s t h e st a r t er fr om da m a ge by a llowin g t h e st a r t er
Or ga n iza t ion (ISO)-t ype r ela y. Th e st a r t er r ela y is a
pin ion gea r t o spin fa st er t h a n t h e pin ion sh a ft .
elect r om ech a n ica l device t h a t swit ch es ba t t er y cu r-
Wh en t h e dr iver r elea ses t h e ign it ion swit ch t o t h e
r en t t o t h e pu ll-in coil of t h e st a r t er solen oid wh en
On posit ion , t h e st a r t er r ela y coil is de-en er gized.
t h e ign it ion swit ch is t u r n ed t o t h e St a r t posit ion .
Th is ca u ses t h e r ela y con t a ct s t o open . Wh en t h e
See t h e Dia gn osis a n d Test in g sect ion of t h is gr ou p
r ela y con t a ct s open , t h e st a r t er solen oid plu n ger
for m or e in for m a t ion on t h e oper a t ion of t h e st a r t er
h old-in coil is de-en er gized.
r ela y.
Wh en t h e solen oid plu n ger h old-in coil is de-en er-
Th e st a r t er r ela y is loca t ed in t h e P ower Dist r ibu -
gized, t h e solen oid plu n ger r et u r n spr in g r et u r n s t h e
t ion Cen t er (P DC), in t h e en gin e com pa r t m en t . Refer
plu n ger t o it s r ela xed posit ion . Th is ca u ses t h e con -
t o t h e P DC la bel for r ela y iden t ifica t ion a n d loca t ion .
XJ STARTING SYSTEMS 8B - 3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e st a r t er r ela y ca n n ot be r epa ir ed a n d, if fa u lt y COLD CRANKING TEST
or da m a ged, it m u st be r epla ced. F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
8W-21 - St a r t in g Syst em in Gr ou p 8W - Wir in g Dia -
gr a m s. Th e ba t t er y m u st be fu lly-ch a r ged a n d loa d-
DI AGN OSI S AN D T EST I N G
t est ed befor e pr oceedin g. Refer t o Gr ou p 8A - Ba t t er y
for m or e in for m a t ion .
STARTING SYSTEM
(1) Con n ect a su it a ble volt -a m per e t est er t o t h e
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
ba t t er y t er m in a ls (F ig. 1). Refer t o t h e oper a t in g
8W-21 - St a r t in g Syst em in Gr ou p 8W - Wir in g Dia -
in st r u ct ion s pr ovided wit h t h e t est er bein g u sed.
gr a m s.
(2) F u lly en ga ge t h e pa r kin g br a ke.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) If t h e veh icle is equ ipped wit h a n a u t om a t ic
BAGS, REFER TO GROUP 8M - PASSIVE t r a n sm ission , pla ce t h e gea r sh ift select or lever in t h e
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY P a r k posit ion . If t h e veh icle is equ ipped wit h a m a n -
STEERING WHEEL, STEERING COLUMN, OR u a l t r a n sm ission , pla ce t h e gea r sh ift select or lever in
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR t h e Neu t r a l posit ion a n d fu lly depr ess t h e clu t ch
SERVICE. FAILURE TO TAKE THE PROPER PRE- peda l.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (4) Ver ify t h a t a ll la m ps a n d a ccessor ies a r e
BAG DEPLOYMENT AND POSSIBLE PERSONAL t u r n ed off.
INJURY. (5) To pr even t t h e en gin e fr om st a r t in g, u n plu g
t h e Au t om a t ic Sh u t Down (ASD) r ela y. Th e ASD r ela y
is loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC).
I N SPECT I ON Refer t o t h e P DC la bel for r ela y iden t ifica t ion a n d
Befor e r em ovin g a n y u n it fr om t h e st a r t in g syst em loca t ion .
for r epa ir or dia gn osis, per for m t h e followin g in spec- (6) 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
t ion s: posit ion . Not e t h e cr a n kin g volt a ge a n d cu r r en t
• B a tte ry - Visu a lly in spect t h e ba t t er y for in di- (a m per a ge) dr a w.
ca t ion s of ph ysica l da m a ge a n d loose or cor r oded (a ) If t h e volt a ge r ea ds below 9.6 volt s, r em ove
ca ble con n ect ion s. Det er m in e t h e st a t e-of-ch a r ge a n d t h e st a r t er for ben ch t est in g. If t h e st a r t er ben ch
cr a n kin g ca pa cit y of t h e ba t t er y. Ch a r ge or r epla ce t est is OK, r efer t o Gr ou p 9 - E n gin e for fu r t h er
t h e ba t t er y, if r equ ir ed. Refer t o Gr ou p 8A - Ba t t er y dia gn osis of t h e en gin e. If t h e st a r t er ben ch t est is
for m or e in for m a t ion . n ot OK, r epla ce t h e fa u lt y st a r t er.
• Ig n itio n S w itc h - Visu a lly in spect t h e ign it ion (b) If t h e volt a ge r ea ds a bove 9.6 volt s a n d t h e
swit ch for in dica t ion s of ph ysica l da m a ge a n d loose cu r r en t (a m per a ge) dr a w r ea ds below specifica -
or cor r oded wir e h a r n ess con n ect ion s. t ion s, see t h e F eed Cir cu it Test pr ocedu r es in t h is
• Clu tc h P e d a l P o s itio n S w itc h - Visu a lly gr ou p.
in spect t h e clu t ch peda l posit ion swit ch for in dica - (c) If t h e volt a ge r ea ds 12.5 volt s or gr ea t er a n d
t ion s of ph ysica l da m a ge a n d loose or cor r oded wir e t h e st a r t er does n ot t u r n , see t h e Con t r ol Cir cu it
h a r n ess con n ect ion s. Test pr ocedu r es in t h is gr ou p.
• P a rk /N e u tra l P o s itio n S w itc h - Visu a lly (d) If t h e volt a ge r ea ds 12.5 volt s or gr ea t er a n d
in spect t h e pa r k/n eu t r a l posit ion swit ch for in dica - t h e st a r t er t u r n s ver y slowly, see t h e F eed Cir cu it
t ion s of ph ysica l da m a ge a n d loose or cor r oded wir e Test pr ocedu r es in t h is gr ou p.
h a r n ess con n ect ion s.
• S ta rte r Re la y - Visu a lly in spect t h e st a r t er NOTE: A cold engine will increase the starter cur-
r ela y for in dica t ion s of ph ysica l da m a ge a n d loose or rent (amperage) draw reading, and reduce the bat-
cor r oded wir e h a r n ess con n ect ion s. tery voltage reading.
• S ta rte r - Visu a lly in spect t h e st a r t er for in di-
ca t ion s of ph ysica l da m a ge a n d loose or cor r oded wir e
h a r n ess con n ect ion s. FEED CIRCUIT TEST
• S ta rte r S o le n o id - Visu a lly in spect t h e st a r t er Th e st a r t er feed cir cu it t est (volt a ge dr op m et h od)
solen oid for in dica t ion s of ph ysica l da m a ge a n d loose will det er m in e if t h er e is excessive r esist a n ce in t h e
or cor r oded wir e h a r n ess con n ect ion s. h igh -a m per a ge cir cu it . F or cir cu it descr ipt ion s a n d
• Wirin g - Visu a lly in spect t h e wir e h a r n ess for dia gr a m s, r efer t o 8W-21 - St a r t in g Syst em in Gr ou p
da m a ge. Repa ir or r epla ce a n y fa u lt y wir in g, a s 8W - Wir in g Dia gr a m s.
r equ ir ed. Wh en per for m in g t h ese t est s, it is im por t a n t t o
r em em ber t h a t t h e volt a ge dr op is givin g a n in dica -
t ion of t h e r esist a n ce bet ween t h e t wo poin t s a t
wh ich t h e volt m et er pr obes a r e a t t a ch ed.
8B - 4 STARTING SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

Starting System Diagnosis


CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS 1. Battery discharged or 1. Refer to Group 8A - Battery. Charge or replace battery, if
TO ENGAGE. faulty. required.
2. Starting circuit wiring 2. See Cold Cranking Test, in this group. Test and repair feed
faulty. and/or control circuits, if required.
3. Starter relay faulty. 3. See Relay Test, in this group. Replace relay, if required.
4. Ignition switch faulty. 4. See Ignition Switch Test, in this group. Replace switch, if
5. Park/Neutral position required.
switch (auto trans) faulty 5. See Park/Neutral Position Switch, in Group 21 - Transmission
or misadjusted. and Transfer Case for the diagnosis and service of this
6. Clutch pedal position component. Replace switch, if required.
switch (man trans) faulty. 6. See Clutch Pedal Position Switch Test, in this group. Replace
7. Starter solenoid faulty. switch, if required.
8. Starter assembly 7. See Solenoid Test, in this Group. Replace starter assembly, if
faulty. required.
8. If all other starting system components and circuits check OK,
replace starter assembly.
STARTER 1. Battery discharged or 1. Refer to Group 8A - Battery. Charge or replace battery, if
ENGAGES, faulty. required.
FAILS TO TURN 2. Starting circuit wiring 2. See Cold Cranking Test, in this group. Test and repair feed
ENGINE. faulty. and/or control circuits, if required.
3. Starter assembly 3. If all other starting system components and circuits check OK,
faulty. replace starter assembly.
4. Engine seized. 4. Refer to Group 9 - Engine, for diagnostic and service
procedures.
STARTER 1. Broken teeth on 1. Remove starter as described in this group. Inspect ring gear
ENGAGES, starter ring gear. and replace, if required.
SPINS OUT 2. Starter assembly 2. If all other starting system components and circuits check OK,
BEFORE faulty. replace starter assembly.
ENGINE
STARTS.
STARTER DOES 1. Starter improperly 1. Install starter as described in this group. Tighten starter
NOT installed. mounting hardware to correct torque specifications.
DISENGAGE. 2. Starter relay faulty. 2. See Relay Test, in this group. Replace relay, if required.
3. Ignition switch faulty. 3. See Ignition Switch Test, in this group. Replace switch, if
4. Starter assembly required.
faulty. 4. If all other starting system components and circuits check OK,
replace starter assembly.

Ex a m p le : Wh en t est in g t h e r esist a n ce of t h e ba t - • Ba t t er y is fu lly-ch a r ged. Refer t o Gr ou p 8A -


t er y posit ive ca ble, t ou ch t h e volt m et er lea ds t o t h e Ba t t er y for m or e in for m a t ion .
ba t t er y posit ive ca ble cla m p a n d t h e ca ble con n ect or • F u lly en ga ge t h e pa r kin g br a ke.
a t t h e st a r t er solen oid. If you pr obe t h e ba t t er y pos- • If t h e veh icle is equ ipped wit h a n a u t om a t ic
it ive t er m in a l post a n d t h e ca ble con n ect or a t t h e t r a n sm ission , pla ce t h e gea r sh ift select or lever in t h e
st a r t er solen oid, you a r e r ea din g t h e com bin ed volt - P a r k posit ion . If t h e veh icle is equ ipped wit h a m a n -
a ge dr op in t h e ba t t er y posit ive ca ble cla m p-t o-t er m i- u a l t r a n sm ission , pla ce t h e gea r sh ift select or lever in
n a l post con n ect ion a n d t h e ba t t er y posit ive ca ble. t h e Neu t r a l posit ion a n d fu lly depr ess t h e clu t ch
Th e followin g oper a t ion will r equ ir e a volt m et er peda l.
a ccu r a t e t o 1/10 (0.10) volt . Befor e per for m in g t h e • Un plu g t h e Au t om a t ic Sh u t Down (ASD) r ela y t o
t est s, be cer t a in t h e followin g pr ocedu r es a r e a ccom - pr even t t h e en gin e fr om st a r t in g. Th e ASD r ela y is
plish ed: loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC).
POSITIVE
CLAMP INDUCTION NEGATIVE
AMMETER
CLAMP
CLAMP

XJ STARTING SYSTEMS 8B - 5
DI AGN OSI S AN D T EST I N G (Cont inue d)

NEGATIVE
CLAMP

Fig. 1 Volts-Amps Tester Connections - Typical STARTER


MOTOR VOLTMETER BATTERY

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 .

Fig. 4 Test Battery Positive Cable Resistance -


Typical
(4) 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 n ega t ive t er m in a l post a n d a good clea n
gr ou n d on t h e en gin e block (F ig. 5). 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
Fig. 2 Test Battery Negative Connection Resistance volt m et er. If t h e r ea din g is a bove 0.2 volt , clea n a n d
- Typical t igh t en t h e ba t t er y n ega t ive ca ble a t t a ch m en t on t h e
(2) Con n ect t h e posit ive lea d of t h e volt m et er t o en gin e block. Repea t t h e t est . If t h e r ea din g is st ill
t h e ba t t er y posit ive t er m in a l post . Con n ect t h e n ega - a bove 0.2 volt , r epla ce t h e fa u lt y ba t t er y n ega t ive
t ive lea d of t h e volt m et er t o t h e ba t t er y posit ive ca ble ca ble.
cla m p (F ig. 3). Rot a t e a n d h old t h e ign it ion swit ch in (5) Con n ect t h e posit ive lea d of t h e volt m et er t o
t h e St a r t posit ion . Obser ve t h e volt m et er. If volt a ge t h e st a r t er h ou sin g. Con n ect t h e n ega t ive lea d of t h e
is det ect ed, cor r ect t h e poor con t a ct bet ween t h e volt m et er t o t h e ba t t er y n ega t ive t er m in a l post (F ig.
ca ble cla m p a n d t h e t er m in a l post . 6). 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
(3) Con n ect t h e volt m et er t o m ea su r e bet ween t h e posit ion . Obser ve t h e volt m et er. If t h e r ea din g is
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- a bove 0.2 volt , cor r ect t h e poor st a r t er t o en gin e
n oid ba t t er y t er m in a l st u d (F ig. 4). Rot a t e a n d h old block gr ou n d con t a ct .
t h e ign it ion swit ch in t h e St a r t posit ion . Obser ve t h e If t h e r esist a n ce t est s det ect n o feed cir cu it pr ob-
volt m et er. If t h e r ea din g is a bove 0.2 volt , clea n a n d lem s, r em ove t h e st a r t er a n d see t h e Solen oid Test
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. pr ocedu r e in t h is gr ou p.
ENGINE
GROUND STARTER
BATTERY
MOTOR VOLTMETER VOLTMETER
BATTERY SOLENOID
SOLENOID SOLENOID
TERMINAL
FIELD
SOLENOID
OHMMETER
OHMMETER
COIL
MINAL
TER-
TERMI-
NAL

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.

Fig. 7 Continuity Test Between Solenoid Terminal


and Field Coil Terminal
(3) Ch eck for con t in u it y bet ween t h e solen oid t er-
Fig. 5 Test Ground Circuit Resistance - Typical
m in a l a n d t h e solen oid ca se (F ig. 8). 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 epla ce t h e
fa u lt y st a r t er a ssem bly.

Fig. 8 Continuity Test Between Solenoid Terminal


and Solenoid Case
(4) Con n ect t h e solen oid field coil wir e t o t h e field
Fig. 6 Test Starter Ground - Typical coil t er m in a l.
(5) In st a ll t h e st a r t er a s descr ibed in t h is gr ou p.
CONTROL CIRCUIT TEST
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o RELAY T EST
8W-21 - St a r t in g Syst em in Gr ou p 8W - Wir in g Dia - Th e st a r t er r ela y is loca t ed in t h e P ower Dist r ibu -
gr a m s. Th e st a r t er con t r ol cir cu it con sist s of: t ion Cen t er (P DC) in t h e en gin e com pa r t m en t . Refer
• Ba t t er y t o t h e P DC la bel for st a r t er r ela y iden t ifica t ion a n d
• St a r t er r ela y loca t ion .
• St a r t er solen oid Rem ove t h e st a r t er r ela y fr om t h e P DC a s
• Ign it ion swit ch descr ibed in t h is gr ou p t o per for m t h e followin g t est s:
• P a r k/n eu t r a l posit ion swit ch (a u t om a t ic t r a n s- (1) A r ela y in t h e de-en er gized posit ion sh ou ld
m ission ) 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
• Clu t ch peda l posit ion swit ch (m a n u a l t r a n sm is- n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go
sion ) t o St ep 2. If n ot OK, r epla ce t h e fa u lt y r ela y.
• Wir e h a r n ess a n d con n ect ion s. (2) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec-
Test pr ocedu r es for t h ese com pon en t s sh ou ld be t r om a gn et ) sh ou ld be 75 6 5 oh m s. If OK, go t o St ep
per for m ed in t h e or der in wh ich t h ey a r e list ed, a s 3. If n ot OK, r epla ce t h e fa u lt y r ela y.
follows: (3) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86.
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls
SOLEN OI D T EST 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
Rem ove t h e st a r t er a s descr ibed in t h is gr ou p. a n d 30. If OK, see t h e Rela y Cir cu it Test pr ocedu r e
Th en pr oceed a s follows: in t h is gr ou p. If n ot OK, r epla ce t h e fa u lt y r ela y.
(1) Rem ove t h e wir e fr om t h e solen oid field coil
t er m in a l. RELAY CI RCU I T T EST
(2) Ch eck for con t in u it y bet ween t h e solen oid t er- (1) Th e r ela y com m on feed t er m in a l ca vit y (30) is
m in a l a n d t h e field coil t er m in a l wit h a con t in u it y 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
NUMBER TERMINAL
COMMON
IDENTIFICATION
FEED
LEGEND
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
XJ STARTING SYSTEMS 8B - 7
DI AGN OSI S AN D T EST I N G (Cont inue d)
m a t ic t r a n sm ission , ch eck for a n open or sh or t cir cu it
t o t h e pa r k/n eu t r a l posit ion swit ch a n d r epa ir, if
r equ ir ed. If t h e cir cu it is OK, see t h e P a r k/Neu t r a l
P osit ion Swit ch Test pr ocedu r e in t h is gr ou p. If n ot
OK wit h a m a n u a l t r a n sm ission , r epa ir t h e cir cu it t o
gr ou n d a s r equ ir ed.

PARK /N EU T RAL POSI T I ON SWI T CH T EST


TERMINAL LEGEND F or t est in g of t h e pa r k/n eu t r a l posit ion swit ch ,
87A 87 85
NUMBER IDENTIFICATION r efer t o Gr ou p 21 - Tr a n sm ission a n d Tr a n sfer Ca se.
tJ~ 30 COMMON FEED
l""~ 85
86
COIL GROUND
COIL BATTERY
I GN I T I ON SWI T CH T EST
30 86 87 NORMALLY OPEN
WARNING: ON VEHICLES EQUIPPED WITH AIR-
87A NORMALLY CLOSED
BAGS, REFER TO GROUP 8M - PASSIVE
9514-16
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
Starter Relay
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
t im es. If OK, go t o St ep 2. If n ot OK, r epa ir t h e open SERVICE. FAILURE TO TAKE THE PROPER PRE-
cir cu it t o t h e P DC fu se a s r equ ir ed. CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(2) Th e r ela y n or m a lly closed t er m in a l (87A) is BAG DEPLOYMENT AND POSSIBLE PERSONAL
con n ect ed t o t er m in a l 30 in t h e de-en er gized posit ion , INJURY.
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 - (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
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- ca ble.
gized posit ion . Th is t er m in a l su pplies ba t t er y volt a ge (2) Rem ove t h e st eer in g colu m n sh r ou ds a n d
t o t h e st a r t er solen oid field coils. Th er e sh ou ld be u n plu g t h e ign it ion swit ch wir e h a r n ess con n ect or.
con t in u it y bet ween t h e ca vit y for r ela y t er m in a l 87 Refer t o Gr ou p 8D - Ign it ion Syst em s for t h e pr oce-
a n d t h e st a r t er solen oid t er m in a l a t a ll t im es. If OK, du r es.
go t o St ep 4. If n ot OK, r epa ir t h e open cir cu it t o t h e (3) Wit h t h e ign it ion swit ch in t h e On posit ion ,
st a r t er solen oid a s r equ ir ed. ch eck for con t in u it y bet ween t h e ign it ion swit ch
(4) Th e coil ba t t er y t er m in a l (86) is con n ect ed t o fu sed B(+) cir cu it t er m in a l a n d t h e ign it ion swit ch
t h e elect r om a gn et in t h e r ela y. It is en er gized wh en ou t pu t (st a r t ) cir cu it t er m in a l. Th er e sh ou ld be n o
t h e ign it ion swit ch is h eld in t h e St a r t posit ion . On con t in u it y. If OK, go t o St ep 4. If n ot OK, r epla ce t h e
veh icles wit h a m a n u a l t r a n sm ission , t h e clu t ch fa u lt y swit ch .
peda l m u st be fu lly depr essed for t h is t est . Ch eck for (4) Wit h t h e ign it ion swit ch h eld in t h e St a r t posi-
ba t t er y volt a ge a t t h e ca vit y for r ela y t er m in a l 86 t ion , ch eck for con t in u it y bet ween t h e ign it ion swit ch
wit h t h e ign it ion swit ch in t h e St a r t posit ion , a n d n o fu sed B(+) cir cu it t er m in a l a n d t h e ign it ion swit ch
volt a ge wh en t h e ign it ion swit ch is r elea sed t o t h e ou t pu t (st a r t ) cir cu it t er m in a l. Th er e sh ou ld n ow be
On posit ion . If OK, go t o St ep 5. If n ot OK wit h a n con t in u it y. If n ot OK, r epla ce t h e fa u lt y swit ch .
a u t om a t ic t r a n sm ission , ch eck for a n open or sh or t
cir cu it t o t h e ign it ion swit ch a n d r epa ir, if r equ ir ed. STARTER NOISE - 2.5L ENGINE
If t h e cir cu it t o t h e ign it ion swit ch is OK, see t h e See t h e St a r t er Noise Dia gn osis ch a r t (F ig. 9). If
Ign it ion Swit ch Test pr ocedu r e in t h is gr ou p. If n ot t h e com pla in t is sim ila r t o Con dit ion s 1 a n d 2 in t h e
OK wit h a m a n u a l t r a n sm ission , ch eck t h e cir cu it ch a r t , cor r ect ion ca n be m a de by sh im m in g t h e
bet ween t h e r ela y a n d t h e clu t ch peda l posit ion st a r t er u sin g t h e followin g pr ocedu r es:
swit ch for a n open or a sh or t . If t h e cir cu it is OK, see
t h e Clu t ch P eda l P osit ion Swit ch Test pr ocedu r e in CAUTION: Disconnect the battery negative cable to
t h is gr ou p. prevent the engine from starting.
(5) Th e coil gr ou n d t er m in a l (85) is con n ect ed t o
(1) If t h e com pla in t is sim ila r t o Con dit ion 1, t h e
t h e elect r om a gn et in t h e r ela y. On veh icles wit h a n
st a r t er m u st be m oved t owa r d t h e st a r t er r in g gea r
a u t om a t ic t r a n sm ission , it is gr ou n ded t h r ou gh t h e
by r em ovin g sh im s (F ig. 10).
pa r k/n eu t r a l posit ion swit ch on ly wh en t h e gea r sh ift
select or lever is in t h e P a r k or Neu t r a l posit ion s. On NOTE: The shim thickness is 0.381 mm (0.015 in.),
veh icles wit h a m a n u a l t r a n sm ission , it is gr ou n ded and the shims may be stacked if additional thick-
a t a ll t im es. Ch eck for con t in u it y t o gr ou n d a t t h e ness is required.
ca vit y for r ela y t er m in a l 85. If n ot OK wit h a n a u t o-
STARTER
MOTOR SHIM FWD SHIM SCREW STARTER CONNECTORS NUTS
FWD

8B - 8 STARTING SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSE CORRECTION

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

Fig. 9 Starter Noise Diagnosis


REM OVAL AN D I N STALLAT I ON
STARTER
2 .5 L EN GI N E
(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. 11).

J908C-1

Fig. 10 Starter Shim


(2) If t h e com pla in t is sim ila r t o Con dit ion 2, t h e
st a r t er m u st be m oved a wa y fr om t h e st a r t er r in g
gea r. Th is is don e by in st a llin g sh im (s) a cr oss bot h
st a r t er m ou n t in g pa ds. Mor e t h a n on e sh im m a y be
r equ ir ed.

NOTE: This is a condition that will generally cause


broken starter (flywheel/drive plate) ring gear teeth
or broken starter housings.
' ) 0

CONNECTORS
~SCREW
80aafb43

Fig. 11 Starter Remove/Install - 2.5L Engine


SCREW STARTER
CONNECTOR FWD SCREW
NUTS

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).

Fig. 13 Power Distribution Center


(3) Refer t o t h e la bel on t h e P DC for st a r t er r ela y
iden t ifica t ion a n d loca t ion .
(4) Un plu g t h e st a r t er r ela y fr om t h e P DC.
Fig. 12 Starter Remove/Install - 4.0L Engine (5) In st a ll t h e st a r t er r ela y by a lign in g t h e r ela y
(4) Rem ove t h e lower st a r t er m ou n t in g scr ew. t er m in a ls wit h t h e ca vit ies in t h e P DC a n d pu sh in g
(5) Rem ove t h e u pper st a r t er m ou n t in g scr ew a n d t h e r ela y fir m ly in t o pla ce.
t h e st a r t er m ot or. (6) In st a ll t h e P DC cover.
(7) Con n ect t h e ba t t er y n ega t ive ca ble.
(8) Test t h e r ela y oper a t ion .
8B - 10 STARTING SYSTEMS XJ

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

GENERAL INFORMATION CHARGING SYSTEM . . . . . . . . . . . . ......... 2


OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . .... 1 CURRENT OUTPUT TEST . . . . . . . . ......... 3
DESCRIPTION AND OPERATION ON-BOARD DIAGNOSTIC TEST FOR
BATTERY TEMPERATURE SENSOR . . . . . . . . . 2 CHARGING SYSTEM . . . . . . . . . . ......... 5
CHARGING SYSTEM OPERATION . . . . . . . . . . 1 REMOVAL AND INSTALLATION
ELECTRONIC VOLTAGE REGULATOR . . . . . . . 2 BATTERY TEMPERATURE SENSOR ......... 7
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERATOR . . . . . . . . . . . . . . . . . . ......... 5
DIAGNOSIS AND TESTING SPECIFICATIONS
BATTERY TEMPERATURE SENSOR . . . . . .... 5 GENERATOR RATINGS . . . . . . . . . . ......... 7
CHARGING SYSTEM RESISTANCE TESTS .... 3 TORQUE CHART . . . . . . . . . . . . . . . ......... 7

GEN ERAL I N FORM AT I ON • E lect r on ic Volt a ge Regu la t or (E VR) cir cu it r y


wit h in t h e P ower t r a in Con t r ol Modu le (P CM)
OVERVIEW • Ign it ion swit ch (r efer t o Gr ou p 8D, Ign it ion Sys-
Th e ba t t er y, st a r t in g, a n d ch a r gin g syst em s oper- t em for in for m a t ion )
a t e wit h on e a n ot h er, a n d m u st be t est ed a s a com - • Ba t t er y (r efer t o Gr ou p 8A, Ba t t er y for in for m a -
plet e syst em . In or der for t h e veh icle t o st a r t a n d t ion )
ch a r ge pr oper ly, a ll of t h e com pon en t s in volved in • Ba t t er y t em per a t u r e sen sor
t h ese syst em s m u st per for m wit h in specifica t ion s. • Gen er a t or La m p (if equ ipped)
Gr ou p 8A cover s t h e ba t t er y, Gr ou p 8B cover s t h e • Ch eck Ga u ges La m p (if equ ipped)
st a r t in g syst em , a n d Gr ou p 8C cover s t h e ch a r gin g • Volt m et er (r efer t o Gr ou p 8E , In st r u m en t P a n el
syst em . Refer t o Gr ou p 8W - Wir in g Dia gr a m s for a n d Ga u ges for in for m a t ion )
com plet e cir cu it descr ipt ion s a n d dia gr a m s. We h a ve • Wir in g h a r n ess a n d con n ect ion s (r efer t o Gr ou p
sepa r a t ed t h ese syst em s t o m a ke it ea sier t o loca t e 8W, Wir in g for in for m a t ion )
t h e in for m a t ion you a r e seekin g wit h in t h is Ser vice Th e ch a r gin g syst em is t u r n ed on a n d off wit h t h e
Ma n u a l. H owever, wh en a t t em pt in g t o dia gn ose a n y ign it ion swit ch . Wh en t h e ign it ion swit ch is t u r n ed t o
of t h ese syst em s, it is im por t a n t t h a t you keep t h eir t h e ON posit ion , ba t t er y volt a ge fr om t h e power t r a in
in t er depen den cy in m in d. con t r ol m odu le (P CM) is su pplied t o t h e gen er a t or
Th e dia gn ost ic pr ocedu r es u sed in t h ese gr ou ps r ot or t o pr odu ce a m a gn et ic field. Th is is don e
in clu de t h e m ost ba sic con ven t ion a l dia gn ost ic m et h - t h r ou gh on e of t h e t wo field t er m in a ls a t t h e r ea r of
ods t o t h e m or e soph ist ica t ed On -Boa r d Dia gn ost ics gen er a t or. On m o d e ls o f p re v io u s y e a rs , ba tte ry
(OBD) bu ilt in t o t h e P ower t r a in Con t r ol Modu le v o lta g e to th is fie ld te rm in a l w a s s u p p lie d
(P CM). Use of a in du ct ion m illia m per e a m m et er, volt / d ire c tly fro m th e AS D re la y.
oh m m et er, ba t t er y ch a r ger, ca r bon pile r h eost a t (loa d Th e a m ou n t of DC cu r r en t pr odu ced by t h e gen er-
t est er ), a n d 12-volt t est la m p m a y be r equ ir ed. a t or is con t r olled by t h e E VR (field con t r ol) cir cu it r y
All OBD-sen sed syst em s a r e m on it or ed by t h e con t a in ed wit h in t h e P CM. Th is cir cu it r y is con -
P CM. E a ch m on it or ed cir cu it is a ssign ed a Dia gn os- n ect ed in ser ies wit h t h e secon d r ot or field t er m in a l
t ic Tr ou ble Code (DTC). Th e P CM will st or e a DTC in a n d gr ou n d.
elect r on ic m em or y for a n y fa ilu r e it det ect s. See t h e A ba t t er y t em per a t u r e sen sor, loca t ed in t h e ba t -
On -Boa r d Dia gn ost ics Test in Gr ou p 8C - Ch a r gin g t er y t r a y h ou sin g, is u sed t o sen se ba t t er y t em per a -
Syst em for m or e in for m a t ion . t u r e. Th is t em per a t u r e da t a , a lon g wit h da t a fr om
m on it or ed lin e volt a ge, is u sed by t h e P CM t o va r y
t h e ba t t er y ch a r gin g r a t e. Th is is don e by cyclin g t h e
DESCRI PT I ON AN D OPERAT I ON gr ou n d pa t h t o con t r ol t h e st r en gt h of t h e r ot or m a g-
n et ic field. Th e P CM t h en com pen sa t es a n d r egu la t es
CHARGING SYSTEM OPERATION gen er a t or cu r r en t ou t pu t a ccor din gly.
Th e ch a r gin g syst em con sist s of: All veh icles a r e equ ipped wit h On -Boa r d Dia gn os-
• Gen er a t or t ics (OBD). All OBD-sen sed syst em s, in clu din g t h e
E VR (field con t r ol) cir cu it r y, a r e m on it or ed by t h e
8C - 2 CHARGING SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
P CM. E a ch m on it or ed cir cu it is a ssign ed a Dia gn os- in g cir cu it loca t ed wit h in t h e P ower t r a in Con t r ol
t ic Tr ou ble Code (DTC). Th e P CM will st or e a DTC in Modu le (P CM). Th e E VR is n ot ser viced sepa r a t ely. If
elect r on ic m em or y for a n y fa ilu r e it det ect s. Refer t o r epla cem en t is n ecessa r y, t h e P CM m u st be r epla ced.
On -Boa r d Dia gn ost ic Test F or Ch a r gin g Syst em in Op e ra tio n : Th e a m ou n t of DC cu r r en t pr odu ced
t h is gr ou p for m or e in for m a t ion . by t h e gen er a t or is con t r olled by E VR cir cu it r y con -
Th e Ch eck Ga u ges La m p m on it or s: c h a rg in g s y s - t a in ed wit h in t h e P CM. Th is cir cu it r y is con n ect ed in
te m v o lta g e , en gin e coola n t t em per a t u r e a n d en gin e ser ies wit h t h e gen er a t or s secon d r ot or field t er m in a l
oil pr essu r e. If a n ext r em e con dit ion is in dica t ed, t h e a n d it s gr ou n d.
la m p will be illu m in a t ed. Th is is don e a s r em in der t o Volt a ge is r egu la t ed by cyclin g t h e gr ou n d pa t h t o
ch eck t h e t h r ee ga u ges. Th e sign a l t o a ct iva t e t h e con t r ol t h e st r en gt h of t h e r ot or m a gn et ic field. Th e
la m p is sen t via t h e CCD bu s cir cu it s. Th e la m p is E VR cir cu it r y m on it or s syst em lin e volt a ge a n d ba t -
loca t ed on t h e in st r u m en t pa n el. Refer t o Gr ou p 8E , t er y t em per a t u r e (r efer t o Ba t t er y Tem per a t u r e Sen -
In st r u m en t P a n el a n d Ga u ges for a ddit ion a l in for m a - sor for m or e in for m a t ion ). It t h en com pen sa t es a n d
t ion . r egu la t es gen er a t or cu r r en t ou t pu t a ccor din gly. Also
see Ch a r gin g Syst em Oper a t ion for a ddit ion a l in for-
GENERATOR m a t ion .
Th e gen er a t or is belt -dr iven by t h e en gin e u sin g a
ser pen t in e t ype dr ive belt . It is ser viced on ly a s a
com plet e a ssem bly. If t h e gen er a t or fa ils for a n y r ea - DI AGN OSI S AN D T EST I N G
son , t h e en t ir e a ssem bly m u st be r epla ced.
As t h e en er gized r ot or begin s t o r ot a t e wit h in t h e CHARGING SYSTEM
gen er a t or, t h e spin n in g m a gn et ic field in du ces a cu r- Th e followin g pr ocedu r es m a y be u sed t o dia gn ose
r en t in t o t h e win din gs of t h e st a t or coil. On ce t h e t h e ch a r gin g syst em if:
gen er a t or begin s pr odu cin g su fficien t cu r r en t , it a lso • t h e gen er a t or la m p (if equ ipped) is illu m in a t ed
pr ovides t h e cu r r en t n eeded t o en er gize t h e r ot or. wit h t h e en gin e r u n n in g
Th e Y t ype st a t or win din g con n ect ion s deliver t h e • t h e volt m et er (if equ ipped) does n ot r egist er
in du ced AC cu r r en t t o 3 posit ive a n d 3 n ega t ive pr oper ly
diodes for r ect ifica t ion . F r om t h e diodes, r ect ified DC • a n u n der ch a r ged or over ch a r ged ba t t er y con di-
cu r r en t is deliver ed t o t h e veh icle elect r ica l syst em t ion occu r s.
t h r ou gh t h e gen er a t or ba t t er y a n d gr ou n d t er m in a ls. Rem em ber t h a t a n u n der ch a r ged ba t t er y is oft en
Alt h ou gh t h e gen er a t or s a ppea r t h e sa m e ext er- ca u sed by:
n a lly, differ en t gen er a t or s wit h differ en t ou t pu t r a t - • a ccessor ies bein g left on wit h t h e en gin e n ot
in gs a r e u sed on t h is veh icle. Be cer t a in t h a t t h e r u n n in g
r epla cem en t gen er a t or h a s t h e sa m e ou t pu t r a t in g • a fa u lt y or im pr oper ly a dju st ed swit ch t h a t
a n d pa r t n u m ber a s t h e or igin a l u n it . Refer t o Gen - a llows a la m p t o st a y on . See Ign it ion -Off Dr a w Test
er a t or Ra t in gs in t h e Specifica t ion s sect ion a t t h e in Gr ou p 8A, Ba t t er y for m or e in for m a t ion .
ba ck of t h is gr ou p for a m per a ge r a t in gs a n d pa r t
I N SPECT I ON
n u m ber s.
To per for m a com plet e t est of t h e ch a r gin g syst em ,
Noise em it t in g fr om t h e gen er a t or m a y be ca u sed
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 oce-
by: wor n , loose or defect ive bea r in gs; a loose or defec-
du r es ser vice m a n u a l a n d t h e DRB sca n t ool. P er-
t ive dr ive pu lley; in cor r ect , wor n , da m a ged or m isa d-
for m t h e followin g in spect ion s befor e a t t a ch in g t h e
ju st ed fa n dr ive belt ; loose m ou n t in g bolt s; a
sca n t ool.
m isa lign ed dr ive pu lley or a defect ive st a t or or diode.
(1) In spect t h e ba t t er y con dit ion . Refer t o Gr ou p
8A, Ba t t er y for pr ocedu r es.
BATTERY TEMPERATURE SENSOR
(2) In spect con dit ion of ba t t er y ca ble t er m in a ls,
Th e ba t t er y t em per a t u r e sen sor is u sed t o det er-
ba t t er y post s, con n ect ion s a t en gin e block, st a r t er
m in e t h e ba t t er y t em per a t u r e a n d con t r ol ba t t er y
solen oid a n d r ela y. Th ey sh ou ld be clea n a n d t igh t .
ch a r gin g r a t e. Th is t em per a t u r e da t a , a lon g wit h
Repa ir a s r equ ir ed.
da t a fr om m on it or ed lin e volt a ge, is u sed by t h e P CM
(3) In spect a ll fu ses in bot h t h e fu seblock a n d
t o va r y t h e ba t t er y ch a r gin g r a t e. Syst em volt a ge will
P ower Dist r ibu t ion Cen t er (P DC) for t igh t n ess in
be h igh er a t colder t em per a t u r es a n d is gr a du a lly
r ecept a cles. Th ey sh ou ld be pr oper ly in st a lled a n d
r edu ced a t wa r m er t em per a t u r es.
t igh t . Repa ir or r epla ce a s r equ ir ed.
(4) In spect gen er a t or m ou n t in g bolt s for t igh t n ess.
ELECTRONIC VOLTAGE REGULATOR
Repla ce or t igh t en bolt s if r equ ir ed. Refer t o t h e Gen -
Th e E lect r on ic Volt a ge Regu la t or (E VR) is n ot a
er a t or Rem ova l/In st a lla t ion sect ion of t h is gr ou p for
sepa r a t e com pon en t . It is a ct u a lly a volt a ge r egu la t -
t or qu e specifica t ion s.
GROUND
FIELD
TERMINAL
TERMI-
NALS B+ (OUTPUT TERMINAL)

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 .

CAUTION: When adjusting rheostat load, do not


allow voltage to rise above 16 volts. Damage to the
battery and electrical system components may
result.

(6) Th e a m m et er r ea din g m u st m eet t h e Min im u m


Test Am ps specifica t ion s a s displa yed in t h e Gen er a -
t or Ra t in gs ch a r t . Th is ca n be fou n d in t h e Specifica -
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
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
ca se. On som e en gin es t h is la bel m a y be loca t ed on
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 -
ber t o t h e Gen er a t or Ra t in g ch a r t .
(7) Rem ove volt /a m p t est er.
(8) Rem ove ju m per wir e.
(9) Use t h e DRB sca n t ool t o er a se t h e DTC. Refer
804d8e94
t o t h e DRB scr een for pr ocedu r es.
Fig. 2 Battery Temperature Sensor
RESU LT S
• If a m p r ea din g m eet s specifica t ion s in Test 2, ON-BOARD DIAGNOSTIC TEST FOR CHARGING
gen er a t or is OK. SYSTEM
• If a m p r ea din g is less t h a n specified in Test 2, Th e P ower t r a in Con t r ol Modu le (P CM) m on it or s
a n d wir e r esist a n ce (volt a ge dr op) t est s wer e OK, t h e cr it ica l in pu t a n d ou t pu t cir cu it s of t h e ch a r gin g sys-
gen er a t or sh ou ld be r epla ced. Refer t o Rem ova l a n d t em , m a kin g su r e t h ey a r e oper a t ion a l. A Dia gn ost ic
In st a lla t ion in t h is gr ou p for pr ocedu r es. Tr ou ble Code (DTC) is a ssign ed t o ea ch in pu t a n d
• If Test 2 r esu lt s wer e OK, bu t Test 1 r esu lt s ou t pu t cir cu it m on it or ed by t h e On -Boa r d Dia gn ost ic
wer e n ot , t h e pr oblem is in E VR cir cu it r y. Refer t o (OBD) syst em . Som e cir cu it s a r e ch ecked con t in u -
a ppr opr ia t e P ower t r a in Dia gn ost ic P r ocedu r es m a n - ou sly a n d som e a r e ch ecked on ly u n der cer t a in con -
u a l for dia gn osis. dit ion s.
F or DTC in for m a t ion , r efer t o Dia gn ost ic Tr ou ble
BATTERY TEMPERATURE SENSOR Codes in Gr ou p 25, E m ission Con t r ol Syst em . Th is
To per for m a com plet e t est of t h is sen sor a n d it s will in clu de a com plet e list of DTC’s in clu din g DTC’s
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- for t h e ch a r gin g syst em .
n ost ic P r ocedu r es m a n u a l. To t est t h e sen sor on ly,
r efer t o t h e followin g:
(1) Th e sen sor is loca t ed u n der t h e ba t t er y a n d is REM OVAL AN D I N STALLAT I ON
a t t a ch ed t o t h e ba t t er y t r a y (F ig. 2). A t wo-wir e pig-
t a il h a r n ess is a t t a ch ed dir ect ly t o t h e sen sor. Th e GENERATOR
opposit e en d of t h is h a r n ess con n ect s t h e sen sor t o
t h e en gin e wir in g h a r n ess. REM OVAL
(2) Discon n ect t h e t wo-wir e pigt a il h a r n ess fr om
WARNING: DISCONNECT NEGATIVE CABLE FROM
t h e en gin e h a r n ess.
BATTERY BEFORE REMOVING BATTERY OUTPUT
(3) At t a ch oh m m et er lea ds t o t h e wir e t er m in a ls of
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
t h e pigt a il h a r n ess.
DO SO CAN RESULT IN INJURY OR DAMAGE TO
(4) At r oom t em per a t u r e of 25° C (75–80° F ), a n
ELECTRICAL SYSTEM.
oh m m et er r ea din g of 9,000 (9K) t o 11,000 (11K) oh m s
sh ou ld be obser ved. (1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(5) If r ea din g is a bove or below t h e specifica t ion , (2) Rem ove gen er a t or dr ive belt . Refer t o Gr ou p 7,
r epla ce t h e sen sor. Coolin g Syst em for pr ocedu r es.
(6) Refer t o t h e Rem ova l a n d In st a lla t ion sect ion (3) Left H a n d Dr ive (LH D) Veh icles On ly: Rem ove
for pr ocedu r es. gen er a t or pivot a n d m ou n t in g bolt s/n u t (F ig. 3) or
UPPER MOUNTING
BRACKET SPACER
SPACER UPPER MOUNTING
GENERATOR
BRACKET
GENERATOR
LOWER
UPPER
UPPERBOLT
BOLT
BOLT WIRE
BELT
HOLDOWN
HARNESS
ADJUSTMENT
NUT
BOLTS B+ TERMINAL GROUND
FWD (-)GENERATOR
TERMINALLOWER
FIELD
UPPERBOLT
NUT
TERMI-
NALS

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

Fig. 5 Remove/Install Generator—4.0L Engine—RHD

B+TERMINAL

LOWER
BOLT

80a592b2

Fig. 3 Remove/Install Generator—2.5L Engine

80a92a67

Fig. 6 Remove/Install Generator Connectors—


Typical
Rem ove wir e con n ect or s. A t ypica l gen er a t or wir in g
h a r n ess is sh own in (F ig. 6). Wir in g h a r n ess r ou t in g
a s sh own m a y be sligh t ly differ en t depen din g on
veh icle m odel a n d/or en gin e. Refer t o Gr ou p 8W, Wir-
in g Dia gr a m s for a ddit ion a l in for m a t ion .
(6) Rem ove gen er a t or fr om veh icle.

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.)

CAUTION: Never force a belt over a pulley rim


using a screwdriver. The synthetic fiber of the belt
can be damaged.

CAUTION: When installing a serpentine accessory


drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Group
7, Cooling System.

(3) LH D Veh icles: In st a ll gen er a t or dr ive belt .


Refer t o Gr ou p 7, Coolin g Syst em for pr ocedu r es. 804d8e94

(4) RH D Veh icles: In st a ll 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. Fig. 7 Battery Temperature Sensor
In st a ll gen er a t or lower n u t /bolt . REM OVAL
(5) RH D Veh icles: On veh icles equ ipped wit h RH D, (1) Rem ove ba t t er y. Refer t o Gr ou p 8A, Ba t t er y for
t h e gen er a t or is u sed t o a dju st t h e ser pen t in e belt . pr ocedu r es.
Refer t o Gr ou p 7, Coolin g Syst em for belt r ou t in g, (2) Discon n ect sen sor pigt a il h a r n ess fr om en gin e
belt a dju st m en t a n d bolt t igh t en in g pr ocedu r es. wir e h a r n ess.
(6) In st a ll n ega t ive ba t t er y ca ble t o ba t t er y. (3) P r y sen sor st r a igh t u p fr om ba t t er y t r a y
m ou n t in g h ole.
BATTERY TEMPERATURE SENSOR
Th e ba t t er y t em per a t u r e sen sor is loca t ed u n der I N STALLAT I ON
veh icle ba t t er y a n d is a t t a ch ed t o a m ou n t in g h ole on (1) F eed pigt a il h a r n ess t h r ou gh h ole in t op of ba t -
ba t t er y t r a y. t er y t r a y a n d pr ess sen sor in t o t op of ba t t er y t r a y.
(2) Con n ect pigt a il h a r n ess.
(3) In st a ll ba t t er y. Refer t o Gr ou p 8A, Ba t t er y for
pr ocedu r es.

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

TORQUE CHART D e s c rip tio n To rqu e


Righ t H a n d Dr ive= RH D, Left H a n d Dr ive= LH D. Ba t t er y Ter m in a l Nu t —LH D or
RH D . . . . . . . . . . . . . . . . . . . 8.5 N·m (75 in . lbs.)
D e s c rip tio n To rqu e Gr ou n d Ter m in a l Nu t —LH D or
Gen er a t or Mou n t in g RH D . . . . . . . . . . . . . . . . . . . 8.5 N·m (75 in . lbs.)
Bolt —LH D—2.5L/4.0L H a r n ess H old-down Nu t —LH D or
E n gin e . . . . . . . . . . . . . . . . . . 55 N·m (41 ft . lbs.) RH D . . . . . . . . . . . . . . . . . . . 8.5 N·m (75 in . lbs.)
Gen er a t or P ivot Bolt / F ield Ter m in a l Nu t s—LH D or
Nu t —LH D—2.5L/4.0L E n gin e . 55 N·m (41 ft . lbs.) RH D . . . . . . . . . . . . . . . . . . . 2.8 N·m (25 in . lbs.)
XJ IGNITION SYSTEM 8D - 1

IGNITION SYSTEM
CON T EN T S

page page

GENERAL INFORMATION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8


INTRODUCTION . . . . . . . . . . . . . . . . . . . ..... 1 MAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION AND OPERATION SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . 8
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . 3 SPARK PLUG CONDITIONS . . . . . . . . . . . . . . . 9
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 3 TESTING FOR SPARK AT COIL . . . . . . . . . . . . . 4
CRANKSHAFT POSITION SENSOR . . . . . . . . . . 3 REMOVAL AND INSTALLATION
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . 13
ENGINE COOLANT TEMPERATURE CAMSHAFT POSITION SENSOR . . . . . . . . . . . 14
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . ..... 4 CRANKSHAFT POSITION SENSOR . . . . . . . . . 13
IGNITION COIL . . . . . . . . . . . . . . . . . . . . ..... 3 DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . 15
IGNITION SWITCH AND KEY LOCK ENGINE COOLANT TEMPERATURE
CYLINDER . . . . . . . . . . . . . . . . . . . . . . ..... 4 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
IGNITION SYSTEM . . . . . . . . . . . . . . . . . ..... 1 IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . 12
INTAKE MANIFOLD AIR TEMPERATURE IGNITION SWITCH AND KEY CYLINDER . . . . . 18
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . ..... 4 INTAKE MANIFOLD AIR TEMPERATURE
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MANIFOLD ABSOLUTE PRESSURE (MAP)
POWERTRAIN CONTROL MODULE . . . . . . . . . . 2 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . 2 POWERTRAIN CONTROL MODULE (PCM) . . . 18
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 2 SHIFTER/IGNITION INTERLOCK . . . . . . . . . . . 20
THROTTLE POSITION SENSOR . . . . . . . . . . . . 4 SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 12
AUTOMATIC SHUTDOWN THROTTLE POSITION SENSOR . . . . . . . . . . . 15
(ASD) RELAY TEST . . . . . . . . . . . . . . . . . . . . 4 SPECIFICATIONS
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 8 ENGINE FIRING ORDER—2.5L 4-CYLINDER
CRANKSHAFT POSITION SENSOR . . . . . . . . . . 7 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . . . 7 ENGINE FIRING ORDER—4.0L 6-CYLINDER
DISTRIBUTOR ROTOR . . . . . . . . . . . . . . . . . . . 7 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ENGINE COOLANT TEMPERATURE IGNITION COIL RESISTANCE . . . . . . . . . . . . . 21
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . 20
FAILURE TO START TEST . . . . . . . . . . . . . . . . . 6 SPARK PLUG CABLE RESISTANCE . . . . . . . . 21
IGNITION COIL TEST . . . . . . . . . . . . . . . . . . . . . 5 SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 21
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . 7 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 21
INTAKE MANIFOLD AIR TEMPERATURE VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

GEN ERAL I N FORM AT I ON DESCRI PT I ON AN D OPERAT I ON


INTRODUCTION IGNITION SYSTEM
Th is gr ou p descr ibes t h e ign it ion syst em s for bot h Th e ign it ion syst em s u sed on t h e 2.5L 4–cylin der
t h e 2.5L 4–cylin der a n d t h e 4.0L 6–cylin der en gin es. a n d t h e 4.0L 6–cylin der en gin e a r e ba sica lly iden t i-
On Boa r d Dia gn ost ics is descr ibed in Gr ou p 25, ca l. Sim ila r it ies a n d differ en ces bet ween t h e syst em s
E m ission Con t r ol Syst em s. will be discu ssed.
Gr ou p 0, Lu br ica t ion a n d Ma in t en a n ce, con t a in s Th e ign it ion syst em is con t r olled by t h e power t r a in
gen er a l m a in t en a n ce in for m a t ion (in t im e or m ilea ge con t r ol m odu le (P CM) on a ll en gin es.
in t er va ls) for ign it ion r ela t ed it em s. Th e Own er ’s Th e ign it ion syst em con sist s of:
Ma n u a l a lso con t a in s m a in t en a n ce in for m a t ion . • Spa r k P lu gs
• Ign it ion Coil
PCM (3)
CONNEC-
32-WAY
TORS SYNC
DISTRIBUTOR
GENERATOR
ASSEMBLY
SIGNAL PULSE RING
CAMSHAFT
POSITION SEN-
SOR

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

POWERTRAIN CONTROL MODULE


Th e P ower t r a in Con t r ol Modu le (P CM) is loca t ed
in t h e en gin e com pa r t m en t (F ig. 1).

DISTRIBUTOR
ASSEMBLY

Fig. 2 Distributor and Camshaft Position Sensor-


Typical
t im in g is con t r olled by t h e P CM, ba s e ig n itio n tim -
in g is n o t a d ju s ta ble o n a n y o f th e s e e n g in e s .
Th e dist r ibu t or is locked in pla ce by a for k wit h a
slot loca t ed on t h e dist r ibu t or h ou sin g ba se. Th e dis-
t r ibu t or h olddown cla m p bolt pa sses t h r ou gh t h is slot
wh en in st a lled. Beca u se t h e dist r ibu t or posit ion is
locked wh en in st a lled, it s r ot a t ion a l posit ion ca n n ot
be ch a n ged. D o n o t a tte m p t to m o d ify th e d is -
Fig. 1 Powertrain Control Module (PCM) Location
tribu to r h o u s in g to g e t d is tribu to r ro ta tio n .
Th e ign it ion syst em is con t r olled by t h e P CM. D is tribu to r p o s itio n w ill h a v e n o e ffe c t o n ig n i-
tio n tim in g . Th e p o s itio n o f th e d is tribu to r w ill
NOTE: Base ignition timing by rotation of distribu- d e te rm in e fu e l s y n c h ro n iza tio n o n ly.
tor is not adjustable. 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 P CM open s a n d closes t h e ign it ion coil gr ou n d Th e sea l is n ot ser vicea ble.
cir cu it t o oper a t e t h e ign it ion coil. Th is is don e t o
a dju st ign it ion t im in g, bot h in it ia l (ba se) a n d SPARK PLUGS
a dva n ce, a n d for ch a n gin g en gin e oper a t in g con di- All en gin es u se r esist or t ype spa r k plu gs. Rem ove
t ion s. t h e spa r k plu gs a n d exa m in e t h em for bu r n ed elec-
Th e a m ou n t of elect r on ic spa r k a dva n ce pr ovided t r odes a n d fou led, cr a cked or br oken por cela in in su -
by t h e P CM is det er m in ed by five in pu t fa ct or s: la t or s. Keep plu gs a r r a n ged in t h e or der in wh ich
en gin e coola n t t em per a t u r e, en gin e r pm , in t a ke m a n - t h ey wer e r em oved fr om t h e en gin e. A sin gle plu g
ifold t em per a t u r e, m a n ifold a bsolu t e pr essu r e a n d displa yin g a n a bn or m a l con dit ion in dica t es t h a t a
t h r ot t le posit ion . pr oblem exist s in t h e cor r espon din g cylin der. Repla ce
spa r k plu gs a t t h e in t er va ls r ecom m en ded in Gr ou p
DISTRIBUTOR O, Lu br ica t ion a n d Ma in t en a n ce
All en gin es a r e equ ipped wit h a ca m sh a ft dr iven Spa r k plu gs t h a t h a ve low m ila ge m a y be clea n ed
m ech a n ica l dist r ibu t or con t a in in g a sh a ft dr iven dis- a n d r eu sed if n ot ot h er wise defect ive, ca r bon or oil
t r ibu t or r ot or. All dist r ibu t or s a r e equ ipped wit h a n fou led. Refer t o t h e Spa r k P lu g Con dit ion sect ion of
in t er n a l ca m sh a ft posit ion (fu el syn c) sen sor (F ig. 2). t h is gr ou p.
Th is sen sor pr ovides fu el in ject ion syn ch r on iza t ion
a n d cylin der iden t ifica t ion . SPARK PLUG CABLES
Th e dist r ibu t or s on bot h t h e 2.5L 4-cylin der a n d Spa r k plu g ca bles a r e som et im es r efer r ed t o a s sec-
t h e 4.0L-6 cylin der en gin es do n ot h a ve bu ilt in cen - on da r y ign it ion wir es. Th ese ca bles t r a n sfer elect r ica l
t r ifu ga l or va cu u m a ssist ed a dva n ce. Ba se ign it ion cu r r en t fr om t h e ign it ion coil(s) a n d/or dist r ibu t or, t o
t im in g a n d a ll t im in g a dva n ce is con t r olled by t h e in dividu a l spa r k plu gs a t ea ch cylin der. Th e r esist ive
power t r a in con t r ol m odu le (P CM). Beca u se ign it ion spa r k plu g ca bles a r e of n on m et a llic con st r u ct ion .
PIGTAIL
CRANKSHAFT
ELECTRICAL
CONNECTOR
RUBBER
NESS
HAR-
GROMMET
POSITION SEN-
SOR
CLAMP NUT MOUNTINGTRANSMISSION
BOLTS (2) HOUSING
BELL- NOTCHES
CRANKSHAFT
TION SENSOR
POSI- FLYWHEEL

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 .

CRANKSHAFT POSITION SENSOR


Th e cr a n ksh a ft posit ion sen sor is m ou n t ed t o t h e
t r a n sm ission bellh ou sin g a t t h e left /r ea r side of
en gin e block (F ig. 3).

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 .

IGNITION SWITCH AND KEY LOCK CYLINDER


Th e ign it ion swit ch is loca t ed on t h e st eer in g col-
u m n . Th e Key-In -Swit ch is loca t ed in t h e ign it ion
swit ch m odu le. F or elect r ica l dia gn osis of t h e Key-In -
Swit ch , r efer t o Gr ou p 8U, Ch im e/Bu zzer Wa r n in g
Syst em s. F or r em ova l/in st a lla t ion of eit h er t h e key
lock cylin der or ign it ion swit ch , r efer t o Ign it ion
Swit ch a n d Key Cylin der Rem ova l/In st a lla t ion in t h is
gr ou p.
On veh icles 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 a n in t er lock device wit h in t h e
st eer in g colu m n a ssem bly t o t h e t r a n sm ission floor
sh ift lever. Th is in t er lock device is u sed t o lock t h e
t r a n sm ission sh ift er in t h e PARK posit ion wh en t h e
key is in t h e LOCKE D or ACCE SSORY posit ion . Th e
J9314-84
in t er lock device is n ot ser vicea ble. If r epa ir is n eces-
sa r y, t h e st eer in g colu m n a ssem bly m u st be r epla ced.
Fig. 5 Sensor Operation—4.0L 6-Cyl. Engine
Refer t o Gr ou p 19, St eer in g for pr ocedu r es. Th e
r ot a t es 180 degr ees t h r ou gh t h e syn c sign a l gen er a - sh ift er in t er lock ca ble ca n be a dju st ed or r epla ced.
t or. It s sign a l is u sed in con ju n ct ion wit h t h e cr a n k- Refer t o Gr ou p 21, Tr a n sm ission s for pr ocedu r es.
sh a ft posit ion sen sor t o differ en t ia t e bet ween fu el
in ject ion a n d spa r k even t s. It is a lso u sed t o syn ch r o-
n ize t h e fu el in ject or s wit h t h eir r espect ive cylin der s. DI AGN OSI S AN D T EST I N G
Wh en t h e lea din g edge of t h e pu lse r in g (sh u t t er )
en t er s t h e syn c sign a l gen er a t or, t h e followin g occu r s: AUTOMATIC SHUTDOWN (ASD) RELAY TEST
Th e in t er r u pt ion of m a gn et ic field ca u ses t h e volt a ge To per for m a com plet e t est of t h is r ela y a n d it s cir-
t o swit ch h igh r esu lt in g in a syn c sign a l of a ppr oxi- cu it r y, r efer t o t h e DRB sca n t ool. Also r efer t o t h e
m a t ely 5 volt s. a ppr opr ia t e P ower t r a in Dia gn ost ics P r ocedu r es m a n -
Wh en t h e t r a ilin g edge of t h e pu lse r in g (sh u t t er ) u a l. To t est t h e r ela y on ly, r efer t o Rela ys—Oper a -
lea ves t h e syn c sign a l gen er a t or, t h e followin g occu r s: t ion /Test in g in t h e Gr ou p 14, F u el Syst em s sect ion .
Th e ch a n ge of t h e m a gn et ic field ca u ses t h e syn c sig-
n a l volt a ge t o swit ch low t o 0 volt s. TESTING FOR SPARK AT COIL

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

Fig. 6 Cable Removal

Fig. 8 Ignition Coil—2.5L Engine

A GOOD
ENGINE
GROUND

Fig. 7 Checking for Spark—Typical


(2) Rot a t e (cr a n k) t h e en gin e wit h t h e st a r t er
m ot or a n d obser ve t h e ca ble t er m in a l for a st ea dy
a r c. If st ea dy a r cin g does n ot occu r, in spect t h e sec-
on da r y coil ca ble. Refer t o Spa r k P lu g Ca bles in t h is
gr ou p. Also in spect t h e dist r ibu t or ca p a n d r ot or for
cr a cks or bu r n m a r ks. Repa ir a s n ecessa r y. If st ea dy
a r cin g occu r s, con n ect ign it ion coil ca ble t o t h e dis-
t r ibu t or ca p. Fig. 9 Ignition Coil—4.0L Engine
(3) Rem ove a ca ble fr om on e spa r k plu g. In spect t h e ign it ion coil for a r cin g. Test t h e coil
(4) Usin g in su la t ed plier s, h old t h e ca ble t er m in a l a ccor din g t o coil t est er m a n u fa ct u r er ’s in st r u ct ion s.
a ppr oxim a t ely 12 m m (1/2 in .) fr om t h e en gin e cylin - Test t h e coil pr im a r y a n d secon da r y r esist a n ce.
der h ea d or block wh ile r ot a t in g t h e en gin e wit h t h e Repla ce a n y coil t h a t does n ot m eet specifica t ion s.
st a r t er m ot or. Obser ve t h e spa r k plu g ca ble t er m in a l Refer t o t h e Ign it ion Coil Resist a n ce ch a r t .
for a n a r c. If st ea dy a r cin g occu r s, it ca n be expect ed If t h e ign it ion coil is bein g r epla ced, t h e secon da r y
t h a t t h e ign it ion secon da r y syst em is oper a t in g cor- spa r k plu g ca ble m u st a lso be ch ecked. Repla ce ca ble
r ect ly. (If th e ig n itio n c o il c a ble is re m o v e d fo r if it h a s been bu r n ed or da m a ged.
th is te s t, in s te a d o f a s p a rk p lu g c a ble , th e Ar cin g a t t h e t ower will ca r bon ize t h e ca ble boot ,
s p a rk in te n s ity w ill be m u c h h ig h e r). If st ea dy wh ich if it is con n ect ed t o a n ew ign it ion coil, will
a r cin g occu r s a t t h e spa r k plu g ca bles, bu t t h e en gin e ca u se t h e coil t o fa il.
will n ot st a r t , con n ect t h e DRB sca n t ool. Refer t o If t h e secon da r y coil ca ble sh ows a n y sign s of da m -
t h e a ppr opr ia t e P ower t r a in Dia gn ost ic P r ocedu r es a ge, it sh ou ld be r epla ced wit h a n ew ca ble a n d n ew
ser vice m a n u a l.
8D - 6 IGNITION SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

PRIMARY RESISTANQ SECONDARY RESISTANQ

COIL (MANUFACTURER) 21-27°C (70-80°F) 21-27°C (70-80°F)

Diamond 0.'17 - 1.18 Ohms 11,300 - 15,300 Ohms

Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms


J918D-2

IGNITION COIL RESISTANCE


t er m in a l. Ca r bon t r a ckin g on t h e old ca ble ca n ca u se
a r cin g a n d t h e fa ilu r e of a n ew ign it ion coil. (3) 32-WAY
CONNECTORS
FAILURE TO START TEST
To pr even t u n n ecessa r y dia gn ost ic t im e a n d wr on g
t est r esu lt s, t h e Test in g F or Spa r k At Coil t est
sh ou ld be per for m ed pr ior t o t h is t est .

WARNING: SET PARKING BRAKE OR BLOCK THE


DRIVE WHEELS BEFORE PROCEEDING WITH THIS
TEST.

(1) Un plu g t h e ign it ion coil h a r n ess con n ect or a t


t h e coil (F ig. 9).
(2) Con n ect a set of sm a ll ju m per wir es (18 ga u ge
or sm a ller ) bet ween t h e discon n ect ed h a r n ess t er m i-
n a ls a n d t h e ign it ion coil t er m in a ls. To det er m in e Fig. 10 PCM and Three 32–Way Connectors
pola r it y a t con n ect or a n d coil, r efer t o t h e Wir in g
Dia gr a m s sect ion . ba t t er y posit ive t er m in a l a n d t h e coil posit ive t er m i-
(3) At t a ch on e lea d of a volt m et er t o t h e posit ive n a l.
(12 volt ) ju m per wir e. At t a ch t h e n ega t ive side of (7) Ma ke t h e specia l ju m per sh own in (F ig. 11).
volt m et er t o a good gr ou n d. Usin g t h e ju m per, m o m e n ta rily gr ou n d t h e ign it ion
(4) Det er m in e t h a t su fficien t ba t t er y volt a ge (12.4 coil dr iver cir cu it a t t h e P CM con n ect or (ca vit y A-7).
volt s) is pr esen t for t h e st a r t in g a n d ign it ion sys- F or ca vit y/t er m in a l loca t ion of t h is cir cu it , r efer t o
t em s. Gr ou p 8W, Wir in g. A spa r k sh ou ld be gen er a t ed a t
(5) Cr a n k t h e en gin e for 5 secon ds wh ile m on it or- t h e coil ca ble wh en t h e gr ou n d is r em oved.
in g t h e volt a ge a t t h e coil posit ive t er m in a l:
• If t h e volt a ge r em a in s n ea r zer o du r in g t h e
en t ir e per iod of cr a n kin g, r efer t o On -Boa r d Dia gn os- /
ALLIGATOR
t ics in Gr ou p 14, F u el Syst em s. Ch eck t h e P ower- CLIP
t r a in Con t r ol Modu le (P CM) a n d a u t o sh u t down MOMENTARILY
r ela y. GROUND THIS
CLIP TO COIL
• If volt a ge is a t or n ea r ba t t er y volt a ge a n d dr ops NEGATIVE
t o zer o a ft er 1-2 secon ds of cr a n kin g, ch eck t h e pow-
er t r a in con t r ol m odu le cir cu it . Refer t o On -Boa r d
Dia gn ost ics in Gr ou p 14, F u el Syst em s. RB1003
• If volt a ge r em a in s a t or n ea r ba t t er y volt a ge Fig. 11 Special Jumper Ground-to-Coil Negative
du r in g t h e en t ir e 5 secon ds, t u r n t h e key off. Rem ove Terminal
t h e t h r ee 32-wa y con n ect or s (F ig. 10) fr om t h e P CM.
Ch eck 32-wa y con n ect or s for a n y spr ea d t er m in a ls or (8) If spa r k is gen er a t ed, r epla ce t h e P CM.
cor r osion . (9) If spa r k is n ot seen , u se t h e specia l ju m per t o
(6) Rem ove t est lea d fr om t h e coil posit ive t er m i- gr ou n d t h e coil n ega t ive t er m in a l dir ect ly.
n a l. Con n ect a n 18 ga u ge ju m per wir e bet ween t h e (10) If spa r k is pr odu ced, r epa ir wir in g h a r n ess for
a n open con dit ion .
XJ IGNITION SYSTEM 8D - 7
DI AGN OSI S AN D T EST I N G (Cont inue d)
(11) If spa r k is n ot pr odu ced, r epla ce t h e ign it ion va r n ish -com pou n d a pplied t o t h e r ot or t ip for r a dio
coil. in t er fer en ce n oise su ppr ession , will a ppea r ch a r r ed.
Th is is n or m a l. D o n o t re m o v e th e c h a rre d c o m -
DISTRIBUTOR CAP p o u n d . Test t h e spr in g for in su fficien t t en sion .
Rem ove t h e dist r ibu t or ca p a n d wipe it clea n wit h Repla ce a r ot or t h a t displa ys a n y of t h ese a dver se
a dr y lin t fr ee clot h . Visu a lly in spect t h e ca p for con dit ion s.
cr a cks, ca r bon pa t h s, br oken t ower s or da m a ged
INSUFFICIENT
r ot or bu t t on (F ig. 12) or (F ig. 13). Also ch eck for SPRING
wh it e deposit s on t h e in side (ca u sed by con den sa t ion TENSION
en t er in g t h e ca p t h r ou gh cr a cks). Repla ce a n y ca p
t h a t displa ys ch a r r ed or er oded t er m in a ls. Th e
m a ch in ed su r fa ce of a t er m in a l en d (fa ces t owa r d
r ot or ) will in dica t e som e eviden ce of er osion fr om
n or m a l oper a t ion . E xa m in e t h e t er m in a l en ds for evi-
den ce of m ech a n ica l in t er fer en ce wit h t h e r ot or t ip.

EVIDENCE OF
PHYSICAL
CONTACT
WITH CAP J908D-48
CARBON
PATH
Fig. 14 Rotor Inspection—Typical
IGNITION TIMING

CRACK J918D-9 NOTE: Base (initial) ignition timing is NOT adjust-


able on any 2.5L 4-cylinder or 4.0L 6-cylinder
Fig. 12 Cap Inspection—External—Typical engine. Do not attempt to adjust ignition timing by
rotating the distributor.

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.

All ign it ion t im in g fu n ct ion s a r e con t r olled by t h e


power t r a in con t r ol m odu le (P CM). F or a ddit ion a l
in for m a t ion , r efer t o t h e a ppr opr ia t e P ower t r a in
WORN OR Dia gn ost ics P r ocedu r es ser vice m a n u a l for oper a t ion
DAMAGED of t h e DRB Sca n Tool.
ROTOR BUTTON
MAP SENSOR
F or a n oper a t ion a l descr ipt ion , dia gn osis or r em ov-
J918D-10 a l/ in st a lla t ion pr ocedu r es, r efer t o Gr ou p 14, F u el
Syst em s.
Fig. 13 Cap Inspection—Internal—Typical
CRANKSHAFT POSITION SENSOR
DISTRIBUTOR ROTOR To per for m a com plet e t est of t h is sen sor a n d it s
Visu a lly in spect t h e r ot or (F ig. 14) for cr a cks, evi- 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
den ce of cor r osion or t h e effect s of a r cin g on t h e a ppr opr ia t e P ower t r a in Dia gn ost ics P r ocedu r es m a n -
m et a l t ip. Also ch eck for eviden ce of m ech a n ica l u a l.
in t er fer en ce wit h t h e ca p. Som e ch a r r in g is n or m a l
on t h e en d of t h e m et a l t ip. Th e silicon e-dielect r ic-
SYNC
DISTRIBUTOR
GENERATOR
ASSEMBLY
SIGNAL PULSE RING
CAMSHAFT
POSITION SEN-
SOR

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

Fig. 18 Electrode Gap Bridging


GROUND
ELECTRODE
COVERED
WITH WHITE
OR YELLOW
DEPOSITS

Fig. 17 Oil or Ash Encrusted


ELECT RODE GAP BRI DGI N G J908D-12
E lect r ode ga p br idgin g m a y be t r a ced t o loose
deposit s in t h e com bu st ion ch a m ber. Th ese deposit s Fig. 19 Scavenger Deposits
a ccu m u la t e on t h e spa r k plu gs du r in g con t in u ou s CH I PPED ELECT RODE I N SU LAT OR
st op-a n d-go dr ivin g. Wh en t h e en gin e is su dden ly A ch ipped elect r ode in su la t or u su a lly r esu lt s fr om
su bject ed t o a h igh t or qu e loa d, deposit s pa r t ia lly liq- ben din g t h e cen t er elect r ode wh ile a dju st in g t h e
u efy a n d br idge t h e ga p bet ween elect r odes (F ig. 18). spa r k plu g elect r ode ga p. Un der cer t a in con dit ion s,
Th is sh or t cir cu it s t h e elect r odes. Spa r k plu gs wit h sever e det on a t ion ca n a lso sepa r a t e t h e in su la t or
elect r ode ga p br idgin g ca n be clea n ed u sin g st a n da r d fr om t h e cen t er elect r ode (F ig. 20). Spa r k plu gs wit h
pr ocedu r es. t h is con dit ion m u st be r epla ced.
SCAV EN GER DEPOSI T S PREI GN I T I ON DAM AGE
F u el sca ven ger deposit s m a y be eit h er wh it e or yel- P r eign it ion da m a ge is u su a lly ca u sed by excessive
low (F ig. 19). Th ey m a y a ppea r t o be h a r m fu l, bu t com bu st ion ch a m ber t em per a t u r e. Th e cen t er elec-
t h is is a n or m a l con dit ion ca u sed by ch em ica l a ddi- t r ode dissolves fir st a n d t h e gr ou n d elect r ode dis-
t ives in cer t a in fu els. Th ese a ddit ives a r e design ed t o solves som ewh a t la t t er (F ig. 21). In su la t or s a ppea r
ch a n ge t h e ch em ica l n a t u r e of deposit s a n d decr ea se r ela t ively deposit fr ee. Det er m in e if t h e spa r k plu g
spa r k plu g m isfir e t en den cies. Not ice t h a t a ccu m u la - h a s t h e cor r ect h ea t r a n ge r a t in g for t h e en gin e.
t ion on t h e gr ou n d elect r ode a n d sh ell a r ea m a y be Det er m in e if ign it ion t im in g is over a dva n ced or if
h ea vy, bu t t h e deposit s a r e ea sily r em oved. Spa r k ot h er oper a t in g con dit ion s a r e ca u sin g en gin e over-
plu gs wit h sca ven ger deposit s ca n be con sider ed n or- h ea t in g. (Th e h ea t r a n ge r a t in g r efer s t o t h e oper a t -
m a l in con dit ion a n d ca n be clea n ed u sin g st a n da r d in g t em per a t u r e of a pa r t icu la r t ype spa r k plu g.
pr ocedu r es. Spa r k plu gs a r e design ed t o oper a t e wit h in specific
t em per a t u r e r a n ges. Th is depen ds u pon t h e t h ick-
GROUND
ELECTRODE
GROUND
STARTING
DISSOLVE
TO CENTER
CHIPPED
ELECTRODE
CENTER
ELECTRODE
INSULATOR
DISSOLVED BLISTERED
GRAY SPARK
CABLE
COLORED
WHITE
BOOT
PLUG
AND
INSULATOR
SPARK
OR PLUG SPARK TWIST
PLUG
PULLER
AND
BOOTPULL

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

Fig. 20 Chipped Electrode Insulator Fig. 22 Spark Plug Overheating


n ess a n d len gt h of t h e cen t er elect r odes por cela in
in su la t or.) SPARK PLUG BOOT
PULLER
GROUND
ELECTRODE
SPARK PLUG
STARTING
TO DISSOLVE CABLE AND
BOOT

CENTER
ELECTRODE
DISSOLVED

SPARK PLUG 958D-9


CLOCKWISE
FIRING ORDER:
1ROTA-
3TION
4 2 FRONT

J908D-14 Fig. 23 Cable Removal


In st a ll ca bles in t o t h e pr oper en gin e cylin der fir in g
Fig. 21 Preignition Damage or der (F ig. 24) or (F ig. 25).
SPARK PLU G OV ERH EAT I N G
Over h ea t in g is in dica t ed by a wh it e or gr a y cen t er
elect r ode in su la t or t h a t a lso a ppea r s blist er ed (F ig.
22). Th e in cr ea se in elect r ode ga p will be con sider-
a bly in excess of 0.001 in ch per 1000 m iles of oper a -
t ion . Th is su ggest s t h a t a plu g wit h a cooler h ea t
r a n ge r a t in g sh ou ld be u sed. Over a dva n ced ign it ion
t im in g, det on a t ion a n d coolin g syst em m a lfu n ct ion s
ca n a lso ca u se spa r k plu g over h ea t in g.

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

Fig. 25 Engine Firing Order—4.0L 6-Cylinder Engine


Wh en r epla cin g t h e spa r k plu g a n d coil ca bles,
SPARK
r ou t e t h e ca bles cor r ect ly a n d secu r e in t h e pr oper i------PLUG
r et a in er s. F a ilu r e t o r ou t e t h e ca bles pr oper ly ca n
ca u se t h e r a dio t o r epr odu ce ign it ion n oise. It cou ld
a lso ca u se cr oss ign it ion of t h e plu gs or sh or t cir cu it
t h e ca bles t o gr ou n d.
Wh en in st a llin g n ew ca bles, m a ke su r e a posit ive
con n ect ion is m a de. A sn a p sh ou ld be felt wh en a
good con n ect ion is m a de bet ween t h e plu g ca ble a n d J908D-10
t h e dist r ibu t or ca p t ower.
Fig. 26 Setting Spark Plug Gap—Typical
SPARK PLUGS SPARK PLU G GAP
• 2.5L 4-Cylin der E n gin e Spa r k P lu g Ga p: .89 m m
PLU G REM OVAL (.035 in ).
(1) Alwa ys r em ove spa r k plu g or ign it ion coil • 4.0L 6-Cylin der E n gin e Spa r k P lu g Ga p: .89 m m
ca bles by gr a spin g a t t h e ca ble boot (F ig. 23). Tu r n (.035 in ).
t h e ca ble boot 1/2 t u r n a n d pu ll st r a igh t ba ck in a
st ea dy m ot ion . Never pu ll dir ect ly on t h e ca ble. PLU G I N STALLAT I ON
In t er n a l da m a ge t o ca ble will r esu lt . Alwa ys t igh t en spa r k plu gs t o t h e specified t or qu e.
(2) P r ior t o r em ovin g t h e spa r k plu g, spr a y com - Over t igh t en in g ca n ca u se dist or t ion . Th is m a y r esu lt
pr essed a ir a r ou n d t h e spa r k plu g h ole a n d t h e a r ea in a ch a n ge in t h e spa r k plu g ga p, or a cr a cked por-
a r ou n d t h e spa r k plu g. Th is will h elp pr even t for eign cela in in su la t or.
m a t er ia l fr om en t er in g t h e com bu st ion ch a m ber. Wh en r epla cin g t h e spa r k plu g a n d ign it ion coil
(3) Rem ove t h e spa r k plu g u sin g a qu a lit y socket ca bles, r ou t e t h e ca bles cor r ect ly a n d secu r e t h em in
wit h a r u bber or foa m in ser t . t h e a ppr opr ia t e r et a in er s. F a ilu r e t o r ou t e t h e ca bles
(4) In spect t h e spa r k plu g con dit ion . Refer t o pr oper ly ca n ca u se t h e r a dio t o r epr odu ce ign it ion
Spa r k P lu gs in t h e Dia gn ost ics/Ser vice P r ocedu r es n oise. It cou ld ca u se cr oss ign it ion of t h e spa r k plu gs,
sect ion of t h is gr ou p. or sh or t cir cu it t h e ca bles t o gr ou n d.
(1) St a r t t h e spa r k plu g in t o t h e cylin der h ea d by
PLU G CLEAN I N G h a n d t o a void cr oss t h r ea din g.
Th e plu gs m a y be clea n ed u sin g com m er cia lly (2) Tigh t en t h e spa r k plu gs t o 35-41 N·m (26-30 ft .
a va ila ble spa r k plu g clea n in g equ ipm en t . Aft er clea n - lbs.) t or qu e.
in g, file t h e cen t er elect r ode fla t wit h a sm a ll poin t (3) In st a ll spa r k plu g ca bles over spa r k plu gs.
file or jeweler s file befor e a dju st in g ga p.
IGNITION COIL
CAUTION: Never use a motorized wire wheel brush
Th e ign it ion coil is a n epoxy filled t ype. If t h e coil
to clean the spark plugs. Metallic deposits will
is r epla ced, it m u st be r epla ced wit h t h e sa m e t ype.
remain on the spark plug insulator and will cause
plug misfire.
SECONDARYMOUNTING
MOUNTING
CABLE BOLTS
BOLTS (2) SECONDARY
CABLEIGNITIONELECTRICAL
COIL
ELECTRICAL
IGNITION
NECTOR
NECTOR
CON-
CON-
COIL POWER DISTRIBUTION
TER (PDC)
CEN-

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--...

Fig. 27 Ignition Coil—2.5L Engine

Fig. 29 PDC Location


REM OVAL
(1) Rem ove P DC cover.
(2) Rem ove r ela y by lift in g st r a igh t u p.

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).

CAMSHAFT POSITION SENSOR


Th e ca m sh a ft posit ion sen sor is loca t ed in t h e dis-
t r ibu t or (F ig. 32).

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

Fig. 31 Crankshaft Position Sensor—Except 2.5L


4-Cyl. Engine With Auto. Trans.
REM OVAL
Som e m odel/en gin e com bin a t ion s m a y r equ ir e
r em ova l of a ir clea n er t u bes for a ccess t o sen sor.
(1) Rem ove a ir clea n er t u be(s) a t t h r ot t le body (if DISTRIBUTOR
n ecessa r y). ASSEMBLY
(2) Nea r r ea r of in t a ke m a n ifold, discon n ect pigt a il
h a r n ess (elect r ica l con n ect or ) fr om m a in elect r ica l
h a r n ess. Fig. 32 Camshaft Position Sensor
ROTOR DRIVE
PULSE
SHAFT
GEAR
RING HOLDDOWN
WASHER
ROLL
FORK
PIN
HOLDDOWN
GASKET
CLAMP
POSITION
CAMSHAFT
WITH
SENSOR
SLOT
BOLT
PLASTICMENT
ALIGN-
HOUSING
PIN
CAP

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.

ENGINE COOLANT TEMPERATURE 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 .
J958D-4
THROTTLE POSITION SENSOR
F or a n oper a t ion a l descr ipt ion , dia gn osis a n d Fig. 33 Plastic Alignment Pin
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 . CAP CAMSHAFT POSITION
SENSOR

INTAKE MANIFOLD AIR TEMPERATURE 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 .

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

Dist r ibu t or r em ova l is n ot n ecessa r y for sen sor


WASHER_-@
r em ova l.
Refer t o (F ig. 34) for a n exploded view of t h e dis-
t r ibu t or .
A for k wit h a slot is su pplied on t h e bot t om of t h e DRIVE
dist r ibu t or h ou sin g wh er e t h e h ou sin g ba se sea t s GEAR J958D-1
a ga in st t h e en gin e block (F ig. 34). Th e cen t er lin e of
t h e slot a lign s wit h t h e dist r ibu t or h olddown bolt Fig. 34 Distributor—2.5L Or 4.0L Engines—Typical
h ole in t h e en gin e block. Beca u se of t h e for k, t h e dis- Th e posit ion of t h e dist r ibu t or det er m in es fu el syn -
t r ibu t or ca n n ot be r ot a t ed. Dist r ibu t or r ot a t ion is n ot ch r on iza t ion on ly. It does n ot det er m in e ign it ion t im -
n ecessa r y a s a ll ign it ion t im in g r equ ir em en t s a r e in g.
h a n dled by t h e power t r a in con t r ol m odu le (P CM).
8D - 16 IGNITION SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
NOTE: Do not attempt to modify this fork to attain (11) Rem ove t h e dist r ibu t or fr om en gin e by slowly
ignition timing. lift in g st r a igh t u p.
(12) Not e t h a t t h e r ot or will r ot a t e sligh t ly in a
cou n t er clockwise dir ect ion wh ile lift in g u p t h e dis-
REM OVAL—2 .5 L OR 4 .0 L EN GI N E t r ibu t or. Th e oil pu m p gea r will a lso r ot a t e sligh t ly in
(1) Discon n ect t h e n ega t ive ba t t er y ca ble a t t h e a cou n t er clockwise dir ect ion wh ile lift in g u p t h e dis-
ba t t er y. t r ibu t or. Th is is du e t o t h e h elica l cu t gea r s on t h e
(2) Discon n ect coil secon da r y ca ble a t coil. dist r ibu t or a n d ca m sh a ft .
(3) Rem ove dist r ibu t or ca p fr om dist r ibu t or (2 (13) Not e t h e r em oved posit ion of t h e r ot or du r in g
scr ews). Do n ot r em ove ca bles fr om ca p. Do n ot dist r ibu t or r em ova l. Du r in g in st a lla t ion , t h is will be
r em ove r ot or. r efer r ed t o a s t h e P r e-posit ion .
(4) Discon n ect t h e dist r ibu t or wir in g h a r n ess fr om (14) 2.5L 4-Cy lin d e r En g in e : Obser ve t h e slot in
t h e m a in en gin e h a r n ess. t h e oil pu m p gea r t h r ou gh t h e h ole on t h e side of t h e
(5) Rem ove t h e cylin der n u m ber 1 spa r k plu g. en gin e. It sh ou ld be sligh t ly befor e (cou n t er clockwise
(6) H old a fin ger over t h e open spa r k plu g h ole. of) t h e 10 o’clock posit ion (F ig. 36).
Rot a t e t h e en gin e a t t h e vibr a t ion da m pen er bolt (15) 4.0L 6-Cy lin d e r En g in e : Obser ve t h e slot in
u n t il com pr ession (pr essu r e) is felt . t h e oil pu m p gea r t h r ou gh t h e h ole on t h e side of t h e
(7) Slowly con t in u e t o r ot a t e t h e en gin e. Do t h is en gin e. It sh ou ld be sligh t ly befor e (cou n t er clockwise
u n t il t h e t im in g in dex m a r k on t h e vibr a t ion da m per of) t h e 11 o’clock posit ion (F ig. 37).
pu lley a lign s wit h t h e t op dea d cen t er (TDC) m a r k (0
degr ee) on t im in g degr ee sca le (F ig. 35). Alwa ys FRONT •
r ot a t e t h e en gin e in dir ect ion of n or m a l r ot a t ion . Do
n ot r ot a t e t h e en gin e ba ckwa r d t o a lign t h e t im in g
m a r ks.
(8) On m odels equ ipped wit h A/C, r em ove t h e elec-
t r ica l coolin g fa n a n d sh r ou d a ssem bly fr om t h e r a di- -- -- ----
a t or. Refer CRANKSHAFT
t o GrDAMPER TIMING
ou p VIBRATION
7, MARK
Coolin g Syst em for
----
/
....
pr ocedu r es.
(9) Th is will pr ovide r oom t o t u r n t h e en gin e
cr a n ksh a ft wit h a socket a n d r a t ch et u sin g t h e vibr a -
t ion da m per bolt . 10 O'CLOCK POSITION

11 O’CLOCK POSITION OIL PUMP SLOT FRONT


OIL
PUMP
SLOT J958D-6

Fig. 36 Slot At 10 O’clock Position—2.5L Engine


FRONT •

Ll-'-\_\..o..'-\-,-------~
11 O'CLOCK POSITION

CRANKSHAFT
VIBRATION DAMPER
TIMING MARK OIL
PUMP
J898D-14 SLOT J958D-7

Fig. 35 Align Timing Marks Fig. 37 Slot At 11 O’clock Position—4.0L Engine


(10) Rem ove t h e dist r ibu t or h olddown bolt a n d (16) Rem ove a n d disca r d t h e old dist r ibu t or-t o-en -
cla m p. gin e block ga sket .
HOUSING
DISTRIBUTOR
PLASTIC RING
VIEW)
(TOP PULSE MATING
RING
DISTRIBUTOR
ACCESS HOUSING
HOLE IN 4.0L
DER
2.5L
DERALIGN.
ALIGN.
6-CYLIN-
4-CYLIN-
ENGINE
ENGINE
HOLE
HOLE

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

Fig. 39 Distributor Pre-position—All Engines Fig. 41 Distributor Engaged Position—4.0L


6-Cylinder Engine
FRONT •
(16) In st a ll t h e dist r ibu t or ca p. Tigh t en dist r ibu t or
ca p h olddown scr ews t o 3 N·m (26 in . lbs.) t or qu e.
DISTRIBUTOR (17) If r em oved, in st a ll t h e spa r k plu g ca bles t o
BASE t h e dist r ibu t or ca p. F or pr oper fir in g or der, r efer t o
SLOT t h e Specifica t ion s sect ion a t t h e en d of t h is gr ou p.
See E n gin e F ir in g Or der.
(18) Con n ect t h e dist r ibu t or wir in g h a r n ess t o t h e
m a in en gin e h a r n ess.
(19) Con n ect ba t t er y ca ble t o ba t t er y.

POWERTRAIN CONTROL MODULE (PCM)


Refer t o Gr ou p 14, F u el Syst em for pr ocedu r es.

DISTRIBUTOR IGNITION SWITCH AND KEY CYLINDER


BASE
CLAMP Th e ign it ion key m u st be in t h e key cylin der for
BOLT MOUNTING cylin der r em ova l. Th e key cylin der m u st be r em oved
HOLE
(ON ENGINE) fir st befor e r em ovin g ign it ion swit ch .

K EY CY LI N DER REM OVAL


J958D-9
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) If equ ipped wit h a n a u t om a t ic t r a n sm ission ,
Fig. 40 Distributor Engaged Position—2.5L pla ce sh ift er in PARK posit ion .
4-Cylinder Engine (3) Rot a t e key t o ON posit ion .
(4) A r elea se t a n g is loca t ed on bot t om of key cyl-
(14) If r em oved, in st a ll t h e ca m sh a ft posit ion sen -
in der (F ig. 42).
sor t o t h e dist r ibu t or. Align t h e wir in g h a r n ess gr om -
(5) P osit ion a sm a ll scr ewdr iver or pin pu n ch in t o
m et t o t h e n ot ch in t h e dist r ibu t or h ou sin g.
t a n g a ccess h ole on bot t om of st eer in g colu m n lower
(15) In st a ll t h e r ot or.
cover (F ig. 43).
CAUTION: If the distributor cap is incorrectly posi- (6) P u sh t h e pin pu n ch u p wh ile pu llin g key cylin -
tioned on distributor housing, the cap or rotor may der fr om st eer in g colu m n .
be damaged when engine is started.
COVER
LOWER
SCREWS
COVER (3) RELEASE
KEY CYLINDER
TANG ACCESS
HOLE PIN PUNCH ROTATE TO ON POSITION SCREWDRIVER IGNITION SWITCHIGNITION SWITCH
LOCK TAB

XJ IGNITION SYSTEM 8D - 19
REM OVAL AN D I N STALLAT I ON (Cont inue d)

KEY CYLINDER

RELEASE TANG 80a43756

Fig. 42 Key Cylinder Release Tang

Fig. 44 Ignition Switch Lock Tab


IGNITION SWITCH

••••••
PIN
PUNCH

ROTATE TO
80a43757 ON POSITION 80a43850

Fig. 43 Key Cylinder and Cover Removal Fig. 45 Switch In ON Position


I GN I T I ON SWI T CH REM OVAL (2) Con n ect t wo elect r ica l con n ect or s t o r ea r of
(1) Rem ove key cylin der. Refer t o pr eviou s st eps. ign it ion swit ch . Ma ke su r e t h a t lockin g t a bs a r e fu lly
(2) Rem ove lower st eer in g colu m n cover scr ews sea t ed in t o wir in g con n ect or s.
a n d r em ove cover (F ig. 43). (3) P osit ion swit ch t o colu m n a n d in st a ll t a m per
(3) Rem ove ign it ion swit ch m ou n t in g scr ew (F ig. pr oof scr ew. Tigh t en scr ew t o 3 N·m (26 in . lbs.).
46). Use t a m per pr oof t or x bit (Sn a p-On t SDMTR10 (4) In st a ll st eer in g colu m n lower cover.
or equ iva len t ) t o r em ove t h e scr ew.
(4) Usin g a sm a ll scr ewdr iver, pu sh on lockin g t a b K EY CY LI N DER I N STALLAT I ON
(F ig. 44) a n d r em ove swit ch fr om st eer in g colu m n . (1) If equ ipped wit h a n a u t om a t ic t r a n sm ission ,
(5) Discon n ect t wo elect r ica l con n ect or s a t r ea r of pla ce sh ift er in PARK posit ion .
ign it ion swit ch (F ig. 46). (2) P osit ion key cylin der in t o st eer in g colu m n a s it
wou ld n or m a lly be in t h e ON posit ion .
I GN I T I ON SWI T CH I N STALLAT I ON (3) P r ess key cylin der in t o colu m n u n t il it sn a ps
(1) Befor e in st a llin g ign it ion swit ch , r ot a t e t h e slot in t o posit ion .
in t h e swit ch t o t h e ON posit ion (F ig. 45). (4) Ch eck m ech a n ica l oper a t ion of swit ch . Au to -
m a tic Tra n s m is s io n : Be su r e t r a n sm ission lever is
ELECTRICAL CONNECTORS IGNITION
TAMPER
PROOF
SSCREW
WITCH CLOCKWISE
FIRING ORDER:
1ROTA-
3TION
4 2 FRONT

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 .

ENGINE FIRING ORDER—2.5L 4-CYLINDER


ENGINE

FIRING ORDER:
1 3 4 2
Fig. 46 Ignition Switch Removal/Installation CLOCKWISE FRONT FIRING
1
CLOCKWISE
5 3 6 ORDER:
2 4 ROTATION

locked in PARK posit ion a ft er key r em ova l. If key is ROTATION


difficu lt t o r ot a t e or is difficu lt t o r em ove, t h e sh ift
lever-t o-st eer in g colu m n ca ble m a y be ou t of a dju st - J908D-6
m en t or defect ive. Refer t o Gr ou p 21, Tr a n sm ission
for pr ocedu r es. Ma n u a l Tra n s m is s io n : Be su r e key
ENGINE FIRING ORDER—4.0L 6-CYLINDER
ca n n ot be r em oved u n t il r elea se lever is oper a t ed. If
key ca n be r em oved, r elea se lever m ech a n ism m a y be ENGINE
defect ive. Relea se lever m ech a n ism is n ot ser viced
sepa r a t ely. If r epa ir is n ecessa 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.
(5) Con n ect n ega t ive ca ble t o ba t t er y.
(6) Ch eck elect r ica l oper a t ion of swit ch .

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.)

IGNITION COIL RESISTANCE


COIL TOYODENSO DIAMOND
Primary Resistance .95 - 1.20 Ohms .96 - 1.18 Ohms
Secondary Resistance at 70° - 80°F 11,300 - 13,300 Ohms 11,300 - 15,300 Ohms

TORQUE CHART

D ES CRIP TION TORQU E


Cr a n ksh a ft P osit ion Sen sor
Mou n t in g Bolt s . . . . . . . . . . . . 19 N·m (14 ft . lbs.)
Cr a n ksh a ft P osit ion Sen sor
Mou n t in g Nu t s . . . . . . . . . . . . 19 N·m (14 ft . lbs.)
Dist r ibu t or H old Down Bolt . . . . 23 N·m (17 ft . lbs.)
Ign it ion Coil Mou n t in g
(if t a pped bolt s a r e u sed) . . . . . 5 N·m (50 in . lbs.)
Ign it ion Coil Mou n t in g
(if n u t s/bolt s a r e u sed) . . . . . 11 N·m (100 in . lbs.)
P ower t r a in Con t r ol Modu le (P CM)
Mou n t in g Scr ews . . . . . . . . . . . . 1 N·m (9 in . lbs.)
Spa r k P lu gs (a ll en gin es) . . . . . . 41 N·m (30 ft . lbs.)
XJ INSTRUMENT PANEL SYSTEMS 8E - 1

INSTRUMENT PANEL SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION CLUSTER ILLUMINATION LAMP . . . . . . . . . . . 17


GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 COOLANT TEMPERATURE GAUGE . . . . . . . . . 10
INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . 3 COOLANT TEMPERATURE WARNING LAMP . . 18
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 2 CRUISE-ON INDICATOR LAMP . . . . . . . . . . . . 18
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 2 FOUR-WHEEL DRIVE INDICATOR LAMP . . . . . 18
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1 FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . 13
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 3 HEADLAMP HIGH BEAM INDICATOR LAMP . . 19
DESCRIPTION AND OPERATION INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 9
AIRBAG INDICATOR LAMP . . . . . . . . . . . . . . . . 6 LOW FUEL WARNING LAMP . . . . . . . . . . . . . . 20
ANTI-LOCK BRAKE SYSTEM LAMP . . . . . . . . . . 6 LOW OIL PRESSURE WARNING LAMP . . . . . . 20
BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . 6 LOW WASHER FLUID WARNING LAMP . . . . . . 20
CHECK GAUGES LAMP . . . . . . . . . . . . . . . . . . . 6 MALFUNCTION INDICATOR LAMP . . . . . . . . . . 21
CIGAR LIGHTER AND POWER OUTLET . . . . . . 6 ODOMETER AND TRIP ODOMETER . . . . . . . . 13
CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . . 6 OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . 13
CLUSTER ILLUMINATION LAMP . . . . . . . . . . . . 7 SEAT BELT REMINDER LAMP . . . . . . . . . . . . . 21
COOLANT TEMPERATURE GAUGE . . . . . . . . . . 4 SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . 14
COOLANT TEMPERATURE WARNING LAMP . . 7 TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 14
CRUISE-ON INDICATOR LAMP . . . . . . . . . . . . . 7 TURN SIGNAL INDICATOR LAMP . . . . . . . . . . 21
FOUR-WHEEL DRIVE INDICATOR LAMP . . . . . . 7 UPSHIFT INDICATOR LAMP . . . . . . . . . . . . . . 22
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . 4 VOLTAGE WARNING LAMP . . . . . . . . . . . . . . . 22
HEADLAMP HIGH BEAM INDICATOR LAMP . . . 7 VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LOW FUEL WARNING LAMP . . . . . . . . . . . . . . . 8 REMOVAL AND INSTALLATION
LOW OIL PRESSURE WARNING LAMP . . . . . . . 8 ACCESSORY SWITCH BEZEL . . . . . . . . . . . . . 24
LOW WASHER FLUID WARNING LAMP . . . . . . . 8 CENTER SUPPORT BRACKET . . . . . . . . . . . . 32
MALFUNCTION INDICATOR LAMP . . . . . . . . . . 8 CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . 24
ODOMETER AND TRIP ODOMETER . . . . . . . . . 4 CLUSTER BEZEL . . . . . . . . . . . . . . . . . . . . . . . 25
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . . 5 CLUSTER BULB . . . . . . . . . . . . . . . . . . . . . . . . 28
SEAT BELT REMINDER LAMP . . . . . . . . . . . . . . 9 CLUSTER COMPONENTS . . . . . . . . . . . . . . . . 27
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 5 GLOVE BOX COMPONENTS . . . . . . . . . . . . . . 30
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GLOVE BOX LAMP AND SWITCH . . . . . . . . . . 29
TURN SIGNAL INDICATOR LAMP . . . . . . . . . . . 9 GLOVE BOX LATCH STRIKER . . . . . . . . . . . . . 31
UPSHIFT INDICATOR LAMP . . . . . . . . . . . . . . . 9 GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . 29
VOLTAGE WARNING LAMP . . . . . . . . . . . . . . . . 9 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . 25
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING INSTRUMENT PANEL ASSEMBLY . . . . . . . . . . 33
AIRBAG INDICATOR LAMP . . . . . . . . . . . . . . . 14 INSTRUMENT PANEL CENTER BEZEL . . . . . . 23
ANTI-LOCK BRAKE SYSTEM LAMP . . . . . . . . . 14 INSTRUMENT PANEL END CAP . . . . . . . . . . . 31
BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . 15 INSTRUMENT PANEL TOP COVER . . . . . . . . . 28
CHECK GAUGES LAMP . . . . . . . . . . . . . . . . . . 16 JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 32
CIGAR LIGHTER AND POWER OUTLET . . . . . 16 KNEE BLOCKER . . . . . . . . . . . . . . . . . . . . . . . 23
CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . 16 STEERING COLUMN OPENING COVER . . . . . 22

GEN ERAL I N FORM AT I ON is a ver y com plex u n it . Th e in st r u m en t pa n el is


design ed t o h ou se t h e con t r ols a n d m on it or s for st a n -
INTRODUCTION da r d a n d opt ion a l power t r a in s, clim a t e con t r ol sys-
Th is gr ou p is r espon sible for cover in g t h e veh icle t em s, a u dio syst em s, ligh t in g syst em s, sa fet y
in st r u m en t pa n el. H owever, beca u se t h e in st r u m en t syst em s, a n d m a n y ot h er com for t or con ven ien ce
pa n el ser ves a s t h e com m a n d cen t er of t h e veh icle, it it em s. It is a lso design ed so t h a t a ll of t h e con t r ols
a n d m on it or s ca n be sa fely r ea ch ed a n d viewed by
8E - 2 INSTRUMENT PANEL SYSTEMS XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
t h e veh icle oper a t or, wh ile st ill a llowin g r ela t ive ea se t ion in g syst em pa n el ou t let s, wh ich gr ea t ly r edu ces
of a ccess t o t h ese it em s for ser vice. t h e n u m ber of com pon en t s u sed over con ven t ion a l
Com plet e ser vice in for m a t ion cover a ge for a ll of t h e in st r u m en t pa n el con st r u ct ion .
syst em s a n d com pon en t s h ou sed in t h e in st r u m en t Modu la r in st r u m en t pa n el con st r u ct ion a llows a ll
pa n el in t h is sect ion of t h e ser vice m a n u a l wou ld n ot of t h e ga u ges a n d con t r ols t o be ser viced fr om t h e
be pr a ct ica l. It wou ld r esu lt in a gr ea t dea l of du pli- fr on t of t h e pa n el. In a ddit ion , m ost of t h e in st r u -
ca t ion a n d m a ke t h is gr ou p t oo la r ge for t h e in for m a - m en t pa n el elect r ica l com pon en t s ca n be a ccessed
t ion t o be ea sily a ccessed a n d u sed. Th er efor e, t h e wit h ou t com plet e in st r u m en t pa n el r em ova l. If n eces-
in for m a t ion fou n d in t h is gr ou p h a s been lim it ed a s sa r y, t h e in st r u m en t pa n el ca n be r em oved fr om t h e
follows: veh icle a s a n a ssem bly.
• Gen er a l In for m a t ion - Cover s n on -elect r ica l com - Rem ova l of t h e st eer in g colu m n open in g cover a n d
pon en t s a n d fea t u r es of t h e in st r u m en t pa n el t h a t kn ee blocker pr ovides a ccess t o t h e st eer in g colu m n
a r e n ot r ela t ed t o ot h er syst em s. m ou n t s, t h e st eer in g colu m n wir in g, t h e h ea dla m p
• Descr ipt ion a n d Oper a t ion - Cover s ga u ges a n d swit ch , t h e elect r on ic com bin a t ion fla sh er, a n d m u ch
t h eir sen din g u n it s, wa r n in g la m ps a n d t h eir of t h e in st r u m en t pa n el wir in g. Rem ova l of t h e glove
swit ch es, a n d in st r u m en t pa n el illu m in a t ion la m ps. box pr ovides a ccess t o t h e h ea t in g a n d a ir con dit ion -
• Dia gn osis a n d Test in g - Cover s ga u ges a n d t h eir in g elect r ica l a n d va cu u m h a r n esses, t h e blower
sen din g u n it s, wa r n in g la m ps a n d t h eir swit ch es, m ot or r ela y, t h e r a dio a n t en n a coa xia l ca ble, t h e
a n d in st r u m en t pa n el illu m in a t ion la m ps. lower pa ssen ger side a ir ba g m ou n t s, a n d a ddit ion a l
• Rem ova l a n d In st a lla t ion - Cover s com pon en t s in st r u m en t pa n el wir in g.
in st a lled on or in t h e in st r u m en t pa n el t h a t r equ ir e Rem ova l of t h e in st r u m en t pa n el cen t er bezel
r em ova l for dia gn osis or ser vice of in st r u m en t pa n el a llows a ccess t o t h e r a dio, t h e h ea t in g a n d a ir con di-
com pon en t s cover ed in t h is gr ou p. t ion in g con t r ols, t h e a ccessor y swit ch es, t h e ciga r
F or m or e in for m a t ion on com pon en t s or syst em s ligh t er, a n d t h e a ccessor y power ou t let . Rem ova l of
n ot cover ed a bove, r efer t o t h e pr oper gr ou p in t h is t h e in st r u m en t clu st er bezel a llows a ccess t o t h e
m a n u a l. If you a r e u n cer t a in a s t o t h e pr oper gr ou p, in st r u m en t clu st er. Rem ova l of t h e clu st er a ssem bly
r efer t o t h e Com pon en t a n d Syst em In dex a t t h e a llows a ccess t o t h e clu st er illu m in a t ion a n d in dica -
ba ck of t h is m a n u a l. Refer t o Gr ou p 8W - Wir in g t or la m p bu lbs, a n d m or e of t h e in st r u m en t pa n el
Dia gr a m s for com plet e cir cu it descr ipt ion s a n d dia - wir in g.
gr a m s. Rem ova l of t h e in st r u m en t pa n el t op cover a llows
a ccess t o t h e u pper pa ssen ger side a ir ba g m ou n t s.
NOTE: This group covers both Left-Hand Drive In st r u m en t pa n el r em ova l is r equ ir ed for ser vice of
(LHD) and Right-Hand Drive (RHD) versions of this m ost in t er n a l com pon en t s of t h e h ea t in g a n d a ir con -
model. Whenever required and feasible, the RHD dit ion in g h ou sin g.
versions of affected vehicle components have been
constructed as mirror-image of the LHD versions. INSTRUMENT CLUSTER
While most of the illustrations used in this group Two ba sic in st r u m en t clu st er s a r e offer ed on t h is
represent only the LHD version, the diagnostic and m odel: low-lin e or h igh -lin e. Bot h clu st er s a r e elect r o-
service procedures outlined can generally be m ech a n ica l u n it s t h a t u t ilize in t egr a t ed cir cu it r y a n d
applied to either version. Exceptions to this rule in for m a t ion ca r r ied on t h e Ch r ysler Collision Det ec-
have been clearly identified as LHD or RHD, if a t ion (CCD) da t a bu s n et wor k for con t r ol of a ll ga u ges
special illustration or procedure is required. a n d m a n y of t h e in dica t or la m ps. Th ese clu st er s a lso
in cor por a t e a va cu u m flu or escen t displa y t u be for t h e
digit a l odom et er /t r ip odom et er displa y fu n ct ion s.
INSTRUMENT PANEL Som e va r ia t ion s of ea ch clu st er exist du e t o opt ion a l
Th is in st r u m en t pa n el u ses a fu ll-widt h st r u ct u r a l equ ipm en t a n d r egu la t or y r equ ir em en t s.
pla st ic fou n da t ion a s it s pr im a r y su ppor t . Wh en t h e Th e low-lin e clu st er in clu des t h e followin g a n a log
t wo pr im a r y m olded pla st ic com pon en t s of t h is st r u c- ga u ges:
t u r e a r e vibr a t ion welded t oget h er t h ey pr ovide su pe- • F u el ga u ge
r ior in st r u m en t pa n el st iffn ess a n d in t egr it y t o h elp • Speedom et er.
r edu ce bu zzes, squ ea ks, a n d r a t t les even on t h e Th is clu st er in clu des pr ovision s for t h e followin g
bu m piest r oa ds. in dica t or la m ps:
Th is t ype of con st r u ct ion a lso pr ovides im pr oved • Air ba g in dica t or la m p
en er gy a bsor pt ion wh ich , in con ju n ct ion wit h t h e • An t i-lock br a ke syst em la m p
du a l a ir ba g m odu les a n d sea t belt s, h elps t o im pr ove • Br a ke wa r n in g la m p
occu pa n t pr ot ect ion . Th is fou n da t ion st r u ct u r e a lso • Coola n t t em per a t u r e wa r n in g la m p
ser ves a s t h e du ct in g for t h e h ea t in g a n d a ir con di-
XJ INSTRUMENT PANEL SYSTEMS 8E - 3
GEN ERAL I N FORM AT I ON (Cont inue d)
• Cr u ise-on in dica t or la m p in dica t e a n y veh icle con dit ion u n less t h e ign it ion
• F ou r-wh eel dr ive (P a r t Tim e a n d/or F u ll Tim e) swit ch is in t h e On or St a r t posit ion s.
in dica t or la m ps All ga u ges, except t h e odom et er, a r e a ir cor e m a g-
• H ea dla m p h igh bea m in dica t or la m p n et ic u n it s. Two fixed elect r om a gn et ic coils a r e
• Low oil pr essu r e wa r n in g la m p loca t ed wit h in t h e ga u ge. Th ese coils a r e wr a pped a t
• Low wa sh er flu id wa r n in g la m p r igh t a n gles t o ea ch ot h er a r ou n d a m ova ble per m a -
• Ma lfu n ct ion in dica t or (Ch eck E n gin e) la m p n en t m a gn et . Th e m ova ble m a gn et is su spen ded
• Sea t belt r em in der la m p wit h in t h e coils on on e en d of a sh a ft . Th e ga u ge n ee-
• Tu r n sign a l in dica t or la m ps dle is a t t a ch ed t o t h e ot h er en d of t h e sh a ft .
• Upsh ift in dica t or la m p (m a n u a l t r a n sm ission ) On e of t h e coils h a s a fixed cu r r en t flowin g
• Volt a ge wa r n in g la m p. t h r ou gh it t o m a in t a in a con st a n t m a gn et ic field
Th e h igh -lin e clu st er r epla ces som e of t h e in dica t or st r en gt h . Cu r r en t flow t h r ou gh t h e secon d coil
la m ps fou n d in t h e low-lin e clu st er wit h a n a log ch a n ges, wh ich ca u ses ch a n ges in it s m a gn et ic field
ga u ges. Th e h igh -lin e clu st er in clu des t h e followin g st r en gt h . Th e cu r r en t flowin g t h r ou gh t h e secon d coil
a n a log ga u ges: is ch a n ged by t h e in st r u m en t clu st er elect r on ic cir-
• Coola n t t em per a t u r e ga u ge cu it r y in r espon se t o m essa ges r eceived on t h e
• F u el ga u ge Ch r ysler Collision Det ect ion (CCD) da t a bu s n et wor k.
• Oil pr essu r e ga u ge Th e ga u ge n eedle m oves a s t h e m ova ble per m a n en t
• Speedom et er m a gn et a lign s it self t o t h e ch a n gin g m a gn et ic fields
• Ta ch om et er cr ea t ed a r ou n d it by t h e elect r om a gn et s. Th e in st r u -
• Volt m et er. m en t clu st er cir cu it r y is pr ogr a m m ed t o m ove a ll of
Th e h igh -lin e clu st er a lso a dds a ch eck ga u ges t h e ga u ge n eedles ba ck t o t h e low en d of t h eir r espec-
la m p a n d a low fu el wa r n in g la m p t o t h e r em a in in g t ive sca les a ft er t h e ign it ion swit ch is t u r n ed t o t h e
in dica t or la m ps fou n d in t h e low-lin e clu st er. Off posit ion .
Bot h in st r u m en t clu st er s fea t u r e cir cu it r y t h a t h a s
a self-dia gn ost ic a ct u a t or t est ca pa bilit y, wh ich will INDICATOR LAMP
t est ea ch of t h e CCD bu s m essa ge-con t r olled fu n c- In dica t or la m ps a r e loca t ed in t h e in st r u m en t clu s-
t ion s of t h e clu st er by ligh t in g t h e a ppr opr ia t e in di- t er a n d a r e ser ved by t h e clu st er cir cu it boa r d a n d
ca t or la m ps a n d posit ion in g t h e ga u ge n eedles a t con n ect or s. Ma n y of t h e in dica t or la m ps in t h e
sever a l pr edet er m in ed loca t ion s on t h e ga u ge fa ces in in st r u m en t clu st er a r e con t r olled by t h e in st r u m en t
a pr escr ibed sequ en ce. F or m or e in for m a t ion on t h is clu st er cir cu it r y in r espon se t o m essa ges r eceived
fu n ct ion , see In st r u m en t Clu st er in t h e Dia gn osis over t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s
a n d Test in g sect ion of t h is gr ou p. n et wor k.
Th e in st r u m en t clu st er cir cu it r y a lso in t egr a t es a Th e a n t i-lock br a ke syst em la m p, br a ke wa r n in g
ch im e t on e gen er a t or a n d a t im er cir cu it . Th ese la m p, fou r-wh eel dr ive in dica t or la m ps, h ea dla m p
it em s r epla ce t h e ch im e or bu zzer m odu le, a n d t h e h igh bea m in dica t or la m p, low wa sh er flu id wa r n in g
sepa r a t e t im er cir cu it for t h e r ea r win dow defogger la m p, sea t belt r em in der la m p dr iver sea t belt swit ch
syst em . Refer t o Gr ou p 8U - Ch im e/Bu zzer Wa r n in g in pu t , a n d t u r n sign a l in dica t or la m ps a r e h a r d-
Syst em s or Gr ou p 8N - E lect r ica lly H ea t ed Syst em s wir ed. Th e in st r u m en t clu st er cir cu it r y u ses CCD
for m or e in for m a t ion on t h ese clu st er cir cu it r y fu n c- da t a bu s m essa ges fr om t h e P ower t r a in Con t r ol Mod-
t ion s. u le (P CM) a n d Air ba g Con t r ol Modu le (ACM) t o con -
Th e in st r u m en t clu st er s for t h is m odel a r e ser viced t r ol a ll of t h e r em a in in g in dica t or la m ps.
on ly a s com plet e u n it s. If a clu st er ga u ge or t h e clu s-
t er cir cu it boa r d a r e fa u lt y, t h e en t ir e clu st er m u st be JUNCTION BLOCK
r epla ced. Th e clu st er len s, t h e h ood a n d m a sk, t h e Th e ju n ct ion block is m ou n t ed on t h e r igh t cowl
r ea r h ou sin g cover a n d t h e odom et er r eset kn ob boot side in n er pa n el u n der t h e in st r u m en t pa n el. It is
a r e a va ila ble for ser vice. Also, t h e in dividu a l clu st er con cea led beh in d t h e r igh t cowl side t r im pa n el. Th e
la m p bu lbs a n d bu lb h older s ca n be ser viced. ju n ct ion block ser ves t o sim plify a n d cen t r a lize
n u m er ou s elect r ica l com pon en t s.
GAUGE Th e ju n ct ion block com bin es t h e fu n ct ion s pr evi-
Wit h t h e ign it ion swit ch in t h e On or St a r t posi- ou sly pr ovided by a sepa r a t e fu seblock m odu le a n d
t ion s, volt a ge is su pplied t o a ll ga u ges t h r ou gh t h e r ela y cen t er. It con t a in s fu ses, cir cu it br ea ker s a n d
in st r u m en t clu st er elect r on ic cir cu it boa r d. Wit h t h e r ela ys. It a lso elim in a t es t h e n eed for n u m er ou s
ign it ion swit ch in t h e Off posit ion , volt a ge is n ot su p- splice con n ect ion s a n d ser ves in pla ce of a bu lkh ea d
plied t o t h e ga u ges. Th e ga u ges do n ot a ccu r a t ely con n ect or bet ween m a n y of t h e en gin e com pa r t m en t ,
in st r u m en t pa n el, a n d body wir e h a r n esses.
8E - 4 INSTRUMENT PANEL SYSTEMS XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
Th e r igh t cowl side t r im pa n el h a s a sn a p-fit fu se in dica t es t h a t t h e fu el level is below on e-eigh t h of a
a ccess cover t h a t ca n be r em oved for ser vice of t h e fu ll t a n k, t h e in st r u m en t clu st er cir cu it r y t u r n s on
ju n ct ion block fu ses. A fu se pu ller a n d spa r e fu se t h e low fu el wa r n in g la m p a n d gen er a t es a sin gle
h older s a r e loca t ed on t h e ba ck of t h e fu se a ccess ch im e t on e.
pa n el. Th e r igh t cowl side t r im pa n el m u st be Th e fu el ga u ge sen din g u n it is m ou n t ed t o t h e elec-
r em oved t o a ccess t h e r ela ys in t h e ju n ct ion block. t r ic fu el pu m p m odu le loca t ed in side t h e fu el t a n k.
Th e ju n ct ion block ca n n ot be r epa ir ed a n d, if fa u lt y Th e sen din g u n it h a s a floa t a t t a ch ed t o t h e en d of a
or da m a ged, it m u st be r epla ced. swin g-a r m . Th e floa t m oves u p or down wit h in t h e
fu el t a n k a s t h e fu el level ch a n ges. As t h e floa t
m oves, a n elect r ica l con t a ct on t h e pivot en d of t h e
DESCRI PT I ON AN D OPERAT I ON swin g-a r m wipes a cr oss a r esist or coil, wh ich ch a n ges
t h e in t er n a l elect r ica l r esist a n ce of t h e sen din g u n it .
COOLANT TEMPERATURE GAUGE Refer t o Gr ou p 14 - F u el Syst em s for m or e in for m a -
Th e coola n t t em per a t u r e ga u ge gives a n in dica t ion t ion on t h e P CM a n d t h e fu el ga u ge sen din g u n it ser-
of t h e en gin e coola n t t em per a t u r e. Th e in st r u m en t vice pr ocedu r es.
clu st er cir cu it r y con t r ols t h e ga u ge poin t er posit ion .
Th e in st r u m en t clu st er cir cu it r y ca lcu la t es t h e ODOMETER AND TRIP ODOMETER
pr oper ga u ge poin t er posit ion ba sed u pon a n en gin e Th e odom et er a n d t h e t r ip odom et er sh a r e t h e
coola n t t em per a t u r e m essa ge r eceived fr om t h e P ow- sa m e va cu u m flu or escen t digit a l displa y t u be in t h e
er t r a in Con t r ol Modu le (P CM) on t h e Ch r ysler Colli- in st r u m en t clu st er cir cu it boa r d. E a ch gives a n in di-
sion Det ect ion (CCD) da t a bu s. ca t ion of t h e dist a n ce t h e veh icle h a s t r a velled. H ow-
Th e P CM u ses a n in pu t fr om t h e en gin e coola n t ever, by depr essin g t h e r eset kn ob on t h e fa ce of t h e
t em per a t u r e sen sor a n d in t er n a l pr ogr a m m in g t o in st r u m en t clu st er, t h e displa y ca n be swit ch ed fr om
decide wh a t en gin e coola n t t em per a t u r e m essa ge is odom et er t o t r ip odom et er. Depr essin g t h e r eset kn ob
r equ ir ed. Th e P CM t h en sen ds t h e pr oper m essa ge t o for lon ger t h a n t wo secon ds wh ile in t h e t r ip odom e-
t h e in st r u m en t clu st er on t h e CCD da t a bu s. t er m ode will r eset t h e t r ip odom et er t o zer o. Th e
If t h e P CM m essa ge in dica t es t h a t coola n t t em per- odom et er a n d t r ip odom et er displa y va lu es a r e ba sed
a t u r e is h igh , t h e in st r u m en t clu st er cir cu it r y m oves on dist a n ce pu lse m essa ges r eceived fr om t h e P ower-
t h e ga u ge n eedle in t o t h e begin n in g of t h e r ed zon e t r a in Con t r ol Modu le (P CM) on t h e Ch r ysler Colli-
on t h e ga u ge fa ce, t u r n s on t h e Ch eck Ga u ges la m p, sion Det ect ion (CCD) da t a bu s.
a n d gen er a t es a sin gle ch im e t on e. If t h e P CM m es- Th e P CM u ses a n in pu t fr om t h e Veh icle Speed
sa ge in dica t es t h a t coola n t t em per a t u r e is cr it ica l, Sen sor (VSS) a n d in t er n a l pr ogr a m m in g t o decide
t h e in st r u m en t clu st er cir cu it r y m oves t h e ga u ge wh a t dist a n ce pu lse sign a l is r equ ir ed. Th e P CM
n eedle t o t h e st op a t t h e en d of t h e r ed zon e on t h e t h en sen ds t h e pr oper m essa ge t o t h e in st r u m en t
ga u ge fa ce. clu st er cir cu it r y on t h e CCD da t a bu s. Th e in st r u -
Th e en gin e coola n t t em per a t u r e sen sor is in st a lled m en t clu st er st or es bot h t h e odom et er a n d t r ip odom -
in a t h r ea ded h ole t h a t pen et r a t es a coola n t pa ssa ge et er dist a n ce in for m a t ion a n d displa ys t h e pr oper
of t h e en gin e. It is a t h er m ist or-t ype sen sor t h a t va lu e ba sed u pon ign it ion key-on a n d t r ip odom et er
ch a n ges it s in t er n a l r esist a n ce wit h ch a n ges in r eset kn ob in pu t s. Th e in st r u m en t clu st er a lso st or es
en gin e coola n t t em per a t u r e. Refer t o Gr ou p 14 - F u el t h e odom et er displa y m ode (odom et er or t r ip odom e-
Syst em s for m or e in for m a t ion on t h e P CM a n d t h e t er ), a n d will r et u r n t o t h e m ode t h a t wa s select ed
coola n t t em per a t u r e sen sor. pr ior t o t h e ign it ion swit ch bein g t u r n ed off.
If t h e in st r u m en t clu st er is n ot r eceivin g dist a n ce
FUEL GAUGE in for m a t ion on t h e CCD da t a bu s wh en t h e ign it ion
Th e fu el ga u ge gives a n in dica t ion of t h e level of swit ch is t u r n ed t o t h e On posit ion , t h e odom et er dis-
fu el in t h e fu el t a n k. Th e in st r u m en t clu st er cir cu it r y pla y will r em a in bla n k. If t h e in st r u m en t clu st er
con t r ols t h e ga u ge poin t er posit ion . Th e in st r u m en t does n ot r eceive a dist a n ce m essa ge on t h e CCD da t a
clu st er cir cu it r y ca lcu la t es t h e pr oper ga u ge poin t er bu s a ft er t h e ign it ion swit ch h a s been t u r n ed t o t h e
posit ion ba sed u pon a fu el level m essa ge r eceived On posit ion , t h e in st r u m en t pa n el cir cu it r y will
fr om t h e P ower t r a in Con t r ol Modu le (P CM) on t h e in ser t t h e la st n or m a lly displa yed dist a n ce in t h e
Ch r ysler Collision Det ect ion (CCD) da t a bu s. odom et er displa y. If t h e in st r u m en t clu st er is r eceiv-
Th e P CM u ses a n in pu t fr om t h e fu el ga u ge sen d- in g CCD m essa ges, bu t ca n n ot displa y odom et er va l-
in g u n it a n d in t er n a l pr ogr a m m in g t o decide wh a t u es du e t o a n in t er n a l er r or, t h e odom et er displa y
fu el level m essa ge is r equ ir ed. Th e P CM t h en sen ds will be bla n k.
t h e pr oper m essa ge t o t h e in st r u m en t clu st er on t h e Th e VSS is a h a ll-effect sen sor t h a t is in st a lled in
CCD da t a bu s. If t h e veh icle is equ ipped wit h t h e t h e t r a n sm ission (t wo-wh eel dr ive) or t r a n sfer ca se
h igh -lin e in st r u m en t clu st er, wh en t h e P CM m essa ge
XJ INSTRUMENT PANEL SYSTEMS 8E - 5
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
(fou r-wh eel dr ive), a n d is dr iven by t h e ou t pu t sh a ft t h r ou gh a speedom et er pin ion gea r. In cor r ect t ir e
t h r ou gh a speedom et er pin ion gea r. In cor r ect t ir e size, in cor r ect a xle r a t io, a fa u lt y or in cor r ect speed-
size, in cor r ect a xle r a t io, a fa u lt y or in cor r ect speed- om et er pin ion gea r, or a fa u lt y VSS ca n ea ch r esu lt
om et er pin ion gea r, or a fa u lt y VSS ca n ea ch r esu lt in in a ccu r a t e speedom et er r ea din gs. Refer t o Gr ou p
in in a ccu r a t e odom et er r ea din gs. Refer t o Gr ou p 14 - 14 - F u el Syst em s for m or e in for m a t ion on t h e P CM
F u el Syst em s for m or e in for m a t ion on t h e P CM a n d a n d t h e VSS. Refer t o Gr ou p 21 - Tr a n sm ission for
t h e VSS. Refer t o Gr ou p 21 - Tr a n sm ission for m or e m or e in for m a t ion on t h e speedom et er pin ion gea r.
in for m a t ion on t h e speedom et er pin ion gea r.
Th e odom et er a n d t r ip odom et er ca n a lso be u sed TACHOMETER
t o digit a lly displa y a st or ed DTC. Refer t o Gr ou p 25 - Th e t a ch om et er gives a n in dica t ion of t h e en gin e
E m ission Con t r ol Syst em s for m or e in for m a t ion on speed in r evolu t ion s-per-m in u t e (RP M). Th e in st r u -
DTCs a n d t h eir r et r ieva l. m en t clu st er cir cu it r y con t r ols t h e ga u ge poin t er
posit ion . Th e in st r u m en t clu st er cir cu it r y ca lcu la t es
OIL PRESSURE GAUGE t h e pr oper ga u ge poin t er posit ion ba sed u pon a n
Th e oil pr essu r e ga u ge gives a n in dica t ion of t h e en gin e speed m essa ge r eceived fr om t h e P ower t r a in
en gin e oil pr essu r e. Th e in st r u m en t clu st er cir cu it r y Con t r ol Modu le (P CM) on t h e Ch r ysler Collision
con t r ols t h e ga u ge poin t er posit ion . Th e in st r u m en t Det ect ion (CCD) da t a bu s.
clu st er cir cu it r y ca lcu la t es t h e pr oper ga u ge poin t er Th e P CM u ses a n in pu t fr om t h e cr a n ksh a ft posi-
posit ion ba sed u pon a n en gin e oil pr essu r e m essa ge t ion sen sor a n d in t er n a l pr ogr a m m in g t o ca lcu la t e
r eceived fr om t h e P ower t r a in Con t r ol Modu le (P CM) wh a t en gin e speed m essa ge is r equ ir ed. Th e P CM
on t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s. t h en sen ds t h e pr oper m essa ge t o t h e in st r u m en t
Th e P CM u ses a n in pu t fr om t h e en gin e oil pr es- clu st er on t h e CCD da t a bu s. Th e cr a n ksh a ft posit ion
su r e sen sor a n d in t er n a l pr ogr a m m in g t o decide sen sor is a h a ll-effect sen sor in st a lled n ea r t h e r ea r
wh a t en gin e oil pr essu r e m essa ge is r equ ir ed. Th e of t h e en gin e, wh er e it is a im ed a t t h e t r igger wh eel
P CM t h en sen ds t h e pr oper m essa ge t o t h e in st r u - a t t a ch ed t o t h e r ea r fla n ge of t h e cr a n ksh a ft .
m en t clu st er on t h e CCD da t a bu s. If t h e P CM m es- Refer t o Gr ou p 14 - F u el Syst em s for m or e in for-
sa ge in dica t es t h a t oil pr essu r e is low, t h e m a t ion on t h e P CM. Refer t o Gr ou p 8D - Ign it ion
in st r u m en t clu st er cir cu it r y m oves t h e ga u ge n eedle Syst em s for m or e in for m a t ion on t h e cr a n ksh a ft posi-
t o below t h e zer o gr a du a t ion on t h e ga u ge fa ce, a n d t ion sen sor.
t u r n s on t h e Ch eck Ga u ges la m p.
Th e en gin e oil pr essu r e sen sor is in st a lled in a VOLTMETER
t h r ea ded h ole t h a t pen et r a t es a n oil pa ssa ge of t h e Th e volt m et er gives a n in dica t ion of t h e elect r ica l
en gin e. Th e en gin e oil pr essu r e sen sor con t a in s a syst em volt a ge. Th e in st r u m en t clu st er cir cu it r y con -
flexible dia ph r a gm a n d a va r ia ble r esist or coil. Th e t r ols t h e ga u ge poin t er posit ion . Th e in st r u m en t clu s-
dia ph r a gm m oves in r espon se t o ch a n ges in t h e t er cir cu it r y ca lcu la t es t h e pr oper ga u ge poin t er
en gin e oil pr essu r e, wh ich ch a n ges t h e in t er n a l elec- posit ion ba sed u pon a syst em volt a ge m essa ge
t r ica l r esist a n ce of t h e sen sor. Refer t o Gr ou p 14 - r eceived fr om t h e P ower t r a in Con t r ol Modu le (P CM)
F u el Syst em s for m or e in for m a t ion on t h e P CM a n d on t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s.
t h e en gin e oil pr essu r e sen sor. Th e P CM u ses a n in pu t fr om t h e elect r ica l syst em
a n d in t er n a l pr ogr a m m in g t o decide wh a t syst em
SPEEDOMETER volt a ge m essa ge is r equ ir ed. Th e P CM t h en sen ds
Th e speedom et er gives a n in dica t ion of t h e cu r r en t t h e pr oper m essa ge t o t h e in st r u m en t clu st er on t h e
veh icle speed. Th e in st r u m en t clu st er cir cu it r y con - CCD da t a bu s.
t r ols t h e ga u ge poin t er posit ion . Th e in st r u m en t clu s- If t h e P CM m essa ge in dica t es t h a t t h e ch a r gin g
t er cir cu it r y ca lcu la t es t h e pr oper ga u ge poin t er syst em h a s fa iled, t h e in st r u m en t clu st er cir cu it r y
posit ion ba sed u pon a veh icle speed m essa ge r eceived m oves t h e ga u ge n eedle t o t h e 9 volt gr a du a t ion on
fr om t h e P ower t r a in Con t r ol Modu le (P CM) on t h e t h e ga u ge fa ce, a n d t u r n s on t h e Ch eck Ga u ges la m p.
Ch r ysler Collision Det ect ion (CCD) da t a bu s. If t h e P CM m essa ge in dica t es t h a t syst em volt a ge is
Th e P CM u ses a n in pu t fr om t h e Veh icle Speed h igh , t h e in st r u m en t clu st er cir cu it r y m oves t h e
Sen sor (VSS) a n d in t er n a l pr ogr a m m in g t o decide ga u ge n eedle t o t h e 19 volt gr a du a t ion on t h e ga u ge
wh a t veh icle speed m essa ge is r equ ir ed. Th e P CM fa ce, a n d t u r n s on t h e Ch eck Ga u ges la m p.
t h en sen ds t h e pr oper m essa ge t o t h e in st r u m en t Refer t o Gr ou p 14 - F u el Syst em s for m or e in for-
clu st er on t h e CCD da t a bu s. m a t ion on t h e P CM. Refer t o Gr ou p 8C - Ch a r gin g
Th e VSS is a h a ll-effect sen sor t h a t is in st a lled in Syst em s for m or e in for m a t ion on ch a r gin g syst em
t h e t r a n sm ission (t wo-wh eel dr ive) or t r a n sfer ca se com pon en t s a n d dia gn osis.
(fou r-wh eel dr ive), a n d is dr iven by t h e ou t pu t sh a ft
8E - 6 INSTRUMENT PANEL SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
AIRBAG INDICATOR LAMP t ion swit ch is in t h e St a r t posit ion a s a bu lb t est .
Th e a ir ba g in dica t or la m p gives a n in dica t ion wh en Aft er t h e bu lb t est , t h e la m p is con t r olled by h a r d-
t h e a ir ba g syst em is fa u lt y or in oper a t ive. Th e la m p wir ed in pu t s fr om t h e pa r kin g br a ke swit ch a n d/or
is t u r n ed on by t h e in st r u m en t clu st er cir cu it r y for t h e br a ke wa r n in g swit ch .
a bou t seven secon ds wh en t h e ign it ion swit ch is Th e br a ke wa r n in g swit ch closes t o gr ou n d wh en it
t u r n ed t o t h e On posit ion a s a bu lb t est . Aft er t h e sen ses u n equ a l h ydr a u lic pr essu r es in t h e t wo h a lves
bu lb t est , t h e la m p is con t r olled by t h e in st r u m en t of t h e split br a ke h ydr a u lic syst em , possibly du e t o
clu st er cir cu it r y ba sed u pon a m essa ge r eceived fr om low br a ke flu id level or br a ke flu id lea ka ge. Th e
t h e Air ba g Con t r ol Modu le (ACM) on t h e Ch r ysler pa r kin g br a ke swit ch closes t o gr ou n d wh en t h e
Collision Det ect ion (CCD) da t a bu s. pa r kin g br a ke is a pplied. Refer t o Gr ou p 5 - Br a kes
Th e ACM con t in u a lly m on it or s t h e a ir ba g syst em for m or e in for m a t ion .
cir cu it s a n d sen sor s t o decide wh et h er t h e syst em is
in good oper a t in g con dit ion . Th e ACM t h en sen ds t h e CHECK GAUGES LAMP
pr oper m essa ge t o t h e in st r u m en t clu st er on t h e Th e ch eck ga u ges la m p gives a n in dica t ion wh en
CCD da t a bu s t o t u r n t h e la m p on or off. If t h e ACM cer t a in ga u ges r eflect a con dit ion r equ ir in g im m edi-
sen ds a la m p-on m essa ge a ft er t h e bu lb t est , it in di- a t e a t t en t ion . Th e la m p is t u r n ed on by t h e in st r u -
ca t es t h a t t h e ACM h a s det ect ed a syst em m a lfu n c- m en t clu st er cir cu it r y for a bou t t h r ee secon ds a ft er
t ion a n d/or t h a t t h e a ir ba g syst em h a s becom e t h e ign it ion swit ch is t u r n ed t o t h e On posit ion a s a
in oper a t ive. bu lb t est . Aft er t h e bu lb t est , t h e la m p is con t r olled
E a ch t im e t h e in st r u m en t clu st er cir cu it r y r eceives by t h e in st r u m en t clu st er cir cu it r y ba sed u pon ga u ge
a la m p-on m essa ge fr om t h e ACM, it will ligh t t h e da t a m essa ges r eceived fr om t h e P ower t r a in Con t r ol
la m p for t welve secon ds or t h e du r a t ion of t h e a ir ba g Modu le (P CM) on t h e Ch r ysler Collision Det ect ion
syst em m a lfu n ct ion , wh ich ever is lon ger. If t h e (CCD) da t a bu s.
in st r u m en t clu st er r eceives n o la m p m essa ges fr om Th e P CM u ses sever a l in pu t s t o decide wh a t ga u ge
t h e ACM for m or e t h a n five secon ds, it will ligh t t h e da t a m essa ges a r e r equ ir ed. Th e P CM t h en sen ds t h e
la m p for t welve secon ds or u n t il a n ot h er la m p-off pr oper m essa ge t o t h e in st r u m en t clu st er on t h e
m essa ge fr om t h e ACM, wh ich ever is lon ger. CCD da t a bu s. Th e ga u ge da t a m essa ges for wh ich
Refer t o Gr ou p 8M - P a ssive Rest r a in t Syst em s for t h e in st r u m en t clu st er is pr ogr a m m ed t o t u r n on t h e
m or e in for m a t ion on t h e a ir ba g syst em . ch eck ga u ges la m p a r e:
• E n gin e coola n t t em per a t u r e is h igh or cr it ica l
ANTI-LOCK BRAKE SYSTEM LAMP • E n gin e oil pr essu r e is low
Th e An t i-Lock Br a ke Syst em (ABS) la m p gives a n • Ch a r gin g syst em fa ilu r e
in dica t ion wh en t h e ABS syst em is fa u lt y or in oper- • Syst em volt a ge is h igh .
a t ive. Th e la m p is h a r d-wir ed in t h e in st r u m en t clu s-
t er, a n d is com plet ely con t r olled by t h e Con t r oller CIGAR LIGHTER AND POWER OUTLET
An t i-lock Br a ke (CAB). It r eceives ba t t er y volt a ge A ciga r ligh t er a n d a n a ccessor y power ou t let a r e
t h r ou gh t h e in st r u m en t clu st er fu sed ign it ion swit ch st a n da r d equ ipm en t on t h is m odel. P ower t o t h e
ou t pu t feed cir cu it , a n d is gr ou n ded by t h e CAB. Th e a ccessor y power ou t let is pr ovided a t a ll t im es,
la m p is t u r n ed on by t h e CAB for a bou t t wo secon ds r ega r dless of t h e ign it ion swit ch posit ion . P ower t o
wh en t h e ign it ion swit ch is t u r n ed t o t h e On posit ion t h e ciga r ligh t er is swit ch ed by a ciga r ligh t er r ela y,
a s a bu lb t est . Aft er t h e bu lb t est , t h e CAB t u r n s t h e wh ich is on ly en er gized wh en t h e ign it ion swit ch is
la m p on or off ba sed u pon t h e r esu lt s of t h e ABS sys- in t h e Accessor y or On posit ion s.
t em self-t est s. Th e ciga r ligh t er a n d a ccessor y power ou t let r ecep-
Th e CAB con t in u a lly m on it or s t h e ABS cir cu it s t a cles a r e loca t ed in , a n d ser viced on ly a s a pa r t of,
a n d sen sor s t o decide wh et h er t h e syst em is in good t h e a ccessor y swit ch bezel u n it . If eit h er r ecept a cle is
oper a t in g con dit ion . If t h e CAB t u r n s t h e la m p on fa u lt y or da m a ged, t h e a ccessor y swit ch bezel m u st
a ft er t h e bu lb t est , it in dica t es t h a t t h e CAB h a s be r epla ced.
det ect ed a syst em m a lfu n ct ion a n d/or t h a t t h e ABS
syst em h a s becom e in oper a t ive. Refer t o Gr ou p 5 - CIGAR LIGHTER RELAY
Br a kes for m or e in for m a t ion . Th e ciga r ligh t er r ela y is a In t er n a t ion a l St a n da r ds
Or ga n iza t ion (ISO)-t ype r ela y. Th e ciga r ligh t er r ela y
BRAKE WARNING LAMP is a elect r om ech a n ica l device t h a t swit ch es fu sed ba t -
Th e br a ke wa r n in g la m p gives a n in dica t ion wh en t er y cu r r en t t o t h e ciga r ligh t er wh en t h e ign it ion
t h e pa r kin g br a ke is a pplied, or wh en t h e pr essu r es swit ch is t u r n ed t o t h e Accessor y or On posit ion s. See
in t h e t wo h a lves of t h e split br a ke h ydr a u lic syst em t h e Dia gn osis a n d Test in g sect ion of t h is gr ou p for
a r e u n equ a l. Th e la m p is t u r n ed on wh en t h e ign i-
XJ INSTRUMENT PANEL SYSTEMS 8E - 7
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
m or e in for m a t ion on t h e oper a t ion of t h e ciga r ligh t er ba sed u pon a m essa ge r eceived fr om t h e P ower t r a in
r ela y. Con t r ol Modu le (P CM) on t h e Ch r ysler Collision
Th e ciga r ligh t er r ela y is loca t ed in t h e ju n ct ion Det ect ion (CCD) da t a bu s.
block, on t h e r igh t cowl side pa n el below t h e in st r u - Th e P CM u ses a n in pu t fr om t h e a n a log r esist or-
m en t pa n el in t h e pa ssen ger com pa r t m en t . Th e ciga r m u lt iplexed veh icle speed con t r ol swit ch es in t h e
ligh t er r ela y ca n n ot be r epa ir ed a n d, if fa u lt y or st eer in g wh eel t o decide wh et h er t o t u r n t h e la m p on
da m a ged, it m u st be r epla ced. or off. Th e P CM t h en sen ds t h e pr oper m essa ge t o
t h e in st r u m en t clu st er on t h e CCD da t a bu s. Refer t o
CLUSTER ILLUMINATION LAMP Gr ou p 8H - Veh icle Speed Con t r ol Syst em for m or e
Th e clu st er illu m in a t ion la m ps a r e h a r d-wir ed in in for m a t ion .
t h e in st r u m en t clu st er. Wh en t h e pa r k or h ea d la m ps
a r e t u r n ed on , t h e clu st er illu m in a t ion la m ps ligh t . FOUR-WHEEL DRIVE INDICATOR LAMP
Illu m in a t ion br igh t n ess is a dju st ed by r ot a t in g t h e
h ea dla m p swit ch kn ob (clockwise t o dim , cou n t er- PART T I M E
clockwise t o br igh t en ). Th e in st r u m en t clu st er illu m i- On veh icles wit h t h e opt ion a l Com m a n d-Tr a c fou r-
n a t ion la m ps r eceive ba t t er y feed fr om t h e pa n el wh eel dr ive syst em , t h e P a r t Tim e in dica t or la m p
dim m er r h eost a t in t h e h ea dla m p swit ch t h r ou gh a ligh t s wh en t h e t r a n sfer ca se is en ga ged in t h e 4H or
fu se in t h e ju n ct ion block. 4L posit ion s. On veh icles wit h t h e opt ion a l Selec-Tr a c
E a ch of t h e illu m in a t ion la m ps is loca t ed on t h e fou r-wh eel dr ive syst em , t h e P a r t Tim e in dica t or
in st r u m en t clu st er cir cu it boa r d. E a ch la m p h a s a la m p ligh t s wh en t h e t r a n sfer ca se is en ga ged in t h e
r epla cea ble bu lb a n d bu lb h older. Refer t o Gr ou p 8L - 4 X 4 P a r t Tim e or 4 Lo posit ion s.
La m ps for m or e in for m a t ion . Wh en t h e ign it ion swit ch is in t h e On posit ion , ba t -
t er y volt a ge is su pplied t o on e side of t h e in dica t or
COOLANT TEMPERATURE WARNING LAMP la m p bu lb. A n or m a lly-open , plu n ger-t ype, fou r-wh eel
Th e coola n t t em per a t u r e wa r n in g la m p gives a n dr ive swit ch t h r ea ded in t o t h e t r a n sfer ca se is h a r d-
in dica t ion wh en t h e en gin e coola n t t em per a t u r e is wir ed in ser ies bet ween t h e ot h er side of t h e in dica -
h igh . Th e la m p is t u r n ed on by t h e in st r u m en t clu s- t or la m p bu lb a n d gr ou n d. Wh en t h e t r a n sfer ca se is
t er cir cu it r y for a bou t t h r ee secon ds a ft er t h e ign it ion sh ift ed in t o t h e pr oper posit ion , t h e plu n ger of t h e
swit ch is t u r n ed t o t h e On posit ion a s a bu lb t est . fou r-wh eel dr ive swit ch is m oved, closin g t h e swit ch
Aft er t h e bu lb t est , t h e la m p is con t r olled by t h e a n d pr ovidin g a pa t h t o gr ou n d. Th is ca u ses t h e P a r t
in st r u m en t clu st er cir cu it r y ba sed u pon a n en gin e Tim e in dica t or la m p bu lb t o ligh t .
coola n t t em per a t u r e m essa ge r eceived fr om t h e P ow- Refer t o Gr ou p 21 - Tr a n sm ission for m or e in for-
er t r a in Con t r ol Modu le (P CM) on t h e Ch r ysler Colli- m a t ion on t h e t r a n sfer ca se sh ift m ech a n ism .
sion Det ect ion (CCD) da t a bu s.
Th e P CM u ses a n in pu t fr om t h e en gin e coola n t FU LL T I M E
t em per a t u r e sen sor a n d in t er n a l pr ogr a m m in g t o Th e F u ll Tim e in dica t or la m p is on ly oper a t ion a l
decide wh a t en gin e coola n t t em per a t u r e m essa ge is on veh icles equ ipped wit h t h e opt ion a l Selec-Tr a c
r equ ir ed. Th e P CM t h en sen ds t h e pr oper m essa ge t o fou r-wh eel dr ive syst em . Th e F u ll Tim e in dica t or
t h e in st r u m en t clu st er on t h e CCD da t a bu s. If t h e la m p ligh t s wh en t h e t r a n sfer ca se is en ga ged in t h e
P CM m essa ge in dica t es t h a t coola n t t em per a t u r e is 4 X 4 F u ll Tim e posit ion .
h igh , t h e in st r u m en t clu st er cir cu it r y t u r n s on t h e Wh en t h e ign it ion swit ch is in t h e On posit ion , ba t -
coola n t t em per a t u r e wa r n in g la m p a n d gen er a t es a t er y volt a ge is su pplied t o on e side of t h e in dica t or
sin gle ch im e t on e. la m p bu lb. A n or m a lly-open , plu n ger-t ype, fou r-wh eel
Th e en gin e coola n t t em per a t u r e sen sor is in st a lled dr ive swit ch t h r ea ded in t o t h e t r a n sfer ca se is h a r d-
in a t h r ea ded h ole t h a t pen et r a t es a coola n t pa ssa ge wir ed in ser ies bet ween t h e ot h er side of t h e in dica -
of t h e en gin e. It is a t h er m ist or-t ype sen sor t h a t t or la m p bu lb a n d gr ou n d. Wh en t h e t r a n sfer ca se is
ch a n ges it s in t er n a l r esist a n ce wit h ch a n ges in sh ift ed in t o t h e pr oper posit ion , t h e plu n ger of t h e
en gin e coola n t t em per a t u r e. Refer t o Gr ou p 14 - F u el fou r-wh eel dr ive swit ch is m oved, closin g t h e swit ch
Syst em s for m or e in for m a t ion on t h e P CM a n d t h e a n d pr ovidin g a pa t h t o gr ou n d. Th is ca u ses t h e F u ll
coola n t t em per a t u r e sen sor. Tim e in dica t or la m p bu lb t o ligh t .
Refer t o Gr ou p 21 - Tr a n sm ission for m or e in for-
CRUISE-ON INDICATOR LAMP m a t ion on t h e t r a n sfer ca se sh ift m ech a n ism .
Th e cr u ise-on in dica t or la m p gives a n in dica t ion
wh en t h e veh icle speed con t r ol syst em is t u r n ed on , HEADLAMP HIGH BEAM INDICATOR LAMP
even wh en t h e syst em is n ot cu r r en t ly en ga ged. Th e Th e h ea dla m p h igh bea m in dica t or la m p gives a n
la m p is con t r olled by t h e in st r u m en t clu st er cir cu it r y in dica t ion wh en t h e h ea dla m p h igh bea m s a r e t u r n ed
on . Th e la m p is con t r olled by a h a r d-wir ed in pu t
8E - 8 INSTRUMENT PANEL SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
fr om t h e h ea dla m p dim m er (m u lt i-fu n ct ion ) swit ch . P CM t h en sen ds t h e pr oper m essa ge t o t h e in st r u -
On e side of t h e in dica t or bu lb is gr ou n ded a t a ll m en t clu st er on t h e CCD da t a bu s. If t h e P CM m es-
t im es. Th e ot h er side of t h e bu lb r eceives a ba t t er y sa ge in dica t es t h a t oil pr essu r e is low, t h e
feed t h r ou gh t h e con t a ct s of t h e dim m er swit ch wh en in st r u m en t clu st er cir cu it r y t u r n s on t h e low oil pr es-
t h e m u lt i-fu n ct ion swit ch st a lk is a ct u a t ed t o t u r n on su r e wa r n in g la m p.
t h e h ea dla m p h igh bea m s. Refer t o Gr ou p 8L - Th e en gin e oil pr essu r e sen sor is in st a lled in a
La m ps for m or e in for m a t ion . t h r ea ded h ole t h a t pen et r a t es a n oil pa ssa ge of t h e
en gin e. Th e en gin e oil pr essu r e sen sor con t a in s a
LOW FUEL WARNING LAMP flexible dia ph r a gm a n d a va r ia ble r esist or coil. Th e
Th e low fu el wa r n in g la m p gives a n in dica t ion dia ph r a gm m oves in r espon se t o ch a n ges in t h e
wh en t h e fu el level in t h e fu el t a n k h a s fa llen below en gin e oil pr essu r e, wh ich ch a n ges t h e in t er n a l elec-
a bou t on e-eigh t h of a fu ll t a n k, a s r egist er ed on t h e t r ica l r esist a n ce of t h e sen sor. Refer t o Gr ou p 14 -
fu el ga u ge. Th e in st r u m en t clu st er cir cu it r y ligh t s F u el Syst em s for m or e in for m a t ion on t h e P CM a n d
t h e la m p for a bou t t h r ee secon ds wh en t h e ign it ion t h e en gin e oil pr essu r e sen sor.
swit ch is t u r n ed t o t h e On posit ion a s a bu lb t est .
Aft er t h e bu lb t est , t h e in st r u m en t clu st er cir cu it r y LOW WASHER FLUID WARNING LAMP
con t r ols t h e la m p ba sed u pon a fu el level m essa ge Th e low wa sh er flu id wa r n in g la m p gives a n in di-
r eceived fr om t h e P ower t r a in Con t r ol Modu le (P CM) ca t ion wh en t h e flu id level in t h e wa sh er flu id r eser-
on t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s. voir is t oo low. Th e in st r u m en t clu st er cir cu it r y
Th e P CM u ses a n in pu t fr om t h e fu el ga u ge sen d- con t r ols t h e la m p ba sed u pon a h a r d-wir ed in pu t
in g u n it a n d in t er n a l pr ogr a m m in g t o decide wh a t fr om t h e wa sh er flu id level sen sor.
fu el level m essa ge is r equ ir ed. Th e P CM t h en sen ds Th e wa sh er flu id level sen sor u ses a floa t in t h e
t h e pr oper m essa ge t o t h e in st r u m en t clu st er on t h e r eser voir t o m on it or t h e flu id level. Th e u p a n d down
CCD da t a bu s. If t h e P CM m essa ge in dica t es t h a t a ct ion of t h e floa t open s or closes t h e swit ch wit h in
t h e fu el level is below on e-eigh t h of a fu ll t a n k for t h e wa sh er flu id level sen sor t h a t pr ovides a gr ou n d
m or e t h a n t en secon ds, t h e in st r u m en t clu st er cir- sign a l t o t h e in st r u m en t clu st er cir cu it r y.
cu it r y t u r n s on t h e low fu el wa r n in g la m p a n d gen - If t h e in st r u m en t clu st er cir cu it r y sen ses a gr ou n d
er a t es a sin gle ch im e t on e. On ce t h e la m p is t u r n ed in pu t fr om t h e wa sh er flu id level sen sor for m or e
on , a n in cr ea se in t h e fu el level m essa ge of a t lea st t h a n a bou t t h ir t y secon ds, it t u r n s on t h e low wa sh er
on e fu ll n eedle widt h for m or e t h a n t wen t y secon ds is flu id wa r n in g la m p. Th is h elps t o r edu ce t h e effect s
r equ ir ed befor e t h e clu st er will t u r n t h e la m p off. of flu id slosh in g wit h in t h e r eser voir. Th is la m p a lso
Th e fu el ga u ge sen din g u n it is m ou n t ed t o t h e elec- la t ch es. On ce t h e la m p h a s been t u r n ed on , it will
t r ic fu el pu m p m odu le in side t h e fu el t a n k. Th e sen d- r em a in on u n t il wa sh er flu id is a dded t o t h e r eser-
in g u n it h a s a floa t a t t a ch ed t o t h e en d of a swin g- voir a n d t h e ign it ion swit ch is cycled.
a r m . Th e floa t m oves u p or down wit h in t h e fu el Refer t o Gr ou p 8K - Wiper a n d Wa sh er Syst em s for
t a n k a s t h e fu el level ch a n ges. As t h e floa t m oves, a n m or e in for m a t ion on t h e wa sh er flu id level sen sor.
elect r ica l con t a ct on t h e pivot en d of t h e swin g-a r m
wipes a cr oss a r esist or coil, wh ich ch a n ges t h e r esis- MALFUNCTION INDICATOR LAMP
t a n ce of t h e sen din g u n it . Refer t o Gr ou p 14 - F u el Th e Ch eck E n gin e or Ma lfu n ct ion In dica t or La m p
Syst em s for m or e in for m a t ion on t h e P CM a n d t h e (MIL) gives a n in dica t ion wh en t h e P ower t r a in Con -
fu el ga u ge sen din g u n it . t r ol Modu le (P CM) h a s r ecor ded a Dia gn ost ic Tr ou ble
Code (DTC) for a n On -Boa r d Dia gn ost ics II (OBDII)
LOW OIL PRESSURE WARNING LAMP em ission s-r ela t ed cir cu it or com pon en t m a lfu n ct ion .
Th e low oil pr essu r e wa r n in g la m p gives a n in dica - Th e la m p is con t r olled by t h e in st r u m en t clu st er cir-
t ion wh en t h e en gin e oil pr essu r e is low. Th e la m p is cu it r y ba sed u pon m essa ges r eceived fr om t h e P CM
t u r n ed on by t h e in st r u m en t clu st er cir cu it r y for on t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s.
a bou t t h r ee secon ds a ft er t h e ign it ion swit ch is Th e P CM sen ds a la m p-on m essa ge for a bou t t h r ee
t u r n ed t o t h e On posit ion a s a bu lb t est . Aft er t h e secon ds wh en t h e ign it ion swit ch is t u r n ed t o t h e On
bu lb t est , t h e la m p is con t r olled by t h e in st r u m en t posit ion a s a bu lb t est .
clu st er cir cu it r y ba sed u pon a n en gin e oil pr essu r e F ollowin g t h e bu lb t est , t h e P CM u ses in pu t s fr om
m essa ge r eceived fr om t h e P ower t r a in Con t r ol Mod- m a n y em ission s-r ela t ed cir cu it s a n d sen sor s, a lon g
u le (P CM) on t h e Ch r ysler Collision Det ect ion (CCD) wit h it s in t er n a l pr ogr a m m in g, t o decide wh et h er a
da t a bu s. con dit ion exist s t h a t r equ ir es t h e MIL la m p t o be
Th e P CM u ses a n in pu t fr om t h e en gin e oil pr es- t u r n ed on . Th e P CM t h en sen ds t h e pr oper m essa ge
su r e sen sor a n d in t er n a l pr ogr a m m in g t o decide t o t h e in st r u m en t clu st er on t h e CCD da t a bu s t o
wh a t en gin e oil pr essu r e m essa ge is r equ ir ed. Th e t u r n t h e la m p on or off.
XJ INSTRUMENT PANEL SYSTEMS 8E - 9
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e MIL la m p ca n a lso be u sed t o displa y a st or ed la m p will t h en r em a in off u n t il t h e veh icle st ops
DTC by fla sh in g on a n d off. Refer t o Gr ou p 14 - F u el a cceler a t in g a n d is br ou gh t ba ck in t o t h e r a n ge of
Syst em s for m or e in for m a t ion on t h e P CM or t h e la m p oper a t ion , or u n t il t h e t r a n sm ission is sh ift ed
P CM in pu t s. Refer t o Gr ou p 25 - E m ission Con t r ol in t o a n ot h er gea r. Refer t o Gr ou p 14 - F u el Syst em s
Syst em s for m or e in for m a t ion on DTCs a n d t h eir for m or e in for m a t ion on t h e P CM a n d t h e P CM
r et r ieva l. in pu t s.

SEAT BELT REMINDER LAMP VOLTAGE WARNING LAMP


Th e sea t belt r em in der la m p gives a visu a l Th e volt a ge wa r n in g la m p gives a n in dica t ion
r em in der t o t h e veh icle occu pa n t s t o fa st en t h eir sea t wh en t h e elect r ica l syst em volt a ge is t oo low or t oo
belt s. Th e la m p is t u r n ed on by t h e in st r u m en t clu s- h igh . Th e la m p is t u r n ed on by t h e in st r u m en t clu s-
t er cir cu it r y for a bou t seven secon ds wh en t h e ign i- t er cir cu it r y for a bou t t h r ee secon ds a ft er t h e ign it ion
t ion swit ch is t u r n ed t o t h e On posit ion . Th e swit ch is t u r n ed t o t h e On posit ion a s a bu lb t est .
in st r u m en t clu st er a lso r eceives a h a r d-wir ed in pu t Aft er t h e bu lb t est , t h e la m p is con t r olled by t h e
fr om t h e dr iver sea t belt swit ch . If t h e dr iver sea t in st r u m en t clu st er cir cu it r y ba sed u pon a syst em
belt swit ch is closed (sea t belt is n ot bu ckled), t h e volt a ge m essa ge r eceived fr om t h e P ower t r a in Con -
in st r u m en t clu st er will gen er a t e a ch im e wa r n in g for t r ol Modu le (P CM) on t h e Ch r ysler Collision Det ec-
t h e du r a t ion of t h e sea t belt r em in der la m p illu m in a - t ion (CCD) da t a bu s.
t ion . Th e ch im e wa r n in g will st op wh en t h e dr iver Th e P CM u ses a n in pu t fr om t h e elect r ica l syst em
sea t belt swit ch is open (sea t belt is bu ckled). a n d in t er n a l pr ogr a m m in g t o decide wh a t syst em
Refer t o Gr ou p 8U - Ch im e/Bu zzer Wa r n in g Sys- volt a ge m essa ge is r equ ir ed. Th e P CM t h en sen ds
t em s for m or e in for m a t ion on t h e dr iver sea t belt t h e pr oper m essa ge t o t h e in st r u m en t clu st er on t h e
swit ch . CCD da t a bu s. If t h e P CM m essa ge in dica t es t h a t
t h e ch a r gin g syst em is t oo low or t oo h igh , t h e
TURN SIGNAL INDICATOR LAMP in st r u m en t clu st er cir cu it r y t u r n s on t h e volt a ge
Th e left a n d r igh t t u r n sign a l in dica t or la m ps give wa r n in g la m p.
a n in dica t ion wh en t h e t u r n sign a l cir cu it s a r e a ct i- Refer t o Gr ou p 14 - F u el Syst em s for m or e in for-
va t ed. Th e la m ps a r e h a r d-wir ed in t h e in st r u m en t m a t ion on t h e P CM. Refer t o Gr ou p 8C - Ch a r gin g
clu st er, a n d a r e com plet ely con t r olled by t h e t u r n sig- Syst em s for m or e in for m a t ion on ch a r gin g syst em
n a l a n d h a za r d wa r n in g (m u lt i-fu n ct ion ) swit ch es. com pon en t s a n d dia gn osis.
Th e in dica t or la m ps a r e gr ou n ded a t a ll t im es a n d
r eceive ba t t er y feed t h r ou gh t h e con t a ct s of t h e
m u lt i-fu n ct ion swit ch wh en t h e t u r n sign a l lever DI AGN OSI S AN D T EST I N G
(m u lt i-fu n ct ion swit ch st a lk) or h a za r d wa r n in g bu t -
t on a r e a ct u a t ed t o t h e On posit ion . Th e in st r u m en t INSTRUMENT CLUSTER
clu st er cir cu it r y does n ot per for m a bu lb t est of t h ese If a ll of t h e ga u ges a n d/or in dica t or la m ps a r e in op-
la m ps. Refer t o Gr ou p 8J - Tu r n Sign a l a n d H a za r d er a t ive, per for m t h e P r elim in a r y Dia gn osis. If a n
Wa r n in g Syst em s for m or e in for m a t ion . in dividu a l ga u ge or Ch r ysler Collision Det ect ion
(CCD) da t a bu s m essa ge-con t r olled in dica t or la m p is
UPSHIFT INDICATOR LAMP in oper a t ive, go dir ect ly t o t h e Act u a t or Test . If a n
Veh icles equ ipped wit h a m a n u a l t r a n sm ission in dividu a l h a r d-wir ed in dica t or la m p is in oper a t ive,
h a ve a n u psh ift in dica t or la m p. Th e u psh ift in dica t or go dir ect ly t o t h e dia gn osis for t h a t la m p. F or cir cu it
la m p gives a n in dica t ion wh en t h e dr iver sh ou ld sh ift descr ipt ion s a n d dia gr a m s, r efer t o 8W-40 - In st r u -
t o t h e n ext h igh est gea r for t h e best fu el econ om y. m en t Clu st er in Gr ou p 8W - Wir in g Dia gr a m s.
Th e la m p is con t r olled by t h e in st r u m en t clu st er cir-
WARNING: ON VEHICLES EQUIPPED WITH AIR-
cu it r y ba sed u pon a m essa ge r eceived fr om t h e P ow-
BAGS, REFER TO GROUP 8M - PASSIVE
er t r a in Con t r ol Modu le (P CM) on t h e Ch r ysler
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
Collision Det ect ion (CCD) da t a bu s.
STEERING WHEEL, STEERING COLUMN, OR
Th e P CM u ses in pu t s fr om m a n y sen sor s a n d it s
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
in t er n a l pr ogr a m m in g t o decide wh et h er t h e en gin e
SERVICE. FAILURE TO TAKE THE PROPER PRE-
speed a n d loa d con dit ion s a r e cor r ect for a t r a n sm is-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
sion u psh ift . Th e P CM t h en sen ds t h e pr oper m es-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
sa ge t o t h e in st r u m en t clu st er on t h e CCD da t a bu s
INJURY.
t o t u r n t h e la m p on or off. Th e P CM will sen d a
la m p-off m essa ge t h r ee t o five secon ds a ft er a
la m p-on m essa ge, if a n u psh ift is n ot per for m ed. Th e
8E - 10 INSTRUMENT PANEL SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
PRELI M I N ARY DI AGN OSI S Th er e sh ou ld be con t in u it y. If OK, go t o t h e Act u a t or
(1) If t h e in dica t or la m ps oper a t e, bu t n on e of t h e Test . If n ot OK, r epa ir t h e open cir cu it t o gr ou n d a s
ga u ges oper a t e, go t o St ep 2. If a ll of t h e ga u ges a n d r equ ir ed.
t h e da t a bu s m essa ge-con t r olled in dica t or la m ps a r e
in oper a t ive, go t o St ep 5. ACT U AT OR T EST
(2) Ch eck t h e Ign it ion -Off Dr a w (IOD) fu se in t h e Th e in st r u m en t clu st er a ct u a t or t est will pu t t h e
P ower Dist r ibu t ion Cen t er (P DC). If OK, go t o St ep clu st er in t o it s self-dia gn ost ic m ode. In t h is m ode t h e
3. If n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t clu st er will posit ion ea ch of t h e ga u ge n eedles a t va r-
a s r equ ir ed a n d r epla ce t h e fa u lt y fu se. iou s specified ca libr a t ion poin t s, a n d t u r n a ll of t h e
(3) Ch eck for ba t t er y volt a ge a t t h e IOD fu se in CCD da t a bu s m essa ge-con t r olled la m ps on a n d off a t
t h e P DC. If OK, go t o St ep 4. If n ot OK, r epa ir t h e specified t im e in t er va ls (F ig. 1) or (F ig. 2).
open cir cu it a s r equ ir ed. Su ccessfu l com plet ion of t h e a ct u a t or t est will con -
(4) Discon n ect a n d isola t e t h e ba t t er y n ega t ive fir m t h a t t h e clu st er cir cu it r y, ga u ges, a n d la m ps a r e
ca ble. Rem ove t h e in st r u m en t clu st er a s descr ibed in ca pa ble of oper a t in g a s design ed. H owever, t h er e m a y
t h is gr ou p. Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck st ill be a pr oblem wit h t h e CCD da t a bu s, t h e P ow-
for ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of er t r a in Con t r ol Modu le (P CM), t h e Air ba g Con t r ol
t h e left in st r u m en t clu st er wir e h a r n ess con n ect or Modu le (ACM), or t h e in pu t s t o on e of t h ese m odu les.
(con n ect or A). If OK, go t o t h e Act u a t or Test . If n ot Use a DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r o-
OK, r epa ir t h e open cir cu it t o t h e IOD fu se a s cedu r es m a n u a l for t est in g of t h ese com pon en t s.
r equ ir ed. If a n in dividu a l ga u ge does n ot r espon d pr oper ly or
(5) Ch eck t h e swit ch ed ign it ion fu se in t h e ju n c- a t a ll du r in g t h e Act u a t or Test , t h e in st r u m en t clu s-
t ion block. If OK, go t o St ep 6. If n ot OK, r epa ir t h e t er sh ou ld be r em oved. H owever, ch eck t h e ga u ge
sh or t ed cir cu it or com pon en t a s r equ ir ed a n d r epla ce m ou n t in g scr ews on t h e pr in t ed cir cu it boa r d for
t h e fa u lt y fu se. pr oper t igh t n ess befor e con sider in g in st r u m en t clu s-
(6) Tu r n t h e ign it ion swit ch t o t h e On posit ion a n d t er r epla cem en t . If t h e m ou n t in g scr ews ch eck OK,
ch eck for ba t t er y volt a ge a t t h e swit ch ed ign it ion r epla ce t h e fa u lt y clu st er.
fu se in t h e ju n ct ion block. If OK, go t o St ep 7. If n ot If a n in dividu a l in dica t or la m p does n ot illu m in a t e
OK, r epa ir t h e open cir cu it t o t h e ign it ion swit ch a s du r in g t h e Act u a t or Test , t h e in st r u m en t clu st er
r equ ir ed. sh ou ld be r em oved. H owever, ch eck t h a t t h e in ca n -
(7) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . descen t la m p bu lb is n ot fa u lt y a n d t h a t t h e bu lb
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. h older is pr oper ly in st a lled on t h e cir cu it boa r d
Rein st a ll t h e in st r u m en t clu st er. Con n ect t h e ba t t er y befor e con sider in g in st r u m en t clu st er r epla cem en t . If
n ega t ive ca ble. Tu r n t h e ign it ion swit ch t o t h e On t h e bu lb a n d bu lb h older ch eck OK, r epla ce t h e
posit ion . Set t h e pa r kin g br a ke. Th e br a ke wa r n in g fa u lt y in st r u m en t clu st er.
la m p sh ou ld ligh t . If OK, go t o St ep 8. If n ot OK, go (1) Begin t h e t est wit h t h e ign it ion swit ch in t h e
t o St ep 9. Off posit ion .
(8) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . (2) Depr ess t h e t r ip odom et er r eset bu t t on .
Tu r n on t h e pa r k la m ps a n d a dju st t h e pa n el la m ps (3) Wh ile h oldin g t h e t r ip odom et er r eset bu t t on
dim m er r h eost a t t o t h e fu ll br igh t posit ion . Th e clu s- depr essed, t u r n t h e ign it ion swit ch t o t h e On posi-
t er illu m in a t ion la m ps sh ou ld ligh t . If OK, go t o t h e t ion , bu t do n ot st a r t t h e en gin e.
Act u a t or Test . If n ot OK, go t o St ep 10. (4) Relea se t h e t r ip odom et er r eset bu t t on .
(9) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . (5) Com pa r e t h e oper a t ion of t h e su spect ga u ge(s)
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. a n d/or la m p(s) wit h t h e ch a r t (F ig. 1) or (F ig. 2).
Rem ove t h e in st r u m en t clu st er a s descr ibed in t h is (6) Th e clu st er will exit t h e self-dia gn ost ic m ode a t
gr ou p. 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 e com plet ion of t h e t est , or if t h e ign it ion swit ch is
ign it ion swit ch t o t h e On posit ion . Ch eck for ba t t er y t u r n ed t o t h e Off posit ion .
volt a ge a t t h e fu sed ign it ion swit ch ou t pu t (r u n /st a r t ) (7) Go ba ck t o St ep 1 t o r epea t t h e t est , if
cir cu it ca vit y of t h e left in st r u m en t clu st er wir e h a r- r equ ir ed.
n ess con n ect or (con n ect or A). If OK, go t o t h e Act u a -
t or Test . If n ot OK, r epa ir t h e open cir cu it t o t h e COOLANT TEMPERATURE GAUGE
ju n ct ion block a s r equ ir ed. If t h e pr oblem bein g dia gn osed is r ela t ed t o coola n t
(10) Discon n ect a n d isola t e t h e ba t t er y n ega t ive t em per a t u r e ga u ge a ccu r a cy, be cer t a in t o con fir m
ca ble. Rem ove t h e in st r u m en t clu st er a s descr ibed in t h a t t h e pr oblem is wit h t h e ga u ge a n d n ot wit h cool-
t h is gr ou p. Ch eck for con t in u it y bet ween t h e gr ou n d in g syst em per for m a n ce. Th e a ct u a l en gin e coola n t
cir cu it ca vit y of t h e left in st r u m en t clu st er wir e h a r- t em per a t u r e sh ou ld be ch ecked wit h a t est ga u ge or
n ess con n ect or (con n ect or A) a n d a good gr ou n d. t h er m om et er a n d com pa r ed t o t h e in st r u m en t clu st er
coola n t t em per a t u r e ga u ge r ea din gs befor e you pr o-
XJ INSTRUMENT PANEL SYSTEMS 8E - 11
DI AGN OSI S AN D T EST I N G (Cont inue d)

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

I 0 40 I 80 I 120 I 210 I 120 I 80 40 0 0


(KILOMETERS PER HOUR) 1KM/H 1 KM/H 1 KM/H 1 KM/H I KM/H 1 KM/H 1 KM/H 1 KM/H 1 KM/H 1 KM/H
I I
I I I
E E 1/2 1/2 F F 1/2 1/2 E E
FUEL I I
I
I I I I I I I I I I
10000001 111111 I 222222 I 333333 I 444444 I 555555 1666666 I 777777 1 888888 I 999999 I
ODOMETER I
I

START DIAGNOSTICS COMPLETE DIAGNOSTICS

NOTE: 1.5 SECONDS AFTER COMPLETING TEST, ALL POINTERS SHOULD RETURN TO POINTER STOP
AND ODOMETER SHOULD BE TURNED OFF.

80aac2c2

Fig. 1 Low-Line Instrument Cluster Actuator Test


8E - 12 INSTRUMENT PANEL SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

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

0 2000 5000 6000 5000 2000 0 0 0 0


TACHOMETER RPM RPM RPM RPM RPM RPM RPM RPM RPM RPM

FUEL E E 1/2 1/2 I F F 1/2 1/2 I E E

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

VOLT 9V I 9V 14V I 14V I 19V I 19V 1 14V I 14V I 9V 9V 1

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

START DIAGNOSTICS COMPLETE DIAGNOSTICS

NOTE: 1.5 SECONDS AFTER COMPLETING TEST, ALL POINTERS SHOULD RETURN TO POINTER STOP
AND ODOMETER SHOULD BE TURNED OFF.

80aac2c3

Fig. 2 High-Line Instrument Cluster Actuator Test


XJ INSTRUMENT PANEL SYSTEMS 8E - 13
DI AGN OSI S AN D T EST I N G (Cont inue d)
ceed wit h ga u ge dia gn osis. Refer t o Gr ou p 7 - Coolin g wit h a n in cor r ect speedom et er pin ion gea r, a xle r a t io,
Syst em for m or e in for m a t ion . Refer t o Gr ou p 8W - or t ir e size. Refer t o Gr ou p 21 - Tr a n sm ission for
Wir in g Dia gr a m s for cir cu it descr ipt ion s a n d dia - m or e in for m a t ion on t h e speedom et er pin ion gea r.
gr a m s. Refer t o Gr ou p 8W - Wir in g Dia gr a m s for cir cu it
descr ipt ion s a n d dia gr a m s.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE WARNING: ON VEHICLES EQUIPPED WITH AIR-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY BAGS, REFER TO GROUP 8M - PASSIVE
STEERING WHEEL, STEERING COLUMN, OR RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR STEERING WHEEL, STEERING COLUMN, OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- SERVICE. FAILURE TO TAKE THE PROPER PRE-
BAG DEPLOYMENT AND POSSIBLE PERSONAL CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
INJURY. BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Dia gn osis of t h e coola n t t em per a t u r e sen sor a n d
cir cu it , t h e Ch r ysler Collision Det ect ion (CCD) da t a Dia gn osis of t h e veh icle speed sen sor a n d cir cu it ,
bu s, a n d/or t h e P ower t r a in Con t r ol Modu le (P CM) t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s,
sh ou ld be per for m ed wit h a DRB sca n t ool a s a n d/or t h e P ower t r a in Con t r ol Modu le (P CM) sh ou ld
descr ibed in t h e pr oper Dia gn ost ic P r ocedu r es m a n - be per for m ed wit h a DRB sca n t ool a s descr ibed in
u a l. F or dia gn osis of t h e coola n t t em per a t u r e ga u ge t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l. F or dia g-
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 n osis of t h e odom et er a n d/or t r ip odom et er a n d t h e
Clu st er in t h is gr ou p. in st r u m en t clu st er cir cu it r y, see In st r u m en t Clu st er
in t h is gr ou p.
FUEL GAUGE
If t h e pr oblem bein g dia gn osed is r ela t ed t o fu el OIL PRESSURE GAUGE
ga u ge a ccu r a cy, be cer t a in t o con fir m t h a t t h e pr ob- If t h e pr oblem bein g dia gn osed is r ela t ed t o oil
lem is wit h t h e ga u ge or sen din g u n it a n d n ot wit h pr essu r e ga u ge a ccu r a cy, be cer t a in t o con fir m t h a t
t h e fu el t a n k. In spect t h e fu el t a n k for sign s of da m - t h e pr oblem is wit h t h e ga u ge a n d n ot wit h t h e
a ge or dist or t ion t h a t cou ld a ffect t h e sen din g u n it en gin e oilin g syst em per for m a n ce. Th e a ct u a l en gin e
per for m a n ce befor e you pr oceed wit h fu el ga u ge dia g- oil pr essu r e sh ou ld be ch ecked wit h a t est ga u ge a n d
n osis. Refer t o Gr ou p 8W - Wir in g Dia gr a m s for cir- com pa r ed t o t h e in st r u m en t clu st er oil pr essu r e
cu it descr ipt ion s a n d dia gr a m s. ga u ge r ea din gs befor e you pr oceed wit h ga u ge dia g-
n osis. Refer t o Gr ou p 9 - E n gin es for m or e in for m a -
WARNING: ON VEHICLES EQUIPPED WITH AIR- t ion . Refer t o Gr ou p 8W - Wir in g Dia gr a m s for cir cu it
BAGS, REFER TO GROUP 8M - PASSIVE descr ipt ion s a n d dia gr a m s.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR WARNING: ON VEHICLES EQUIPPED WITH AIR-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR BAGS, REFER TO GROUP 8M - PASSIVE
SERVICE. FAILURE TO TAKE THE PROPER PRE- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- STEERING WHEEL, STEERING COLUMN, OR
BAG DEPLOYMENT AND POSSIBLE PERSONAL INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
INJURY. SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
Dia gn osis of t h e fu el ga u ge sen din g u n it a n d cir- BAG DEPLOYMENT AND POSSIBLE PERSONAL
cu it , t h e Ch r ysler Collision Det ect ion (CCD) da t a INJURY.
bu s, a n d/or t h e P ower t r a in Con t r ol Modu le (P CM)
sh ou ld be per for m ed wit h a DRB sca n t ool a s Dia gn osis of t h e oil pr essu r e sen sor a n d cir cu it , t h e
descr ibed in t h e pr oper Dia gn ost ic P r ocedu r es m a n - Ch r ysler Collision Det ect ion (CCD) da t a bu s, a n d/or
u a l. F or dia gn osis of t h e fu el ga u ge a n d t h e in st r u - t h e P ower t r a in Con t r ol Modu le (P CM) sh ou ld be per-
m en t clu st er cir cu it r y, see In st r u m en t Clu st er in t h is for m ed wit h a DRB sca n t ool a s descr ibed in t h e
gr ou p. pr oper Dia gn ost ic P r ocedu r es m a n u a l. F or dia gn osis
of t h e oil pr essu r e ga u ge a n d t h e in st r u m en t clu st er
ODOMETER AND TRIP ODOMETER cir cu it r y, see In st r u m en t Clu st er in t h is gr ou p.
If t h e pr oblem bein g dia gn osed is r ela t ed t o odom -
et er a n d/or t r ip odom et er a ccu r a cy, be cer t a in t o con -
fir m t h a t t h e pr oblem is wit h t h e displa y a n d n ot
8E - 14 INSTRUMENT PANEL SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
SPEEDOMETER Gr ou p 8W - Wir in g Dia gr a m s for cir cu it descr ipt ion s
If t h e pr oblem bein g dia gn osed is r ela t ed t o speed- a n d dia gr a m s.
om et er a ccu r a cy, be cer t a in t o con fir m t h a t t h e pr ob-
lem is wit h t h e speedom et er ga u ge a n d n ot wit h a n WARNING: ON VEHICLES EQUIPPED WITH AIR-
in cor r ect speedom et er pin ion gea r, a xle r a t io, or t ir e BAGS, REFER TO GROUP 8M - PASSIVE
size. Refer t o Gr ou p 21 - Tr a n sm ission for m or e in for- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
m a t ion on t h e speedom et er pin ion gea r. Refer t o STEERING WHEEL, STEERING COLUMN, OR
Gr ou p 8W - Wir in g Dia gr a m s for cir cu it descr ipt ion s INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
a n d dia gr a m s. SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL
BAGS, REFER TO GROUP 8M - PASSIVE INJURY.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR Dia gn osis of t h e syst em volt a ge in pu t cir cu it , t h e
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR Ch r ysler Collision Det ect ion (CCD) da t a bu s, a n d/or
SERVICE. FAILURE TO TAKE THE PROPER PRE- t h e P ower t r a in Con t r ol Modu le (P CM) sh ou ld be per-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- for m ed wit h a DRB sca n t ool a s descr ibed in t h e
BAG DEPLOYMENT AND POSSIBLE PERSONAL pr oper Dia gn ost ic P r ocedu r es m a n u a l. F or dia gn osis
INJURY. of t h e volt m et er 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 Clu st er in t h is gr ou p.
Dia gn osis of t h e veh icle speed sen sor a n d cir cu it ,
t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s, AIRBAG INDICATOR LAMP
a n d/or t h e P ower t r a in Con t r ol Modu le (P CM) sh ou ld Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
be per for m ed wit h a DRB sca n t ool a s descr ibed in a ir ba g in dica t or la m p con dit ion . If t h e a ir ba g in dica -
t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l. F or dia g- t or la m p st a ys on wit h t h e ign it ion swit ch in t h e On
n osis of t h e speedom et er a n d t h e in st r u m en t clu st er posit ion , or com es on a n d st a ys on wh ile dr ivin g,
cir cu it r y, see In st r u m en t Clu st er in t h is gr ou p. r efer t o Gr ou p 8M - P a ssive Rest r a in t Syst em s for
dia gn osis. F or cir cu it descr ipt ion s a n d dia gr a m s,
TACHOMETER r efer t o 8W-40 - In st r u m en t Clu st er, a n d 8W-43 - Air-
ba g Syst em in Gr ou p 8W - Wir in g Dia gr a m s.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE WARNING: ON VEHICLES EQUIPPED WITH AIR-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY BAGS, REFER TO GROUP 8M - PASSIVE
STEERING WHEEL, STEERING COLUMN, OR RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR STEERING WHEEL, STEERING COLUMN, OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- SERVICE. FAILURE TO TAKE THE PROPER PRE-
BAG DEPLOYMENT AND POSSIBLE PERSONAL CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
INJURY. BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Refer t o Gr ou p 8W - Wir in g Dia gr a m s for cir cu it
descr ipt ion s a n d dia gr a m s. Dia gn osis of t h e cr a n k- If t h e a ir ba g in dica t or la m p fa ils t o ligh t wh en t h e
sh a ft posit ion sen sor a n d cir cu it , t h e Ch r ysler Colli- ign it ion swit ch is t u r n ed t o t h e On posit ion , r epla ce
sion Det ect ion (CCD) da t a bu s, a n d/or t h e P ower t r a in t h e a ir ba g in dica t or la m p bu lb wit h a kn own good
Con t r ol Modu le (P CM) sh ou ld be per for m ed wit h a u n it . If t h e a ir ba g in dica t or la m p st ill fa ils t o oper-
DRB sca n t ool a s descr ibed in t h e pr oper Dia gn ost ic a t e, dia gn osis of t h e a ir ba g la m p a n d t h e in st r u m en t
P r ocedu r es m a n u a l. F or dia gn osis of t h e t a ch om et er clu st er cir cu it r y sh ou ld be per for m ed a s descr ibed in
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 In st r u m en t Clu st er in t h is gr ou p. If t h e a ir ba g la m p
Clu st er in t h is gr ou p. a n d in st r u m en t clu st er cir cu it r y a r e OK, dia gn osis of
t h e a ir ba g syst em a n d t h e CCD da t a bu s sh ou ld be
VOLTMETER per for m ed wit h a DRB sca n t ool a s descr ibed in t h e
If t h e pr oblem bein g dia gn osed is r ela t ed t o volt - pr oper Dia gn ost ic P r ocedu r es m a n u a l.
m et er ga u ge a ccu r a cy, be cer t a in t o con fir m pr oper
ch a r gin g syst em oper a t ion befor e con sider in g in st r u - ANTI-LOCK BRAKE SYSTEM LAMP
m en t clu st er r epla cem en t . Refer t o Gr ou p 8C - Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
Ch a r gin g Syst em for m or e in for m a t ion . Refer t o An t i-lock Br a ke Syst em (ABS) la m p con dit ion . If t h e
ABS la m p st a ys on wit h t h e ign it ion swit ch in t h e
XJ INSTRUMENT PANEL SYSTEMS 8E - 15
DI AGN OSI S AN D T EST I N G (Cont inue d)
On posit ion , or com es on a n d st a ys on wh ile dr ivin g, posit ion a n d t h e pa r kin g br a ke r elea sed, or com es on
r efer t o Gr ou p 5 - Br a kes for dia gn osis. If n o ABS wh ile dr ivin g, r efer t o Gr ou p 5 - Br a kes for dia gn osis.
pr oblem is fou n d, t h e followin g pr ocedu r e will h elp If n o ser vice br a ke or pa r kin g br a ke pr oblem is
loca t e a sh or t or open in t h e ABS la m p cir cu it . F or fou n d, t h e followin g pr ocedu r e will h elp loca t e a
cir cu it descr ipt ion s a n d dia gr a m s, r efer t o 8W-40 - sh or t or open cir cu it , or a fa u lt y swit ch . Refer t o
In st r u m en t Clu st er, a n d 8W-35 - All-Wh eel An t i-Lock 8W-40 - In st r u m en t Clu st er, a n d 8W-35 - All-Wh eel
Br a kes in Gr ou p 8W - Wir in g Dia gr a m s. An t i-Lock Br a kes in Gr ou p 8W - Wir in g Dia gr a m s for
cir cu it descr ipt ion s a n d dia gr a m s.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE WARNING: ON VEHICLES EQUIPPED WITH AIR-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY BAGS, REFER TO GROUP 8M - PASSIVE
STEERING WHEEL, STEERING COLUMN, OR RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR STEERING WHEEL, STEERING COLUMN, OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- SERVICE. FAILURE TO TAKE THE PROPER PRE-
BAG DEPLOYMENT AND POSSIBLE PERSONAL CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
INJURY. BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go
t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or (1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go
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 o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or
(2) Tu r n t h e ign it ion swit ch in t h e On posit ion . 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.
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 (2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
block. If OK, go t o St ep 3. If n ot OK, r epa ir t h e open 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
cir cu it t o t h e ign it ion swit ch a s r equ ir ed. block. If OK, go t o St ep 3. If n ot OK, r epa ir t h e open
(3) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . cir cu it t o t h e ign it ion swit ch a s r equ ir ed.
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. (3) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Rem ove t h e in st r u m en t clu st er a s descr ibed in t h is Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
gr ou p. Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e Un plu g t h e wir e h a r n ess con n ect or a t t h e pa r k br a ke
ign it ion swit ch t o t h e On posit ion a n d wit h in five swit ch . Wit h t h e pa r k br a ke r elea sed, ch eck for con -
secon ds ch eck for con t in u it y bet ween t h e ABS wa r n - t in u it y bet ween t h e pa r k br a ke swit ch t er m in a l a n d
in g la m p dr iver cir cu it ca vit y of t h e left in st r u m en t a good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK,
clu st er wir e h a r n ess con n ect or (con n ect or A) a n d a go t o St ep 4. If n ot OK, a dju st or r epla ce t h e fa u lt y
good gr ou n d. Th er e sh ou ld be con t in u it y for five sec- pa r k br a ke swit ch .
on ds a ft er ign it ion On , a n d t h en a n open cir cu it . If (4) Un plu g t h e wir e h a r n ess con n ect or a t t h e
OK, r epla ce t h e fa u lt y bu lb. If n ot OK, go t o St ep 4. br a ke wa r n in g swit ch . Ch eck for con t in u it y bet ween
(4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . t h e t wo t er m in a ls of t h e br a ke wa r n in g swit ch . Th er e
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. sh ou ld be con t in u it y. If OK, go t o St ep 5. If n ot OK,
Discon n ect t h e Con t r oller An t i-lock Br a ke (CAB) wir e r epla ce t h e fa u lt y br a ke wa r n in g swit ch .
h a r n ess con n ect or. Ch eck for con t in u it y bet ween t h e (5) Ch eck for con t in u it y bet ween ea ch of t h e t wo
ABS wa r n in g la m p dr iver cir cu it ca vit y of t h e left br a ke wa r n in g swit ch t er m in a ls a n d a good gr ou n d.
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 In ea ch ca se, t h er e sh ou ld be n o con t in u it y. If OK, go
A) a n d a good gr ou n d. Th er e sh ou ld be n o con t in u it y. t o St ep 6. If n ot OK, r epla ce t h e fa u lt y br a ke wa r n -
If OK, go t o St ep 5. If n ot OK, r epa ir t h e sh or t cir cu it in g swit ch .
a s r equ ir ed. (6) Wit h bot h t h e pa r k br a ke swit ch a n d t h e br a ke
(5) Ch eck for con t in u it y bet ween t h e ABS wa r n in g wa r n in g swit ch wir e h a r n ess con n ect or s st ill
la m p dr iver cir cu it ca vit ies of t h e left in st r u m en t u n plu gged, ch eck for con t in u it y bet ween t h e pa r k
clu st er wir e h a r n ess con n ect or (con n ect or A) a n d t h e br a ke swit ch wir e h a r n ess con n ect or ca vit y a n d a
CAB wir e h a r n ess con n ect or. Th er e sh ou ld be con t i- good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go
n u it y. If OK, r efer t o Gr ou p 5 - Br a kes for dia gn osis t o St ep 7. If n ot OK, r epa ir t h e sh or t cir cu it a s
of t h e CAB. If n ot OK, r epa ir t h e open cir cu it a s r equ ir ed.
r equ ir ed. (7) Wit h t h e ign it ion swit ch h eld in t h e St a r t posi-
t ion , ch eck for con t in u it y bet ween t h e pa r k br a ke
BRAKE WARNING LAMP swit ch wir e h a r n ess con n ect or ca vit y a n d a good
Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o St ep
br a ke wa r n in g la m p con dit ion . If t h e br a ke wa r n in g 8. If n ot OK, r efer t o Gr ou p 8D - Ign it ion Syst em s for
la m p st a ys on wit h t h e ign it ion swit ch in t h e On dia gn osis of t h e ign it ion swit ch .
8E - 16 INSTRUMENT PANEL SYSTEMS XJ
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 . SERVICE. FAILURE TO TAKE THE PROPER PRE-
Rem ove t h e in st r u m en t clu st er a s descr ibed in t h is CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
gr ou p. Ch eck for con t in u it y bet ween t h e r ed br a ke BAG DEPLOYMENT AND POSSIBLE PERSONAL
wa r n in g la m p dr iver cir cu it ca vit y of t h e left in st r u - INJURY.
m en t clu st er wir e h a r n ess con n ect or (con n ect or A)
a n d a good gr ou n d. Th er e sh ou ld be n o con t in u it y. If
OK, go t o St ep 9. If n ot OK, r epa ir t h e sh or t cir cu it ACCESSORY POWER OU T LET
a s r equ ir ed. (1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go
(9) Ch eck for con t in u it y bet ween t h e r ed br a ke t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or
wa r n in g la m p dr iver (G99) cir cu it ca vit ies of t h e left 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.
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 (2) Ch eck for ba t t er y volt a ge a t t h e fu se in t h e
A) a n d t h e br a ke wa r n in g swit ch wir e h a r n ess con - ju n ct ion block. If OK, go t o St ep 3. If n ot OK, r epa ir
n ect or. Th er e sh ou ld be con t in u it y. If OK, r epla ce t h e t h e open cir cu it t o t h e P ower Dist r ibu t ion Cen t er
fa u lt y bu lb. If n ot OK, r epa ir t h e open cir cu it a s (P DC) a s r equ ir ed.
r equ ir ed. (3) 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 a ccessor y swit ch bezel a s
CHECK GAUGES LAMP descr ibed in t h is gr ou p. Ch eck for con t in u it y bet ween
Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive t h e gr ou n d cir cu it ca vit y of t h e a ccessor y power ou t -
ch eck ga u ges la m p con dit ion . If t h e ch eck ga u ges let wir e h a r n ess con n ect or a n d a good gr ou n d. Th er e
la m p st a ys on wit h t h e ign it ion swit ch in t h e On sh ou ld be con t in u it y. If OK, go t o St ep 4. If n ot OK,
posit ion , or com es on wh ile dr ivin g wit h n o u n u su a l r epa ir t h e open cir cu it t o gr ou n d a s r equ ir ed.
ga u ge r ea din gs eviden t , dia gn osis of t h e P ower t r a in (4) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
Con t r ol Modu le (P CM) a n d t h e Ch r ysler Collision ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
Det ect ion (CCD) da t a bu s sh ou ld be per for m ed wit h a ccessor y power ou t let wir e h a r n ess con n ect or. If OK,
a DRB sca n t ool a s descr ibed in t h e pr oper Dia gn os- r epla ce t h e fa u lt y a ccessor y swit ch bezel. If n ot OK,
t ic P r ocedu r es m a n u a l. F or cir cu it descr ipt ion s a n d r epa ir t h e open cir cu it t o t h e ju n ct ion block fu se a s
dia gr a m s, r efer t o 8W-40 - In st r u m en t Clu st er in r equ ir ed.
Gr ou p 8W - Wir in g Dia gr a m s.
CI GAR LI GH T ER
WARNING: ON VEHICLES EQUIPPED WITH AIR- (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
BAGS, REFER TO GROUP 8M - PASSIVE ca ble. Rem ove t h e a ccessor y swit ch bezel a s
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY descr ibed in t h is gr ou p. Ch eck for con t in u it y bet ween
STEERING WHEEL, STEERING COLUMN, OR t h e gr ou n d cir cu it ca vit y of t h e ciga r ligh t er wir e
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR h a r n ess con n ect or a n d a good gr ou n d. Th er e sh ou ld
SERVICE. FAILURE TO TAKE THE PROPER PRE- be con t in u it y. If OK, go t o St ep 2. If n ot OK, r epa ir
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- t h e open cir cu it t o gr ou n d a s r equ ir ed.
BAG DEPLOYMENT AND POSSIBLE PERSONAL (2) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
INJURY. ign it ion swit ch t o t h e Accessor y or On posit ion s.
Ch eck for ba t t er y volt a ge a t t h e ciga r ligh t er r ela y
If t h e ch eck ga u ges la m p fa ils t o ligh t du r in g t h e ou t pu t cir cu it ca vit y of t h e ciga r ligh t er wir e h a r n ess
bu lb t est (a bou t t h r ee secon ds a ft er t h e ign it ion con n ect or. If OK, r epla ce t h e fa u lt y a ccessor y swit ch
swit ch is t u r n ed t o t h e On posit ion ), r epla ce t h e bezel. If n ot OK, see t h e dia gn osis for t h e ciga r
ch eck ga u ges la m p bu lb wit h a kn own good u n it . If ligh t er r ela y in t h is gr ou p.
t h e coola n t t em per a t u r e ga u ge, oil pr essu r e ga u ge, or
volt m et er a r e givin g a n in dica t ion t h a t sh ou ld t r igger CIGAR LIGHTER RELAY
t h e ch eck ga u ges la m p, bu t t h e ch eck ga u ges la m p F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
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 8W-41 - H or n s/Ciga r Ligh t er in Gr ou p 8W - Wir in g
gr ou p for dia gn osis of t h e ch eck ga u ges la m p a n d t h e Dia gr a m s.
in st r u m en t clu st er cir cu it r y.

CIGAR LIGHTER AND POWER OUTLET


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
XJ INSTRUMENT PANEL SYSTEMS 8E - 17
DI AGN OSI S AN D T EST I N G (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) Th e r ela y n or m a lly open t er m in a l (87) is con -
BAGS, REFER TO GROUP 8M - PASSIVE 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-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY gized posit ion . Th is t er m in a l su pplies ba t t er y volt a ge
STEERING WHEEL, STEERING COLUMN, OR t o t h e ciga r ligh t er. Th er e sh ou ld be con t in u it y
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR bet ween t h e ca vit y for r ela y t er m in a l 87 a n d t h e
SERVICE. FAILURE TO TAKE THE PROPER PRE- ciga r ligh t er r ela y ou t pu t cir cu it ca vit y of t h e ciga r
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- ligh t er wir e h a r n ess con n ect or a t a ll t im es. If OK, go
BAG DEPLOYMENT AND POSSIBLE PERSONAL t o St ep 4. If n ot OK, r epa ir t h e open cir cu it t o t h e
INJURY. ciga r ligh t er a s r equ ir ed.
(4) Th e coil ba t t er y t er m in a l (86) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. It is con n ect ed t o
RELAY T EST fu sed ign it ion swit ch ou t pu t a n d sh ou ld be h ot wh en
Th e ciga r ligh t er r ela y is loca t ed in t h e ju n ct ion t h e ign it ion swit ch is in t h e On or Accessor y posi-
block. Th e ju n ct ion block is a t t a ch ed t o t h e r igh t cowl t ion s. Ch eck for ba t t er y volt a ge a t t h e ca vit y for
side in n er pa n el, below t h e in st r u m en t pa n el a n d r ela y t er m in a l 86 wit h t h e ign it ion swit ch in t h e On
beh in d t h e r igh t cowl side t r im pa n el. or Accessor y posit ion s. If OK, go t o St ep 5. If n ot OK,
Rem ove t h e ciga r ligh t er r ela y fr om t h e ju n ct ion r epa ir t h e open cir cu it t o t h e ign it ion swit ch a s
block a s descr ibed in t h is gr ou p t o per for m t h e fol- r equ ir ed.
lowin g t est s: (5) Th e coil gr ou n d t er m in a l (85) is con n ect ed t o
(1) A r ela y in t h e de-en er gized posit ion sh ou ld t h e elect r om a gn et in t h e r ela y. It is gr ou n ded a t a ll
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 t im es. Ch eck for con t in u it y t o gr ou n d a t t h e ca vit y
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go for r ela y t er m in a l 85. Th er e sh ou ld be con t in u it y. If
t o St ep 2. If n ot OK, r epla ce t h e fa u lt y r ela y. n ot OK, r epa ir t h e open cir cu it t o gr ou n d a s
(2) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec- r equ ir ed.
t r om a gn et ) sh ou ld be 75 6 5 oh m s. If OK, go t o St ep
3. If n ot OK, r epla ce t h e fa u lt y r ela y. CLUSTER ILLUMINATION LAMP
(3) Con n ect a ba t t er y t o t er m inRELAY
a ls CAVITIES
RELAY TERMINALS
85 a n d 86. Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls in st r u m en t clu st er illu m in a t ion la m p con dit ion . If
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 t h e pr oblem bein g dia gn osed in clu des in oper a t ive
a n d 30. If OK, see t h e Rela y Cir cu it Test in t h is ext er ior ligh t in g con t r olled by t h e h ea dla m p swit ch ,
gr ou p. If n ot OK, r epla ce t h e fa u lt y r ela y. t h a t syst em n eeds t o be r epa ir ed fir st . If t h e ext er ior
RELAY TERMINALS RELAY CAVITIES la m ps con t r olled by t h e h ea dla m p swit ch a r e in oper-
a t ive, r efer t o Gr ou p 8L - La m ps for dia gn osis. If n o
ext er ior ligh t in g syst em pr oblem s a r e fou n d, t h e fol-
lowin g pr ocedu r e will h elp loca t e a sh or t or open in
t h e clu st er illu m in a t ion la m p cir cu it . 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.

WARNING: ON VEHICLES EQUIPPED WITH AIR-


85 J958A-2
BAGS, REFER TO GROUP 8M - PASSIVE
87
TERMINAL LEGEND
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
NUMBER IDENTIFICATION STEERING WHEEL, STEERING COLUMN, OR
30 COMMON FEED
85 COIL GROUND INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
86 COIL BAillRY SERVICE. FAILURE TO TAKE THE PROPER PRE-
87 NORMALLY OPEN
t---
8 7-A---+-- N~ORMALLY CLOSED CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
Cigar Lighter Relay INJURY.
RELAY CI RCU I T T EST (1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go
(1) Th e r ela y com m on feed t er m in a l ca vit y (30) is t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or
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 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 im es. If OK, go t o St ep 2. If n ot OK, r epa ir t h e open (2) Tu r n t h e pa r k la m ps on wit h t h e h ea dla m p
cir cu it t o t h e fu se in t h e ju n ct ion block a s r equ ir ed. swit ch . Rot a t e t h e h ea dla m p swit ch kn ob cou n t er-
(2) Th e r ela y n or m a lly closed t er m in a l (87A) is clockwise t o ju st befor e t h e in t er ior la m ps det en t .
con n ect ed t o t er m in a l 30 in t h e de-en er gized posit ion , 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
bu t is n ot u sed for t h is a pplica t ion . Go t o St ep 3. block. Rot a t e t h e h ea dla m p swit ch kn ob clockwise
8E - 18 INSTRUMENT PANEL SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
wh ile obser vin g t h e t est volt m et er. Th e r ea din g wit h a DRB sca n t ool a s descr ibed in t h e pr oper
sh ou ld go fr om ba t t er y volt a ge t o zer o volt s. If OK, Dia gn ost ic P r ocedu r es m a n u a l. F or dia gn osis of t h e
go t o St ep 3. If n ot OK, r epa ir t h e open cir cu it t o t h e coola n t t em per a t u r e wa r n in g la m p a n d t h e in st r u -
h ea dla m p swit ch or r efer t o Gr ou p 8L - La m ps t o m en t clu st er cir cu it r y, see In st r u m en t Clu st er in t h is
dia gn ose t h e h ea dla m p swit ch . gr ou p.
(3) 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 CRUISE-ON INDICATOR LAMP
t h is gr ou p. Tu r n t h e h ea dla m p swit ch off. Rem ove Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
t h e fu se fr om t h e ju n ct ion block. P r obe t h e fu sed cr u ise-on in dica t or la m p con dit ion . If t h e pr oblem
pa n el la m p dim m er swit ch sign a l cir cu it ca vit y of t h e bein g dia gn osed is a n in a ccu r a t e cr u ise-on in dica t or
left in st r u m en t clu st er wir e h a r n ess con n ect or (con - la m p, r efer t o Gr ou p 8H - Veh icle Speed Con t r ol for
n ect or A). Ch eck for con t in u it y t o a good gr ou n d. dia gn osis of t h e veh icle speed con t r ol syst em . F or cir-
Th er e sh ou ld be n o con t in u it y. If OK, go t o St ep 4. If cu it descr ipt ion s a n d dia gr a m s, r efer t o 8W-33 - Veh i-
n ot OK, r epa ir t h e sh or t cir cu it a s r equ ir ed. cle Speed Con t r ol a n d 8W-40 - In st r u m en t Clu st er in
(4) Rein st a ll t h e fu se in t h e ju n ct ion block. Con - Gr ou p 8W - Wir in g Dia gr a m s.
n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e pa r k la m ps
on wit h t h e h ea dla m p swit ch . Rot a t e t h e h ea dla m p WARNING: ON VEHICLES EQUIPPED WITH AIR-
swit ch kn ob cou n t er clockwise t o ju st befor e t h e in t e- BAGS, REFER TO GROUP 8M - PASSIVE
r ior la m ps det en t . Ch eck for ba t t er y volt a ge a t t h e RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
fu sed pa n el la m p dim m er swit ch sign a l cir cu it ca vit y STEERING WHEEL, STEERING COLUMN, OR
of t h e left in st r u m en t clu st er wir e h a r n ess con n ect or INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
(con n ect or A). If OK, r epla ce t h e fa u lt y bu lb(s) a n d SERVICE. FAILURE TO TAKE THE PROPER PRE-
bu lb h older (s). If n ot OK, r epa ir t h e open cir cu it a s CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
r equ ir ed. BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
COOLANT TEMPERATURE WARNING LAMP
If t h e pr oblem bein g dia gn osed is r ela t ed t o coola n t If t h e cr u ise-on in dica t or la m p fa ils t o ligh t wh en
t em per a t u r e wa r n in g la m p a ccu r a cy, be cer t a in t o t h e veh icle speed con t r ol is t u r n ed on , r epla ce t h e
con fir m t h a t t h e pr oblem is wit h t h e la m p a n d n ot cr u ise-on in dica t or la m p bu lb wit h a kn own good
wit h coolin g syst em per for m a n ce. Th e a ct u a l en gin e u n it . If t h e cr u ise-on la m p st ill fa ils t o oper a t e, dia g-
coola n t t em per a t u r e sh ou ld be ch ecked wit h a t est n osis of t h e P ower t r a in Con t r ol Modu le (P CM) a n d
ga u ge or t h er m om et er a n d com pa r ed t o t h e coola n t t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s
t em per a t u r e wa r n in g la m p oper a t ion befor e you pr o- sh ou ld be per for m ed wit h a DRB sca n t ool a s
ceed wit h la m p dia gn osis. Refer t o Gr ou p 7 - Coolin g descr ibed in t h e pr oper Dia gn ost ic P r ocedu r es m a n -
Syst em for m or e in for m a t ion . Refer t o Gr ou p 8W - u a l. F or dia gn osis of t h e cr u ise-on in dica t or la m p a n d
Wir in g Dia gr a m s for cir cu it descr ipt ion s a n d dia - 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
gr a m s. Clu st er in t h is gr ou p.

WARNING: ON VEHICLES EQUIPPED WITH AIR- FOUR-WHEEL DRIVE INDICATOR LAMP


BAGS, REFER TO GROUP 8M - PASSIVE Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY fou r-wh eel dr ive in dica t or la m p con dit ion . If t h e
STEERING WHEEL, STEERING COLUMN, OR pr oblem bein g dia gn osed is r ela t ed t o la m p a ccu r a cy,
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR be cer t a in t o con fir m t h a t t h e pr oblem is wit h t h e
SERVICE. FAILURE TO TAKE THE PROPER PRE- la m p or swit ch a n d n ot wit h a da m a ged or in oper a -
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- t ive t r a n sfer ca se or t r a n sfer ca se lin ka ge. Refer t o
BAG DEPLOYMENT AND POSSIBLE PERSONAL Gr ou p 21 - Tr a n sm ission for m or e in for m a t ion . If n o
INJURY. t r a n sfer ca se pr oblem is fou n d, t h e followin g pr oce-
du r e will h elp loca t e a sh or t or open in t h e in dica t or
If t h e coola n t t em per a t u r e wa r n in g la m p fa ils t o la m p cir cu it . F or cir cu it dia gr a m s a n d descr ipt ion s,
ligh t du r in g t h e bu lb t est (a bou t t wo secon ds a ft er r efer t o 8W-40 - In st r u m en t Clu st er in Gr ou p 8W -
t h e ign it ion swit ch is t u r n ed t o t h e On posit ion ), Wir in g Dia gr a m s.
r epla ce t h e coola n t t em per a t u r e wa r n in g la m p bu lb
wit h a kn own good u n it . If t h e coola n t t em per a t u r e
wa r n in g la m p st ill fa ils t o oper a t e, dia gn osis of t h e
coola n t t em per a t u r e sen sor a n d 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-
er t r a in Con t r ol Modu le (P CM) sh ou ld be per for m ed
XJ INSTRUMENT PANEL SYSTEMS 8E - 19
DI AGN OSI S AN D T EST I N G (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR- FU LL T I M E
BAGS, REFER TO GROUP 8M - PASSIVE (1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or
STEERING WHEEL, STEERING COLUMN, OR 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.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
SERVICE. FAILURE TO TAKE THE PROPER PRE- 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
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- block. If OK, go t o St ep 3. If n ot OK, r epa ir t h e open
BAG DEPLOYMENT AND POSSIBLE PERSONAL cir cu it t o t h e ign it ion swit ch a s r equ ir ed.
INJURY. (3) 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.
Un plu g t h e t r a n sfer ca se swit ch wir e h a r n ess con n ec-
PART T I M E t or. Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it
(1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go ca vit y of t h e t r a n sfer ca se swit ch wir e h a r n ess con -
t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or n ect or a n d a good gr ou n d. Th er e sh ou ld be con t in u -
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. it y. If OK, go t o St ep 4. If n ot OK, r epa ir t h e open
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion . cir cu it t o gr ou n d a s r equ ir ed.
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 (4) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
block. If OK, go t o St ep 3. If n ot OK, r epa ir t h e open ign it ion swit ch t o t h e On posit ion . In st a ll a ju m per
cir cu it t o t h e ign it ion swit ch a s r equ ir ed. wir e bet ween t h e fu ll t im e fou r wh eel dr ive in dica t or
(3) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . la m p dr iver cir cu it ca vit y of t h e t r a n sfer ca se swit ch
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. wir e h a r n ess con n ect or a n d a good gr ou n d. Th e fou r-
Un plu g t h e t r a n sfer ca se swit ch wir e h a r n ess con n ec- wh eel dr ive in dica t or la m p sh ou ld ligh t . If OK,
t or. Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it r epla ce t h e fa u lt y t r a n sfer ca se swit ch . If n ot OK, go
ca vit y of t h e t r a n sfer ca se swit ch wir e h a r n ess con - t o St ep 5.
n ect or a n d a good gr ou n d. Th er e sh ou ld be con t in u - (5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
it y. If OK, go t o St ep 4. If n ot OK, r epa ir t h e open Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
cir cu it t o gr ou n d a s r equ ir ed. Rem ove t h e in st r u m en t clu st er a s descr ibed in t h is
(4) 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 p. Wit h t h e t r a n sfer ca se swit ch wir e h a r n ess
ign it ion swit ch t o t h e On posit ion . In st a ll a ju m per con n ect or st ill u n plu gged, ch eck for con t in u it y
wir e bet ween t h e pa r t t im e fou r wh eel dr ive in dica t or bet ween t h e fu ll t im e fou r wh eel dr ive in dica t or la m p
la m p dr iver cir cu it ca vit y of t h e t r a n sfer ca se swit ch dr iver cir cu it ca vit y 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 a n d a good gr ou n d. Th e fou r- wir e h a r n ess con n ect or (con n ect or B) a n d a good
wh eel dr ive in dica t or la m p sh ou ld ligh t . If OK, 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 epla ce t h e fa u lt y t r a n sfer ca se swit ch . If n ot OK, go St ep 6. If n ot OK, r epa ir t h e sh or t cir cu it a s
t o St ep 5. r equ ir ed.
(5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . (6) Ch eck for con t in u it y bet ween t h e fu ll t im e fou r
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. wh eel dr ive in dica t or la m p dr iver cir cu it ca vit ies of
Rem ove t h e in st r u m en t clu st er a s descr ibed in t h is 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
gr ou p. Wit h t h e t r a n sfer ca se swit ch wir e h a r n ess (con n ect or B) a n d t h e t r a n sfer ca se swit ch wir e h a r-
con n ect or st ill u n plu gged, ch eck for con t in u it y n ess con n ect or. Th er e sh ou ld be con t in u it y. If OK,
bet ween t h e pa r t t im e fou r wh eel dr ive in dica t or r epla ce t h e fa u lt y bu lb. If n ot OK, r epa ir t h e open
la m p dr iver cir cu it ca vit y of t h e r igh t in st r u m en t cir cu it a s r equ ir ed.
clu st er wir e h a r n ess con n ect or (con n ect or B) a n d a
good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go HEADLAMP HIGH BEAM INDICATOR LAMP
t o St ep 6. If n ot OK, r epa ir t h e sh or t cir cu it a s Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
r equ ir ed. h ea dla m p h igh bea m in dica t or la m p con dit ion . If t h e
(6) Ch eck for con t in u it y bet ween t h e pa r t t im e pr oblem bein g dia gn osed is r ela t ed t o in oper a t ive
fou r wh eel dr ive in dica t or la m p dr iver cir cu it ca vit ies h ea dla m p h igh bea m s, r efer t o Gr ou p 8L - La m ps for
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- dia gn osis of t h e h ea dla m p syst em . If n o h ea dla m p
t or (con n ect or B) a n d t h e t r a n sfer ca se swit ch wir e syst em pr oblem s a r e fou n d, t h e followin g pr ocedu r e
h a r n ess con n ect or. Th er e sh ou ld be con t in u it y. If OK, will h elp loca t e a n open in t h e h igh bea m in dica t or
r epla ce t h e fa u lt y bu lb. If n ot OK, r epa ir t h e open la m p cir cu it . F or cir cu it descr ipt ion s a n d dia gr a m s,
cir cu it a s r equ ir ed. r efer t o 8W-40 - In st r u m en t Clu st er a n d 8W-50 -
F r on t Ligh t in g in Gr ou p 8W - Wir in g Dia gr a m s.
8E - 20 INSTRUMENT PANEL SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR- LOW OIL PRESSURE WARNING LAMP
BAGS, REFER TO GROUP 8M - PASSIVE If t h e pr oblem bein g dia gn osed is r ela t ed t o low oil
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY pr essu r e wa r n in g la m p a ccu r a cy, be cer t a in t o con -
STEERING WHEEL, STEERING COLUMN, OR fir m t h a t t h e pr oblem is wit h t h e la m p a n d n ot wit h
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR t h e en gin e oilin g syst em per for m a n ce. Th e a ct u a l
SERVICE. FAILURE TO TAKE THE PROPER PRE- en gin e oil pr essu r e sh ou ld be ch ecked wit h a t est
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- ga u ge a n d com pa r ed t o t h e low oil pr essu r e wa r n in g
BAG DEPLOYMENT AND POSSIBLE PERSONAL la m p oper a t ion befor e you pr oceed wit h la m p dia gn o-
INJURY. sis. Refer t o Gr ou p 9 - E n gin es for m or e in for m a t ion .
Refer t o Gr ou p 8W - Wir in g Dia gr a m s for cir cu it
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive descr ipt ion s a n d dia gr a m s.
ca ble. Rem ove t h e in st r u m en t clu st er a s descr ibed in
t h is gr ou p. WARNING: ON VEHICLES EQUIPPED WITH AIR-
(2) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e BAGS, REFER TO GROUP 8M - PASSIVE
h ea dla m ps on a n d select t h e h igh bea m s wit h t h e RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
m u lt i-fu n ct ion swit ch st a lk. Ch eck for ba t t er y volt a ge STEERING WHEEL, STEERING COLUMN, OR
a t t h e h igh bea m in dica t or dr iver cir cu it ca vit y of t h e INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
left in st r u m en t clu st er wir e h a r n ess con n ect or (con - SERVICE. FAILURE TO TAKE THE PROPER PRE-
n ect or A). If OK, r epla ce t h e fa u lt y bu lb. If n ot OK, CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
r epa ir t h e open cir cu it t o t h e h ea dla m p dim m er BAG DEPLOYMENT AND POSSIBLE PERSONAL
(m u lt i-fu n ct ion ) swit ch a s r equ ir ed. INJURY.

LOW FUEL WARNING LAMP If t h e low oil pr essu r e wa r n in g la m p fa ils t o ligh t


Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive du r in g t h e bu lb t est (a bou t t wo secon ds a ft er t h e
low fu el wa r n in g la m p con dit ion . If t h e pr oblem ign it ion swit ch is t u r n ed t o t h e On posit ion ), r epla ce
bein g dia gn osed is r ela t ed t o la m p a ccu r a cy, be cer- t h e low oil pr essu r e wa r n in g la m p bu lb wit h a kn own
t a in t o con fir m t h e pr oblem is t h e wit h t h e low fu el good u n it . If t h e low oil pr essu r e wa r n in g la m p st ill
wa r n in g la m p a n d n ot wit h t h e fu el ga u ge cir cu it . fa ils t o oper a t e, dia gn osis of t h e oil pr essu r e sen sor
See t h e dia gn osis for t h e F u el Ga u ge in t h is gr ou p. If a n d cir cu it , t h e Ch r ysler Collision Det ect ion (CCD)
n o fu el ga u ge pr oblem is fou n d, r efer t o t h e In st r u - da t a bu s, a n d/or t h e P ower t r a in Con t r ol Modu le
m en t Clu st er dia gn osis in t h is gr ou p. F or cir cu it (P CM) sh ou ld be per for m ed wit h a DRB sca n t ool a s
descr ipt ion s a n d dia gr a m s, r efer t o 8W-40 - In st r u - descr ibed in t h e pr oper Dia gn ost ic P r ocedu r es m a n -
m en t Clu st er in Gr ou p 8W - Wir in g Dia gr a m s. u a l. F or dia gn osis of t h e low oil pr essu r e 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 cu it r y, see In st r u -
WARNING: ON VEHICLES EQUIPPED WITH AIR- m en t Clu st er in t h is gr ou p.
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY LOW WASHER FLUID WARNING LAMP
STEERING WHEEL, STEERING COLUMN, OR Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR low wa sh er flu id wa r n in g la m p con dit ion . If t h e pr ob-
SERVICE. FAILURE TO TAKE THE PROPER PRE- lem bein g dia gn osed is r ela t ed t o la m p a ccu r a cy, be
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- cer t a in t o con fir m t h a t t h e pr oblem is wit h t h e la m p
BAG DEPLOYMENT AND POSSIBLE PERSONAL or wa sh er flu id level sen sor a n d n ot wit h a da m a ged
INJURY. or em pt y wa sh er flu id r eser voir. In spect t h e r eser voir
for pr oper flu id level a n d sign s of da m a ge or dist or-
If t h e low fu el wa r n in g la m p fa ils t o ligh t wh en t h e t ion t h a t cou ld a ffect sen sor per for m a n ce befor e you
fu el level is below a bou t on e-eigh t h of a fu ll t a n k a s pr oceed wit h la m p dia gn osis. Refer t o Gr ou p 8K -
in dica t ed by t h e fu el ga u ge, r epla ce t h e low fu el Wiper a n d Wa sh er Syst em s for m or e in for m a t ion . F or
wa r n in g la m p bu lb wit h a kn own good u n it . If t h e cir cu it descr ipt ion s a n d dia gr a m s, r efer t o 8W-40 -
in dica t or la m p st ill fa ils t o oper a t e, dia gn osis of t h e In st r u m en t Clu st er in Gr ou p 8W - Wir in g Dia gr a m s.
fu el ga u ge sen din g u n it a n d cir cu it , t h e P ower t r a in
Con t r ol Modu le (P CM), a n d t h e Ch r ysler Collision
Det ect ion (CCD) da t a bu s sh ou ld be per for m ed wit h
a DRB sca n t ool a s descr ibed in t h e pr oper Dia gn os-
t ic P r ocedu r es m a n u a l. F or dia gn osis of t h e low fu el
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 cu it r y,
see In st r u m en t Clu st er in t h is gr ou p.
XJ INSTRUMENT PANEL SYSTEMS 8E - 21
DI AGN OSI S AN D T EST I N G (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR- WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. INJURY.

(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

WARNING: ON VEHICLES EQUIPPED WITH AIR- STEERING COLUMN OPENING COVER


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
If t h e u psh ift in dica t or la m p fa ils t o ligh t wh en a INJURY.
t r a n sm ission u psh ift is obviou sly r equ ir ed, r epla ce
t h e u psh ift in dica t or la m p bu lb wit h a kn own good (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
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- ca ble.
n osis of t h e P ower t r a in Con t r ol Modu le (P CM) a n d (2) If t h e veh icle is so equ ipped, m ove t h e t ilt
t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s st eer in g colu m n t o t h e fu lly r a ised posit ion .
XJ INSTRUMENT PANEL SYSTEMS 8E - 23
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rem ove t h e t h r ee scr ews t h a t secu r e t h e st eer-
in g colu m n open in g cover t o t h e lower in st r u m en t
pa n el r ein for cem en t (F ig. 3).
KNEE
BLOCKER

SCREW

·~

SLOT

SNAP
CLIPS 80abac40

Fig. 4 Knee Blocker Remove/Install


SCREW (6) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Be
80abac3c
cer t a in t h a t t h e m ou n t in g scr ews a r e loca t ed in t h e
Fig. 3 Steering Column Opening Cover Remove/ scr ew h ole on ea ch side of t h e st eer in g colu m n t h a t is
Install closest t o t h e dr iver side fr on t door of t h e veh icle
(4) Usin g a t r im st ick or a n ot h er su it a ble wide (F ig. 5). Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20
fla t -bla ded t ool, gen t ly pr y t h e u pper edge of t h e in . lbs.).
st eer in g colu m n open in g cover a wa y fr om t h e in st r u - KNEE
m en t pa n el on ea ch side of t h e st eer in g colu m n t o BLOCKER
r elea se t h e t wo sn a p clip r et a in er s t h a t secu r e t h e
cover t o t h e in st r u m en t pa n el.
(5) Rem ove t h e st eer in g colu m n open in g cover
fr om t h e veh icle. ' '-----/
(6) 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 m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).
A...,..,__ _ _ _ SCREWS----~•~£
KNEE BLOCKER "'
LEFT-HAND DRIVE RIGHT-HAND DRIVE
WARNING: ON VEHICLES EQUIPPED WITH AIR- 80abac42
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY Fig. 5 Knee Blocker Mounting Screw Location
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR INSTRUMENT PANEL CENTER BEZEL
SERVICE. FAILURE TO TAKE THE PROPER PRE-
WARNING: ON VEHICLES EQUIPPED WITH AIR-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
BAG DEPLOYMENT AND POSSIBLE PERSONAL
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
INJURY.
STEERING WHEEL, STEERING COLUMN, OR
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
ca ble. SERVICE. FAILURE TO TAKE THE PROPER PRE-
(2) Rem ove t h e st eer in g colu m n open in g cover a s CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
descr ibed in t h is gr ou p. BAG DEPLOYMENT AND POSSIBLE PERSONAL
(3) Rem ove t h e t wo scr ews t h a t secu r e t h e kn ee INJURY.
blocker t o t h e in st r u m en t pa n el (F ig. 4).
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(4) P u ll t h e kn ee blocker a wa y fr om t h e in st r u -
ca ble.
m en t pa n el fa r en ou gh t o disen ga ge t h e t wo m ou n t -
(2) Usin g a t r im st ick or a n ot h er su it a ble wide
in g t a bs fr om t h e slot s in t h e lower in st r u m en t pa n el
fla t -bla ded t ool, gen t ly pr y t h e in st r u m en t pa n el cen -
r ein for cem en t .
t er bezel a wa y fr om t h e in st r u m en t pa n el t o r elea se
(5) Rem ove t h e kn ee blocker fr om t h e veh icle.
t h e six sn a p clip r et a in er s (F ig. 6).
8E - 24 INSTRUMENT PANEL SYSTEMS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)

INSTRUMENT PANEL ACCESSORY


SWITCH BEZEL

Fig. 7 Accessory Switch Bezel Remove/Install


(7) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Be
cer t a in t h a t bot h of t h e swit ch sn a p r et a in er s in t h e
r ecept a cles on t h e ba ck of t h e a ccessor y swit ch bezel
S0ab87bc a r e fu lly en ga ged. Tigh t en t h e m ou n t in g scr ews t o
2.2 N·m (20 in . lbs.).
Fig. 6 Center Bezel Remove/Install
(3) Rem ove t h e cen t er bezel fr om t h e veh icle. CIGAR LIGHTER RELAY
(4) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
ACCESSORY SWITCH BEZEL 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) Rem ove t h e fu se a ccess pa n el by u n sn a ppin g it
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive fr om t h e r igh t cowl side t r im pa n el.
ca ble. (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
(2) Rem ove t h e in st r u m en t pa n el cen t er bezel a s cowl side t r im t o t h e ju n ct ion block st u d (F ig. 8).
descr ibed in t h is gr ou p. (4) Rem ove t h e scr ew loca t ed a bove t h e fu se a ccess
(3) Rem ove t h e t h r ee scr ews t h a t secu r e t h e a cces- 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
sor y swit ch bezel t o t h e in st r u m en t pa n el (F ig. 7). r igh t cowl side in n er pa n el.
(4) P u ll t h e a ccessor y swit ch bezel ou t fr om t h e (5) Rem ove t h e scr ew t h a t secu r es t h e r igh t door
in st r u m en t pa n el fa r en ou gh t o u n plu g t h e wir e h a r- 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
n ess con n ect or s. door open in g sill.
(5) Rem ove t h e a ccessor y swit ch bezel fr om t h e (6) Rem ove t h e r igh t cowl side t r im pa n el fr om t h e
in st r u m en t pa n el. veh icle.
(6) Ca r efu lly pr y t h e sn a p r et a in er s a t t h e t op a n d (7) Un plu g t h e ciga r ligh t er r ela y fr om t h e ju n c-
bot t om of t h e a ccessor y swit ch (fog la m p swit ch , r ea r t ion block.
win dow defogger swit ch , r ea r wiper a n d wa sh er (8) In st a ll t h e ciga r ligh t er r ela y by a lign in g t h e
swit ch ) r ecept a cles on t h e ba ck of t h e a ccessor y r ela y t er m in a ls wit h t h e ca vit ies in t h e ju n ct ion
swit ch bezel wit h a sm a ll t h in -bla ded scr ewdr iver block a n d pu sh in g t h e r ela y fir m ly in t o pla ce.
a n d pu ll t h e swit ch es ou t of t h e r ecept a cles. (9) Con n ect t h e ba t t er y n ega t ive ca ble.
(10) Test t h e r ela y oper a t ion .
XJ INSTRUMENT PANEL SYSTEMS 8E - 25
REM OVAL AN D I N STALLAT I ON (Cont inue d)

INSTRUMENT
PANEL

RIGHT FRONT
DOOR SILL

COWL SIDE
TRIM PANEL
=----- STEERING COLUMN
SIGHT SHIELD
CONNECTOR

HEADLAMP SWITCH
KNOB AND SHAFT 80abac43

Fig. 9 Cluster Bezel Remove/Install


(6) Rem ove t h e fou r scr ews t h a t secu r e t h e clu st er
bezel t o t h e in st r u m en t pa n el beh in d t h e cen t er
bezel.
(7) 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 a r ou n d t h e per im et er of
t h e clu st er bezel t o disen ga ge t h e five sn a p clip
80ab249a
r et a in er s t h a t secu r e t h e bezel t o t h e in st r u m en t
pa n el.
Fig. 8 Right Cowl Side Trim Remove/Install (8) Rem ove t h e clu st er bezel fr om t h e veh icle.
(11) In st a ll t h e r igh t cowl side t r im a n d t h e fu se (9) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
a ccess pa n el. Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).
Be cer t a in t o en ga ge t h e t wo en ds of t h e st eer in g col-
CLUSTER BEZEL u m n sigh t sh ield con n ect or wit h ea ch ot h er befor e
r ein st a llin g t h e kn ee blocker a n d st eer in g colu m n
WARNING: ON VEHICLES EQUIPPED WITH AIR- open in g cover.
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY HEADLAMP SWITCH
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR WARNING: ON VEHICLES EQUIPPED WITH AIR-
SERVICE. FAILURE TO TAKE THE PROPER PRE- BAGS, REFER TO GROUP 8M - PASSIVE
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
BAG DEPLOYMENT AND POSSIBLE PERSONAL STEERING WHEEL, STEERING COLUMN, OR
INJURY. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
ca ble. BAG DEPLOYMENT AND POSSIBLE PERSONAL
(2) Rem ove t h e kn ee blocker a n d t h e in st r u m en t INJURY.
pa n el cen t er bezel, a s descr ibed in t h is gr ou p.
(3) Rem ove t h e h ea dla m p swit ch kn ob a n d sh a ft
fr om t h e h ea dla m p swit ch . See H ea dla m p Swit ch in WARNING: IF THE HEADLAMP SWITCH WAS ON,
t h is gr ou p for t h e pr ocedu r es. WAIT FIVE MINUTES TO ALLOW THE CERAMIC
(4) Disen ga ge t h e t wo en ds of t h e st eer in g colu m n DIMMER RESISTOR TO COOL. IF THE CERAMIC
sigh t sh ield fr om ea ch ot h er a t t h e con n ect or loca t ed DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT
below t h e lower st eer in g colu m n sh r ou d (F ig. 9). CAN BURN YOUR FINGERS.
(5) If t h e veh icle is so equ ipped, set t h e t ilt st eer-
in g colu m n in it s lowest posit ion . (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
8E - 26 INSTRUMENT PANEL SYSTEMS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Rem ove t h e kn ee blocker a s descr ibed in t h is WIRE HARNESS
gr ou p. CONNECTORsr--~ ~~....__
(3) P u ll t h e h ea dla m p swit ch con t r ol kn ob ou t t o
t h e On posit ion st op.
INSTRUMENT
WARNING: IF THE HEADLAMP SWITCH WAS ON, PANEL
WAIT FIVE MINUTES TO ALLOW THE CERAMIC
DIMMER RESISTOR TO COOL. IF THE CERAMIC
DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT
CAN BURN YOUR FINGERS.
VIEWED FROM UNDERSIDE OF DASH PUSH RETAINER BUTTON

(4) Rea ch u p t h r ou gh t h e ou t boa r d side of t h e


st eer in g colu m n open in g a n d depr ess t h e h ea dla m p
swit ch kn ob a n d sh a ft r elea se bu t t on on t h e in boa r d
side of t h e swit ch (F ig. 10).

80abac44

Fig. 11 Headlamp Switch Remove/Install


0 STEERING WHEEL, STEERING COLUMN, OR

• C INSTRUMENT PANEL COMPONENT DIAGNOSIS OR


SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
SCREW SELF-DOCKING
HARNESS
INSTRUMENT
INSTRUMENT
CONNECTORS
CLUSTER
PANEL
WIRE

© (1) Rem ove t h e clu st er bezel a s descr ibed in t h is


gr ou p.
~ (2) Rem ove t h e fou r scr ews t h a t secu r e t h e clu st er
v t o t h e in st r u m en t pa n el (F ig. 12).

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

(9) Rem ove t h e h ea dla m p swit ch fr om t h e in st r u -


m en t pa n el. Fig. 12 Instrument Cluster Remove/Install
(10) Rever se t h e r em ova l pr ocedu r es t o in st a ll. (3) P u ll t h e clu st er r ea r wa r d t o disen ga ge t h e t wo
Tigh t en t h e spa n n er n u t t o 2.7 N·m (24 in . lbs.). self-dockin g wir e h a r n ess con n ect or s.

INSTRUMENT CLUSTER NOTE: The instrument cluster has two self-docking


wire harness connectors that will be automatically
WARNING: ON VEHICLES EQUIPPED WITH AIR- aligned with, and connected to the instrument panel
BAGS, REFER TO GROUP 8M - PASSIVE wire harness when the cluster is installed in the
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY instrument panel.
INSTRUMENT
CLUSTER REARHOUSING
CLUSTER
COVER CLUSTER HOOD AND MASK CLUSTER
ODOMETER
LENS RESET BOOT
KNOB

XJ INSTRUMENT PANEL SYSTEMS 8E - 27


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) Rem ove t h e in st r u m en t clu st er fr om t h e veh i- (5) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
cle.
(5) Rever se t h e r em ova l pr ocedu r es t o in st a ll. CLU ST ER H OOD AN D M ASK
Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
CLUSTER COMPONENTS BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
CLU ST ER LEN S AN D ODOM ET ER RESET STEERING WHEEL, STEERING COLUMN, OR
K N OB BOOT INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
WARNING: ON VEHICLES EQUIPPED WITH AIR- CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAGS, REFER TO GROUP 8M - PASSIVE BAG DEPLOYMENT AND POSSIBLE PERSONAL
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY INJURY.
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
SERVICE. FAILURE TO TAKE THE PROPER PRE- ca ble.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (2) Rem ove t h e in st r u m en t clu st er a s descr ibed in
BAG DEPLOYMENT AND POSSIBLE PERSONAL t h is gr ou p.
INJURY. (3) Rem ove t h e clu st er len s a s descr ibed in t h is
gr ou p.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (4) Wor k a r ou n d t h e per im et er of t h e clu st er
ca ble. depr essin g t h e sn a p clips t h a t secu r e t h e clu st er
(2) Rem ove t h e in st r u m en t clu st er a s descr ibed in h ood a n d m a sk t o t h e clu st er h ou sin g, a n d gen t ly
t h is gr ou p. pu ll t h e h ood a n d m a sk a wa y fr om t h e clu st er (F ig.
(3) Wor k a r ou n d t h e per im et er of t h e clu st er 13).
depr essin g t h e sn a p clips t h a t secu r e t h e clu st er len s (5) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
t o t h e clu st er h ou sin g, a n d gen t ly pu ll t h e len s a wa y
fr om t h e clu st er (F ig. 13).
(4) Rem ove t h e t r ip odom et er r eset kn ob boot by
pu llin g it ou t of t h e len s.

CLUSTER
HOOD AND MASK

INSTRUMENT
CLUSTER
HOUSING

ODOMETER
RESET KNOB
BOOT
80a9f12c

Fig. 13 Instrument Cluster Components


CLUSTER ILLUMINATION BULBS INSTRUMENT PANEL
TOP COVER FRONT EDGE REAR FWD
EDGE

8E - 28 INSTRUMENT PANEL SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
CLU ST ER REAR COV ER may overheat and cause damage to the instrument
cluster printed circuit and/or the gauges.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE (3) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL TOP COVER
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- WARNING: ON VEHICLES EQUIPPED WITH AIR-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAGS, REFER TO GROUP 8M - PASSIVE
BAG DEPLOYMENT AND POSSIBLE PERSONAL RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
INJURY. STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive SERVICE. FAILURE TO TAKE THE PROPER PRE-
ca ble. CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(2) Rem ove t h e in st r u m en t clu st er a s descr ibed in BAG DEPLOYMENT AND POSSIBLE PERSONAL
t h is gr ou p. INJURY.
(3) Wor k a r ou n d t h e per im et er of t h e clu st er
r elea sin g t h e sn a p clips t h a t secu r e t h e r ea r cover t o (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
t h e clu st er h ou sin g, a n d gen t ly pu ll t h e r ea r cover ca ble.
a wa y fr om t h e clu st er (F ig. 13). (2) Rem ove t h e in st r u m en t clu st er bezel a s
(4) Rever se t h e r em ova l pr ocedu r es t o in st a ll. descr ibed in t h is gr ou p.
(3) Usin g a t r im st ick or a n ot h er su it a ble wide
CLUSTER BULB fla t -bla ded t ool, gen t ly pr y t h e r ea r edge (n ea r est t h e
pa ssen ger com pa r t m en t ) of t h e in st r u m en t pa n el t op
WARNING: ON VEHICLES EQUIPPED WITH AIR- cover u p a n d a wa y fr om t h e t op of t h e in st r u m en t
BAGS, REFER TO GROUP 8M - PASSIVE pa n el t o r elea se t h e seven r ea r sn a p clip r et a in er s
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (F ig. 15).
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR TOP FRONT REAR
SERVICE. FAILURE TO TAKE THE PROPER PRE- COVER EDGE EDGE
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Rem ove t h e in st r u m en t clu st er a s descr ibed in


t h is gr ou p.
(2) Rem ove t h e bu lb a n d bu lb h older fr om t h e cir-
cu it boa r d on t h e r ea r of t h e clu st er h ou sin g by t u r n -
in g t h e h older cou n t er clockwise (F ig. 14).

80abac46

Fig. 15 Instrument Panel Top Cover Remove/Install


(4) Lift t h e r ea r edge of t h e t op cover u p a n d a wa y
fr om t h e in st r u m en t pa n el u n t il a ll of t h e r ea r sn a p
clip r et a in er s (seven ) on t h e t op cover a r e disen ga ged
fr om t h e r ecept a cles in t h e t op of t h e in st r u m en t
pa n el.
(5) P u ll t h e t op cover sh a r ply r ea r wa r ds t o disen -
80a4d2ef
ga ge t h e fou r fr on t sn a p clip r et a in er s fr om t h e
r ecept a cles n ea r t h e ba se of t h e win dsh ield.
Fig. 14 Cluster Bulb Locations
(6) Rem ove t h e t op cover fr om t h e veh icle.
CAUTION: Always use the correct bulb size and (7) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
type for replacement. An incorrect bulb size or type Wh en in st a llin g t h e t op cover, be cer t a in t o en ga ge
t h e fou r fr on t (n ea r est t h e win dsh ield) sn a p clip
BOXDOOR
GLOVE GLOVE
UPPER REINFORCEMENT
BOX OPENING GLOVE STOP
BOXBUMPERS
STRIKER
LATCH SCREWS LATCH GLOVE BOX

XJ INSTRUMENT PANEL SYSTEMS 8E - 29


REM OVAL AN D I N STALLAT I ON (Cont inue d)
r et a in er s fir st , t h en en ga ge t h e seven r ea r sn a p clip INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
r et a in er s. SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
GLOVE BOX BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
ROLL DOWN
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
WARNING: ON VEHICLES EQUIPPED WITH AIR- ca ble.
BAGS, REFER TO GROUP 8M - PASSIVE (2) Rem ove t h e t h r ee scr ews t h a t secu r e t h e glove
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY box h in ge t o t h e in st r u m en t pa n el lower glove box
STEERING WHEEL, STEERING COLUMN, OR open in g r ein for cem en t (F ig. 17).
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive LATCH


ca ble.
(2) Open t h e glove box.
(3) Loca t e t h e t wo r u bber st op bu m per s on t h e
u pper edge of t h e glove box open in g (F ig. 16).
GLOVE BOX OPENING
UPPER REINFORCEMENT
Fig. 17 Glove Box Remove/Install
(3) Relea se t h e glove box la t ch .
(4) Rem ove t h e glove box fr om t h e in st r u m en t
pa n el.
(5) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
Wh en r ein st a llin g t h e glove box, be cer t a in t h a t t h e
st ops on t h e glove box bin a r e or ien t ed beh in d t h e
glove box st op bu m per s on t h e in st r u m en t pa n el
u pper glove box open in g r ein for cem en t .

GLOVE BOX LAMP AND SWITCH


WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
Fig. 16 Glove Box Stop Bumpers Remove/Install
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
(4) Rem ove t h e t wo glove box st op bu m per s by STEERING WHEEL, STEERING COLUMN, OR
slidin g t h em down wa r d a n d ou t of t h e slot s in t h e INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
in st r u m en t pa n el u pper glove box open in g r ein for ce- SERVICE. FAILURE TO TAKE THE PROPER PRE-
m en t . CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(5) Roll t h e glove box down wa r d so t h a t t h e st ops BAG DEPLOYMENT AND POSSIBLE PERSONAL
on t h e glove box bin pa ss t h r ou gh t h e st op bu m per INJURY.
slot s in t h e in st r u m en t pa n el u pper glove box open -
in g r ein for cem en t . (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(6) Rever se t h e r oll down pr ocedu r e t o r oll t h e ca ble.
glove box ba ck u p. (2) Roll down t h e glove box a s descr ibed in t h is
gr ou p.
REM OVAL (3) Rea ch in side a n d a bove t h e glove box open in g
t o u n la t ch a n d u n plu g t h e wir e h a r n ess con n ect or
WARNING: ON VEHICLES EQUIPPED WITH AIR- fr om t h e glove box la m p a n d swit ch (F ig. 18).
BAGS, REFER TO GROUP 8M - PASSIVE (4) F r om in side a n d a bove t h e glove box open in g,
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY squ eeze t h e r et a in in g t a bs on t h e t op a n d bot t om of
STEERING WHEEL, STEERING COLUMN, OR t h e glove box la m p a n d swit ch h ou sin g t oget h er a n d
WIRE HARNESS
LATCH STRIKER
CONNEC-
TOR MOUNTING HOLE STOPLAMP
BUMPER
ANDSLOT
SWITCH OUTER DOOR HINGE
SCREWS STOPS LATCH INNER DOOR BIN

8E - 30 INSTRUMENT PANEL SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

LATCH STRIKER STOP BUMPER SLOT STOPS

WIRE HARNESS MOUNTING


HINGE
CONNECTOR HOLE 80abac5a 80abac65

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

XJ INSTRUMENT PANEL SYSTEMS 8E - 31


REM OVAL AN D I N STALLAT I ON (Cont inue d)

LOCK LATCH (4) Rem ove t h e la t ch st r iker fr om t h e glove box


CYLINDER HANDLE open in g.
(5) 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 m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).

INSTRUMENT PANEL END CAP


WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
RELEASE
STEERING WHEEL, STEERING COLUMN, OR
HOLE
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
80abac66
SERVICE. FAILURE TO TAKE THE PROPER PRE-
Fig. 20 Glove Box Lock Cylinder Remove/Install CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
t ion . P u sh t h e lock cylin der fir m ly in t o t h e lock cyl-
INJURY.
in der bor e wh ile r ot a t in g t h e key a n d cylin der
cou n t er clockwise t o t h e 6 o’clock posit ion , wh er e t h e
lock cylin der r et a in in g t u m bler will sn a p ba ck in t o DRI V ER SI DE
pla ce. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
GLOVE BOX LATCH STRIKER (2) Rem ove t h e kn ee blocker a s descr ibed in t h is
gr ou p.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) Rem ove t h e in st r u m en t pa n el t op cover a s
BAGS, REFER TO GROUP 8M - PASSIVE descr ibed in t h is gr ou p.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (4) Rem ove t h e five scr ews t h a t secu r e t h e en d ca p
STEERING WHEEL, STEERING COLUMN, OR t o t h e in st r u m en t pa n el (F ig. 22).
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) 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 pa ssen ger side a ir ba g m odu le.
Refer t o Gr ou p 8M - P a ssive Rest r a in t Syst em s for
t h e pr ocedu r es.
(3) Rem ove t h e t wo scr ews t h a t secu r e t h e glove
box la t ch st r iker t o t h e in st r u m en t pa n el on t h e t op
of t h e u pper glove box open in g r ein for cem en t (F ig.
21).

Fig. 22 Instrument Panel End Cap Remove/Install


(5) Rem ove t h e en d ca p fr om t h e in st r u m en t
pa n el.
(6) 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 m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).

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

8E - 32 INSTRUMENT PANEL SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) Rem ove t h e pa ssen ger side a ir ba g m odu le. (7) Rem ove t h e cen t er su ppor t br a cket fr om t h e
Refer t o Gr ou p 8M - P a ssive Rest r a in t Syst em s for veh icle.
t h e pr ocedu r es. (8) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
(5) Rem ove t h e six scr ews t h a t secu r e t h e en d ca p Tigh t en t h e m ou n t in g n u t s t o 28 N·m (250 in . lbs.).
t o t h e in st r u m en t pa n el (F ig. 22).
(6) Rem ove t h e en d ca p fr om t h e in st r u m en t JUNCTION BLOCK
pa n el.
(7) Rever se t h e r em ova l pr ocedu r es t o in st a ll. WARNING: ON VEHICLES EQUIPPED WITH AIR-
Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.). BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
CENTER SUPPORT BRACKET STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
WARNING: ON VEHICLES EQUIPPED WITH AIR- SERVICE. FAILURE TO TAKE THE PROPER PRE-
BAGS, REFER TO GROUP 8M - PASSIVE CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY BAG DEPLOYMENT AND POSSIBLE PERSONAL
STEERING WHEEL, STEERING COLUMN, OR INJURY.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- ca ble.
BAG DEPLOYMENT AND POSSIBLE PERSONAL (2) Rem ove t h e fu se a ccess pa n el by u n sn a ppin g it
INJURY. fr om t h e r igh t cowl side t r im pa n el.
(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
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive cowl side t r im t o t h e ju n ct ion block st u d (F ig. 24).
ca ble.
(2) Rem ove t h e in st r u m en t pa n el cen t er bezel a s
descr ibed in t h is gr ou p.
(3) Rem ove t h e floor con sole fr om t h e floor pa n
t r a n sm ission t u n n el. Refer t o Gr ou p 23 - Body for t h e
pr ocedu r es.
(4) P u ll t h e ca r pet ba ck fr om t h e fr on t of t h e floor
pa n t r a n sm ission t u n n el fa r en ou gh t o a ccess t h e
cen t er su ppor t br a cket m ou n t in g n u t s. RIGHT FRONT
(5) Rem ove t h e t wo n u t s t h a t secu r e t h e cen t er DOOR SILL
su ppor t br a cket t o t h e st u ds on t h e lower in st r u m en t
pa n el (F ig. 23).
COWL SIDE
TRIM PANEL

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

XJ INSTRUMENT PANEL SYSTEMS 8E - 33


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(5) Rem ove t h e scr ew t h a t secu r es t h e r igh t door (5) Rem ove t h e in st r u m en t pa n el cen t er bezel, t h e
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 clu st er bezel a n d t h e in st r u m en t pa n el t op cover a s
door open in g sill. descr ibed in t h is gr ou p.
(6) Rem ove t h e r igh t cowl side t r im pa n el fr om t h e (6) Rem ove t h e cen t er su ppor t br a cket a s
veh icle. descr ibed in t h is gr ou p.
(7) Un plu g a ll of t h e wir e h a r n ess con n ect or s fr om (7) Rem ove t h e st eer in g colu m n . Refer t o Gr ou p 19
t h e ju n ct ion block ca vit ies. - St eer in g for t h e pr ocedu r es.
(8) Rem ove t h e t h r ee n u t s t h a t secu r e t h e ju n ct ion (8) Rem ove t h e scr ews fr om t h e cen t er s of t h e
block t o t h e st u ds on t h e r igh t cowl side in n er pa n el in st r u m en t pa n el-t o-body a n d in st r u m en t pa n el-t o-
(F ig. 25). h ea dla m p a n d da sh wir e h a r n ess con n ect or s n ea r t h e
left cowl side in n er pa n el a n d u n plu g t h e con n ect or s.
(9) Rem ove t h e scr ew fr om t h e cen t er of t h e
in st r u m en t pa n el-t o-floor wir e h a r n ess con n ect or
n ea r t h e floor pa n t r a n sm ission t u n n el u n der t h e
in st r u m en t pa n el a n d u n plu g t h e con n ect or.
(10) Un plu g t h e t wo wir e h a r n ess con n ect or s
loca t ed n ea r t h e in st r u m en t pa n el-t o-floor wir e h a r-
n ess con n ect or a t t h e floor pa n t r a n sm ission t u n n el
RIGHT u n der t h e in st r u m en t pa n el.
COWL (11) Roll down t h e glove box a s descr ibed in t h is
SIDE gr ou p.
INNER
(12) Rea ch t h r ou gh t h e in boa r d side of t h e in st r u -
PANEL
m en t pa n el glove box open in g t o u n plu g t h e va cu u m
h a r n ess con n ect or bet ween t h e h ea t er-A/C con t r ol
a n d t h e h ea t er-A/C h ou sin g h a lves of t h e va cu u m
h a r n ess.
(13) Rea ch u n der t h e r igh t en d of t h e in st r u m en t
pa n el t o u n plu g t h e coa xia l ca ble con n ect or bet ween
80abac68
t h e r a dio a n d a n t en n a h a lves of t h e a n t en n a coa xia l
Fig. 25 Junction Block Remove/Install ca ble. On Left -H a n d Dr ive m odels on ly, a lso disen -
ga ge t h e r et a in er on t h e r a dio h a lf of t h e coa xia l
(9) Rem ove t h e ju n ct ion block fr om t h e veh icle. ca ble fr om t h e h ea t er-A/C h ou sin g kick cover.
(10) Rever se t h e r em ova l pr ocedu r es t o in st a ll. (14) Rem ove t h e t em per a t u r e con t r ol ca ble a n d
Tigh t en t h e m ou n t in g n u t s t o 2.7 N·m (24 in . lbs.). blen d-a ir door cr a n k a r m fr om t h e h ea t er-A/C h ou s-
in g a s a u n it . Refer t o Gr ou p 24 - H ea t in g a n d Air
INSTRUMENT PANEL ASSEMBLY Con dit ion in g for t h e t em per a t u r e con t r ol ca ble ser-
vice pr ocedu r es.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (15) Loosen t h e r igh t a n d left in st r u m en t pa n el
BAGS, REFER TO GROUP 8M - PASSIVE cowl side r oll down scr ews a bou t 6 m m (0.25 in ch )
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (F ig. 26).
STEERING WHEEL, STEERING COLUMN, OR (16) Rem ove t h e fou r scr ews a n d t wo n u t s t h a t
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR secu r e t h e t op of t h e in st r u m en t pa n el t o t h e t op of
SERVICE. FAILURE TO TAKE THE PROPER PRE- t h e da sh pa n el n ea r t h e ba se of t h e win dsh ield.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (17) Wit h t h e a id of a n a ssist a n t , lift t h e t op of t h e
BAG DEPLOYMENT AND POSSIBLE PERSONAL in st r u m en t pa n el a ssem bly off of t h e t wo da sh pa n el
INJURY. st u ds. Th en pu ll t h e lower in st r u m en t pa n el r ea r-
wa r d t o clea r t h e cowl side r oll down scr ews.
(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
(18) Rem ove t h e in st r u m en t pa n el a ssem bly fr om
posit ion .
t h e veh icle.
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(19) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
ca ble.
Tigh t en t h e m ou n t in g h a r dwa r e a s follows:
(3) Rem ove t h e left a n d r igh t cowl side in n er t r im
• In st r u m en t pa n el t op t o da sh pa n el scr ews - 7
pa n els. Refer t o Gr ou p 23 - Body for t h e pr ocedu r es.
N·m (60 in . lbs.)
(4) Rem ove t h e st eer in g colu m n open in g cover a n d
• In st r u m en t pa n el t op t o da sh pa n el n u t s - 7 N·m
t h e kn ee blocker a s descr ibed in t h is gr ou p.
(60 in . lbs.)
SCREW NUT INSTRUMENT
SIDE ROLL DOWN
PANEL
SCREWS
COWL

8E - 34 INSTRUMENT PANEL SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

INSTRUM
COWL SIDE ERNT PANEL
OLLDOWN
Sc REWS

80a9f12b

Fig. 26 Instrument Panel Assembly Remove/Install


• In st r u m en t pa n el cowl side r oll down scr ews - 28
N·m (250 in . lbs.)
• Wir e h a r n ess con n ect or scr ews - 4 N·m (35 in .
lbs.).
XJ AUDIO SYSTEMS 8F - 1

AUDIO SYSTEMS
CON T EN T S

page page

GENERAL INFORMATION AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2


INTRODUCTION . . . . . . . . . . . ............. 1 RADIO FREQUENCY INTERFERENCE . . . . . . . 7
DESCRIPTION AND OPERATION RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
RADIO NOISE SUPPRESSION . . . . . . . . . . . . . . 2 AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING SOUND BAR . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ANTENNA . . . . . . . . . . . . . . . . ............. 6 SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

GEN ERAL I N FORM AT I ON IGNITION-OFF DRAW FUSE


All veh icles a r e equ ipped wit h a n Ign it ion -Off
INTRODUCTION Dr a w (IOD) fu se t h a t is r em oved wh en t h e veh icle is
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor sh ipped fr om t h e fa ct or y. Th is fu se feeds va r iou s
com pon en t s u sed in bot h t h e st a n da r d a n d opt ion a l a ccessor ies t h a t r equ ir e ba t t er y cu r r en t wh en t h e
fa ct or y-in st a lled a u dio syst em s. Refer t o 8W-47 Au dio ign it ion swit ch is in t h e Off posit ion , in clu din g t h e
Syst em in Gr ou p 8W - Wir in g Dia gr a m s for com plet e clock a n d r a dio st a t ion pr eset m em or y fu n ct ion s. Th e
cir cu it descr ipt ion s a n d dia gr a m s. fu se is r em oved t o pr even t ba t t er y disch a r ge du r in g
veh icle st or a ge.
NOTE: This group covers both Left-Hand Drive Wh en r em ovin g or in st a llin g t h e IOD fu se, it is
(LHD) and Right-Hand Drive (RHD) versions of this im por t a n t t h a t t h e ign it ion swit ch be in t h e Off posi-
model. Whenever required and feasible, the RHD t ion . F a ilu r e t o pla ce t h e ign it ion swit ch in t h e Off
versions of affected vehicle components have been posit ion ca n ca u se t h e r a dio displa y t o becom e scr a m -
constructed as mirror-image of the LHD versions. bled wh en t h e IOD fu se is r em oved a n d r epla ced.
While most of the illustrations used in this group Rem ovin g a n d r epla cin g t h e IOD fu se a ga in , wit h t h e
represent only the LHD version, the diagnostic and ign it ion swit ch in t h e Off posit ion , will cor r ect t h e
service procedures outlined can generally be scr a m bled displa y con dit ion .
applied to either version. Exceptions to this rule Th e IOD fu se sh ou ld be ch ecked if t h e r a dio st a t ion
have been clearly identified as LHD or RHD, if a pr eset m em or y or clock fu n ct ion s a r e er r a t ic or in op-
special illustration or procedure is required. er a t ive. Th e IOD fu se is loca t ed in t h e P ower Dist r i-
bu t ion Cen t er (P DC). Refer t o t h e P DC la bel for IOD
fu se iden t ifica t ion a n d loca t ion .
DESCRI PT I ON AN D OPERAT I ON
SPEAKER
RADIO Th e st a n da r d equ ipm en t spea ker syst em in clu des
Ava ila ble fa ct or y-in st a lled r a dio r eceiver s for t h is t wo 13.3 cen t im et er (5.25 in ch ) dia m et er fu ll-r a n ge
m odel in clu de a n AM/F M (RAL sa les code), a n spea ker s. E a ch spea ker is m ou n t ed t o t h e fr on t lower
AM/F M/ca sset t e (RAS sa les code), a n d a n AM/F M/ in n er door pa n el beh in d t h e door t r im pa n el.
CD/ca sset t e/3-ba n d gr a ph ic equ a lizer (RAZ sa les Th e sou n d ba r opt ion a dds t wo 13.3 cen t im et er
code). All fa ct or y-in st a lled r a dio r eceiver s a r e st er eo (5.25 in ch ) dia m et er fu ll-r a n ge spea ker s t o t h e st a n -
E lect r on ica lly Tu n ed Ra dios (E TR) a n d in clu de a n da r d spea ker syst em , for a t ot a l of fou r spea ker s.
elect r on ic digit a l clock fu n ct ion . E a ch of t h e a ddit ion a l spea ker s is m ou n t ed beh in d a
F or m or e in for m a t ion on r a dio fea t u r es, set t in g gr ille loca t ed on t h e ou t boa r d en ds of t h e sou n d ba r,
pr ocedu r es, a n d con t r ol fu n ct ion s r efer t o t h e own er ’s wh ich is loca t ed on t h e h ea dlin er ju st for wa r d of t h e
m a n u a l in t h e veh icle glove box. u pper lift ga t e open in g r ein for cem en t n ea r t h e r ea r of
t h e veh icle ca r go a r ea .
8F - 2 AUDIO SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e pr em iu m spea ker opt ion u pgr a des a ll of t h e In a ddit ion , if t h e sou r ce of RF I or E MI n oise is
spea ker s t o In fin it y m odels, a n d in clu des a 100 wa t t iden t ified a s a com pon en t on t h e veh icle (i.e., gen er-
In fin it y a m plifier. E a ch fr on t door h a s t wo sepa r a t e a t or, blower m ot or, et c.), t h e gr ou n d pa t h for t h a t
In fin it y spea ker s: a woofer m ou n t ed low in t h e door, com pon en t sh ou ld be ch ecked. If excessive r esist a n ce
a n d a t weet er m ou n t ed beh in d t h e door fla g t r im is fou n d in t h a t cir cu it , r epa ir t h a t cir cu it a s
pa n el. In fin it y coa xia l spea ker s a r e m ou n t ed in t h e r equ ir ed befor e con sider in g a n y com pon en t r epla ce-
sou n d ba r. Th e In fin it y a m plifier is m ou n t ed t o t h e m en t .
floor pa n u n der t h e left r ea r sea t cu sh ion . If t h e sou r ce of t h e n oise is iden t ified a s t wo-wa y
m obile r a dio or t eleph on e equ ipm en t , ch eck t h e
ANTENNA equ ipm en t in st a lla t ion for t h e followin g:
All m odels u se a fixed-len gt h st a in less st eel r od- • P ower con n ect ion s sh ou ld be m a de dir ect ly t o
t ype a n t en n a m a st , in st a lled a t t h e r igh t fr on t fen der t h e ba t t er y, a n d fu sed a s closely t o t h e ba t t er y a s
of t h e veh icle. Th e a n t en n a m a st is con n ect ed t o t h e possible.
cen t er wir e of t h e coa xia l a n t en n a ca ble, a n d is n ot • Th e a n t en n a sh ou ld be m ou n t ed on t h e r oof or
gr ou n ded t o a n y pa r t of t h e veh icle. t owa r d t h e r ea r of t h e veh icle. Rem em ber t h a t m a g-
To elim in a t e st a t ic, t h e a n t en n a ba se m u st h a ve a n et ic a n t en n a m ou n t s on t h e r oof pa n el ca n a dver sely
good gr ou n d. Th e coa xia l a n t en n a ca ble sh ield (t h e a ffect t h e oper a t ion of a n over h ea d con sole com pa ss,
ou t er wir e m esh of t h e ca ble) is gr ou n ded t o t h e if t h e veh icle is so equ ipped.
a n t en n a ba se a n d t h e r a dio ch a ssis. • Th e a n t en n a ca ble sh ou ld be fu lly sh ielded coa x-
Th e a n t en n a coa xia l ca ble h a s a n a ddit ion a l dis- ia l ca ble, sh ou ld be a s sh or t a s is pr a ct ica l, a n d
con n ect , loca t ed n ea r t h e r igh t cowl side pa n el sh ou ld be r ou t ed a wa y fr om t h e fa ct or y-in st a lled
beh in d t h e in st r u m en t pa n el. Th is a ddit ion a l discon - veh icle wir e h a r n esses wh en ever possible.
n ect a llows t h e in st r u m en t pa n el a ssem bly t o be • Th e a n t en n a a n d ca ble m u st be ca r efu lly
r em oved a n d in st a lled wit h ou t r em ovin g t h e r a dio. m a t ch ed t o en su r e a low St a n din g Wa ve Ra t io
Th e fa ct or y-in st a lled E lect r on ica lly Tu n ed Ra dios (SWR).
(E TRs) a u t om a t ica lly com pen sa t e for r a dio a n t en n a F leet veh icles a r e a va ila ble wit h a n ext r a -cost RF I-
t r im . Th er efor e, n o a n t en n a t r im m er a dju st m en t is su ppr essed P ower t r a in Con t r ol Modu le (P CM). Th is
r equ ir ed or possible wh en r epla cin g t h e r eceiver or u n it r edu ces in t er fer en ce gen er a t ed by t h e P CM on
t h e a n t en n a . som e r a dio fr equ en cies u sed in t wo-wa y r a dio com -
m u n ica t ion s. H owever, t h is u n it will n ot r esolve com -
RADIO NOISE SUPPRESSION pla in t s of RF I in t h e com m er cia l AM or F M r a dio
Ra dio F r equ en cy In t er fer en ce (RF I) a n d E lect r o- fr equ en cy r a n ges.
Ma gn et ic In t er fer en ce (E MI) n oise su ppr ession is
a ccom plish ed pr im a r ily t h r ou gh cir cu it r y in t er n a l t o
t h e r a dio r eceiver s. Th ese in t er n a l su ppr ession DI AGN OSI S AN D T EST I N G
devices a r e on ly ser viced a s pa r t of t h e r a dio r eceiver.
E xt er n a l su ppr ession devices t h a t a r e ser viced, a n d AUDIO SYSTEM
sh ou ld be ch ecked in t h e ca se of RF I or E MI n oise
WARNING: ON VEHICLES EQUIPPED WITH AIR-
com pla in t s, in clu de t h e followin g:
BAGS, REFER TO GROUP 8M - PASSIVE
• Ra dio a n t en n a ba se gr ou n d
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
• Ra dio ch a ssis gr ou n d wir e, st r a p, or br a cket
STEERING WHEEL, STEERING COLUMN, OR
• E n gin e-t o-body gr ou n d st r a p (if t h e veh icle is so
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
equ ipped)
SERVICE. FAILURE TO TAKE THE PROPER PRE-
• Ca b-t o-bed gr ou n d st r a p (if t h e veh icle is so
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
equ ipped)
BAG DEPLOYMENT AND POSSIBLE PERSONAL
• H ea t er cor e gr ou n d st r a p (if t h e veh icle is so
INJURY.
equ ipped)
• Resist or-t ype spa r k plu gs
• Ra dio su ppr ession -t ype secon da r y ign it ion wir-
in g.
XJ AUDIO SYSTEMS 8F - 3
DI AGN OSI S AN D T EST I N G (Cont inue d)
AU DI O SY ST EM DI AGN OSI S

CONDITION POSSIBLE CAUSE CORRECTION


NO AUDIO. 1. Fuse faulty. 1. Check radio fuses in fuseblock
2. Radio connector faulty. module. Replace fuses, if required.
3. Wiring faulty. 2. Check for loose or corroded radio
4. Ground faulty. connector. Repair, if required.
5. Radio faulty. 3. Check for battery voltage at radio
6. Speakers faulty. connector. Repair wiring, if required.
4. Check for continuity between
radio chassis and a known good
ground. There should be continuity.
Repair ground, if required.
5. Exchange or replace radio, if
required.
6. See speaker diagnosis, in this
group.
NO DISPLAY. 1. Fuse faulty. 1. Check radio fuses in fuseblock
2. Radio connector faulty. module. Replace fuses, if required.
3. Wiring faulty. 2. Check for loose or corroded radio
4. Ground faulty. connector. Repair, if required.
5. Radio faulty. 3. Check for battery voltage at radio
connector. Repair wiring, if required.
4. Check for continuity between
radio chassis and a known good
ground. There should be continuity.
Repair ground, if required.
5. Exchange or replace radio, if
required.
CLOCK WILL NOT KEEP SET 1. Fuse faulty. 1. Check ignition-off draw fuse.
TIME. 2. Radio connector faulty. Replace fuse, if required.
3. Wiring faulty. 2. Check for loose or corroded radio
4. Ground faulty. connector. Repair, if required.
5. Radio faulty. 3. Check for battery voltage at radio
connector. Repair wiring, if required.
4. Check for continuity between
radio chassis and a known good
ground. There should be continuity.
Repair ground, if required.
5. Exchange or replace radio, if
required.
POOR RADIO RECEPTION. 1. Antenna faulty. 1. See antenna diagnosis, in this
2. Ground faulty. group. Repair or replace antenna, if
3. Radio faulty. required.
2. Check for continuity between
radio chassis and a known good
ground. There should be continuity.
Repair ground, if required..
3. Exchange or replace radio, if
required.
8F - 4 AUDIO SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)

CONDITION POSSIBLE CAUSE CORRECTION


NO AUDIO. 1. Fuse faulty. 1. Check radio fuses in fuseblock
2. Radio connector faulty. module. Replace fuses, if required.
3. Wiring faulty. 2. Check for loose or corroded radio
4. Ground faulty. connector. Repair, if required.
5. Radio faulty. 3. Check for battery voltage at radio
6. Speakers faulty. connector. Repair wiring, if required.
4. Check for continuity between
radio chassis and a known good
ground. There should be continuity.
Repair ground, if required.
5. Exchange or replace radio, if
required.
6. See speaker diagnosis, in this
group.
NO/POOR TAPE OPERATION. 1. Faulty tape. 1. Insert known good tape and test
2. Foreign objects behind tape door. operation.
3. Dirty cassette tape head. 2. Remove foreign objects and test
4. Faulty tape deck. operation.
3. Clean head with Mopar Cassette
Head Cleaner.
4. Exchange or replace radio, if
required.
NO COMPACT DISC OPERATION 1. Faulty CD. 1. Insert known good CD and test
2. Foreign material on CD. operation.
3. Condensation on CD or optics. 2. Clean CD and test operation.
4. Faulty CD player. 3. Allow temperature of vehicle
interior to stabilize and test
operation.
4. Exchange or replace radio, if
required.

RADIO (1) Ch eck t h e fu se(s) in t h e ju n ct ion block a n d t h e


F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o P ower Dist r ibu t ion Cen t er (P DC). If OK, go t o St ep
8W-47 - Au dio Syst em in Gr ou p 8W - Wir in g Dia - 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t
gr a m s. a s r equ ir ed a n d r epla ce t h e fa u lt y fu se(s).
(2) Ch eck for ba t t er y volt a ge a t t h e fu se in t h e
WARNING: ON VEHICLES EQUIPPED WITH AIR- P DC. If OK, go t o St ep 3. If n ot OK, r epa ir t h e open
BAGS, REFER TO GROUP 8M - PASSIVE cir cu it t o t h e ba t t er y a s r equ ir ed.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (3) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
STEERING WHEEL, STEERING COLUMN, OR 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
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR block. If OK, go t o St ep 4. If n ot OK, r epa ir t h e open
SERVICE. FAILURE TO TAKE THE PROPER PRE- cir cu it t o t h e ign it ion swit ch a s r equ ir ed.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (4) 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. Rem ove t h e r a dio a s descr ibed in t h is gr ou p, bu t do
n ot u n plu g t h e r a dio wir e h a r n ess con n ect or s. Ch eck
for con t in u it y bet ween t h e r a dio ch a ssis a n d a good
CAUTION: The speaker output of the radio is a gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o St ep
“floating ground” system. Do not allow any speaker 5. If n ot OK, r epa ir t h e open r a dio ch a ssis gr ou n d
lead to short to ground, as damage to the radio cir cu it a s r equ ir ed.
may result. (5) Con n ect 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 t o t h e On posit ion . Ch eck for ba t t er y
volt a ge a t t h e fu sed ign it ion swit ch ou t pu t cir cu it
XJ AUDIO SYSTEMS 8F - 5
DI AGN OSI S AN D T EST I N G (Cont inue d)
ca vit y of t h e left (gr a y) r a dio wir e h a r n ess con n ect or. (4) In st a ll a kn own good r a dio. Con n ect t h e ba t -
If OK, go t o St ep 6. If n ot OK, r epa ir t h e open cir cu it t er y n ega t ive ca ble. Tu r n t h e ign it ion swit ch t o t h e
a s r equ ir ed. On posit ion . Tu r n on t h e r a dio a n d t est t h e spea ker
(6) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . oper a t ion . If OK, r epla ce t h e fa u lt y r a dio. If n ot OK,
Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) cir cu it t u r n t h e r a dio off, t u r n t h e ign it ion swit ch t o t h e Off
ca vit y of t h e left (gr a y) r a dio wir e h a r n ess con n ect or. posit ion , discon n ect a n d isola t e t h e ba t t er y n ega t ive
If OK, r epla ce t h e fa u lt y r a dio. If n ot OK, r epa ir t h e ca ble, r em ove t h e t est r a dio, a n d go t o St ep 5.
open cir cu it t o t h e Ign it ion -Off Dr a w (IOD) fu se a s (5) Un plu g t h e spea ker wir e h a r n ess con n ect or a t
r equ ir ed. t h e in oper a t ive spea ker. Ch eck for con t in u it y
bet ween t h e spea ker feed (+) cir cu it ca vit ies of t h e
SPEAKER r a dio wir e h a r n ess con n ect or a n d t h e spea ker wir e
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o h a r n ess con n ect or. Repea t t h e ch eck bet ween t h e
8W-47 - Au dio Syst em in Gr ou p 8W - Wir in g Dia - spea ker r et u r n (–) cir cu it ca vit ies of t h e r a dio wir e
gr a m s. h a r n ess con n ect or a n d t h e spea ker wir e h a r n ess con -
n ect or. In ea ch ca se, t h er e sh ou ld be con t in u it y. If
WARNING: ON VEHICLES EQUIPPED WITH AIR- OK, r epla ce t h e fa u lt y spea ker. If n ot OK, r epa ir t h e
BAGS, REFER TO GROUP 8M - PASSIVE open cir cu it (s) a s r equ ir ed.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (6) F or ea ch in oper a t ive spea ker loca t ion , ch eck for
STEERING WHEEL, STEERING COLUMN, OR con t in u it y bet ween t h e spea ker feed (+) cir cu it ca vi-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR t ies of t h e r a dio wir e h a r n ess con n ect or s a n d t h e
SERVICE. FAILURE TO TAKE THE PROPER PRE- a m plifier wir e h a r n ess con n ect or s. Repea t t h e ch eck
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- for ea ch in oper a t ive spea ker loca t ion bet ween t h e
BAG DEPLOYMENT AND POSSIBLE PERSONAL spea ker r et u r n (–) cir cu it ca vit ies of t h e r a dio wir e
INJURY. h a r n ess con n ect or s a n d t h e a m plifier wir e h a r n ess
con n ect or s. In ea ch ca se, t h er e sh ou ld be con t in u it y.
If OK, go t o St ep 7. If n ot OK, r epa ir t h e open cir cu it
CAUTION: The speaker output of the radio is a
a s r equ ir ed.
“floating ground” system. Do not allow any speaker
(7) Ch eck for con t in u it y bet ween t h e t wo gr ou n d
lead to short to ground, as damage to the radio
cir cu it ca vit ies of t h e a m plifier wir e h a r n ess con n ec-
may result.
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
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion . OK, go t o St ep 8. If n ot OK, r epa ir t h e open cir cu it (s)
Tu r n t h e r a dio on . Adju st t h e ba la n ce a n d fa der con - a s r equ ir ed.
t r ols t o ch eck t h e per for m a n ce of ea ch in dividu a l (8) Ch eck t h e a m plifier fu se in t h e ju n ct ion block.
spea ker. Not e t h e spea ker loca t ion s t h a t a r e n ot per- If OK, go t o St ep 9. If n ot OK, r epa ir t h e sh or t ed cir-
for m in g cor r ect ly. Go t o St ep 2. cu it or com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y
(2) Tu r n t h e r a dio off. Tu r n t h e ign it ion swit ch t o fu se.
t h e Off posit ion . Discon n ect a n d isola t e t h e ba t t er y (9) Ch eck for ba t t er y volt a ge a t t h e a m plifier fu se
n ega t ive ca ble. Rem ove t h e r a dio a s descr ibed in t h is in t h e ju n ct ion block. If OK, go t o St ep 10. If n ot OK,
gr ou p. If t h e veh icle is equ ipped wit h t h e In fin it y r epa ir t h e open cir cu it t o t h e P DC a s r equ ir ed.
spea ker pa cka ge, a lso u n plu g t h e wir e h a r n ess con - (10) In st a ll t h e r a dio. Con n ect t h e ba t t er y n ega t ive
n ect or s a t t h e a m plifier. Ch eck bot h t h e spea ker feed ca ble. Ch eck for ba t t er y volt a ge a t t h e t wo fu sed B(+)
(+) cir cu it a n d r et u r n (–) cir cu it ca vit ies for t h e in op- cir cu it ca vit ies of t h e a m plifier wir e h a r n ess con n ec-
er a t ive spea ker loca t ion (s) a t t h e r a dio wir e h a r n ess t or. If OK, go t o St ep 11. If n ot OK, r epa ir t h e open
con n ect or s for con t in u it y t o gr ou n d. In ea ch ca se, cir cu it t o t h e fu se in t h e ju n ct ion block a s r equ ir ed.
t h er e sh ou ld be n o con t in u it y. If OK, go t o St ep 3. If (11) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
n ot OK, r epa ir t h e sh or t ed spea ker cir cu it (s) a s Tu r n t h e r a dio on . Ch eck for ba t t er y volt a ge a t t h e
r equ ir ed. r a dio 12 volt ou t pu t cir cu it ca vit y of t h e a m plifier
(3) If t h e veh icle is equ ipped wit h t h e In fin it y wir e h a r n ess con n ect or. If OK, go t o St ep 12. If n ot
spea ker pa cka ge, go t o St ep 6. If t h e veh icle is OK, r epa ir t h e open cir cu it t o t h e r a dio a s r equ ir ed.
equ ipped wit h t h e st a n da r d spea ker syst em , ch eck (12) Tu r n t h e r a dio off. Tu r n t h e ign it ion swit ch t o
t h e r esist a n ce bet ween t h e spea ker feed (+) cir cu it t h e Off posit ion . Discon n ect a n d isola t e t h e ba t t er y
a n d r et u r n (–) cir cu it ca vit ies of t h e r a dio wir e h a r- n ega t ive ca ble. F or ea ch in oper a t ive spea ker loca t ion ,
n ess con n ect or s for t h e in oper a t ive spea ker loca - ch eck bot h t h e a m plified feed (+) cir cu it a n d t h e
t ion (s). Th e m et er sh ou ld r ea d bet ween 2 a n d 12 a m plified r et u r n (–) cir cu it ca vit ies of t h e a m plifier
oh m s (spea ker r esist a n ce). If OK, go t o St ep 4. If n ot wir e h a r n ess con n ect or s for con t in u it y t o gr ou n d. In
OK, go t o St ep 5. ea ch ca se t h er e sh ou ld be n o con t in u it y. If OK, go t o
8F - 6 AUDIO SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
St ep 13. If n ot OK, r epa ir t h e sh or t cir cu it a s
r equ ir ed.
(13) F or ea ch in oper a t ive spea ker loca t ion , ch eck 2
t h e r esist a n ce bet ween t h e a m plified feed (+) cir cu it
a n d t h e a m plified r et u r n (–) cir cu it ca vit ies of t h e
a m plifier wir e h a r n ess con n ect or s. Th e m et er sh ou ld
+
r ea d bet ween 2 a n d 12 oh m s (spea ker r esist a n ce). If
OK, r epla ce t h e fa u lt y a m plifier. If n ot OK, go t o
St ep 14.
(14) Un plu g t h e spea ker wir e h a r n ess con n ect or a t 3
t h e in oper a t ive spea ker. Ch eck for con t in u it y
bet ween t h e a m plified feed (+) cir cu it ca vit ies of t h e
spea ker wir e h a r n ess con n ect or a n d t h e a m plifier
wir e h a r n ess con n ect or. Repea t t h e ch eck bet ween
t h e a m plified r et u r n (–) cir cu it ca vit ies of t h e spea ker
wir e h a r n ess con n ect or a n d t h e a m plifier wir e h a r-
n ess con n ect or. In ea ch ca se t h er e sh ou ld be con t in u -
it y. If OK, r epla ce t h e fa u lt y spea ker. If n ot OK,
r epa ir t h e open cir cu it a s r equ ir ed.
J898F-7
ANTENNA
Fig. 1 Antenna Tests
WARNING: ON VEHICLES EQUIPPED WITH AIR- (2) Con n ect on e oh m m et er t est lea d t o t h e t ip of
BAGS, REFER TO GROUP 8M - PASSIVE t h e a n t en n a m a st . Con n ect t h e ot h er t est lea d t o t h e
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY a n t en n a ba se. Ch eck for con t in u it y.
STEERING WHEEL, STEERING COLUMN, OR (3) Th er e sh ou ld be n o con t in u it y. If con t in u it y is
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR fou n d, r epla ce t h e fa u lt y or da m a ged a n t en n a ba se
SERVICE. FAILURE TO TAKE THE PROPER PRE- a n d ca ble a ssem bly.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL T EST 2
INJURY. Test 2 ch ecks t h e a n t en n a for a n open cir cu it a s
follows:
Th e followin g fou r t est s a r e u sed t o dia gn ose t h e (1) Un plu g t h e a n t en n a coa xia l ca ble con n ect or
a n t en n a wit h a n oh m m et er : fr om t h e r a dio ch a ssis.
• Te s t 1 - Ma st t o gr ou n d t est (2) Con n ect on e oh m m et er t est lea d t o t h e t ip of
• Te s t 2 - Tip-of-m a st t o t ip-of-con du ct or t est t h e a n t en n a m a st . Con n ect t h e ot h er t est lea d t o t h e
• Te s t 3 - Body gr ou n d t o ba t t er y gr ou n d t est cen t er pin of t h e a n t en n a coa xia l ca ble con n ect or.
• Te s t 4 - Body gr ou n d t o coa xia l sh ield t est . (3) Con t in u it y sh ou ld exist (t h e oh m m et er sh ou ld
Th e oh m m et er t est lea d con n ect ion s for ea ch t est on ly r egist er a fr a ct ion of a n oh m ). H igh or in fin it e
a r e sh own in An t en n a Test s (F ig. 1). r esist a n ce in dica t es da m a ge t o t h e ba se a n d ca ble
a ssem bly. Repla ce t h e fa u lt y ba se a n d ca ble, if
NOTE: This model has a two-piece antenna coaxial r equ ir ed.
cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the T EST 3
coaxial cable connection under the right end of the Test 3 ch ecks t h e con dit ion of t h e veh icle body
instrument panel near the right cowl side panel to gr ou n d con n ect ion . Th is t est sh ou ld be per for m ed
the antenna base, and then from the coaxial cable wit h t h e ba t t er y posit ive ca ble r em oved fr om t h e ba t -
connection to the radio chassis connection. t er y. Discon n ect bot h ba t t er y ca bles, t h e n ega t ive
ca ble fir st . Recon n ect t h e ba t t er y n ega t ive ca ble a n d
per for m t h e t est a s follows:
T EST 1
(1) Con n ect on e oh m m et er t est lea d t o t h e veh icle
Test 1 det er m in es if t h e a n t en n a m a st is in su la t ed
fen der. Con n ect t h e ot h er t est lea d t o t h e ba t t er y
fr om t h e ba se. P r oceed a s follows:
n ega t ive post .
(1) Un plu g t h e a n t en n a coa xia l ca ble con n ect or
(2) Th e r esist a n ce sh ou ld be less t h a n on e oh m .
fr om t h e r a dio ch a ssis a n d isola t e.
(3) If t h e r esist a n ce is m or e t h a n on e oh m , ch eck
t h e br a ided gr ou n d st r a p con n ect ed t o t h e en gin e a n d
XJ AUDIO SYSTEMS 8F - 7
DI AGN OSI S AN D T EST I N G (Cont inue d)
t h e veh icle body for bein g loose, cor r oded, or da m - INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
a ged. Repa ir t h e gr ou n d st r a p con n ect ion , if r equ ir ed. SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
T EST 4 BAG DEPLOYMENT AND POSSIBLE PERSONAL
Test 4 ch ecks t h e con dit ion of t h e gr ou n d bet ween INJURY.
t h e a n t en n a ba se a n d t h e veh icle body a s follows:
(1) Con n ect on e oh m m et er t est lea d t o t h e veh icle (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
fen der. Con n ect t h e ot h er t est lea d t o t h e ou t er cr im p ca ble.
on t h e a n t en n a coa xia l ca ble con n ect or. (2) Usin g a t r im st ick or a n ot h er su it a ble wide
(2) Th e r esist a n ce sh ou ld be less t h en on e oh m . fla t -bla ded t ool, gen t ly pr y t h e in st r u m en t pa n el cen -
(3) If t h e r esist a n ce is m or e t h en on e oh m , clea n t er bezel a wa y fr om t h e in st r u m en t pa n el t o r elea se
a n d/or t igh t en t h e a n t en n a ba se t o fen der m ou n t in g t h e six sn a p clip r et a in er s (F ig. 2).
h a r dwa r e.
INSTRUMENT PANEL
RADIO FREQUENCY INTERFERENCE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

In spect t h e gr ou n d con n ect ion s a t t h e followin g:


• Blower m ot or
• E lect r ic fu el pu m p
• Gen er a t or
• Ign it ion m odu le
• Wiper m ot or
• An t en n a coa xia l gr ou n d
• Ra dio gr ou n d S0ab87bc

• Body-t o-en gin e br a ided gr ou n d st r a p (if t h e veh i- FWD RADIO SCREW

cle is so equ ipped). Fig. 2 Center Bezel Remove/Install


Clea n , t igh t en , or r epa ir t h e con n ect ion s a s (3) Rem ove t h e cen t er bezel fr om t h e veh icle.
r equ ir ed. (4) Rem ove t h e t wo scr ews fr om t h e fr on t of t h e
Also in spect t h e followin g secon da r y ign it ion sys- r a dio t h a t secu r e it t o t h e in st r u m en t pa n el (F ig. 3).
t em com pon en t s, a s descr ibed in Gr ou p 8D - Ign it ion
Syst em s: RADIO
• Spa r k plu g wir e r ou t in g a n d con dit ion
• Dist r ibu t or ca p a n d r ot or
• Ign it ion coil
• Spa r k plu gs.
Rer ou t e t h e spa r k plu g wir es or r epla ce t h e fa u lt y
com pon en t s a s r equ ir ed.

REM OVAL AN D I N STALLAT I ON


RADIO
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR Fig. 3 Radio Remove/Install
8F - 8 AUDIO SYSTEMS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(5) P u ll t h e r a dio ou t fr om t h e in st r u m en t pa n el (6) Rem ove t h e a m plifier fr om t h e veh icle.
fa r en ou gh t o u n plu g t h e wir e h a r n ess con n ect or s (7) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
a n d t h e a n t en n a coa xia l ca ble con n ect or (F ig. 4). Tigh t en t h e a m plifier m ou n t in g scr ews t o 2.8 N·m
(25 in . lbs.).
RADIO
ANTENNA SPEAKER
CABLE
FRON T DOOR
~ LOWER
(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) If t h e veh icle is so equ ipped, r em ove t h e m a n -
u a l win dow r egu la t or cr a n k h a n dle wit h a r em ova l
t ool (F ig. 6).
DOOR HANDLE
REMOVAL TOOL

80abac28

Fig. 4 Radio Connections - Typical


(6) Rem ove t h e r a dio fr om t h e veh icle.
(7) 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 r a dio m ou n t in g scr ews t o 5 N·m (45 in .
lbs.).

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.

(5) Lift t h e door t r im pa n el u pwa r ds a n d a wa y

~"
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)

SOUND BAR STUDS LIFTGATE


WIRE HARNESS OPENING UPPER
REINFORCEMENT

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

Fig. 15 Antenna Cap Nut and Adapter Remove/


Install - Typical

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

ou t er pa n el a n d t h e fen der (F ig. 16).


(7) Disen ga ge t h e coa xia l ca ble gr om m et fr om t h e Fig. 16 Antenna Mounting
h ole in t h e r igh t cowl side ou t er pa n el. (10) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
(8) P u ll t h e coa xia l ca ble ou t t h r ou gh t h e r igh t Tigh t en t h e a n t en n a ca p n u t t o 8 N·m (70 in . lbs.).
cowl side ou t er pa n el. Tigh t en t h e a n t en n a m a st t o 3.3 N·m (30 in . lbs.).
(9) Rem ove t h e a n t en n a body a n d ca ble fr om t h e
veh icle.
XJ HORN SYSTEMS 8G - 1

HORN SYSTEMS
CON T EN T S

page page

GENERAL INFORMATION HORN SWITCH . . . . . . . . . . . .............. 2


INTRODUCTION . . . . . . . . . . . ............. 1 HORN . . . . . . . . . . . . . . . . . . .............. 3
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
HORN RELAY . . . . . . . . . . . . . ............. 1 HORN RELAY . . . . . . . . . . . . .............. 3
HORN SWITCH . . . . . . . . . . . . ............. 1 HORN SWITCH . . . . . . . . . . . .............. 4
HORN . . . . . . . . . . . . . . . . . . . ............. 1 HORN . . . . . . . . . . . . . . . . . . .............. 4
DIAGNOSIS AND TESTING
HORN RELAY . . . . . . . . . . . . . ............. 2

GEN ERAL I N FORM AT I ON r ela y fr om t h e ju n ct ion block u n t il fu r t h er dia gn osis


is com plet ed.
INTRODUCTION Th e h or n r ela y ca n n ot be r epa ir ed a n d, if fa u lt y or
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor da m a ged, it m u st be r epla ced.
com pon en t s in t h e fa ct or y-in st a lled h or n syst em s.
Refer t o 8W-41 - H or n s/Ciga r Ligh t er in Gr ou p 8W - HORN SWITCH
Wir in g Dia gr a m s for com plet e cir cu it descr ipt ion s A cen t er-blow, r esist ive m em br a n e t ype h or n
a n d dia gr a m s. swit ch is in st a lled on t h e ba ck side of t h e dr iver side
a ir ba g m odu le t r im cover in t h e cen t er of t h e st eer-
NOTE: This group covers both Left-Hand Drive in g wh eel. Wh en t h e cen t er a r ea of t h e a ir ba g t r im
(LHD) and Right-Hand Drive (RHD) versions of this cover is depr essed, t h e h or n swit ch com plet es a cir-
model. Whenever required and feasible, the RHD cu it t o gr ou n d for t h e coil side of t h e h or n r ela y. Th e
versions of affected vehicle components have been st eer in g wh eel a n d st eer in g colu m n m u st be pr oper ly
constructed as mirror-image of the LHD versions. gr ou n ded for t h e h or n swit ch t o fu n ct ion .
While most of the illustrations used in this group Th e h or n swit ch is on ly ser viced a s a pa r t of t h e
represent only the LHD version, the diagnostic and a ir ba g m odu le t r im cover. If t h e h or n swit ch sh ou ld
service procedures outlined can generally be fa il, or if t h e a ir ba g is deployed, t h e a ir ba g m odu le
applied to either version. Exceptions to this rule t r im cover a n d h or n swit ch u n it m u st be r epla ced.
have been clearly identified as LHD or RHD, if a
special illustration or procedure is required. HORN
Du a l-n ot e, elect r om a gn et ic dia ph r a gm -t ype h or n s
a r e st a n da r d equ ipm en t . Th e low-n ot e h or n is
m ou n t ed a n d gr ou n ded t o t h e left r a dia t or closu r e
DESCRI PT I ON AN D OPERAT I ON
pa n el br a ce, beh in d t h e fr on t bu m per. Th e h igh -n ot e
h or n is con n ect ed in pa r a llel wit h t h e low-n ot e h or n .
HORN RELAY
Th e h igh -n ot e h or n is m ou n t ed a n d gr ou n ded t o t h e
Th e h or n r ela y is a In t er n a t ion a l St a n da r ds Or ga -
r igh t r a dia t or closu r e pa n el br a ce, beh in d t h e fr on t
n iza t ion (ISO) r ela y. Th e r ela y is a elect r om ech a n ica l
bu m per. Bot h h or n s r eceive ba t t er y feed t h r ou gh t h e
device t h a t swit ch es ba t t er y cu r r en t t o t h e h or n
closed con t a ct s of t h e h or n r ela y.
wh en t h e h or n swit ch gr ou n ds t h e r ela y coil. See t h e
Th e h or n s ca n n ot be r epa ir ed or a dju st ed a n d, if
Dia gn osis a n d Test in g sect ion of t h is gr ou p for m or e
fa u lt y or da m a ged, t h ey m u st be r epla ced.
in for m a t ion on t h e oper a t ion of t h e h or n r ela y.
Th e h or n r ela y is loca t ed in t h e ju n ct ion block, on NOTE: A cadmium-plated screw is used to mount
t h e r igh t cowl side pa n el below t h e in st r u m en t pa n el the horns. Do not substitute other types of screws,
in t h e pa ssen ger com pa r t m en t . If a pr oblem is as they may become corroded and cause a loss of
en cou n t er ed wit h a con t in u ou sly sou n din g h or n , it horn ground.
ca n u su a lly be qu ickly r esolved by r em ovin g t h e h or n
8G - 2 HORN SYSTEMS XJ

DI AGN OSI S AN D T EST I N G RELAY CI RCU I T T EST


(1) Th e r ela y com m on feed t er m in a l ca vit y (30) is
HORN RELAY 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
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o t im es. If OK, go t o St ep 2. If n ot OK, r epa ir t h e open
8W-41 - H or n s/Ciga r Ligh t er in Gr ou p 8W - Wir in g cir cu it t o t h e fu se in t h e ju n ct ion block a s r equ ir ed.
Dia gr a m s. (2) Th e r ela y n or m a lly closed t er m in a l (87A) is
con n ect ed t o t er m in a l 30 in t h e de-en er gized posit ion ,
WARNING: ON VEHICLES EQUIPPED WITH AIR- bu t is n ot u sed for t h is a pplica t ion . Go t o St ep 3.
BAGS, REFER TO GROUP 8M - PASSIVE (3) Th e r ela y n or m a lly open t er m in a l (87) is con -
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY 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-
STEERING WHEEL, STEERING COLUMN, OR gized posit ion . Th is t er m in a l su pplies ba t t er y volt a ge
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR t o t h e h or n (s). Th er e sh ou ld be con t in u it y bet ween
SERVICE. FAILURE TO TAKE THE PROPER PRE- t h e ca vit y for r ela y t er m in a l 87 a n d t h e r ela y ou t pu t
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- cir cu it ca vit y of ea ch h or n wir e h a r n ess con n ect or a t
BAG DEPLOYMENT AND POSSIBLE PERSONAL a ll t im es. If OK, go t o St ep 4. If n ot OK, r epa ir t h e
INJURY. open cir cu it t o t h e h or n (s) a s r equ ir ed.
(4) Th e coil ba t t er y t er m in a l (86) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. It is con n ect ed t o ba t -
RELAY T EST t er y volt a ge a n d sh ou ld be h ot a t a ll t im es. Ch eck for
Th e h or n r ela y is loca t ed in t h e ju n ct ion block. Th e ba t t er y volt a ge a t t h e ca vit y for r ela y t er m in a l 86. If
ju n ct ion block is a t t a ch ed t o t h e r igh t cowl side in n er OK, go t o St ep 5. If n ot OK, r epa ir t h e open cir cu it t o
pa n el, below t h e in st r u m en t pa n el a n d beh in d t h e t h e fu se in t h e ju n ct ion block a s r equ ir ed.
r igh t cowl side t r im pa n el. (5) Th e coil gr ou n d t er m in a l (85) is con n ect ed t o
Rem ove t h e h or n r ela y fr om t h e ju n ct ion block a s t h e elect r om a gn et in t h e r ela y. It is gr ou n ded
descr ibed in t h is gr ou p t o per for m t h e followin g t est s: t h r ou gh t h e h or n swit ch wh en t h e h or n swit ch is
(1) A r ela y in t h e de-en er gized posit ion sh ou ld depr essed. Ch eck for con t in u it y t o gr ou n d a t t h e ca v-
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 it y for r ela y t er m in a l 85. Th er e sh ou ld be con t in u it y
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go wit h t h e h or n swit ch depr essed, a n d n o con t in u it y
t o St ep 2. If n ot OK, r epla ce t h e fa u lt y r ela y. wit h t h e h or n swit ch r elea sed. If n ot OK, see t h e
(2) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec- dia gn osis for t h e H or n Swit ch in t h is gr ou p.
t r om a gn et ) sh ou ld be 75 6 5 oh m s. If OK, go t o St ep
3. If n ot OK, r epla ce t h e fa u lt y r ela y. HORN SWITCH
(3) Con n ect a ba t t er y t o t er m inRELAY a ls CAVITIES
RELAY TERMINALS
85 a n d 86. 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 n ow be con t in u it y bet ween t er m in a ls 8W-41 - H or n s/Ciga r Ligh t er in Gr ou p 8W - Wir in g
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 Dia gr a m s.
a n d 30. If OK, see t h e Rela y Cir cu it Test in t h is
gr ou p. If n ot OK, r epla ce t h e fa u lt y r ela y. WARNING: ON VEHICLES EQUIPPED WITH AIR-
RELAY TERMINALS RELAY CAVITIES BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive


85 87 J958A-2
ca ble. Rem ove t h e st eer in g colu m n open in g cover a n d
TERMINAL LEGEND
NUMBER IDENTIFICATION kn ee blocker. Ch eck for con t in u it y bet ween t h e m et a l
30 COMMON FEED st eer in g colu m n ja cket a n d a good gr ou n d. Th er e
85 COIL GROUND
86 COIL BATTERY sh ou ld be con t in u it y. If OK, go t o St ep 2. If n ot OK,
87 NORMALLY OPEN
t--~87~A--+--N~ORMALLY CLOSED
r efer t o Gr ou p 19 - St eer in g a n d ch eck for pr oper
in st a lla t ion of t h e st eer in g colu m n m ou n t in g n u t s.
(2) Rem ove t h e dr iver side a ir ba g m odu le a s
Horn Relay
descr ibed in Gr ou p 8M - P a ssive Rest r a in t Syst em s.
Un plu g t h e h or n swit ch wir e h a r n ess con n ect or fr om
t h e a ir ba g m odu le. Un plu g t h e h or n r ela y fr om t h e
FWD PUSH-NUT FUSE
RIGHT
ACCESS
FRONT
PANEL
DOOR SILL COWL SIDE
SCREW
TRIM SILL
PANELTRIM

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.

NOTE: Do not remove the horn from its mounting


bracket.

(4) Rem ove t h e h or n m ou n t in g br a cket scr ew a n d


lower t h e h or n a n d m ou n t in g br a cket u n it fa r en ou gh J918G-l
t o a ccess t h e wir e h a r n ess con n ect or (F ig. 2).
(5) Un plu g t h e wir e h a r n ess con n ect or fr om t h e Fig. 2 Horns Remove/Install
h or n . N·m (21 ft . lbs.).
(6) Rem ove t h e h or n a n d m ou n t in g br a cket fr om
t h e veh icle.
(7) 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 h or n m ou n t in g br a cket scr ew t o 28.5
XJ VEHICLE SPEED CONTROL SYSTEM 8H - 1

VEHICLE SPEED CONTROL SYSTEM


CON T EN T S

page page

GENERAL INFORMATION SPEED CONTROL ELECTRICAL TEST . . . . . . . 2


INTRODUCTION . . . . . . . . . . . . . . . . . . . . . ... 1 SPEED CONTROL SERVO . . . . . . . . . . . . . . . . 3
DESCRIPTION AND OPERATION SPEED CONTROL SWITCHES . . . . . . . . . . . . . 3
POWERTRAIN CONTROL MODULE . . . . . . . . . . 2 STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 3
SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 2 VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . . . 3
SPEED CONTROL SERVO . . . . . . . . . . . . . . . . 1 VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 3
SPEED CONTROL SWITCHES . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 1 POWERTRAIN CONTROL MODULE . . . . . . . . . . 6
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . 2 SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 5
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 2 SPEED CONTROL SERVO . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING SPEED CONTROL SWITCH . . . . . . . . . . . . . . . . 5
ON-BOARD DIAGNOSTIC TEST FOR SPEED STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 5
CONTROL SYSTEM . . . . . . . . . . . . . . . . . ... 2 VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . 6
OVERSHOOT/UNDERSHOOT FOLLOWING VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 6
SPEED CONTROL SET . . . . . . . . . . . . . . . ... 4 SPECIFICATIONS
POWERTRAIN CONTROL MODULE (PCM) . ... 4 TORQUE CHART . . . . . . . . . . . . . . . . ........ 6
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . ... 2

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 .

VACUUM RESERVOIR CAUTION: When test probing for voltage or conti-


Th e va cu u m r eser voir con t a in s a on e-wa y ch eck nuity at electrical connectors, care must be taken
va lve t o t r a p en gin e va cu u m in t h e r eser voir. Wh en not to damage connector, terminals or seals. If
en gin e va cu u m dr ops, a s in clim bin g a gr a de wh ile these components are damaged, intermittent or
dr ivin g, t h e r eser voir su pplies t h e va cu u m n eeded t o complete system failure may occur.
m a in t a in pr oper speed con t r ol oper a t ion . Th e va cu u m
r eser voir ca n n ot be r epa ir ed a n d m u st be r epla ced if
ON-BOARD DIAGNOSTIC TEST FOR SPEED
fa u lt y.
CONTROL SYSTEM
VEHICLE SPEED SENSOR Th e P ower t r a in Con t r ol Modu le (P CM) m on it or s
Th e Veh icle Speed Sen sor (VSS) is a pu lse gen er a - cr it ica l in pu t a n d ou t pu t cir cu it s of t h e speed con t r ol
t or m ou n t ed t o a n a da pt er n ea r t h e t r a n sm ission ou t - syst em , m a kin g su r e t h ey a r e oper a t ion a l. A Dia gn os-
pu t sh a ft . Th e sen sor is dr iven t h r ou gh t h e a da pt er t ic Tr ou ble Code (DTC) is a ssign ed t o ea ch in pu t a n d
by a speedom et er pin ion gea r. Th e VSS pu lse sign a l ou t pu t cir cu it m on it or ed by t h e On -Boa r d Dia gn ost ic
t o t h e speedom et er /odom et er is m on it or ed by t h e (OBD) syst em . Som e cir cu it s a r e ch ecked con t in u -
P CM speed con t r ol cir cu it r y t o det er m in e veh icle ou sly a n d som e a r e ch ecked on ly u n der cer t a in con -
speed a n d t o m a in t a in speed con t r ol set speed. Refer dit ion s.
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 F or DTC in for m a t ion , r efer t o Dia gn ost ic Tr ou ble
m a n u a l for dia gn osis a n d t est in g of t h is com pon en t . Codes in Gr ou p 25, E m ission Con t r ol Syst em . Th is
Refer t o Gr ou p 14, F u el Syst em for r em ova l/in st a lla - will in clu de a com plet e list of DTC’s in clu din g DTC’s
t ion pr ocedu r es. for t h e speed con t r ol syst em .

SPEED CONTROL ELECTRICAL TEST


DI AGN OSI S AN D T EST I N G Two differ en t t est m et h ods m a y be u sed t o ch eck
t h e elect r on ic speed con t r ol syst em . On e in volves
ROAD TEST u sin g t h e DRB sca n t ool. If t h is t est m et h od is
P er for m a veh icle r oa d t est t o ver ify r epor t s of desir ed, r efer t o t h e a ppr opr ia t e P ower t r a in Dia gn os-
speed con t r ol syst em m a lfu n ct ion . Th e r oa d t est t ic P r ocedu r es ser vice m a n u a l.
sh ou ld in clu de a t t en t ion t o t h e speedom et er. Speed- Th e ot h er t est m et h od will in volve t h e u se of a
om et er oper a t ion sh ou ld be sm oot h a n d wit h ou t flu t - volt /oh m m et er. Th e volt /oh m m et er m et h od is
t er a t a ll speeds. descr ibed wit h in t h e t est s on t h e followin g pa ges.
F lu t t er in t h e speedom et er in dica t es a pr oblem Refer t o Gr ou p 8W, Wir in g Dia gr a m s for speed con -
wh ich m igh t ca u se su r gin g in t h e speed con t r ol sys- t r ol elect r ica l sch em a t ics a n d con n ect or loca t ion .
t em . Th e ca u se of a n y speedom et er pr oblem s sh ou ld
be cor r ect ed befor e pr oceedin g. Refer t o Gr ou p 8E ,
PIN 1 PIN 2 SWITCH

XJ VEHICLE SPEED CONTROL SYSTEM 8H - 3


DI AGN OSI S AN D T EST I N G (Cont inue d)
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.

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.

(1) Discon n ect n ega t ive ba t t er y ca ble. Wa it 2 m in - SPEED CONTROL SERVO


u t es for a ir ba g syst em ca pa cit or t o disch a r ge. F or com plet e speed con t r ol syst em dia gn osis, r efer
(2) Rem ove t h e t wo speed con t r ol swit ch m odu les 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
fr om st eer in g wh eel. Refer t o t h e r em ova l/in st a lla t ion m a n u a l. To t est t h e speed con t r ol ser vo on ly, r efer t o
sect ion for pr ocedu r es. t h e followin g:
(3) Ch eck con t in u it y of ea ch in dividu a l speed con - Th e en gin e m u st be st a r t ed a n d r u n n in g for t h e
t r ol swit ch m odu le a s sh own in ch a r t (F ig. 1). If OK, followin g volt a ge t est s.
r ein st a ll swit ch . If n ot OK, r epla ce swit ch m odu le (1) St a r t en gin e.
a ssem bly. (2) Discon n ect 4–wa y elect r ica l con n ect or a t ser vo.
(3) Tu r n speed con t r ol swit ch t o ON posit ion .
STOP LAMP SWITCH (4) Ch eck for ba t t er y volt a ge a t pin –3 of wir in g
F or con t in u it y ch ecks a n d swit ch a dju st m en t , r efer h a r n ess 4–wa y con n ect or (F ig. 2). Th is is t h e 12 volt
t o Gr ou p 5, Br a kes. feed fr om t h e st opla m p swit ch . Wh en t h e br a ke peda l
is depr essed, volt a ge sh ou ld n ot be pr esen t a t pin –3.
VACUUM SUPPLY TEST If volt a ge is n ot pr esen t wit h br a ke peda l n o t
(1) Discon n ect va cu u m h ose a t speed con t r ol ser vo depr essed, ch eck for con t in u it y bet ween ser vo a n d
a n d in st a ll a va cu u m ga u ge in t o t h e discon n ect ed st op la m p swit ch . Also ch eck st op la m p swit ch
h ose. a dju st m en t . Refer t o Gr ou p 5, Br a kes for pr ocedu r es.
8H - 4 VEHICLE SPEED CONTROL SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
(5) Con n ect a sm a ll ga u ge ju m per wir e bet ween To “u n lea r n ” t h e over sh oot /u n der sh oot con dit ion ,
t h e discon n ect ed ser vo h a r n ess 4–wa y con n ect or t h e veh icle oper a t or h a s t o pr ess a n d r elea se t h e set
pin –3, a n d pin –3 on t h e ser vo. Ch eck for ba t t er y volt - bu t t on wh ile m a in t a in in g t h e desir ed set speed wit h
a ge a t pin s–1, 2 a n d 4 of t h e ser vo. If ba t t er y volt a ge t h e a cceler a t or peda l (n ot deceler a t in g or a cceler a t -
is n ot a t t h ese pin s, r epla ce t h e ser vo. in g), a n d t h en t u r n t h e cr u ise con t r ol swit ch t o t h e
OF F posit ion (or pr ess t h e CANCE L bu t t on if
equ ipped) a ft er wa it in g 10 secon ds. Th is pr ocedu r e
m u st be per for m ed a ppr oxim a t ely 10–15 t im es t o
PIN 2 PIN 3 com plet ely u n lea r n t h e over sh oot /u n der sh oot con di-
t ion .

REM OVAL AN D I N STALLAT I ON


SPEED CONTROL SERVO
REM OVAL
CONNECTORS SHOWN
FROM TERMINAL END (1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Discon n ect va cu u m h ose a t ser vo.
(3) Discon n ect elect r ica l con n ect or a t ser vo.
(4) Block t h r ot t le t o fu ll open posit ion .
(5) Rem ove 2 ser vo m ou n t in g n u t s h oldin g ca ble
a n d ca ble sleeve t o m ou n t in g br a cket .
80a51268 (6) P u ll ser vo a wa y fr om m ou n t in g br a cket t o
expose ca ble r et a in in g clip (F ig. 3) a n d r em ove clip.
Fig. 2 Servo 4–Way Harness Connector
(6) Tu r n ign it ion swit ch t o OF F posit ion . Ch eck for
con t in u it y bet ween discon n ect ed ser vo h a r n ess
4–wa y con n ect or pin –4 a n d a good gr ou n d. Th er e
sh ou ld be con t in u it y. If n ot OK, r epa ir open cir cu it t o
gr ou n d a s r equ ir ed.

POWERTRAIN CONTROL MODULE (PCM)


F or com plet e P CM dia gn osis of t h e speed con t r ol
syst em , r efer t o t h e DRB sca n t ool a n d t h e a ppr opr i- SERVO
a t e P ower t r a in Dia gn ost ic P r ocedu r es ser vice m a n - CABLE AND
u a l. SLEEVE

OVERSHOOT/UNDERSHOOT FOLLOWING SPEED


CONTROL SET CABLE RETAINING CLIP 80a92a68
If t h e oper a t or r epea t edly pr esses a n d r elea ses t h e
set bu t t on wit h t h eir foot off of t h e a cceler a t or (a “lift Fig. 3 Servo Cable Clip Remove/Install
foot set ” t o begin speed con t r ol oper a t ion ), t h e veh icle
(7) P u ll ser vo a wa y fr om ca ble a n d r em ove fr om
m a y a cceler a t e a n d exceed t h e desir ed set speed by
veh icle.
u p t o 5 MP H (8 km /h ) a n d t h en deceler a t e t o less
t h a n t h e desir ed set speed befor e fin a lly a ch ievin g I N STALLAT I ON
t h e desir ed set speed. (1) P osit ion ser vo n ea r en d of ser vo ca ble.
Th e Speed Con t r ol h a s a n a da pt ive st r a t egy t h a t (2) Block t h r ot t le t o fu ll open posit ion . Align h ole
com pen sa t es for veh icle-t o-veh icle va r ia t ion s in speed in ca ble sleeve wit h h ole in ser vo pin a n d in st a ll
con t r ol ca ble len gt h s. Wh en t h e speed con t r ol is set ca ble r et a in in g clip (F ig. 3).
wit h t h e veh icle oper a t or s foot off of t h e a cceler a t or (3) In ser t ser vo st u ds t h r ou gh h oles in ser vo
peda l, t h e speed con t r ol t h in ks t h er e is excessive m ou n t in g br a cket .
speed con t r ol ca ble sla ck a n d a da pt s. If t h e lift foot (4) In st a ll ser vo m ou n t in g n u t s. Tigh t en t o 8.5
set s a r e con t in u a lly u sed, t h e speed con t r ol over- N·m (75 in . lbs.) t or qu e.
sh oot /u n der sh oot con dit ion will develop. (5) Con n ect va cu u m h ose a t ser vo.
(6) Con n ect elect r ica l con n ect or a t ser vo.
XJ VEHICLE SPEED CONTROL SYSTEM 8H - 5
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(7) Rem ove t h r ot t le block. STOP LAMP SWITCH
(8) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y. Refer t o St op La m p Swit ch in Gr ou p 5, Br a kes for
r em ova l/in st a lla t ion a n d a dju st m en t pr ocedu r es.
SPEED CONTROL SWITCH
SERVO CABLE
WARNING: BEFORE ATTEMPTING TO DIAGNOSE,
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR REM OVAL
RELATED STEERING WHEEL AND STEERING COL- (1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
UMN COMPONENTS YOU MUST FIRST DISCON- (2) Usin g fin ger pr essu r e on ly, r em ove ca ble con -
NECT AND ISOLATE THE BATTERY NEGATIVE n ect or by pu sh in g con n ect or off t h e t h r ot t le body
(GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM bellcr a n k pin (F ig. 5). D O N OT try to p u ll c a ble
CAPACITOR TO DISCHARGE BEFORE FURTHER c o n n e c to r o ff p e rp e n d ic u la r to th e be llc ra n k
SYSTEM SERVICE. FAILURE TO DO SO COULD p in . Co n n e c to r w ill be bro k e n .
RESULT IN ACCIDENTAL DEPLOYMENT AND POS- (3) Two squ eeze t a bs a r e loca t ed on sides of speed
SIBLE PERSONAL INJURY. con t r ol ca ble a t ca ble lockin g pla t e (F ig. 6). Squ eeze
t h e t a bs t oget h er a n d pu sh ca ble ou t of ca ble lockin g
plaBELLCRANK
t e. CABLEPUSH
SPEED
CONTROL
CONNEC-
CABLE
TOR
REM OVAL
(4) Un clip ca ble fr om ca ble gu ide a t va lve cover
(1) Discon n ect a n d isola t e n ega t ive ba t t er y ca ble
(F ig. 6).
fr om ba t t er y.
(5) Discon n ect ser vo ca ble a t ser vo. Refer t o Speed
(2) Rem ove a ir ba g m odu le. Refer t o Gr ou p 8M,
Con t r ol Ser vo—Rem ova l/In st a lla t ion .
P a ssive Rest r a in t Syst em s for pr ocedu r es.
(3) F r om u n der side of st eer in g wh eel, r em ove
speed con t r ol swit ch m ou n t in g scr ew (F ig. 4).

SPEED
CONTROL
SWITCH

SCREW
r
MOUNTING
80aac283

Fig. 4 Speed Control Switch Remove/Install


(4) Rem ove swit ch fr om st eer in g wh eel a n d u n plu g
elect r ica l con n ect or.
SPEED
I N STALLAT I ON CONTROL
J948H-24 CABLE
(1) P lu g elect r ica l con n ect or in t o swit ch .
(2) P osit ion swit ch t o st eer in g wh eel.
Fig. 5 Servo Cable to Bellcrank—Remove/Install
(3) In st a ll swit ch m ou n t in g scr ew a n d t igh t en t o
1.5 N·m (14 in . lbs.) t or qu e. I N STALLAT I ON
(4) In st a ll a ir ba g m odu le. Refer t o Gr ou p 8M, P a s- (1) At t a ch en d of ca ble t o speed con t r ol ser vo.
sive Rest r a in t Syst em s for pr ocedu r es. Refer t o Speed Con t r ol Ser vo Rem ova l/In st a lla t ion .
(5) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y. (2) In st a ll ca ble in t o ca ble lockin g pla t e (sn a ps in ).
(3) In st a ll ca ble con n ect or a t t h r ot t le body
bellcr a n k pin (sn a ps on ).
TRANSMISSION
CABLE SPEED CONTROL
CABLE ACCELERATOR
CABLE BUMPER
VACUUM
END CAP
RESER-
VOIR VACUUM LINE
VACUUM
RESERVOIR
RESERVOIR
SCREWS
CABLE SQUEEZE
LOCKING
GUIDE PLATE
TABS

8H - 6 VEHICLE SPEED CONTROL SYSTEM XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)

BUMPER
END CAP

. \ \\
VACUUM \ \~,
RESERVOIR\ so:a~~s1

Fig. 7 Vacuum Reservoir Location

Fig. 6 Squeeze Tabs at Cable Locking Plate


(4) Clip ca ble t o ca ble gu ide a t va lve cover.
(5) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y.

POWERTRAIN CONTROL MODULE


F or Rem ova l/In st a lla t ion r efer t o P ower t r a in Con -
t r ol Modu le in Gr ou p 14, F u el In ject ion Syst em .

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

TURN SIGNAL AND HAZARD WARNING SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION TURN SIGNAL SYSTEM . . . . . . . . . . . . ...... 1


INTRODUCTION . . . . . . . . . . . . . . . . ........ 1 DIAGNOSIS AND TESTING
DESCRIPTION AND OPERATION INTRODUCTION . . . . . . . . . . . . . . . . . . ...... 2
COMBINATION FLASHER . . . . . . . . . . . . . . . . . 1 MULTI-FUNCTION SWITCH . . . . . . . . . . ...... 3
HAZARD WARNING SYSTEM . . . . . . . . . . . . . . 1 TURN SIGNAL AND HAZARD WARNING
TURN SIGNAL INDICATOR LAMP . . . . . . . . . . . 2 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . ...... 2
TURN SIGNAL LAMP . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL AND INSTALLATION
TURN SIGNAL SWITCH AND HAZARD COMBINATION FLASHER . . . . . . . . . . . ...... 3
WARNING SWITCH . . . . . . . . . . . . ........ 2 MULTI-FUNCTION SWITCH . . . . . . . . . . ...... 4

GEN ERAL I N FORM AT I ON m u lt i-fu n ct ion swit ch , t h e t u r n sign a l swit ch a u t o-


m a t ica lly r et u r n s t o t h e off posit ion .
INTRODUCTION Wh en t h e t u r n sign a l syst em is a ct iva t ed, t h e
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor select ed (r igh t or left ) t u r n sign a l in dica t or la m p,
com pon en t s in t h e t u r n sign a l a n d h a za r d wa r n in g fr on t pa r k/t u r n sign a l la m p, fr on t side m a r ker la m p,
syst em s. Refer t o 8W-52 - Tu r n Sign a ls in Gr ou p 8W a n d r ea r t a il/st op/t u r n sign a l la m p bu lbs will fla sh .
- Wir in g Dia gr a m s for com plet e cir cu it descr ipt ion s Wit h t h e h ea dla m p swit ch in t h e Off posit ion , t h e
a n d dia gr a m s. fr on t t u r n sign a l a n d fr on t side m a r ker la m ps fla sh
in u n ison . Wit h t h e h ea dla m p swit ch in t h e On posi-
NOTE: This group covers both Left-Hand Drive t ion , t h e fr on t t u r n sign a l a n d fr on t side m a r ker
(LHD) and Right-Hand Drive (RHD) versions of this la m ps fla sh a lt er n a t ely.
model. Whenever required and feasible, the RHD
versions of affected vehicle components have been HAZARD WARNING SYSTEM
constructed as mirror-image of the LHD versions. Th e h a za r d wa r n in g syst em is a ct iva t ed by a
While most of the illustrations used in this group swit ch bu t t on in t h e m u lt i-fu n ct ion swit ch . Th e bu t -
represent only the LHD version, the diagnostic and t on is loca t ed on t h e t op of t h e st eer in g colu m n
service procedures outlined can generally be bet ween t h e st eer in g wh eel a n d t h e in st r u m en t
applied to either version. Exceptions to this rule pa n el. Th e h a za r d wa r n in g swit ch bu t t on is iden t i-
have been clearly identified as LHD or RHD, if a fied wit h a dou ble t r ia n gle.
special illustration or procedure is required. Th e h a za r d wa r n in g syst em is con n ect ed t o a n on -
swit ch ed ba t t er y feed so t h a t t h e syst em r em a in s
fu n ct ion a l, r ega r dless of t h e ign it ion swit ch posit ion .
Slide t h e swit ch bu t t on t o t h e left t o a ct iva t e t h e h a z-
DESCRI PT I ON AN D OPERAT I ON
a r d wa r n in g syst em , a n d slide t h e swit ch bu t t on t o
t h e r igh t t o t u r n t h e syst em off.
TURN SIGNAL SYSTEM
Wh en t h e h a za r d wa r n in g syst em is a ct iva t ed, t h e
Wit h t h e ign it ion swit ch in t h e On posit ion , a n d
r igh t a n d left t u r n sign a l in dica t or s, fr on t pa r k/t u r n
t h e m u lt i-fu n ct ion swit ch con t r ol lever m oved u p
sign a l la m ps, fr on t side m a r ker la m ps, a n d r ea r t a il/
(r igh t t u r n ) or down (left t u r n ), t h e t u r n sign a l sys-
st op/t u r n sign a l la m ps will fla sh . Wit h t h e h ea dla m p
t em is a ct iva t ed. Th e swit ch h a s a det en t posit ion in
swit ch in t h e Off posit ion , t h e fr on t t u r n sign a l a n d
ea ch dir ect ion t h a t pr ovides t u r n sign a ls wit h a u t o-
fr on t side m a r ker la m ps fla sh in u n ison . Wit h t h e
m a t ic ca n cella t ion , a n d a n in t er m edia t e m om en t a r y
h ea d or pa r k la m ps t u r n ed on , t h e fr on t t u r n sign a l
posit ion t h a t pr ovides t u r n sign a ls on ly u n t il t h e
a n d fr on t side m a r ker la m ps fla sh a lt er n a t ely.
m u lt i-fu n ct ion swit ch lever is r elea sed.
Wh en t h e t u r n sign a l swit ch is in a det en t posi-
COMBINATION FLASHER
t ion , it is t u r n ed off by on e of t wo ca n cellin g ca m
Th e com bin a t ion fla sh er is a sm a r t r ela y t h a t fu n c-
lobes m olded in t o t h e h u b of t h e clockspr in g m ech a -
t ion s a s bot h t h e t u r n sign a l syst em a n d h a za r d
n ism . Wh en t u r n in g t h e st eer in g wh eel ca u ses on e of
wa r n in g syst em fla sh er. Th e com bin a t ion fla sh er is
t h e ca m lobes t o con t a ct a ca n cel a ct u a t or in t h e
HAZARD WARNING
CONTROLBUTTON
STALK CANCEL
ACTUATOR

8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS XJ


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
design ed t o h a n dle t h e cu r r en t flow r equ ir em en t s of
t h e fa ct or y-in st a lled ligh t in g.
If su pplem en t a l ligh t in g is a dded t o t h e t u r n sign a l
la m p cir cu it s, su ch a s wh en t owin g a t r a iler wit h
ligh t s, t h e com bin a t ion fla sh er will a u t om a t ica lly
com pen sa t e. Th is a llows t h e fla sh r a t e t o r em a in t h e
sa m e, r ega r dless of elect r ica l loa d in cr ea ses. H ow-
ever, if a bu lb fa ils in t h e t u r n sign a l la m p cir cu it s,
t h e fla sh r a t e of t h e r em a in in g bu lbs in t h a t cir cu it
will in cr ea se t o 120 fla sh es-per-m in u t e, or h igh er.
Wh ile t h e com bin a t ion fla sh er sh a r es t h e t er m in a l
or ien t a t ion (foot pr in t ) of a In t er n a t ion a l St a n da r ds
Or ga n iza t ion (ISO)-t ype r ela y, t h e in t er n a l cir cu it r y
is m u ch differ en t . Th e com bin a t ion fla sh er con t a in s CONTROL STALK
a ct ive elect r on ic in t egr a t ed cir cu it r y elem en t s. Do n ot 948J-15
su bst it u t e a n y ot h er r ela y for t h e com bin a t ion
fla sh er. Fig. 1 Multi-Function Switch
Beca u se of t h e a ct ive elect r on ic elem en t s wit h in
TURN SIGNAL LAMP
t h e com bin a t ion fla sh er, it ca n n ot be t est ed wit h con -
Th e ext er ior la m ps in t h e t u r n sign a l a n d h a za r d
ven t ion a l a u t om ot ive elect r ica l t est equ ipm en t . If t h e
wa r n in g cir cu it s in clu de t h e fr on t pa r k/t u r n sign a l,
com bin a t ion fla sh er is believed t o be fa u lt y, t est t h e
t h e fr on t side m a r ker, a n d t h e r ea r t a il/st op/t u r n sig-
t u r n sign a l a n d h a za r d wa r n in g syst em cir cu it s a s
n a l. F or dia gn osis a n d ser vice of t h ese la m ps, r efer t o
descr ibed in t h is gr ou p. Th en r epla ce t h e com bin a -
Gr ou p 8L - La m ps.
t ion fla sh er wit h a kn own good u n it t o con fir m sys-
t em oper a t ion .
Th e com bin a t ion fla sh er ca n n ot be r epa ir ed a n d, if DI AGN OSI S AN D T EST I N G
fa u lt y, it m u st be r epla ced.
INTRODUCTION
TURN SIGNAL SWITCH AND HAZARD WARNING Wh en dia gn osin g t h e t u r n sign a l or h a za r d wa r n -
SWITCH in g cir cu it s, r em em ber t h a t h igh gen er a t or ou t pu t
Th e t u r n sign a l a n d h a za r d wa r n in g swit ch es a r e ca n bu r n ou t bu lbs r a pidly a n d r epea t edly. If t h is is a
in t egr a l t o t h e m u lt i-fu n ct ion swit ch a ssem bly. Th e pr oblem on t h e veh icle bein g dia gn osed, r efer t o
m u lt i-fu n ct ion swit ch a ssem bly is m ou n t ed t o t h e left Gr ou p 8C - Ch a r gin g Syst em for fu r t h er dia gn osis of
side of t h e st eer in g colu m n (F ig. 1). Th is swit ch con - a possible gen er a t or over ch a r gin g con dit ion .
t a in s cir cu it r y for t h e followin g fu n ct ion s:
• Tu r n sign a ls WARNING: ON VEHICLES EQUIPPED WITH AIR-
• H a za r d wa r n in g BAGS, REFER TO GROUP 8M - PASSIVE
• H ea dla m p bea m select ion RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
• H ea dla m p opt ica l h or n . STEERING WHEEL, STEERING COLUMN, OR
Th e in for m a t ion con t a in ed in t h is gr ou p a ddr esses INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
on ly t h e m u lt i-fu n ct ion swit ch fu n ct ion s for t h e t u r n SERVICE. FAILURE TO TAKE THE PROPER PRE-
sign a l a n d h a za r d wa r n in g cir cu it s. F or in for m a t ion CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
r ela t ive t o t h e ot h er swit ch fu n ct ion s, r efer t o t h e BAG DEPLOYMENT AND POSSIBLE PERSONAL
pr oper gr ou p. H owever, t h e m u lt i-fu n ct ion swit ch INJURY.
ca n n ot be r epa ir ed. If a n y fu n ct ion of t h e m u lt i-fu n c-
t ion swit ch is fa u lt y, or if t h e swit ch is da m a ged, t h e
en t ir e swit ch a ssem bly m u st be r epla ced. TURN SIGNAL AND HAZARD WARNING SYSTEMS
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
TURN SIGNAL INDICATOR LAMP 8W-52 - Tu r n Sign a ls in Gr ou p 8W - Wir in g Dia -
Th e t u r n sign a l in dica t or la m ps a r e loca t ed in t h e gr a m s.
in st r u m en t clu st er. Th ey fla sh wit h t h e ext er ior t u r n
sign a l la m ps t o give t h e dr iver a visu a l in dica t ion
t h a t a t u r n sign a l or t h e h a za r d wa r n in g syst em is
oper a t in g. F or dia gn osis a n d ser vice of t h ese la m ps,
r efer t o Gr ou p 8E - In st r u m en t P a n el Syst em s.
XJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3
DI AGN OSI S AN D T EST I N G (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR- (8) Un plu g t h e m u lt i-fu n ct ion swit ch wir e h a r n ess
BAGS, REFER TO GROUP 8M - PASSIVE con n ect or a s descr ibed in t h is gr ou p. Ch eck for con -
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY t in u it y bet ween t h e com bin a t ion fla sh er t u r n sign a l
STEERING WHEEL, STEERING COLUMN, OR cir cu it ca vit ies in t h e com bin a t ion fla sh er wir e h a r-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR n ess con n ect or a n d in t h e m u lt i-fu n ct ion swit ch wir e
SERVICE. FAILURE TO TAKE THE PROPER PRE- h a r n ess con n ect or. Th er e sh ou ld be con t in u it y. If OK,
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- go t o St ep 9. If n ot OK, r epa ir t h e open cir cu it a s
BAG DEPLOYMENT AND POSSIBLE PERSONAL r equ ir ed.
INJURY. (9) Ch eck for con t in u it y bet ween t h e com bin a t ion
fla sh er h a za r d wa r n in g cir cu it ca vit ies in t h e com bi-
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion . n a t ion fla sh er wir e h a r n ess con n ect or a n d in t h e
Act u a t e t h e t u r n sign a l lever or h a za r d wa r n in g bu t - m u lt i-fu n ct ion swit ch wir e h a r n ess con n ect or. Th er e
t on . Obser ve t h e t u r n sign a l in dica t or la m p(s) in t h e sh ou ld be con t in u it y. If OK, t est t h e m u lt i-fu n ct ion
in st r u m en t clu st er. If t h e fla sh r a t e is ver y h igh , swit ch a s descr ibed in t h is gr ou p. If n ot OK, r epa ir
ch eck for a t u r n sign a l bu lb t h a t is n ot lit or is ver y t h e open cir cu it a s r equ ir ed.
dim ly lit . Repa ir t h e cir cu it s t o t h a t la m p or r epla ce
t h e fa u lt y bu lb, a s r equ ir ed. Test t h e oper a t ion of t h e MULTI-FUNCTION SWITCH
t u r n sign a l a n d h a za r d wa r n in g syst em s a ga in . If t h e P er for m t h e dia gn osis of t h e h a za r d wa r n in g
t u r n sign a l in dica t or (s) fa il t o ligh t , go t o St ep 2. a n d/or t u r n sign a l syst em s a s descr ibed in t h is gr ou p
(2) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . befor e t est in g t h e m u lt i-fu n ct ion swit ch . F or cir cu it
Ch eck t h e t u r n sign a l fu se in t h e ju n ct ion block descr ipt ion s a n d dia gr a m s, r efer t o 8W-52 - Tu r n Sig-
a n d/or t h e h a za r d wa r n in g fu se in t h e P ower Dist r i- n a ls in Gr ou p 8W - Wir in g Dia gr a m s.
bu t ion Cen t er (P DC). If OK, go t o St ep 3. If n ot OK,
r epa ir t h e sh or t ed cir cu it or com pon en t a s r equ ir ed WARNING: ON VEHICLES EQUIPPED WITH AIR-
a n d r epla ce t h e fa u lt y fu se(s). BAGS, REFER TO GROUP 8M - PASSIVE
(3) Tu r n t h e ign it ion swit ch t o t h e On posit ion t o RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
ch eck for ba t t er y volt a ge a t t h e t u r n sign a l fu se in STEERING WHEEL, STEERING COLUMN, OR
t h e ju n ct ion block; or, lea ve t h e ign it ion swit ch in t h e INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
Off posit ion t o ch eck for ba t t er y volt a ge a t t h e h a z- SERVICE. FAILURE TO TAKE THE PROPER PRE-
a r d wa r n in g fu se in t h e P DC. If OK, go t o St ep 4. If CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
n ot OK, r epa ir t h e open cir cu it a s r equ ir ed. BAG DEPLOYMENT AND POSSIBLE PERSONAL
(4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . INJURY.
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Un plu g t h e com bin a t ion fla sh er fr om it s wir e h a r- (1) Un plu g t h e m u lt i-fu n ct ion swit ch wir e h a r n ess
n ess con n ect or a n d r epla ce it wit h a kn own good con n ect or a s descr ibed in t h is gr ou p.
u n it . Con n ect t h e ba t t er y n ega t ive ca ble. Test t h e (2) Usin g a n oh m m et er, per for m t h e swit ch con t i-
oper a t ion of t h e t u r n sign a l a n d h a za r d wa r n in g sys- 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
t em s. If OK, disca r d t h e fa u lt y com bin a t ion fla sh er. Mu lt i-F u n ct ion Swit ch Con t in u it y ch a r t (F ig. 2).
If n ot OK, r em ove t h e t est fla sh er a n d go t o St ep 5. (3) If t h e swit ch fa ils a n y of t h e con t in u it y ch ecks,
(5) Tu r n t h e ign it ion swit ch t o t h e On posit ion . r epla ce t h e fa u lt y swit ch . If t h e swit ch is OK, r epa ir
Ch eck for ba t t er y volt a ge a t t h e com bin a t ion fla sh er t h e ligh t in g cir cu it s a s r equ ir ed.
fu sed ign it ion cir cu it ca vit y in t h e com bin a t ion
fla sh er wir e h a r n ess con n ect or. If OK, go t o St ep 6. If
REM OVAL AN D I N STALLAT I ON
n ot OK, go t o St ep 8.
(6) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
COMBINATION FLASHER
Ch eck for ba t t er y volt a ge a ga in a t t h e com bin a t ion
fla sh er fu sed B+ cir cu it ca vit y in t h e com bin a t ion WARNING: ON VEHICLES EQUIPPED WITH AIR-
fla sh er wir e h a r n ess con n ect or. If OK, go t o St ep 7. If BAGS, REFER TO GROUP 8M - PASSIVE
n ot OK, go t o St ep 8. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
(7) Discon n ect a n d isola t e t h e ba t t er y n ega t ive STEERING WHEEL, STEERING COLUMN, OR
ca ble. Ch eck for con t in u it y bet ween t h e gr ou n d cir- INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
cu it ca vit y of t h e com bin a t ion fla sh er wir e h a r n ess SERVICE. FAILURE TO TAKE THE PROPER PRE-
con n ect or a n d a good gr ou n d. Th er e sh ou ld be con t i- CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
n u it y. If OK, go t o St ep 8. If n ot OK, r epa ir t h e cir- BAG DEPLOYMENT AND POSSIBLE PERSONAL
cu it t o gr ou n d a s r equ ir ed. INJURY.
DIAGNOSTICS
OUTBOARD
DATA JLINK
HI—
K
STEERING

UMN

RIGHT
CONNECTOR
LEFT
RIGHT
LEFT
OPENING
SPLICE
BLOCK
FRONT
REAR
COL- DIAGNOSTICS MOUNTING
BRACKET
COMBINATION
INSTRUMENT
AND
FWD
PANEL
CONNECTOR
TESY
FLASHER
COUR-
LAMP

8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) P u ll t h e com bin a t ion fla sh er a n d wir e h a r n ess
SWITCH con n ect or in t o t h e st eer in g colu m n open in g fa r
POSITION CONTINUITY
BETWEEN en ou gh t o u n plu g t h e fla sh er fr om t h e wir e h a r n ess
TURN HAZARD con n ect or.
SIGNAL WARNING (5) In st a ll t h e com bin a t ion fla sh er by a lign in g t h e
NEUTRAL OFF F and H L fla sh er t er m in a ls wit h t h e ca vit ies in t h e wir e h a r-
F and K
IB
El n ess con n ect or a n d pu sh in g t h e fla sh er fir m ly in t o
Aand E - B2 pla ce.
IA H
LEFT OFF F and H 11 (6) Rein st a ll t h e r et a in er t h a t secu r es t h e com bi-
Cand
Cand
K
I
- le Bl n a t ion fla sh er a n d wir e h a r n ess con n ect or t o t h e
Aand E
Kl in st r u m en t pa n el dia gon a l m ou n t in g br a cket .
IH (7) Rein st a ll t h e kn ee blocker a n d t h e st eer in g col-
RIGHT OFF F and K GI
Cand H - u m n open in g cover a s descr ibed in Gr ou p 8E -
Cand J
IF In st r u m en t P a n el Syst em s.
Aand E DI (8) Con n ect t h e ba t t er y n ega t ive ca ble.
NEUTRAL ON Band E ~ (9) Test t h e fla sh er oper a t ion .
Cand H H - RIGHT REAR
Cand K I - LEFT FRONT MULTI-FUNCTION SWITCH
Cand I J - RIGHT FRONT
C and J K - LEFT REAR WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
948J- l 2
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
Fig. 2 Multi-Function Switch Continuity STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
SERVICE. FAILURE TO TAKE THE PROPER PRE-
ca ble.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(2) Rem ove t h e st eer in g colu m n open in g cover a n d
BAG DEPLOYMENT AND POSSIBLE PERSONAL
t h e kn ee blocker a s descr ibed in Gr ou p 8E - In st r u -
INJURY.
m en t P a n el Syst em s.
(3) Rea ch t h r ou gh t h e ou t boa r d side of t h e st eer- (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
in g colu m n open in g a n d r em ove t h e com bin a t ion ca ble.
fla sh er a n d wir e h a r n ess con n ect or fr om t h e in st r u - (2) Rem ove t h e st eer in g colu m n open in g cover a s
m en t pa n el dia gon a l m ou n t in g br a cket by gen t ly pr y- descr ibed in Gr ou p 8E - In st r u m en t P a n el Syst em s.
in g t h e con n ect or r et a in er fr om t h e br a cket m ou n t in g (3) If t h e veh icle is so equ ipped, m ove t h e t ilt
h ole (F ig. 3). st eer in g colu m n t o t h e fu lly r a ised posit ion .
DIAGNOSTICS (4) In ser t t h e key in t h e ign it ion lock cylin der a n d
MOUNTING BRACKET t u r n t h e ign it ion swit ch t o t h e On posit ion .
(5) In ser t a sm a ll scr ewdr iver or pin pu n ch
COMBINATION t h r ou gh t h e a ccess h ole in t h e lower st eer in g colu m n
FLASHER AND sh r ou d a n d depr ess t h e ign it ion lock cylin der r et a in -
CONNECTOR in g t u m bler (F ig. 4).
(6) Wh ile h oldin g t h e r et a in in g t u m bler depr essed,
pu ll t h e ign it ion lock cylin der a n d key ou t of t h e ign i-
OUTBOARD t ion lock h ou sin g.
STEERING (7) Rem ove t h e t h r ee scr ews t h a t secu r e t h e lower
COLUMN st eer in g colu m n sh r ou d t o t h e u pper sh r ou d.
INSTRUMENT (8) If t h e veh icle is equ ipped wit h a st a n da r d n on -
OPENING
PANEL t ilt st eer in g colu m n , loosen t h e t wo u pper st eer in g
COURTESY
colu m n m ou n t in g n u t s. If t h e veh icle is equ ipped
LAMP
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
st eer in g colu m n t o t h e fu lly lower ed posit ion .
DATA LINK (9) Rem ove bot h t h e u pper a n d lower sh r ou ds fr om
CONNECTOR 80ab36d6
t h e st eer in g colu m n .
(10) Rem ove t h e t wo scr ews t h a t secu r e t h e swit ch
Fig. 3 Combination Flasher Remove/Install wa t er sh ield a n d br a cket t o t h e t op of t h e st eer in g
colu m n (F ig. 5).
WIPER
SWITCH
WATER
LOWER
AND
MULTI-FUNCTION
SCREWS
SHROUD
LEVER
BRACKET
SHIELD
SWITCH
(3) LEVER ACCESS HOLE PIN
MOUNTING
PUNCH
STEERING
SWITCHKNOB
WARNING
HAZARD
SCREWS
WHEEL

XJ TURN SIGNAL AND HAZARD WARNING SYSTEMS


LOWER MOUNTING
MULTI-FUNCTION
WATER
LOWERTAB SHIELD8J
MOUNTING
SCREW -AND5
BRACKET
SWITCH
LEVER

REM OVAL AN D I N STALLAT I ON (Cont inue d)


wa t er sh ield a n d br a cket t o t h e st eer in g colu m n (F ig.
6).

LOWER MOUNTING
PIN PUNCH TAB 80a4d2f2

Fig. 6 Water Shield Lower Screw Remove/Install


/ 80a483e5 (12) Gen t ly pu ll t h e lower m ou n t in g t a b of t h e
swit ch wa t er sh ield br a cket a wa y fr om t h e st eer in g
Fig. 4 Steering Column Shrouds Remove/Install colu m n fa r en ou gh t o clea r t h e scr ew boss below t h e
m u lt i-fu n ct ion swit ch lever.
(13) Lift t h e wa t er sh ield a n d br a cket wit h t h e
m u lt i-fu n ct ion swit ch a wa y fr om t h e st eer in g colu m n
fa r en ou gh t o a ccess t h e t wo m u lt i-fu n ct ion swit ch

~
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

WIPER AND WASHER SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION WIPER SWITCH AND WASHER SWITCH . . . . . . 3


INTRODUCTION . . . . . . . . . . . . . . . . ........ 1 DIAGNOSIS AND TESTING
DESCRIPTION AND OPERATION WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . 5
REAR WIPER AND WASHER SYSTEM . . . . . . . 2 WIPER SWITCH AND WASHER SWITCH . . . . . . 6
WASHER FLUID LEVEL SENSOR . . . . . . . . . . . 4 WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 4
WASHER NOZZLE AND PLUMBING . . . . . . . . . 4 REMOVAL AND INSTALLATION
WASHER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 3 WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . 13
WASHER RESERVOIR . . . . . . . . . . . . . . . . . . . . 3 WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WINDSHIELD WASHER SYSTEM . . . . . . . . . . . 1 WIPER BLADE AND ELEMENT . . . . . . . . . . . . . 7
WINDSHIELD WIPER SYSTEM . . . . . . . . . . . . . 1 WIPER LINKAGE AND PIVOT . . . . . . . . . . . . . . 9
WIPER ARM AND BLADE . . . . . . . . . . . . . . . . . 2 WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . 9
WIPER LINKAGE AND PIVOT . . . . . . . . . . . . . . 2 WIPER SWITCH AND WASHER SWITCH . . . . . 11
WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . 2

GEN ERAL I N FORM AT I ON in t er m it t en t wipe r ela y is a lso con t a in ed wit h in t h e


swit ch .
INTRODUCTION Th e win dsh ield wiper s will oper a t e on ly wh en t h e
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor ign it ion swit ch is in t h e Accessor y or On posit ion s. A
com pon en t s in t h e wiper a n d wa sh er syst em s. Refer cir cu it br ea ker loca t ed in t h e ju n ct ion block pr ot ect s
t o 8W-53 - Wiper s in Gr ou p 8W - Wir in g Dia gr a m s t h e cir cu it r y of t h e win dsh ield wiper syst em . Refer t o
for com plet e cir cu it descr ipt ion s a n d dia gr a m s. t h e own er ’s m a n u a l for m or e in for m a t ion on t h e
win dsh ield wiper syst em con t r ols a n d oper a t ion .
NOTE: This group covers both Left-Hand Drive
(LHD) and Right-Hand Drive (RHD) versions of this WINDSHIELD WASHER SYSTEM
model. Whenever required and feasible, the RHD A elect r ica lly oper a t ed win dsh ield wa sh er syst em is
versions of affected vehicle components have been st a n da r d equ ipm en t . Th e wa sh er r eser voir is loca t ed
constructed as mirror-image of the LHD versions. bet ween t h e in n er a n d ou t er fr on t fen der s, a bove a n d
While most of the illustrations used in this group for wa r d of t h e left fr on t wh eel h ou sin g. Th e r eser voir
represent only the LHD version, the diagnostic and filler n eck is loca t ed in t h e en gin e com pa r t m en t on
service procedures outlined can generally be t h e left in n er fen der sh ield.
applied to either version. Exceptions to this rule Th e r eser voir h olds t h e wa sh er flu id, wh ich is pr es-
have been clearly identified as LHD or RHD, if a su r ized by a pu m p wh en t h e win dsh ield wa sh er
special illustration or procedure is required. swit ch lever is a ct u a t ed. Th e win dsh ield wa sh er
pu m p feeds t h e pr essu r ized wa sh er flu id t h r ou gh t h e
wa sh er syst em plu m bin g t o t h e win dsh ield wa sh er
n ozzles.
DESCRI PT I ON AN D OPERAT I ON
A low wa sh er flu id wa r n in g la m p is st a n da r d
equ ipm en t on a ll m odels equ ipped wit h t h e opt ion a l
WINDSHIELD WIPER SYSTEM
r ea r wiper a n d wa sh er syst em . Th is wa r n in g la m p in
An in t er m it t en t win dsh ield wiper syst em is st a n -
t h e in st r u m en t clu st er will wa r n t h e dr iver wh en t h e
da r d equ ipm en t . Th is syst em let s t h e dr iver select
wa sh er flu id level n eeds t o be ch ecked. Refer t o
fr om eit h er of t wo wiper speeds, or t h e in t er m it t en t
Gr ou p 8E - In st r u m en t P a n el Syst em s for m or e in for-
wipe m ode.
m a t ion on t h is fea t u r e.
Th e in t er m it t en t wipe m ode dela y t im es a r e dr iver
Th e wa sh er s will oper a t e on ly wh en t h e ign it ion
a dju st a ble fr om a bou t on e secon d t o a bou t fift een sec-
swit ch is in t h e Accessor y or On posit ion s. A fu se
on ds. Th e in t er m it t en t wipe m ode is pr ovided by
loca t ed in t h e ju n ct ion block pr ot ect s t h e cir cu it r y of
dela y logic a n d r ela y con t r ol cir cu it r y con t a in ed
t h e wa sh er syst em . Refer t o t h e own er ’s m a n u a l for
wit h in t h e in t er m it t en t wiper /wa sh er swit ch . Th e
m or e in for m a t ion on t h e win dsh ield wa sh er syst em
con t r ols a n d oper a t ion .
8K - 2 WIPER AND WASHER SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
REAR WIPER AND WASHER SYSTEM pivot m odu le br a cket . Th e wiper pivot s a r e secu r ed
A r ea r wiper a n d wa sh er syst em is a n a va ila ble t o t h e en ds of t h e m odu le br a cket .
opt ion on t h is m odel. Th e r ea r wiper syst em is a Th e t wo wiper pivot cr a n k a r m s a n d t h e wiper
fixed-cycle wiper syst em . A sin gle swit ch in t h e m ot or cr a n k a r m ea ch h a ve ba ll st u ds on t h eir en ds.
in st r u m en t pa n el cen t er bezel con t r ols bot h t h e r ea r Th e left pivot ba ll st u d is t h e lon ger of t h e t h r ee. A
wiper a n d wa sh er fu n ct ion s. Th e r ea r wa sh er syst em con n ect in g lin k wit h a pla st ic socket -t ype bu sh in g in
sh a r es t h e r eser voir of t h e win dsh ield wa sh er sys- t h e r igh t en d, a n d a pla st ic sleeve-t ype bu sh in g in
t em , bu t h a s it s own dedica t ed wa sh er pu m p a n d t h e left en d, is fit over t h e pivot ba ll st u ds t o join t h e
plu m bin g. t wo pivot s.
Th e r ea r wiper a n d wa sh er syst em s will oper a t e Th e wiper dr ive lin k h a s a pla st ic socket -t ype
on ly wh en t h e ign it ion swit ch is in t h e Accessor y or bu sh in g on ea ch en d. On e en d of t h e dr ive lin k is fit
On posit ion s. A fu se in t h e ju n ct ion block pr ot ect s t h e over t h e exposed en d of t h e lon ger left pivot ba ll
cir cu it r y of bot h t h e r ea r wiper a n d wa sh er syst em s. st u d, wh ile t h e ot h er en d is sn a p-fit over t h e ba ll
Refer t o t h e own er ’s m a n u a l for m or e in for m a t ion st u d on t h e wiper m ot or cr a n k a r m .
on t h e r ea r wiper a n d wa sh er syst em con t r ols a n d Th e wiper lin ka ge, pivot s, bu sh in gs, a n d m ou n t in g
oper a t ion . br a cket a r e on ly ser viced a s a com plet e u n it . If a n y
pa r t of t h is a ssem bly is fa u lt y or da m a ged, t h e en t ir e
WIPER ARM AND BLADE lin ka ge a n d pivot m odu le m u st be r epla ced. Th e
All Ch er okee m odels h a ve t wo 45.72-cen t im et er wiper m ot or a n d m ot or cr a n k a r m a r e ser viced sepa -
(18-in ch ) win dsh ield wiper bla des wit h r epla cea ble r a t ely.
r u bber elem en t s (squ eegees). Th e opt ion a l r ea r wiper
u ses a sin gle 34.8-cen t im et er (13.7-in ch ) wiper bla de WIPER MOTOR
wit h a r epla cea ble r u bber elem en t (squ eegee).
Ca u t ion sh ou ld be exer cised t o pr ot ect t h e r u bber FRON T
squ eegees fr om a n y pet r oleu m -ba sed clea n er s or con - Th e t wo-speed per m a n en t m a gn et wiper m ot or h a s
t a m in a n t s, wh ich will r a pidly det er ior a t e t h e r u bber. a n in t egr a l t r a n sm ission a n d pa r k swit ch . Th e m ot or
If t h e squ eegees a r e da m a ged, wor n , or con t a m i- a lso con t a in s a n in t er n a l a u t om a t ic r eset t in g cir cu it
n a t ed, t h ey m u st be r epla ced. br ea ker t o pr ot ect t h e m ot or fr om over loa ds. Th e
Wiper squ eegees exposed t o t h e elem en t s for a lon g m ot or is secu r ed t o a br a cket on t h e lin ka ge a n d
t im e t en d t o lose t h eir wipin g effect iven ess. P er iodic pivot m odu le in t h e cowl plen u m a r ea . A r ein for ce-
clea n in g of t h e squ eegees is su ggest ed t o r em ove m en t /st u d pla t e wit h a r u bber-isola t ed m ou n t in g
deposit s of sa lt a n d r oa d film . Th e wiper bla des, br a cket ext en ds fr om t h e cowl plen u m side of t h e
a r m s, a n d win dsh ield or r ea r gla ss sh ou ld be clea n ed da sh pa n el t o t h e m ot or m ou n t in g br a cket t o pr ovide
wit h a spon ge or clot h a n d win dsh ield wa sh er flu id, a a ddit ion a l su ppor t . Th e wiper m ot or ou t pu t sh a ft
m ild det er gen t , or a n on -a br a sive clea n er. If t h e pa sses t h r ou gh a h ole in t h e m odu le br a cket , wh er e a
squ eegees con t in u e t o st r ea k or sm ea r, t h ey sh ou ld n u t secu r es t h e wiper m ot or cr a n k a r m t o t h e m ot or
be r epla ced. ou t pu t sh a ft .
Th e bla des a r e m ou n t ed t o spr in g-loa ded wiper Wiper speed is con t r olled by cu r r en t flow t o t h e
a r m s. Th e spr in g t en sion of t h e wiper a r m s con t r ols pr oper set of br u sh es. Th e wiper m ot or com plet es it s
t h e pr essu r e a pplied t o t h e bla des on t h e gla ss. Th e wipe cycle wh en t h e win dsh ield wiper swit ch st a lk is
win dsh ield wiper a r m s a r e secu r ed by a n in t egr a l m oved t o t h e Off posit ion , a n d pa r ks t h e bla des in
la t ch t o t h e t wo wiper pivot s on t h e cowl plen u m cov- t h e lowest por t ion of t h e wipe pa t t er n .
er /gr ille pa n el a t t h e ba se of t h e win dsh ield. Th e r ea r Th e win dsh ield wiper m ot or ca n n ot be r epa ir ed. If
wiper a r m is secu r ed by a n u t dir ect ly t o t h e r ea r fa u lt y or da m a ged, t h e en t ir e wiper m ot or a ssem bly
wiper m ot or ou t pu t sh a ft on t h e lift ga t e below t h e m u st be r epla ced. Th e m ot or cr a n k a r m , t h e lin ka ge
lift ga t e gla ss. a n d pivot m odu le, a n d t h e r ein for cem en t /st u d pla t e
Th e wiper a r m s a n d bla des ca n n ot be a dju st ed or a r e a va ila ble for ser vice.
r epa ir ed. If fa u lt y or da m a ged, t h ey m u st be
REAR
r epla ced.
Th e r ea r wiper m ot or is secu r ed wit h a br a cket t o
t h e lift ga t e in n er pa n el, below t h e lift ga t e gla ss a n d
WIPER LINKAGE AND PIVOT
beh in d t h e lift ga t e t r im pa n el. Th e m ot or ou t pu t
Th e wiper lin ka ge a n d pivot m odu le is secu r ed
sh a ft pa sses t h r ou gh t h e lift ga t e ou t er pa n el wh er e a
wit h scr ews t o t h e cowl t op pa n el ben ea t h t h e cowl
ga sket , bezel, a n d n u t , sea l a n d secu r e t h e u n it t o
plen u m cover /gr ille pa n el. Th e wiper m ot or is
t h e lift ga t e ou t er pa n el. Th e r ea r wiper a r m is
secu r ed wit h scr ews t o t h e cen t er of t h e lin ka ge a n d
secu r ed dir ect ly t o t h e m ot or ou t pu t sh a ft .
XJ WIPER AND WASHER SYSTEMS 8K - 3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e r ea r wiper m ot or u n it pr ovides t h r ee oper a t in g REAR
m odes: Th e sin gle t wo-fu n ct ion r ea r wiper a n d wa sh er
• Con st a n t wipe t h a t oper a t es wh en t h e r ea r swit ch is in st a lled n ea r t h e bot t om of t h e in st r u m en t
wiper swit ch is t u r n ed t o t h e On posit ion . pa n el cen t er bezel, below t h e h ea t er-A/C con t r ols.
• Con st a n t wipe t h a t oper a t es wh en t h e r ea r Th e r ea r wiper a n d wa sh er swit ch con t r ols t h e r ea r
wa sh er swit ch is depr essed. wiper a n d wa sh er fu n ct ion s.
• A pa r k m ode t h a t oper a t es t h e wiper m ot or u n t il Th e t oggle-t ype swit ch fea t u r es a det en t in t h e On
t h e bla de r ea ch es it s pa r k posit ion wh en eit h er t h e posit ion , a n d a m om en t a r y wa sh posit ion . Th e r ea r
r ea r wiper swit ch or t h e ign it ion swit ch is pla ced in wiper a n d wa sh er swit ch a lso h a s a n in t egr a l illu m i-
t h e Off posit ion . n a t ion la m p wit h a ser vicea ble bu lb. Th e swit ch kn ob
Th e r ea r wiper m ot or ca n n ot be r epa ir ed. If fa u lt y is pu sh ed down t o it s det en t t o a ct iva t e t h e r ea r
or da m a ged, t h e en t ir e r ea r wiper m ot or a ssem bly wiper syst em , a n d down a ga in t o t h e m om en t a r y
m u st be r epla ced. posit ion t o a ct iva t e t h e r ea r wa sh er syst em . Bot h t h e
r ea r wiper a n d r ea r wa sh er m ot or s will oper a t e con -
WIPER SWITCH AND WASHER SWITCH t in u ou sly for a s lon g a s t h e swit ch is h eld in t h e
m om en t a r y Wa sh posit ion .
FRON T Th e r ea r wiper a n d wa sh er swit ch ca n n ot be
Th e win dsh ield wiper a n d wa sh er swit ch es a r e r epa ir ed a n d, if fa u lt y or da m a ged, t h e en t ir e swit ch
m ou n t ed on t h e r igh t side of t h e st eer in g colu m n u n it m u st be r epla ced.
(F ig. 1). Th e swit ch st a lk is m oved u p or down t o
select t h e wiper swit ch m ode, a n d pu lled t owa r ds t h e WASHER RESERVOIR
st eer in g wh eel t o a ct iva t e t h e wa sh er syst em . An A sin gle wa sh er flu id r eser voir is u sed for bot h t h e
in t er m it t en t wipe syst em con t r ol kn ob on t h e en d of st a n da r d fr on t a n d opt ion a l r ea r wa sh er syst em s.
t h e swit ch st a lk is r ot a t ed t o select t h e desir ed dela y Th e wa sh er flu id r eser voir is secu r ed bet ween t h e
in t er va l. Th e win dsh ield wiper a n d wa sh er swit ch left fr on t in n er a n d ou t er fen der pa n els, a bove a n d in
con t a in s cir cu it r y for t h e followin g fu n ct ion s: fr on t of t h e left fr on t wh eel h ou se.
• Win dsh ield wiper s E a ch wa sh er pu m p a n d m ot or u n it h a s a ba r bed
• In t er m it t en t wiper dela y r ela y con t r ol a n d logic n ipple, wh ich is in st a lled t h r ou gh a r u bber gr om m et
• In t er m it t en t wipe r ela y sea l in ser t ed in a h ole n ea r t h e bot t om of t h e r eser-
• Win dsh ield wa sh er s. voir. Th e wa sh er pu m ps a r e r et a in ed by a n in t er fer-
Th e win dsh ield wiper a n d wa sh er swit ch ca n n ot be en ce fit bet ween t h e ba r bed n ipple a n d t h e gr om m et
r epa ir ed. If a n y fu n ct ion of t h e swit ch is fa u lt y, or if sea l, wh ich is a ligh t pr ess fit .
t h e swit ch is da m a ged, t h e en t ir e swit ch a ssem bly Th e wa sh er r eser voir h a s a sepa r a t e filler n eck.
m u st be r epla ced. Th e filler n eck sn a ps in t o t h e r eser voir fr om t h e
en gin e com pa r t m en t side of t h e left in n er fen der
sh ield. Th e r eser voir a lso h a s a pr ovision for a
wa sh er flu id level sen sor.
Th e wa sh er r eser voir, filler n eck, filler ca p, a n d
sen sor a r e ea ch a va ila ble for ser vice.

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

XJ WIPER AND WASHER SYSTEMS 8K - 7


DI AGN OSI S AN D T EST I N G (Cont inue d)
Win dsh ield Wiper a n d Wa sh er Swit ch Con t in u it y
ch a r t (F ig. 2). 4 5

H Pl L W P2 H Pl L W P2 E
DD ODD
3
DODD==

TWO SPEED WIPER INTERMITTENT WIPER


SWITCH PINS SWITCH PINS 0

SWITCH POSITION CONTINUITY


BETWEEN
OFF PIN P2 and PIN L
SWITCH CONTINUITY
LOW PIN Pl and PIN L POSITION BETWEEN
HIGH PIN Pl and PIN H OFF 1 AND4
WIPE 4AND5
WASH PIN Pl and PIN W
WASH 2AND 5,4AND 5
INTERMITTENT CANNOT BE CHECKED ILLUMINATION LAMP 1 AND3
80a5035e

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

NOTE: The notched retainer end of the wiper ele-


ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot.

To r em ove t h e r ea r wiper bla de a n d/or elem en t ,


pr oceed a s follows:
(1) Lift t h e r ea r wiper a r m t o r a ise t h e wiper bla de
a n d elem en t off of t h e r ea r win dow gla ss.
(2) Rem ove t h e wiper bla de fr om t h e wiper a r m , or
t h e wiper elem en t fr om t h e wiper bla de a s follows:
(a ) To r em ove t h e wiper bla de fr om t h e wiper
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
slide t h e bla de a wa y fr om t h e t ip t owa r ds t h e r ea r
wiper m ot or ou t pu t sh a ft en d of t h e a r m (F ig. 4). Fig. 5 Wiper Arm Remove/Install
(b) To r em ove t h e wiper elem en t fr om t h e wiper (2) Rem ove t h e a r m fr om t h e pivot u sin g a r ockin g
bla de, pin ch t h e n ot ch ed (pivot ) en d r elea se clip of m ot ion .
t h e wiper elem en t t igh t ly bet ween t h e t h u m b a n d (3) In st a ll t h e a r m a n d bla de wit h t h e wiper m ot or
for efin ger. Th en , pu ll t h e elem en t fir m ly t owa r ds in t h e P a r k posit ion . See t h e Wiper Ar m In st a lla t ion
t h e r ea r wiper m ot or ou t pu t sh a ft t o r elea se t h e illu st r a t ion
wiper elem en t pin ch -r elea se clip fr om t h e wiper (4) (F ig. 6). Mou n t t h e a r m s on t h e pivot sh a ft s so
bla de cla ws. On ce t h e clip is r elea sed fr om t h e t h a t t h e dist a n ce fr om t h e lower edge of t h e wiper
cla ws, t h e elem en t will slide ea sily ou t of t h e a r m t ip t o t h e u pper edge of t h e lower win dsh ield
r em a in in g cla ws. m ou ldin g is:
(3) In st a ll t h e wiper bla de on t h e wiper a r m , or • 23 t o 52 m m (0.90 t o 2.04 in ch ) on t h e dr iver
t h e wiper elem en t in t h e wiper bla de a s follows: side
(a ) To in st a ll t h e wiper bla de on t h e wiper a r m , • 33 t o 62 m m (1.29 t o 2.44 in ch ) on t h e pa ssen ger
slide t h e bla de r et a in er in t o t h e U-sh a ped for m a - side.
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 (5) Lift t h e wiper a r m a wa y fr om t h e win dsh ield
t a b sn a ps in t o it s locked posit ion . Be cer t a in t h a t sligh t ly t o r elieve t h e spr in g t en sion on t h e la t ch .
WIPER ARM RETAINING NUT PIVOT COVER IN
UPPER
PARKED
EDGE
POSITION
OF LOWER
—27GLASS
TO 35 mm
SEAL
(1.06
AT TIP
TO 1.38
OF WIPER
INCH) ABOVE
BLADE

XJ WIPER AND WASHER SYSTEMS 8K - 9


REM OVAL AN D I N STALLAT I ON (Cont inue d)
gla ss open in g, a n d in st a ll t h e wiper a r m r et a in in g
nut.
(5) Oper a t e t h e r ea r wiper on t h e wet lift ga t e
gla ss, t h en t u r n t h e r ea r wiper swit ch t o t h e Off posi-
t ion so t h a t t h e bla de m oves t o t h e P a r k posit ion .
Th e t ip of t h e bla de sh ou ld n ow be fr om 27 t o 35 m m
(1.06 t o 1.38 in ch ) a bove t h e u pper edge of t h e lower
lift ga t e gla ss sea l (F ig. 8). Ch eck for t h e cor r ect
wiper a r m posit ion in g a n d r ea dju st if r equ ir ed.

33-62 MM 23-52MM

J898K-29

Fig. 6 Front Wiper Arm Installation IN PARKED POSITION -27 TO 35 mm (1.06 TO


1.38 INCH) ABOVE UPPER EDGE OF LOWER
P u sh t h e la t ch in t o t h e locked posit ion a n d slowly GLASS SEAL AT TIP OF WIPER BLADE
r elea se t h e a r m u n t il t h e wiper bla de r est s on t h e 80ab5cc2

win dsh ield.


(6) Oper a t e t h e wiper s wit h t h e win dsh ield gla ss Fig. 8 Rear Wiper Arm Installation
wet , t h en t u r n t h e wiper swit ch t o t h e Off posit ion . (6) Tigh t en t h e wiper a r m r et a in in g n u t t o 18 N·m
Ch eck for t h e cor r ect wiper a r m posit ion in g a n d (160 in . lbs.) a n d close t h e pivot cover.
r ea dju st if r equ ir ed.
WIPER LINKAGE AND PIVOT
REAR Th e wiper lin ka ge a n d pivot s m odu le ca n on ly be
(1) Discon n ect t h e wa sh er n ozzle h ose a n d clip r em oved fr om or in st a lled in t h e veh icle a s a u n it
fr om t h e ext er n a l n ipple of t h e r ea r wiper m ot or ou t - wit h t h e wiper m ot or. See Wiper Mot or in t h is gr ou p
pu t sh a ft bezel. for t h e ser vice pr ocedu r es.
(2) Lift t h e wiper a r m pivot cover a n d r em ove t h e
r et a in in g n u t (F ig. 7). WIPER MOTOR
FRON T
(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 wiper a r m s a s descr ibed in t h is
gr ou p.
PIVOT (3) Rem ove t h e eigh t scr ews t h a t secu r e t h e cowl
COVER 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. 9).
(4) Lift t h e cowl plen u m cover /gr ille pa n el a n d
scr een fr om t h e veh icle fa r en ou gh t o a ccess t h e
win dsh ield wa sh er plu m bin g. Use ca r e so a s n ot t o
da m a ge t h e pa in t a r ou n d t h e pivot open in gs of t h e
pa n el.
WIPER ARM (5) Discon n ect t h e win dsh ield wa sh er su pply h ose
RETAINING NUT J948K-14
a n d t h e pa ssen ger side wa sh er n ozzle h ose fr om t h e
wa sh er n ozzle h ose t ee fit t in g.
Fig. 7 Rear Wiper Arm Remove/Install
(6) Rem ove t h e cowl plen u m cover /gr ille pa n el a n d
(3) Rem ove t h e wiper a r m fr om t h e m ot or ou t pu t scr een fr om t h e veh icle.
sh a ft u sin g a r ockin g m ot ion . (7) Rea ch in t o t h e cowl plen u m a n d u n plu g t h e
(4) In st a ll t h e r ea r wiper a r m wit h t h e wiper wiper m ot or wir e h a r n ess con n ect or.
m ot or in t h e P a r k posit ion . P la ce t h e r ea r wiper
bla de on t h e gla ss so t h a t it is pa r a llel t o t h e lift ga t e
LINKAGE
FWD
BRACKET
AND PIVOT
SCREW
ANDMOD-
GROMMET
ULE NUT WASHER
SCREW
BRACKET
HOSE
GRILLE
SCREW
SCREEN
PANEL
NUT
FWD
NUT MOTORBRACKET
AND BLADE SCREW
BEZEL CLIPHOSE LIFTGATE
ARM NUT

8K - 10 WIPER AND WASHER SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rem ove t h e m ot or ou t pu t sh a ft r et a in in g n u t
(F ig. 11).

LIFTGATE

Fig. 9 Cowl Plenum Cover/Grille Panel Remove/Install


(8) Open t h e h ood a n d r em ove t h e t wo n u t s t h a t
secu r e t h e st u ds of t h e wiper m odu le m ou n t in g
br a cket a n d gr om m et t o t h e cowl plen u m pa n el (F ig.
10).
SCREW
80ab5cc3

Fig. 11 Rear Wiper Motor Remove/Install


(4) P u ll t h e bezel a n d sea l a wa y fr om t h e lift ga t e
fa r en ou gh t o a ccess t h e wa sh er su pply h ose.
(5) Discon n ect t h e wa sh er su pply h ose fr om t h e
in t er n a l n ipple on t h e bezel.
(6) Rem ove t h e bezel a n d sea l fr om t h e m ot or ou t -
pu t sh a ft .
TRIM PANEL PUSH
PLUGNUT ASSIST HANDLE LIFTGATE
(7) Open t h e lift ga t e.
(8) 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 t wo scr ew cover plu gs
\_~NUT ou t of t h e lift ga t e a ssist h a n dle.
80ab5cc7 (9) Rem ove t h e t wo scr ews t h a t secu r e t h e lift ga t e
a ssist h a n dle t o t h e lift ga t e in n er pa n el (F ig. 12).
Fig. 10 Wiper Linkage Module Remove/Install
PUSH NUT
(9) Rem ove t h e fou r scr ews n ea r t h e wiper pivot s t h a t
secu r e t h e wiper m odu le t o t h e cowl plen u m pa n el. TRIM
(10) Rem ove t h e wiper m odu le fr om t h e cowl ple- PANEL
n u m a s a u n it .
(11) Rem ove t h e t h r ee scr ews t h a t secu r e t h e
wiper m ot or t o t h e wiper lin ka ge m odu le a n d r em ove
t h e m ot or.
(12) 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 m ou n t in g h a r dwa r e a s follows:
• Wiper m ot or m ou n t in g scr ews - 4 N·m (35 in . lbs.)
• Wiper m odu le m ou n t in g scr ews - 6 N·m (50 in . lbs.)
• Wiper m odu le m ou n t in g br a cket n u t s - 6 N·m (50 in .
lbs.).

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.

NOTE: To aid in the removal of the trim panel, start


at the bottom of the panel.

(12) Rem ove t h e lift ga t e t r im pa n el fr om t h e veh i-


cle.
(13) Un plu g t h e r ea r wiper m ot or wir e h a r n ess
con n ect or.
(14) Rem ove t h e t wo scr ews t h a t secu r e t h e r ea r
wiper m ot or m ou n t in g br a cket t o t h e lift ga t e in n er
pa n el.
(15) Rem ove t h e r ea r wiper m ot or a n d m ou n t in g
br a cket fr om t h e lift ga t e a s a u n it .
(16) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
/ 80a483e5
Tigh t en t h e m ou n t in g h a r dwa r e a s follows:
• Rea r wiper m ot or m ou n t in g br a cket scr ews - 5 Fig. 13 Steering Column Shrouds Remove/Install
N·m (45 in . lbs.)
(7) Rem ove t h e t h r ee scr ews t h a t secu r e t h e lower
• Rea r wiper m ot or ou t pu t sh a ft r et a in in g n u t - 3
st eer in g colu m n sh r ou d t o t h e u pper sh r ou d.
N·m (27 in . lbs.).
(8) If t h e veh icle is equ ipped wit h a st a n da r d n on -
t ilt st eer in g colu m n , loosen t h e t wo u pper st eer in g
WIPER SWITCH AND WASHER SWITCH
colu m n m ou n t in g n u t s. If t h e veh icle is equ ipped
FRON T 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
st eer in g colu m n t o t h e fu lly lower ed posit ion .
SWITCH
WIPER
WATER
AND
MULTI-FUNCTION
(9) LEVER
BRACKET
SHIELD
Rem SWITCH LEVER
ove bot h t h e u pper a n d lower sh MOUNTING
r HAZARD
WARNING
SWITCHKNOB
SCREWS
ou ds fr om
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE t h e st eer in g colu m n .
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (10) Rem ove t h e t wo scr ews t h a t secu r e t h e swit ch
STEERING WHEEL, STEERING COLUMN, OR wa t er sh ield a n d br a cket t o t h e t op of t h e st eer in g
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR colu m n (F ig. 14).
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(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 st eer in g colu m n open in g cover a s
descr ibed in Gr ou p 8E - In st r u m en t P a n el Syst em s.
(3) If t h e veh icle is so equ ipped, m ove t h e t ilt
st eer in g colu m n t o t h e fu lly r a ised posit ion .
(4) In ser t t h e key in t h e ign it ion lock cylin der a n d
t u r n t h e ign it ion swit ch t o t h e On posit ion .
(5) In ser t a sm a ll scr ewdr iver or pin pu n ch
t h r ou gh t h e a ccess h ole in t h e lower st eer in g colu m n
sh r ou d a n d depr ess t h e ign it ion lock cylin der r et a in -
in g t u m bler (F ig. 13). Fig. 14 Water Shield Upper Screws Remove/Install
(6) Wh ile h oldin g t h e r et a in in g t u m bler depr essed,
pu ll t h e ign it ion lock cylin der a n d key ou t of t h e ign i- (11) Rem ove t h e on e scr ew loca t ed below t h e
t ion lock h ou sin g. m u lt i-fu n ct ion swit ch lever t h a t secu r es t h e swit ch
LOWER MOUNTING
MULTI-FUNCTION
WATER
LOWERTAB SHIELD
MOUNTING
SCREW
BRACKET
SWITCH
LEVER
AND INSTRUMENT
CENTER PANEL
BEZEL

8K - 12 WIPER AND WASHER SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
wa t er sh ield a n d br a cket t o t h e st eer in g colu m n (F ig. t er bezel a wa y fr om t h e in st r u m en t pa n el t o r elea se
15). t h e six sn a p clip r et a in er s (F ig. 16).

INSTRUMENT PANEL

LOWER MOUNTING
TAB aoa4d212

Fig. 15 Water Shield Lower Screw Remove/Install CENTER _ _ __,..../


(12) Gen t ly pu ll t h e lower m ou n t in g t a b of t h e BEZEL
swit ch wa t er sh ield br a cket a wa y fr om t h e st eer in g
colu m n fa r en ou gh t o clea r t h e scr ew boss below t h e
m u lt i-fu n ct ion swit ch lever. 80ab87bc

(13) Lift t h e wa t er sh ield a n d br a cket wit h t h e ACCESSORY SWITCH BEZEL SCREW

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

WARNING: ON VEHICLES EQUIPPED WITH AIR-


BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR Fig. 17 Accessory Switch Bezel Remove/Install
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (5) P u ll t h e a ccessor y swit ch bezel ou t fr om t h e
SERVICE. FAILURE TO TAKE THE PROPER PRE- in st r u m en t pa n el fa r en ou gh t o u n plu g t h e wir e h a r-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- n ess con n ect or s.
BAG DEPLOYMENT AND POSSIBLE PERSONAL (6) Rem ove t h e a ccessor y swit ch bezel fr om t h e
INJURY. in st r u m en t pa n el.
(7) Ca r efu lly pr y t h e sn a p r et a in er s a t t h e t op a n d
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive bot t om of t h e r ea r wiper a n d wa sh er swit ch r ecept a -
ca ble. cle on t h e ba ck of t h e a ccessor y swit ch bezel wit h a
(2) Usin g a t r im st ick or a n ot h er su it a ble wide sm a ll t h in -bla ded scr ewdr iver a n d pu ll t h e swit ch ou t
fla t -bla ded t ool, gen t ly pr y t h e in st r u m en t pa n el cen - of t h e r ecept a cle.
XJ WIPER AND WASHER SYSTEMS 8K - 13
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(8) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Be
cer t a in t h a t bot h of t h e swit ch sn a p r et a in er s in t h e
r ecept a cle on t h e ba ck of t h e a ccessor y swit ch bezel
a r e fu lly en ga ged. Tigh t en t h e m ou n t in g scr ews t o
2.2 N·m (20 in . lbs.).

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

(2) Th e wa sh er r eser voir filler n eck is h eld in t h e


r eser voir by a n in t er fer en ce fit . Rem ove t h e filler
n eck fr om t h e r eser voir u sin g a pu llin g a n d t wist in g
a ct ion (F ig. 18).

FRONT WASHER PUMP J958K-11

Fig. 19 Washer Reservoir Remove/Install


(2) Ra ise a n d su ppor t t h e veh icle.
(3) Rem ove t h e left fr on t in n er wh eelh ou se spla sh
sh ield. Refer t o Gr ou p 23 - Body for t h e pr ocedu r es.
(4) Rem ove t h e wa sh er su pply h ose(s) fr om t h e
wa sh er pu m p(s) a n d dr a in t h e wa sh er flu id fr om t h e
r eser voir in t o a clea n con t a in er for r eu se.
(5) Un plu g t h e wir e h a r n ess con n ect or s fr om t h e
wa sh er pu m p(s).
Fig. 18 Washer Reservoir Filler Neck Remove/Install (6) Usin g a t r im st ick or a n ot h er su it a ble wide
(3) Rem ove t h e en gin e a ir filt er h ou sin g. Refer t o fla t -bla ded t ool, gen t ly pr y t h e wa sh er pu m p ou t of
Gr ou p 14 - F u el Syst em for t h e pr ocedu r es. t h e r u bber gr om m et sea l. Ca r e m u st be t a ken n ot t o
(4) Rem ove t h e t wo scr ews t h a t secu r e t h e r eser- da m a ge t h e r eser voir.
voir t o t h e in n er fen der sh ield (F ig. 19). (7) Rem ove t h e r u bber gr om m et sea l fr om t h e r es-
(5) Ra ise a n d su ppor t t h e veh icle. er voir a n d disca r d.
(6) Rem ove t h e left fr on t in n er wh eelh ou se spla sh (8) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
sh ield. Refer t o Gr ou p 23 - Body for t h e pr ocedu r es. Alwa ys u se a n ew r u bber gr om m et sea l on t h e r eser-
(7) Rem ove t h e wa sh er su pply h ose(s) fr om t h e voir.
wa sh er pu m p(s) a n d dr a in t h e wa sh er flu id fr om t h e
WASH ER FLU I D LEV EL SEN SOR
r eser voir in t o a clea n con t a in er for r eu se.
(1) Rem ove t h e wa sh er r eser voir a s descr ibed in
(8) Un plu g t h e wir e h a r n ess con n ect or s fr om t h e
t h is gr ou p.
wa sh er pu m p(s) a n d t h e wa sh er flu id level sen sor.
(9) Slide t h e r eser voir sligh t ly t owa r ds t h e r ea r of NOTE: The pivoting float of the washer fluid sensor
t h e veh icle t o r elea se t h e t wo h ooks fr om t h e in n er must be in a horizontal position within the reservoir
fen der ledge slot s. in order to be removed. With the reservoir empty
(10) Lower t h e fr on t of t h e r eser voir a n d slide t h e and held in an upright position, the pivoting float
u n it for wa r d t o r em ove it fr om t h e veh icle. will be oriented to the horizontal position when the
(11) Rever se t h e r em ova l pr ocedu r es t o in st a ll. sensor connector is pointed straight downwards.
Tigh t en t h e r eser voir m ou n t in g scr ews t o 3 N·m (26
in . lbs.). (2) 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 wa sh er flu id level sen -
WASH ER PU M P sor ou t of t h e r u bber gr om m et sea l. Ca r e m u st be
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive t a ken n ot t o da m a ge t h e r eser voir.
ca ble.
RIVET GRILLENOZZLE
PANELSCREW TEE WASHER
SCREEN
HOSE TO
TO CHECK
LIFTGATE
RESER-
VOIR
VALVE
SUPPLY
ANDHOSE
BODY
PLY HOSE
SUP-
BEZEL
FLOW
CHECKBALL
CLIP HOSE LIFTGATE
NOZZLE
TOGROMMET
SPRING
GUARD
NOZZLE

8K - 14 WIPER AND WASHER SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rem ove t h e r u bber gr om m et sea l fr om t h e r es-
er voir a n d disca r d. LIFTGATE
(4) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
Alwa ys u se a n ew r u bber gr om m et sea l on t h e r eser-
voir.

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

Fig. 21 Rear Washer Nozzle Remove/Install


CH ECK VALV E
(1) Rem ove t h e fou r scr ews t h a t secu r e t h e lift ga t e
open in g u pper ga r n ish m ou ldin g t o t h e u pper lift ga t e
open in g r ein for cem en t .
Fig. 20 Front Washer Nozzles Remove/Install (2) Usin g a t r im st ick or a n ot h er su it a ble wide-
(3) Lift t h e cowl plen u m cover /gr ille pa n el a n d bla ded fla t t ool, gen t ly pr y t h e lift ga t e open in g u pper
scr een fr om t h e veh icle fa r en ou gh t o a ccess t h e ga r n ish m ou ldin g a wa y fr om t h e u pper lift ga t e open -
win dsh ield wa sh er plu m bin g. Use ca r e so a s n ot t o in g r ein for cem en t t o r elea se t h e sn a p clip r et a in er s.
da m a ge t h e pa in t a r ou n d t h e pivot open in gs of t h e (3) Rem ove t h e u pper lift ga t e open in g ga r n ish
pa n el. m ou ldin g fr om t h e veh icle.
(4) Discon n ect t h e win dsh ield wa sh er su pply h ose (4) Discon n ect t h e lift ga t e h a lf of t h e wa sh er su p-
a n d t h e pa ssen ger side wa sh er n ozzle h ose fr om t h e ply h ose fr om t h e ch eck va lve.
wa sh er n ozzle h ose t ee fit t in g. (5) Discon n ect t h e body h a lf of t h e wa sh er su pply
(5) Rem ove t h e cowl plen u m cover /gr ille pa n el a n d h ose fr om t h e ch eck va lve.
scr een fr om t h e veh icle. (6) Rem ove t h e ch eck va lve fr om t h e veh icle.
(6) F r om t h e u n der side of t h e cowl plen u m cover / (7) Wh en r ein st a llin g t h e ch eck va lve, be cer t a in
gr ille pa n el, discon n ect t h e wa sh er h ose fr om t h e t h e va lve is pr oper ly or ien t ed wit h in t h e syst em flow
n ozzle fit t in g. (F ig. 22).
(7) F r om t h e u n der side of t h e cowl plen u m cover /
gr ille pa n el, r em ove t h e r ivet t h a t secu r es t h e n ozzle
t o t h e open in g in t h e cowl plen u m cover /gr ille pa n el.
(8) Rem ove t h e wa sh er n ozzle fr om t h e cowl ple- TO - - ~ R I N G TO
n u m cover /gr ille pa n el.
(9) Rever se t h e r em ova l pr ocedu r es t o in st a ll. RESERVOIR ti~~~t ~ NOZZLE
REAR
(1) Un sn a p t h e r ea r wa sh er n ozzle fr om t h e r ea r FLOW¢
80abfece
wiper a r m (F ig. 21).
(2) Discon n ect t h e wa sh er h ose fr om t h e n ozzle fit - Fig. 22 Rear Washer System Check Valve
t in g.
(3) Rever se t h e r em ova l pr ocedu r es t o in st a ll. (8) 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 .
XJ LAMPS 8L - 1

LAMPS
CON T EN T S

page page

BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . 15 LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 1


HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . 4 LAMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 10
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . . 7 LAMP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 14

LAM P DI AGN OSI S

INDEX
page page

GENERAL INFORMATION DIAGNOSIS AND TESTING


DAYTIME RUNNING LAMP MODULE . . . . . . . . . 1 DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 1 FOG LAMP DIAGNOSIS . . . . .. . . . . . . . . . . . . . 3
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 1 HEADLAMP DELAY MODULE . . . . . . . . . . . . . . 3
SENTINEL HEADLAMP DELAY MODULE . . . . . . 1 HEADLAMP DIAGNOSIS . . . .. . . . . . . . . . . . . . 2

GEN ERAL I N FORM AT I ON Wh en it is n ecessa r y t o r em ove com pon en t s t o ser-


vice a n ot h er, it sh ou ld n ot be n ecessa r y t o a pply
GENERAL INFORMATION excessive for ce or ben d a com pon en t t o r em ove it .
E a ch veh icle is equ ipped wit h va r iou s la m p a ssem - Befor e da m a gin g a t r im com pon en t , ver ify h idden
blies. A good gr ou n d is n ecessa r y for pr oper ligh t in g fa st en er s or ca pt u r ed edges a r e n ot h oldin g t h e com -
oper a t ion . Gr ou n din g is pr ovided by t h e la m p socket pon en t in pla ce.
wh en it com es in con t a ct wit h t h e m et a l body, or
t h r ou gh a sepa r a t e gr ou n d wir e. SENTINEL HEADLAMP DELAY MODULE
Wh en ch a n gin g la m p bu lbs ch eck t h e socket for Th e H ea dla m p Modu le dela ys t h e de-a ct iva t ion of
cor r osion . If cor r osion is pr esen t , clea n it wit h a wir e t h e h ea dla m ps for 45 6 15 secon ds a ft er t h e ign it ion
br u sh a n d coa t t h e in side of t h e socket ligh t ly wit h swit ch is t u r n ed OF F. Th e dr iver en ga ges t h e m odu le
Mopa r Mu lt i-P u r pose Gr ea se or equ iva len t . by t u r n in g t h e ign it ion swit ch OF F, t h en t u r n in g t h e
h ea dla m ps OF F.
SAFETY PRECAUTIONS
DAYTIME RUNNING LAMP MODULE
WARNING: EYE PROTECTION SHOULD BE USED Th e Da yt im e Ru n n in g Ligh t s (H ea dla m ps) Syst em
WHEN SERVICING GLASS COMPONENTS. PER- is in st a lled on veh icles m a n u fa ct u r ed for sa le in Ca n -
SONAL INJURY CAN RESULT. a da on ly. Th e h ea dla m ps a r e illu m in a t ed wh en t h e
ign it ion swit ch is t u r n ed t o t h e ON posit ion a n d t h e
veh icle is pu t in t o m ot ion . Th e DRL m odu le r eceives
CAUTION: Do not touch the glass of halogen bulbs a veh icle-m ovin g sign a l fr om t h e veh icle speed sen -
with fingers or other possibly oily surface, reduced sor. Th is pr ovides a con st a n t h e a d la m p s -o n con di-
bulb life will result. t ion a s lon g a s t h e veh icle is m ovin g. Th e la m ps a r e
Do not use bulbs with higher candle power than illu m in a t ed a t a ppr oxim a t ely 30 per cen t of n or m a l
indicated in the Bulb Application table at the end of in t en sit y.
this group. Damage to lamp can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
8L - 2 LAMPS XJ

DI AGN OSI S AN D T EST I N G HEADLAMP DIAGNOSIS


Alwa ys begin a n y dia gn osis by t est in g a ll of t h e
DIAGNOSTIC PROCEDURES fu ses a n d cir cu it br ea ker s in t h e syst em . Refer t o
Wh en a veh icle exper ien ces pr oblem s wit h t h e Gr ou p 8W, Wir in g Dia gr a m s.
h ea dla m p syst em , ver ify t h e con dit ion of t h e ba t t er y Con ven t ion a l a n d h a logen h ea dla m ps a r e in t er-
con n ect ion s, ch a r gin g syst em , h ea dla m p bu lbs, wir e ch a n gea ble. It is r ecom m en ded t h a t t h ey n ot be
con n ect or s, r ela y, h igh bea m dim m er swit ch a n d in t er m ixed on a given veh icle.
h ea dla m p swit ch . Refer t o Gr ou p 8W, Wir in g Dia -
gr a m s for com pon en t loca t ion s a n d cir cu it in for m a -
t ion .

H EADLAM P DI AGN OSI S

CONDITION POSSIBLE CAUSES CORRECTION


HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
WITH ENGINE IDLING OR and posts.
IGNITION TURNED OFF. 2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Group 8A
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Group 8A
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS 1. Charging system output too high. 1. Test and repair charging system, refer to
BURN OUT Group 8A
FREQUENTLY.
2. Loose or corroded terminals or 2. Inspect and repair all connectors and
splices in circuit. splices, refer to Group 8W.
HEADLAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system, refer to
WITH ENGINE RUNNING Group 8A.
ABOVE IDLE.* 2. Poor headlamp circuit ground. 2. Test voltage drop across Z1-ground,
refer to Group 8W.
3. High resistance in headlamp circuit. 3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.
HEADLAMPS FLASH 1. Poor headlamp circuit ground. 1. Repair circuit ground, refer to Group 8W.
RANDOMLY. 2. High resistance in headlamp circuit. 2. Test amperage draw of headlamp circuit.
3. Faulty headlamp switch circuit 3. Replace headlamp switch.
breaker.
4. Loose or corroded terminals or 4. Repair connector terminals or splices,
splices in circuit. refer to Group 8W.
HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Replace fuse, refer to group 8W.
ILLUMINATE. 2. No ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer switch. 4. Replace headlamp dimmer switch.
5. Broken connector terminal or wire 5. Repair connector terminal or wire
splice in headlamp circuit. splices.
* Canada vehicles must have lamps ON.
XJ LAMPS 8L - 3
DI AGN OSI S AN D T EST I N G (Cont inue d)
FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
WITH ENGINE IDLING OR and posts.
IGNITION TURNED OFF. 2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Group 8A
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Both fog lamp bulbs defective. 7. Replace both lamp bulbs.
FOG LAMP BULBS BURN 1. Charging system output too high. 1. Test and repair charging system, refer to
OUT FREQUENTLY. Group 8A.
2. Loose or corroded terminals or 2. Inspect and repair all connectors and
splices in circuit. splices, refer to Group 8W.
FOG LAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system, refer to
WITH ENGINE RUNNING Group 8A.
ABOVE IDLE. 2. Poor fog lamp circuit ground. 2. Test voltage drop across Z1-ground,
refer to Group 8W.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
4. Both fog lamp bulbs defective. 4. Replace both fog lamp bulbs.
FOG LAMPS FLASH 1. Poor fog lamp circuit ground. 1. Repair circuit ground, refer to Group 8W.
RANDOMLY. 2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch circuit 3. Replace fog lamp switch.
breaker.
4. Loose or corroded terminals or 4. Repair connector terminals or splices,
splices in circuit. refer to Group 8W.
FOG LAMPS DO NOT 1. Blown fuse for fog lamps. 1. Replace fuse, refer to group 8W.
ILLUMINATE. 2. No ground at fog lamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or wire 4. Repair connector terminal or wire
splice in fog lamp circuit. splices.

HEADLAMP DELAY MODULE (5) Tu r n h ea dla m ps on a n d m ea su r e volt a ge a t t er-


m in a l 6. Th e volt m et e sh ou ld in dica t e ba t t er y volt -
DELAY FU N CT I ON I N OPERAT I V E a ge. If n ot r epa ir open cir cu it bet ween L2 a n d H DLP
(1) E n su r e h ea dla m ps oper a t e befor e pr oceedin g. dela y m odu le.
(2) Rem ove, in spect a n d t est t h e H DLP dela y 10 (6) Mea su r e t h e volt a ge bet ween t h e dela y m odu le
a m p fu se in ju n ct ion box. Repla ce if defect ive. t er m in a l 2 a n d veh icle body gr ou n d. Th e volt m et er
(3) Wit h t h e key off a n d t h e con n ect or discon - sh ou ld in dica t e ba t t er y volt a ge. If n ot , r epa ir t h e
n ect ed, m ea su r e t h e r esist a n ce fr om t h e dela y m od- open cir cu it in t h e wir e h a r n ess t o t h e H DLP fu se in
u le t er m in a l 4 t o veh icle body gr ou n d. Th e oh m m et er t h e P DC.
sh ou ld in dica t e zer o oh m s. If n ot , r epa ir t h e open cir- (7) If st eps 1 t h r ou gh 6 pr ove ou t good, r epla ce
cu it in t h e wir e h a r n ess t o veh icle body gr ou n d. h ea dla m p dela y m odu le.
(4) Wit h t h e key on m ea su r e t h e volt a ge bet ween
t h e dela y m odu le t er m in a l 8 a n d veh icle body
gr ou n d. Th e volt m et er sh ou ld in dica t e ba t t er y volt -
a ge. If n ot , r epa ir t h e open cir cu it in t h e wir e h a r-
n ess fr om ign it ion swit ch t o H DLP dela y m odu le.
CENTER
TO CENTER
OF
LAMP
OF
VEHICLE
HEAD-
LENS TOP EDGE OF
FLOOR
OFHIGH
HEADLAMP
TO
INTENSITY
CENTER
LENSZONELEFT EDGE
7.62OF HIGH
METERS
SITYINTEN-
ZONE
FEET)
(25 VEHICLE CENTERLINE
FRONT OF HEADLAMP

8L - 4 LAMPS XJ

H EADLAM P ALI GN M EN T

INDEX
page page

GENERAL INFORMATION HEADLAMP ADJUSTMENT . . . . . . . . . . . . . . . . 5


HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . 4 HEADLAMP ALIGNMENT PREPARATION . . . . . . 4
SERVICE PROCEDURES SPECIAL TOOLS
FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . . . 6 HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . 6

GEN ERAL I N FORM AT I ON SERV I CE PROCEDU RES


HEADLAMP ALIGNMENT HEADLAMP ALIGNMENT PREPARATION
H ea dla m ps ca n be a lign ed u sin g t h e scr een m et h od (1) Ver ify h ea dla m p dim m er swit ch a n d h igh bea m
pr ovided in t h is sect ion . Align m en t Tool C-4466-A or in dica t or oper a t ion .
equ iva len t ca n a lso be u sed. Refer t o in st r u ct ion s (2) Cor r ect defect ive com pon en t s t h a t cou ld h in der
pr ovided wit h t h e t ool for pr oper pr ocedu r es. Th e pr oper h ea dla m p a lign m en t .
p re fe rre d h e a d la m p a lig n m e n t s e ttin g is 0 fo r (3) Ver ify pr oper t ir e in fla t ion .
th e le ft/rig h t a d ju s tm e n t a n d 1” d o w n fo r th e (4) Clea n h ea dla m p len ses.
u p /d o w n a d ju s tm e n t. (5) Ver ify t h a t lu gga ge a r ea is n ot h ea vily loa ded.
(6) F u el t a n k sh ou ld be F ULL. Add 2.94 kg (6.5
lbs.) of weigh t over t h e fu el t a n k for ea ch est im a t ed
ga llon of m issin g fu el.

TOP EDGE OF FLOOR TO CENTER


CENTER OF VEHICLE HIGH INTENSITY OF HEADLAMP
TO CENTER OF ZONE LENS
HEADLAMP LENS

LEFT EDGE OF HIGH


INTENSITY ZONE

VEHICLE I
CENTERLINE
7
7.62 ME ERS
(25 FEET)

I
803f58ad

Fig. 1 Headlamp Alignment Screen—Typical


ADJUSTMENT
LEFT/RIGHT
HEADLAMP
SCREW UP/DOWN
MENTADJUST-
SCREW

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)

CENTER OF HIGH-INTENSITY FLOOR TO


VEHICLE TO AREA CENTER OF
CENTER O F ~ FOG LAMP
FOG LAMP ...____________ LENS

LENS ~~~~~g.L/
-
100 mm
(4 in.)

7.62 METERS
(25 FEET)
/
938L-26

Fig. 3 Fog Lamp Alignment —Typical


FOG LAMP ADJUSTMENT SPECI AL T OOLS
P r epa r e a n a lign m en t scr een . Refer t o Align m en t
Scr een P r epa r a t ion pa r a gr a ph in t h is sect ion . A pr op- HEADLAMP ALIGNMENT
er ly a lign ed fog la m p will pr oject a pa t t er n on t h e
a lign m en t scr een 100 m m (4 in .) below t h e fog la m p
cen t er lin e a n d st r a igh t a h ea d (F ig. 3).
Rot a t e t h e a dju st m en t scr ew t o a dju st bea m h eigh t
(F ig. 4).

Headlamp Aiming Kit C-4466–A

Fig. 4 Fog Lamp Adjustment


BUMPERSPRING HEADLAMP
PARK/TURN
NUT
ADJUSTMENT
LAMP HEADLAMP BEZEL BULBSOCKET ACCESS
FOG
CLIP
BULB
COVER
LAMP

XJ LAMPS 8L - 7

LAM P BU LB SERV I CE

INDEX
page page

REMOVAL AND INSTALLATION FRONT PARK/TURN SIGNAL LAMP BULB . . . . . 7


BACK-UP/REAR TURN SIGNAL/TAIL LAMP HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . 7
BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 8 LICENSE PLATE LAMP BULB . . . . . . . . . . . . . . 8
CENTER HIGH MOUNTED STOP LAMP MAP READING LAMP BULB . . . . . . . . . . . . . . . 9
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . .... 8 SIDE MARKER LAMP BULB . . . . . . . . . . . . . . . . 8
DOME LAMP BULB . . . . . . . . . . . . . . . . . . .... 9 UNDERHOOD LAMP BULB . . . . . . . . . . . . . . . . 9
FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . .... 7 VISOR VANITY LAMP BULB . . . . . . . . . . . . . . . . 9

REM OVAL AN D I N STALLAT I ON FOG LAMP BULB


HEADLAMP BULB REM OVAL
(1) Rem ove t h e scr ews a t t a ch in g t h e a ccess cover
REM OVAL t o t h e bot t om of t h e fog la m p (F ig. 2).
(1) Rem ove t h e scr ews a t t a ch in g t h e bezel t o t h e (2) Rem ove spr in g clip secu r in g bu lb t o fog la m p.
gr ille open in g pa n el (F ig. 1). (3) Discon n ect wir e con n ect or s a t bu lb.
(4) Rem ove bu lb elem en t fr om fog la m p.

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.

FRONT PARK/TURN SIGNAL LAMP BULB


REM OVAL
(1) Rem ove h ea dla m p bezel.
PARK LAMP
BULB SIDE MARKER
LAMP SIDE MARKER
PARK LAMP
LAMP
BULB TAIL LAMP
BULB TAIL LAMP

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

(4) In st a ll h ea dla m p bezel.


Fig. 5 Bulb Socket Removal
SIDE MARKER LAMP BULB I N STALLAT I ON
(1) In st a ll bu lb in socket .
REM OVAL (2) In st a ll bu lb a n d socket in la m p.
(1) Rem ove side m a r ker la m p. (3) In st a ll la m p.
(2) Rem ove bu lb a n d socket fr om ba ck side of la m p
h ou sin g (F ig. 4). LICENSE PLATE LAMP BULB
(3) Rem ove bu lb fr om socket .
REM OVAL
(1) Rem ove scr ews a t t a ch in g licen se pla t e la m p t o
lift ga t e.
(2) Rem ove bu lb fr om la m p socket .

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.

CENTER HIGH MOUNTED STOP LAMP (CHMSL)


BULB
REM OVAL
(1) Rem ove t h e scr ews a t t a ch in g t h e la m p h ou sin g
t o t h e lift ga t e.
(2) Rot a t e bu lb socket 1/4 t u r n a n d pu ll fr om h ou s-
Fig. 4 Side Marker Lamp in g (F ig. 6).
I N STALLAT I ON (3) Gr a sp bu lb a n d pu ll fr om socket .
(1) In st a ll bu lb in socket .
CHMSL CHMSLBULB

XJ LAMPS 8L - 9
REM OVAL AN D I N STALLAT I ON (Cont inue d) CONSOLE
LENS FLAT BLADE

(2) P osit ion t h e len s a t t h e la m p h ou sin g a n d for ce


it u pwa r d in t o t h e h ou sin g u n t il t h e r et a in er t a bs a r e
sea t ed on t h e la m p h ou sin g sh ou lder s.

MAP READING LAMP BULB


REM OVAL
(1) In ser t a fla t bla de scr ewdr iver in slot a t fr on t
CHMSL
BULB of len s (F ig. 7).
(2) Rot a t e t h e scr ewdr iver u n t il len s sn a ps ou t of
CHMSL
t h e h ou sin g.
(3) Rem ove len s fr om h ou sin g.
(4) Rem ove bu lb fr om t er m in a ls.

80ab5cce

Fig. 6 CHMSL Bulb


I N STALLAT I ON
(1) P u sh bu lb in t o socket .
(2) P osit ion socket in la m p a n d r ot a t e 1/4 t u r n .
(3) In st a ll t h e scr ews a t t a ch in g t h e la m p h ou sin g
t o t h e lift ga t e.

UNDERHOOD LAMP BULB


REM OVAL
(1) Discon n ect t h e wir e h a r n ess con n ect or fr om t h e
u n der h ood la m p. J9523-88~
(2) Rot a t e t h e bu lb cou n t er clock-wise. Rem ove it
fr om t h e la m p socket . Fig. 7 Reading Lamp Bulb
I N STALLAT I ON
I N STALLAT I ON
(1) In ser t bu lb in t o r ea din g la m p t er m in a ls.
(1) In ser t t h e r epla cem en t bu lb in t h e la m p ba se
(2) Repla ce len s by h oldin g len s level a n d pu sh in g
socket . Rot a t e it clockwise.
r ea r wa r d in t o h ou sin g.
(2) Con n ect t h e wir e h a r n ess con n ect or t o t h e
(3) P u sh len s u p t o sn a p in t o h ou sin g.
la m p.
VISOR VANITY LAMP BULB
DOME LAMP BULB
REM OVAL
REM OVAL
(1) Usin g a sm a ll fla t bla de, ca r efu lly pr y ea ch cor-
(1) Rem ove t h e dom e la m p len s by squ eezin g it a t
n er of len s ou t wa r d fr om la m p.
bot h sides. Th is will sepa r a t e t h e len s r et a in er t a bs
(2) Sepa r a t e len s fr om la m p.
fr om t h e la m p h ou sin g sh ou lder s.
(3) Gr a sp bu lb a n d pu ll ou t wa r d.
(2) P u ll t h e len s down wa r d t o r em ove it fr om t h e
la m p h ou sin g. I N STALLAT I ON
(3) Gr a sp bu lb a n d pu ll fr om la m p. (1) P osit ion bu lb in socket a n d pu sh in t o pla ce.
(2) P osit ion len s on la m p a n d sn a p in t o pla ce.
I N STALLAT I ON
(1) P osit ion bu lb in la m p a n d sn a p in t o pla ce.
BUMPERSPRING HEADLAMP
PARK/TURN
NUT
ADJUSTMENT
LAMP HEADLAMP BEZEL
FOG LAMP BUMPER

8L - 10 LAMPS XJ

LAM P SERV I CE

INDEX
page page

REMOVAL AND INSTALLATION HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10


BACK-UP/REAR TURN SIGNAL/TAIL LAMP . . . 11 LICENSE PLATE LAMP . . . . . . . . . . . . . . . . . . 12
CENTER HIGH MOUNTED STOP LAMP MAP/READING LAMP . . . . . . . . . . . . . . . . . . . 13
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SIDE MARKER LAMP . . . . . . . . . . . . . . . . . . . . 11
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 12 UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . 12
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 VISOR VANITY LAMP . . . . . . . . . . . . . . . . . . . . 13
FRONT PARK/TURN SIGNAL LAMP . . . . . . . . . 10

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

(1) P osit ion t h e fog la m p in t h e su ppor t br a cket


I N STALLAT I ON a n d in st a ll t h e scr ews.
(1) P osit ion t h e h ea dla m p bu cket in t h e gr ille (2) Con n ect t h e fog la m p wir e h a r n ess con n ect or.
open in g pa n el a n d slide t h e h ea dla m p bu cket u pwa r d
t o en ga ge it wit h t h e h ea dla m p a dju st in g scr ews. FRONT PARK/TURN SIGNAL LAMP
(2) In st a ll t h e spr in g a t t a ch in g t h e h ea dla m p
bu cket t o t h e gr ille open in g pa n el. REM OVAL
(1) Rem ove t h e h ea dla m p bezel.
BUMPER
SIDE GRILLE
PARK/TURN
ING
MARKER
LAMP
PANEL
OPEN-LAMP NUT
BEZEL FENDER GROMMET TAIL LAMP REAR BUMPER

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

Fig. 3 Park/Turn Signal Lamp


I N STALLAT I ON
(1) In st a ll bu lbs a n d socket s in t h e la m p h ou sin g.
(2) P osit ion t h e pa r k/t u r n sign a l la m p h ou sin g on
t h e gr ille open in g pa n el a n d in st a ll t h e scr ews.
(3) In st a ll t h e h ea dla m p bezel. REAR
BUMPER
SIDE MARKER LAMP B0aa0fcd

REM OVAL Fig. 5 Tail Lamp


(1) Rem ove scr ews a t t a ch in g side m a r ker la m p I N STALLAT I ON
len s t o gr ille open in g pa n el (F ig. 4). (1) In st a ll t h e bu lb a n d socket s in t h e la m p h ou s-
(2) Rem ove bu lb a n d socket fr om ba ck side of in g.
la m p. (2) P osit ion t h e la m p h ou sin g in t h e qu a r t er pa n el
a n d pu sh t o en ga ge t h e gr om m et .
(3) In st a ll t h e la m p h ou sin g scr ews. Tigh t en t h e
scr ews secu r ely.
(4) In st a ll 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.
(5) Close t h e lift ga t e.

CENTER HIGH MOUNTED STOP LAMP (CHMSL)


FENDER
REM OVAL
(1) Rem ove t h e scr ews a t t a ch in g t h e CH MSL t o

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

HOOD INNER PANEL

CONVOLUTED
CHMSL WIRE HARNESS COVER

80aa0fcb GROMMET J9223-443

Fig. 6 Center High Mounted Stop lamp Fig. 7 Underhood Lamp


LICENSE PLATE LAMP DOME LAMP
REM OVAL REM OVAL
(1) Rem ove scr ews a t t a ch in g t h e licen se pla t e (1) Rem ove t h e dom e la m p len s by squ eezin g it a t
la m p t o t h e lift ga t e. bot h sides. Th is will sepa r a t e t h e len s r et a in er t a bs
(2) Rem ove t h e bu lb fr om t h e la m p socket . fr om t h e la m p h ou sin g sh ou lder s.
(2) P u ll t h e len s down wa r d t o r em ove it fr om t h e
I N STALLAT I ON la m p h ou sin g.
(1) In st a ll bu lb in t h e la m p socket . (3) Rem ove t h e fa st en er s a t t a ch in g t h e la m p t o t h e
(2) P osit ion t h e licen se pla t e la m p on t h e lift ga t e r oof (F ig. 8).
a n d in st a ll scr ews.

UNDERHOOD LAMP ~ ~HEADLINER


Th e u n der h ood la m p is in st a lled on t h e h ood in n er
pa n el. Th e la m p illu m in a t es wh en t h e h ood is
open ed. Th e liqu id ON/OF F swit ch t h a t is in t egr a l
t+
I I
wit h t h e la m p ba se con t r ols t h e oper a t ion . Th e I ,
swit ch pr ovides a u t om a t ic ON/OF F fu n ct ion s ea ch __________,.,. I
t im e t h e h ood is open ed a n d closed.
BULB
REM OVAL
(1) Discon n ect t h e wir e h a r n ess con n ect or fr om t h e
la m p.
(2) Rot a t e t h e bu lb cou n t er clock-wise. Rem ove it
fr om t h e la m p ba se socket .
(3) Rem ove t h e scr ew t h a t a t t a ch es t h e la m p 80aafb62

r eflect or a n d su ppor t br a cket (F ig. 7).


(4) Rem ove t h e la m p fr om t h e h ood in n er pa n el. Fig. 8 Dome Lamp
(4) Discon n ect t h e wir e h a r n ess con n ect or.
I N STALLAT I ON (5) Rem ove t h e la m p h ou sin g fr om t h e h ea dlin er
(1) P osit ion t h e u n der h ood la m p on t h e h ood in n er ca vit y.
pa n el.
(2) In st a ll t h e scr ew t h r ou gh t h e la m p a n d in t o I N STALLAT I ON
t h e h ood pa n el. Tigh t en t h e scr ew secu r ely. (1) P osit ion t h e dom e la m p h ou sin g a t t h e h ea d-
(3) In ser t a r epla cem en t bu lb in t h e la m p ba se lin er ca vit y.
socket . Rot a t e it clockwise. (2) Con n ect t h e wir e h a r n ess con n ect or.
(4) Con n ect t h e wir e h a r n ess con n ect or t o t h e (3) In st a ll t h e fa st en er s a t t a ch in g t h e la m p t o t h e
la m p. r oof.
XJ LAMPS 8L - 13
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) P osit ion t h e len s a t t h e la m p h ou sin g a n d for ce (2) St a r t in g a t t h e ba se of t h e la m p a ssem bly a n d
it u pwa r d in t o t h e h ou sin g u n t il t h e r et a in er t a bs a r e wor kin g r igh t -t o-left , u se a sm a ll fla t bla de, ca r efu lly
sea t ed on t h e la m p h ou sin g sh ou lder s. pr y la m p fr om visor.
(3) Discon n ect visor la m p wir e con n ect or a n d
MAP/READING LAMP r em ove fr om veh icle.
Th e m a p/r ea din g la m p ca n be ser viced by r em ovin g
t h e over h ea d con sole. Refer t o Gr ou p 8C, Over h ea d I N STALLAT I ON
Con sole for r em ova l/in st a lla t ion pr ocedu r es. (1) P osit ion visor la m p a t visor a n d con n ect visor
la m p wir e con n ect or.
VISOR VANITY LAMP (2) P osit ion visor la m p in visor a n d pr ess in t o
pla ce.
REM OVAL
(1) F old down su n visor.
HEADLAMP DELAY MOD-
ULE BRACKET

8L - 14 LAMPS XJ

LAM P SY ST EM S DAYTIME RUNNINGMODULE


LIGHT

INDEX
page page

REMOVAL AND INSTALLATION SENTINEL HEADLAMP DELAY MODULE . . . . . 14


DAYTIME RUNNING LAMP MODULE . . . . . . . . 14

REM OVAL AN D I N STALLAT I ON DAYTIME RUNNING LAMP MODULE


SENTINEL HEADLAMP DELAY MODULE REM OVAL
Th e Da yt im e Ru n n in g Ligh t s (DRL) m odu le is
REM OVAL loca t ed on t h e r igh t fen der in n er pa n el a dja cen t t o
(1) Rem ove t h e kn ee blocker. t h e da sh pa n el (F ig. 2).
(2) Rem ove t h e scr ew t h a t a t t a ch es t h e m odu le t o
t h e in side of t h e in st r u m en t pa n el (F ig. 1).
(3) Discon n ect t h e wir e h a r n ess con n ect or a n d
r em ove t h e m odu le fr om t h e in st r u m en t pa n el.

Fig. 1 Headlamp Delay Module


I N STALLAT I ON
(1) P osit ion t h e m odu le in side t h e I/P a n d con n ect Fig. 2 Daytime Running Lamp Module
t h e wir e h a r n ess con n ect or t o t h e m odu le.
(1) Discon n ect t h e wir e h a r n ess con n ect or fr om t h e
(2) In st a ll t h e scr ew t h a t a t t a ch es t h e m odu le t o
m odu le.
t h e in side of t h e in st r u m en t pa n el.
(2) Rem ove t h e scr ews t h a t a t t a ch t h e m odu le t o
(3) In st a ll t h e kn ee blocker.
t h e fen der in n er pa n el.
(3) Rem ove t h e m odu le fr om t h e fen der in n er
pa n el.

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

GENERAL INFORMATION INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . 15


GENERAL INFORMATION . . . . . . . . . . . . . . . . 15
SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 15

GEN ERAL I N FORM AT I ON LAMP B U LB


Dom e/Rea din g . . . . . . . . . . . . . . . . . . . . . . . . . . 906
GENERAL INFORMATION Glove Com pa r t m en t . . . . . . . . . . . . . . . . . . . . . . 194
Th e followin g Bu lb Applica t ion Ta bles list s t h e Over h ea d Con sole . . . . . . . . . . . . . . . . . . . . . . . . 912
la m p t it le on t h e left side of t h e colu m n a n d t r a de Un der H ood . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
n u m ber or pa r t n u m ber on t h e r igh t . Va n it y Mir r or . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Un der pa n el Cou r t esy . . . . . . . . . . . . . . . . . . . . . 168
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli- I N DI CAT OR LAM PS
cation Table. Damage to lamp can result. Do not Ser vice pr ocedu r es for m ost of t h e la m ps in t h e
touch halogen bulbs with fingers or other oily sur- 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
faces. Bulb life will be reduced. 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
Ga u ges.

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

PASSIVE RESTRAINT SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION CLEANUP PROCEDURE . . . . . . . . . . . . . . . . . . 4


INTRODUCTION . . . . . . . . . . . ............. 1 REMOVAL AND INSTALLATION
DESCRIPTION AND OPERATION AIRBAG CONTROL MODULE . . . . . . . . . . . . . . 8
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . 3 AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . 5
AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . 2 CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . 9
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . 3 DRIVER SIDE AIRBAG TRIM COVER AND
IMPACT SENSOR . . . . . . . . . . . . . . . . . . . . . . . 3 HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING PASSENGER SIDE AIRBAG DOOR . . . . . . . . . . 7
AIRBAG SYSTEM . . . . . . . . . . ............. 3 ADJUSTMENTS
SERVICE PROCEDURES CLOCKSPRING CENTERING . . . . . . . . . . . . . . 10
AIRBAG SYSTEM . . . . . . . . . . ............. 4

GEN ERAL I N FORM AT I ON F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor


com pon en t s in t h e a ir ba g syst em . Refer t o 8W-43 -
INTRODUCTION Air ba g Syst em in Gr ou p 8W - Wir in g Dia gr a m s for
A du a l fr on t a ir ba g syst em is a st a n da r d equ ip- com plet e cir cu it descr ipt ion s a n d dia gr a m s.
m en t sa fet y fea t u r e on t h is m odel. Th e syst em
in clu des a n in fla t a ble a ir ba g m odu le in t h e cen t er of NOTE: This group covers both Left-Hand Drive
t h e st eer in g wh eel, a n d a secon d in fla t a ble a ir ba g (LHD) and Right-Hand Drive (RHD) versions of this
m odu le in t h e in st r u m en t pa n el a bove t h e glove box. model. Whenever required and feasible, the RHD
Th is syst em is design ed t o r edu ce ser iou s in ju r ies t o versions of affected vehicle components have been
t h e dr iver a n d fr on t sea t pa ssen ger du r in g a fr on t a l constructed as mirror-image of the LHD versions.
im pa ct of t h e veh icle. While most of the illustrations used in this group
To t est t h is pa ssive r est r a in t syst em , r efer t o t h e represent only the LHD version, the diagnostic and
pr oper Dia gn ost ic P r ocedu r es m a n u a l. If a n a ir ba g service procedures outlined can generally be
m odu le a ssem bly is defect ive a n d n on -deployed, r efer applied to either version. Exceptions to this rule
t o t h e Ch r ysler Cor por a t ion cu r r en t pa r t s r et u r n list have been clearly identified as LHD or RHD, if a
in t h e Wa r r a n t y P olicies a n d P r ocedu r es m a n u a l for special illustration or procedure is required.
t h e pr oper h a n dlin g pr ocedu r es.
8M - 2 PASSIVE RESTRAINT SYSTEMS XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
WARNING: DESCRI PT I ON AN D OPERAT I ON
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE AIRBAG MODULE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL, DRI V ER SI DE
STEERING COLUMN, OR INSTRUMENT PANEL Th e a ir ba g m odu le pr ot ect ive t r im cover is t h e
COMPONENTS YOU MUST FIRST DISCONNECT m ost visible pa r t of t h e dr iver side a ir ba g syst em .
AND ISOLATE THE BATTERY NEGATIVE (GROUND) Th e m odu le is m ou n t ed dir ect ly t o t h e st eer in g
CABLE. THEN WAIT TWO MINUTES FOR THE SYS- wh eel. Loca t ed u n der t h e a ir ba g m odu le t r im cover
TEM CAPACITOR TO DISCHARGE BEFORE FUR- a r e t h e h or n swit ch , t h e a ir ba g cu sh ion , a n d t h e a ir-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE ba g cu sh ion su ppor t in g com pon en t s. Th e a ir ba g m od-
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE u le in clu des a h ou sin g t o wh ich t h e cu sh ion a n d
TO DO THIS COULD RESULT IN ACCIDENTAL AIR- in fla t or a r e a t t a ch ed a n d sea led. Th e a ir ba g m odu le
BAG DEPLOYMENT AND POSSIBLE PERSONAL ca n n ot be r epa ir ed, a n d m u st be r epla ced if deployed
INJURY. or in a n y wa y da m a ged.
• THE AIRBAG MODULE INFLATOR ASSEMBLY Th e in fla t or a ssem bly is m ou n t ed t o t h e ba ck of
CONTAINS SODIUM AZIDE AND POTASSIUM t h e a ir ba g m odu le. Th e in fla t or sea ls t h e h ole in t h e
NITRATE. THESE MATERIALS ARE POISONOUS a ir ba g cu sh ion so it ca n disch a r ge t h e ga s it pr odu ces
AND EXTREMELY FLAMMABLE. CONTACT WITH dir ect ly in t o t h e cu sh ion wh en su pplied wit h t h e
ACID, WATER, OR HEAVY METALS MAY PRODUCE pr oper elect r ica l sign a l. Th e pr ot ect ive t r im cover is
HARMFUL AND IRRITATING GASES (SODIUM fit t ed t o t h e fr on t of t h e a ir ba g m odu le a n d for m s a
HYDROXIDE IS FORMED IN THE PRESENCE OF decor a t ive cover in t h e cen t er of t h e st eer in g wh eel.
MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN Upon a ir ba g deploym en t , t h is cover will split a t a
ADDITION, THE PASSENGER AIRBAG MODULE pr edet er m in ed br ea kou t lin e.
CONTAINS ARGON GAS PRESSURIZED TO OVER
2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN PASSEN GER SI DE
AIRBAG MODULE OR TAMPER WITH ITS INFLA- Th e a ir ba g door on t h e in st r u m en t pa n el a bove t h e
TOR. DO NOT PUNCTURE, INCINERATE, OR BRING glove box is t h e m ost visible pa r t of t h e pa ssen ger
INTO CONTACT WITH ELECTRICITY. DO NOT side a ir ba g syst em . Loca t ed u n der t h e a ir ba g door
STORE AT TEMPERATURES EXCEEDING 93° C a r e t h e a ir ba g cu sh ion a n d it s su ppor t in g com po-
(200° F). n en t s. Th e a ir ba g m odu le in clu des a h ou sin g t o
• REPLACE AIRBAG SYSTEM COMPONENTS wh ich t h e cu sh ion a n d in fla t or a r e a t t a ch ed a n d
ONLY WITH PARTS SPECIFIED IN THE CHRYSLER sea led. Th e a ir ba g m odu le ca n n ot be r epa ir ed, a n d
MOPAR PARTS CATALOG. SUBSTITUTE PARTS m u st be r epla ced if deployed or in a n y wa y da m a ged.
MAY APPEAR INTERCHANGEABLE, BUT INTERNAL Th e in fla t or a ssem bly is m ou n t ed t o t h e ba ck of
DIFFERENCES MAY RESULT IN INFERIOR OCCU- t h e a ir ba g m odu le. Th e in fla t or sea ls t h e h ole in t h e
PANT PROTECTION. a ir ba g cu sh ion so it ca n disch a r ge t h e ga s it pr odu ces
• THE FASTENERS, SCREWS, AND BOLTS dir ect ly in t o t h e cu sh ion wh en su pplied wit h t h e
ORIGINALLY USED FOR THE AIRBAG SYSTEM pr oper elect r ica l sign a l. Th e a ir ba g door is secu r ed t o
COMPONENTS HAVE SPECIAL COATINGS AND t h e a ir ba g m odu le a n d t h e in st r u m en t pa n el ba se,
ARE SPECIFICALLY DESIGNED FOR THE AIRBAG a n d h a s pr edet er m in ed br ea kou t lin es con cea led
SYSTEM. THEY MUST NEVER BE REPLACED WITH ben ea t h it s decor a t ive cover. Upon a ir ba g deploy-
ANY SUBSTITUTES. ANY TIME A NEW FASTENER m en t , t h e a ir ba g door will split a t t h e br ea kou t lin es
IS NEEDED, REPLACE IT WITH THE CORRECT FAS- a n d t h e door will pivot ou t of t h e wa y.
TENERS PROVIDED IN THE SERVICE PACKAGE OR Th e a ir ba g m odu le is secu r ed wit h scr ews a t t h e
SPECIFIED IN THE CHRYSLER MOPAR PARTS CAT- bot t om t o t h e in st r u m en t pa n el ba se a bove t h e glove
ALOG. box open in g, a n d a t t h e t op t o t h e in st r u m en t pa n el
• WHEN A STEERING COLUMN HAS AN AIRBAG ba se u n der n ea t h t h e in st r u m en t pa n el t op cover. Th e
MODULE ATTACHED, NEVER PLACE THE COLUMN a ir ba g m odu le a n d a ir ba g door a r e a va ila ble a s sep-
ON THE FLOOR OR ANY OTHER SURFACE WITH a r a t e ser vice it em s. F ollowin g a n a ir ba g deploym en t ,
THE STEERING WHEEL OR AIRBAG MODULE FACE t h e a ir ba g m odu le a n d a ir ba g door m u st be r epla ced.
DOWN.
ST ORAGE
An a ir ba g m odu le m u st be st or ed in it s or igin a l,
specia l con t a in er u n t il u sed for ser vice. Also, it m u st
be st or ed in a clea n , dr y en vir on m en t ; a wa y fr om
sou r ces of ext r em e h ea t , spa r ks, a n d h igh elect r ica l
16–WAY DATA LINK
BOTTOM
CONNECTOR
MENT
OF INSTRU-
PANEL

XJ PASSIVE RESTRAINT SYSTEMS 8M - 3


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
en er gy. Alwa ys pla ce or st or e a n a ir ba g m odu le on a Th e ACM a lso con t a in s a n en er gy-st or a ge ca pa ci-
su r fa ce wit h it s t r im cover or a ir ba g side fa cin g u p, t or. Th is ca pa cit or st or es en ou gh elect r ica l en er gy t o
t o m in im ize m ovem en t in ca se of a n a cciden t a l deploy t h e a ir ba gs for u p t o on e secon d followin g a
deploym en t . ba t t er y discon n ect or fa ilu r e du r in g a n im pa ct . Th e
pu r pose of t h e ca pa cit or is t o pr ovide a ir ba g syst em
IMPACT SENSOR pr ot ect ion in a sever e secon da r y im pa ct , if t h e in it ia l
Th e im pa ct sen sor pr ovides ver ifica t ion of t h e im pa ct h a s da m a ged or discon n ect ed t h e ba t t er y, bu t
dir ect ion a n d sever it y of a n im pa ct . On e im pa ct sen - wa s n ot sever e en ou gh t o deploy t h e a ir ba gs.
sor is u sed. It is loca t ed in side t h e Air ba g Con t r ol Th e ACM ca n n ot be r epa ir ed a n d, if da m a ged or
Modu le (ACM), wh ich is secu r ed t o a br a cket u n der fa u lt y, it m u st be r epla ced.
t h e left side fr on t bu cket sea t in side t h e veh icle.
Th e im pa ct sen sor is a n a cceler om et er t h a t sen ses
t h e r a t e of deceler a t ion . Th e m icr opr ocessor in t h e DI AGN OSI S AN D T EST I N G
ACM m on it or s t h e im pa ct sen sor sign a l. A pr e-pr o-
gr a m m ed decision a lgor it h m in t h e m icr opr ocessor AIRBAG SYSTEM
det er m in es wh en t h e deceler a t ion r a t e in dica t es a n A DRB sca n t ool is r equ ir ed for dia gn osis of t h e
im pa ct is sever e en ou gh t o r equ ir e a ir ba g syst em a ir ba g syst em . Refer t o t h e pr oper Dia gn ost ic P r oce-
pr ot ect ion . Wh en t h e pr ogr a m m ed con dit ion s a r e du r es m a n u a l for m or e in for m a t ion .
m et , t h e ACM sen ds a n elect r ica l sign a l t o deploy 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
a ir ba g syst em com pon en t s. ca ble. If t h e a ir ba g h a s n ot been deployed, wa it t wo
Th e im pa ct sen sor is ca libr a t ed for t h e specific m in u t es for t h e syst em ca pa cit or t o disch a r ge befor e
veh icle. Th e sen sor is on ly ser viced a s a u n it wit h t h e fu r t h er ser vice.
ACM. Th e sen sor ca n n ot be r epa ir ed or a dju st ed a n d, (2) Con n ect t h e DRB sca n t ool t o t h e 16-wa y da t a
if fa u lt y or da m a ged, t h e ACM u n it m u st be r epla ced. lin k wir e h a r n ess con n ect or. Th e con n ect or is loca t ed
on t h e dr iver side lower edge of t h e in st r u m en t
CLOCKSPRING pa n el, ou t boa r d of t h e st eer in g colu m n (F ig. 1).
Th e clockspr in g is m ou n t ed on t h e st eer in g colu m n
beh in d t h e st eer in g wh eel. Th is a ssem bly con sist s of 16-WAY
a pla st ic h ou sin g wh ich con t a in s a fla t , r ibbon -like, DATA LINK
elect r ica lly con du ct ive t a pe t h a t win ds a n d u n win ds CONNECTOR
wit h t h e st eer in g wh eel r ot a t ion .
Th e clockspr in g is u sed t o m a in t a in a con t in u ou s
elect r ica l cir cu it bet ween t h e wir e h a r n ess a n d t h e
dr iver side a ir ba g m odu le, t h e h or n swit ch , a n d t h e
veh icle speed con t r ol swit ch es on veh icles t h a t a r e so
equ ipped.
Th e clockspr in g m u st be pr oper ly cen t er ed wh en it
is in st a lled on t h e st eer in g colu m n followin g a n y ser-
vice r em ova l, or it will be da m a ged. See t h e Clock-
spr in g Cen t er in g pr ocedu r e in t h is gr ou p for m or e
in for m a t ion .
Th e clockspr in g ca n n ot be r epa ir ed. If t h e clock-
spr in g is fa u lt y, da m a ged, or if t h e a ir ba g h a s been
deployed, t h e clockspr in g m u st be r epla ced.

AIRBAG CONTROL MODULE


Th e Air ba g Con t r ol Modu le (ACM) con t a in s t h e
im pa ct sen sor, a n d a m icr opr ocessor t h a t m on it or s
t h e im pa ct sen sor a n d t h e a ir ba g syst em elect r ica l Fig. 1 16-Way Data Link Connector - Typical
cir cu it s t o det er m in e t h e syst em r ea din ess. Th e ACM (3) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
con t a in s On -Boa r d Dia gn ost ics (OBD), a n d will sen d E xit t h e veh icle wit h t h e DRB. Use t h e la t est ver sion
a n a ir ba g la m p-on m essa ge t o t h e in st r u m en t clu st er of t h e pr oper DRB ca r t r idge.
on t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s (4) Aft er ch eckin g t h a t n obody is in side t h e veh i-
t o ligh t t h e a ir ba g in dica t or la m p in t h e in st r u m en t cle, r econ n ect t h e ba t t er y n ega t ive ca ble.
clu st er wh en a m on it or ed a ir ba g syst em fa u lt occu r s. (5) Usin g t h e DRB, r ea d a n d r ecor d t h e a ct ive
Dia gn ost ic Tr ou ble Code (DTC) da t a .
8M - 4 PASSIVE RESTRAINT SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
(6) Rea d a n d r ecor d a n y st or ed DTC da t a . Ot h er veh icle com pon en t s sh ou ld be closely
(7) Refer t o t h e pr oper Dia gn ost ic P r ocedu r es m a n - in spect ed, bu t a r e t o be r epla ced on ly a s r equ ir ed by
u a l, if a n y DTC is fou n d in St ep 5 or St ep 6. t h e ext en t of t h e visible da m a ge in cu r r ed.
(8) E r a se t h e st or ed DTC da t a . If a n y pr oblem s
r em a in , t h e st or ed DTC da t a will n ot er a se. CLEANUP PROCEDURE
(9) Wit h t h e ign it ion swit ch st ill in t h e On posi- F ollowin g a n a ir ba g syst em deploym en t , t h e veh i-
t ion , m a ke su r e n obody is in t h e veh icle. cle in t er ior will con t a in a powder y r esidu e. Th is r es-
(10) F r om ou t side of t h e veh icle (a wa y fr om t h e idu e is pr im a r ily sodiu m bica r bon a t e (ba kin g soda ),
a ir ba g m odu les in ca se of a n a cciden t a l deploym en t ) u sed a s a n a ir ba g cu sh ion lu br ica n t . H owever, t h er e
t u r n t h e ign it ion swit ch t o t h e Off posit ion for a bou t will a lso be t r a ces of sodiu m h ydr oxide powder, a
t en secon ds, a n d t h en ba ck t o t h e On posit ion . ch em ica l by-pr odu ct of t h e gen er a n t u sed for a ir ba g
Obser ve t h e a ir ba g in dica t or la m p in t h e in st r u m en t deploym en t . Sin ce t h is powder ca n ir r it a t e t h e skin ,
clu st er. It sh ou ld ligh t for six t o eigh t secon ds, a n d eyes, n ose, or t h r oa t , be su r e t o wea r sa fet y gla sses,
t h en go ou t . Th is in dica t es t h a t t h e a ir ba g syst em is r u bber gloves, a n d a lon g-sleeved sh ir t du r in g
fu n ct ion in g n or m a lly. clea n u p (F ig. 2).

NOTE: If the airbag indicator lamp fails to light, or


lights and stays on, there is an airbag system mal-
function. Refer to the proper Diagnostic Procedures
manual to diagnose the problem.

SERV I CE PROCEDU RES


AIRBAG SYSTEM
N ON -DEPLOY ED
At n o t im e sh ou ld a n y sou r ce of elect r icit y be per-
m it t ed n ea r t h e in fla t or on t h e ba ck of a n a ir ba g
m odu le. Wh en ca r r yin g a n on -deployed a ir ba g m od- 918M-4
u le, t h e t r im cover or a ir ba g side of t h e m odu le
sh ou ld be poin t ed a wa y fr om t h e body t o m in im ize Fig. 2 Wear Safety Glasses and Rubber Gloves
in ju r y in t h e even t of a n a cciden t a l deploym en t . If
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
t h e m odu le is pla ced on a ben ch or a n y ot h er su r fa ce,
DURING CLEANUP, RUN COOL WATER OVER THE
t h e t r im cover or a ir ba g side of t h e m odu le sh ou ld be
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
fa ce u p t o m in im ize m ovem en t in t h e even t of a n
IRRITATION OF THE NOSE OR THROAT, EXIT THE
a cciden t a l deploym en t .
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
In a ddit ion , t h e a ir ba g syst em sh ou ld be disa r m ed
CEASES. IF IRRITATION CONTINUES, SEE A PHYSI-
wh en ever a n y st eer in g wh eel, st eer in g colu m n , or
CIAN.
in st r u m en t pa n el com pon en t s r equ ir e dia gn osis or
ser vice. F a ilu r e t o obser ve t h is wa r n in g cou ld r esu lt Begin t h e clea n u p by r em ovin g t h e a ir ba g m odu les
in a cciden t a l a ir ba g deploym en t a n d possible per- fr om t h e veh icle a s descr ibed in t h is gr ou p.
son a l in ju r y. Refer t o Gr ou p 8E - In st r u m en t P a n el Use a va cu u m clea n er t o r em ove a n y r esidu a l pow-
Syst em s for a ddit ion a l ser vice pr ocedu r es on t h e der fr om t h e veh icle in t er ior. Clea n fr om ou t side t h e
in st r u m en t pa n el. Refer t o Gr ou p 19 - St eer in g for veh icle a n d wor k you r wa y in side, so t h a t you a void
a ddit ion a l ser vice pr ocedu r es on t h e st eer in g wh eel kn eelin g or sit t in g on a n on -clea n ed a r ea .
a n d st eer in g colu m n . Be su r e t o va cu u m t h e h ea t er a n d a ir con dit ion in g
ou t let s a s well (F ig. 3). Ru n t h e h ea t er a n d a ir con -
DEPLOY ED
dit ion in g blower on t h e lowest speed set t in g a n d va c-
An y veh icle wh ich is t o be r et u r n ed t o u se a ft er a n
u u m a n y powder expelled fr om t h e ou t let s. You m a y
a ir ba g deploym en t , m u st h a ve bot h a ir ba g m odu les,
n eed t o va cu u m t h e in t er ior of t h e veh icle a secon d
a n d t h e clockspr in g r epla ced. Th ese com pon en t s will
t im e t o r ecover a ll of t h e powder .
be da m a ged or wea ken ed a s a r esu lt of a n a ir ba g
P la ce t h e deployed a ir ba g m odu les in you r veh icu -
deploym en t , wh ich m a y or m a y n ot be obviou s du r in g
la r scr a p pile.
a visu a l in spect ion , a n d a r e n ot in t en ded for r eu se.
CLOCKSPRING
AIRBAG WIRE SCREW
HORN
SPEED
FWD SWITCH
CONTROL
WIRE
WIRE
DRIVER
STEERING
AIRBAG
NUTWHEEL
MODULE

XJ PASSIVE RESTRAINT SYSTEMS 8M - 5

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

REM OVAL AN D I N STALLAT I ON (4) Un plu g t h e a ir ba g m odu le a n d h or n swit ch


wir e h a r n ess con n ect or s fr om t h e ba ck of t h e a ir ba g
AIRBAG MODULE m odu le.
(5) Rem ove t h e dr iver side a ir ba g m odu le fr om t h e
WARNING: veh icle.
• THE AIRBAG SYSTEM IS A SENSITIVE, COM- (6) If t h e a ir ba g h a s been deployed, see t h e pr oce-
PLEX ELECTROMECHANICAL UNIT. BEFORE du r e for r epla cin g t h e clockspr in g in t h is gr ou p.
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- (7) Wh en in st a llin g t h e a ir ba g m odu le, con n ect t h e
BAG SYSTEM OR RELATED STEERING WHEEL, clockspr in g wir e h a r n ess con n ect or t o t h e m odu le by
STEERING COLUMN, OR INSTRUMENT PANEL pr essin g st r a igh t in on t h e con n ect or. Be cer t a in t h a t
COMPONENTS YOU MUST FIRST DISCONNECT t h e con n ect or is fu lly en ga ged by obser vin g t h e la t ch -
AND ISOLATE THE BATTERY NEGATIVE (GROUND) in g clip a r m s on t h e t op of t h e con n ect or.
CABLE. THEN WAIT TWO MINUTES FOR THE SYS- (8) In st a ll t h e t wo a ir ba g m odu le m ou n t in g scr ews
TEM CAPACITOR TO DISCHARGE BEFORE FUR- a n d t igh t en t o 10.2 N·m (90 in . lbs.).
THER SYSTEM SERVICE. THIS IS THE ONLY SURE (9) Do n ot con n ect t h e ba t t er y n ega t ive ca ble a t
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE t h is t im e. See Air ba g Syst em in Dia gn osis a n d Test -
TO DO THIS COULD RESULT IN ACCIDENTAL AIR- in g for t h e pr oper pr ocedu r es.
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. PASSEN GER SI DE
• WHEN REMOVING A DEPLOYED AIRBAG (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
MODULE, RUBBER GLOVES, EYE PROTECTION, ca ble. If t h e a ir ba g m odu le h a s n ot been deployed,
AND A LONG-SLEEVED SHIRT SHOULD BE WORN. wa it t wo m in u t es for t h e syst em ca pa cit or t o dis-
THERE MAY BE DEPOSITS ON THE AIRBAG MOD- ch a r ge befor e fu r t h er ser vice.
ULE AND OTHER INTERIOR SURFACES. IN LARGE (2) Rem ove t h e in st r u m en t pa n el t op cover. Refer
DOSES, THESE DEPOSITS MAY CAUSE IRRITATION t o Gr ou p 8E - In st r u m en t P a n el Syst em s for t h e pr o-
TO THE SKIN AND EYES. cedu r es.
(3) Un plu g t h e pa ssen ger side a ir ba g m odu le wir e
h a r n ess con n ect or loca t ed on t h e t op of t h e in st r u -
DRI V ER SI DE m en t pa n el bet ween t h e a ir ba g m odu le a n d t h e win d-
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive sh ield (F ig. 5).
ca ble. If t h e a ir ba g m odu le h a s n ot been deployed, (4) Disen ga ge t h e pa ssen ger side a ir ba g m odu le
wa it t wo m in u t es for t h e syst em ca pa cit or t o dis- wir e h a r n ess con n ect or r et a in er fr om t h e h ole on t h e
ch a r ge befor e fu r t h er ser vice. t op of t h e in st r u m en t pa n el.
(2) F r om t h e u n der side of t h e st eer in g wh eel, (5) Rem ove t h e fou r scr ews t h a t secu r e t h e u pper
r em ove t h e t wo scr ews t h a t secu r e t h e dr iver side fla n ge of t h e pa ssen ger side a ir ba g door t o t h e
a ir ba g m odu le t o t h e st eer in g wh eel (F ig. 4). in st r u m en t pa n el (F ig. 6).
(3) P u ll t h e a ir ba g m odu le a wa y fr om t h e st eer in g (6) Rem ove t h e t wo scr ews t h a t secu r e t h e u pper
wh eel fa r en ou gh t o a ccess t h e wir e h a r n ess con n ec- a ir ba g m odu le m ou n t in g br a cket s t o t h e t op of t h e
t or s on t h e ba ck of t h e a ir ba g m odu le. in st r u m en t pa n el.
INSTRUMENT
PASSENGER
GLOVE
PANEL
SIDE
BOX AIRBAG
DOOR WIRE
CONNECTOR
HARNESS SCREW
SCREW
PASSENGER MODULE
AIRBAG HORN SWITCH FEED
WIRE RETAINER
WIRE HORN SWITCH GROUND
WIRE
AIRBAG AIRBAG HOUS-
DOOR ING

8M - 6 PASSIVE RESTRAINT SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
, PASSENGER SIDE AIRBAG -AIRBAG (13) Do n ot con n ect t h e ba t t er y n ega t ive ca ble a t
WIRE HARNESS CONNECTOR I HOUSING 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.
~~>"~~~I LJ
DRIVER SIDE AIRBAG TRIM COVER AND HORN
SWITCH
WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
80abac53
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
Fig. 5 Passenger Side Airbag Connector Remove/ COMPONENTS YOU MUST FIRST DISCONNECT
Install AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
INSTRUMENT TEM CAPACITOR TO DISCHARGE BEFORE FUR-
PANEL ~SCREW
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• THE HORN SWITCH IS INTEGRAL TO THE AIR-
BAG MODULE TRIM COVER. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
80ab88a1
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Fig. 6 Passenger Side Airbag Module Remove/Install (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(7) Open t h e glove box door a n d r em ove t h e t wo ca ble. If t h e a ir ba g m odu le h a s n ot been deployed,
glove box door st op bu m per s by slidin g t h em down wa it t wo m in u t es for t h e syst em ca pa cit or t o dis-
t owa r ds t h e glove box bin a n d ou t of t h eir slot t ed ch a r ge befor e fu r t h er ser vice.
h oles in t h e in st r u m en t pa n el. Roll t h e glove box (2) Rem ove t h e dr iver side a ir ba g m odu le a s
door down t o it s fu lly open ed posit ion . descr ibed in t h is gr ou p.
(8) Rem ove t h e fou r scr ews t h a t secu r e t h e lower (3) Rem ove t h e pla st ic h or n swit ch feed wir e
fla n ge of t h e pa ssen ger side a ir ba g door t o t h e r et a in er fr om t h e st u d on t h e a ir ba g h ou sin g (F ig. 7).
in st r u m en t pa n el n ea r t h e u pper edge of t h e glove
HORN HORN
box open in g.
SWITCH SWITCH
(9) Rea ch t h r ou gh t h e glove box open in g a n d u p t o FEED GROUND
r em ove t h e t wo scr ews t h a t secu r e t h e lower a ir ba g WIRE WIRE
m odu le m ou n t in g br a cket s t o t h e in st r u m en t pa n el.
(10) Rem ove t h e pa ssen ger side a ir ba g m odu le a n d
a ir ba g door fr om t h e in st r u m en t pa n el a s a u n it .
(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 h a r dwa r e a s follows:
• Air ba g m odu le m ou n t in g br a cket scr ews - 11.8
N·m (105 in . lbs.)
• Air ba g door m ou n t in g scr ews - 2.2 N·m (20 in .
lbs.).
(12) Befor e r ein st a llin g t h e in st r u m en t pa n el t op
cover, be cer t a in t h a t t h e a ir ba g m odu le wir e h a r n ess
con n ect or la t ch es a r e fu lly en ga ged. 80ab88a3

Fig. 7 Horn Switch Feed Wire Remove/Install


TRIM
LOWERRETAINER
HORN
UPPER
COVER
RETAINER
INFLATOR
SWITCH RETAINER
LOCKING
RETAINER
RETAINER
BLOCKS
STUDS
SLOTS
SLOTS
SLOTS NUT
AIRBAG
(4)TRIM
HOUSING
COVER TRIM
LOCKING
COVER
BLOCK
LIP HORNAIRBAG
SWITCHHOUSING

XJ PASSIVE RESTRAINT SYSTEMS 8M - 7


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) Rem ove t h e fou r n u t s t h a t secu r e t h e u pper TRIM COVER
a n d lower t r im cover r et a in er s t o t h e st u ds on t h e
a ir ba g h ou sin g (F ig. 8).
UPPER s s s

'
RETAINER
@~@
HORN
SWITCH

Fig. 8 Airbag Trim Cover Retainers Remove/Install


(5) Rem ove t h e u pper a n d lower t r im cover r et a in - 80a0119f
er s fr om t h e a ir ba g h ou sin g st u ds. Fig. 10 Airbag Trim Cover Locking Blocks Installed
(6) Rem ove t h e h or n swit ch gr ou n d wir e eyelet
fr om t h e u pper a ir ba g h ou sin g st u d. (9) Wh en in st a llin g t h e u pper a n d lower t r im cover
(7) Disen ga ge t h e fou r t r im cover lockin g blocks fr om r et a in er s, be cer t a in t h a t t h e t a bs on ea ch r et a in er a r e
t h e lip a r ou n d t h e ou t side edge of t h e a ir ba g h ou sin g en ga ged in t h e r et a in er slot s of t h e t r im cover (F ig. 9).
a n d r em ove t h e h ou sin g fr om t h e cover (F ig. 9). (10) In st a ll a n d t igh t en t h e t r im cover r et a in er
n u t s t o 10 N·m (90 in . lbs.).
RETAINER SLOTS (11) 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 , bu t 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.

PASSENGER SIDE AIRBAG DOOR


WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
HORN ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
SWITCH BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL COM-
PONENTS YOU MUST FIRST DISCONNECT AND ISO-
RETAINER SLOTS 80ab88a6 LATE THE BATTERY NEGATIVE (GROUND) CABLE.
THEN WAIT TWO MINUTES FOR THE SYSTEM
Fig. 9 Airbag Trim Cover Remove/Install
CAPACITOR TO DISCHARGE BEFORE FURTHER
WARNING: USE EXTREME CARE TO PREVENT SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO
ANY FOREIGN MATERIAL FROM ENTERING THE DISABLE THE AIRBAG SYSTEM. FAILURE TO DO
DRIVER SIDE AIRBAG MODULE, OR BECOMING THIS COULD RESULT IN ACCIDENTAL AIRBAG
ENTRAPPED BETWEEN THE DRIVER SIDE AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
MODULE TRIM COVER AND THE DRIVER SIDE AIR- • WHEN REMOVING A DEPLOYED AIRBAG
BAG MODULE. FAILURE TO OBSERVE THIS WARN- MODULE, RUBBER GLOVES, EYE PROTECTION,
ING COULD RESULT IN OCCUPANT INJURIES AND A LONG-SLEEVED SHIRT SHOULD BE WORN.
UPON AIRBAG DEPLOYMENT. THERE MAY BE DEPOSITS ON THE AIRBAG MOD-
ULE AND OTHER INTERIOR SURFACES. IN LARGE
(8) Wh en in st a llin g t h e t r im cover a n d h or n DOSES, THESE DEPOSITS MAY CAUSE IRRITATION
swit ch , be cer t a in t h a t t h e lockin g blocks a r e fu lly TO THE SKIN AND EYES.
en ga ged on t h e lip of t h e a ir ba g h ou sin g (F ig. 10).
AIRBAGCONNECTOR
DOOR TABS KEYEDAIRBAG
SLOTS HOUSING
AIRBAG
DOOR
MODULE
FLANGE

8M - 8 PASSIVE RESTRAINT SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
ca ble. If t h e a ir ba g m odu le h a s n ot been deployed, TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
wa it t wo m in u t es for t h e syst em ca pa cit or t o dis- BAG DEPLOYMENT AND POSSIBLE PERSONAL
ch a r ge befor e fu r t h er ser vice. INJURY.
(2) Rem ove t h e pa ssen ger side a ir ba g m odu le fr om • NEVER STRIKE OR KICK THE AIRBAG CON-
t h e in st r u m en t pa n el a s descr ibed in t h is gr ou p. TROL MODULE, AS IT CAN DAMAGE THE IMPACT
(3) Wit h t h e a ir ba g m odu le on a ben ch , slide t h e SENSOR OR AFFECT ITS CALIBRATION. IF AN AIR-
a ir ba g door sidewa ys u n t il t h e keyed slot s in t h e BAG CONTROL MODULE IS ACCIDENTALLY
u pper a n d lower a ir ba g door fla n ges clea r t h e t h r ee DROPPED DURING SERVICE, THE MODULE MUST
t a bs on t h e t op a n d t h e bot t om of t h e a ir ba g h ou sin g BE SCRAPPED AND REPLACED WITH A NEW UNIT.
(F ig. 11). ALWAYS REINSTALL THE AIRBAG CONTROL MOD-
ULE PROTECTIVE COVER.
CONNECTOR AIRBAG MODULE
HOUSING (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. If t h e a ir ba g h a s n ot been deployed, wa it t wo
m in u t es for t h e syst em ca pa cit or t o disch a r ge befor e
fu r t h er ser vice.
(2) Rem ove t h e left fr on t bu cket sea t a ssem bly a s
LEFT
AIRBAG
SEAT NUT
FRONT
MOUNTING
CONTROL
descr ibed inFLOOR
BRACKET
GrMODULE
PAN
ou p 23 - Body.BRACKET
FWD SCREW
RETAINER
COVER

(3) Rem ove t h e t h r ee scr ews t h a t secu r e t h e Air-


ba g Con t r ol Modu le (ACM) pr ot ect ive cover t o t h e
left fr on t floor pa n a n d t h e ACM m ou n t in g br a cket
- (F ig. 12).
AIRBAG DOOR 80abac54

Fig. 11 Passenger Side Airbag Door Remove/Install LEFT FRONT


FLOOR PAN
(4) Rem ove t h e pa ssen ger side a ir ba g door fr om
SEAT MOUNTING SCREW
t h e a ir ba g m odu le. BRACKET
WARNING: USE EXTREME CARE TO PREVENT
ANY FOREIGN MATERIAL FROM ENTERING THE
PASSENGER SIDE AIRBAG MODULE, OR BECOM-
ING ENTRAPPED BETWEEN THE PASSENGER SIDE
AIRBAG DOOR AND THE PASSENGER SIDE AIR-
BAG MODULE. FAILURE TO OBSERVE THIS WARN-
ING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.

(5) Rever se t h e r em ova l pr ocedu r es t o com plet e


t h e in st a lla t ion , bu t do n ot con n ect t h e ba t t er y n eg-
a t ive ca ble a t t h is t im e. See Air ba g Syst em in Dia g- AIRBAG CONTROL
n osis a n d Test in g for t h e pr oper pr ocedu r es. MODULE

AIRBAG CONTROL MODULE BRACKET


80ababed
WARNING:
• THE AIRBAG CONTROL MODULE CONTAINS Fig. 12 Airbag Control Module Remove/Install
THE IMPACT SENSOR, WHICH ENABLES THE SYS- (4) P u ll t h e ACM pr ot ect ive cover a wa y fr om t h e
TEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPT- ACM fa r en ou gh t o a ccess a n d r elea se t h e ACM wir e
ING TO DIAGNOSE OR SERVICE ANY AIRBAG h a r n ess r et a in er fr om t h e slot t ed h ole n ea r t h e r ea r
SYSTEM OR RELATED STEERING WHEEL, STEER- of t h e cover.
ING COLUMN, OR INSTRUMENT PANEL COMPO- (5) Rem ove t h e ACM pr ot ect ive cover fr om t h e
NENTS YOU MUST FIRST DISCONNECT AND veh icle.
ISOLATE THE BATTERY NEGATIVE (GROUND) (6) Un plu g t h e ACM wir e h a r n ess con n ect or. To
CABLE. THEN WAIT TWO MINUTES FOR THE SYS- u n plu g t h e con n ect or, squ eeze t h e t wo con n ect or
TEM CAPACITOR TO DISCHARGE BEFORE FUR- la t ch t a bs bet ween t h e t h u m b a n d for efin ger, wh ile
THER SYSTEM SERVICE. THIS IS THE ONLY SURE pu llin g t h e con n ect or ou t fr om t h e ACM.
XJ PASSIVE RESTRAINT SYSTEMS 8M - 9
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(7) Rem ove t h e t h r ee n u t s t h a t secu r e t h e ACM (7) Rem ove t h e st eer in g colu m n open in g cover a s
m ou n t in g br a cket t o t h e floor pa n m ou n t in g br a cket . descr ibed in Gr ou p 8E - In st r u m en t P a n el Syst em s.
(8) Rem ove t h e ACM fr om t h e veh icle. (8) If t h e veh icle is so equ ipped, m ove t h e t ilt
(9) Wh en in st a llin g t h e ACM, posit ion t h e u n it st eer in g colu m n t o t h e fu lly r a ised posit ion .
wit h t h e a r r ow on t h e ACM h ou sin g poin t in g for- (9) In ser t t h e key in t h e ign it ion lock cylin der a n d
wa r d. t LOWER
u r nSCREWS
SHROUD
t h e (3)
ign it ion swit chACCESS
t o t hHOLE
e On positPIN
ionPUNCH
STEERING
. WHEEL

(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

WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, Fig. 14 Clockspring


COMPLEX ELECTROMECHANICAL UNIT. BEFORE (8) F r om t h e en d of t h e clockwise t r a vel, r ot a t e t h e
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- r ot or a bou t t wo a n d on e-h a lf t u r n s cou n t er clockwise,
BAG SYSTEM OR RELATED STEERING WHEEL, u n t il t h e r ot or fla t s a r e h or izon t a l. If t h e clockspr in g
STEERING COLUMN, OR INSTRUMENT PANEL wir e h a r n ess is n ot a t t h e bot t om , r ot a t e a n ot h er
COMPONENTS YOU MUST FIRST DISCONNECT on e-h a lf t u r n .
AND ISOLATE THE BATTERY NEGATIVE (GROUND) (9) Th e fr on t wh eels sh ou ld st ill be in t h e st r a igh t -
CABLE. THEN WAIT TWO MINUTES FOR THE SYS- a h ea d posit ion . In st a ll t h e st eer in g wh eel bein g cer-
TEM CAPACITOR TO DISCHARGE BEFORE FUR- 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
THER SYSTEM SERVICE. THIS IS THE ONLY SURE 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.
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE P u ll t h e wir e h a r n ess fr om t h e clockspr in g t h r ou gh
TO DO THIS COULD RESULT IN ACCIDENTAL AIR- 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
BAG DEPLOYMENT AND POSSIBLE PERSONAL st eer in g wh eel n u t t o 61 N·m (45 ft . lbs.). Be cer t a in
INJURY. n ot t o pin ch a n y of t h e wir in g bet ween t h e st eer in g
wh eel a n d t h e n u t .
(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 (10) In st a ll t h e a ir ba g m odu le a s descr ibed in t h is
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 gr ou p.
cen t er in g pr ocedu r e.
XJ ELECTRICALLY HEATED SYSTEMS 8N - 1

ELECTRICALLY HEATED SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . 3


INTRODUCTION . . . . . . . . . . . . . . .......... 1 DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 5
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . 2 REAR GLASS HEATING GRID . . . . . . . . . . . . . . 3
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . 2 SERVICE PROCEDURES
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 2 REAR GLASS HEATING GRID REPAIR ....... 5
OUTSIDE MIRROR HEATING GRID . . . . . . . . . . 2 REMOVAL AND INSTALLATION
REAR GLASS HEATING GRID . . . . . . . . . . . . . . 1 DEFOGGER RELAY . . . . . . . . . . . . . . ........ 7
DIAGNOSIS AND TESTING DEFOGGER SWITCH . . . . . . . . . . . . ........ 6
DEFOGGER RELAY . . . . . . . . . . . . .......... 4

GEN ERAL I N FORM AT I ON F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor


com pon en t s in t h e defogger syst em . Refer t o 8W-48 -
INTRODUCTION Rea r Win dow Defogger a n d 8W-62 - P ower Mir r or s in
An elect r ica lly h ea t ed r ea r win dow defogger a n d Gr ou p 8W - Wir in g Dia gr a m s for com plet e cir cu it
elect r ica lly h ea t ed ou t side r ea r view m ir r or s a r e descr ipt ion s a n d dia gr a m s.
a va ila ble fa ct or y-in st a lled opt ion s on t h is m odel. Th e
defogger will on ly oper a t e wh en t h e ign it ion swit ch is NOTE: This group covers both Left-Hand Drive
in t h e On posit ion . Wh en t h e defogger swit ch is in (LHD) and Right-Hand Drive (RHD) versions of this
t h e On posit ion , elect r ic h ea t er gr ids on t h e r ea r win - model. Whenever required and feasible, the RHD
dow gla ss a n d beh in d t h e ou t side r ea r view m ir r or versions of affected vehicle components have been
gla ss a r e en er gized. Th ese gr ids pr odu ce h ea t t o h elp constructed as mirror-image of the LHD versions.
clea r t h e r ea r win dow gla ss a n d ou t side r ea r view While most of the illustrations used in this group
m ir r or s of ice, sn ow, or fog. represent only the LHD version, the diagnostic and
Th e defogger syst em is con t r olled by a swit ch service procedures outlined can generally be
loca t ed in t h e a ccessor y swit ch bezel, wh ich is n ea r applied to either version. Exceptions to this rule
t h e bot t om of t h e in st r u m en t pa n el cen t er bezel. An have been clearly identified as LHD or RHD, if a
a m ber in dica t or la m p in t h e swit ch bu t t on will ligh t special illustration or procedure is required.
t o in dica t e wh en t h e defogger syst em is t u r n ed on .
Th e in st r u m en t clu st er cir cu it r y, wh ich con t a in s t h e
defogger syst em t im er logic, m on it or s t h e st a t e of t h e DESCRI PT I ON AN D OPERAT I ON
defogger swit ch t h r ou gh a h a r d-wir ed in pu t . Th e
in st r u m en t clu st er cir cu it r y con t r ols t h e defogger REAR GLASS HEATING GRID
syst em t h r ou gh a h a r d-wir ed con t r ol ou t pu t t o t h e Th e h ea t ed r ea r win dow gla ss h a s t wo elect r ica lly
defogger r ela y. con du ct ive ver t ica l bu s ba r s a n d a ser ies of h or izon -
Th e defogger syst em will be a u t om a t ica lly t u r n ed t a l gr id lin es m a de of a silver-cer a m ic m a t er ia l,
off a ft er a pr ogr a m m ed t im e in t er va l of a bou t t en wh ich is ba ked on a n d bon ded t o t h e in side su r fa ce of
m in u t es. Aft er t h e in it ia l t im e in t er va l h a s expir ed, if t h e gla ss. Th e gr id lin es a n d bu s ba r s com pr ise a
t h e defogger swit ch is t u r n ed on a ga in du r in g t h e pa r a llel elect r ica l cir cu it .
sa m e ign it ion cycle, t h e defogger syst em will a u t o- Wh en t h e r ea r win dow defogger swit ch is pla ced in
m a t ica lly t u r n off a ft er a bou t five m in u t es. t h e On posit ion , elect r ica l cu r r en t is dir ect ed t o t h e
Th e defogger syst em will a u t om a t ica lly sh u t off if r ea r win dow gr id lin es t h r ou gh t h e bu s ba r s. Th e
t h e ign it ion swit ch is t u r n ed t o t h e Off posit ion , or it gr id lin es h ea t t h e r ea r win dow t o clea r t h e su r fa ce
ca n be t u r n ed off m a n u a lly by depr essin g t h e in st r u - of fog or sn ow. P r ot ect ion for t h e h ea t ed gr id cir cu it
m en t pa n el swit ch . Refer t o t h e own er ’s m a n u a l for is pr ovided by a fu se in t h e P ower Dist r ibu t ion Cen -
m or e in for m a t ion on t h e defogger syst em con t r ols t er (P DC).
a n d oper a t ion . Th e gr id lin es a n d bu s ba r s a r e h igh ly r esist a n t t o
a br a sion . H owever, it is possible for a n open cir cu it
8N - 2 ELECTRICALLY HEATED SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
t o occu r in a n in dividu a l gr id lin e, r esu lt in g in n o H owever, t h er e a r e n o dia gn ost ics a va ila ble for t h e
cu r r en t flow t h r ou gh t h e lin e. r ea r win dow defogger t im er a n d logic cir cu it r y.
Th e gr id lin es ca n be da m a ged or scr a ped off wit h Th er efor e, t h e dia gn osis for t h is syst em con sist s of
sh a r p in st r u m en t s. Ca r e sh ou ld be t a ken wh en clea n - con fir m in g t h e pr esen ce of a r ea r win dow defogger
in g t h e gla ss or r em ovin g for eign m a t er ia ls, deca ls, swit ch in pu t sign a l a t t h e in st r u m en t clu st er con n ec-
or st icker s fr om t h e gla ss. Nor m a l gla ss clea n in g sol- t or, a n d t h e r esu lt in g r ea r win dow defogger r ela y
ven t s or h ot wa t er u sed wit h r a gs or t owelin g is r ec- con t r ol ou t pu t sign a l a t t h e defogger r ela y. F or dia g-
om m en ded. n osis of t h e CCD da t a bu s a n d t h e da t a bu s m essa ge
A r epa ir kit is a va ila ble t o r epa ir t h e gr id lin es a n d in pu t s, a DRB sca n t ool a n d t h e pr oper Dia gn ost ic
bu s ba r s, or t o r ein st a ll t h e h ea t ed gla ss pigt a il P r ocedu r es m a n u a l a r e r ecom m en ded.
wir es. Refer t o Gr ou p 8E - In st r u m en t P a n el Syst em s for
t h e ser vice pr ocedu r es for t h e in st r u m en t clu st er.
OUTSIDE MIRROR HEATING GRID Th e r ea r win dow defogger t im er a n d logic cir cu it r y
Th e h ea t ed m ir r or s a r e con t r olled by t h e r ea r win - ca n n ot be a dju st ed or r epa ir ed a n d, if fa u lt y, t h e
dow defogger swit ch . Th e h ea t in g gr ids beh in d t h e in st r u m en t clu st er a ssem bly m u st be r epla ced.
m ir r or gla ss in side t h e m ir r or a r e a ct iva t ed on ly
wh en t h e r ea r win dow defogger swit ch is in t h e On DEFOGGER RELAY
posit ion . Th e h ea t in g gr ids in side t h e m ir r or s ca n n ot Th e r ea r win dow defogger r ela y is a In t er n a t ion a l
be r epa ir ed a n d, if fa u lt y, t h e en t ir e m ir r or u n it m u st St a n da r ds Or ga n iza t ion (ISO)-t ype r ela y. Th e r ea r
be r epla ced. Refer t o Gr ou p 8T - P ower Mir r or s for win dow defogger r ela y is a elect r om ech a n ica l device
t h e dia gn osis a n d ser vice of t h is com pon en t . t h a t swit ch es fu sed ba t t er y cu r r en t t o t h e r ea r gla ss
a n d ou t side m ir r or h ea t in g gr ids a n d t h e in dica t or
DEFOGGER SWITCH la m p of t h e defogger swit ch , wh en t h e in st r u m en t
Th e r ea r win dow defogger swit ch is m ou n t ed in t h e clu st er r ea r win dow defogger t im er a n d logic cir-
a ccessor y swit ch bezel, wh ich is loca t ed in t h e lower cu it r y gr ou n ds t h e r ela y coil. See t h e Dia gn osis a n d
in st r u m en t pa n el cen t er bezel. Th e m om en t a r y-t ype Test in g sect ion of t h is gr ou p for m or e in for m a t ion on
swit ch pr ovides a h a r d-wir ed gr ou n d sign a l t o t h e t h e oper a t ion of t h e r ea r win dow defogger r ela y.
in st r u m en t clu st er ea ch t im e it is depr essed. Th e Th e r ea r win dow defogger r ela y is loca t ed in t h e
in st r u m en t clu st er r ea r win dow defogger t im er a n d ju n ct ion block, on t h e r igh t cowl side pa n el below t h e
logic cir cu it r y r espon ds by en er gizin g or de-en er giz- in st r u m en t pa n el in t h e pa ssen ger com pa r t m en t . Th e
in g t h e r ea r win dow defogger r ela y. r ea r win dow defogger r ela y ca n n ot be r epa ir ed a n d, if
E n er gizin g t h e r ea r win dow defogger r ela y pr o- fa u lt y or da m a ged, it m u st be r epla ced.
vides elect r ica l cu r r en t t o t h e r ea r win dow defogger
gr id, t h e h ea t ed ou t side r ea r view m ir r or gr ids, a n d
t h e a m ber in dica t or la m p in t h e swit ch , wh ich ligh t s DI AGN OSI S AN D T EST I N G
t o in dica t e wh en t h e defogger syst em is t u r n ed On .
Th e defogger illu m in a t ion la m p a n d in dica t or la m p DEFOGGER SYSTEM
bu lbs a r e ser vicea ble. Th e defogger swit ch ca n n ot be F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
r epa ir ed a n d, if fa u lt y, it m u st be r epla ced. 8W-48 - Rea r Win dow Defogger or 8W-62 P ower Mir-
r or s in Gr ou p 8W - Wir in g Dia gr a m s. Th e oper a t ion
INSTRUMENT CLUSTER of t h e elect r ica lly h ea t ed r ea r win dow defogger sys-
Th e in st r u m en t clu st er is a n elect r om ech a n ica l t em ca n be con fir m ed in on e of t h e followin g m a n -
u n it t h a t con t a in s in t egr a t ed cir cu it r y a n d in t er n a l n er s:
pr ogr a m m in g t o per for m a va r iet y of fu n ct ion s. Th e 1. Tu r n t h e ign it ion swit ch t o t h e On posit ion .
in st r u m en t clu st er cir cu it r y m on it or s h a r d-wir ed Wh ile m on it or in g t h e in st r u m en t pa n el volt m et er, set
swit ch in pu t s, a s well a s m essa ge in pu t s r eceived t h e defogger swit ch in t h e On posit ion . Wh en t h e
fr om ot h er veh icle elect r on ic con t r ol m odu les on t h e defogger swit ch is t u r n ed On , a dist in ct volt m et er
Ch r ysler Collision Det ect ion (CCD) da t a bu s n et wor k. n eedle deflect ion sh ou ld be n ot ed.
Th e in st r u m en t clu st er u ses t h ese m a n y in pu t s 2. Tu r n t h e ign it ion swit ch t o t h e On posit ion . Set
a lon g wit h it s in t er n a l pr ogr a m m in g a n d in t egr a l t h e defogger swit ch in t h e On posit ion . Th e r ea r win -
t im er a n d logic cir cu it r y t o per for m t h e fu n ct ion s of dow defogger oper a t ion ca n be ch ecked by feelin g t h e
t h e r ea r win dow defogger t im er on t h is m odel. Th e r ea r win dow or ou t side r ea r view m ir r or gla ss. A dis-
in st r u m en t clu st er cir cu it r y a lso h a s a self-dia gn ost ic t in ct differ en ce in t em per a t u r e bet ween t h e gr id lin es
ca pa bilit y. Refer t o Gr ou p 8E - In st r u m en t P a n el a n d t h e a dja cen t clea r gla ss or t h e m ir r or gla ss ca n
Syst em s for m or e in for m a t ion on t h is fea t u r e. be det ect ed wit h in t h r ee t o fou r m in u t es of oper a t ion .
3. Usin g a 12-volt DC volt m et er, con t a ct t h e r ea r
gla ss h ea t in g gr id t er m in a l A (r igh t side) wit h t h e
TERMINAL
GROUND
WIRE“A” VOLTMETER
HEATED
DEFOGGER
REAR WINDOW
MID-POINT
GRID(TYPICAL)
“C” TERMINAL
FEED
“B”WIRE

XJ ELECTRICALLY HEATED SYSTEMS 8N - 3


DI AGN OSI S AN D T EST I N G (Cont inue d)
n ega t ive lea d, a n d t er m in a l B (left side) wit h t h e pos- in g Dia gr a m s. To det ect br ea ks in t h e gr id lin es, t h e
it ive lea d (F ig. 1). Th e volt m et er sh ou ld r ea d ba t t er y followin g pr ocedu r e is r equ ir ed:
volt a ge. (1) Tu r n t h e ign it ion swit ch t o t h e On posit ion . Set
t h e defogger swit ch in t h e On posit ion . Th e in dica t or
VOLTMETER TERMINAL "B" la m p sh ou ld ligh t . If OK, go t o St ep 2. If n ot OK, see
t h e Defogger Rela y dia gn osis in t h is gr ou p.
(2) Usin g a 12-volt DC volt m et er, con t a ct t h e ver-
t ica l bu s ba r on t h e r igh t side of t h e veh icle wit h t h e
n ega t ive lea d. Wit h t h e posit ive lea d, con t a ct t h e ver-
t ica l bu s ba r on t h e left side of t h e veh icle. Th e volt -
m et er sh ou ld r ea d ba t t er y volt a ge. If OK, go t o St ep
3. If n ot OK, r epa ir t h e open cir cu it t o t h e defogger
r ela y a s r equ ir ed.

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

8N - 4 ELECTRICALLY HEATED SYSTEMS XJ


DI AGN OSI S AN D T EST I N G (Cont inue d)
it y. If OK, see t h e dia gn osis for t h e In st r u m en t RELAY TERMINALS RELAY CAVITIES
Clu st er in t h is gr ou p. If n ot OK, r epla ce t h e fa u lt y
swit ch .

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

XJ ELECTRICALLY HEATED SYSTEMS 8N - 5


DI AGN OSI S AN D T EST I N G (Cont inue d)
If OK, see t h e dia gn osis for In st r u m en t Clu st er in SERV I CE PROCEDU RES
t h is gr ou p. If n ot OK, r epa ir t h e open cir cu it t o t h e
fu se in t h e ju n ct ion block a s r equ ir ed. REAR GLASS HEATING GRID REPAIR
Repa ir of t h e gr id lin es, bu s ba r s, or pigt a il wir es
INSTRUMENT CLUSTER ca n be a ccom plish ed u sin g a Mopa r Rea r Win dow
Befor e per for m in g t h is t est , com plet e t h e Defogger Defogger Repa ir Kit (P /N 4267922) or equ iva len t .
Swit ch a n d t h e Defogger Rela y t est s a s descr ibed in
t h is gr ou p. F or cir cu it descr ipt ion s a n d dia gr a m s, WARNING: MATERIALS CONTAINED IN THE
r efer t o 8W-48 - Rea r Win dow Defogger in Gr ou p 8W REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION.
- Wir in g Dia gr a m s. THE KIT CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, WHICH ARE HARMFUL IF SWAL-
WARNING: ON VEHICLES EQUIPPED WITH AIR- LOWED. AVOID CONTACT WITH THE SKIN AND
BAGS, REFER TO GROUP 8M - PASSIVE EYES. FOR SKIN CONTACT, WASH THE AFFECTED
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY AREAS WITH SOAP AND WATER. FOR CONTACT
STEERING WHEEL, STEERING COLUMN, OR WITH THE EYES, FLUSH WITH PLENTY OF WATER.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR DO NOT TAKE INTERNALLY. IF TAKEN INTER-
SERVICE. FAILURE TO TAKE THE PROPER PRE- NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- IMMEDIATELY. USE WITH ADEQUATE VENTILA-
BAG DEPLOYMENT AND POSSIBLE PERSONAL TION. DO NOT USE NEAR FIRE OR FLAME. CON-
INJURY. TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.
(1) 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 defogger r ela y fr om t h e ju n ct ion (1) Ma sk t h e r epa ir a r ea so t h a t t h e con du ct ive
block a n d u n plu g t h e defogger swit ch wir e h a r n ess epoxy ca n be a pplied n ea t ly. E xt en d t h e epoxy a ppli-
con n ect or. ca t ion on t o t h e gr id lin e or t h e bu s ba r on ea ch side
(2) Rem ove t h e in st r u m en t clu st er fr om t h e in st r u - of t h e br ea k (F ig. 3).
m en t pa n el. Refer t o Gr ou p 8E - In st r u m en t P a n el
Syst em s for t h e pr ocedu r es.
(3) Ch eck for con t in u it y bet ween t h e r ea r win dow
GRID! LINE
defogger swit ch sen se cir cu it ca vit y 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 a n d a
good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go
t o St ep 4. If n ot OK, r epa ir t h e sh or t cir cu it a s
r equ ir ed.
(4) Ch eck for con t in u it y bet ween t h e r ea r win dow
defogger swit ch 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 a n d t h e
defogger swit ch wir e h a r n ess con n ect or. Th er e sh ou ld
be con t in u it y. If OK, go t o St ep 5. If n ot OK, r epa ir MASKING TAPE PR1509A
t h e open 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 win dow Fig. 3 Grid Line Repair - Typical
defogger r ela y con t r ol cir cu it ca vit y of t h e r igh t (2) F ollow t h e in st r u ct ion s in t h e r epa ir kit for
in st r u m en t clu st er wir e h a r n ess con n ect or a n d a pr epa r in g t h e da m a ged a r ea .
good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go (3) Rem ove t h e pa cka ge sepa r a t or cla m p a n d m ix
t o St ep 6. If n ot OK, r epa ir t h e sh or t cir cu it a s t h e t wo con du ct ive epoxy com pon en t s t h or ou gh ly
r equ ir ed. wit h in t h e pa cka gin g. F old t h e pa cka ge in h a lf a n d
(6) Ch eck for con t in u it y bet ween t h e r ea r win dow cu t t h e cen t er cor n er t o dispen se t h e epoxy.
defogger r ela y con t r ol cir cu it ca vit ies of t h e r igh t (4) F or gr id lin e r epa ir s, m a sk t h e a r ea t o be
in st r u m en t clu st er wir e h a r n ess con n ect or a n d t h e r epa ir ed wit h m a skin g t a pe or a t em pla t e.
defogger r ela y r ecept a cle (ISO r ela y ca vit y 85) in t h e (5) Apply t h e epoxy t h r ou gh t h e slit in t h e m a sk-
ju n ct ion block. Th er e sh ou ld be con t in u it y. If OK, in g t a pe or t em pla t e. Over la p bot h en ds of t h e br ea k
r epla ce t h e fa u lt y in st r u m en t clu st er. If n ot OK, by a t lea st 19 m m (0.75 in .).
r epa ir t h e open cir cu it a s r equ ir ed. (6) F or a t er m in a l or pigt a il wir e r epla cem en t ,
m a sk t h e a dja cen t a r ea s so t h e epoxy ca n be
ext en ded on t o t h e a dja cen t gr id lin e a s well a s t h e
bu s ba r. Apply a t h in la yer of epoxy t o t h e a r ea
ACCESSORY
INSTRUMENT
CENTER
SWITCH
PANEL
BEZELBEZEL SCREW

8N - 6 ELECTRICALLY HEATED SYSTEMS XJ


SERV I CE PROCEDU RES (Cont inue d)
wh er e t h e t er m in a l or pigt a il wir e wa s fa st en ed a n d INSTRUMENT PANEL
on t o t h e a dja cen t gr id lin e.
(7) Apply a t h in la yer of con du ct ive epoxy t o t h e
t er m in a l or ba r e wir e en d of t h e pigt a il a n d pla ce it
in t h e pr oper loca t ion on t h e bu s ba r. To pr even t t h e
t er m in a l or pigt a il wir e fr om m ovin g wh ile t h e epoxy
is cu r in g, it m u st be wedged or cla m ped.
(8) Ca r efu lly r em ove t h e m a skin g t a pe or t em -
pla t e.

CAUTION: Do not allow the glass surface to exceed


204° C (400° F) or the glass may fracture.

(9) Allow t h e epoxy t o cu r e 24 h ou r s a t r oom t em -


per a t u r e, or u se a h ea t gu n wit h a 260° t o 371° C
(500° t o 700° F ) r a n ge for fift een m in u t es. H old t h e
h ea t gu n a ppr oxim a t ely 25.4 cm (10 in .) fr om t h e
r epa ir.
(10) Aft er t h e con du ct ive epoxy is pr oper ly cu r ed,
r em ove t h e wedge or cla m p fr om t h e t er m in a l or pig-
t a il wir e. Do n ot a t t a ch t h e wir e h a r n ess con n ect or s
S0ab87bc
u n t il t h e cu r in g pr ocess is com plet e.
(11) Ch eck t h e oper a t ion of t h e r ea r win dow defog- Fig. 4 Center Bezel Remove/Install
ger r ea r gla ss h ea t in g gr id.

REM OVAL AN D I N STALLAT I ON


DEFOGGER SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive


Fig. 5 Accessory Switch Bezel Remove/Install
ca ble.
(2) Usin g a t r im st ick or a n ot h er su it a ble wide (7) Ca r efu lly pr y t h e sn a p r et a in er s a t t h e t op a n d
fla t -bla ded t ool, gen t ly pr y t h e in st r u m en t pa n el cen - bot t om of t h e r ea r win dow defogger swit ch r ecept a cle
t er bezel a wa y fr om t h e in st r u m en t pa n el t o r elea se on t h e ba ck of t h e a ccessor y swit ch bezel wit h a
t h e six sn a p clip r et a in er s (F ig. 4). sm a ll t h in -bla ded scr ewdr iver a n d pu ll t h e swit ch ou t
(3) Rem ove t h e cen t er bezel fr om t h e veh icle. of t h e r ecept a cle.
(4) Rem ove t h e t h r ee scr ews t h a t secu r e t h e a cces- (8) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Be
sor y swit ch bezel t o t h e in st r u m en t pa n el (F ig. 5). cer t a in t h a t bot h of t h e swit ch sn a p r et a in er s in t h e
(5) P u ll t h e a ccessor y swit ch bezel ou t fr om t h e r ecept a cle on t h e ba ck of t h e a ccessor y swit ch bezel
in st r u m en t pa n el fa r en ou gh t o u n plu g t h e wir e h a r- a r e fu lly en ga ged. Tigh t en t h e m ou n t in g scr ews t o
n ess con n ect or s. 2.2 N·m (20 in . lbs.).
(6) Rem ove t h e a ccessor y swit ch bezel fr om t h e
in st r u m en t pa n el.
XJ ELECTRICALLY HEATED SYSTEMS 8N - 7
REM OVAL AN D I N STALLAT I ON (Cont inue d)
DEFOGGER RELAY
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- RIGHT FRONT
DOOR SILL
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
COWL SIDE
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive TRIM PANEL
ca ble.
(2) Rem ove t h e fu se a ccess pa n el by u n sn a ppin g it
fr om t h e r igh t cowl side t r im pa n el.
(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
cowl side t r im t o t h e ju n ct ion block st u d (F ig. 6).
(4) Rem ove t h e scr ew loca t ed a bove t h e fu se a ccess
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.
(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
door open in g sill.
(6) Rem ove t h e r igh t cowl side t r im pa n el fr om t h e
veh icle.
(7) Un plu g t h e r ea r win dow defogger r ela y fr om 80ab249a
t h e ju n ct ion block.
(8) In st a ll t h e defogger r ela y by a lign in g t h e r ela y Fig. 6 Right Cowl Side Trim Remove/Install
t er m in a ls wit h t h e ca vit ies in t h e ju n ct ion block a n d
(11) In st a ll t h e r igh t cowl side t r im a n d t h e fu se
pu sh in g t h e r ela y fir m ly in t o pla ce.
a ccess pa n el.
(9) Con n ect t h e ba t t er y n ega t ive ca ble.
(10) Test t h e r ela y oper a t ion .
XJ POWER LOCK SYSTEMS 8P - 1

POWER LOCK SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION KEYLESS ENTRY SYSTEM . . . . . . . . . . .... 3


INTRODUCTION . . . . . . . . . . . . . . . . . . . . .... 1 REMOTE KEYLESS ENTRY RECEIVER . . . .... 5
POWER LOCK SYSTEM . . . . . . . . . . . . . . .... 1 REMOTE KEYLESS ENTRY TRANSMITTER ... 5
REMOTE KEYLESS ENTRY SYSTEM . . . . .... 1 SERVICE PROCEDURES
DESCRIPTION AND OPERATION REMOTE KEYLESS ENTRY RECEIVER
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 2 PROGRAMMING . . . . . . . . . . . . . . . . . . . .... 6
POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . 2 REMOTE KEYLESS ENTRY TRANSMITTER
POWER LOCK SWITCH . . . . . . . . . . . . . . . . . . . 2 BATTERY REPLACEMENT . . . . . . . . . . . .... 6
REMOTE KEYLESS ENTRY RECEIVER . . . . . . . 2 REMOTE KEYLESS ENTRY TRANSMITTER
REMOTE KEYLESS ENTRY TRANSMITTER . . . 2 PROGRAMMING . . . . . . . . . . . . . . . . . . . .... 6
DIAGNOSIS AND TESTING REMOVAL AND INSTALLATION
DOOR MODULE . . . . . . . . . . . . . . . . . . . . .... 3 DOOR MODULE . . . . . . . . . . . . . . . . . . . . .... 6
POWER LOCK MOTOR . . . . . . . . . . . . . . . .... 5 POWER LOCK MOTOR . . . . . . . . . . . . . . . .... 7
POWER LOCK SYSTEM AND REMOTE REMOTE KEYLESS ENTRY RECEIVER . . . .... 8

GEN ERAL I N FORM AT I ON m or e in for m a t ion on t h e fea t u r es a n d u se of t h ese


syst em s.
INTRODUCTION
P ower locks a r e opt ion a l fa ct or y-in st a lled equ ip- POWER LOCK SYSTEM
m en t on t h ese m odels. Th e power win dow syst em Th e power lock syst em a llows a ll of t h e door s a n d
a n d t h e power m ir r or syst em a r e in clu ded on veh i- t h e lift ga t e t o be locked or u n locked elect r ica lly by
cles equ ipped wit h t h e power lock opt ion . On veh icles oper a t in g t h e swit ch on eit h er fr on t door t r im pa n el.
equ ipped wit h t h e power lock opt ion , a ll of t h e door s Th is syst em oper a t es wit h ba t t er y power su pplied
a n d t h e lift ga t e ca n be locked a n d u n locked elect r i- t h r ou gh a fu se in t h e ju n ct ion block, in depen den t of
ca lly by oper a t in g t h e swit ch on eit h er fr on t door t h e ign it ion swit ch .
t r im pa n el. Th e power lock syst em in clu des a lock Th e power lock syst em in clu des t h e fr on t door
in h ibit fea t u r e, wh ich pr even t s t h e door s fr om bein g power lock swit ch es in t egr a l t o t h e dr iver a n d pa s-
locked by t h e power lock syst em if t h e dr iver door is sen ger door m odu les, a n d t h e power lock m ot or s
open wit h t h e key in t h e ign it ion swit ch or wit h t h e m ou n t ed in ea ch door a n d t h e lift ga t e. Th e power
h ea dla m p swit ch in t h e On posit ion . H owever, t h e lock con t r ol cir cu it r y a n d t h e power lock a n d u n lock
door s ca n st ill be locked m a n u a lly. r ela ys a r e in t egr a l t o t h e P a ssen ger Door Modu le
Th e Rem ot e Keyless E n t r y (RKE ) syst em is a n (P DM).
a ddit ion a l opt ion a va ila ble on veh icles equ ipped wit h
t h e power lock opt ion . On veh icles wit h t h e RKE REMOTE KEYLESS ENTRY SYSTEM
opt ion , t h e power locks ca n a lso be oper a t ed by Th e Rem ot e Keyless E n t r y (RKE ) syst em is a r a dio
depr essin g t h e Lock or Un lock bu t t on s of t h e RKE fr equ en cy syst em t h a t a llows t h e u se of a r em ot e
r a dio t r a n sm it t er. Th e RKE syst em in clu des a n illu - r a dio t r a n sm it t er t o con t r ol t h e power lock a n d illu -
m in a t ed en t r y fea t u r e, wh ich t u r n s on t h e cou r t esy m in a t ed en t r y syst em s. Th e RKE syst em con sist s of
la m ps for a t im ed in t er va l (a bou t t h ir t y secon ds), t h e r em ot e key fob t r a n sm it t er a n d a r a dio r eceiver
wh en t h e power locks a r e u n locked u sin g t h e RKE wit h pr ogr a m logic, wh ich is in st a lled in a n RKE
t r a n sm it t er. h ou sin g on t h e h ea dlin er of t h e veh icle, or in t h e
Th e power locks a n d RKE syst em s oper a t e wit h h ou sin g of t h e opt ion a l over h ea d con sole, depen din g
ba t t er y power su pplied in depen den t of t h e ign it ion u pon h ow t h e veh icle is equ ipped.
swit ch . F ollowin g a r e gen er a l descr ipt ion s of t h e Th e RKE syst em ca n r et a in t h e veh icle a ccess
m a jor com pon en t s in t h e power lock, a n d RKE sys- codes of u p t o fou r t r a n sm it t er s. Th e t r a n sm it t er
t em s. Refer t o 8W-61 - P ower Door Locks in Gr ou p codes a r e r et a in ed in m em or y, even if t h e ba t t er y is
8W - Wir in g Dia gr a m s for com plet e cir cu it descr ip- discon n ect ed. If a t r a n sm it t er is fa u lt y or lost , n ew
t ion s a n d dia gr a m s. Refer t o t h e own er ’s m a n u a l for t r a n sm it t er veh icle a ccess codes ca n be pr ogr a m m ed
8P - 2 POWER LOCK SYSTEMS XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
in t o t h e syst em u sin g a DRB sca n t ool a n d t h e POWER LOCK MOTOR
pr oper Dia gn ost ic P r ocedu r es m a n u a l. In t h e power lock a n d Rem ot e Keyless E n t r y
Th e RKE syst em for t h is veh icle a lso fea t u r es a (RKE ) syst em s, t h e locks a r e a ct u a t ed by a r ever sible
cu st om er-pr ogr a m m a ble h or n ch ir p fea t u r e. Th is fea - m ot or m ou n t ed wit h in ea ch door a n d t h e lift ga t e.
t u r e a llows t h e cu st om er t h e opt ion of en a blin g or Th e power lock m ot or dir ect ion is con t r olled by t h e
disa blin g t h e h or n ch ir p r equ est t h a t t h e RKE ba t t er y a n d gr ou n d feeds fr om t h e power lock a n d
r eceiver issu es a s a n a u dible in dica t ion t h a t a va lid u n lock r ela ys in t egr a l t o t h e P a ssen ger Door Modu le
Lock sign a l h a s been r eceived fr om t h e RKE t r a n s- (P DM).
m it t er. See Rem ot e Keyless E n t r y Receiver P r ogr a m - Th e power lock m ot or s ca n n ot be r epa ir ed a n d, if
m in g in t h is gr ou p for m or e in for m a t ion on t h is fa u lt y or da m a ged, t h e en t ir e m ot or m u st be
fea t u r e. r epla ced.

REMOTE KEYLESS ENTRY TRANSMITTER


DESCRI PT I ON AN D OPERAT I ON
Th e Rem ot e Keyless E n t r y (RKE ) syst em t r a n sm it -
t er is equ ipped wit h t wo bu t t on s, la beled Lock a n d
POWER LOCK SWITCH
Un lock. It is a lso equ ipped wit h a key r in g a n d is
Th e power locks a r e con t r olled by a t wo-wa y swit ch
design ed t o ser ve a s a key fob. Th e oper a t in g r a n ge
t h a t is in t egr a l t o t h e Dr iver Door Modu le (DDM)
of t h e t r a n sm it t er r a dio sign a l is u p t o 7 m et er s (23
a n d t h e P a ssen ger Door Modu le (P DM) m ou n t ed in
feet ) fr om t h e RKE r eceiver.
t h e t r im pa n el of it s r espect ive fr on t door. E a ch
E a ch t r a n sm it t er h a s a differ en t veh icle a ccess
swit ch is illu m in a t ed by a ligh t -em it t in g diode wh en
code, wh ich m u st be pr ogr a m m ed in t o t h e m em or y of
t h e ign it ion swit ch is t u r n ed t o t h e On posit ion . Th e
t h e RKE r eceiver in t h e veh icle in or der t o oper a t e
power lock swit ch es pr ovide a h a r d-wir ed lock or
t h e RKE syst em . Refer t o t h e ser vice pr ocedu r e for
u n lock sign a l t o t h e power lock syst em con t r ol cir-
Rem ot e Keyless E n t r y Tr a n sm it t er P r ogr a m m in g in
cu it r y, wh ich is loca t ed in t h e P DM.
t h is gr ou p for m or e in for m a t ion .
Th e power lock swit ch es a n d t h eir la m ps ca n n ot be
Th e t r a n sm it t er oper a t es on t wo Du r a cell DL2016
r epa ir ed. If t h e swit ch es a r e da m a ged or fa u lt y, t h e
(or equ iva len t ) ba t t er ies. Typica l ba t t er y life is fr om
en t ir e P DM or DDM m u st be r epla ced.
on e t o t wo yea r s. Th e t r a n sm it t er ca n n ot be r epa ir ed
a n d, if fa u lt y or da m a ged, it m u st be r epla ced.
DOOR MODULE
A Dr iver Door Modu le (DDM) a n d a P a ssen ger
REMOTE KEYLESS ENTRY RECEIVER
Door Modu le (P DM) a r e u sed on a ll m odels equ ipped
On m odels wit h t h e Rem ot e Keyless E n t r y (RKE )
wit h power locks a n d power win dows. E a ch door
opt ion , a n RKE r eceiver is m ou n t ed in a n RKE h ou s-
m odu le h ou ses bot h t h e fr on t power lock a n d power
in g, or in t h e over h ea d con sole h ou sin g on t h e veh icle
win dow swit ch es. Th e DDM a lso h ou ses in dividu a l
h ea dlin er. Th e RKE r eceiver is a r a dio fr equ en cy u n it
swit ch es for ea ch pa ssen ger door power win dow, a
t h a t a lso con t a in s t h e RKE syst em pr ogr a m logic.
power win dow lockou t swit ch a n d t h e power m ir r or
Th e RKE r eceiver a lso per for m s a s a sm a r t r ela y for
swit ch . Th e P DM a lso h ou ses t h e con t r ol cir cu it r y
t h e illu m in a t ed en t r y fea t u r e.
a n d t h e power lock a n d u n lock r ela ys for t h e power
Th e RKE r eceiver h a s a m em or y fu n ct ion t o r et a in
lock syst em .
t h e veh icle a ccess code of a t lea st on e, bu t n o m or e
In it s r ole a s t h e power lock con t r ol m odu le, t h e
t h a n fou r t r a n sm it t er s. Th e r eceiver is design ed t o
P DM r eceives in pu t s fr om t h e ba t t er y, t h e ign it ion
r et a in t h e t r a n sm it t er codes in m em or y, even if t h e
swit ch , t h e DDM, t h e dr iver door a ja r swit ch , t h e
ba t t er y is discon n ect ed.
key-in ign it ion swit ch , a n d t h e h ea dla m p swit ch . It
Th e RKE m odu le r eceives in pu t s fr om t h e ba t t er y,
a lso r eceives a h a r d-wir ed in pu t fr om t h e RKE
t h e dr iver door a ja r swit ch , a n d t h e Ch r ysler Colli-
r eceiver, if t h e veh icle is so equ ipped. In r espon se t o
sion Det ect ion (CCD) da t a bu s. It a lso r eceives t h e
t h ese in pu t s, t h e P DM sen ds t h e pr oper ou t pu t s t o
r a dio sign a l in pu t fr om t h e RKE t r a n sm it t er. In
con t r ol t h e power lock m ot or s t h r ou gh it s in t egr a l
r espon se t o t h ose in pu t s, it is pr ogr a m m ed t o con t r ol
power lock a n d u n lock r ela ys.
ou t pu t s t o t h e power lock m ot or s, t h e cou r t esy la m p
Th e DDM a n d t h e P DM a r e m ou n t ed t o t h eir
cir cu it s, a n d t h e veh icle h or n .
r espect ive fr on t door t r im pa n els. Th e DDM a n d
Th e RKE syst em for t h is veh icle a lso fea t u r es a
P DM a r e ser viced in dividu a lly a n d ca n n ot be
cu st om er-pr ogr a m m a ble h or n ch ir p fea t u r e. Th is fea -
r epa ir ed. If t h e DDM or P DM, or a n y of t h e swit ch es
t u r e a llows t h e cu st om er t h e opt ion of en a blin g or
a n d cir cu it r y t h ey con t a in a r e fa u lt y or da m a ged, t h e
disa blin g t h e h or n ch ir p r equ est t h a t t h e RKE
com plet e m odu le m u st be r epla ced.
r eceiver issu es a s a n a u dible in dica t ion t h a t a va lid
Lock sign a l h a s been r eceived fr om t h e RKE t r a n s-
CONNECTOR 2 (C2)

XJ POWER LOCK SYSTEMS 8P - 3


DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
m it t er. See Rem ot e Keyless E n t r y Receiver P r ogr a m - (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
m in g in t h is gr ou p for m or e in for m a t ion on t h is ca ble. Rem ove t h e dr iver side fr on t door t r im pa n el
fea t u r e. a n d u n plu g t h e 12-wa y DDM wir e h a r n ess con n ec-
Th e RKE r eceiver ca n n ot be r epa ir ed a n d, if fa u lt y t or (C-2) fr om t h e DDM. Ch eck for con t in u it y
or da m a ged, it m u st be r epla ced. bet ween t h e gr ou n d cir cu it ca vit y of t h e 12-wa y
DDM wir e h a r n ess con n ect or a n d a good gr ou n d.
Th er e sh ou ld be con t in u it y. If OK, go t o St ep 2. If
DI AGN OSI S AN D T EST I N G n ot OK, r epa ir t h e open cir cu it t o gr ou n d a s
r equ ir ed.
POWER LOCK SYSTEM AND REMOTE KEYLESS (2) If t h e pr oblem bein g dia gn osed is in oper a t ive
ENTRY SYSTEM power lock swit ch illu m in a t ion , pr oceed a s follows.
On m odels wit h ou t t h e Rem ot e Keyless E n t r y If t h e pr oblem is n ot power lock swit ch illu m in a -
(RKE ) opt ion , pr oceed dir ect ly t o t h e Door Modu le t ion , go t o St ep 4. Con n ect t h e ba t t er y n ega t ive
dia gn osis. As a pr elim in a r y dia gn osis for m odels wit h ca ble. Tu r n t h e ign it ion swit ch t o t h e Accessor y or
t h e RKE syst em , n ot e t h e power lock syst em a n d On posit ion s. Ch eck for ba t t er y volt a ge a t bot h
illu m in a t ed en t r y syst em oper a t ion wh ile you a ct u a t e sides of t h e power win dow cir cu it br ea ker in t h e
bot h t h e Lock a n d Un lock fu n ct ion s wit h t h e power ju n ct ion block. If OK, go t o St ep 3. If n ot OK,
lock swit ch es a n d t h e RKE t r a n sm it t er. Th en , pr o- r epla ce t h e fa u lt y cir cu it br ea ker.
ceed a s follows: (3) Wit h t h e ign it ion swit ch st ill in t h e On or
• If t h e en t ir e power lock syst em fa ils t o fu n ct ion Accessor y posit ion , ch eck for ba t t er y volt a ge a t t h e
wit h eit h er t h e power lock swit ch es or t h e RKE fu sed ign it ion swit ch ou t pu t cir cu it ca vit y of t h e
t r a n sm it t er, see t h e Door Modu le dia gn osis in t h is 12-wa y DDM wir e h a r n ess con n ect or. If OK, r epla ce
gr ou p. t h e fa u lt y DDM. If n ot OK, r epa ir t h e open cir cu it
• If t h e syst em fu n ct ion s wit h bot h power lock t o t h e ju n ct ion block a s r equ ir ed.
swit ch es, bu t n ot wit h t h e RKE t r a n sm it t er, see t h e (4) Test t h e power lock swit ch con t in u it y t h r ou gh
Rem ot e Keyless E n t r y Tr a n sm it t er dia gn osis in t h is t h e DDM 12-wa y wir e h a r n ess con n ect or r ecept a cle.
gr ou p. See t h e DDM P ower Lock Swit ch Con t in u it y ch a r t
• If on e power lock m ot or fa ils t o oper a t e wit h (F ig. 1) t o det er m in e if t h e con t in u it y is cor r ect in
bot h of t h e power lock swit ch es a n d/or t h e RKE t h e Lock a n d Un lock swit ch posit ion s. If OK, r epa ir
t r a n sm it t er, see t h e P ower Lock Mot or dia gn osis in t h e lock r equ est cir cu it a n d/or t h e u n lock r equ est
t h is gr ou p. cir cu it bet ween t h e DDM a n d t h e P DM a s r equ ir ed.
• If t h e RKE a n d power lock syst em s a r e fu n ct ion - If n ot OK, r epla ce t h e fa u lt y DDM.
in g, bu t t h e illu m in a t ed en t r y syst em fa ils t o oper a t e,
see t h e Rem ot e Keyless E n t r y Receiver dia gn osis in

/[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$

8P - 4 POWER LOCK SYSTEMS XJ


DI AGN OSI S AN D T EST I N G (Cont inue d)
swit ch con t a ct s t o in dica t e a lock r equ est or u n lock t h e On posit ion . Ch eck for con t in u it y bet ween t h e
r equ est . door a ja r /key-in cir cu it ca vit y of t h e 8-wa y P DM
In it s r ole a s t h e power lock con t r ol m odu le, t h e wir e h a r n ess con n ect or a n d a good gr ou n d. Th er e
P DM r eceives in pu t s fr om t h e ba t t er y, t h e ign it ion sh ou ld be con t in u it y. If OK, go t o St ep 8. If n ot OK,
swit ch , t h e DDM, t h e dr iver door a ja r swit ch , t h e r epa ir t h e open door a ja r a n d/or key-in ign it ion cir-
key-in ign it ion swit ch , a n d t h e h ea dla m p swit ch . It cu it s a s r equ ir ed. Refer t o Gr ou p 8U - Ch im e/
a lso r eceives a h a r d-wir ed in pu t fr om t h e RKE Bu zzer Wa r n in g Syst em s for m or e in for m a t ion .
r eceiver, if t h e veh icle is so equ ipped. In r espon se t o (7) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
t h ese in pu t s, t h e P DM sen ds t h e pr oper ou t pu t s t o ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of
con t r ol t h e power lock m ot or s t h r ou gh it s in t egr a l t h e 8-wa y P DM wir e h a r n ess con n ect or. If OK, go t o
power lock a n d u n lock r ela ys. Th e P DM power lock St ep 8. If n ot OK, r epa ir t h e open cir cu it t o t h e fu se
syst em fu n ct ion s ca n be t est ed a s ou t lin ed below. If in t h e ju n ct ion block a s r equ ir ed.
t h e power lock syst em oper a t es, bu t t h e RKE syst em (8) Test t h e P DM power lock swit ch con t in u it y
lock a n d/or u n lock fu n ct ion s a r e in oper a t ive, see t h e t h r ou gh t h e t wo P DM wir e h a r n ess con n ect or r ecep-
dia gn osis for t h e Rem ot e Keyless E n t r y Tr a n sm it t er t a cles. See t h e P DM P ower Lock Swit ch Con t in u it y
in t h is gr ou p. ch a r t (F ig. 2) t o det er m in e if t h e con t in u it y is cor-
(1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go r ect in t h e Lock a n d Un lock swit ch posit ion s. If OK,
t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or see t h e dia gn osis for P ower Lock Mot or s in t h is
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. gr ou p. If n ot OK, r epla ce t h e fa u lt y P DM.
(2) 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 pa ssen ger side fr on t door t r im
pa n el a n d u n plu g t h e 8-wa y P DM wir e h a r n ess con -
n ect or (C-1) fr om t h e P DM. Ch eck for con t in u it y
bet ween t h e gr ou n d cir cu it ca vit y of t h e 8-wa y P DM
wir e h a r n ess con n ect or a n d a good gr ou n d. 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 epa ir t h e open cir cu it t o gr ou n d a s r equ ir ed. CONNECTOR 1 (C-1)
(3) If t h e pr oblem bein g dia gn osed is in oper a t ive
power lock swit ch illu m in a t ion , pr oceed a s follows. If
t h e pr oblem is n ot power lock swit ch illu m in a t ion , go
t o St ep 5. Con n ect 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 t o t h e Accessor y or On posit ion s.
Ch eck for ba t t er y volt a ge a t bot h sides of t h e power
CONNECTOR 2 (C-2)
win dow cir cu it br ea ker in t h e ju n ct ion block. If OK,
go t o St ep 4. If n ot OK, r epla ce t h e fa u lt y cir cu it LEFT-HAND DRIVE (LHD)
br ea ker. SWITCH POSITION CONTINUITY BETWEEN
(4) Wit h t h e ign it ion swit ch st ill in t h e Accessor y
LOCK C1 PIN 3 & C1 PIN 6
or On posit ion s, ch eck for ba t t er y volt a ge a t t h e
C1 PIN 3 & C2 PIN 1
fu sed ign it ion swit ch ou t pu t cir cu it ca vit y of t h e
8-wa y P DM wir e h a r n ess con n ect or. If OK, r epla ce C1 PIN 3 & C2 PIN 5
t h e fa u lt y P DM. If n ot OK, r epa ir t h e open cir cu it t o UNLOCK C1 PIN 6 & C1 PIN 7
t h e ju n ct ion block a s r equ ir ed. C1 PIN 7 & C2 PIN 1
(5) If t h e pr oblem bein g dia gn osed is a n in oper a - C1 PIN 7 & C2 PIN 5
t ive door lock in h ibit fea t u r e or a power lock syst em
t h a t r espon ds t o a n Un lock com m a n d, bu t n ot a Lock
com m a n d, pr oceed a s follows. Ot h er wise, go t o St ep RIGHT-HAND DRIVE (RHD)
7. Wit h t h e dr iver side fr on t door closed, ch eck for SWITCH POSITION CONTINUITY BETWEEN
con t in u it y bet ween t h e door a ja r /key-in cir cu it ca vit y LOCK C1 PIN 7 & C1 PIN 6
of t h e 8-wa y P DM wir e h a r n ess con n ect or a n d a good C1 PIN 7 & C2 PIN 1
gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go t o
C1 PIN 7 & C2 PIN 5
St ep 6. If n ot OK, r epa ir t h e sh or t ed door a ja r a n d/or
key-in ign it ion cir cu it s a s r equ ir ed. Refer t o Gr ou p UNLOCK C1 PIN 6 & C1 PIN 3
8U - Ch im e/Bu zzer Wa r n in g Syst em s for m or e in for- C1 PIN 3 & C2 PIN 1
m a t ion . C1 PIN 3 & C2 PIN 5
(6) Open t h e dr iver side fr on t door wit h t h e key in
t h e ign it ion swit ch or wit h t h e h ea dla m p swit ch in Fig. 2 PDM Power Lock Switch Continuity
80abd2c8
XJ POWER LOCK SYSTEMS 8P - 5
DI AGN OSI S AN D T EST I N G (Cont inue d)
POWER LOCK MOTOR NOTE: Be certain to perform the Remote Keyless
Befor e you pr oceed wit h t h is dia gn osis, con fir m Entry Transmitter Programming procedure again
pr oper power door lock swit ch oper a t ion . See Door following this test. This procedure will erase the
Modu le in t h is gr ou p for t h e dia gn ost ic pr ocedu r es. access code of the test transmitter from the RKE
Rem em ber, t h e P a ssen ger Door Modu le (P DM) cir- receiver.
cu it r y con t r ols t h e ou t pu t t o ea ch of t h e power lock
m ot or s. F or cir cu it descr ipt ion s a n d dia gr a m s, r efer
t o 8W-61 - P ower Door Locks in Gr ou p 8W - Wir in g REMOTE KEYLESS ENTRY RECEIVER
Dia gr a m s. If t h e pr oblem bein g dia gn osed is a n in oper a t ive
(1) Ch eck ea ch power lock m ot or for cor r ect oper a - RKE h or n ch ir p fea t u r e, be cer t a in t h a t t h e h or n
t ion wh ile m ovin g t h e power lock swit ch t o bot h t h e ch ir p fea t u r e h a s n ot been disa bled by per for m in g
Lock a n d Un lock posit ion s. If a ll of t h e power lock t h e Rem ot e Keyless E n t r y Receiver P r ogr a m m in g
m ot or s a r e in oper a t ive, go t o St ep 2. If on e power pr ocedu r e a s descr ibed in t h is gr ou p. Also be cer t a in
lock m ot or is in oper a t ive, go t o St ep 3. t h a t t h e veh icle h or n syst em is oper a t ion a l. See
(2) If a ll of t h e power lock m ot or s a r e in oper a t ive, Gr ou p 8G - H or n Syst em s for m or e in for m a t ion .
t h e pr oblem m a y be ca u sed by on e sh or t ed m ot or. If t h e pr oblem bein g dia gn osed is a n in oper a t ive
Un plu ggin g a sh or t ed power lock m ot or fr om t h e RKE illu m in a t ed en t r y syst em , be cer t a in t h a t t h e
power lock cir cu it will a llow t h e good power lock in t er ior cou r t esy la m p syst em is oper a t ion a l. See
m ot or t o oper a t e. Un plu g ea ch power lock m ot or wir e Gr ou p 8L - La m ps for m or e in for m a t ion .
h a r n ess con n ect or, on e a t a t im e, a n d r ech eck bot h Befor e you pr oceed wit h dia gn osis of t h e RKE
t h e lock a n d u n lock fu n ct ion s by oper a t in g t h e power r eceiver, see t h e dia gn osis for Rem ot e Keyless E n t r y
lock swit ch . If a ll of t h e power lock m ot or s a r e st ill Tr a n sm it t er in t h is gr ou p. F or cir cu it descr ipt ion s
in oper a t ive a ft er t h e a bove t est , ch eck for a sh or t or a n d dia gr a m s, r efer t o 8W-61 - P ower Door Locks in
open cir cu it bet ween t h e power lock m ot or s a n d t h e Gr ou p 8W - Wir in g Dia gr a m s.
P DM. If u n plu ggin g on e power lock m ot or ca u ses t h e (1) Ch eck t h e fu ses in t h e P ower Dist r ibu t ion Cen -
ot h er m ot or s t o becom e fu n ct ion a l, go t o St ep 3 t o t er (P DC) a n d t h e ju n ct ion block. If OK, go t o St ep 2.
t est t h e u n plu gged m ot or. If n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
(3) On ce it is det er m in ed wh ich lock m ot or is in op- r equ ir ed a n d r epla ce t h e fa u lt y fu se.
er a t ive, t h a t m ot or ca n be t est ed a s follows. Un plu g (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
t h e wir e h a r n ess con n ect or a t t h e in oper a t ive m ot or. ca ble. Rem ove t h e Rem ot e Keyless E n t r y (RKE )
Apply 12 volt s t o t h e m ot or t er m in a ls t o ch eck it s r eceiver a s descr ibed in t h is gr ou p. Un plu g t h e wir e
oper a t ion in on e dir ect ion . Rever se t h e pola r it y t o h a r n ess con n ect or fr om t h e RKE r eceiver.
ch eck t h e oper a t ion in t h e ot h er dir ect ion . If OK, (3) Ch eck t h e wir e h a r n ess con n ect or a n d t h e
r epa ir t h e sh or t or open cir cu it s t o t h e P DM a s r ecept a cle in t h e r eceiver for loose, cor r oded, or da m -
r equ ir ed. If n ot OK, r epla ce t h e fa u lt y power lock a ged t er m in a ls a n d pin s. If OK, go t o St ep 4. If n ot
m ot or. OK, r epa ir a s r equ ir ed.
(4) Ch eck for con t in u it y bet ween ea ch of t h e t wo
REMOTE KEYLESS ENTRY TRANSMITTER gr ou n d cir cu it ca vit ies of t h e RKE r eceiver wir e h a r-
(1) Repla ce t h e Rem ot e Keyless E n t r y (RKE ) n ess con n ect or a n d a good gr ou n d. In ea ch ca se,
t r a n sm it t er ba t t er ies a s descr ibed in t h is gr ou p. Test t h er e sh ou ld be con t in u it y. If OK, go t o St ep 5. If n ot
ea ch of t h e t r a n sm it t er fu n ct ion s. If OK, disca r d t h e OK, r epa ir t h e cir cu it t o gr ou n d a s r equ ir ed.
fa u lt y ba t t er ies. If n ot OK, go t o St ep 2. (5) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
(2) P er for m t h e Rem ot e Keyless E n t r y Tr a n sm it t er ba t t er y volt a ge a t ea ch of t h e t wo fu sed B(+) cir cu it
P r ogr a m m in g pr ocedu r e wit h t h e su spect t r a n sm it t er ca vit ies of t h e RKE r eceiver wir e h a r n ess con n ect or.
a n d a n ot h er kn own good t r a n sm it t er u sin g a DRB If OK, go t o St ep 6. If n ot OK, r epa ir t h e open cir cu it
sca n t ool, a s descr ibed in t h e pr oper Dia gn ost ic P r o- t o t h e P DC or t h e ju n ct ion block a s r equ ir ed.
cedu r es m a n u a l. (6) If t h e pr oblem bein g dia gn osed in volves on ly
(3) Test t h e RKE syst em oper a t ion wit h bot h t h e RKE h or n ch ir p fea t u r e, go t o St ep 10. If t h e
t r a n sm it t er s. If bot h t r a n sm it t er s fa il t o oper a t e t h e pr oblem bein g dia gn osed in volves on ly t h e RKE illu -
power lock syst em , see t h e dia gn osis for t h e Rem ot e m in a t ed en t r y fea t u r e, go t o St ep 9. If t h e pr oblem
Keyless E n t r y Receiver in t h is gr ou p. If t h e kn own bein g dia gn osed in volves on ly t h e RKE power locks
good t r a n sm it t er oper a t es t h e power locks a n d t h e fea t u r e, go t o St ep 7.
su spect t r a n sm it t er does n ot , r epla ce t h e fa u lt y (7) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
t r a n sm it t er. ca ble. Un plu g t h e 8-wa y P a ssen ger Door Modu le
(P DM) wir e h a r n ess con n ect or. Ch eck for con t in u it y
bet ween t h e lock r equ est cir cu it ca vit y of t h e RKE
r eceiver wir e h a r n ess con n ect or a n d a good gr ou n d.
8P - 6 POWER LOCK SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
Repea t t h e t est bet ween t h e u n lock r equ est cir cu it r equ ir es t h e u se of a DRB sca n t ool. Refer t o t h e
ca vit y of t h e RKE r eceiver wir e h a r n ess con n ect or pr oper Dia gn ost ic P r ocedu r es m a n u a l for m or e in for-
a n d a good gr ou n d. In ea ch ca se, t h er e sh ou ld be n o m a t ion .
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 ed cir cu it a s r equ ir ed. REMOTE KEYLESS ENTRY RECEIVER
(8) Ch eck for con t in u it y bet ween t h e lock r equ est PROGRAMMING
cir cu it ca vit ies of t h e RKE r eceiver wir e h a r n ess con - Th e opt ion a l Rem ot e Keyless E n t r y (RKE ) syst em
n ect or a n d t h e 8-wa y P DM wir e h a r n ess con n ect or. for t h is veh icle h a s a cu st om er-pr ogr a m m a ble h or n
Repea t t h e t est bet ween t h e u n lock r equ est cir cu it ch ir p fea t u r e. Th e h or n ch ir p is r equ est ed by t h e
ca vit ies of t h e RKE r eceiver wir e h a r n ess con n ect or RKE r eceiver t h r ou gh a h a r d-wir ed cir cu it t o t h e
a n d t h e 8-wa y P DM wir e h a r n ess con n ect or. In ea ch h or n r ela y wh en ever a va lid Lock m essa ge is
ca se, t h er e sh ou ld be con t in u it y. If OK, r epla ce t h e r eceived fr om a pr ogr a m m ed RKE r a dio t r a n sm it t er.
fa u lt y RKE r eceiver. If n ot OK, r epa ir t h e open cir- Th e pu r pose of t h e h or n ch ir p is t o pr ovide t h e
cu it a s r equ ir ed. veh icle oper a t or wit h a n a u dible ver ifica t ion t h a t t h e
(9) Ch eck for con t in u it y bet ween t h e door a ja r cir- Lock r equ est h a s been r eceived by t h e RKE r eceiver.
cu it ca vit y of t h e RKE r eceiver wir e h a r n ess con n ec- H owever, for a n y nFAS-
u m ber of r ea son s, somDOOR
e cu st om er s
U-NUTPUSH-IN TENER TRIM PANEL
t or a n d a good gr ou n d wit h t h e dr iver door closed. m a y pr efer t h a t t h is fea t u r e be disa bled. Th is RKE
Th er e sh ou ld be n o con t in u it y u n t il t h e dr iver door is syst em a llows t h em t h a t opt ion .
open ed. If OK, r epla ce t h e fa u lt y RKE r eceiver. If n ot To pr ogr a m t h e Rem ot e Keyless E n t r y (RKE )
OK, r epa ir t h e cir cu it or r epla ce t h e fa u lt y dr iver r eceiver t o disa ble t h e h or n ch ir p fea t u r e, pr oceed a s
door a ja r swit ch a s r equ ir ed. follows:
(10) Un plu g t h e h or n r ela y fr om t h e ju n ct ion (1) P r ess a n d h old t h e Lock bu t t on of a pr o-
block. Ch eck for con t in u it y bet ween t h e h or n r ela y gr a m m ed RKE t r a n sm it t er depr essed for five t o t en
ou t pu t cir cu it ca vit y of t h e RKE r eceiver wir e h a r- secon ds.
n ess con n ect or a n d a good gr ou n d. Th er e sh ou ld be (2) Wh ile h oldin g t h e RKE t r a n sm it t er Lock bu t -
n o con t in u it y. If OK, go t o St ep 11. If n ot OK, r epa ir t on depr essed, pr ess a n d r elea se t h e RKE t r a n sm it -
t h e sh or t cir cu it t o t h e h or n r ela y a s r equ ir ed. t er Un lock bu t t on .
(11) Ch eck for con t in u it y bet ween t h e h or n r ela y (3) Th e h or n ch ir p fea t u r e is n ow disa bled.
ou t pu t cir cu it ca vit y of t h e RKE r eceiver wir e h a r- Repea t in g t h e pr ecedin g st eps will a ga in en a ble
n ess con n ect or a n d t h e ju n ct ion block ca vit y for t h e t h e h or n ch ir p fea t u r e.
h or n r ela y coil gr ou n d t er m in a l (85). 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 RKE r eceiver. If
n ot OK, r epa ir t h e open cir cu it t o t h e ju n ct ion block REM OVAL AN D I N STALLAT I ON
a s r equ ir ed.
DOOR MODULE
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
SERV I CE PROCEDU RES ca ble.
(2) Rem ove t h e scr ews t h a t secu r e t h e door t r im
REMOTE KEYLESS ENTRY TRANSMITTER pa n el t o t h e in n er door pa n el (F ig. 3).
BATTERY REPLACEMENT
To r epla ce t h e Rem ot e Keyless E n t r y (RKE ) t r a n s- DOOR
m it t er ba t t er ies, sepa r a t e t h e t r a n sm it t er ca se h a lves TRIM PANEL
a t t h e cen t er sea m by pr yin g gen t ly wit h a t r im
st ick, or a n ot h er su it a ble wide fla t -bla ded t ool. Th e
ca se sn a ps open a n d sh u t .
Repla ce t h e t wo ba t t er ies wit h n ew Du r a cell
DL2016, or t h eir equ iva len t . Be cer t a in t h a t t h e ba t -
t er ies a r e in st a lled wit h t h eir pola r it y cor r ect ly or i-
en t ed. Th en , a lign t h e t wo t r a n sm it t er ca se h a lves
wit h ea ch ot h er, a n d squ eeze t h em fir m ly t oget h er
u n t il t h ey sn a p ba ck in t o pla ce.

REMOTE KEYLESS ENTRY TRANSMITTER


PROGRAMMING 80aafb5e
To pr ogr a m t h e Rem ot e Keyless E n t r y (RKE )
t r a n sm it t er a ccess codes in t o t h e RKE r eceiver Fig. 3 Front Door Trim Panel Remove/Install
INSIDE
LOCKDOOR
REMOTE
DOORTRIM
LATCH
CONTROLS
PANEL
AND SCREWS CONNECTOR
CONNECTOR 2DOOR
1 RECEP-
TACLE
MODULE
RECEPTA-
CLE TRIM PANEL PUSH
PLUGNUT ASSIST HANDLE LIFTGATE

XJ POWER LOCK SYSTEMS 8P - 7


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Usin g a t r im st ick or a n ot h er su it a ble wide m u st be r epla ced. Refer t o Gr ou p 23 - Body for t h e
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 r ea r door la t ch ser vice pr ocedu r es.
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
pa n el r et a in er s. LI FT GAT E
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
NOTE: To aid in the removal of the trim panel, start ca ble.
at the bottom of the panel. (2) Open t h e lift ga t e.
(3) Usin g a t r im st ick or a n ot h er su it a ble wide
(4) Lift t h e door t r im pa n el u pwa r ds a n d a wa y fla t -bla ded t ool, gen t ly pr y t h e t wo scr ew cover plu gs
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 ou t of t h e lift ga t e a ssist h a n dle.
t h e in n er belt wea t h er st r ip. (4) Rem ove t h e t wo scr ews t h a t secu r e t h e lift ga t e
(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 a ssist h a n dle t o t h e lift ga t e in n er pa n el (F ig. 5).
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 PUSH NUT
in side door r em ot e con t r ols.
TRIM
(6) Un sn a p t h e pla st ic r et a in er clips fr om t h e
PANEL
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 ols.
(7) Un plu g t h e wir e h a r n ess con n ect or s fr om t h e
door m odu le.
(8) Rem ove t h e fr on t door t r im pa n el fr om t h e
veh icle.
(9) Rem ove t h e t h r ee scr ews t h a t secu r e t h e door
m odu le t o t h e door t r im pa n el (F ig. 4).

80abd2e1

Fig. 5 Liftgate Trim Panel Remove/Install


(5) 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.
(6) 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.

NOTE: To aid in the removal of the trim panel, start


Fig. 4 Door Module Remove/Install at the bottom of the panel.
(10) Rem ove t h e door m odu le fr om t h e t r im pa n el.
(11) Rever se t h e r em ova l pr ocedu r es t o in st a ll. (7) Rem ove t h e lift ga t e t r im pa n el fr om t h e veh icle.
Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.). (8) Rea ch t h r ou gh t h e lift ga t e in n er pa n el a ccess
h ole a n d discon n ect t h e lin k fr om t h e clip on t h e
POWER LOCK MOTOR power lock m ot or (F ig. 6).
(9) Rem ove t h e t wo scr ews t h a t secu r e t h e power
FRON T DOOR lock m ot or t o t h e lift ga t e in n er pa n el.
Th e fr on t door power lock m ot or is in t egr a l t o t h e (10) P u ll t h e power lock m ot or ou t t h r ou gh t h e lift -
fr on t door la t ch u n it . If t h e fr on t door power lock ga t e in n er pa n el a ccess h ole fa r en ou gh t o r ea ch t h e
m ot or is fa u lt y or da m a ged, t h e en t ir e la t ch u n it wir e h a r n ess con n ect or.
m u st be r epla ced. Refer t o Gr ou p 23 - Body for t h e (11) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
fr on t door la t ch ser vice pr ocedu r es. power lock m ot or.
(12) Rem ove t h e power lock m ot or fr om t h e lift -
REAR DOOR ga t e.
Th e r ea r door power lock m ot or is in t egr a l t o t h e (13) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
r ea r door la t ch u n it . If t h e r ea r door power lock Tigh t en t h e power lock m ot or m ou n t in g scr ews t o 3
m ot or is fa u lt y or da m a ged, t h e en t ir e la t ch u n it N·m (28 in . lbs.).
CONNECTORSSCREW LIFTGATE INNER
MOTOR
PANEL LINK
CLIPS LOCK
LEVER

8P - 8 POWER LOCK SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(6) Rem ove t h e RKE m in i-dom e u n it fr om t h e
CLIPS
veh icle.
(7) Rem ove t h e t wo scr ews t h a t secu r e t h e RKE
r eceiver cir cu it boa r d t o t h e m in i-dom e h ou sin g.
(8) Rem ove t h e RKE r eceiver cir cu it boa r d fr om
t h e m in i-dom e h ou sin g.

OV ERH EAD CON SOLE M OU N T ED T Y PE


(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 t wo scr ews loca t ed for wa r d of t h e
displa y m odu le t h a t secu r e t h e over h ea d con sole t o
t h e u pper win dsh ield open in g r ein for cem en t (F ig. 8).

Fig. 6 Liftgate Power Lock Motor Remove/Install


REMOTE KEYLESS ENTRY RECEIVER
M I N I -DOM E M OU N T ED T Y PE
(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 t wo scr ews t h a t secu r e t h e Rem ot e
Keyless E n t r y (RKE ) m in i-dom e h ou sin g t o t h e r oof
pa n el r ein for cem en t (F ig. 7).

/HEADLINER 80abd253

Fig. 8 Overhead Console Remove/Install


MOUNTING
TAB
REINFORCEMENT (3) To r elea se t h e over h ea d con sole fr om t h e r ea r
m ou n t in g br a cket , u se you r fin ger t ips t o gen t ly pu ll
t h e sides of t h e over h ea d con sole h ou sin g ou t wa r d
n ea r t h e r ea r m ou n t in g br a cket .
(4) Move t h e over h ea d con sole for wa r d t o disen -
ga ge t h e r ea r m ou n t in g t a b fr om t h e h ea dlin er.
(5) Lower t h e over h ea d con sole fa r en ou gh t o
a ccess t h e t wo wir e h a r n ess con n ect or s.
(6) Un plu g on e wir e h a r n ess con n ect or n ea r t h e
pu sh bu t t on m odu le t owa r ds t h e fr on t of t h e over-
h ea d con sole.
(7) Un plu g on e wir e h a r n ess con n ect or fr om t h e
80abd2e6
Rem ot e Keyless E n t r y (RKE ) r eceiver n ea r t h e cen t er
of t h e over h ea d con sole.
Fig. 7 Mini-Dome Housing Remove/Install (8) Rem ove t h e over h ea d con sole fr om t h e veh icle.
(9) Rem ove t h e six scr ews t h a t secu r e t h e r ea r
(3) Lower t h e fr on t of t h e m in i-dom e h ou sin g a n d
over h ea d con sole h ou sin g t o t h e over h ea d con sole
slide t h e u n it for wa r d t o disen ga ge t h e r ea r m ou n t -
bezel (F ig. 9).
in g t a b fr om t h e h ea dlin er.
(10) Gen t ly flex t h e sides of t h e over h ea d con sole
(4) Lower t h e m in i-dom e h ou sin g fa r en ou gh t o
bezel fa r en ou gh t o clea r t h e t a bs on t h e r ea r con sole
r ea ch t h e RKE r eceiver wir e h a r n ess con n ect or.
h ou sin g a n d r em ove t h e h ou sin g fr om t h e bezel.
(5) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
RKE r eceiver.
REAR
OVERHEAD
OVERHEADSCREWS
CONSOLE
HOUSING
CONSOLE
BEZEL TABS
RKE RECEIVER

XJ POWER LOCK SYSTEMS 8P - 9


REM OVAL AN D I N STALLAT I ON (Cont inue d)

REAR OVERHEAD CONSOLE (12) Rem ove t h e RKE cir cu it boa r d fr om t h e r ea r


----HOUSING _ _ _-,,,,,c. over h ea d con sole h ou sin g.
~;;;~¼==-r~~~-~-t'!II_~-/----,--,=-=-~::::;---- (13) Rever se t h e r em ova l pr ocedu r es t o in st a ll.

80abd2e7

Fig. 9 RKE Receiver Remove/Install


(11) Rem ove t h e t wo scr ews t h a t secu r e t h e RKE
r eceiver cir cu it boa r d t o t h e r ea r over h ea d con sole
h ou sin g.
XJ POWER SEAT SYSTEMS 8R - 1

POWER SEAT SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION POWER SEAT ADJUSTER AND MOTORS ..... 2


INTRODUCTION . . . . . . . . . . . . . . . . . . . ..... 1 POWER SEAT SWITCH . . . . . . . . . . . . . . ..... 2
DESCRIPTION AND OPERATION POWER SEAT SYSTEM . . . . . . . . . . . . . . ..... 2
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . ..... 2 REMOVAL AND INSTALLATION
POWER SEAT ADJUSTER AND MOTORS ..... 1 POWER SEAT ADJUSTER AND MOTORS ..... 3
POWER SEAT SWITCH . . . . . . . . . . . . . . ..... 1 POWER SEAT SWITCH . . . . . . . . . . . . . . ..... 2
DIAGNOSIS AND TESTING
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . ..... 2

GEN ERAL I N FORM AT I ON or fa u lt y, t h e en t ir e power sea t swit ch m odu le m u st


be r epla ced.
INTRODUCTION
A six-wa y dr iver side power sea t is a n a va ila ble POWER SEAT ADJUSTER AND MOTORS
fa ct or y-in st a lled opt ion for Left -H a n d Dr ive (LH D) Th er e a r e t h r ee r ever sible m ot or s t h a t oper a t e t h e
ver sion s of t h is m odel. Th e power sea t syst em power sea t a dju st er. Th e m ot or s a r e con n ect ed t o
r eceives ba t t er y feed t h r ou gh a fu se in t h e P ower wor m -dr ive gea r boxes t h a t m ove t h e sea t a dju st er
Dist r ibu t ion Cen t er a n d a cir cu it br ea ker in t h e ju n c- t h r ou gh a com bin a t ion of scr ew-t ype dr ive u n it s.
t ion block a t a ll t im es. Th e fr on t a n d r ea r of a sea t a r e oper a t ed by differ-
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor en t m ot or s. Th ey ca n be r a ised or lower ed in depen -
com pon en t s in t h e power sea t syst em . Refer t o 8W-63 den t ly of ea ch ot h er. Wh en t h e cen t er sea t swit ch is
- P ower Sea t in Gr ou p 8W - Wir in g Dia gr a m s for pu sh ed t o t h e Up or Down posit ion , bot h t h e fr on t
com plet e cir cu it descr ipt ion s a n d dia gr a m s. a n d r ea r m ot or s oper a t e in u n ison , m ovin g t h e en t ir e
sea t u p or down . Th e for wa r d-r ea r wa r d m ot or is
NOTE: This group covers both Left-Hand Drive oper a t ed by pu sh in g t h e cen t er sea t swit ch t o t h e
(LHD) and Right-Hand Drive (RHD) versions of this F or wa r d or Rea r wa r d posit ion .
model. Whenever required and feasible, the RHD Wh en a swit ch is a ct u a t ed, a ba t t er y feed a n d a
versions of affected vehicle components have been gr ou n d pa t h a r e a pplied t h r ou gh t h e swit ch con t a ct s
constructed as mirror-image of the LHD versions. t o t h e m ot or (s). Th e m ot or (s) a n d dr ives oper a t e t o
While most of the illustrations used in this group m ove t h e sea t in t h e select ed dir ect ion u n t il t h e
represent only the LHD version, the diagnostic and swit ch is r elea sed, or u n t il t h e t r a vel lim it of t h e
service procedures outlined can generally be power sea t a dju st er is r ea ch ed. Wh en t h e swit ch is
applied to either version. Exceptions to this rule m oved in t h e opposit e dir ect ion , t h e ba t t er y feed a n d
have been clearly identified as LHD or RHD, if a gr ou n d pa t h t o t h e m ot or (s) a r e r ever sed t h r ou gh t h e
special illustration or procedure is required. swit ch con t a ct s. Th is ca u ses t h e m ot or t o r u n in t h e
opposit e dir ect ion .
E a ch m ot or con t a in s a self-r eset t in g cir cu it br ea ker
t o pr ot ect it fr om over loa d. Con secu t ive or fr equ en t
DESCRI PT I ON AN D OPERAT I ON
r eset t in g of t h e cir cu it br ea ker s m u st n ot be a llowed
t o con t in u e, or t h e m ot or s m a y be da m a ged. Ma ke
POWER SEAT SWITCH
t h e n ecessa r y r epa ir s.
Th e power sea t ca n be a dju st ed in six differ en t
Th e power sea t a dju st er a n d m ot or s ca n n ot be
wa ys u sin g t h e power sea t swit ch . Th e swit ch is
r epa ir ed, a n d a r e ser viced on ly a s a com plet e u n it . If
loca t ed on t h e lower ou t boa r d side of t h e sea t cu sh ion
a n y com pon en t in t h is u n it is fa u lt y or da m a ged, t h e
fr a m e. Refer t o t h e own er ’s m a n u a l for m or e in for m a -
en t ir e power sea t a dju st er a n d m ot or s a ssem bly m u st
t ion on power sea t swit ch fu n ct ion s a n d sea t a dju st -
be r epla ced.
in g pr ocedu r es.
Th e in dividu a l swit ch es in t h e power sea t swit ch
m odu le ca n n ot be r epa ir ed. If on e swit ch is da m a ged
8R - 2 POWER SEAT SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
CIRCUIT BREAKER (1) Test t h e cir cu it br ea ker in t h e ju n ct ion block a s
An a u t om a t ic r eset t in g cir cu it br ea ker in t h e ju n c- descr ibed in t h is gr ou p. If OK, go t o St ep 2. If n ot
t ion block is u sed t o pr ot ect t h e power sea t syst em OK, r epla ce t h e fa u lt y cir cu it br ea ker.
cir cu it . Th e cir cu it br ea ker ca n pr ot ect t h e syst em (2) Rem ove t h e power sea t swit ch a s descr ibed in
fr om a sh or t cir cu it , or fr om a n over loa d con dit ion t h is gr ou p. Ch eck for ba t t er y volt a ge a t t h e fu sed
ca u sed by a n obst r u ct ed or st u ck sea t a dju st er. B(+) cir cu it ca vit y of t h e power sea t swit ch wir e h a r-
Th e cir cu it br ea ker ca n n ot be r epa ir ed a n d, if n ess con n ect or. If OK, go t o St ep 3. If n ot OK, r epa ir
fa u lt y or da m a ged, it m u st be r epla ced. t h e open cir cu it t o t h e ju n ct ion block a s r equ ir ed.
(3) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it ca vit y of t h e power sea t swit ch wir e h a r n ess con -
DI AGN OSI S AN D T EST I N G n ect or a n d a good gr ou n d. 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
POWER SEAT SYSTEM open cir cu it t o gr ou n d a s r equ ir ed.
Befor e a n y t est in g of t h e power sea t syst em is (4) Test t h e power sea t swit ch a s descr ibed in t h is
a t t em pt ed, t h e ba t t er y sh ou ld be fu lly-ch a r ged a n d gr ou p. If t h e swit ch t est s OK, ch eck t h e wir e h a r n ess
a ll wir e h a r n ess con n ect ion s a n d pin s clea n ed a n d for t h e in oper a t ive m ot or bet ween t h e swit ch a n d t h e
t igh t en ed t o en su r e pr oper con t in u it y a n d gr ou n ds. m ot or for sh or t s or open s. If t h e cir cu it s ch eck OK,
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o 8W-63 r epla ce t h e fa u lt y power sea t a dju st er a n d m ot or s
- P ower Sea t in Gr ou p 8W - Wir in g Dia gr a m s. a ssem bly. If t h e cir cu it s a r e n ot OK, r epa ir t h e wir e
Wit h t h e dom e la m p on , a pply t h e power sea t h a r n ess a s r equ ir ed.
swit ch in t h e dir ect ion of t h e fa ilu r e. If t h e dom e
la m p dim s, t h e sea t m a y be ja m m in g. Ch eck u n der POWER SEAT SWITCH
a n d beh in d t h e sea t for bin din g or obst r u ct ion s. If F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
t h e dom e la m p does n ot dim , pr oceed wit h t est in g of 8W-63 - P ower Sea t in Gr ou p 8W - Wir in g Dia gr a m s.
t h e in dividu a l com pon en t s a n d cir cu it s. (1) Rem ove t h e power sea t swit ch a s descr ibed in
t h is gr ou p.
CIRCUIT BREAKER (2) Use a n oh m m et er t o t est t h e con t in u it y of t h e
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o swit ch es in ea ch posit ion . See t h e P ower Sea t Swit ch
8W-63 - P ower Sea t in Gr ou p 8W - Wir in g Dia gr a m s. Con t in u it y ch a r t (F ig. 1). If OK, see t h e dia gn osis for
(1) Loca t e t h e cor r ect cir cu it br ea ker in t h e ju n c- t h e P ower Sea t Adju st er a n d Mot or s in t h is gr ou p. If
t ion block. P u ll ou t t h e cir cu it br ea ker sligh t ly, bu t n ot OK, r epla ce t h e fa u lt y power sea t swit ch m odu le.
be su r e t h a t t h e t er m in a ls st ill con t a ct t h e t er m in a ls
in t h e ju n ct ion block ca vit ies.
(2) Con n ect t h e n ega t ive lea d of a 12-volt DC volt - REM OVAL AN D I N STALLAT I ON
m et er t o a good gr ou n d.
(3) Wit h t h e volt m et er posit ive lea d, ch eck bot h POWER SEAT SWITCH
t er m in a ls of t h e cir cu it br ea ker for ba t t er y volt a ge. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
If on ly on e t er m in a l h a s ba t t er y volt a ge, t h e cir cu it ca ble.
br ea ker is fa u lt y a n d m u st be r epla ced. If n eit h er t er- (2) Rem ove t h e t h r ee scr ews t h a t secu r e t h e sea t
m in a l h a s ba t t er y volt a ge, r epa ir t h e open cir cu it side sh ield t o t h e ou t boa r d sea t cu sh ion fr a m e.
fr om t h e P ower Dist r ibu t ion Cen t er (P DC) a s (3) P u ll t h e sea t side sh ield a wa y fr om t h e sea t
r equ ir ed. cu sh ion fr a m e fa r en ou gh t o a ccess t h e power sea t
swit ch wir e h a r n ess con n ect or.
POWER SEAT ADJUSTER AND MOTORS (4) Un plu g t h e power sea t swit ch wir e h a r n ess
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o con n ect or fr om t h e swit ch .
8W-63 - P ower Sea t in Gr ou p 8W - Wir in g Dia gr a m s. (5) Rem ove t h e sea t side sh ield fr om t h e veh icle.
Oper a t e t h e power sea t swit ch t o m ove a ll t h r ee (6) Rem ove t h e t wo scr ews t h a t secu r e t h e power
sea t m ot or s. Th e sea t sh ou ld m ove in ea ch select ed sea t swit ch t o t h e in side of t h e sea t side sh ield (F ig.
dir ect ion . If a m ot or fa ils t o oper a t e in on ly on e dir ec- 2).
t ion , m ove t h e sea t a sh or t dist a n ce in t h e opposit e (7) Rem ove t h e power sea t swit ch fr om t h e sea t
dir ect ion a n d t est a ga in t o be cer t a in t h e a dju st er is side sh ield.
n ot a t it s t r a vel lim it . If on e or m or e of t h e m ot or s (8) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
oper a t e, see t h e dia gn osis for t h e P ower Sea t Swit ch Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).
in t h is gr ou p. If n o m ot or s oper a t e, pr oceed a s fol-
lows:
OFF SWITCH
SEAT SIDE
POSITION
SHIELD SCREWS CONTINUITY BETWEEN
POWER SEAT SWITCH BODY
NESS CONNECTOR
WIRE HAR- TERMINALS
VIEWED FROM
SHOWN
DOWN
REAR
SWITCH
OF
AS
UP AFT/FORWARD
DRIVER
SEAT
SIDEBELT
FRONT
CONNECTOR
SWITCH
SEAT

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

B-N, B-J, B-M,


B-E, 8-L, 8-K
l
UP
-AFT/FORWARD-

FRONT TILT DOWN


VERTICAL UP A-E, A-M, B-N, 8-J
REAR TILT UP

VERTICAL DOWN A-J, A-N, 8-M, B-E


REAR TILT DOWN

HORIZONTAL FORWARD A-L, B-K

HORIZONTAL AFT A-K, B-L


DOWN

FRONT TILT UP A-M, B-N


j
FRONT TILT DOWN A-N, B-M
TERMINALS SHOWN AS VIEWED
REAR TILT UP A-E, B-J FROM REAR OF SWITCH

REAR TILT DOWN A-J, B-E 908R-4

Fig. 1 Power Seat Switch Continuity

SEAT SIDE SHIELD


DRIVER SIDE
FRONT SEAT

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

8R - 4 POWER SEAT SYSTEMS XJ


REM OVAL AN D I N STALLAT I ON (Cont inue d)
• Sea t a dju st er t o floor pa n el scr ews - 27 N·m (20
NUT DRIVER SIDE ft . lbs.)
FRONT SEAT • Sea t a dju st er t o floor pa n el n u t - 40 N·m (30 ft .

~
lbs.).

80abd26f

Fig. 4 Power Seat Remove/Install


POWER
SEAT
---ADJUSTER---.,,;..u.._
AND MOTORS

80abd270

Fig. 5 Power Seat Adjuster and Motors Remove/


Install
• Sea t a dju st er t o sea t cu sh ion fr a m e n u t s - 25
N·m (18 ft . lbs.)
XJ POWER WINDOW SYSTEMS 8S - 1

POWER WINDOW SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 3


INTRODUCTION . . . . . . . . . . . ............. 1 POWER WINDOW MOTOR . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION POWER WINDOW SWITCH . . . . . . . . . . . . . . . . 3
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 2 POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . 2
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL AND INSTALLATION
POWER WINDOW MOTOR . . . . . . . . . . . . . . . . 2 DOOR MODULE . . . . . . . . . . .............. 4
POWER WINDOW SWITCH . . . . . . . . . . . . . . . . 1 POWER WINDOW MOTOR . . .............. 5
DIAGNOSIS AND TESTING POWER WINDOW SWITCH . . .............. 5
CIRCUIT BREAKER . . . . . . . . . ............. 3

GEN ERAL I N FORM AT I ON a n d, on fou r-door m odels, on ea ch of t h e r ea r door


t r im pa n els. Two-wa y m om en t a r y m a st er swit ch es on
INTRODUCTION t h e dr iver side fr on t door t r im pa n el con t r ol a ll of t h e
P ower win dows a r e a va ila ble a s fa ct or y-in st a lled power win dows in t h e veh icle. Th e dr iver side fr on t
opt ion a l equ ipm en t on t h is m odel. Th e power lock door t r im pa n el a lso h a s a t wo-posit ion power win -
syst em a n d power m ir r or syst em a r e in clu ded on dow lockou t swit ch .
veh icles equ ipped wit h t h e power win dow opt ion . Th e fr on t door power win dow swit ch es a n d t h e
Th is gr ou p cover s dia gn osis a n d ser vice of on ly t h e power win dow lockou t swit ch a r e in t egr a l t o t h e
elect r ica l com pon en t s in t h e power win dow syst em . Dr iver Door Modu le (DDM) or P a ssen ger Door Mod-
F or ser vice of m ech a n ica l com pon en t s, su ch a s t h e u le (P DM), r espect ively. Th e r ea r door power win dow
r egu la t or, lift pla t e, win dow t r a cks, or gla ss r efer t o swit ch es a r e st a n d-a lon e u n it s.
Gr ou p 23 - Body. E a ch power win dow swit ch con t r ols it s power win -
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor dow m ot or by swit ch in g ba t t er y cu r r en t a n d gr ou n d
com pon en t s in t h e power win dow syst em . Refer t o bet ween t h e t er m in a ls of t h e power win dow m ot or.
8W-60 - P ower Win dows in Gr ou p 8W - Wir in g Dia - Th e pa ssen ger side fr on t door a n d, on fou r-door m od-
gr a m s for com plet e cir cu it descr ipt ion s a n d dia gr a m s. els, bot h r ea r door power win dow swit ch es r eceive
Refer t o t h e own er ’s m a n u a l for m or e in for m a t ion on t h eir ba t t er y feed t h r ou gh t h e power win dow lockou t
t h e fea t u r es a n d u se of t h is syst em . swit ch or t h r ou gh t h e m a st er swit ch es in t h e DDM.
Also, ea ch of t h e in dividu a l power win dow swit ch es
NOTE: This group covers both Left-Hand Drive r eceives it s gr ou n d t h r ou gh t h e DDM. Wh en t h e lock-
(LHD) and Right-Hand Drive (RHD) versions of this ou t swit ch is pla ced in t h e Lock posit ion , t h e in divid-
model. Whenever required and feasible, the RHD u a l power win dow swit ch es becom e in oper a t ive
versions of affected vehicle components have been beca u se t h ey h a ve n o ba t t er y cu r r en t a va ila ble t o
constructed as mirror-image of the LHD versions. t h em . H owever, t h e m a st er swit ch es a r e u n a ffect ed
While most of the illustrations used in this group by t h e lockou t swit ch posit ion .
represent only the LHD version, the diagnostic and E a ch power win dow swit ch , except t h e lockou t
service procedures outlined can generally be swit ch , is illu m in a t ed by a Ligh t -E m it t in g Diode
applied to either version. Exceptions to this rule (LE D) wh en t h e ign it ion swit ch is t u r n ed t o t h e On
have been clearly identified as LHD or RHD, if a posit ion . H owever, wh en t h e lockou t swit ch is pla ced
special illustration or procedure is required. in t h e Lock posit ion , t h e LE D for t h e locked-ou t pa s-
sen ger side fr on t a n d, on fou r-door m odels, t h e r ea r
pa ssen ger door power win dow swit ch es is t u r n ed off.
Th e fr on t door power win dow swit ch es a n d t h eir
DESCRI PT I ON AN D OPERAT I ON
la m ps ca n n ot be r epa ir ed a n d, if fa u lt y or da m a ged,
t h e en t ir e door m odu le m u st be r epla ced. Th e r ea r
POWER WINDOW SWITCH
door power win dow swit ch es a n d t h eir la m ps ca n n ot
Th e in dividu a l power win dows a r e con t r olled by a
be r epa ir ed bu t , if fa u lt y or da m a ged, on ly t h e
t wo-wa y m om en t a r y swit ch m ou n t ed on t h e t r im
a ffect ed swit ch u n it m u st be r epla ced.
pa n el of t h e pa ssen ger side fr on t door t r im pa n el
8S - 2 POWER WINDOW SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
DOOR MODULE (2) Rem ove t h e Dr iver Door Modu le (DDM) a s
A Dr iver Door Modu le (DDM) a n d a P a ssen ger descr ibed in t h is gr ou p. Ch eck for con t in u it y bet ween
Door Modu le (P DM) a r e u sed on a ll m odels equ ipped t h e gr ou n d cir cu it ca vit y of t h e swit ch wir e h a r n ess
wit h power locks a n d power win dows. E a ch door con n ect or a n d a good gr ou n d. If OK, go t o St ep 3. If
m odu le h ou ses bot h t h e fr on t door power lock a n d n ot OK, r epa ir t h e cir cu it t o gr ou n d a s r equ ir ed.
power win dow swit ch es. Th e DDM a lso h ou ses in di- (3) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
vidu a l swit ch es for ea ch pa ssen ger door power win - Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
dow, a power win dow lockou t swit ch , a power m ir r or ou t pu t cir cu it ca vit y of t h e DDM wir e h a r n ess con -
swit ch , a n d cir cu it r y t o su ppor t t h e on e-t ou ch down n ect or. If OK, see t h e dia gn osis for t h e Door Modu le
fea t u r e of t h e dr iver side fr on t door power win dow. in t h is gr ou p. If n ot OK, r epa ir t h e open cir cu it t o
Th e P DM a lso h ou ses t h e con t r ol cir cu it r y a n d t h e t h e cir cu it br ea ker in t h e ju n ct ion block a s r equ ir ed.
power lock a n d u n lock r ela ys for t h e power lock sys-
t em . ON E WI N DOW I N OPERAT I V E
Th e DDM a n d t h e P DM a r e m ou n t ed t o t h eir Th e win dow gla ss m u st be fr ee t o slide u p a n d
r espect ive fr on t door t r im pa n els. Th e DDM a n d down for t h e power win dow m ot or t o fu n ct ion pr op-
P DM a r e ser viced in dividu a lly a n d ca n n ot be er ly. If t h e gla ss is n ot fr ee t o m ove u p a n d down , t h e
r epa ir ed. If t h e DDM or P DM, or a n y of t h e swit ch es m ot or will over loa d a n d t r ip t h e in t egr a l cir cu it
a n d cir cu it r y t h ey con t a in a r e fa u lt y or da m a ged, t h e br ea ker. To det er m in e if t h e gla ss is fr ee, discon n ect
com plet e m odu le m u st be r epla ced. t h e r egu la t or pla t e fr om t h e gla ss. Th en slide t h e
win dow u p a n d down by h a n d.
POWER WINDOW MOTOR Th er e is a n a lt er n a t e m et h od t o ch eck if t h e gla ss
A per m a n en t m a gn et r ever sible m ot or m oves t h e is fr ee. P osit ion t h e gla ss bet ween t h e u p a n d down
win dow r egu la t or t h r ou gh a n in t egr a l gea r box m ech - st ops. Th en , sh a ke t h e gla ss in t h e door. Ch eck t h a t
a n ism . A posit ive a n d n ega t ive ba t t er y con n ect ion t o t h e gla ss ca n be m oved sligh t ly fr om side t o side,
t h e t wo m ot or t er m in a ls will ca u se t h e m ot or t o fr on t t o r ea r, a n d u p a n d down . Th en ch eck t h a t t h e
r ot a t e in on e dir ect ion . Rever sin g cu r r en t t h r ou gh gla ss is n ot bou n d t igh t in t h e t r a cks. If t h e gla ss is
t h ese sa m e t wo con n ect ion s will ca u se t h e m ot or t o fr ee, pr oceed wit h t h e dia gn osis t h a t follows. If t h e
r ot a t e in t h e opposit e dir ect ion . gla ss is n ot fr ee, r efer t o Gr ou p 23 - Body for t h e
In a ddit ion , ea ch power win dow m ot or is equ ipped door win dow gla ss a n d h a r dwa r e ser vice a n d a dju st -
wit h a n in t egr a l self-r eset t in g cir cu it br ea ker t o pr o- m en t pr ocedu r es.
t ect t h e m ot or fr om over loa ds. Th e power win dow (1) Ch eck t h e power win dow swit ch con t in u it y a s
m ot or a n d gea r box a ssem bly ca n n ot be r epa ir ed a n d, descr ibed in t h e dia gn osis for t h e Door Modu le (fr on t
if fa u lt y or da m a ged, t h e en t ir e power win dow r egu - door s) or P ower Win dow Swit ch (r ea r door s) in t h is
la t or a ssem bly m u st be r epla ced. gr ou p. If OK a n d t h e dr iver side fr on t win dow is
in oper a t ive, see t h e P ower Win dow Mot or dia gn osis
CIRCUIT BREAKER in t h is gr ou p. If OK a n d t h e in oper a t ive win dow is
An a u t om a t ic r eset t in g cir cu it br ea ker in t h e ju n c- ot h er t h a n t h e dr iver side fr on t , go t o St ep 2. If n ot
t ion block is u sed t o pr ot ect t h e power win dow sys- OK, r epla ce t h e fa u lt y door m odu le or swit ch .
t em cir cu it . Th e cir cu it br ea ker ca n pr ot ect t h e (2) Refer t o t h e cir cu it dia gr a m s in 8W-60 - P ower
syst em fr om a sh or t cir cu it , or fr om a n over loa d con - Win dows in Gr ou p 8W - Wir in g Dia gr a m s. Ch eck t h e
dit ion ca u sed by a n obst r u ct ed or st u ck win dow gla ss con t in u it y in ea ch cir cu it bet ween t h e in oper a t ive
or r egu la t or. P a ssen ger Door Modu le (P DM) or power win dow
Th e cir cu it br ea ker ca n n ot be r epa ir ed a n d, if swit ch wir e h a r n ess con n ect or ca vit ies a n d t h e cor r e-
fa u lt y, it m u st be r epla ced. spon din g Dr iver Door Modu le (DDM) wir e h a r n ess
con n ect or ca vit ies. If OK, see t h e dia gn osis for t h e
P ower Win dow Mot or in t h is gr ou p. If n ot OK, r epa ir
DI AGN OSI S AN D T EST I N G t h e open cir cu it (s) a s r equ ir ed.

POWER WINDOW SYSTEM NOTE: All individual power window switches


F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o receive their battery and ground feeds through the
8W-60 - P ower Win dows in Gr ou p 8W - Wir in g Dia - Driver Door Module (DDM) and wire harness con-
gr a m s. nectors.

ALL WI N DOWS I N OPERAT I V E


(1) Ch eck t h e cir cu it br ea ker in t h e ju n ct ion block,
a s descr ibed in t h is gr ou p. 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.
CONNECTOR
CONNECTOR
2 (C-2) 1 (C-1)

XJ POWER WINDOW SYSTEMS 8S - 3


DI AGN OSI S AN D T EST I N G (Cont inue d)
CIRCUIT BREAKER
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o ~
8W-60 - P ower Win dows in Gr ou p 8W - Wir in g Dia -
gr a m s.
l_Uj_jJ
(1) Loca t e t h e cir cu it br ea ker in t h e ju n ct ion block. CONNECTOR 1 (C-1) CONNECTOR 2 (C-2)
P u ll ou t t h e cir cu it br ea ker sligh t ly, bu t be su r e t h a t POWER WI N DOWS
t h e t er m in a ls st ill con t a ct t h e t er m in a ls in t h e ju n c- CON N ECT OR 2 (C2 )
t ion block ca vit ies. SWITCH POSITION CONTINUITY BETWEEN
(2) Con n ect t h e n ega t ive lea d of a 12-volt DC volt - OFF (NORMAL) 1&8, 2&8, 3&8, 4&8, 5&8, 6&8, 10&8, 12&8
m et er t o a good gr ou n d. RIGHT REAR DOWN 1&9
(3) Wit h t h e volt m et er posit ive lea d, ch eck bot h RIGHT REAR UP 2&9
t er m in a ls of t h e cir cu it br ea ker for ba t t er y volt a ge. RIGHT FRONT UP 3&9
If on ly on e t er m in a l h a s ba t t er y volt a ge, t h e cir cu it LEFT REAR UP 4&9
br ea ker is fa u lt y a n d m u st be r epla ced. If n eit h er t er- LEFT FRONT UP 5&9
RIGHT FRONT DOWN 6&9
m in a l h a s ba t t er y volt a ge, r epa ir t h e open cir cu it
LEFT REAR DOWN 10&9
fr om t h e P ower Dist r ibu t ion Cen t er (P DC) a s
LEFT FRONT DOWN 12&9
r equ ir ed.
WI N DOW LOCK OU T
DOOR MODULE CON N ECT OR 1 (C1 ), CON N ECT OR 2 (C2 )
Th e Dr iver Door Modu le (DDM) con t a in s t h e m a s- SWITCH POSITION CONTINUITY BETWEEN
t er swit ch es a n d t h e lockou t swit ch in t h e power win - LOCKOUT OFF (UP) C1 PIN 8 & C2 PIN 9 CONNECTOR 2 (C-2)

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

8S - 4 POWER WINDOW SYSTEMS XJ


DI AGN OSI S AN D T EST I N G (Cont inue d)

3
==
5 6
==
~

SWITCH POSITION CONTINUITY BETWEEN


OFF (NORMAL) 1&4
2&5
UP 1&6
2&5
DOWN 1&4
5&6 Fig. 4 Front Door Trim Panel Remove/Install
80abd2ed (3) Usin g a t r im st ick or a n ot h er su it a ble wide
Fig. 3 Rear Door Power Window Switch Continuity 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
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
POWER WINDOW MOTOR
pa n el r et a in er s.
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
8W-60 - P ower Win dows in Gr ou p 8W - Wir in g Dia - NOTE: To aid in the removal of the trim panel, start
gr a m s. Befor e you pr oceed wit h t h is dia gn osis, con - at the bottom of the panel.
fir m pr oper swit ch oper a t ion . See t h e Door Modu le
a n d/or P ower Win dow Swit ch dia gn osis in t h is gr ou p. (4) Lift t h e door t r im pa n el u pwa r ds a n d a wa y
(1) Rem ove t h e door t r im pa n el a s descr ibed in 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
Door Modu le (fr on t door ) or P ower Win dow Swit ch t h e in n er belt wea t h er st r ip.
(r ea r door ) in t h is gr ou p. (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
(2) Un plu g t h e power win dow m ot or wir e h a r n ess door fa r en ou gh t o a ccess t h e in side door la t ch
con n ect or. Apply 12 volt s a cr oss t h e m ot or t er m in a ls r elea se a n d lock lin ka ge r ods n ea r t h e ba ck of t h e
t o ch eck it s oper a t ion in on e dir ect ion . Rever se t h e in side door r em ot e con t r ols.
con n ect ion s a cr oss t h e m ot or t er m in a ls t o ch eck t h e (6) Un sn a p t h e pla st ic r et a in er clips fr om t h e
oper a t ion in t h e ot h er dir ect ion . Rem em ber, if 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
win dow is in t h e fu ll u p or fu ll down posit ion , t h e a n d lock lin ka ge r ods, a n d r em ove t h e r od en ds fr om
m ot or will n ot oper a t e in t h a t dir ect ion by design . If t h e in side door r em ot e con t r ols.
OK, r epa ir t h e cir cu it s fr om t h e m ot or t o t h e door (7) Un plu g t h e wir e h a r n ess con n ect or s fr om t h e
m odu le or t h e swit ch a s r equ ir ed. If n ot OK, r epla ce door m odu le.
t h e fa u lt y m ot or. (8) Rem ove t h e fr on t door t r im pa n el fr om t h e
(3) If t h e m ot or oper a t es in bot h dir ect ion s, ch eck veh icle.
t h e oper a t ion of t h e win dow gla ss a n d lift m ech a n ism (9) Rem ove t h e t h r ee scr ews t h a t secu r e t h e door
t h r ou gh it s com plet e u p a n d down t r a vel. Th er e m odu le t o t h e door t r im pa n el (F ig. 5).
sh ou ld be n o bin din g or st ickin g of t h e win dow gla ss
or lift m ech a n ism t h r ou gh t h e en t ir e t r a vel r a n ge. If
n ot OK, r efer t o Gr ou p 23 - Body t o ch eck t h e win -
dow gla ss, t r a cks, a n d r egu la t or for st ickin g, bin din g,
or im pr oper a dju st m en t .

REM OVAL AN D I N STALLAT I ON

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

XJ POWER WINDOW SYSTEMS 8S - 5


REM OVAL AN D I N STALLAT I ON (Cont inue d)
(10) Rem ove t h e door m odu le fr om t h e t r im pa n el. (7) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
(11) Rever se t h e r em ova l pr ocedu r es t o in st a ll. r ea r door power win dow swit ch .
Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.). REAR
WINDOW
(8)DOOR
Rem SWITCH
POWER
ove t h e r ea r door t r im pa n el fr SWITCH
om tRECEPTACLE
h eTRIM
vehPANEL
i-
cle.
POWER WINDOW SWITCH (9) Ca r efu lly pr y t h e sn a p r et a in er s a t ea ch side of
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive t h e swit ch r ecept a cle in t h e t r im pa n el a n d pu ll t h e
ca ble. swit ch ou t of t h e r ecept a cle (F ig. 7).
(2) Rem ove t h e scr ews t h a t secu r e t h e door t r im
_REAR DOOR TRIM
pa n el t o t h e in n er door pa n el (F ig. 6). PANEL
POWER WINDOW

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

POWER MIRROR SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION DIAGNOSIS AND TESTING


INTRODUCTION . . . . . . . . . . . ............. 1 POWER MIRROR SYSTEM . . .............. 2
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
DOOR MODULE . . . . . . . . . . . ............. 1 DOOR MODULE . . . . . . . . . . .............. 4
POWER MIRROR SWITCH . . . ............. 1 POWER MIRROR SWITCH . . .............. 2
POWER MIRROR . . . . . . . . . . . ............. 1 POWER MIRROR . . . . . . . . . . .............. 4

GEN ERAL I N FORM AT I ON syst em is t u r n ed on . Refer t o Gr ou p 8N - E lect r ica lly


H ea t ed Syst em s for m or e in for m a t ion on t h e oper a -
INTRODUCTION t ion of t h e r ea r win dow defogger syst em .
P ower oper a t ed or power oper a t ed a n d h ea t ed ou t - Th e power m ir r or a ssem bly ca n n ot be r epa ir ed.
side r ea r view m ir r or s a r e a va ila ble fa ct or y-in st a lled On ly t h e m ir r or gla ss is ser viced sepa r a t ely. If a n y
opt ion s on t h is m odel. F ollowin g a r e gen er a l descr ip- ot h er com pon en t of t h e power m ir r or u n it is fa u lt y or
t ion s of t h e m a jor com pon en t s in t h e power m ir r or da m a ged, t h e en t ir e a ssem bly m u st be r epla ced.
syst em .
Refer t o 8W-62 - P ower Mir r or s in Gr ou p 8W - Wir- POWER MIRROR SWITCH
in g Dia gr a m s for com plet e cir cu it descr ipt ion s a n d Bot h t h e r igh t a n d left power ou t side m ir r or s a r e
dia gr a m s. Refer t o t h e own er ’s m a n u a l for m or e con t r olled by a sin gle m u lt i-fu n ct ion swit ch u n it
in for m a t ion on t h e fea t u r es a n d u se of t h is syst em . loca t ed on t h e dr iver side fr on t door t r im pa n el. Two
ver sion s of t h is swit ch a r e offer ed. Models wit h ou t
NOTE: This group covers both Left-Hand Drive power win dows or power locks h a ve a st a n d-a lon e
(LHD) and Right-Hand Drive (RHD) versions of this swit ch m ou n t ed in t h e dr iver side fr on t door t r im
model. Whenever required and feasible, the RHD pa n el. Models equ ipped wit h power win dows a n d
versions of affected vehicle components have been power locks h a ve a power m ir r or swit ch t h a t is in t e-
constructed as mirror-image of the LHD versions. gr a l t o t h e Dr iver Door Modu le (DDM).
While most of the illustrations used in this group Bot h ver sion s of t h e swit ch a r e oper a t ed in t h e
represent only the LHD version, the diagnostic and sa m e m a n n er. A t h r ee posit ion r ocker-t ype m ir r or
service procedures outlined can generally be select or swit ch is m oved r igh t (r igh t m ir r or con t r ol),
applied to either version. Exceptions to this rule left (left m ir r or con t r ol), or cen t er t o t u r n t h e power
have been clearly identified as LHD or RHD, if a m ir r or s off. Th en on e of fou r dir ect ion a l con t r ol bu t -
special illustration or procedure is required. t on s is depr essed t o con t r ol m ovem en t of t h e select ed
m ir r or u p, down , r igh t , or left . Th e dir ect ion a l con t r ol
bu t t on s of t h e DDM-m ou n t ed swit ch a r e illu m in a t ed
wh en t h e ign it ion swit ch is in t h e On posit ion . Th e
DESCRI PT I ON AN D OPERAT I ON
st a n d-a lon e swit ch is n ot illu m in a t ed.
Th e st a n d-a lon e power m ir r or swit ch ca n n ot be
POWER MIRROR
r epa ir ed a n d, if fa u lt y or da m a ged, it m u st be
Th e power m ir r or s a r e con n ect ed t o a n ign it ion -
r epla ced a s a com plet e u n it . Th e DDM power m ir r or
swit ch ed ba t t er y feed so t h a t t h e m ir r or s will on ly
swit ch r equ ir es r epla cem en t of t h e en t ir e DDM if t h e
oper a t e wit h t h e ign it ion swit ch in t h e On posit ion .
swit ch is fa u lt y or da m a ged.
E a ch m ir r or h ea d con t a in s t wo elect r ic m ot or s, t wo
dr ive m ech a n ism s, a n d t h e m ir r or gla ss. On e m ot or
DOOR MODULE
a n d dr ive con t r ols m ir r or u p-a n d-down m ovem en t ,
A Dr iver Door Modu le (DDM) a n d a P a ssen ger
a n d t h e ot h er con t r ols r igh t -a n d-left m ovem en t .
Door Modu le (P DM) a r e u sed on a ll m odels equ ipped
Th e power m ir r or s in veh icles equ ipped wit h t h e
wit h power locks a n d power win dows. E a ch door
a va ila ble h ea t ed m ir r or opt ion a lso in clu de a n elec-
m odu le h ou ses bot h t h e fr on t door power lock a n d
t r ic h ea t in g gr id loca t ed beh in d t h e m ir r or gla ss.
power win dow swit ch es. Th e DDM a lso h ou ses in di-
Th is h ea t in g gr id is en er gized by t h e r ea r win dow
vidu a l swit ch es for ea ch pa ssen ger door power win -
defogger r ela y wh en ever t h e r ea r win dow defogger
dow, a power win dow lockou t swit ch , a power m ir r or
8T - 2 POWER MIRROR SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
swit ch , a n d cir cu it r y t o su ppor t t h e on e-t ou ch down n ot OK, r epla ce t h e fa u lt y power m ir r or. If OK, ch eck
fea t u r e of t h e dr iver side fr on t door power win dow. t h e r esist a n ce t h r ou gh t h e elect r ic h ea t in g gr id cir-
Th e P DM a lso h ou ses t h e con t r ol cir cu it r y a n d t h e cu it . Cor r ect r esist a n ce t h r ou gh t h e elect r ic h ea t in g
power lock a n d u n lock r ela ys for t h e power lock sys- gr id sh ou ld be fr om 10 t o 16 oh m s wh en m ea su r ed a t
t em . a n a m bien t t em per a t u r e of 21°C (70°F ). If n ot OK,
Th e DDM a n d t h e P DM a r e m ou n t ed t o t h eir r epla ce t h e fa u lt y power m ir r or.
r espect ive fr on t door t r im pa n els. Th e DDM a n d (7) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
P DM a r e ser viced in dividu a lly a n d ca n n ot be ca ble. Rem ove t h e st a n d-a lon e power m ir r or swit ch
r epa ir ed. If t h e DDM or P DM, or a n y of t h e swit ch es or t h e DDM a s descr ibed in t h is gr ou p. Un plu g t h e
a n d cir cu it r y t h ey con t a in a r e fa u lt y or da m a ged, t h e wir e h a r n ess con n ect or fr om t h e st a n d-a lon e swit ch
com plet e m odu le m u st be r epla ced. or t h e 8-wa y wir e h a r n ess con n ect or fr om t h e DDM.
Con n ect 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 t o t h e On posit ion . Ch eck for ba t t er y volt a ge
DI AGN OSI S AN D T EST I N G a t t h e fu sed ign it ion swit ch ou t pu t cir cu it ca vit y of
t h e st a n d-a lon e swit ch wir e h a r n ess con n ect or or t h e
POWER MIRROR SYSTEM 8-wa y DDM wir e h a r n ess con n ect or. If OK, go t o St ep
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o 8. If n ot OK, r epa ir t h e open cir cu it t o t h e ju n ct ion
8W-62 - P ower Mir r or s in Gr ou p 8W - Wir in g Dia - block a s r equ ir ed.
gr a m s. (8) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
(1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v-
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. it y of t h e st a n d-a lon e swit ch wir e h a r n ess con n ect or
(2) If t h e pr oblem bein g dia gn osed is in oper a t ive or t h e 8-wa y DDM wir e h a r n ess con n ect or a n d a
power m ir r or swit ch dir ect ion a l bu t t on illu m in a t ion good gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o
for t h e Dr iver Door Modu le (DDM)-t ype swit ch , pr o- St ep 9. If n ot OK, r epa ir t h e cir cu it t o gr ou n d a s
ceed a s follows. If n ot , go t o St ep 4. Ch eck t h e power r equ ir ed.
win dow cir cu it br ea ker in t h e ju n ct ion block. If OK, (9) Ch eck t h e st a n d-a lon e power m ir r or swit ch or
go t o St ep 3. If n ot OK, r epla ce t h e fa u lt y cir cu it DDM-m ou n t ed power m ir r or swit ch con t in u it y a s
br ea ker. sh own in (F ig. 1) or (F ig. 2). If OK, go t o St ep 10. If
(3) Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion n ot OK, r epla ce t h e fa u lt y st a n d-a lon e power m ir r or
swit ch ou t pu t cir cu it ca vit y of t h e 12-wa y DDM wir e swit ch or t h e fa u lt y DDM.
h a r n ess con n ect or wit h t h e ign it ion swit ch in t h e On (10) Con n ect t h e ba t t er y n ega t ive ca ble. Use t wo
posit ion . If OK, r epla ce t h e fa u lt y DDM. If n ot OK, ju m per wir es, on e con n ect ed t o a 12-volt ba t t er y feed,
r epa ir t h e open cir cu it t o t h e power win dow cir cu it a n d t h e ot h er con n ect ed t o a good body gr ou n d. See
br ea ker in t h e ju n ct ion block a s r equ ir ed. t h e P ower Mir r or Test ch a r t for t h e cor r ect ju m per
(4) If t h e pr oblem bein g dia gn osed is a n in oper a - wir e con n ect ion s a t t h e m ir r or h a lf of t h e power m ir-
t ive power m ir r or elect r ic h ea t in g gr id, pr oceed a s r or wir e h a r n ess con n ect or (F ig. 3). If t h e m ir r or
follows. If n ot , go t o St ep 7. Discon n ect a n d isola t e r ea ct ion s a r e OK, r epa ir t h e wir e h a r n ess bet ween
t h e ba t t er y n ega t ive ca ble. Un plu g t h e wir e h a r n ess t h e m ir r or a n d t h e st a n d-a lon e power m ir r or swit ch
con n ect or a t t h e in oper a t ive m ir r or a s descr ibed in or t h e DDM a s r equ ir ed. If t h e m ir r or r ea ct ion s a r e
t h is gr ou p. Ch eck for con t in u it y bet ween t h e gr ou n d n ot OK, r epla ce t h e fa u lt y power ou t side m ir r or
cir cu it ca vit y in t h e body h a lf of t h e power m ir r or a ssem bly.
wir e h a r n ess con n ect or a n d a good gr ou n d. If OK, go
t o St ep 5. If n ot OK, r epa ir t h e open cir cu it t o gr ou n d
a s r equ ir ed. REM OVAL AN D I N STALLAT I ON
(5) Con n ect 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 t o t h e On posit ion . Tu r n on t h e r ea r POWER MIRROR SWITCH
win dow defogger syst em . Ch eck for ba t t er y volt a ge a t Th is pr ocedu r e cover s r em ova l of on ly t h e st a n d-
t h e r ea r win dow defogger r ela y ou t pu t cir cu it ca vit y a lon e power m ir r or swit ch . Veh icles wit h power win -
in t h e body h a lf of t h e power m ir r or wir e h a r n ess dows a n d power locks h a ve t h e a power m ir r or
con n ect or. If OK, go t o St ep 6. If n ot OK, r epa ir t h e swit ch in t egr a l t o t h e Dr iver Door Modu le (DDM).
open cir cu it t o t h e r ea r win dow defogger r ela y a s See Door Modu le in t h is gr ou p for t h e ser vice pr oce-
r equ ir ed. du r es.
(6) Ch eck for con t in u it y bet ween t h e gr ou n d cir- (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
cu it a n d t h e r ea r win dow defogger r ela y ou t pu t cir- ca ble.
cu it ca vit ies in t h e m ir r or h a lf of t h e power m ir r or (2) Usin g a t r im st ick or a n ot h er su it a ble wide
wir e h a r n ess con n ect or. Th er e sh ou ld be con t in u it y. If fla t -bla ded t ool, gen t ly pr y t h e edge of t h e swit ch ou t
XJ POWER MIRROR SYSTEMS 8T - 3
REM OVAL AN D I N STALLAT I ON (Cont inue d)

4 5 6
000
000
3 2 1

SELECT RIGHT MIRROR


SWITCH POSITION CONTINUITY BETWEEN POWER MIRROR TEST
OFF 1 & 3, 1 & 4, 1 & 5, 1 & 6
UP 2 & 4, 1 & 3, 1 & 5, 1 & 6 12 VOLTS GROUND MIRROR REACTION
DOWN 2 & 5, 1 & 3, 1 & 4, 1 & 6
RIGHT 2 & 6, 1 & 3, 1 & 4, 1 & 5 PIN 1 PIN 4 UP
LEFT 2 & 3, 1 & 4, 1 & 5, 1 & 6
PIN 4 PIN 1 DOWN
SELECT LEFT MIRROR
SWITCH POSITION CONTINUITY BETWEEN PIN 2 PIN 3 LEFT
OFF 1 & 5, 1 & 6, 1 & 7, 1 & 8
UP 2 & 8, 1 & 5, 1 & 6, 1 & 7 PIN 3 PIN 2 RIGHT
DOWN 2 & 5, 1 & 6, 1 & 7, 1 & 8
RIGHT 2 & 6, 1 & 5, 1 & 7, 1 & 8 PIN 5
DOOR TRIM PANEL PIN 6 HEATER
CONNECTOR
FWD STAND-ALONE ROR
POWER
SWITCH
MIR-

LEFT 2 & 7, 1 & 5, 1 & 6, 1 & 8


80abfeca 80ac2c55

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)

SELECT RIGHT MIRROR


SWITCH POSITION CONTINUITY BETWEEN
UP 7 & 3, 2 &5
DOWN 2 & 3, 7 & 5
RIGHT 4 & 3, 2 &5
LEFT 2 & 3, 4 &5

SELECT LEFT MIRROR


SWITCH POSITION CONTINUITY BETWEEN
UP 1 & 3, 2 & 5
DOWN 2 & 3, 1 & 5
80abfecd
RIGHT 6 & 3, 2 &5
LEFT 2 & 3, 6 & 5 Fig. 4 Stand-Alone Power Mirror Switch Remove/
80abfecb Install
(3) P u ll t h e power m ir r or swit ch a wa y fr om t h e
Fig. 2 Driver Door Module Power Mirror Switch t r im pa n el fa r en ou gh t o a ccess t h e wir e h a r n ess con -
Continuity n ect or.
of t h e t r im pa n el t o r elea se t h e sn a p clip r et a in er s (4) Un plu g t h e power m ir r or swit ch wir e h a r n ess
(F ig. 4). con n ect or.
8T - 4 POWER MIRROR SYSTEMS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(5) Rem ove t h e power m ir r or swit ch fr om t h e veh i-
cle.
(6) Rever se t h e r em ova l pr ocedu r es t o in st a ll.

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

Fig. 6 Door Module Remove/Install


POWER MIRROR
(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) If t h e veh icle is so equ ipped, r em ove t h e m a n -
u a l win dow r egu la t or cr a n k h a n dle wit h a r em ova l
t ool (F ig. 7).
DOOR HANDLE
REMOVAL TOOL

80aafb5e

Fig. 5 Front 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
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
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
pa n el r et a in er s.

NOTE: To aid in the removal of the trim panel, start


at the bottom of the panel.

(4) Lift t h e door t r im pa n el u pwa r ds a n d a wa y


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.
Fig. 7 Window Regulator Crank Handle Remove -
(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
Typical
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 (3) Rem ove t h e scr ews t h a t secu r e t h e door t r im
in side door r em ot e con t r ols. pa n el t o t h e in n er door pa n el (F ig. 8) or (F ig. 9).
(6) Un sn a p t h e pla st ic r et a in er clips fr om t h e (4) Usin g a t r im st ick or a n ot h er su it a ble wide
in side door r em ot e con t r ol en ds of t h e la t ch r elea se 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
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 door a r ou n d t h e per im et er t o r elea se t h e t r im
t h e in side door r em ot e con t r ols. pa n el r et a in er s.
(7) Un plu g t h e wir e h a r n ess con n ect or s fr om t h e
door m odu le. NOTE: To aid in the removal of the trim panel, start
(8) Rem ove t h e fr on t door t r im pa n el fr om t h e at the bottom of the panel.
veh icle.
(5) Lift t h e door t r im pa n el u pwa r ds a n d a wa y
(9) Rem ove t h e t h r ee scr ews t h a t secu r e t h e door
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
m odu le t o t h e door t r im pa n el (F ig. 6).
t h e in n er belt wea t h er st r ip.
(10) Rem ove t h e door m odu le fr om t h e t r im pa n el.
(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
(11) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
door fa r en ou gh t o a ccess t h e in side door la t ch
Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).
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.
U-NUT
U-NUT
PUSH-IN
PUSH-INTENER
TENER
FAS-
FAS- SPACER
WINDOW
DOOR
DOOR
C
TRIM
RANK
TRIM
PANEL
PANEL SIDE VIEW
UPPERMIRROR
FRONT
SPEAKER
WIRE
DOOR
HARNESS
NESS
HAR-
WIRE SEALGROMMET
SCREW
DOOR FLAG
RETAINER
TRIMDOOR
PANEL

XJ POWER MIRROR SYSTEMS 8T - 5


REM OVAL AN D I N STALLAT I ON (Cont inue d)

DOOR
WFRONTDOOR FLAG TRIM
PANEL

__.__---~ ~" ~

UPPER SPEAKER
WIRE HARNESS - ~ " " "
Fig. 8 Front Door Trim Panel Remove/Install -
Manual Window 80abd273

Fig. 10 Front Door Flag Trim Panel Remove/Install


(12) Un plu g t h e power m ir r or wir e h a r n ess con -
n ect or.
(13) Rem ove t h e t h r ee scr ews t h a t secu r e t h e
power m ir r or t o t h e in n er door pa n el (F ig. 11).

SIDE VIEW
MIRROR
WIRE
HARNESS

Fig. 9 Front Door Trim Panel Remove/Install - Power


Window
(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 80aafb5f
t h e in side door r em ot e con t r ol.
(8) Un plu g t h e wir e h a r n ess con n ect or s fr om t h e Fig. 11 Power Mirror Remove/Install
door power swit ch m odu le or, on t h e dr iver side on ly, (14) Un sea t t h e power m ir r or wir e h a r n ess gr om -
t h e st a n d-a lon e power m ir r or swit ch . m et by pu sh in g it ou t t h r ou gh t h e h ole in t h e door
(9) Rem ove t h e fr on t door t r im pa n el fr om t h e fla g fr om t h e in side.
veh icle. (15) P u ll t h e m ir r or a n d sea l fr om t h e ou t side of
(10) Rem ove t h e on e scr ew t h a t secu r es t h e door t h e door wh ile feedin g t h e wir e h a r n ess, gr om m et ,
fla g t r im t o t h e in n er door pa n el (F ig. 10). a n d con n ect or ou t t h r ou gh t h e h ole fr om t h e in side of
(11) Usin g a t r im st ick or a n ot h er su it a ble wide t h e door.
fla t -bla ded t ool, gen t ly pr y t h e door fla g t r im a wa y (16) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
fr om t h e in n er door t o r elea se t h e t r im pa n el Tigh t en t h e m ir r or m ou n t in g scr ews t o 4.3 N·m (38
r et a in er. in . lbs.).
XJ CHIME/BUZZER WARNING SYSTEMS 8U - 1

CHIME/BUZZER WARNING SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION DIAGNOSIS AND TESTING


INTRODUCTION . . . . . . . . . . . ............. 1 DRIVER DOOR JAMB SWITCH . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION DRIVER SEAT BELT SWITCH . . . . . . . . . . . . . . 2
DRIVER DOOR JAMB SWITCH . . . . . . . . . . . . . 2 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 3
DRIVER SEAT BELT SWITCH . . . . . . . . . . . . . . 2 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 3
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2 KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . . . . 3
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . . . . 2 CHIME WARNING SYSTEM SWITCHES ...... 4

GEN ERAL I N FORM AT I ON DESCRI PT I ON AN D OPERAT I ON


INTRODUCTION INSTRUMENT CLUSTER
Th is gr ou p cover s t h e ch im e wa r n in g syst em , Th e in st r u m en t clu st er is a n elect r om ech a n ica l
wh ich is st a n da r d fa ct or y-in st a lled equ ipm en t on t h is u n it t h a t con t a in s in t egr a t ed cir cu it r y a n d in t er n a l
m odel. Th e ch im e wa r n in g syst em pr ovides a n a u di- pr ogr a m m in g t o per for m a va r iet y of fu n ct ion s. Th e
ble wa r n in g t o t h e dr iver u n der t h e followin g con di- in st r u m en t clu st er cir cu it r y m on it or s h a r d-wir ed
t ion s: swit ch in pu t s, a s well a s m essa ge in pu t s r eceived
• Dr iver side sea t belt is n ot fa st en ed wit h t h e fr om ot h er veh icle elect r on ic m odu les on t h e Ch r ysler
ign it ion swit ch in t h e On posit ion Collision Det ect ion (CCD) da t a bu s n et wor k.
• E n gin e coola n t t em per a t u r e is h igh Th e in st r u m en t clu st er u ses t h ese m a n y in pu t s
• H ea d or pa r k la m ps a r e t u r n ed on wit h t h e ign i- a lon g wit h it s in t er n a l pr ogr a m m in g a n d a n in t egr a l
t ion swit ch Off a n d t h e dr iver side fr on t door open ch im e t on e gen er a t or t o per for m t h e fu n ct ion s of t h e
• Key is in t h e ign it ion swit ch wit h t h e ign it ion ch im e wa r n in g m odu le on t h is m odel. Th e in st r u -
swit ch Off a n d t h e dr iver side fr on t door open m en t clu st er cir cu it r y a lso h a s a self-dia gn ost ic ca pa -
• Low fu el wa r n in g la m p illu m in a t ion - less t h a n bilit y. Refer t o Gr ou p 8E - In st r u m en t P a n el Syst em s
a bou t on e-eigh t h t a n k of fu el r em a in in g for m or e in for m a t ion on t h is fea t u r e.
• Over h ea d con sole t r ip com pu t er is r eset . H a r d-wir ed ch im e wa r n in g syst em in pu t s t o t h e
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor in st r u m en t clu st er in clu de t h e followin g:
com pon en t s in t h e ch im e wa r n in g syst em . Refer t o • Dr iver door ja m b swit ch
8W-40 In st r u m en t Clu st er or 8W-44 - In t er ior Ligh t - • Dr iver sea t belt swit ch
in g in Gr ou p 8W - Wir in g Dia gr a m s for com plet e cir- • H ea dla m p swit ch
cu it descr ipt ion s a n d dia gr a m s. • Key-in ign it ion swit ch .
Th e on ly in st r u m en t clu st er dia gn osis fou n d in t h is
NOTE: This group covers both Left-Hand Drive gr ou p con sist s of con fir m in g t h e via bilit y of t h e h a r d-
(LHD) and Right-Hand Drive (RHD) versions of this wir ed ch im e r equ est in pu t s t o t h e in st r u m en t clu st er
model. Whenever required and feasible, the RHD cir cu it r y. F or dia gn osis of t h e CCD da t a bu s a n d t h e
versions of affected vehicle components have been da t a bu s m essa ge in pu t s, a DRB sca n t ool a n d t h e
constructed as mirror-image of the LHD versions. pr oper Dia gn ost ic P r ocedu r es m a n u a l a r e r ecom -
While most of the illustrations used in this group m en ded.
represent only the LHD version, the diagnostic and Refer t o Gr ou p 8E - In st r u m en t P a n el Syst em s for
service procedures outlined can generally be t h e ser vice pr ocedu r es for t h e in st r u m en t clu st er.
applied to either version. Exceptions to this rule Th e in st r u m en t clu st er ch im e wa r n in g cir cu it r y a n d
have been clearly identified as LHD or RHD, if a ch im e t on e gen er a t or ca n n ot be r epa ir ed a n d, if
special illustration or procedure is required. fa u lt y, t h e in st r u m en t clu st er a ssem bly m u st be
r epla ced.
8U - 2 CHIME/BUZZER WARNING SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
DRIVER DOOR JAMB SWITCH DI AGN OSI S AN D T EST I N G
Th e dr iver door ja m b swit ch is m ou n t ed t o t h e
dr iver side fr on t door h in ge pilla r. Th e swit ch closes DRIVER DOOR JAMB SWITCH
a pa t h t o gr ou n d for t h e in st r u m en t clu st er ch im e F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
wa r n in g cir cu it r y t h r ou gh t h e key-in ign it ion swit ch 8W-40 - In st r u m en t Clu st er or 8W-44 - In t er ior
a n d/or t h e h ea dla m p swit ch wh en t h e dr iver door is Ligh t in g in Gr ou p 8W - Wir in g Dia gr a m s.
open ed, a n d open s t h e gr ou n d pa t h wh en t h e dr iver
door is closed. WARNING: ON VEHICLES EQUIPPED WITH AIR-
Th e dr iver door ja m b swit ch ca n n ot be r epa ir ed BAGS, REFER TO GROUP 8M - PASSIVE
a n d, if fa u lt y or da m a ged, it m u st be r epla ced. Refer RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
t o Gr ou p 8L - La m ps for t h e ser vice pr ocedu r es. STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
DRIVER SEAT BELT SWITCH SERVICE. FAILURE TO TAKE THE PROPER PRE-
Th e dr iver sea t belt swit ch is in t egr a l t o t h e dr iver CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
sea t belt bu ckle-h a lf a ssem bly. Th e swit ch is n or- BAG DEPLOYMENT AND POSSIBLE PERSONAL
m a lly closed, pr ovidin g a gr ou n d pa t h t o t h e in st r u - INJURY.
m en t pa n el ch im e wa r n in g cir cu it r y. Wh en t h e t ip-
h a lf of t h e sea t belt is in ser t ed in t o t h e sea t belt (1) Rot a t e t h e h ea dla m p swit ch kn ob cou n t er clock-
bu ckle, t h e swit ch open s t h e gr ou n d pa t h . wise t o en su r e t h a t t h e dom e la m ps a r e n ot swit ch ed
Th e dr iver sea t belt swit ch ca n n ot be r epa ir ed a n d, off. Open t h e dr iver door a n d n ot e wh et h er t h e in t e-
if fa u lt y or da m a ged, t h e en t ir e dr iver sea t belt bu ck- r ior la m ps ligh t . Th ey sh ou ld ligh t . If OK, see t h e
le-h a lf u n it m u st be r epla ced. Refer t o Gr ou p 23 - dia gn osis for t h e Key-In Ign it ion Swit ch or t h e H ea d-
Body for t h e ser vice pr ocedu r es. la m p Swit ch in t h is gr ou p. If n ot OK, go t o St ep 2.
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
KEY-IN IGNITION SWITCH ca ble. Un plu g t h e dr iver door ja m b swit ch fr om it s
Th e key-in ign it ion swit ch is in t egr a l t o t h e ign i- wir e h a r n ess con n ect or. Ch eck for con t in u it y bet ween
t ion swit ch , wh ich is m ou n t ed on t h e left side of t h e t h e gr ou n d cir cu it ca vit y of t h e dr iver door ja m b
st eer in g colu m n , opposit e t h e ign it ion lock cylin der. swit ch wir e h a r n ess con n ect or a n d a good gr ou n d.
It closes a pa t h t o gr ou n d for t h e in st r u m en t clu st er Th er e sh ou ld be con t in u it y. If OK, go t o St ep 3. If n ot
ch im e wa r n in g cir cu it r y wh en t h e ign it ion key is OK, r epa ir t h e cir cu it t o gr ou n d a s r equ ir ed.
in ser t ed in t h e ign it ion lock cylin der a n d t h e dr iver (3) Ch eck for con t in u it y bet ween t h e door ja m b
door ja m b swit ch is closed (dr iver door is open ). Th e swit ch gr ou n d cir cu it t er m in a l a n d t h e left fr on t door
key-in ign it ion swit ch open s t h e gr ou n d pa t h wh en ja m b swit ch sen se t er m in a l of t h e door ja m b swit ch .
t h e key is r em oved fr om t h e ign it ion lock cylin der. Th er e sh ou ld be con t in u it y wit h t h e swit ch plu n ger
Th e key-in ign it ion swit ch ca n n ot be r epa ir ed a n d, r elea sed, a n d n o con t in u it y wit h t h e swit ch plu n ger
if fa u lt y or da m a ged, t h e en t ir e ign it ion swit ch m u st depr essed. If n ot OK, r epla ce t h e fa u lt y swit ch .
be r epla ced. Refer t o Gr ou p 8D - Ign it ion Syst em s for
t h e ser vice pr ocedu r es. DRIVER SEAT BELT SWITCH
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
HEADLAMP SWITCH 8W-40 - In st r u m en t Clu st er or 8W-44 - In t er ior
Th e h ea dla m p swit ch is loca t ed in t h e in st r u m en t Ligh t in g in Gr ou p 8W - Wir in g Dia gr a m s.
pa n el, ou t boa r d of t h e st eer in g colu m n . It closes a
WARNING: ON VEHICLES EQUIPPED WITH AIR-
pa t h t o gr ou n d for t h e in st r u m en t clu st er ch im e
BAGS, REFER TO GROUP 8M - PASSIVE
wa r n in g cir cu it r y wh en t h e pa r k or h ea d la m ps a r e
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
on a n d t h e dr iver door ja m b swit ch is closed (dr iver
STEERING WHEEL, STEERING COLUMN, OR
door is open ). Th e h ea dla m p swit ch open s t h e gr ou n d
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
pa t h wh en t h e h ea dla m p swit ch is t u r n ed off.
SERVICE. FAILURE TO TAKE THE PROPER PRE-
Th e h ea dla m p swit ch ca n n ot be r epa ir ed a n d, if
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
fa u lt y or da m a ged, it m u st be r epla ced. Refer t o
BAG DEPLOYMENT AND POSSIBLE PERSONAL
Gr ou p 8E - In st r u m en t P a n el Syst em s for t h e ser vice
INJURY.
pr ocedu r es.
XJ CHIME/BUZZER WARNING SYSTEMS 8U - 3
DI AGN OSI S AN D T EST I N G (Cont inue d)
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive HEADLAMP SWITCH
ca ble. Un plu g t h e dr iver sea t belt swit ch wir e h a r- F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
n ess con n ect or on t h e floor u n der t h e dr iver sea t 8W-40 - In st r u m en t Clu st er or 8W-44 - In t er ior
n ea r t h e sea t belt bu ckle-h a lf a n ch or. Ch eck for con - Ligh t in g in Gr ou p 8W - Wir in g Dia gr a m s.
t in u it y bet ween t h e sea t belt swit ch sen se cir cu it a n d
t h e gr ou n d cir cu it ca vit ies of t h e sea t belt h a lf of t h e WARNING: ON VEHICLES EQUIPPED WITH AIR-
dr iver sea t belt swit ch wir e h a r n ess con n ect or. Th er e BAGS, REFER TO GROUP 8M - PASSIVE
sh ou ld be con t in u it y wit h t h e sea t belt u n bu ckled, RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
a n d n o con t in u it y wit h t h e sea t belt bu ckled. If OK, STEERING WHEEL, STEERING COLUMN, OR
go t o St ep 2. If n ot OK, r epla ce t h e fa u lt y sea t belt INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
bu ckle-h a lf a ssem bly. SERVICE. FAILURE TO TAKE THE PROPER PRE-
(2) Ch eck for con t in u it y bet ween t h e gr ou n d cir- CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
cu it ca vit y in t h e body h a lf of t h e dr iver sea t belt BAG DEPLOYMENT AND POSSIBLE PERSONAL
swit ch wir e h a r n ess con n ect or a n d a good gr ou n d. INJURY.
Th er e sh ou ld be con t in u it y. If OK, see t h e In st r u -
m en t Clu st er dia gn osis in t h is gr ou p. If n ot OK, (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
r epa ir t h e cir cu it t o gr ou n d a s r equ ir ed. ca ble. Rem ove t h e h ea dla m p swit ch fr om t h e in st r u -
m en t pa n el. Refer t o Gr ou p 8E - In st r u m en t P a n el
KEY-IN IGNITION SWITCH Syst em s for t h e pr ocedu r es. Un plu g t h e h ea dla m p
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o swit ch wir e h a r n ess con n ect or s. Ch eck for con t in u it y
8W-40 - In st r u m en t Clu st er or 8W-44 - In t er ior bet ween t h e left fr on t door ja m b swit ch sen se cir cu it
Ligh t in g in Gr ou p 8W - Wir in g Dia gr a m s. ca vit y of t h e h ea dla m p swit ch wir e h a r n ess con n ect or
a n d a good gr ou n d. Th er e sh ou ld be con t in u it y wit h
WARNING: ON VEHICLES EQUIPPED WITH AIR- t h e dr iver door closed, a n d n o con t in u it y wit h t h e
BAGS, REFER TO GROUP 8M - PASSIVE dr iver door open . If OK, go t o St ep 2. If n ot OK,
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY r epa ir t h e cir cu it t o t h e dr iver door ja m b swit ch a s
STEERING WHEEL, STEERING COLUMN, OR r equ ir ed.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (2) Ch eck for con t in u it y bet ween t h e key-in swit ch
SERVICE. FAILURE TO TAKE THE PROPER PRE- sen se cir cu it t er m in a l a n d t h e left fr on t door ja m b
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- swit ch sen se t er m in a l of t h e h ea dla m p swit ch . Th er e
BAG DEPLOYMENT AND POSSIBLE PERSONAL sh ou ld be n o con t in u it y wit h t h e swit ch in t h e Off
INJURY. posit ion , a n d con t in u it y wit h t h e swit ch in t h e pa r k
or h ea d la m ps On posit ion . If OK, see t h e dia gn osis
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive for t h e In st r u m en t Clu st er in t h is gr ou p. If n ot OK,
ca ble. Rem ove t h e st eer in g colu m n sh r ou ds. Refer t o r epla ce t h e fa u lt y h ea dla m p swit ch .
Gr ou p 8D - Ign it ion Syst em s for t h e pr ocedu r es.
Un plu g t h e key-in ign it ion swit ch wir e h a r n ess con - INSTRUMENT CLUSTER
n ect or fr om t h e ign it ion swit ch . Befor e per for m in g t h is t est , com plet e t h e t est in g of
(2) Ch eck for con t in u it y bet ween t h e key-in swit ch t h e h a r d-wir ed ch im e wa r n in g syst em swit ch es a s
sen se cir cu it a n d t h e left fr on t door ja m b swit ch descr ibed in t h is gr ou p. F or cir cu it descr ipt ion s a n d
sen se cir cu it t er m in a ls of t h e key-in ign it ion swit ch . dia gr a m s, r efer t o 8W-40 - In st r u m en t Clu st er or
Th er e sh ou ld be con t in u it y wit h t h e key in t h e ign i- 8W-44 - In t er ior Ligh t in g in Gr ou p 8W - Wir in g Dia -
t ion lock cylin der, a n d n o con t in u it y wit h t h e key gr a m s.
r em oved fr om t h e ign it ion lock cylin der. If OK, go t o
St ep 3. If n ot OK, r epla ce t h e fa u lt y ign it ion swit ch WARNING: ON VEHICLES EQUIPPED WITH AIR-
a ssem bly. BAGS, REFER TO GROUP 8M - PASSIVE
(3) Ch eck for con t in u it y bet ween t h e left fr on t door RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
ja m b swit ch sen se cir cu it ca vit y of t h e key-in ign it ion STEERING WHEEL, STEERING COLUMN, OR
swit ch wir e h a r n ess con n ect or a n d a good gr ou n d. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
Th er e sh ou ld be con t in u it y wit h t h e dr iver door open , SERVICE. FAILURE TO TAKE THE PROPER PRE-
a n d n o con t in u it y wit h t h e dr iver door closed. If OK, CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
see t h e dia gn osis for In st r u m en t Clu st er in t h is BAG DEPLOYMENT AND POSSIBLE PERSONAL
gr ou p. If n ot OK, r epa ir t h e cir cu it t o t h e dr iver door INJURY.
ja m b swit ch a s r equ ir ed.
(1) 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 fr om t h e
8U - 4 CHIME/BUZZER WARNING SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
in st r u m en t pa n el. Refer t o Gr ou p 8E - 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
P a n el Syst em s for t h e pr ocedu r es. dr iver sea t belt swit ch wir e h a r n ess con n ect or. Th er e
(2) Un plu g t h e h ea dla m p swit ch a n d t h e key-in sh ou ld be con t in u it y. If OK, t est t h e in st r u m en t clu s-
ign it ion swit ch wir e h a r n ess con n ect or s. Ch eck for t er a s descr ibed in Gr ou p 8E - In st r u m en t P a n el Sys-
con t in u it y bet ween t h e key-in swit ch sen se cir cu it t em s. If n ot OK, r epa ir t h e open cir cu it a s r equ ir ed.
ca vit y 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 a good gr ou n d. Th er e
sh ou ld be n o con t in u it y. If OK, go t o St ep 3. If n ot REM OVAL AN D I N STALLAT I ON
OK, r epa ir t h e sh or t cir cu it a s r equ ir ed.
(3) Ch eck for con t in u it y bet ween t h e key-in swit ch CHIME WARNING SYSTEM SWITCHES
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 Ser vice pr ocedu r es for t h e va r iou s h a r d-wir ed
wir e h a r n ess con n ect or (con n ect or B) a n d t h e h ea d- swit ch es u sed in t h e ch im e wa r n in g syst em ca n be
la m p swit ch wir e h a r n ess con n ect or. Th er e sh ou ld be fou n d in t h e pr oper gr ou p a s follows:
con t in u it y. If OK, go t o St ep 4. If n ot OK, r epa ir t h e • Dr iver door ja m b swit ch - r efer t o Gr ou p 8L -
open cir cu it a s r equ ir ed. La m ps
(4) Un plu g t h e dr iver sea t belt swit ch wir e h a r- • Dr iver sea t belt swit ch - r efer t o Gr ou p 23 -
n ess con n ect or. Ch eck for con t in u it y bet ween t h e sea t Body
belt swit ch sen se cir cu it ca vit y of t h e r igh t in st r u - • H ea dla m p swit ch - r efer t o Gr ou p 8E - 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) m en t P a n el Syst em s
a n d a good gr ou n d. Th er e sh ou ld be n o con t in u it y. If • Key-in ign it ion swit ch - r efer t o Gr ou p 8D - Ign i-
OK, go t o St ep 5. If n ot OK, r epa ir t h e sh or t cir cu it t ion Syst em s.
a s r equ ir ed.
(5) Ch eck for con t in u it y bet ween t h e sea t belt
swit ch sen se cir cu it ca vit ies of t h e r igh t in st r u m en t
XJ OVERHEAD CONSOLE SYSTEMS 8V - 1

OVERHEAD CONSOLE SYSTEMS


CON T EN T S

page page

GENERAL INFORMATION COMPASS DEMAGNETIZING . . . . . . . . . ..... 5


INTRODUCTION . . . . . . . . . . . . . . . . . . . ..... 1 COMPASS VARIATION ADJUSTMENT . . . ..... 4
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
COMPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AMBIENT TEMPERATURE SENSOR . . . . ..... 8
GARAGE DOOR OPENER STORAGE BIN . . . . . 2 GARAGE DOOR OPENER STORAGE BIN
READING AND COURTESY LAMP . . . . . . . . . . . 2 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SUNGLASSES STORAGE BIN . . . . . . . . . . . . . . 3 OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . 6
THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . 2 PUSH BUTTON MODULE . . . . . . . . . . . . . . . . . 7
TRIP COMPUTER . . . . . . . . . . . . . . . . . . . . . . . 1 READING AND COURTESY LAMP BULB . . . . . . 7
DIAGNOSIS AND TESTING SUNGLASSES STORAGE BIN . . . . . . . . . . . . . . 8
THERMOMETER . . . . . . . . . . . . . . . . . . . ..... 4 TRIP COMPUTER, COMPASS, AND
TRIP COMPUTER, COMPASS, AND THERMOMETER DISPLAY MODULE . . ..... 7
THERMOMETER DISPLAY MODULE . . ..... 3
SERVICE PROCEDURES
COMPASS CALIBRATION . . . . . . . . . . . . ..... 5

GEN ERAL I N FORM AT I ON DESCRI PT I ON AN D OPERAT I ON


INTRODUCTION TRIP COMPUTER
An over h ea d con sole fea t u r in g a m in i t r ip com - A m in i t r ip com pu t er is a va ila ble on t h is m odel t o
pu t er, a n elect r on ic com pa ss, a n d a n ou t side a m bien t pr ovide sever a l elect r on ic fu n ct ion s a n d fea t u r es. Th e
t em per a t u r e t h er m om et er a r e a va ila ble fa ct or y-in - t r ip com pu t er con t a in s a cen t r a l pr ocessin g u n it a n d
st a lled opt ion s on t h is m odel. Th e over h ea d con sole in t er fa ces wit h ot h er m odu les in t h e veh icle on t h e
a lso in clu des t wo fr on t -m ou n t ed a n d t wo r ea r- Ch r ysler Collision Det ect ion (CCD) da t a bu s n et wor k.
m ou n t ed r ea din g a n d cou r t esy la m ps, a ga r a ge door Th e CCD da t a bu s n et wor k a llows t h e sh a r in g of
open er st or a ge bin , a n d a su n gla sses st or a ge bin . sen sor in for m a t ion . Th is h elps t o r edu ce wir e h a r-
On m odels equ ipped wit h t h e Rem ot e Keyless n ess com plexit y, r edu ce in t er n a l con t r oller h a r dwa r e,
E n t r y (RKE ) opt ion , t h e over h ea d con sole a lso h ou ses a n d r edu ce com pon en t sen sor cu r r en t loa ds. At t h e
t h e RKE r eceiver. Refer t o Gr ou p 8P - P ower Lock sa m e t im e, t h is syst em pr ovides in cr ea sed r elia bilit y,
Syst em s for m or e in for m a t ion on t h is fea t u r e. en h a n ced dia gn ost ics, a n d a llows t h e a ddit ion of
F ollowin g a r e gen er a l descr ipt ion s of t h e m a jor m a n y n ew fea t u r e ca pa bilit ies.
com pon en t s u sed in t h e over h ea d con sole. Refer t o Som e of t h e fu n ct ion s a n d fea t u r es t h a t t h e t r ip
8W-49 - Over h ea d Con sole in Gr ou p 8W - Wir in g com pu t er su ppor t s a n d/or con t r ols, in clu de t h e fol-
Dia gr a m s for com plet e cir cu it descr ipt ion s a n d dia - lowin g displa y opt ion s:
gr a m s. • Com pa ss a n d t em per a t u r e
• Tr ip odom et er (ODO)
NOTE: This group covers both Left-Hand Drive • Aver a ge fu el econ om y (AVG E CO)
(LHD) and Right-Hand Drive (RHD) versions of this • In st a n t fu el econ om y (E CO)
model. Whenever required and feasible, the RHD • Dist a n ce t o em pt y (DTE )
versions of affected vehicle components have been • E la psed t im e (E T)
constructed as mirror-image of the LHD versions. • Bla n k displa y.
While most of the illustrations used in this group Mom en t a r ily depr essin g a n d r elea sin g t h e St ep
represent only the LHD version, the diagnostic and bu t t on wh en t h e ign it ion swit ch is in t h e On posit ion
service procedures outlined can generally be will ca u se t h e over h ea d con sole displa y t o st ep
applied to either version. Exceptions to this rule sequ en t ia lly t h r ou gh t h e list ed displa y opt ion s.
have been clearly identified as Mom en t a r ily depr essin g a n d r elea sin g t h e U.S./Met -
r ic bu t t on t oggles t h e displa y bet ween U.S. a n d Met -
r ic m ea su r em en t s. F or m or e in for m a t ion on t h e t r ip
8V - 2 OVERHEAD CONSOLE SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
com pu t er fea t u r es a n d fu n ct ion s, r efer t o t h e own er ’s ch a n ged fr om F a h r en h eit t o Celsiu s u sin g t h e U.S./
m a n u a l in t h e veh icle glove box. Met r ic bu t t on , loca t ed ju st r ea r wa r d of t h e displa y
Th e pu sh bu t t on (St ep a n d U.S./Met r ic) swit ch m odu le. Th e displa yed t em per a t u r e is n ot a n in st a n t
m odu le in t h e over h ea d con sole is h a r d-wir ed t o t h e r ea din g of con dit ion s, bu t a n a ver a ge t em per a t u r e. It
t r ip com pu t er. Th e com pa ss flu x-ga t e u n it is in t egr a l m a y t a ke t h e t h er m om et er displa y sever a l m in u t es
t o t h e t r ip com pu t er, com pa ss, a n d t h er m om et er dis- t o r espon d t o a m a jor t em per a t u r e ch a n ge, su ch a s
pla y m odu le u n it . Da t a in pu t for a ll ot h er t r ip com - dr ivin g ou t of a h ea t ed ga r a ge in t o win t er t em per a -
pu t er fu n ct ion s is r eceived t h r ou gh CCD da t a bu s t u r es.
m essa ges. Th e t r ip com pu t er u ses it s in t er n a l pr o- Wh en t h e ign it ion swit ch is t u r n ed t o t h e Off posi-
gr a m m in g a n d a ll of t h ese in pu t s t o ca lcu la t e a n d t ion , t h e la st displa yed t em per a t u r e r ea din g st a ys in
displa y t h e r equ est ed da t a . If t h e da t a displa yed is t h e t h er m om et er u n it m em or y. Wh en t h e ign it ion
in cor r ect , per for m t h e self-dia gn ost ic t est s a s swit ch is t u r n ed t o t h e On posit ion a ga in , t h e t h er-
descr ibed in t h is gr ou p. If t h ese t est s pr ove in con clu - m om et er will displa y t h e m em or y t em per a t u r e if t h e
sive, t h e u se of a DRB sca n t ool a n d t h e pr oper Dia g- en gin e coola n t t em per a t u r e is a bove a bou t 52° C
n ost ic P r ocedu r es m a n u a l a r e r ecom m en ded for (125° F ). If t h e en gin e coola n t t em per a t u r e is below
fu r t h er t est in g of t h e t r ip com pu t er a n d t h e CCD a bou t 52° C (125° F ), t h e t h er m om et er will displa y
da t a bu s. t h e a ct u a l t em per a t u r e sen sed by t h e a m bien t t em -
Th e t r ip com pu t er, com pa ss, a n d t h er m om et er dis- per a t u r e sen sor. Th e t h er m om et er t em per a t u r e dis-
pla y m odu le ca n n ot be r epa ir ed, a n d a r e on ly a va il- pla y u pda t e in t er va l va r ies wit h t h e veh icle speed.
a ble for ser vice a s a u n it . If fa u lt y, t h e com plet e Th e t h er m om et er fu n ct ion is su ppor t ed by a n
m odu le m u st be r epla ced. Th e pu sh bu t t on (St ep a n d a m bien t t em per a t u r e sen sor. Th e sen sor is m ou n t ed
U.S./Met r ic) swit ch m odu le is ser viced sepa r a t ely. ou t side t h e pa ssen ger com pa r t m en t n ea r t h e fr on t
a n d cen t er of t h e veh icle a n d is h a r d-wir ed t o t h e
COMPASS m odu le. Th e a m bien t t em per a t u r e sen sor is a va ila ble
Th e com pa ss will displa y t h e dir ect ion in wh ich t h e a s a sepa r a t e ser vice it em .
veh icle is poin t ed u sin g t h e eigh t m a jor com pa ss Th e t h er m om et er, com pa ss, a n d t r ip com pu t er dis-
h ea din gs (E xa m ples: n or t h is N, n or t h ea st is NE ). It pla y m odu le ca n n ot be r epa ir ed, a n d a r e on ly a va il-
does n ot displa y t h e h ea din gs in a ct u a l degr ees. a ble for ser vice a s a u n it . If fa u lt y or da m a ged, t h e
Th e self-ca libr a t in g com pa ss u n it r equ ir es n o com plet e m odu le m u st be r epla ced. Th e pu sh bu t t on
a dju st in g in n or m a l u se. Th e on ly ca libr a t ion t h a t (St ep a n d U.S./Met r ic) swit ch m odu le a n d a m bien t
m a y pr ove n ecessa r y is t o dr ive t h e veh icle in t h r ee t em per a t u r e sen sor a r e ser viced sepa r a t ely.
com plet e cir cles, on level gr ou n d, in n ot less t h a n 48
secon ds. Th is will r eor ien t t h e com pa ss u n it t o it s READING AND COURTESY LAMP
veh icle. All r ea din g a n d cou r t esy la m ps loca t ed in t h e over-
Th e com pa ss u n it a lso will com pen sa t e for m a gn e- h ea d con sole a r e a ct iva t ed by t h e door a ja r swit ch es.
t ism t h e body of t h e veh icle m a y a cqu ir e du r in g n or- Wh en t h e door s a r e closed, t h e la m ps ca n be in divid-
m a l u se. H owever, a void pla cin g a n yt h in g m a gn et ic u a lly a ct iva t ed by depr essin g t h e cor r espon din g len s.
dir ect ly on t h e r oof of t h e veh icle. Ma gn et ic m ou n t s Wh en a door is open , depr essin g t h e la m p len s
for a n a n t en n a , a r epa ir or der h a t , or a fu n er a l pr o- swit ch es will n ot t u r n t h e la m ps off. Refer t o Gr ou p
cession fla g ca n exceed t h e com pen sa t in g a bilit y of 8L - La m ps, for dia gn osis of t h e r ea din g a n d cou r t esy
t h e com pa ss u n it if pla ced on t h e r oof pa n el. Ma g- la m ps.
n et ic bit dr iver s u sed on t h e fa st en er s t h a t h old t h e Th e r ea din g a n d cou r t esy la m p len s, a n d bu lbs a r e
a ssem bly t o t h e r oof h ea der ca n a lso a ffect com pa ss a va ila ble for ser vice r epla cem en t . Th e r ea din g a n d
oper a t ion . If t h e veh icle r oof sh ou ld becom e m a gn e- cou r t esy la m p h older s a n d swit ch es a r e on ly a va il-
t ized, t h e dem a gn et izin g a n d ca libr a t ion pr ocedu r es a ble a s pa r t of t h e over h ea d con sole wir e h a r n ess. If
fou n d in t h is gr ou p m a y be r equ ir ed t o r est or e pr oper a n y r ea din g la m p swit ch is fa u lt y or da m a ged, t h e
com pa ss oper a t ion . wir e h a r n ess a n d a ll fou r swit ch es m u st be r epla ced.
Th e com pa ss, t r ip com pu t er, a n d t h er m om et er dis-
pla y m odu le ca n n ot be r epa ir ed, a n d a r e on ly a va il- GARAGE DOOR OPENER STORAGE BIN
a ble for ser vice a s a u n it . If fa u lt y, t h e com plet e A com pa r t m en t in t h e over h ea d con sole is design ed
m odu le m u st be r epla ced. Th e pu sh bu t t on (St ep a n d t o h old m ost ga r a ge door open er r em ot e con t r ol
U.S./Met r ic) swit ch m odu le is ser viced sepa r a t ely. t r a n sm it t er s. Th e t r a n sm it t er is m ou n t ed wit h in t h e
com pa r t m en t wit h a n a dh esive-ba cked h ook a n d loop
THERMOMETER fa st en er pa t ch .
Th e t h er m om et er displa ys t h e ou t side a m bien t Wit h t h e t r a n sm it t er m ou n t ed in t h e st or a ge bin ,
t em per a t u r e. Th e t em per a t u r e displa y ca n be a da pt er pegs loca t ed on t h e fr on t of t h e st or a ge bin
XJ OVERHEAD CONSOLE SYSTEMS 8V - 3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
door a r e select ed a n d m ou n t ed on a post n ea r t h e con n ect or a n d a good gr ou n d. Th er e sh ou ld be con t i-
cen t er of t h e st or a ge bin door. Th e peg(s) select ed n u it y. If OK, go t o St ep 4. If n ot OK, r epa ir t h e open
a n d/or t h e post m u st be lon g en ou gh t o depr ess t h e cir cu it t o gr ou n d a s r equ ir ed.
bu t t on of t h e t r a n sm it t er wh en t h e ga r a ge door (4) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
open er st or a ge bin door is depr essed. Th e pegs m a y ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
be st a cked, if n ecessa r y. Refer t o t h e own er ’s m a n u a l over h ea d con sole wir e h a r n ess con n ect or. If OK, go t o
in t h e veh icle glove box for m or e in for m a t ion . St ep 5. If n ot OK, r epa ir t h e open cir cu it t o t h e ju n c-
A t r a n sm it t er m ou n t in g kit in clu din g t h e a dh esive- t ion block a s r equ ir ed.
ba cked h ook a n d loop fa st en er m a t er ia l a n d a selec- (5) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
t ion of pegs is a va ila ble for ser vice. Th e ga r a ge door Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
open er st or a ge bin door a ssem bly is a lso a va ila ble for ou t pu t cir cu it ca vit y of t h e over h ea d con sole wir e
ser vice r epla cem en t . h a r n ess con n ect or. If OK, pr oceed t o t h e Self-Dia g-
n ost ic Test in t h is gr ou p for fu r t h er dia gn osis of t h e
SUNGLASSES STORAGE BIN m odu le a n d t h e CCD da t a bu s. If n ot OK, r epa ir t h e
A su n gla sses st or a ge bin is in clu ded in t h e over- open cir cu it t o t h e ju n ct ion block a s r equ ir ed.
h ea d con sole. Th e in t er ior of t h e bin is lin ed wit h a
foa m r u bber pa ddin g m a t er ia l t o pr ot ect t h e su n - SELF-DI AGN OST I C T EST
gla sses fr om bein g scr a t ch ed. Th is bin fea t u r es a A self-dia gn ost ic t est is u sed t o det er m in e t h a t t h e
pu sh /pu sh -t ype la t ch in g m ech a n ism , a n d a viscou s t r ip com pu t er, com pa ss, t h er m om et er, a n d a ll of t h e
da m pen in g syst em for a flu id open in g a ct ion . displa y m odu le segm en t s a r e oper a t in g pr oper ly elec-
Th e su n gla sses st or a ge bin door, la t ch , viscou s t r ica lly. In it ia t e t h e self-dia gn ost ic t est a s follows:
da m per, h in ge spr in g a n d h ou sin g a r e a va ila ble for (1) Wit h t h e ign it ion swit ch in t h e Off posit ion ,
ser vice on ly a s a com plet e m odu le. If a n y pa r t of t h is sim u lt a n eou sly pr ess a n d h old t h e St ep bu t t on a n d
u n it is fa u lt y or da m a ged, t h e en t ir e m odu le m u st be t h e U.S./Met r ic bu t t on .
r epla ced. (2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
(3) Con t in u e t o h old bot h bu t t on s u n t il t h e displa y
m odu le per for m s a displa y segm en t t est . In t h is t est ,
DI AGN OSI S AN D T EST I N G a ll of t h e va cu u m flu or escen t displa y segm en t s a r e
ligh t ed. Th is t est will:
TRIP COMPUTER, COMPASS, AND a . Ver ify t h a t a ll displa y segm en t s a r e fu n ct ion a l
THERMOMETER DISPLAY MODULE b. Ch eck t h e in t er n a l cir cu it r y of t h e m odu le
If t h e pr oblem wit h t h e t r ip com pu t er, com pa ss, c. Ch eck t h a t a ll of t h e CCD da t a bu s m essa ges
a n d t h er m om et er displa y m odu le is a n in a ccu r a t e or n eeded a r e bein g r eceived.
scr a m bled displa y, u se t h e Self-Dia gn ost ic Test pr oce- (4) Respon d t o t h e r espect ive t est r esu lt s a s fol-
du r es. If t h e pr oblem is in cor r ect displa y ligh t in g lev- lows. If a ll t est s a r e pa ssed, t h e m odu le will a u t om a t -
els, u se a DRB sca n t ool a n d t h e pr oper Dia gn ost ic ica lly r et u r n t o n or m a l oper a t ion .
P r ocedu r es m a n u a l t o t est for t h e cor r ect dim m in g d. In t h e displa y segm en t t est , if a n y segm en t
m essa ge in pu t s bein g r eceived fr om t h e in st r u m en t sh ou ld fa il t o ligh t t h e u n it is fa u lt y a n d m u st be
clu st er over t h e Ch r ysler Collision Det ect ion (CCD) r epla ced.
da t a bu s. If t h e pr oblem is a n o-displa y con dit ion , e. If t h e in t er n a l cir cu it r y t est is fa iled, t h e m odu le
u se t h e followin g pr ocedu r es. F or cir cu it descr ipt ion s will displa y “FAIL”. If “FAIL” is displa yed, t h e u n it is
a n d dia gr a m s, r efer t o 8W-49 - Over h ea d Con sole in fa u lt y a n d m u st be r epla ced.
Gr ou p 8W - Wir in g Dia gr a m s. f. If t h e CCD da t a bu s m essa ge t est is fa iled, t h e
(1) Ch eck t h e fu ses in t h e ju n ct ion block a n d t h e m odu le will displa y “CCD”. If “CCD” is displa yed, t h e
P ower Dist r ibu t ion Cen t er (P DC). If OK, go t o St ep u se of a DRB sca n t ool a n d t h e pr oper Dia gn ost ic
2. If n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t P r ocedu r es m a n u a l a r e r equ ir ed for fu r t h er dia gn o-
a s r equ ir ed a n d r epla ce t h e fa u lt y fu se(s). sis.
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion . (5) Mom en t a r ily depr ess a n d r elea se eit h er bu t t on
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch on e t im e t o exit t h e self-dia gn ost ic t est m ode a n d
ou t pu t fu se in t h e ju n ct ion block. If OK, go t o St ep 3. r et u r n t h e t r ip com pu t er, com pa ss, a n d t h er m om et er
If n ot OK, r epa ir t h e open cir cu it t o t h e ign it ion displa y m odu le t o n or m a l oper a t ion .
swit ch a s r equ ir ed.
(3) 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.
Rem ove t h e over h ea d con sole a s descr ibed in t h is
gr ou p. Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it ca vit ies of t h e over h ea d con sole wir e h a r n ess
8V - 4 OVERHEAD CONSOLE SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
NOTE: If the compass functions, but accuracy is Un plu g t h e a m bien t t em per a t u r e sen sor wir e h a r-
suspect, it may be necessary to perform a variation n ess con n ect or a n d t h e over h ea d con sole wir e h a r-
adjustment. This procedure allows the compass n ess con n ect or.
unit to accommodate variations in the earth’s mag- (2) Con n ect a ju m per wir e bet ween t h e t wo t er m i-
netic field strength, based on geographic location. n a ls in t h e body h a lf of t h e sen sor wir e h a r n ess con -
See the Compass Variation Adjustment procedures, n ect or.
in this group. (3) Ch eck for con t in u it y bet ween t h e sen sor r et u r n
cir cu it a n d t h e a m bien t t em per a t u r e sen sor sign a l
cir cu it ca vit ies of t h e over h ea d con sole wir e h a r n ess
NOTE: If the compass reading has blanked out, and con n ect or. Th er e sh ou ld be con t in u it y. If OK, go t o
only “CAL” appears in the display module, demag- St ep 4. If n ot OK, r epa ir t h e open cir cu it a s r equ ir ed.
netizing may be necessary to remove excessive (4) Rem ove t h e ju m per wir e fr om t h e a m bien t t em -
residual magnetic fields from the vehicle. See the per a t u r e sen sor wir e h a r n ess con n ect or. Ch eck for
Compass Demagnetizing procedure, in this group. con t in u it y bet ween t h e sen sor r et u r n cir cu it ca vit y of
t h e over h ea d con sole wir e h a r n ess con n ect or a n d a
good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go
THERMOMETER
t o St ep 5. If n ot OK, r epa ir t h e sh or t cir cu it a s
Th e t h er m om et er fu n ct ion is su ppor t ed by a a m bi-
r equ ir ed.
en t t em per a t u r e sen sor, a wir in g cir cu it , a n d a por-
(5) Ch eck for con t in u it y bet ween t h e a m bien t t em -
t ion of t h e over h ea d con sole t r ip com pu t er, com pa ss,
per a t u r e sen sor sign a l cir cu it ca vit y of t h e over h ea d
a n d t h er m om et er displa y m odu le displa y. Th e sen sor
con sole wir e h a r n ess con n ect or a n d a good gr ou n d.
is m ou n t ed ou t side t h e pa ssen ger com pa r t m en t n ea r
Th er e sh ou ld be n o con t in u it y. If OK, see t h e Tr ip
t h e fr on t a n d cen t er of t h e veh icle.
Com pu t er, Com pa ss, a n d Th er m om et er Displa y Mod-
If a

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