JEEP CHEROKEE 1988 Service Repair Manual

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FU EL IN JE C TIO N S YSTE M - T B I

1 988 J e ep C hero ke e
1988 Electronic Fuel Injection
JEEP/RENIX THROTTLE BODY INJECTION
2.5L Cherokee, Comanche, Wagoneer, Wrangler
DESCRIPTION
The Throttle Body Injection (TBI) system is a single
injector system that introduces fuel into throttle body from above
throttle plate. Fuel injector, located within throttle body, is
controlled by the Electronic Control Unit (ECU).
The ECU is a sealed microprocessor that receives input
signals from several sensors and other related engine components.
Based on these inputs, ECU generates output signals that control and
adjust air/fuel mixture and ignition timing as necessary for proper
engine performance.
ECU also controls engine idle speed, emission control
systems, upshift indicator light (manual transmission only), and A/C
compressor clutch.
OPERATION
ELECTRONIC CONTROL UNIT (ECU)
On Cherokee, Comanche and Wagoneer, ECU is located under
instrument panel, above accelerator pedal. On Wrangler, ECU is
located behind glove box. Input information from various engine
sensors to ECU is used to determine engine operating conditions and
needs. Battery voltage input is used to ensure that correct output
voltage is supplied by ECU during fluctuations in battery voltage.
FUEL INJECTOR
Fuel injector is mounted in throttle body so that fuel is
injected into incoming airflow. When injector solenoid is energized,
armature and plunger move upward against spring. Check ball above
injector nozzle moves off seat and opens small orifice at end of
injector.
Fuel supplied to injector is forced around ball and through
orifice, resulting in fine spray of fuel. Volume of fuel injected is
dependent only on length of time that injector is energized by ECU,
as fuel pressure is constant at injector. During cold engine starts,
extra fuel is supplied so richer mixture will aid in starting.
FUEL PRESSURE REGULATOR
Fuel pressure regulator is integral part of throttle body.
Pressure regulator has a spring chamber that is vented to same
pressure as tip of injector. Because differential pressure between
injector nozzle and spring chamber is same, only the length of time
that injector is energized controls volume of fuel injected.
Fuel pump delivers more fuel than is required by engine.
Excess fuel goes to fuel tank from pressure regulator via fuel return
hose. Fuel pressure regulator function is mechanical and ECU does not
control it.
FUEL PUMP

Electric roller type fuel pump is located in fuel tank.
Integral check valve is used to maintain pressure in fuel delivery
system after pump stops running. Fuel pump operation is controlled by
ECU through a fuel pump relay.
IDLE SPEED ACTUATOR (ISA) MOTOR
ISA motor acts as movable idle stop to change throttle stop
angle. Both engine idle speed and deceleration throttle stop angle
are set by ISA. ECU controls ISA motor by providing appropriate
voltage outputs to produce idle speed or throttle stop angle required
for engine operating condition.
OXYGEN (O2) SENSOR
Oxygen sensor is equipped with a heating element that keeps
sensor at proper operating temperature at all times. Oxygen sensor is
located in exhaust pipe.
Maintaining proper sensor temperature at all times, system
enters "Closed Loop" operation sooner and remains in "Closed Loop"
during periods of extended idle. Electrical feed to oxygen sensor is
through ignition switch.
The ECU receives sensor voltage signal which varies with
oxygen content in exhaust gas. Signal is used by ECU as reference for
setting air/fuel mixture ratio. ECU varies voltage to injector both
to compensate for battery voltage fluctuations and to change duration
of injector opening for control of air/fuel mixture.
MANIFOLD AIR/FUEL TEMPERATURE (MAT) SENSOR
MAT sensor provides a signal to ECU that changes depending
upon temperature of air/fuel mixture in intake manifold. During high
temperature conditions, ECU will compensate for changes in density of
air.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
MAP sensor measures absolute pressure in intake manifold.
Both mixture density and ambient barometric pressure are supplied to
ECU by MAP sensor. Sensor is mounted in middle of firewall in engine
compartment. Sensor receives manifold pressure information through
vacuum line from throttle body. See Fig. 1.
Fig. 1: Manifold Absolute Pressure (MAP) Sensor
Courtesy of Chrysler Motors.
COOLANT TEMPERATURE SENSOR (CTS)

Coolant temperature sensor is installed in intake manifold
water jacket to provide coolant temperature input signal for ECU.
During cold engine operation, ECU will make mixture richer, make up
for fuel condensation in cold intake manifold, increase idle speed
during warm-up period, increase ignition advance and keep EGR system
inoperative until engine warms up.
THROTTLE POSITION SENSOR (TPS)
Throttle position sensor provides ECU with input signal, up
to about 5 volts, to indicate throttle position. This allows ECU to
control air/fuel mixture according to throttle position. TPS is
mounted on throttle body assembly.
WIDE OPEN THROTTLE (WOT) SWITCH
WOT switch provides an input signal to ECU when engine is at
wide open throttle. The ECU enriches air/fuel mixture. The WOT switch
is located on the side of throttle body.
CLOSED THROTTLE (IDLE) SWITCH
Idle switch is integral with ISA motor and provides voltage
signal to ECU. ECU will signal ISA motor to change throttle stop
angle in response to engine operating conditions.
UPSHIFT INDICATOR LIGHT
On vehicles equipped with a manual transmission, ECU
controls upshift indicator light. Indicator light is normally
illuminated when ignition is turned on without engine running.
Indicator light is turned off when engine is started.
Indicator light will be illuminated during engine operation
in response to engine load and speed. If transmission is not shifted,
ECU will turn light off after 3 to 5 seconds. A switch located on
transmission prevents indicator light from being illuminated when
transmission is shifted to highest gear.
ENGINE SPEED SENSOR
Engine speed sensor is attached to bellhousing. It senses
and counts teeth on flywheel gear ring as they pass during engine
operation. Signal from speed sensor provides ECU with engine speed
and crankshaft angle. On flywheel gear ring, large trigger tooth and
notch is located 90 degrees before each TDC point. Each trigger tooth
is followed by 12 smaller teeth and notches before TDC point is
reached.
As each of 12 small teeth and notches pass magnetic core in
speed sensor, concentration and collapse of magnetic field induces
slight voltage (spike) in sensor pick-up coil winding. See Fig. 2.
Larger trigger teeth and notches induce higher voltage (spike) in
sensor pick-up coil winding. These voltage spikes enable ECU to count
teeth as they pass speed sensor.
Higher voltage spike (from larger tooth and notch) indicates
to ECU that piston will be at TDC position after 12 smaller voltage
spikes have been counted. ECU will then either advance or retard
ignition timing depending upon remaining sensor inputs.

Fig. 2: Engine Speed Sensor
Courtesy of Chrysler Motors.
A/C CONTROLS

ECU receives inputs from A/C when either A/C switch is in
"ON" position or compressor clutch engages to lower temperature. ECU
changes engine idle speed depending upon A/C compressor operation.
POWER STEERING PRESSURE SWITCH
ECU receives input from pressure switch during periods of
high pump load and low engine RPM. Input signals from pressure switch
to ECU are routed through A/C request and A/C select input circuits.
When pump pressure exceeds 250-300 psi (17.5-21.0 kg/cm
), switch
contacts close transmitting an input signal to ECU. ECU raises engine
idle speed immediately after receiving input from pressure switch.
RELAYS
Starter Motor Relay
Starter motor relay provides an input signal to ECU when
starter motor is engaged.
System Power Relay
System power relay, located on right fender inner panel, is
energized when engine is started. It remains energized for 3 to 5
seconds after ignition is off. This allows ECU to extend ISA for next
start before ECU shuts down.
Fuel Pump Control Relay
Fuel pump control relay is located on right fender inner
panel. Battery voltage is supplied to relay from ignition switch.
When ground is provided by ECU, relay becomes energized and provides
voltage to fuel pump.
A/C Compressor Clutch Relay
ECU controls A/C compressor clutch through this relay. The
A/C compressor clutch relay is located beside fuel pump control relay
on right fender inner panel.
EGR Valve/Canister Purge Solenoid
Vacuum to both EGR valve and vapor canister is controlled by
this solenoid. When solenoid is energized, neither EGR valve nor
vapor canister receive vacuum.
Solenoid is energized during closed (idle) and wide open
throttle operations, engine warm-up and rapid acceleration or
deceleration. If solenoid wire connector is disconnected, both EGR
valve and vapor canister will receive vacuum at all times.
Load Swap Relay
The load swap relay works in conjunction with power steering
switch to disengage A/C compressor clutch. If compressor clutch is
engaged when power steering pressure switch contacts close, input
signal from switch to ECU also activates load swap relay. Relay then
cuts off current to A/C compressor clutch.
The A/C compressor clutch remains disengaged until pressure
switch contacts reopen and engine idle returns to normal. The load
swap relay contains a timer that delays engaging the compressor
clutch for 0.5 second to ensure smooth engagement.
ADJUSTMENTS
CAUTION: When working on or near engine that is running, be very
careful to avoid pulleys, belts and fan. DO NOT stand in
direct line with blades of fan. DO NOT wear clothing that is
loose enough to get caught in moving parts.

IDLE SPEED ACTUATOR (ISA) MOTOR
1) Adjust ISA motor plunger to establish initial position of
plunger only if motor has been removed or replaced. Remove air filter
elbow and start engine. Run engine until engine reaches normal
operating temperature. Turn A/C off (if equipped).
2) Connect tachometer leads to diagnostic connector D1,
attaching negative lead to terminal D1-3 and positive lead to
terminal D1-1. See Fig. 4. Turn ignition off. ISA motor plunger
should move to fully extended position.
3) When ISA motor plunger is fully extended, disconnect ISA
motor wiring connector and start engine. Engine speed should be
3300-3700 RPM. If incorrect, turn hex head screw at end of plunger to
provide engine speed of 3500 RPM.
4) Fully retract ISA motor by holding closed throttle (idle)\
switch plunger inward as throttle is opened. Closed throttle switch
plunger should not touch throttle lever in closed position. If
contact is made, check linkage and/or cable for binding or damage.
Repair as necessary.
5) Connect ISA motor wiring harness connector and turn
ignition off for 10 seconds. ISA motor should move to fully extended
position. Start engine. Engine speed should be 3500 RPM for short
period of time and then decrease to normal idle speed.
6) Turn ignition off. Disconnect tachometer. After final
adjustment of ISA motor, use thread penetrating sealant (Loctite 290)
on adjustment screw to prevent movement and maintain adjustment.
NOTE: If adjustment screw must be moved after thread sealant
hardens, loosen threads by heating screw with flameless heat
such as soldering gun. DO NOT use flame or torch type of
heat as damage to ISA motor will result.
FUEL PRESSURE REGULATOR
WARNING: Always relieve residual fuel pressure in fuel delivery
system before opening system. To prevent chance of personal
injury, cover fittings with shop towel while disconnecting
fittings.
1) Replacement fuel pressure regulator must be adjusted to
establish correct pressure. Remove air filter elbow and hose. Connect
tachometer leads to diagnostic connector D1, attaching negative lead
to terminal D1-3 and positive lead to terminal D1-1. See Fig. 4.
Remove screw plug and install fuel pressure test fitting.
NOTE: Fuel pressure test fitting is not included with throttle
body. Fitting (8983 501 572) must be obtained separately.
2) Connect fuel pressure gauge to test fitting. Start engine
and increase speed to approximately 2000 RPM. Turn Torx head screw at
bottom of regulator to set correct pressure. Turning screw inward
increases pressure and turning screw outward decreases pressure. See
Fig. 3 .
3) All models require fuel pressure of 14.5 psi (1.0 kg/cm
).
Install lead sealing ball to cover regulator adjustment
screw after adjusting fuel pressure. Turn ignition off. Remove
measuring equipment and test fitting. Install original plug screw and
air filter assembly.

Fig. 3: Adjusting Fuel Pressure Regulator
Courtesy of Chrysler Motors.
THROTTLE POSITION SENSOR (TPS)
1) Turn ignition on. Check throttle position sensor input
voltage. Connect voltmeter negative lead to terminal "B" (M/T), or
terminal "D" (A/T) of sensor connector. Connect voltmeter positive
lead to terminal "C" (M/T), or terminal "A" (A/T) of sensor connecto\
r.
NOTE: On (A/T) models, connector terminals are identified by
letters molded into back of connector. On all models, do not
disconnect TPS harness connector. Insert voltmeter test
leads through back of wire harness connector. On some
models, it may be necessary to remove throttle body from
intake manifold to gain access to sensor wire harness.
2) Move and hold throttle plate at wide open throttle
position (M/T), or close throttle plate completely (A/T). Ensure
throttle linkage contacts stop. Note voltmeter reading. Input voltage
at terminals "B" and "C" (M/T), or terminals "A" and "D" (A/T) shoul\
d
be 5 volts.

3) Return throttle plate to closed throttle position (M/T),
or maintain throttle plate in closed position (A/T). Check sensor
output voltage. To do so, disconnect voltmeter positive lead from
terminal "C" and connect it to terminal "A" (top) of sensor (M/T), o\
r
from terminal "A" and connect it to terminal "B" (A/T).
4) Move and hold throttle plate in wide open throttle
position (M/T), or maintain throttle plate in closed position (A/T).\
Ensure throttle linkage contacts stop. Note voltmeter reading. Output
voltage should be 4.6-4.7 volts (M/T), or .2 volt (A/T).
5) If output voltage is incorrect, loosen bottom sensor
retaining screw and pivot sensor in adjustment slot for a coarse
adjustment. Loosen top sensor retaining screw for fine adjustments.
Tighten screws after adjustment.
TESTING & TROUBLE SHOOTING
PRELIMINARY CHECKS & PRECAUTIONS
Subsystem Checks
Before testing fuel injection system for cause of
malfunction, check that following subsystems and components are in
good operating condition:
* Battery and charging system.
* Engine state of tune.
* Emission control devices.
* Fuel system pressure and delivery volume.
* Wiring connectors at components.
General Precautions
In order to prevent injury to operator or damage to system
or component parts, use following techniques:
* Turn ignition off before connecting or disconnecting any
component parts.
* DO NOT apply DC voltage greater than 12 volts or any AC voltage
to system.
* Disconnect battery cables before charging.
* Remove ECU from vehicle if ambient temperature could exceed
176

F (80
C).
* DO NOT modify or circumvent any system functions.
RESISTANCE & VOLTAGE TESTS
MAT Sensor
1) Disconnect wiring from MAT sensor. Using high input
impedance digital volt-ohmmeter (DVOM), check resistance of sensor.
Resistance should be less than 1000 ohms when engine is warm. Replace
sensor if it does not fall within range shown in
TEMPERATURE-TO-RESISTANCE VALUES table.
2) Test resistance in wiring harness between ECU connector
terminal No. 32 and sensor connector terminal. Also test resistance
in wiring harness between ECU harness terminal No. 14 and sensor
connector terminal. See Fig. 5. Repair wiring harness if open circuit
or resistance greater than one ohm is indicated.
Coolant Temperature Sensor (CTS)
1) Disconnect wiring harness from CTS. Using high input
impedance digital volt-ohmmeter (DVOM), check resistance of sensor.
Resistance should be less than 1000 ohms when engine is warm. Replace
sensor if it does not fall within range shown in
TEMPERATURE-to-RESISTANCE VALUES table.

2) Test resistance in wiring harness between ECU harn
terminal No. 32 and sensor connector terminal. Also test resistance
in wiring harness between ECU harness terminal No. 15 and sensor
connector terminal. See Fig. 5. Repair wiring harness if open circuit
or resistance greater than one ohm is indicated.
TEMPERATURE-TO-RESISTANCE VALUES (CTS & MAT SENSOR) TABLE
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F
C Ohms
(Approximate)
212 ......................... 100 ........................... 185
160 ......................... 70 ............................ 450
100 ......................... 38 ........................... 1600
70 .......................... 20 ........................... 3400
40 ........................... 4 ........................... 7500
20 .......................... -7 ......................... 13,500
0 ........................... -18 ........................ 25,000
-40 ......................... -40 ....................... 100,700
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Throttle Position Sensor (TPS) Test
Turn ignition on. Check voltage at terminal connector
without disconnecting from TPS. Terminal "A" (M/T), or terminal "B"
(A/T ) is output voltage, which should be 4.6-4.7 volts at wide open
throttle (M/T), or .2 volt at closed throttle (A/T). Terminal "B"
(M/T), or terminal "A" (A/T) is sensor ground. Terminal "C" (M/T),\
or
terminal "D" (A/T) is input voltage, which is about 5 volts.
Closed Throttle (Idle) Switch Test
NOTE: ALL testing of idle switch must be done with ISA motor
plunger in fully extended position. If switch cannot be
tested without extending plunger, it is possible that ISA
motor has failed. See IDLE SPEED ACTUATOR MOTOR ADJUSTMENT.
1) Turn ignition on. Check idle switch voltage at diagnostic
connector D2, between terminals No. 13 and 7. See Fig. 4. At closed
throttle, voltage should be near zero volts. When switch is off
closed throttle position, voltage reading should be greater than 2
volts.
2) If voltage is always zero, test for short to ground in
harness or switch. Also check for open circuit between switch and
terminal No. 25 of ECU connector. If reading is always greater than 2
volts, check for open circuit in wiring harness between switch
connector and ECU. Also check for open between ground and switch
connector. Replace or repair wiring harness as necessary.
Manifold Absolute Pressure (MAP) Sensor Test
1) Check and repair vacuum hose connections at throttle body
and MAP sensor. Check output voltage at MAP sensor connector terminal
"B" (marked on sensor body) with ignition on, engine off. Voltage
reading should be 4-5 volts. If engine is hot and idling in Neutral,
reading should be 1.5-2.1 volts. Check voltage at terminal No. 33 of
ECU connector. Reading should be same as that at terminal "B" on MAP
sensor connector. See Fig. 4.
2) With ignition on, check MAP sensor supply voltage at
terminal "C". Reading should be 4.5-5.5 volts. Same voltage reading
should be obtained at terminal No. 16 on ECU harness connector. If
necessary, repair or replace wiring harness. Using Diagnostic Tester
(MS 1700), test ECU if necessary. Check MAP sensor ground circuit at
terminal "A" and terminal No. 17 of ECU connector. Repair wiring if
necessary.

3) Using ohmmeter, check MAP sensor ground circuit between
terminals No. 17 and 2 of ECU connector. If circuit is incomplete,
check sensor ground connection on bellhousing, near starter motor.
Replace ECU if ground is good. If terminal No. 17 is shorted to 12
volts, repair problem BEFORE ECU is replaced.
DIAGNOSTIC TOOLS
To properly test throttle body fuel injection system,
service technician must have the following equipment available:
* Digital volt-ohmmeter (DVOM) or volt-ohmmeter with minimum input
impedance of one megohm.
* 12-volt test light, jumper wires and probes.
* Hand vacuum pump with gauge.
* Ignition timing light.
Fig. 4: Jeep/Renix Fuel Injection Diagnostic Connectors
Courtesy of Chrysler Motors.
DIAGNOSTIC TESTS