battery replacement JEEP CHEROKEE 1994 Service User Guide

CAUTION: Never force a belt over a pulley rim us-
ing a screwdriver as the synthetic fiber may be
damaged.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. The
engine may overheat because the water pump will
be rotating in the wrong direction if the belt is in-
stalled incorrectly. Refer to the belt routing label in
engine compartment, or see Group 7 - Belt Sche-
matics.
(10) Place serpentine belt over pulley.
(11) Belt tension adjustment is made at power
steering pump (Fig. 6).
(12) Turn adjusting bolt until belt has correct ten-
sion. See Belt Tension in Specifications.
(13) Tighten rear mounting bolts, pivot bolt, and
lock nut to 27 Nzm (20 ft. lbs.) torque.
(14) Remove support and lower vehicle.
(15) Connect negative cable to battery.
GENERATOR REPLACEMENTÐRIGHT HAND DRIVE
The generator used on the right hand drive is the
same as used on left hand drive. However, the
mounting and accessory drive belt installation are
different.
WARNING: FAILURE TO DISCONNECT NEGATIVE
CABLE FROM BATTERY BEFORE DISCONNECTING
RED (OUTPUT) WIRE CONNECTOR FROM GENER-
ATOR CAN RESULT IN INJURY.
(1) Remove negative cable from battery.
(2) Remove 2 screws holding electric cooling fan
(Fig. 8).
(3) Unplug electric cooling fan connector.
(4) Pull fan up and out of vehicle.
(5) Remove generator drive belt. See Group 7 -
Cooling System, for instructions.
(6) Remove generator mounting bolts.
(7) Position generator to gain access to all of the
wire connectors.(8) Remove B+ terminal nut, 2 field terminal
nuts, ground and harness holddown nuts (Fig. 9). Re-
move wire connector assembly.
(9) Remove generator from vehicle.
(10) To install generator, reverse the removal pro-
cedures. Refer to Group 7 for belt installation.
(11) Tighten battery cable bolts to 10-20 Nzm (90-
178 in. lbs.).
Fig. 8 Electric Cooling Fan Removal/Installation
Fig. 9 Remove or Install Connector Assembly
JBATTERY/STARTER/GENERATOR SERVICE 8B - 9

The camshaft position sensor is located in the dis-
tributor on all engines (Fig. 9).
Refer to figure 9 for an exploded view of the dis-
tributor.
(1) Disconnect the negative battery cable at bat-
tery.
(2) On XJ models equipped with A/C, remove the
electrical cooling fan and shroud assembly from the
radiator. This will provide room to turn the engine
with a socket and ratchet using the vibration damper
bolt.
(3) Scribe a mark on the distributor housing. Do
this below the left side of (past) the number one
spark plug cable post of the distributor cap. This will
be used as a reference for #1 cylinder firing position
(Fig. 14).
(4) Remove the distributor cap from distributor (2
screws).
(5) Turn the engine in a clockwise direction until
the rotor is approaching the scribe mark on the dis-
tributor housing. Then slowly turn the engine until
the timing mark on the crankshaft vibration damper
lines up with zero on the front cover timing scale
(Fig. 15).
The timing mark is on the edge of the vibra-
tion damper closest to the engine front cover.
(6) Align the trailing edge of the rotor blade with
the scribe mark on the distributor housing (Fig. 16).
(7) Remove the distributor holddown bolt and
clamp.
(8) Remove the distributor from the engine by lift-
ing straight up. Remove and discard old distributor-
to-engine block gasket. Note that the rotor willrotate slightly in a counterclockwise direction while
lifting up the distributor. Note this position after re-
moval.
INSTALLATIONÐ4.0L ENGINE
(1) Clean the distributor mounting area of the cyl-
inder block.
(2) Install a replacement distributor-to-engine
block gasket.
(3) Using a flat blade screwdriver, turn the oil
pump gear shaft. Do this until the slot is slightly
past the 11 o'clock position (Fig. 17).
Fig. 13 Distributor Rotor PositionÐ2.5L EngineFig. 14 Mark Distributor Housing
Fig. 15 Align Timing Marks
JIGNITION SYSTEMS 8D - 25

INSTRUMENT CLUSTER SERVICE PROCEDURES
INDEX
page page
Gauge ReplacementÐInstrument Cluster Removed.. 5
Gear Selector Indicator ReplacementÐInstrument
Cluster Removed........................ 6
Instrument Cluster Replacement.............. 5
Instrument Panel Replacement (Fig. 9)......... 8
Printed Circuit ReplacementÐInstrumentCluster Removed........................ 6
Speedometer ReplacementÐInstrument
Cluster Removed........................ 5
Tachometer ReplacementÐInstrument
Cluster Removed........................ 5
INSTRUMENT CLUSTER REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove 4 instrument panel bezel attaching
screws and remove instrument panel bezel. Bezel is
snap fit at locations shown (Fig. 2).
(3) Remove cigar lighter housing attaching screws
(Fig. 3).
(4) Remove switch housing attaching screws (if
equipped).
(5) Remove instrument panel cluster attaching
screws.
(6) Pull out cluster assembly far enough to discon-
nect 2 multiple plugs and remove instrument cluster.
To install cluster, reverse the removal procedures.
GAUGE REPLACEMENTÐINSTRUMENT CLUSTER
REMOVED
(1) Remove cluster lens and gauge bezel (Fig. 4). If
equipped with trip odometer, gently pull knob off trip
odometer push pin.
(2) Remove gauge attaching screws from rear of
mounting bezel. Remove gauge from front.
(3) Install gauge. Install attaching screws.
(4) Install cluster bezel and lens.
(5) Install knob on trip odometer push pin.
SPEEDOMETER REPLACEMENTÐINSTRUMENT
CLUSTER REMOVED
(1) Remove cluster lens and gauge bezel. If
equipped with trip odometer, gently pull knob off trip
odometer push pin.
(2) Remove 6 mounting screws from cluster hous-
ing.
(3) Remove 3 screws from rear of cluster housing
(Fig. 5).
(4) Remove speedometer assembly including circuit
board.
(5) Install speedometer with 3 screws.
(6) Install gauge bezel and lens.
(7) Install knob on trip odometer push pin.
TACHOMETER REPLACEMENTÐINSTRUMENT
CLUSTER REMOVED
(1) Remove cluster lens and gauge bezel. If
equipped with trip odometer, gently pull knob off trip
odometer push pin.
Fig. 2 Instrument Bezel Removal/InstallationÐXJFig. 3 Instrument Cluster Removal/InstallationÐXJ
JXJ INSTRUMENT PANEL AND GAUGES 8E - 5

INSTRUMENT PANEL REPLACEMENT (Fig. 9)
(1) Disconnect negative cable from battery.
(2) Remove:
²Parking brake release handle
²lower heat/AC duct below steering column
²ash receiver²lower instrument panel (Fig. 10)
²cluster bezel
²cluster assembly
²clock (if equipped)
²radio and heater control panel
²instrument panel switches
²headlamp switch
Fig. 8 Gear Selector Indicator
Fig. 9 Instrument Panel Exploded View
Fig. 10 Lower Instrument Panel Removal/Installation
8E - 8 XJ INSTRUMENT PANEL AND GAUGESJ

INSTRUMENT CLUSTER SERVICE PROCEDURES
INDEX
page page
Headlamp Switch/Illumination Rheostat........ 21
Indicator Bezel Replacement................ 17
Instrument Cluster Bulb Replacement......... 19
Instrument Cluster Replacement............. 17Printed Circuit Replacement................ 19
Rear Defogger/Fog Lamp/Rear Wiper Switches . . 21
Speedometer Replacement................. 17
Tachometer Replacement.................. 17
INSTRUMENT CLUSTER REPLACEMENT
(1) Remove 6 shroud screws (Fig. 1).
(2) Slide shroud toward steering wheel.
(3) Remove 3 screws holding right side switch
panel (Fig. 2).
(4) Remove 3 screws holding left side switch bezel.(5) Remove 2 screws holding cluster in place.
(6) Lift up top of cluster. Roll cluster out between
steering column and instrument panel far enough to
reach connector located behind tachometer.
(7) Disconnect cluster connector and remove clus-
ter (Fig. 3).
(8) To install cluster, reverse the removal proce-
dures.
TACHOMETER REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove instrumentation shroud (Fig. 1). Refer
to Instrument Cluster Replacement.
(3) Remove cluster as described in Instrument
Cluster replacement.
(4) Remove 3 screws and tachometer lens (Fig. 4).
(5) Gently pry up clip to release lens from bezel
(Fig. 5).
(6) Remove 3 screws from rear of housing (Fig. 6).
Remove tachometer.
(7) Install tachometer with 3 screws.
(8) Snap lens into place.
(9) Install lens with 3 screws.
(10) To install the cluster, reverse the removal pro-
cedures.
SPEEDOMETER REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove instrument shroud (Fig. 1). Refer to In-
strument Cluster Replacement.
(3) Remove cluster as described in Instrument
Cluster Replacement.
(4) Remove 3 screws and speedometer lens (Fig. 7).
(5) Gently pry up clip to release lens from bezel
(Fig. 5).
(6) Remove 3 screws from rear of housing (Fig. 8).
Remove speedometer.
(7) Install speedometer with 3 screws.
(8) Snap lens into place.
(9) Install lens with 3 screws.
(10) To install the cluster, reverse the removal pro-
cedures.
INDICATOR BEZEL REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove instrumentation shroud (Fig. 1).
(3) Remove 3 screws and tachometer lens (Fig. 4).
Fig. 2 Cluster Removal
Fig. 1 Instrument Shroud Removal/Installation
JYJ INSTRUMENT PANEL AND GAUGES 8E - 17

(4) Gently pry up clip to release lens from bezel
(Fig. 5).
(5) Remove 3 screws and speedometer lens (Fig. 7).
(6) Gently pry up clip to release lens from bezel
(Fig. 5).
(7) Remove indicator bezel (Fig. 3).
(8) Lift indicator panel off locating pins.
(9) Reverse removal procedures to install new
panel and bezel.
(10) Install speedometer and tachometer lenses.
(11) Install shroud.(12) Install negative cable to battery.INSTRUMENT CLUSTER BULB REPLACEMENT
Refer to Printed Circuit Replacement for bulb re-
placement.
PRINTED CIRCUIT REPLACEMENT
Remove cluster as described in cluster replacement.
DISASSEMBLY
(1) Remove all attaching screws for speedometer
and tachometer (Fig. 9).
Fig. 4 Tachometer Lens
Fig. 5 Cluster Lens Retaining Clip
Fig. 6 Tachometer Removal/Installation
Fig. 7 Speedometer Lens
JYJ INSTRUMENT PANEL AND GAUGES 8E - 19

XJ SERVICE PROCEDURES
RADIO REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove instrument panel bezel attaching
screws (Fig. 1) and remove the bezel.
(3) Remove radio attaching screws (Fig. 2).
(4) Disconnect radio electrical connector, ground
lead and antenna lead (Fig. 3).
(5) To install radio, route harness above and to the
right of the radio cavity. Install the radio making
sure that clip on top of radio (Fig. 4) is installed in
mating slot of dash.
(6) Reverse removal procedures to finish installing
the radio.
RADIO SPEAKERS
INSTRUMENT PANEL MOUNTED SPEAKERS
(1) Remove park brake retaining screw from lower
instrument panel (Fig. 5).
(2) Remove retaining screws and the lower instru-
ment panel (Fig. 6).
(3) Unplug wire harness connector.
Fig. 3 Disconnect/Connect Radio Wiring Harnesses
Fig. 4 Install Clip In Underside of Dash
Fig. 5 Park Brake Release Handle
Fig. 1 Instrument Bezel Removal/Installation
Fig. 2 Remove/Install Radio Mounting Screws
8F - 4 AUDIO SYSTEMSJ

INSTALLATION
(1) Connect speaker at wiring harness.
(2) Install speaker.
(3) Install trim panel by pushing in the plastic
trees.
(4) Install door panel screws.
YJ SERVICE PROCEDURES
RADIO REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove gauge cluster panel bezel attaching
screws (Fig. 1).
(3) Remove radio bezel.
(4) Remove radio attaching screws.
(5) Disconnect radio antenna cable.
(6) Disconnect radio wire harness.
(7) Remove radio.(8) To install radio, reverse the removal proce-
dures.
RADIO SPEAKERS
PASSENGER SIDE
The speaker is located behind grille panel at right
end of the instrument panel.
(1) Reach up behind instrument panel and remove
4 stamped nuts holding the speaker in place.
(2) Disconnect speaker electrical connector and re-
move speaker.
DRIVERS SIDE
The speaker is located behind grille panel at left
end of the dash panel.
(1) Remove nuts that attach the parking brake
pedal assembly mounting studs to the dash panel.
The nuts are accessible from the engine compartment
(Fig. 2).
CAUTION: If vehicle is equipped with a rear window
wiper, there is a ground wire attached to top of bolt
that attaches the pedal assembly to the instrument
panel.
Fig. 10 Trim Panel Removal
Fig. 11 Liftgate Trim Panel Removal
Fig. 12 Liftgate Speaker
Fig. 1 Gauge Cluster Bezel Removal/Installation
8F - 6 AUDIO SYSTEMSJ

HORNS
CONTENTS
page page
GENERAL INFORMATION.................. 1
HORN SWITCH (HORN PAD) REPLACEMENT . . 3
TORQUE SPECIFICATIONS................. 3XJ ..................................... 1
YJ ..................................... 2
GENERAL INFORMATION
For XJ/YJ vehicles battery voltage is applied to the
horn relay through a fuse.
When the horn switch is depressed, the horn relay
is grounded, pulling the contact closed and providing
battery voltage to the horns.
A slip ring and brush arrangement in the steering
wheel allows the switch circuit to maintain contact
while allowing rotation of the steering wheel.On XJ models, a cadmium-plated ground
screw is used to attach the horn(s) to the body.
Do not substitute other types of ground screws
as they may become corroded and cause a loss
of ground.
XJ
REPLACEMENT
(1) Raise and support the vehicle.
(2) Remove the splash shield.
(3) Remove horn mounting bolt and horn mounted
on the drivers side (Fig. 1).
(4) Remove wire from horn.
(5) To install horn, reverse the removal proce-
dures.
DIAGNOSIS AND REPAIR
Refer to Group 8W - Wiring Diagrams for a com-
plete circuit diagram.
HORN RELAY
²Inspect 25 amp, #11 fuse. Replace fuse as re-
quired.
²Depress horn switch. The relay contacts should
click. If OK, go to HORNS. If not, go to next step.
²Remove the horn relay located in the relay center.
The relay center is on the lower instrument panel
trim cover just right of the steering column (Fig. 2).
There should be 12 volts at relay connector pins 1
and 2. If not, repair open in circuit to relay.
²Depress horn switch. Measure resistance between
relay connector pin 5 and ground. The meter should
read zero ohms. If not, repair open to horn switch
ground.
²Measure resistance between relay connector pin 4
and ground. The meter should read almost zero ohms
(horn resistance) If OK, replace relay. If not, repair
open in circuit between relay and horns.
Fig. 1 Drivers Side Horn
JHORNS 8G - 1

HORN SWITCH (HORN PAD) REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove horn button by pulling straight up.
(3) Remove horn button components (Fig. 4).
(4) To install the switch, reverse the removal pro-
cedures.
(5) Connect negative cable to battery.
TORQUE SPECIFICATIONS
Fig. 4 Steering Wheel Removal/Installation
JHORNS 8G - 3