ignition JEEP CHEROKEE 1994 Service Repair Manual

(33 in. lbs.) torque. Thread the hazard warning
switch knob into the switch and pull the knob out-
ward.
(38) Install and seat the upper bearing race in the
key/lock cylinder housing.
(39) Install the upper bearing preload spring, the
canceling cam and the lockplate.
(40) Install a replacement lockplate retaining snap
ring on the sleeve of the Lock Plate Compressor
C-4156 (J-23653-B). Install the tool on the steering
shaft (Fig. 24).(41) Compress the lockplate with the compressor
tool and position the retaining snap ring in the steer-
ing shaft groove.
(42) Remove the compressor tool. Ensure that the
retaining ring is completely seated in the groove be-
fore removing the tool.
(43) Position the wire harness protectors if
equipped, over the harnesses and snap in place on
steering column.
(44) Install the lockplate cover.
(45) Install the gear selector lever and the retain-
ing pin.
(46) Install the steering wheel. Refer to the instal-
lation procedure.
(47) Insert the ignition key in the key/lock cylin-
der; turn the cylinder to the OFF-UNLOCK position;
move the ignition switch downward to eliminate any
switch-to-remote rod lash; and tighten the ignition
switch attaching screws to 4 Nzm (35 in. lbs.) torque.
(48) Depress the dimmer switch slightly and insert
a 3/32-inch drill bit into the adjustment hole.
(49) Loosen the retaining screws and move the
dimmer switch toward the steering wheel. Tighten
the dimmer switch retaining screws to 4 Nzm (35 in.
lbs.) torque.
(50) Remove the drill bit and test operation by
moving the dimmer switch stalk. Test the dimmer
switch operation in the full-up, down and center
steering wheel positions.
(51) Install the steering column, if applicable. Re-
fer to the installation procedure.
CONSOLE SHIFT ASSEMBLY
(1) Position the key-release lever spring on the le-
ver and install the lever with the spring in the
shroud.
(2) Align and install the shroud on the steering
column jacket.
(3) Install the retainer plate. Tilt the plate toward
the 12 o'clock position, slide it under the steering col-
umn jacket opening, and seat it in the jacket notches.
(4) Align the steering column jacket V-notch with
the correspondingVon the support. Install the sup-
port in the steering column. To completely seat the
support, press the key-release lever downward while
pressing the support into place (Fig. 25).
(5) Install all the support retaining screws finger-
tight. Next, tighten the screws alternately and evenly
to7Nzm (60 in. lbs.) torque.
(6) Install the remote rod in the support. Route the
rod through the upper end of the shroud and insert it
into the rod slot located in the support.
(7) Install the dimmer switch and the ignition
switch.
(8) Install the steering shaft in the steering col-
umn.
Fig. 23 Key/Lock Cylinder Installation
Fig. 24 Lockplate Retaining Ring Installation
19 - 66 STEERINGJ

(9) Install replacement races and bearings in the
key/lock cylinder, if removed.Ensure that the bear-
ings are lubricated with chassis lubricant be-
fore installation.
(10) Install the lock shoes, the lock shoe springs
and the lock shoe pin the key/lock cylinder housing.
Use a 4.5-mm (0.18-in) diameter rod to align the
shoes and the pin during installation.
(11) Install the tilt-release lever, the lever spring
and the lever pin in the key/lock cylinder housing.
Insert a wedge between the housing and the lever to
relieve the spring tension. This will allow easier re-
lease lever pin installation.
(12) Install the lock bolt in the key/lock cylinder
housing and engage it in the lock sector cam surface.
(13) Install the lock rack, the rack preload spring
and a replacement shim in the key/lock cylinder
housing. The square block tooth on the lock rack and
lock sector must mate.
(14) Install the lock spring and the spring retain-
ing screw. Tighten the screw to 4 Nzm (35 in. lbs.)
torque.
(15) Align and install the assembled key/lock cylin-
der housing on the support. Retain the lock shoes in
the disengaged position for easier housing installa-
tion.
(16) Align the pivot pin holes in the key/lock cylin-
der housing with those in the support and insert the
pivot pins.Press the housing firmly downward
when inserting the pivot pins to prevent dam-
aging the holes in the support.When the pivot
pins are within both the housing and the support
holes, seat them fully with a punch and a hammer.(17) Insert the tilt-release lever in the key/lock cyl-
inder housing and place the housing in the full-up-
ward tilt position.
(18) Lubricate tilt spring guide and tilt spring lib-
erally with chassis lubricant. Then position spring on
guide.
(19) Insert the tilt spring guide and the spring into
the key/lock cylinder housing. Install the guide re-
tainer over the spring. Engage the retainer lock tabs
with the housing lugs by pressing the retainer down-
ward and turning clockwise with a screwdriver.
(20) Place the cover on the key/lock cylinder hous-
ing. Align and install the cover retaining screws.
Tighten the screws to 7 Nzm (60 in. lbs.) torque.
(21) Route the dimmer switch wire harness down
through the steering column.
(22) To install ignition switch lock, turn the key to
the LOCK position and remove the key. This will
cause the buzzer operating lever to retract in the
key/lock cylinder. Now insert the key/lock cylinder
into the housing far enough to contact the drive
shaft. Force it inward and move the ignition switch
actuator rod up and down to align the components.
When the components align, the key/lock cylinder
will move inward and the spring-loaded retainer will
snap and lock it in place (Fig. 26).
(23) Insert the ignition key in the cylinder and
turn it to the ON position. Install the key warning
buzzer switch.
(24) Install the turn signal switch. Fold the wires
against the connector. Route the wire harness and
connector down through the steering column. Posi-
tion the switch in the key/lock cylinder housing.Do
notinstall the switch retaining screws at this time.
Fig. 26 Key/Lock Cylinder
Fig. 25 Steering Column Support Installation
JSTEERING 19 - 67

(25) Install the windshield wiper wire harness and
switch. Route the wire harness down through steer-
ing column jacket.
(26) If equipped, install the cruise control wire har-
ness. Install the turn signal stalk by pushing it
straight into the column.
(27) Insert the hazard warning knob in the hazard
warning switch and press it inward. Align and install
the turn signal switch retaining screws. Ensure that
the turn signal switch is properly seated before tight-
ening the screws. Tighten the screws to 4 Nzm (33 in.
lbs.) torque. Thread the hazard warning switch knob
into the switch and pull the knob outward.
(28) Install and seat the upper bearing race in the
key/lock cylinder housing.
(29) Install the upper bearing preload spring, the
canceling cam and the lockplate.
(30) Install a replacement lockplate retaining snap
ring on the sleeve of the Lock Plate Compressor C-
4156 (J-23653-B). Install the tool on the steering
shaft (Fig. 27).
(31) Compress the lockplate with the compressor
tool and position the retaining snap ring in the steer-
ing shaft groove.
(32) Remove the compressor tool. Ensure that the
retaining ring is completely seated in the groove be-
fore removing the tool.
(33) Position the wire harness protectors, if
equipped, over the wire harnesses and snap them in
place on the steering column.
(34) Install the lockplate cover.
(35) Install the steering wheel. Refer to the instal-
lation procedure.
(36) Insert the ignition key in the key/lock cylin-
der; turn the cylinder to the OFF-UNLOCK position ;
move the ignition switch downward to eliminateany switch-to-remote rod lash; and tighten the igni-
tion switch attaching screws to 4 Nzm (35 in. lbs.)
torque.
(37) Depress the dimmer switch slightly and insert
a 3/32-inch drill bit into the adjustment hole.
(38) Loosen the retaining screws and move the
dimmer switch toward the steering wheel to remove
any lash. Tighten the dimmer switch retaining
screws to 4 Nzm (35 in. lbs.) torque.
(39) Remove the drill bit and test operation by
moving the dimmer switch stalk. Test the dimmer
switch operation in the full-up, down and center
steering wheel positions.
(40) Install the steering column and steering
wheel. Refer to the installation procedure.
(41) Connect the battery negative cable.
Fig. 27 Lockplate Retaining Ring Installation
19 - 68 STEERINGJ

(11) Confirm proper adjustment by starting engine
in Park and Neutral. Engine should start in these
positions only.If engine starts in any position
other than Park or Neutral, adjustment is incor-
rect or neutral switch is faulty.
(12) Lower vehicle and verify that steering lock op-
erates correctly.
SHIFT CABLE ADJUSTMENT (XJ)
(1) Shift transmission into Park.
(2) Raise vehicle.
(3) Release cable adjuster clamp to unlock cable
(Figs. 2 and 3). Clamp is at transmission end of ca-
ble.
(4) Unsnap cable from transmission cable bracket
(Figs. 2 and 3).
(5) Move transmission shift lever fully rearward to
Park detent. Lever is on manual valve shaft at
driver side of case.
(6) Verify positive engagement of park lock by at-
tempting to rotate propeller shaft. Shaft will not ro-
tate when park lock is engaged.
(7) Snap cable into cable bracket.
(8) Lock shift cable by pressing cable adjuster
clamp down until it snaps into place.
(9) Check engine starting. Engine should start
only in Park and Neutral.
(10) Lower vehicle.
PARK INTERLOCK CABLE ADJUSTMENT (XJ)
(1) Shift transmission into Park.
(2) Turn ignition switch to Lock position.
(3) Remove shift lever bezel and console screws.
Raise bezel and console for access to cable.
Fig. 1 Gearshift Linkage (YJ)
Fig. 2 Shift Cable (XJ)
J30RH/32RH IN-VEHICLE SERVICE 21 - 97

(4) Pull cable lock button up to release cable (Fig.
3).
(5) Pull cable forward. Then release cable and
press cable lock button down until it snaps in place.
(6) Check adjustment as follows:
(a) Check movement of release shift handle but-
ton (floor shift) or release lever (column shift). You
should not be able to press button inward or move
column lever.
(b) Turn ignition switch to On position.
(c) Press floor shift lever release button or move
column lever. Then shift into Neutral. If cable ad-
justment is correct, ignition switch can not be
turned to Lock position. Perform same check with
transmission in D range.
(7) Move shift lever back to Park and check igni-
tion switch operation. You should be able to turn
switch to Lock position and shift lever release but-
ton/lever should not move.
TRANSMISSION THROTTLE CABLE ADJUSTMENT
(XJ/YJ)
A cable is used to control throttle pressure and
kickdown on 30RH/32RH transmissions (Fig. 4).
Correct cable adjustment is important to proper op-
eration. The cable positions the throttle valve which
controls shift speed, shift quality and part throttle
downshift sensitivity. If the setting is incorrect, shiftquality and shift speeds will be unsatisfactory.
Fig. 3 Park Lock Cable Attachment (XJ)
Fig. 4 Transmission Throttle Valve (Kickdown) Cable
21 - 98 30RH/32RH IN-VEHICLE SERVICEJ

SHIFT CABLE ADJUSTMENT
(1) Shift transmission into Park.
(2) Raise vehicle.
(3) Release cable adjuster clamp to unlock cable
(Figs. 46 and 47). Clamp is at transmission end of ca-
ble.
(4) Unsnap cable from transmission cable bracket
(Figs. 46 and 47).
(5) Move transmission shift lever fully rearward to
Park detent. Lever is on manual valve shaft at driver
side of case.
(6) Verify positive engagement of park lock by at-
tempting to rotate propeller shaft. Shaft will not ro-
tate when park lock is engaged.
(7) Snap cable into cable bracket.
(8) Lock shift cable by pressing cable adjuster
clamp down until it snaps into place.
(9) Check engine starting. Engine should start only
in Park and Neutral.
(10) Lower vehicle.
PARK INTERLOCK CABLE ADJUSTMENT
(1) Shift transmission into Park.
(2) Turn ignition switch to Lock position.
(3) Remove shift lever bezel and console screws.
Raise bezel and console for access to cable.
(4) Pull cable lock button up to release cable (Fig.
47).
(5) Pull cable forward. Then release cable and
press cable lock button down until it snaps in place.
(6) Check adjustment as follows:(a) Check movement of release shift handle but-
ton (floor shift) or release lever (column shift). You
should not be able to press button inward or move
column lever.
(b) Turn ignition switch to On position.
(c) Press floor shift lever release button or move
column lever. Then shift into Neutral. If cable ad-
justment is correct, ignition switch can not be
turned to Lock position. Perform same check with
transmission in D range.
(7) Move shift lever back to Park and check igni-
tion switch operation. You should be able to turn
switch to Lock position and shift lever release button/
lever should not move.
Fig. 46 Shift Cable
Fig. 47 Park Lock Cable Attachment (XJ)
21 - 186 AW-4 IN-VEHICLE SERVICEJ

KEY LOCK CYLINDERS
The ignition switch, glove box door, front doors and
liftgate all have key lock cylinders (Fig. 6). When
lock cylinder access or replacement is necessary, re-
fer to the applicable service information source:
²Ignition SwitchÐGroup 8D,
²Instrument Panel,
²Front Doors, and
²Liftgate.
Fig. 4 XJ VIN PlateFig. 5 XJ Jack Usage & Storage Instruction Labels
Fig. 6 Ignition Switch & Glove Box Door Key Lock
Cylinders
23 - 2 BODY COMPONENTSÐXJ VEHICLESJ

BODY COMPONENTSÐYJ VEHICLES
CONTENTS
page page
ADD-A-TRUNK........................ 198
DOORS.............................. 172
EXTERIOR COMPONENTS............... 134FIXED WINDOW GLASS................ 181
GENERAL SERVICE INFORMATION........ 132
INTERIOR COMPONENTS............... 188
GENERAL SERVICE INFORMATION
LABELS/DECALS/PLATES
Most of the labels, decals and metal plates that are
affixed to YJ vehicles (Figs. 1, 2, 3, 4 and 5) contain
either safety or otherwise essential information.
Refer to the Introduction of this manual for addi-
tional information involving labels and metal plates.
INSTALLATION
Follow the instructions included with each replace-
ment label/decal/plate to affix it to a panel, compo-
nent or window glass.
KEY LOCK CYLINDERS
The ignition switch, glove box door, floor console,
metal front doors and the tailgate all have key lock
cylinders. When lock cylinder service is necessary,
refer to the applicable service information source:
²Ignition SwitchÐGroup 8D,
²Instrument Panel,
²Floor Consoles,
²Front Doors, and
²Tailgate.
Fig. 1 YJ Underhood Labels/DecalsFig. 2 YJ Interior and License Plate Holder Labels/
Decals
23 - 132 BODY COMPONENTSÐXJ VEHICLESJ

BODY COMPONENTSÐREFINISHING
CONTENTS
page page
PAINT APPLICATION................... 201SERVICE INFORMATION................ 200
SERVICE INFORMATION
SAFETY PRECAUTIONS
Protective eye shields, masks, respirators, should
be used.
For maximum protection from paint solvent vapor,
use a fresh-air type, compressor-powered respirator.
PREPARATION
Do not allow any type of open flame or other source
of vapor ignition in the painting area. Paint vapor is
highly flammable when it is concentrated.
²Paint only in a well ventilated area.
²Use a good quality, high capacity respirator.
²Use protective goggles and clothing.
²Use rubber or latex gloves when mixing paint and
other, similar liquid products.
²When not in use, keep paint containers in a pro-
tective cabinet or locker.
²Keep the paint storage area well ventilated.
TECHNICAL TERMS
SINGLE COAT
A single-coat spray pattern is applied from left-to-
right. Then, the returning right-to-left spray pattern is
applied so that it overlaps the lower one-half of the ini-
tial spray pattern. This process is repeated until a com-
plete, single-coat coverage of a body panel is obtained.
DOUBLE COAT
A double-coat spray pattern is applied from left-to-
right. Then, the returning right-to-left spray pattern
is applied.
DRYING
Drying and hardening of paint film involves three
stages of evaporation.
The first stage is referred to as dust-free stage.
The second stage is referred to as tack-free stage.
The third and final stage is referred to as hard-dry0
stage.
DE-GREASE/DE-WAX
De-greasing/de-waxing involves cleaning a panel sur-
face with either 3M All purpose cleaner, or a similar
product. This removes the surface grease, or wax.
FEATHEREDGING
Tapering and blending the edges of repaired areas
is referred to as featheredging.
FERROUS AND NON-FERROUS METAL
Iron and steel are ferrous metals. Non-ferrous
metal includes aluminum, brass, copper, magnesium
and several types of alloy metal.
FLASH TIME
The time required for most of the solvent to evap-
orate from an applied primer/paint coat.
MIST COAT
A mist coat is frequently used as the final color
coat. Mist coats are over-thinned paint that is
sprayed wet.
SURFACE PRIMER COAT
A surface primer coat must be applied over re-
paired as well as bare metal substrate. The primer
provides a bond between the metal and the color
(base) coat. Various types of surface primers and
primer/sealants are available. Surface primers are
available in either sandable or non-sandable form.
Glazing or spot putty can be applied to primer cov-
ered surfaces. The putty is used to fill the small im-
perfections that a standard primer will not to cover.
REDUCERS/THINNERS
Enamel reducers and lacquer thinners are mix-
tures of volatile liquids and are used to reduce sur-
face primers and color-coat paints. Use only the type
of reducer/thinner that is specified by the paint man-
ufacturer.Do not intermix different types of re-
ducer/thinner.
TACK RAG
Tack rags are used to wipe dust from a body panel
surface prior to primer/paint application. Dust parti-
cles will adhere to the tacky surface of the rag when
it is moved over a panel surface.
23 - 200 BODY COMPONENTSÐXJ VEHICLESJ

SERVICE DIAGNOSISÐELECTRICAL
BLOWER CONTROLSÐXJ VEHICLES
DESCRIPTION
The blower motor delivers air to the inside of the
vehicle. Its speed is controlled by the blower switch
and the blower resistors. With the switch in LO, part
of the battery voltage is supplied to the motor
through all of the resistors. The motor runs slowly.
As the blower switch is moved to a higher speed, the
switch allows more voltage to be applied to the
blower motor, which will increase its speed. When
the switch is in HI, the blower resistors are bypassed
and battery voltage is applied directly to the blower
motor. The motor runs at the fastest speed in this
mode.
DIAGNOSIS
Refer to the Group 8W, Wiring Diagrams for com-
plete system schematic.
1. BLOWER MOTOR INOPERATIVE
²Remove and inspect fuse. If the fuse is blown, re-
place fuse.
2. BLOWER MOTOR INOPERATIVE (HI Posi-
tion)
Put the ignition switch in RUN, the select switch
in HEAT and the blower switch on HI.
²Blower motor connector (Terminal A) should be
battery voltage. If not go to next step.
²Blower motor connector (Terminal B) should be 0
ohms. If not, repair wire to ground.
²Blower switch connector (Terminal C) should be
battery voltage. If battery voltage replace blower
switch. If not, replace select switch.
3. BLOWER MOTOR INOPERATIVE (LO, M1
& M2 Positions)
Ignition switch in RUN, select switch in HEAT.
²Blower resistors connector (Terminal D) should be
battery voltage. If not, replace select switch.
²Blower resistors connector (Terminal C) should be
battery voltage. If not, replace blower switch.
²Blower resistors connector (Terminal A) should be
battery voltage. If not, replace blower switch.
²Blower resistors connector (Terminal B) should be
battery voltage. If not, replace blower resistor.
AIR CONDITIONING SYSTEMÐXJ VEHICLES
DESCRIPTION
The A/C Compressor Clutch is belt-driven by the
engine. A clutch, operated by a solenoid, automati-
cally turns the compressor on and off to control evap-
orator icing.
The A/C Compressor Clutch operation is controlled
by several components: the A/C Low-Pressure
Switch, Thermostat Switch, Fuel Pump Relay, A/C
Clutch Relay and the Engine Controller.The A/C low pressure switch opens when there is
not enough refrigerant in the system. When this hap-
pens, voltage is no longer present at the Engine Con-
troller. The Engine Controller will turn off the A/C
clutch relay. With the proper refrigerant level in the
system, the low pressure switch remains closed.
When the evaporator temperature is low enough to
ice the cooling coils, the thermostat switch opens.
The Engine Controller will turn off the A/C clutch.
The thermostat switch closes when the temperature
rises. The Engine Controller will then turn the A/C
clutch relay on again.
DIAGNOSIS
Refer to the Group 8W, Wiring Diagrams for com-
plete system schematic.
With engine running, Engine Controller may delay
A/C clutch up to 30 seconds.
1. A/C COMPRESSOR CLUTCH INOPERA-
TIVE
Clutch connector disconnected.
²Jumper fused test lead, battery to clutch connec-
tor, clutch should operate. If not, replace compressor
clutch assembly.
2. A/C LOW PRESSURE SWITCH
Ignition in RUN, A/C controls in MAX or NORM.
²Low pressure switch connector (Terminal A)
should be battery voltage. If not, repair open to select
switch.
²Low pressure switch connector (Terminal C)
should be battery voltage. If not, check switch resis-
tance and check freon pressure.
3. A/C CLUTCH RELAY
Engine RUNNING, A/C controls in MAX or
NORM.
²Relay connector Pin 4 to ground should be battery
voltage. If not, check fuse F6 in Power Distribution
Center.
²Ground A/C clutch relay (Terminal 5) should have
A/C compressor clutch engagement. If not, check En-
gine Controller Terminals 27, 28 and 34.
HEATING SYSTEMÐYJ VEHICLES
DESCRIPTION
The blower motor circuit begins at a 25 amp fuse
that receives its battery feed from the ignition
switch. From the fuse the circuit extends to a micro-
switch mounted on the heater control.
The micro-switch is normally closed is operated by
a cam on the heater control lever. In all heater con-
trol lever positions, except OFF and VENT, the
blower motor electrical circuit is complete. In the
OFF and VENT positions the cam depresses the mi-
cro-switch lever opening the electrical circuit to the
blower motor.
24 - 14 HEATING AND AIR CONDITIONINGJ