battery JEEP CHEROKEE 1994 Service Owner's Guide

DIAGNOSTIC TROUBLE CODE DESCRIPTIONSÐCONTINUED
Diagnostic
Trouble
CodeDRB Scan Tool
DisplayDescription of Diagnostic Trouble Code
41**..........Generator Field Not
Switching ProperlyAn open or shorted condition detected in the generator field control circuit.
42* ..........Auto Shutdown Relay
Control CircuitAn open or shorted condition detected in the auto shutdown relay circuit.
44* ..........Battery Temp Sensor
Volts out of LimitAn open or shorted condition exists in the engine coolant temperature sensor
circuit or a problem exists in the PCM's battery temperature voltage circuit.
46**..........Charging System Voltage
Too HighBattery voltage sense input above target charging voltage during engine
operation.
47**..........Charging System Voltage
Too LowBattery voltage sense input below target charging during engine operation.
Also, no significant change detected in battery voltage during active test of
generator output.
51**.......... O2SSignal Stays Below
Center (Lean)Oxygen sensor signal input indicates lean air/fuel ratio condition during
engine operation.
52**.......... O2SSignal Stays Above
Center (Rich)Oxygen sensor signal input indicates rich air/fuel ratio condition during
engine operation.
53* ..........Internal PCM Failure PCM Internal fault condition detected.
or
PCM Failure SPI
CommunicationsPCM Internal fault condition detected.
54* .......... NoCamSync Signal at
PCMNo fuel sync (camshaft signal) detected during engine cranking.
55* .......... N/ACompletion of diagnostic trouble code display on the Malfunction Indicator
Lamp (Check Engine Lamp).
62* .......... PCMFailure SPI miles not
storedUnsuccessful attempt to update SPI miles in the PCM EEPROM.
63* .......... PCMFailure EEPROM
Write DeniedUnsuccessful attempt to write to an EEPROM location by the PCM.
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as
described in manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
JFUEL SYSTEM 14 - 53

INSTALLATION
(1) Install the fuel injector(s) into the fuel rail as-
sembly and install retaining clip(s).
(2) Install fuel rail. Refer to Fuel Rail Installation
in this section.
(3) Start engine and check for fuel leaks.
FUEL PUMP MODULE
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
FUEL PUMP RELAY
The Fuel Pump relay is located in the Power Dis-
tribution Center (PDC) (Figs. 1 or 2). For location of
this relay within the PDC, refer to label on PDC
cover.
FUEL RAIL ASSEMBLY
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE (EVEN WITH THE ENGINE
OFF) OF APPROXIMATELY 131-269 KPA (19-39
PSI). THIS PRESSURE MUST BE RELEASED BE-
FORE SERVICING THE FUEL RAIL.
(1) Remove fuel tank filler tube cap.
(2) Disconnect the negative battery cable from bat-
tery.
(3) Perform the Fuel System Pressure Release Pro-
cedure as described in the Fuel Delivery System sec-
tion of this Group.
(4) Remove and numerically attach a tag (if fuel
injector is not already tagged), the injector harness
connectors. Do this at each injector (Fig. 7).
(5) Disconnect vacuum line from fuel pressure reg-
ulator (Fig. 7).
(6) Disconnect fuel supply line from fuel rail and
the fuel return line from fuel pressure regulator (Fig.7). Refer to Fuel Tubes/Lines/Hoses and Clamps, or
Quick-Connect Fittings. These can both be found in
the Fuel Delivery section of this group.
(7) Remove fuel rail mounting bolts.
On models with automatic transmissions, it may be
necessary to remove automatic transmission throttle
line pressure cable (and bracket). This will aid in fuel
rail assembly removal.
(8) Remove fuel rail by gently rocking until all the
fuel injectors are out of the intake manifold.
INSTALLATION
(1) Position tips of all fuel injectors into the corre-
sponding injector bore in the intake manifold. Seat
injectors into manifold.
(2) Tighten fuel rail mounting bolts to 27 Nzm (20
ft. lbs.) torque.
(3) Connect injector harness connectors to appro-
priate (tagged) injector.
(4) Connect both fuel lines to fuel rail.
(5) Connect vacuum supply line to fuel pressure
regulator.
(6) Install protective cap to pressure test port fit-
ting.
(7) Install fuel tank cap.
(8) Connect negative battery cable to battery.
(9) Start engine and check for fuel leaks.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF)
OF APPROXIMATELY 100 KPA (14.5 PSI). BEFORE
SERVICING THE FUEL PUMP, FUEL LINES, FUEL
FILTER OR FUEL INJECTOR, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
Refer to the Fuel Delivery System section of this
group. See Fuel Pressure Release procedure.
FUEL TANKS
Refer to the Fuel Tank section of this group for re-
moval/installation procedures.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
Refer to the Fuel Tank section of this group for re-
moval/installation procedures.
FUEL TUBES/LINES/HOSES AND CLAMPS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures. Also refer
to Quick-Connect Fittings in the Fuel Delivery sec-
tion of this group.
IDLE AIR CONTROL (IAC) MOTOR
The IAC motor is mounted to the throttle body ad-
jacent to the throttle position sensor (Fig. 8).
Fig. 7 Fuel Injector HarnessÐTypical
14 - 56 FUEL SYSTEMJ

(3) Lower the vehicle.
PARK NEUTRAL SWITCH
Refer to Group 21, Transmissions for park neutral
switch service.
POWER STEERING PRESSURE SWITCHÐ2.5L
ENGINE ONLY
The power steering pressure switch is installed in
the power steering high pressure hose (Figs. 11 or
12).
REMOVAL
(1) Disconnect the electrical connector from the
power steering pressure switch.
(2) Place a small container or shop towel beneath
the switch to collect any excess fluid.
(3) Remove the switch.
INSTALLATION
(1) Install the power steering switch.
(2) Connect the electrical connector to the switch.(3) Check power steering fluid and add as neces-
sary.
(4) Start the engine and again check power steer-
ing fluid. Add fluid if necessary.
POWERTRAIN CONTROL MODULE (PCM)
On XJ models, the PCM is located in the engine
compartment next to the air cleaner (Fig. 13). On YJ
models, the PCM is located in the engine compart-
ment behind the windshield washer fluid reservoir
(Fig. 14).
REMOVAL
(1) Disconnect the negative battery cable at the
battery.
(2) YJ Models Only: Remove the windshield
washer fluid tank.
(3) Loosen the 60-Way connector mounting bolt
(Figs. 13 or 14).
(4) Remove the electrical connector by pulling
straight back.
(5) Remove the three PCM mounting bolts.
(6) Remove PCM.
Fig. 11 Power Steering Pressure SwitchÐYJ Models
Fig. 12 Power Steering Pressure SwitchÐXJ Models
Fig. 13 PCM LocationÐXJ Models
Fig. 14 PCM LocationÐYJ Models
14 - 58 FUEL SYSTEMJ

INSTALLATION
(1) After the PCM electrical connector has been
separated from the PCM, inspect the pins for corro-
sion, being spread apart, bent or misaligned. Also in-
spect the pin heights in the connector. If the pin
heights are different, this would indicate a pin has
separated from the connector. Repair as necessary.
(2) Install PCM. Tighten three mounting bolts to 1
Nzm (9 in. lbs.) torque.
(3) Engage 60-way connector into PCM. Tighten
connector mounting bolt to 4 Nzm (35 in. lbs.) torque.
(4) YJ Models: Install windshield washer fluid
tank.
(5) Connect negative cable to battery.
QUICK-CONNECT FITTINGS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
THROTTLE BODY
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect air cleaner hose from throttle body.
(3) Disconnect idle air control motor and throttle
position sensor wire connectors.
(4) Disconnect accelerator cable, throttle cable (au-
tomatic transmission) and speed control cable (if
equipped) from throttle arm (Fig. 15).
(5) Remove throttle body mounting bolts, throttle
body and gasket. Discard old gasket (Fig. 16).
INSTALLATION
(1) Install throttle body and new gasket. Tighten
throttle body mounting bolts to 12 Nzm (9 ft. lbs.)
torque.
(2) Connect idle air control motor and throttle po-
sition sensor wire connectors.
(3) Connect throttle linkage to throttle arm.CAUTION: When the automatic transmission throttle
cable is connected, it MUST be adjusted.
(4) If equipped with an automatic transmission,
connect and adjust the transmission line pressure ca-
ble. Refer to Group 21, Transmissions for adjustment
procedure.
(5) Install air cleaner hose to throttle body.
(6) Connect negative battery cable to battery.
THROTTLE POSITION SENSOR (TPS)
The TPS is mounted to the throttle body (Figs. 17
or 18).
REMOVAL
(1) Disconnect TPS electrical connector.
(2) Remove TPS mounting bolts.
(3) Remove TPS.
INSTALLATION
The throttle shaft end of the throttle body slides
into a socket in the TPS (Fig. 19). The TPS must be
installed so that it can be rotated a few degrees. (If
Fig. 16 Throttle
BodyÐRemoval/InstallationÐTypical
Fig. 17 TPS LocationÐ2.5L Engine
Fig. 15 Cables at Throttle Body
JFUEL SYSTEM 14 - 59

4). The engine intake manifold serves as the vacuum
source for booster operation.
The booster is mounted on the engine compartment
side of the dash panel. The master cylinder is
mounted on attaching studs at the front of the
booster. The master cylinder central valves are di-
rectly actuated by the booster push rod.
The pedal travel sensor is mounted in the forward
face of the booster shell. The sensor plunger is actu-
ated by the booster diaphragm plate.
PEDAL TRAVEL SENSOR
The pedal travel sensor signals brake pedal posi-
tion to the antilock ECU. The sensor signal is based
on changes in electrical resistance. The resistance
changes occur in steps that are generated by changes
in brake pedal position. A resistance signal gener-
ated by changing brake pedal position, will cause the
ECU to run the antilock pump when necessary.
The sensor is a plunger-type, electrical switch
mounted in the forward housing of the power brake
booster (Fig. 5). The sensor plunger is actuated by
movement of the booster diaphragm plate.
The tip on the sensor plunger is color coded. The
tip must be matched to the color dot on the face of
the brake booster front shell (Fig. 5).
WHEEL SPEED SENSORS
A sensor is used at each wheel. The sensors convert
wheel speed into an electrical signal. This signal is trans-
mitted to the antilock electronic control unit (ECU).
A gear-type tone ring serves as the trigger mecha-
nism for each sensor. The tone rings are mounted at
the outboard ends of the front and rear axle shafts.
Different sensors are used at the front and rear
wheels (Fig. 6). The front/rear sensors have the same
electrical values but are not interchangeable.
ELECTRONIC CONTROL UNIT (ECU)
A separate electronic control unit (ECU) monitors,
operates and controls the antilock system (Fig. 7).
The ECU contains dual microprocessors. The logic
block in each microprocessor receives identical sensor
signals. These signals are processed and compared si-
multaneously (Fig. 8).
The ECU is located under the instrument panel. It
is located at the right side of the steering column.
The power up voltage source for the ECU is through
the ignition switch in the On and Run positions.
The antilock ECU is separate from the other vehi-
cle electronic control units. It contains a self check
program that illuminates the amber warning light
when a system fault is detected. Faults are stored in
a diagnostic program memory and are accessible
with the DRB II scan tool.
ABS faults remain in memory until cleared, or until af-
ter the vehicle is started approximately 50 times. Stored
faults arenoterased if the battery is disconnected.
ACCELERATION SWITCH
An acceleration switch (Fig. 9), provides an addi-
tional vehicle deceleration reference during 4-wheel
drive operation. The switch is monitored by the anti-
lock ECU at all times.
The switch reference signal is utilized by the ECU
when all wheels are decelerating at the same speed.
Equal wheel speeds occur during braking in undiffer-
entiated 4-wheel ranges.
Fig. 5 Pedal Travel Sensor Location
Fig. 6 Wheel Speed Sensors
JBRAKES 5 - 41

ANTILOCK BRAKE SYSTEM OPERATION
INDEX
page page
ABS Operation in Antilock Braking Mode....... 43
ABS Operation in Normal Braking Mode....... 43
Acceleration Switch Operation............... 45
ECY Operation.......................... 46HCU Pump and Pedal Travel Sensor Operation . 44
HCU Solenoid Valve Operation.............. 43
System Power-Up and Initialization........... 43
Wheel Speed Sensor Operation............. 45
SYSTEM POWER-UP AND INITIALIZATION
The antilock system is in standby mode with the
ignition switch in Off or Accessory position. The an-
tilock electrical components are not operational.
Turning the ignition switch to On or Run position
allows battery voltage to flow through the switch to
the ECU ignition terminal.
The ABS system is activated when battery voltage
is supplied to the ECU. The ECU performs a system
initialization procedure at this point. Initialization
consists of a static and dynamic self check of system
electrical components.
The static check occurs immediately after the igni-
tion switch is turned to the On position. The dynamic
check occurs when vehicle road speed reaches ap-
proximately 10 kph (6 mph). During the dynamic
check, the ECU briefly cycles the pump to verify op-
eration. The HCU solenoids are checked continu-
ously.
If an ABS component exhibits a fault during ini-
tialization, the ECU illuminates the amber warning
light and registers a fault code in the microprocessor
memory.
ABS OPERATION IN NORMAL BRAKING MODE
The ECU monitors wheel speed sensor inputs con-
tinuously while the vehicle is in motion. However,
the ECU will not activate any ABS components as
long as sensor inputs and the acceleration switch in-
dicate normal braking.
During normal braking, the master cylinder, power
booster and wheel brake units all function as they
would in a vehicle without ABS. The HCU compo-
nents are not activated.
ABS OPERATION IN ANTILOCK BRAKING MODE
The purpose of the antilock system is to prevent
wheel lockup during periods of high wheel slip. Pre-
venting lockup helps maintain vehicle braking action
and steering control.
The antilock ECU activates the system whenever
sensor signals indicate periods of high wheel slip.
High wheel slip can be described as the point where
wheel rotation begins approaching zero (or lockup)
during braking. Periods of high wheel slip occur
when brake stops involve high pedal pressure and
rate of vehicle deceleration.The antilock system retards lockup during high
slip conditions by modulating fluid apply pressure to
the wheel brake units.
Brake fluid apply pressure is modulated according
to wheel speed, degree of slip and rate of decelera-
tion. A sensor at each wheel converts wheel speed
into electrical signals. These signals are transmitted
to the ECU for processing and determination of
wheel slip and deceleration rate.
The Jeep ABS system has three fluid pressure con-
trol channels. The front brakes are controlled sepa-
rately and the rear brakes in tandem (Fig. 10). A
speed sensor input signal indicating high slip condi-
tions activates the ECU antilock program.
Two solenoid valves are used in each antilock con-
trol channel (Fig. 11). The valves are all located
within the HCU valve body and work in pairs to ei-
ther increase, hold, or decrease apply pressure as
needed in the individual control channels.
The solenoid valves are not static during antilock
braking. They are cycled continuously to modulate
pressure. Solenoid cycle time in antilock mode can be
measured in milliseconds.
HCU SOLENOID VALVE OPERATION
Normal Braking
During normal braking, the HCU solenoid valves
and pump are not activated. The master cylinder and
power booster operate the same as a vehicle without
an ABS brake system.
Antilock Pressure Modulation
Solenoid valve pressure modulation occurs in three
stages which are: pressure increase, pressure hold,
and pressure decrease. The valves are all contained
in the valve body portion of the HCU.
Pressure Decrease
The outlet valve is opened and the inlet valve is
closed during the pressure decrease cycle (Fig. 11).
A pressure decrease cycle is initiated when speed
sensor signals indicate high wheel slip at one or
more wheels. At this point, the ECU opens the outlet
valve. Opening the outlet valve also opens the hy-
draulic return circuit to the master cylinder reser-
JANTILOCK BRAKE SYSTEM OPERATION 5 - 43

ECU REPLACEMENTÐXJ
ECU Removal
(1) Turn ignition key to Off position.
(2) Remove screws attaching ECU to mounting
bracket (Fig. 12).
(3) Disconnect ECU wiring harness.
(4) Remove ECU.
ECU Installation
(1) If new ECU is being installed, transfer mount-
ing bracket to new ECU.
(2) Tighten ECU-to-mounting bracket screws to
8-13 Nzm (75-115 in. lbs.) torque.
(3) Connect wire harness to ECU.
(4) Position and install ECU.
(5) Tighten ECU attaching nuts to 10-14 Nzm (85-
125 in. lbs.) torque.
ECU REPLACEMENTÐYJ
The antilock electronic control unit (ECU) is attached
to the dash panel inside the passenger compartment. It
is positioned just above the heater/air conditioning ple-
num housing, in line with the glove box (Fig. 13).
The ECU is attached to the dash panel by bolts
and nuts that are accessible from the engine com-
partment. The fasteners are located just to the right
of the battery.
On models with air conditioning, it will be neces-
sary to remove the air conditioning fascia panel and
ducts for access to the ECU and harness connecter.
HCU REMOVALÐXJ
(1) Remove air cleaner.
(2) Remove clamp that secures air cleaner hose
and pipe to fender apron (Fig. 14).(3) Position suitable size fluid drain container un-
der master cylinder reservoir hoses. Disconnect reser-
voir hoses from HCU and drain fluid into container.
Discard old fluid and remove reservoir.
(4) Disconnect pump motor and solenoid harness
wires at HCU (Fig. 15).
Fig. 12 Antilock ECU Mounting (XJ)
Fig. 13 ECU Location (YJ)
Fig. 14 Air Cleaner And Harness Connector Location (XJ)
Fig. 15 HCU Wire Harness Connections
JABS COMPONENT SERVICE 5 - 53

DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM THE COOL-
ANT CAN OCCUR.
(1) Drain sufficient coolant from the radiator to de-
crease the level below the water pump heater hose
inlet.
(2) Remove the heater hose.
(3) Inspect the inlet for metal casting flash or
other restrictions.
Remove the pump from engine before remov-
ing restriction to prevent contamination of the
coolant with debris. Refer to Water Pump Re-
moval.
WATER PUMPSÐREMOVAL/INSTALLATION
REMOVALÐALL MODELS
The water pump on all models can be removed
without discharging the air conditioning system (if
equipped).
CAUTION: All engines have a reverse (counter-
clockwise) rotating water pump. The letter R is
stamped into the back of the water pump impeller
(Fig. 1) to identify. Engines from previous model
years, depending upon application, may be
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump will
cause engine over heating.The water pump impeller is pressed on the rear of
the pump shaft and bearing assembly. The water
pump is serviced only as a complete assembly.
WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
DO NOT WASTE reusable coolant. If the solution
is clean, drain coolant into a clean container for re-
use.
(1) Disconnect negative battery cable at battery.
(2) Drain the cooling system. Refer to Draining
Cooling System in this group.
(3)XJ models with 4.0L engine equipped with
A/C or heavy duty cooling system:
Loosen (but do not remove at this time) the four
water pump pulley-to-water pump hub mounting
bolts (Fig. 3).
XJ models with 4.0L engine without A/C or
heavy duty cooling system; or any 2.5L engines;
or any YJ models:
Loosen (but do not remove at this time) the four
fan hub-to-water pump pulley mounting nuts (Fig.
4).
The engine accessory drive belt must be removed
prior to removing the fan (if installed at pump) or
fan pulley.
(4) Remove engine drive belt as follows:
(a) Loosen two rear power steering pump mount-
ing bolts A (Fig. 5).
(b) Loosen upper pump pivot bolt B and lower
lock nut C (Figs. 6 or 7).
(c) Loosen pump adjusting bolt D (Fig. 5) until
belt can be removed.
(d) Remove belt.
(5) Check condition of all pulleys.
(6) The power steering pump must be removed
from its cast mounting bracket to gain access to bolt
Fig. 2 Impeller TestÐTypical
Fig. 3 Water Pump Pulley Bolts
7 - 10 COOLING SYSTEMJ

(14) Tighten pivot bolt B (Fig. 6) to 27 Nzm (20 ft.
lbs.) torque.
(15) Tighten locknut C (Fig. 6) to 27 Nzm (20 ft.
lbs.) torque.
(16) After the power steering pump has been tight-
ened, recheck belt tension.
(17) Fill cooling system with coolant and check for
leaks. Refer to Refilling Cooling System in this
group.
(18) Connect battery cable to battery.
(19) Start and warm the engine. Check for leaks.
THERMOSTAT
DESCRIPTION AND OPERATION
A pellet-type thermostat controls the operating
temperature of the engine by controlling the amount
of coolant flow to the radiator. On all engines the
thermostat is closed below 195ÉF (90ÉC). Above this
temperature, coolant is allowed to flow to the radia-
tor. This provides quick engine warmup and overall
temperature control.
An arrow plus the wordUPis stamped on the
front flange next to the air bleed. The wordsTO
RADare stamped on one arm of the thermostat.
They indicate the proper installed position.
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes other prob-
lems. These are: longer engine warmup time, unreli-
able warmup performance, increased exhaust
emissions and crankcase condensation. This conden-
sation can result in sludge formation.
Fig. 10 YJ Models with 4.0L Engine and XJ Models
with 2.5L EngineÐWith A/C
Fig. 11 YJ Models With 2.5L or 4.0L Engine and XJ
Models with 2.5L EngineÐWithout A/C
Fig. 12 XJ Models with 4.0L EngineÐWithout A/C
Fig. 13 XJ Models With 4.0L EngineÐWith A/C
JCOOLING SYSTEM 7 - 13

RADIATORS
GENERAL INFORMATION
All radiators are down flow types except XJ models
with 4.0L engines. Radiators in XJ models equipped
with the 4.0L six-cylinder engine, are the cross flow
type. Plastic tanks are used on all radiators.
CAUTION: Plastic tanks, while stronger than brass,
are subject to damage by impact, such as
wrenches.
If plastic tank has been damaged, plastic tank
and/or O-rings are available for service repair. Tank
replacement should be done by qualified personal
with proper equipment.
RADIATOR COOLANT FLOW CHECK
The following procedure will determine if coolant is
flowing through the cooling system.
If engine is cold, idle engine until normal operating
temperature is reached. Then feel the upper radiator
hose. If hose is hot, the thermostat is open and water
is circulating through cooling system.
RADIATOR REMOVAL/INSTALLATION
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS, RADIATOR CAP, OR
LOOSEN THE RADIATOR DRAINCOCK WITH THE
SYSTEM HOT AND PRESSURIZED. SERIOUS
BURNS FROM THE COOLANT CAN OCCUR.
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
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 (NUM-
BER 6094) (FIG. 26). SNAP-ON CLAMP TOOL (NUM-
BER HPC-20) MAY BE USED FOR LARGER
CLAMPS. ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
XJ MODELS WITH 2.5L ENGINE
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Observe the previousWARNINGS.Remove ra-
diator cap.(3) Position drain pan under draincock. Open radi-
ator draincock. Drain radiator.
(4) Remove radiator upper and lower hose clamps
and hoses.
(5) Remove alignment dowel E-clip from radiator
lower mounting bracket (Fig. 27).
(6) Disconnect coolant reserve/overflow tank hose
from radiator.
(7) Remove radiator fan shroud mounting bolts
(Fig. 28). Push shroud back against front of engine.
(8) If equipped, disconnect and plug automatic
transmission fluid cooler lines.
(9) Remove radiator top mounting bolts (Fig. 28).
(10) Remove the radiator grille mounting screws.
Remove grille (Fig. 29).
(11) Remove the air conditioning condenser-to-ra-
diator mounting bolt. Use an open end wrench to re-
Fig. 26 Hose Clamp ToolÐTypical
Fig. 27 Radiator Remove/InstallÐXJ ModelsÐ2.5L
Engine
7 - 22 COOLING SYSTEMJ