air condition JEEP CHEROKEE 1994 Service Service Manual

(8) Install and tighten caliper mounting bolts to
10-20 Nzm (7-15 ft. lbs.) torque.
CAUTION: If new caliper bolts are being installed,
or if the original reason for repair was a drag/pull
condition, check caliper bolt length before proceed-
ing. If the bolts have a shank length greater than
67.6 mm (2.66 in.), they will contact the inboard
brakeshoe causing a partial apply condition. Refer
to Figure 14 for required caliper bolt length.
(9) Install wheels. Tighten lug nuts to 102 Nzm (75
ft. lbs.) torque.
(10) Pump brake pedal until caliper pistons and
brakeshoes are seated.
(11) Top off brake fluid level if necessary. Use Mo-
par brake fluid or equivalent meeting SAE J1703
and DOT 3 standards only.
CALIPER REMOVAL
(1) Raise vehicle and remove front wheels.
(2) Remove caliper mounting bolts (Fig. 4).(3) Rotate caliper rearward by hand or with pry
tool (Fig. 5). Then rotate caliper and brakeshoes off
mounting ledges.
(4) Remove caliper hose fitting bolt and disconnect
front brake hose at caliper. Discard fitting bolt wash-
ers. They are not reusable and should be replaced.
(5) Remove caliper from vehicle.
CALIPER DISASSEMBLY
(1) Remove brakeshoes from caliper.
(2) Pad interior of caliper with minimum, 2.54 cm
(1 in.) thickness of shop towels or rags (Fig. 15). Tow-
els are needed to protect caliper piston during re-
moval.
(3) Remove caliper piston withshort burstsof low
pressure compressed air. Direct air through fluid in-
let port and ease piston out of bore (Fig. 16).
Fig. 11 Installing Inboard Brakeshoe
Fig. 12 Installing Outboard Brakeshoe
Fig. 13 Caliper Installation
Fig. 14 Caliper Mounting Bolt Dimensions
JBRAKES 5 - 27

ence) of piston and caliper boot groove (Fig. 24).
Grease serves as corrosion protection for these areas.
(8) Press caliper piston to bottom of bore.
(9) Seat dust boot in caliper with Installer Tool
C-4842 and Tool Handle C-4171 (Fig. 25).
(10) Install caliper bleed screw if removed.
CALIPER INSTALLATION
(1) Install brakeshoes in caliper (Figs. 11, 12).
(2) Connect brake hose fitting to caliper but do not
tighten fitting bolt completely at this time.Be sure
to use new washers on fitting bolt to avoid leaks
(Fig. 26).
(3) Install caliper. Position mounting notches at
lower end of brakeshoes on bottom mounting ledge(Fig. 13). Then rotate caliper over rotor and seat
notches at upper end of shoes on mounting ledge
(Fig. 13).
(4) Coat caliper mounting bolts with GE 661 or
Dow 111 silicone grease. Then install and tighten
bolts to 10-20 Nzm (7-15 ft. lbs.) torque.
CAUTION: If new caliper bolts are being installed,
or if the original reason for repair was a drag/pull
condition, check caliper bolt length before proceed-
ing. If the bolts have a shank length greater than
67.6 mm (2.66 in.), they may contact the inboard
brakeshoe causing a partial apply condition. Refer
to Figure 14 for the required caliper bolt length.
(5) Position front brake hose clear of all chassis
components and tighten caliper fitting bolt to 31 Nzm
(23 ft. lbs.) torque.
CAUTION: Be sure the brake hose is not twisted or
kinked at any point. Also be sure the hose is clear
of all steering and suspension components. Loosen
and reposition the hose if necessary.
(6) Install wheels. Tighten wheel lug nuts to 109-
150 Nzm (80-110 ft. lbs.) torque.
(7) Fill and bleed brake system. Refer to proce-
dures in Service Adjustments section.
ROTOR REMOVAL
(1) Raise vehicle and remove wheel.
(2) Remove caliper.
(3) Remove retainers securing rotor to hub studs
(Fig. 27).
(4) Remove rotor from hub (Fig. 27).
(5) If rotor shield requires service, remove front
hub and bearing assembly.
ROTOR INSTALLATION
(1) Install rotor on hub.
(2) Install caliper.
Fig. 24 Typical Caliper/Piston Areas To Be Lightly
Coated With Silicone Grease
Fig. 25 Seating Caliper Piston Piston Dust Boot
Fig. 26 Front Brake Hose And Fitting Components
5 - 30 BRAKESJ

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

Check flywheel runout if misalignment is sus-
pected. Runout should not exceed 0.08 mm (0.003
in.). Measure runout at the outer edge of the fly-
wheel face with a dial indicator. Mount the dial indi-
cator on a stud installed in place of one of the
flywheel attaching bolts.
Clean the crankshaft flange before mounting the
flywheel. Dirt and grease on the flange surface may
cock the flywheel causing excessive runout.
Check condition of the flywheel hub and attaching
bolts. Replace the flywheel if the hub exhibits cracks
in the area of the attaching bolt holes.
Install new attaching bolts whenever the flywheel
is replaced and use Mopar Lock N' Seal, or Loctite
242 on the replacement bolt threads.
Recommended flywheel bolt torques are:
²142 Nzm (105 ft. lbs.) for 6-cylinder flywheels
²68 Nzm (50 ft. lbs.) plus an additional turn of 60É
for 4-cylinder flywheels
Inspect the teeth on the starter ring gear.If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom-
mended and preferred method of repair.
In cases where a new flywheel is not readily avail-
able, a replacement ring gear can be installed. How-
ever, the following precautions must be observed to
avoid damaging the flywheel and replacement gear.
(a) Mark position of the old gear for alignment
reference on the flywheel. Use a scriber for this
purpose.
(b) Wear protective goggles or approved safety
glasses. Also wear heat resistent gloves when han-
dling a heated ring gear.
(c) Remove the old gear by cutting most of the
way through it (at one point) with an abrasive cut-
off wheel. Then complete removal with a cold chisel
or punch.(d) The ring gear is a shrink fit on the flywheel.
This means the gear must be expanded by heating
in order to install it.The method of heating and
expanding the gear is extremely important.
Every surface of the gear must be heated at the
same time to produce uniform expansion. An oven
or similar enclosed heating device must be used.
Temperature required for uniform expansion is ap-
proximately 375É F.
CAUTION: Do not use an oxy/acetylene torch to re-
move 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-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
(e) The heated gear must be installed evenly to
avoid misalignment or distortion. A shop press and
suitable press plates should be used to install the
gear if at all possible.
(f) Be sure to wear eye and hand protection.
Heat resistent gloves and safety goggles are needed
for personal safety. Also use metal tongs, vise grips,
or similar tools to position the gear as necessary
for installation.
(g) Allow the flywheel and ring gear to cool down
before installation. Set the assembly on a work-
bench and let it cool in normal shop air.
CAUTION: Do not use water, or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air can distort, or crack the
gear and flywheel.
6 - 16 CLUTCH SERVICEJ

DIAGNOSIS
INDEX
page page
DRB Scan Tool........................... 5
On-Board Diagnostics (OBD)................. 4Preliminary Checks........................ 5
ON-BOARD DIAGNOSTICS (OBD)
FOR COOLING SYSTEM COMPONENTS
The powertrain control module (PCM) has been
programmed to monitor the certain following cooling
system components:
²If the engine has remained cool for too long a pe-
riod, such as with a stuck open thermostat, a Diag-
nostic Trouble Code (DTC) number 17 can be
observed at the Check Engine Lamp.
²If an open or shorted condition has developed in
the relay circuit controlling the electric radiator fan,
a Diagnostic Trouble Code (DTC) number 35 can be
observed at the Check Engine Lamp.
If the problem is sensed in a monitored circuit of-
ten enough to indicate an actual problem, a DTC is
stored. The DTC will be stored in the PCM memory
for eventual display to the service technician. If the
problem is repaired or ceases to exist, the PCM can-
cels the DTC after 51 engine starts.
Certain criteria must be met for a DTC to be en-
tered into PCM memory. The criteria may be a spe-
cific range of engine rpm, engine temperature and/or
input voltage to the PCM.
A DTC indicates that the PCM has recognized an
abnormal signal in a circuit or the system. A DTC
may indicate the result of a failure, but never iden-
tify the failed component directly.
It is possible that a DTC for a monitored circuit
may not be entered into memory even though a mal-
function has occurred. Refer to On-Board Diagnostics
(OBD) in Group 14, Fuel Systems for additional in-
formation.
ACCESSING DIAGNOSTIC TROUBLE CODES
A stored Diagnostic Trouble Code (DTC) can be dis-
played by cycling the ignition key On-Off-On-Off-On
within three seconds and observing the Malfunction
Indicator Lamp. This lamp was formerly referred to
as the Check Engine Lamp. The lamp is located on
the instrument panel.
They can also be displayed through the use of the
Diagnostic Readout Box (DRB) scan tool. The DRB
connects to the data link connector in the engine
compartment (Figs. 5 or 6). For operation of the
DRB, refer to the appropriate Powertrain Diagnostic
Procedures service manual.EXAMPLES:
²If the lamp flashes 1 time, pauses and flashes 7
more times, a flashing Diagnostic Trouble Code
(DTC) number 17 is indicated.
²If the lamp flashes 3 times, pauses and flashes 5
more times, a flashing Diagnostic Trouble Code
(DTC) number 35 is indicated.
After any stored DTC information has been ob-
served, the display will end with a flashing DTC
number 55. This will indicate the end of all stored
information.
Fig. 5 Data Link ConnectorÐYJ ModelsÐTypical
Fig. 6 Data Link ConnectorÐXJ ModelsÐTypical
7 - 4 COOLING SYSTEMJ

ERASING TROUBLE CODES
After the problem has been repaired, the DRB scan
tool must be used to erase a DTC. Refer to the ap-
propriate Powertrain Diagnostic Procedures service
manual for operation of the DRB scan tool.
DRB SCAN TOOL
For operation of the DRB scan tool, refer to the ap-
propriate Powertrain Diagnostic Procedures service
manual.
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establish what driving conditions caused the com-
plaint. Abnormal loads on the cooling system such as
the following may be the cause.
1. PROLONGED IDLE, VERY HIGH AMBI-
ENT TEMPERATURE, SLIGHT TAIL WIND AT
IDLE, SLOW TRAFFIC, TRAFFIC JAMS, HIGH
SPEED, OR STEEP GRADES:
Driving techniques that avoid overheating are:
²Idle with A/C off when temperature gauge is at
end of normal range.
²Increasing engine speed for more air flow is recom-
mended.2. TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.
3. AIR CONDITIONING; ADD-ON OR AFTER
MARKET:
A maximum cooling package should have been or-
dered with vehicle if add-on or after market A/C is
installed. If not, maximum cooling system compo-
nents should be installed for model involved per
manufacturer's specifications.
4. RECENT SERVICE OR ACCIDENT RE-
PAIR:
Determine if any recent service has been performed
on vehicle that may effect cooling system. This may
be:
²Engine adjustments (incorrect timing)
²Slipping engine accessory drive belt(s)
²Brakes (possibly dragging)
²Changed parts (incorrect water pump rotating in
wrong direction)
²Reconditioned radiator or cooling system refilling
(possibly under-filled or air trapped in system).
If investigation reveals none of the above as a
cause for engine overheating complaint, refer to fol-
lowing Symptom and Action chart.
JCOOLING SYSTEM 7 - 5

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

CAUTION: Tightening the thermostat housing un-
evenly or with the thermostat out of its recess, may
result in a cracked housing.
(3) Tighten the housing bolts to 20 Nzm (15 ft. lbs.)
torque.
(4) Install hoses to thermostat housing.
(5) Install electrical connector to coolant tempera-
ture sensor.
(6) Be sure that the radiator draincock is tightly
closed. Fill the cooling system to the correct level
with the required coolant mixture. Refer to Refilling
Cooling System in this group.
(7) Start and warm the engine. Check for leaks.
COOLANT
GENERAL INFORMATION
The cooling system is designed around the coolant.
Coolant flows through the engine water jackets ab-
sorbing heat produced during engine operation. The
coolant carries heat to the radiator and heater core.
Here it is transferred to the ambient air passing
through the radiator and heater core fins. The cool-
ant also removes heat from the automatic transmis-
sion fluid in vehicles equipped with an automatic
transmission.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix-
tures follows:
Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur-pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.
100 percent Ethylene-Glycol-The corrosion inhib-
iting additives in ethylene-glycol need the presence
of water to dissolve. Without water, additives form
deposits in system. These act as insulation causing
temperature to rise to as high as 149ÉC (300ÉF). This
temperature is hot enough to melt plastic and soften
solder. The increased temperature can result in en-
gine detonation. In addition, 100 percent ethylene-
glycol freezes at -22ÉC (-8ÉF).
50/50 Ethylene-Glycol and Water-Is the recom-
mended mixture, it provides protection against freez-
ing to -37ÉC (-35ÉF). The antifreeze concentration
must alwaysbe a minimum of 44 percent, year-
round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec-
tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7ÉC (-90ÉF). A higher percentage will
freeze at a warmer temperature. Also, a higher per-
centage of antifreeze can cause the engine to over-
heat because specific heat of antifreeze is lower than
that of water.
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION-ADDITIVES
Coolant should be maintained at the specified level
with a mixture of ethylene glycol-based antifreeze
and low mineral content water. Only use an anti-
freeze containing ALUGARD 340-2 Ÿ.
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
COOLANT SERVICE
It is recommended that the cooling system be
drained and flushed at 84,000 kilometers (52,500
miles), or 3 years, whichever occurs first. Then every
two years, or 48,000 kilometers (30,000 miles),
whichever occurs first.
COOLANT LEVEL CHECKÐROUTINE
Do not remove radiator cap for routine coolant
level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
The coolant reserve/overflow system provides a
quick visual method for determining coolant level
without removing radiator pressure cap. With engine
idling and at normal operating temperature, observe
coolant level in reserve/overflow tank. The coolant
level should be between ADD and FULL marks.
Fig. 16 Thermostat Recess
JCOOLING SYSTEM 7 - 15

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