check engine light JEEP CHEROKEE 1994 Service Service Manual

the sensor will not rotate, install the sensor with the
throttle shaft on the other side of the socket tangs).
The TPS will be under slight tension when rotated.
(1) Install the TPS and retaining bolts.
(2) Connect TPS electrical connector to TPS.
(3) Manually operate the throttle (by hand) to
check for any TPS binding before starting the en-
gine.
TORQUE CONVERTER CLUTCH RELAY
On YJ models, the TCC relay is located in the en-
gine compartment. It is attached to the cowl panel
with one bolt (Fig. 20). On XJ models, the TCC relay
is located in the power distribution center (PDC)
(Fig. 21). For location of this relay within the PDC,
refer to label on PDC cover.
VEHICLE SPEED SENSOR
The vehicle speed sensor (Fig. 22) is located on the
extension housing of the transmission on 2WD mod-
els. It is located on the transfer case on 4WD models.
REMOVAL
(1) Raise and support vehicle.
(2) Disconnect the electrical connector from the
sensor.
(3) Remove the sensor mounting bolt (Fig. 23).
Fig. 18 TPS LocationÐ4.0L Engine
Fig. 19 Throttle Position SensorÐInstallation
Fig. 20 TCC Relay LocationÐYJ Models
Fig. 21 Power Distribution CenterÐXJ Models
Fig. 22 Vehicle Speed Sensor LocationÐTypical
14 - 60 FUEL SYSTEMJ

(2) Remove fitting from pump housing (Fig. 10).
Prevent flow control valve and spring from
sliding out of housing bore.
(3) Remove and discard O-ring seal.
INSTALLATION
(1) If necessary, clean and install flow control valve
and spring in pump housing bore.Be sure the hex
nut end of the valve is facing in toward pump.
(2) Install O-ring seal onto fitting (Fig. 10).(3) Install flow control valve in pump housing and
tighten to 75 Nzm (55 ft. lbs.) torque.
(4) Install pressure hose to valve.
POWER STEERING PUMPÐINITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only Mopar Power Steering Fluid. Do not
use automatic transmission fluid. Do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicate FULL COLD when the
fluid is at normal temperature 21ÉC to 27ÉC (70ÉF to
80ÉF).
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let run for a few seconds.
Then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
Fig. 10 Flow Control Valve Fitting
JSTEERING 19 - 13

A correct lubricant level check can only be made
when the vehicle is level; use a drive-on hoist to en-
sure this. Also allow the lubricant to settle for a
minute or so before checking. These recommenda-
tions will ensure an accurate check and avoid an un-
der-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, compo-
nent damage, incorrect clutch adjustment, or by a
damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
rail, synchro and bearing damage. If a leak goes un-
detected for an extended period, the first indications
of a problem are usually hard shifting and noise.
Incorrect or contaminated lubricants can also con-
tribute to hard shifting. The consequence of using
non-recommended lubricants is noise, excessive wear,
internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. If
the clutch problem is advanced, gear clash during
shifts can result.
Worn or damaged synchro rings can cause gear
clash when shifting into any forward gear. In some
new or rebuilt transmissions, new synchro rings maytend to stick slightly causing hard or noisy shifts. In
most cases, this condition will decline as the rings
wear-in.
TRANSMISSION NOISE
Most manual transmissions make some noise dur-
ing normal operation. Rotating gears can generate a
mild whine that may only be audible at extreme
speeds.
Severe, obviously audible transmission noise is
generally the result of a lubricant problem. Insuffi-
cient, improper, or contaminated lubricant can pro-
mote rapid wear of gears, synchros, shift rails, forks
and bearings. The overheating caused by a lubricant
problem, can also lead to gear breakage.
TRANSMISSION REMOVAL
(1) Shift transmission into first or third gear. Then
raise vehicle on hoist.
(2) Support engine with adjustable jack stand. Be
sure to position wood block between jack and oil pan.
(3) Disconnect necessary exhaust system compo-
nents.
(4) Disconnect rear cushion and bracket from
transmission (Fig. 5). Then remove skid plate, or
rear crossmember.
(5) Disconnect transfer case shift linkage, vehicle
speed sensor wires, and vent hose.
Fig. 5 Rear Mount Components (YJ Shown)
JAX 4/5 MANUAL TRANSMISSION 21 - 3

(12) Align transfer case and transmission shafts
and install transfer case. Tighten transfer case-to-
transmission nuts/bolts to 35 Nzm (26 ft. lbs.) torque.
(13) Remove jack stand from under engine and re-
position jack under transmission. Then remove trans-
mission jack.
(14) Connect transfer case vent hose and shift link-
age. Check and adjust linkage if necessary.
(15) Connect transmission and transfer case vent
hoses.
(16) Connect backup light switch wires.
(17) Connect vehicle speed sensor wires.
(18) Install and connect crankshaft position sensor
if equipped.
(19) Install rear crossmember, or skid plate (Fig. 5).
On XJ, tighten crossmember-to-frame bolts to 41 Nzm
(31 ft. lbs.) torque. Then tighten transmission-to-rear
support bolts/nuts to 45 Nzm (33 ft. lbs.) torque. On YJ,
tighten bolts/nuts to indicated torque (Fig. 5).
(20) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(21) On XJ, install skid plate, if removed. Tighten
bolts to 42 Nzm (31 ft. lbs.) torque. Tighten stud nuts
to 17 Nzm (150 in. lbs.) torque.
(22) Top off transmission and transfer case lubri-
cant levels.
(23) Lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING AND FRONT BEARING
RETAINER REMOVAL
(1) Drain transmission lubricant.
(2) Remove concentric bearing.
(3) Remove clutch housing bolts and remove housing.
(4) On 2-wheel drive models, remove vehicle speed
sensor, speedometer adapter and speedometer driven
gear. Then remove extension housing seal (Fig. 9).(5) Remove detent spring and ball. Remove detent
plug (Fig. 10) and remove detent spring and ball
with pencil magnet.
(6) Remove shift arm set bolt (Fig. 11) and remove
bolt and lockplate.
Fig. 10 Detent Ball Plug Location
Fig. 11 Set Bolt Removal
Fig. 9 Removing 2-Wheel Drive Extension Housing Seal
JAX 4/5 MANUAL TRANSMISSION 21 - 5

(10) Remove jack from under transmission and
mount transfer case on jack.
(11) Align transfer case and transmission shafts
and install transfer case. Tighten transfer case-to-
transmission nuts/bolts to 35 Nzm (26 ft. lbs.) torque.
(12) Move jack stand from under engine and repo-
sition it under transmission. Then remove transmis-
sion jack.
(13) Connect transfer case vacuum hoses and link-
age. Check and adjust linkage if necessary.
(14) Connect transmission and transfer case vent
hoses and backup light switch wires.
(15) Install clutch sleeve cylinder.
(16) Connect vehicle speed sensor and wires.
(17) On XJ, install rear crossmember and attach
cushion and bracket. Tighten crossmember-to-frame
bolts to 41 Nzm (30 ft. lbs.) torque. Tighten transmis-
sion-to-rear cushion and bracket bolts/nuts to 45 Nzm
(33 ft. lbs.) torque.
(18) On YJ, install rear cushion and bracket and
skid plate. Tighten attaching bolts/nuts to indicated
torque (Fig. 1).
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) On XJ, install skid plate if removed. Tighten
bolts to 42 Nzm (31 ft. lbs.) torque. Tighten stud nuts
to 17 Nzm (150 in. lbs.) torque.
(21) Top off transmission and transfer lubricant
levels.
(22) Remove supports and lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER/EXTENSION HOUSING REMOVAL
(1) Remove release bearing, fork, retainer clip and
clutch housing from transmission. Also remove shift
lever if not previously removed.
(2) On 2-wheel drive models, remove extension
housing seal (Fig. 1).(3) Remove shift tower bolts and remove tower
from adapter or extension housing (Fig. 2).
(4) Remove gasket from shift tower (Fig. 3).
(5) Remove shift arm retainer bolt (Fig. 4).
Fig. 1 Removing Extension Housing Seal
Fig. 2 Shift Tower Removal/Installation
Fig. 3 Shift Tower Gasket Removal/Installation
Fig. 4 Shift Arm Retainer Bolt Removal/Installation
21 - 36 AX 15 MANUAL TRANSMISSIONJ

(8) Check fluid condition. Fluid should be dark to
light red in color and free of dirt or debris.
(9) If fluid is discolored or smells burned but trans-
mission operation was OK, check cooler flow, flush
cooler and lines and change fluid and filter. Then
road test again to confirm proper operation.
(10) If fluid is black or dark brown, burned/turned
to sludge, contains large quantities of metal or fric-
tion material particles, transmission will need over-
haul. Especially if problems were evident during
road test and preliminary diagnosis. Fluid cooler
should also be flow tested and flushed if necessary.
EFFECTS OF INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn
the fluid into foam. This aerates the fluid causing
the same conditions that occur with a low level.
In either case, air bubbles cause fluid overheating,
oxidation and varnish buildup which interferes with
valve, clutch and servo operation. Foaming also
causes fluid expansion which can result in fluid over-
flow from the transmission vent or fill tube. Fluid
overflow can easily be mistaken for a leak if inspec-
tion is not careful.
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT
Throttle cable adjustment is important to proper
operation. This adjustment positions the throttle
valve which controls shift speed, quality and part
throttle downshift sensitivity.
If cable adjustment setting is too short, early shifts
and slippage between shifts may occur. If the setting
is too long, shifts may be delayed and part throttle
downshifts may be very sensitive. Refer to the In-Ve-
hicle Service section for adjustment procedure.
GEARSHIFT LINKAGE
Gearshift linkage adjustment is important because
it positions the valve body manual valve. Incorrect
adjustment will cause creeping in Neutral, prema-
ture clutch wear, delayed engagement in any gear, or
a no-start in Park or Neutral position.
Proper operation of the neutral start switch will
provide a quick check of linkage adjustment. Refer to
the In-Vehicle Service section for adjustment proce-
dure.
ROAD TEST
Before road testing, be sure the fluid level and all
linkage adjustments have been checked and adjusted
if necessary.
Observe engine performance during the road test.
A poorly tuned engine will not allow an accurate
analysis of transmission operation.Operate the transmission in all gear ranges. Check
for slippage and shift variations. Note whether the
shifts are harsh, spongy, delayed, early, or if part
throttle downshifts are sensitive.
Watch closely for slippage or engine flare which
usually indicates clutch, band or overrunning clutch
problems. If the condition is advanced, an overhaul
may be necessary to restore normal operation.
A slipping clutch or band can often be determined
by comparing which internal units are applied in the
various gear ranges. The Clutch and Band Applica-
tion chart (Fig. 3) provides a basis for analyzing road
test results.
ANALYZING THE ROAD TEST
Refer to the Clutch and Band Application chart
(Fig. 3) and note which elements are in use in the
various gear ranges.
The rear clutch is applied in all forward ranges (D,
2, 1). The overrunning clutch is applied in first gear
(D and 2 range only). The rear band is applied in 1
and R range only.
For example: If slippage occurs in first gear in D
and 2 range but not in 1 range, the overrunning
clutch is slipping. Similarly, if slippage occurs in any
two forward gears, the rear clutch is slipping.
Applying the same method of analysis, note that
both clutches are applied in D range third gear only.
If the transmission slips in third gear, either the
front clutch or the rear clutch is slipping. By select-
ing another gear which does not use one of these
units, the slipping clutch can be determined.
Although road test analysis will help determine
the slipping unit, the actual cause of a malfunction
may not be determined until hydraulic and air pres-
sure tests are performed. Practically any condition
Fig. 3 Clutch And Band Application Chart
21 - 70 30RH/32RH TRANSMISSION DIAGNOSISJ

STALL TEST PROCEDURE
(1) Connect tachometer to engine.
(2) Check and adjust transmission fluid level.
(3) Start and run engine until transmission fluid
reaches normal operating temperature.
(4) Block front wheels.
(5) Fully apply service and parking brakes.
(6) Open throttle completely for no more than five
seconds and record maximum engine rpm registered
on tachometer.
CAUTION: Stall testing causes a rapid increase in
transmission fluid temperature. Do not hold the
throttle open any longer than five seconds. If more
than one stall test is required, run the engine at
1000 rpm with the transmission in Neutral for at
least 20 seconds to cool the fluid.
(7) If engine speed exceeds maximum shown in
stall speed chart, release accelerator immediately.
This indicates that transmission clutch slippage is
occurring.
(8) Shift transmission into Neutral. Run engine for
20 seconds to cool fluid. Then stop engine, shift
transmission into Park and release brakes.
(9) Stall speeds should be in 1700-2000 rpm range.
(10) Refer to Stall Test Diagnosis.
STALL TEST DIAGNOSIS
Stall Speed Too High
If the stall speed exceeds specifications by more
than 200 rpm, transmission clutch slippage is indi-
cated.
Stall Speed Too Low
Low stall speeds with a properly tuned engine in-
dicate a torque converter overrunning clutch prob-
lem. The condition should be confirmed by road
testing prior to converter replacement.
The converter overrunning clutch is slipping when
stall speeds are 250 to 350 rpm below specified min-
imum. And when the vehicle operates properly at
highway speeds but has poor low speed acceleration.
Stall Speed Normal
If stall speeds are normal but abnormal throttle
opening is required to maintain highway speeds, the
converter overrunning clutch is seized and the torque
converter must be replaced.
Converter Noise During Test
A whining noise caused by fluid flow is normal
during a stall test. However, loud metallic noises in-
dicate a damaged converter. To confirm that noise is
originating from the converter, operate the vehicle at
light throttle in Drive and Neutral on a hoist and lis-
ten for noise coming from the converter housing.
AIR PRESSURE TEST
Air pressure testing can be used to check clutch
and band operation with the transmission either in
the vehicle, or on the work bench as a final check af-
ter overhaul.
Air pressure testing requires that the oil pan and
valve body be removed from the transmission.
The servo and clutch apply passages are shown in
Figure 8.
Air Test Procedure
(1) Place one or two fingers on the clutch housing
and apply air pressure through front clutch apply
passage (Fig. 8). Piston movement can be felt and a
soft thud heard as the clutch applies.
(2) Place one or two fingers on the clutch housing
and apply air pressure through rear clutch apply pas-
sage (Fig. 8). Piston movement can be felt and a soft
thud heard as the clutch applies.
(3) Apply air pressure to the front servo apply pas-
sage. The servo rod should extend and cause the
band to tighten around the drum. Spring tension
should release the servo when air pressure is re-
moved.
(4) Apply air pressure to the rear servo apply pas-
sage. The servo rod should extend and cause the
band to tighten around the drum. Spring tension
should release the servo when air pressure is re-
moved.
CONVERTER HOUSING LEAK DIAGNOSIS
Two items must be established when diagnosing
leaks from the converter housing area. First, it must
be verified that a leak condition actually exists. And
second, the true source of the leak must be deter-
mined.
Fig. 8 Air Pressure Test Passages
J30RH/32RH TRANSMISSION DIAGNOSIS 21 - 73

30RH/32RH IN-VEHICLE SERVICE
INDEX
page page
Checking Fluid Level and Condition........... 96
Front Band Adjustment.................... 99
Gearshift Linkage Adjustment (YJ)............ 96
Governor and Park Gear Service............ 101
Oil Filter Replacement.................... 100
Park Interlock Cable Adjustment (XJ)......... 97
Park Lock Component Replacement......... 102
Park/Neutral Position Switch Service......... 103
Rear Band Adjustment.................... 99
Recommended Fluid...................... 96
Servicing Transmission Cooler Lines and Fittings. 106
Shift Cable Adjustment (XJ)................ 97
Speedometer Service.................... 103
Transmission Cooler Flow Testing........... 106
Transmission Cooler Reverse Flushing....... 105
Transmission Throttle Cable Adjustment (XJ/YJ) . 98
Valve Body Installation................... 101
Valve Body Removal..................... 100
Valve Body Service...................... 100
RECOMMENDED FLUID
The recommended and preferred fluid for 30RH/
32RH transmissions is Mopar ATF Plus, Type 7176.
Mopar Dexron II is acceptable but should only be
used when ATF Plus is not available.
Transmission fluid capacity is approximately 17
pints (7.9 liters). This is the approximate amount of
fluid required to fill the transmission and torque con-
verter after overhaul.
CHECKING FLUID LEVEL AND CONDITION
(1) Position vehicle on flat, level surface. This is
important in obtaining an accurate fluid level check.
(2) To avoid false readings, which could produce
under or over fill condition, do not check level until
fluid is at normal operating temperature.
(3) Shift transmission into Neutral.
(4) Apply parking brakes.
(5) Operate engine at curb idle speed.
WARNING: WHEN PERFORMING UNDERHOOD OP-
ERATIONS WITH THE ENGINE RUNNING, KEEP
YOUR HANDS WELL AWAY FROM HOT OR ROTAT-
ING ENGINE COMPONENTS. DO NOT WEAR
LOOSE ARTICLES OF CLOTHING WHICH COULD
BECOME ENTANGLED IN ENGINE COMPONENTS
OR ACCESSORIES.
(6) Shift transmission through all gear ranges and
back to Neutral (leave engine running).
(7) Clean exterior of dipstick cap and fill tube be-
fore removing transmission dipstick.
(8) Remove dipstick and inspect fluid level.
²Correct level is to FULL mark
²Acceptable level is between ADD and FULL marks
(9) Check fluid condition. Fluid should be dark to
light red in color and free of dirt or debris.
(10) If fluid is discolored or smells burned but
transmission operation was OK, check cooler flow,
flush cooler and lines and change fluid and filter.
Then road test again to confirm proper operation.(11) If fluid is black or dark brown, burned/turned
to sludge, contains large quantities of metal or fric-
tion material particles, transmission will need over-
haul. Especially if problems were evident during
road test and preliminary diagnosis. Fluid cooler
should also be flow tested and flushed if necessary.
GEARSHIFT LINKAGE ADJUSTMENT (YJ)
(1) Check linkage adjustment by starting engine in
Park and Neutral.
(2) Adjustment is OK if engine starts only in park
and Neutral. Adjustment is incorrect if engine starts
in one but not both positions.
(3) If engine starts in any position other than Park
or Neutral, or if engine will not start at all, park/
neutral position switch may be faulty.
(4) Shift transmission into Park.
(5) Raise vehicle.
(6) Check condition of shift rods, bellcrank, bell-
crank brackets and linkage bushings/grommets (Fig.
1). Tighten, repair, replace worn, damaged parts. Do
not attempt adjustment if linkage components are
worn or damaged.
(7) Loosen shift rod trunnion lock bolt or nut. Be
sure upper shift rod slides freely in trunnion (Fig. 1).
Also be sure shift rods and bellcrank rotate freely
and do not bind at any point.
(8) Verify that manual lever is in Park detent
(Fig. 1). Move lever all the way rearward to be sure
it is in Park.
(9) Check for positive engagement of park lock by
attempting to rotate propeller shaft. Shaft will not
turn when park pawl is engaged.
(10) Adjust shift rod trunnion to a obtain free pin
fit in bellcrank arm and tighten trunnion lock bolt or
nut. Prevent shift rod from turning while tightening
bolt or nut. Gearshift linkage lash must be elimi-
nated to obtain proper adjustment. Eliminate lash by
pulling downward on shift rod and pressing upward
on bellcrank.
21 - 96 30RH/32RH IN-VEHICLE SERVICEJ

SERVICE DIAGNOSISÐMECHANICAL
GENERAL
The reason for a decrease in cooling or heating ef-
ficiency must be understood before attempting repair
or replacement of parts. Determined if the condition
is the air conditioner, the heating system, its compo-
nents or the in the air flow system.
The air conditioning system generally operates at
peak efficiency at normal highway speeds. However,
a slight reduction in A/C performance may be expe-
rienced in congested city driving conditions; espe-
cially when ambient temperatures are high.
When diagnosing a gradual decrease in A/C perfor-
mance, remember to check condition of the condenser
and radiator fins. Air flow blockage of either compo-
nent, caused by dirt, foreign material or insects, will
affect the air conditioning and engine cooling sys-
tems. Vehicles equipped with a protective screen, can
restrict air flow to the radiator and condenser.
During high outside operating temperatures, a
slight increase in engine coolant temperature will oc-
cur when the air conditioner is operating.
A/C PERFORMANCE TEST
The pressure developed on the high side and low
side of the compressor indicates whether the system
is operating properly.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A DI-
RECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
WARNING: WEAR SAFETY GOGGLES WHEN SER-
VICING THE REFRIGERATION SYSTEM
(1) Attach an engine tachometer and refrigerant
Pressure Gauge and Manifold Assembly Tool
C-4740-A.
(2) Close both hand valves on the gauge and man-
ifold assembly.
(3) Set both service hand valve stems to the mid-
position.
(4) Engine should be warmed up with doors, win-
dows and hood closed.
(5) Operate air conditioning system with the en-
gine running at 1,000 RPM. Set the controls for max-
imum A/C, temperature control on full cool and
blower switch on high.
(6) Insert a thermometer into center discharge air
outlet and observe the air temperature. The temper-
ature should be approximately 7ÉC (45ÉF) at 27ÉC
(80ÉF) ambient temperature after 5 minutes of oper-
ation.(7) Observe the high and low side pressures. The
evaporator suction pressure should be 207-241 kPag
(30-35 psig). The compressor discharge pressure
should be 1103-1633 kPag (160-235 psig). It should
be noted that high ambient temperature and humid-
ity conditions will cause higher pressures and tem-
perature conditions. If the clutch cycles, take
readings before clutch disengages.
(8) If pressures are abnormal, refer to the Pressure
and Performance Diagnosis Charts.
The following charts have been developed for quick
reference. If the step by step method used is not com-
pletely understood, refer to the correct section of the
Service Manual for more detailed information.
COMPRESSOR VALVE PLATEÐLEAK TESTS
This test can be preformed with the compressor in-
stalled in the vehicle.
Discharge or Suction Valve BreakageÐWhen
compressor is operating at idle speed, compressor
makes a ``clacking'' sound. Preform the Pressure Bal-
ancing Test.
Head Gasket BreakageÐAt idle speed, discharge
pressure does not increase to normal condition and
suction pressure is high. Preform the Pressure Bal-
ancing Test.
Pressure Balancing Test:
(1) Connect manifold gauge set to suction and dis-
charge ports.
(2) Run compressor for 5 minutes at idle speed and
stop.
(3) Measure elapsed time that discharge pressure
is balanced to suction pressure. If less than 2 min-
utes, it is determined that discharge valve or head
gasket is broken.
REFRIGERANT LEAK TEST
External leaks in the system can be located using
an electronic detector.
The electronic leak detector is recommended be-
cause it is light, accurate and most important, does
not expose the user to toxic gas fumes. An electronic
leak detector will locate R-12 leaks as small as 15 ml
(0.5 fluid oz.) per year.
WARNING: DO NOT USE A HALIDE TORCH. THE
HALIDE TORCH REQUIRES AN OPEN FLAME FOR
LEAK DETECTION. WHEN R-12 IS EXPOSED TO AN
OPEN FLAME, IT TURNS INTO PHOSGENE GAS
WHICH IS POISONOUS.
(1) Calibrate the detector as outlined in the manu-
facturer's instructions.
(2) Remove the flexible detector probe from the
case.
(3) Turn the detector control switch ON.
24 - 8 HEATING AND AIR CONDITIONINGJ

BODY SOLENOIDS, TRANSMISSION
VALVE ............................21-175
BODY STRIPES/DECALS...........23-25,23-153
BODY, THROTTLE.................14-29,14-59
BODY UNDERCOAT....................23-203
BOOSTER CHECK VALVE TEST, POWER......5-11
BOOSTER INSTALLATION, POWER
BRAKE..........................5-23,5-51
BOOSTER OPERATION, POWER BRAKE......5-22
BOOSTER, POWER BRAKE............5-22,5-40
BOOSTER REMOVAL, POWER BRAKE . . . 5-22,5-51
BOOSTER TEST, MASTER CYLINDER/
POWER.............................5-11
BOOSTER VACUUM TEST, POWER..........5-12
BORES, HONING CYLINDER................9-2
BOX, GLOVE.........................23-194
BRACKET, FUEL FILTER.................23-86
BRACKET, FUEL FILTER SHIELD...........13-17
BRACKET, I/P TWEETER SPEAKER/
COURTESY LAMP SUPPORT............23-95
BRACKET, MUFFLER/TAILPIPE HANGER.....13-16
BRACKET, REARVIEW MIRROR
RETAINING........................23-183
BRACKET REPLACEMENT, INTERIOR
REARVIEW MIRROR SUPPORT..........23-75
BRACKETS, CATALYTIC CONVERTER/
MUFFLER/TAILPIPE SUPPORT...........23-85
BRACKETSÐXJ VEHICLES, SPARE TIRE/
WHEEL HOLDDOWN AND FLOOR.......23-128
BRAKE ADJUSTMENT, DRUM..............5-35
BRAKE ADJUSTMENT PARKING............5-63
BRAKE BLEEDINGÐBRAKE FLUID AND
LEVELÐBRAKELINES AND HOSES........5-13
BRAKE BLEEDINGÐWITH ABS BRAKES.....5-14
BRAKE BLEEDINGÐWITH STANDARD
BRAKES.............................5-13
BRAKE BOOSTER INSTALLATION,
POWER.........................5-23,5-51
BRAKE BOOSTER OPERATION, POWER......5-22
BRAKE BOOSTER, POWER............5-22,5-40
BRAKE BOOSTER REMOVAL, POWER . . . 5-22,5-51
BRAKE CABLE TENSIONER REPLACEMENT
(XJ), PARKING........................5-61
BRAKE CHECK, PRELIMINARY..............5-7
BRAKE COMPONENTS, WHEEL.............5-1
BRAKE DIAGNOSIS, ABS..................5-3
BRAKE DIAGNOSIS, SERVICE..............5-7
BRAKE DRUM REFINISHING..............5-37
BRAKE FLUID CONTAMINATION............5-13
BRAKE FLUID, IMPORTANCE OF CLEAN.....5-48
BRAKE FLUID LEVEL....................5-13
BRAKE FLUID, RECOMMENDED........5-13,5-48
BRAKE FLUID TUBE RETAINER CLIP,
FUEL AND; BODY COMPONENTSÐXJ
VEHICLES..........................23-86
BRAKE FLUID TUBE RETAINER CLIP,
FUEL AND; FRAME AND BUMPERS......13-16
BRAKE FLUID/LUBRICANTS/CLEANING
SOLVENTS............................5-1
BRAKE FRONT CABLE REPLACEMENT
(YJ), PARKING........................5-62
BRAKE INDICATOR INOPERATIVE..........8E-4
BRAKE INDICATOR LAMP; INSTRUMENT
PANEL AND GAUGESÐXJ...............8E-2
BRAKE INDICATOR LAMP; INSTRUMENT
PANEL AND GAUGESÐYJ
..............8E-16
BRAKE LEVER INSTALLATION (XJ WITH
FULLCONSOLE), PARKING
..............5-60
BRAKE LEVER INSTALLATION (XJ WITH
MINICONSOLE), PARKING
...............5-58
BRAKE LEVER INSTALLATION (XJ
WITHOUT CONSOLE), PARKING
..........5-60
BRAKE LEVER REMOVAL (XJ WITH FULL
CONSOLE), PARKING
..................5-59
BRAKE LEVER REMOVAL (XJ WITH MINI
CONSOLE), PARKING
..................5-58
BRAKE LEVER REMOVAL (XJ WITHOUT
CONSOLE), PARKING
..................5-60
BRAKE OPERATION, PARKING
.............5-56
BRAKE OVERHAUL, SECOND
............21-232
BRAKE PACK REQUIREMENTS, AW-4
CLUTCH
...........................21-328
BRAKE PEDAL AND BRAKELIGHT
SWITCH
.............................5-65
BRAKE PEDAL INSTALLATION
.............5-66BRAKE PEDAL INSTALLATION (YJ),
PARKING............................5-61
BRAKE PEDAL REMOVAL.................5-65
BRAKE PEDAL REMOVAL (YJ), PARKING....5-61
BRAKE PEDAL SERVICE..................5-65
BRAKE PISTON AND TRANSMISSION
CASE OVERHAUL, FIRST-REVERSE......21-237
BRAKE PROBLEMS, DIAGNOSING
PARKING............................5-10
BRAKE PROBLEMS, DIAGNOSING
SERVICE.............................5-8
BRAKE REAR CABLE REPLACEMENT
(XJ), PARKING........................5-62
BRAKE REAR CABLE REPLACEMENT (YJ),
PARKING............................5-63
BRAKE ROTOR REFINISHING, DISC.........5-32
BRAKE ROTOR RUNOUT, DISC............5-31
BRAKE ROTOR THICKNESS, DISC..........5-31
BRAKE ROTOR THICKNESS VARIATION,
DISC...............................5-31
BRAKE SAFETY PRECAUTIONS.............5-2
BRAKE SERVO, SECOND COAST.........21-181
BRAKE SWITCH.......................14-54
BRAKE SWITCHÐPCM INPUT............14-20
BRAKE SYSTEM (ABS), ANTILOCK..........5-1
BRAKE SYSTEM (ABS) INDICATOR
LAMP, ANTI-LOCK.....................8E-2
BRAKE SYSTEM OPERATION, ANTILOCK.....5-43
BRAKE SYSTEM, POWER.................0-32
BRAKE TORQUE SPECIFICATIONS..........5-67
BRAKE WARNING LIGHT DISPLAY...........5-4
BRAKE WARNING LIGHTS.................5-1
BRAKELIGHT SWITCH ADJUSTMENT........5-66
BRAKELIGHT SWITCH, BRAKE PEDAL.......5-65
BRAKELIGHT SWITCH INSTALLATION.......5-66
BRAKELIGHT SWITCH REMOVAL...........5-66
BRAKELINE CHARTS....................5-15
BRAKELINES AND HOSES................5-15
BRAKELINING MATERIAL..................5-1
BRAKES, BRAKE BLEEDINGÐWITH ABS.....5-14
BRAKES, BRAKE BLEEDINGÐWITH
STANDARD..........................5-13
BRAKES, DISC.........................5-24
BRAKES, DRUM........................5-34
BRAKES, PARKING......................5-56
BRAKES, POWER........................5-1
BRAKESHOE INSTALLATION, DISC..........5-26
BRAKESHOE INSTALLATION, DRUM........5-34
BRAKESHOE REMOVAL, DISC.............5-25
BRAKESHOE REMOVAL, DRUM............5-34
BRAKING MODE, ABS OPERATION IN
ANTILOCK...........................5-43
BRAKING MODE, ABS OPERATION
IN NORMAL..........................5-43
BREAK-IN, ENGINE......................0-13
BRUSH GUARD........................23-3
BUCKET SEAT COMPONENTS, POWER....23-106
BUCKET SEAT CUSHION AND COVER......23-98
BUCKET SEAT PLATFORM AND TRACKS . . . 23-105
BUCKET SEATBACK COVER AND FRAME . . . 23-100
BUCKET SEATBACK RECONDITIONING.....23-102
BUCKET SEATS, FRONT.................23-97
BUFFING AND POLISHING..............23-203
BULB REPLACEMENT, BACK-UP/REAR
TURN SIGNAL/TAIL LAMP...............8L-9
BULB REPLACEMENT, FRONT PARK/
TURN SIGNAL LAMP
...................8L-8
BULB REPLACEMENT, HEADLAMP
..........8L-3
BULB REPLACEMENT, INSTRUMENT
CLUSTER
...........................8E-19
BULB REPLACEMENT, SIDE MARKER
LAMP
...............................8L-7
BULB REPLACEMENT, UNDERHOOD
LAMP
..............................8L-18
BULB REPLACEMENTÐYJ VEHICLES,
HARDTOP DOME/CARGO LAMP
.........8L-20
BULB/ELEMENT REPLACEMENT, FOG
LAMP
..............................8L-13
BUMPER, FRONT
..................13-3,13-14
BUMPER, LIFTGATE LICENSE PLATE
SCREW ANCHOR
.....................23-72
BUMPER, REAR
...................13-6,13-18
BUMPER, REAR JOUNCE
................13-18
BUMPERÐXJ VEHICLES, REAR
SEATBACK LATCH STRIKER
...........23-111BUMPERS AND FRAME ATTACHED
COMPONENTS, YJ....................13-14
BUMPERS, FUEL FILLER DOOR...........23-31
BUMPERS, XJ.........................13-3
BUSHING AND PISTON CLEARANCE, AW-
4 ................................21-326
BUSHING REPLACEMENT, AXLE.......2-11,2-32
BUSHING REPLACEMENT, LEAF SPRING
EYE; FRONT SUSPENSION AND AXLE.....2-15
BUSHING REPLACEMENT, LEAF SPRING
EYE; REAR SUSPENSION AND AXLES . . . 3-4,3-6
BUZZER SYSTEM, CHIME/WARNING........8A-1
CABLE, ACCELERATOR PEDAL AND
THROTTLE.....................14-16,14-54
CABLE ADJUSTMENT, PARK INTERLOCK . . . 21-186
CABLE ADJUSTMENT, SHIFT............21-186
CABLE ADJUSTMENT, TRANSMISSION
THROTTLE....................21-98,21-185
CABLE ADJUSTMENT, TRANSMISSION
THROTTLE VALVE....................21-70
CABLE ADJUSTMENT (XJ), PARK
INTERLOCK.........................21-97
CABLE ADJUSTMENT (XJ), SHIFT.........21-97
CABLE REPLACEMENT, HEATER
CONTROL..........................24-30
CABLE REPLACEMENT, LATCH
RELEASE...........................23-10
CABLE REPLACEMENT, SERVO............8H-9
CABLE REPLACEMENT, TRANSMISSION
THROTTLE.........................21-184
CABLE REPLACEMENT (XJ),
PARKING BRAKE REAR.................5-62
CABLE REPLACEMENT (YJ), PARKING
BRAKE FRONT........................5-62
CABLE REPLACEMENT (YJ), PARKING
BRAKE REAR.........................5-63
CABLE RESISTANCE, SPARK PLUG........8D-18
CABLE TENSIONER REPLACEMENT (XJ),
PARKING BRAKE......................5-61
CABLE, THROTTLE.....................14-16
CABLEÐCONSOLE SHIFT AUTOMATIC,
PARK-LOCK.........................19-45
CABLES, DISTRIBUTOR CAP AND ROTOR,
IGNITION............................0-18
CABLES, SPARK PLUG SECONDARY . . 8D-17,8D-29
CABLES, VENT DOOR CONTROL..........24-39
CALIBRATION VALUES, GAUGE...........8E-22
CALIPER ASSEMBLY....................5-29
CALIPER CLEANING AND INSPECTION......5-28
CALIPER DISASSEMBLY..................5-27
CALIPER INSTALLATION..................5-30
CALIPER OPERATION AND WEAR
COMPENSATION......................5-24
CALIPER REMOVAL.....................5-27
CAMSHAFT........................9-29,9-69
CAMSHAFT PIN REPLACEMENT........9-31,9-71
CAMSHAFT POSITION SENSOR; FUEL
SYSTEM............................14-54
CAMSHAFT POSITION SENSOR;
IGNITION SYSTEMS..............8D-1,8D-20
CAMSHAFT POSITION SENSORÐPCM
INPUT.............................14-20
CAMSHAFT POSITION SENSOR TEST;
FUEL SYSTEM.......................14-43
CAMSHAFT POSITION SENSOR TEST;
IGNITION SYSTEMS...................8D-8
CANADA ONLY, DAYTIME RUNNING
LIGHTS............................8L-16
CANISTER, EVAP...................25-4,25-9
CAP AND ROTOR, IGNITION CABLES,
DISTRIBUTOR........................0-18
CAP, DISTRIBUTOR.....................8D-9
CAP, FUEL TANK FILLER TUBE; EMISSION
CONTROL SYSTEMS...............25-4,25-9
CAP, FUEL TANK FILLER TUBE; FUEL
SYSTEM............................14-12
CAP, RADIATOR PRESSURE...............7-20
CAPACITIES, COOLING SYSTEM...........7-38
CAPACITIES, FLUID......................0-4
CAPACITIES, FUEL TANK...........14-12,14-62
CAPACITY TEST, FUEL PUMP..............14-7
CAR REPLACEMENT, PITMAN SHAFT
SEALSÐIN
.........................19-21
CARDAN (CV), DOUBLE
.................16-10
CARDAN, SINGLE
.......................16-9
CARDAN U-JOINT, AXLE SHAFT
............2-25
JINDEX3
Description Group-Page Description Group-Page Description Group-Page