warning light JEEP CHEROKEE 1994 Service Service Manual

Wiring Diagram Name Sheet Number
Right Power Mirror.........................73
Power Mirrors.............................73
Power Seat..............................77,78
Left Power Seat Motor Assembly................77
Left Power Seat Switch.......................78
Power Steering Pressure Switch...................15
Powertrain Control Module......11,12,13,14,15,16,17,18,19,
20,21,22,23,35,36,45,55,69
Powertrain Control Module (PCM) Connector..........111
Power Windows.......................79,80,81,82
Left Front Door Window Motor..................81
Left Rear Door Window Motor..................82
Left Rear Door Window Switch..................82
Power Window Switch.......................79
Right Front Door Window Switch................81
Right Front Door Window Motor.................81
Right Rear Door Window Motor.................82
Right Rear Door Window Switch.................82
Power Window Switch.........................79
Printed Circuit Boards.................57,58,59,60,61
Pumps
Front Washer...........................63,64
Rear Washer..............................65
Radiator Fan Motor...........................23
Radio....................................71
Antenna Mast.............................71
Left Front Door Speaker......................71
Left Instrument Panel Speaker..................71
Left Liftgate Speaker.........................72
Right Front Door Speaker.....................72
Right Instrument Panel Speaker.................72
Right Liftgate Speaker........................72
Reading Lamps..............................51
Rear Lighting...................91,92,93,94,95,96,97
Left Back-Up Lamp........................91,93
Left Side Marker Lamp (Rear)................91,93
Left Tail/Stop Lamp.......................91,93
Left Turn Lamp (Amber)....................91,93
Left Turn Relay............................97
License Lamp...........................91,95
Right Back-Up Lamp.......................92,96
Right Side Marker Lamp (Rear)...............92,96
Right Tail/Stop Lamp......................92,96
Right Turn Lamp (Amber)...................92,96
Right Turn Relay...........................97
Stop Lamp Relay...........................97
Trailer Tow Connector........................93
Trailer Tow In-Line Circuit Breaker................97
Rear Lighting With Trailer Tow............93,94,95,96,97
Rear Lighting Without Trailer Tow................91,92
Rear Washer Pump...........................65
Rear Wiper Motor............................65
Rear Wiper/Washer Motor.......................65
Rear Washer Pump...........................65
Rear Wiper Motor............................65
Rear Wiper/Washer Switch......................65
Rear Wiper/Washer Switch Lamp..................47
Reed Switch................................26Wiring Diagram Name Sheet Number
Relays
ABS #1 Relay............................3,31
ABS #2 Relay............................3,31
A/C Compressor Clutch Relay..................3,69
Automatic Shut Down Relay.................3,12,17
Cooling Fan Relay...........................3
EMCC Relay.............................3,27
Engine Starter Relay.......................3,7,8
Fan Control Relay...........................23
Fuel Pump Relay........................3,12,17
Heated Rear Window Relay....................66
High Beam Relay...........................40
Horn Relay...............................34
L.C.D. Illumination Relay......................52
Left Turn Relay............................97
Park Lamp Relay...........................39
Power Door Lock Relay.......................83
Power Door Unlock Relay.....................83
Right Turn Relay...........................97
Stop Lamp Relay...........................97
Relay Center Identification......................113
Remote Keyless Entry System....................28
Remote Keyless Entry Module...................28
Remote Keyless Entry Module Connector...........114
Resistor,Ballast..............................39
Resistor,Blower..............................68
Right Front Door Jamb Switch....................76
Right Front Door Speaker.......................72
Right Front Door Window Switch..................81
Right Front Wheel Sensor.......................29
Right Front Door Connector and Door Lock Switch
Function Chart.............................87
Right Front Door Lock Motor.....................86
Right Instrument Panel Speaker...................72
Right Liftgate Speaker.........................72
Right Front Door Window Connector and Window Lift
Switch Function Chart........................87
Right Rear Door Jamb Switch....................76
Right Rear Door Window Connector and Window Lift
Function Chart.............................88
Right Rear Wheel Sensor.......................29
Right Turn Relay.............................97
Seat Belt Switch.............................74
Seat Belt Warning Indicator Lamp................57,58
Sensors
Ambient Temperature Sensor...................53
Camshaft Position Sensor...................11,20
Crankshaft Position Sensor...................11,20
Engine Coolant Temperature Sensor.............14,19
G Sensor................................30
Heated Oxygen Sensor.....................13,21
Intake Air Temperature Sensor................14,19
Left Front Wheel Sensor......................29
Left Rear Wheel Sensor.......................29
MAP Sensor............................14,19
Pedal Travel Sensor.........................30
Right Front Wheel Sensor.....................29
Right Rear Wheel Sensor......................29
JWIRING DIAGRAMS 8W - 153

WIRING DIAGRAMS XJ-RHD
INDEX
Wiring Diagram Name Sheet Number
A/C Compressor Clutch........................45
A/C Compressor Clutch Relay....................45
A/C Heater Blower Motor.......................46
A/C Low Pressure Switch.......................45
A/C Mode Selector Switch.......................46
A/C System.............................45, 46
A/C Thermostat..............................45
Antenna Mast...............................47
Ashtray Illumination Lamp.......................26
Automatic Shut Down Relay......................9
Back-up Lamp Switch.........................16
Battery....................................6
Blower Motor............................44, 46
Blower Resistor...........................44, 46
Blower Switch............................44, 46
Body Ground...............................59
Brake Warning Switch.........................42
Camshaft Position Sensor.......................12
Cargo Lamp................................30
Charging System.............................5
Generator.................................5
Check Engine Indicator Lamp..................39, 40
Chime Module..............................43
Chime Module Connector.......................71
Cigar Lighter...............................58
Circuit Breakers
Windshield Wiper Circuit Breaker...............2,33
Connectors
Chime Module Connector......................71
Dash to Instrument Panel Connector A.............64
Dash to Instrument Panel Connector B.............65
Dash to Instrument Panel Connector C.............66
Data Link Connector.........................10
Instrument Cluster Connector 16 Way...........37, 69
Main Body Connector 1.......................70
Power Mirror Connector......................61
Powertrain Control Module Connector..............73
Steering Column Connector 11 Way...............67
Telltale Connector........................38, 68
Transmission Control Module Connector............72
Transmission Data Link Connector................17
Coolant Temperature Switch......................16
Crankshaft Position Sensor......................12
Dash to Instrument Panel Connector A..............64
Dash to Instrument Panel Connector B..............65
Dash to Instrument Panel Connector C..............66
Data Link Connector..........................10
Distributor Ignition Coil........................10
Dome Lamp................................31
Dome and Courtesy Lamps.................29, 30, 31
Cargo Lamp..............................30
Dome Lamp..............................31Wiring Diagram Name Sheet Number
Dome/Reading Lamp.........................31
Glove Box Lamp...........................29
Reading Lamp.............................31
Vanity Lamps.............................31
Dome/Reading Lamp..........................31
Door Jamb Switch System....................49, 50
Left Front Door Jamb Switch...................50
Left Rear Door Jamb Switch...................50
Liftgate Switch............................46
Right Front Door Jamb Switch..................49
Right Rear Door Jamb Switch..................49
Electronic Fuel Injection
Ignition System................9,10,11,12,13,14
Automatic Shut Down Relay.....................9
Camshaft Position Sensor.....................12
Crankshaft Position Sensor.....................12
Data Link Connector.........................10
Distributor Ignition Coil.......................10
Engine Coolant Temperature Sensor...............11
Fuel Injectors.............................14
Fuel Pump Relay............................9
Heated Oxygen Sensor.......................13
Idle Air Control Motor........................14
Intake Air Temp Sensor.......................11
Map Sensor..............................11
Powertrain Control Module........9,10,11,12,13,14
Throttle Position (Sensor).....................11
Engine Block Heater...........................58
Engine Coolant Temperature Sensor................11
Engine Coolant Temperature Switch.................15
Engine Oil Pressure and Temperature System..........15
Engine Oil Pressure Switch......................15
Engine Starter System..........................6
Battery..................................6
Engine Starter Motor.........................6
Engine Starter Relay..........................6
Fan Control Relay...........................3,7
Fog Lamp Illumination Lamp.....................20
Fog Lamp Relay.............................21
Fog Lamp Switch............................20
4WD Select Trac Indicator Lamp................39, 40
Front Axle Switch............................16
Front End Lighting.........................21, 22
Fog Lamp Relay...........................21
Left Fog Lamp.............................21
Left Headlamp.............................21
Left Park/Turn Signal Lamp....................21
Left Side Marker Lamp.......................21
Right Fog Lamp............................22
Right Headlamp............................22
Right Park/Turn Signal Lamp...................22
Right Side Marker Lamp......................22
Front Wipers/Washer - Intermittent..............33, 34
JWIRING DIAGRAMS 8W - 271

Wiring Diagram Name Sheet Number
Front Washer Pump.........................34
Front Wiper Motor..........................34
Intermittent Wiper Module.....................33
Park Switch..............................34
Washer Fluid Level Switch.....................33
Washer Switch............................33
Windshield Wiper/Washer Circuit Breaker...........33
Wiper/Washer Switch........................33
Fuel Gauge Sensor...........................54
Fuel Injectors...............................14
Fuel Pump.................................54
Fuel Pump Module...........................54
Fuel Pump Relay............................3,9
Fuel Tank System............................54
Full Time Indicator Lamp.....................39, 40
Fuse Application Chart........................1,2
Fuse Panel..............................62, 63
Fuses
Fuse #2.............................2,4,60
Fuse #4..........................2,33,44,46
Fuse #5.............................1,4,27
Fuse #6.............................1,4,51
Fuse #9...............................1,19
Fuse #10..............................1,19
Fuse #13............................2,47,58
Fuse #14.........................2,23,33,60
Fuse #19............................2,33,35
Fuse #25............................1,19,25
Fuse #26..........................1,8,37,43
F1 ...................................3,4
F2 ...................................3,9
F3 ...................................3,17
F4 ...................................3,4
F5 .................................3,6,17
F6 .................................3,9,10
F7 .....................................3
F8 ...................................3,4
F9 .....................................3
F10 ...................................3,4
F11 ...................................3,4
F12 ...................................3,4
F13 ...................................3,4
F14 ...................................3,4
F15 ...................................3,4
F16 ...................................3,4
Generator..................................5
Glove Box Lamp.............................29
Hazard Flasher..............................32
Headlamp Dimmer Switch.......................19
Headlamp Switch...........................1,19
Headlamp Switch System.....................19, 20
Fog Lamp Illumination........................20
Fog Lamp Switch...........................20
Headlamp Dimmer Switch.....................19
Headlamp Switch...........................19
Headlamps..............................21, 22
Heated Oxygen Sensor.........................13
Heated Rear Window..........................60Wiring Diagram Name Sheet Number
Relay...................................60
Switch..................................60
Switch Illumination..........................25
Heater A/C Panel Lamp........................25
Heater and A/C System......................45, 46
A/C Compressor Clutch.......................45
A/C Compressor Clutch Relay...................45
A/C Heater Blower Motor......................46
A/C Low Pressure Switch.....................45
A/C Mode Selector Switch.....................46
A/C Thermostat............................45
Blower Resistor............................46
Blower Switch.............................46
Powertrain Control Module.....................45
Heater System..............................44
Blower Resistor............................44
Blower Switch.............................44
Heater Blower Motor.........................44
Heat Mode Select Switch......................44
Heater Blower Motor..........................44
Heater Element..............................52
Heavy Duty Cooling (4.0L).......................7
Fan Control Relay...........................7
Powertrain Control Module.....................7
Radiator Fan Motor..........................7
High-Beam Indicator Lamp......................41
Horn System...............................27
Horn Brush/Slip Ring........................27
Horn Relay...............................27
Horn Switch..............................27
Left Side Horn.............................27
Right Side Horn............................27
Idle Air Control Motor.........................14
Ignition Key Warning Switch.....................43
Ignition Switch...............................8
Ignition System..............................8
Instrument Cluster............................37
Instrument Cluster Connector.....................37
Instrument Cluster Connector 16 Way...............69
Instrument Cluster Indicator Printed Circuit Board.......40
Instrument Cluster Printed Circuit Board (Standard)......41
Instrument Panel Ground.......................32
Instrument Panel Illumination..................25, 26
Heated Rear Window Switch Illumination...........25
Heater A/C Panel Lamp.......................25
Rear Wiper/Wash Switch Lamp..................26
Transfer Case Lamp.........................26
Transmission Range Lamp.....................26
Intake Air Temp Sensor........................11
Intermittent Front Wipers/Washers...............33, 34
Intermittent Wiper Module.......................33
Lamps
Ashtray Illumination Lamp.....................26
Back-Up Lamp..........................55, 56
Cargo Lamp..............................30
Check Engine Indicator Lamp................39, 40
Cigar Lighter Illumination......................58
Dome Lamp..............................31
8W - 272 WIRING DIAGRAMSJ

(3) Connect the CCV hoses (Fig. 1).
(4) Connect negative cable to battery.
ROCKER ARMS
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Remove the engine cylinder head cover.
(2) Remove the capscrews at each bridge and pivot
assembly (Fig. 2). Alternately loosen the capscrews
one turn at a time to avoid damaging the bridges.
(3) Check for rocker arm bridges which are caus-
ing misalignment of the rocker arm to valve tip area.
(4) Remove the bridges, pivots and corresponding
pairs of rocker arms (Fig. 2). Place them on a bench
in the same order as removed.
(5) Remove the push rods and place them on a
bench in the same order as removed.
CLEANING
Clean all the components with cleaning solvent.
Use compressed air to blow out the oil passages in
the rocker arms and push rods.
INSPECTION
Inspect the pivot surface area of each rocker arm.
Replace any that are scuffed, pitted, cracked or ex-
cessively worn.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply
pitted.
Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessivelyworn because of lack of oil, replace it and inspect the
corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for ob-
struction if this condition exists.
INSTALLATION
(1) Lubricate the ball ends of the push rods with
Mopar Engine Oil Supplement, or equivalent and in-
stall push rods in their original locations. Ensure
that the bottom end of each push rod is centered in
the tappet plunger cap seat.
(2) Using Mopar Engine Oil Supplement, or equiv-
alent, lubricate the area of the rocker arm that the
pivot contacts. Install rocker arms, pivots and bridge
above each cylinder in their originally position.
(3) Loosely install the capscrews through each
bridge.
(4) At each bridge, tighten the capscrews alter-
nately, one turn at a time, to avoid damaging the
bridge. Tighten the capscrews to 28 Nzm (21 ft. lbs.)
torque.
(5) Install the engine cylinder head cover.
ENGINE CYLINDER HEAD
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Disconnect negative cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the coolant and disconnect the hoses at
the engine thermostat housing. DO NOT waste reus-
able coolant. If the solution is clean and is being
drained only to service the engine or cooling system,
drain the coolant into a clean container for reuse.
(3) Remove the air cleaner assembly.
(4) Remove the engine cylinder head cover.
(5) Remove the capscrews, bridge and pivot assem-
blies and rocker arms (Fig. 2).
(6) Remove the push rods (Fig. 2).Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the serpentine drive belt at the power
steering pump, if equipped or at the idler pulley (re-
fer to Group 7, Cooling System for the proper proce-
dure).
(8) If equipped with air conditioning, perform the
following:
Fig. 2 Rocker Arm Assembly
J2.5L ENGINE 9 - 19

(3) Check for rocker arm bridges which are caus-
ing misalignment of the rocker arm to valve tip area.
(4) Remove the bridges, pivots and corresponding
pairs of rocker arms (Fig. 2). Place them on a bench
in the same order as removed.
(5) Remove the push rods and place them on a
bench in the same order as removed.
CLEANING
Clean all the components with cleaning solvent.
Use compressed air to blow out the oil passages in
the rocker arms and push rods.
INSPECTION
Inspect the pivot surface area of each rocker arm.
Replace any that are scuffed, pitted, cracked or ex-
cessively worn.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply
pitted.
Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessively
worn because of lack of oil, replace it and inspect the
corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for ob-
struction if this condition exists.
INSTALLATION
(1) Lubricate the ball ends of the push rods with
Mopar Engine Oil Supplement, or equivalent and in-
stall push rods in their original locations. Ensurethat the bottom end of each push rod is centered in
the tappet plunger cap seat.
(2) Using Mopar Engine Oil Supplement, or equiv-
alent, lubricate the area of the rocker arm that the
pivot contacts. Install rocker arms, pivots and bridge
above each cylinder in their originally position.
(3) Loosely install the capscrews through each
bridge.
(4) At each bridge, tighten the capscrews alter-
nately, one turn at a time, to avoid damaging the
bridge. Tighten the capscrews to 28 Nzm (21 ft. lbs.)
torque.
(5) Install the engine cylinder head cover.
ENGINE CYLINDER HEAD
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Disconnect negative cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the coolant and disconnect the hoses at
the engine thermostat housing. DO NOT waste reus-
able coolant. If the solution is clean and is being
drained only to service the engine or cooling system,
drain the coolant into a clean container for reuse.
(3) Remove the air cleaner assembly.
(4) Remove the engine cylinder head cover.
(5) Remove the capscrews, bridge and pivot assem-
blies and rocker arms (Fig. 2).
(6) Remove the push rods (Fig. 2).Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the serpentine drive belt at the power
steering pump, if equipped or at the idler pulley (re-
fer to Group 7, Cooling System for the proper proce-
dure).
(8) If equipped with air conditioning, perform the
following:
(a) Remove the bolts from the A/C compressor
mounting bracket and set the compressor aside.
(b) Remove the air conditioner compressor
bracket bolts from the engine cylinder head.
(c) Loosen the through bolt at the bottom of the
bracket.
(9) If equipped, disconnect the power steering
pump bracket. Set the pump and bracket aside. DO
NOT disconnect the hoses.
(10) Remove the fuel lines and vacuum advance
hose.
Fig. 2 Rocker Arm Assembly
9 - 60 4.0L ENGINEJ

REMOVALÐYJ MODELS
WARNING: EXTINGUISH ALL TOBACCO SMOKING
PRODUCTS BEFORE SERVICING THE FUEL SYS-
TEM. KEEP OPEN FLAME AWAY FROM FUEL SYS-
TEM COMPONENTS.
(1) Disconnect negative battery cable.
(2) Remove the fuel filler cap. Using an approved por-
table gasoline siphon/storage tank, drain fuel tank.
(3) Raise and support vehicle.
(4) Using a small straight blade screwdriver, pull
back the stems of the push clips that secure the fuel
filler neck shroud (located at bottom of left rear
wheel well) in place (Fig. 4). This unlocks the push
clip allowing them to be removed by pulling assem-
bly out of shroud. Remove shroud.
(5) Disconnect fuel fill hose and fill vent hose from
filler neck (Fig. 5).
WARNING: WRAP SHOP TOWELS AROUND FUEL
HOSES TO ABSORB ANY FUEL SPILLAGE DURING
FUEL TANK REMOVAL.(6) Disconnect fuel tank vent hose from vent tube.
Disconnect fuel supply and return hoses from tubes
(Fig. 6).
The fuel tank and skid plate are removed as an as-
sembly.
(7) Centrally position a transmission jack under
skid plate/fuel tank assembly.
(8) Remove skid plate/fuel tank assembly mount-
ing nuts (Fig. 7).Do not loosen tank strap nuts.
(9) Lower the skid plate/fuel tank assembly
slightly and disconnect the gauge sender wire con-
nector.
(10) Lower the fuel tank on transmission jack.
(11) Remove tank strap nuts to remove tank from
skid plate.
Fig. 4 Fuel Filler Neck ShroudÐYJ Models
Fig. 5 Filler Neck HosesÐYJ Models
Fig. 6 Fuel Tank HosesÐYJ Models
Fig. 7 Fuel TankÐRemove/InstallÐYJ Models
14 - 14 FUEL SYSTEMJ

ing the IAC motor pintle in and out of the air control
passage. The IAC motor is positioned when the igni-
tion key is turned to the On position.
A (factory adjusted) set screw is used to mechani-
cally limit the position of the throttle body throttle
plate.Never attempt to adjust the engine idle
speed using this screw.All idle speed functions are
controlled by the PCM.
IGNITION COILÐPCM OUTPUT
System voltage is supplied to the ignition coil pos-
itive terminal. The powertrain control module (PCM)
operates the ignition coil.Base (initial) ignition
timing is not adjustable.The PCM adjusts ignition
timing to meet changing engine operating conditions.
The ignition coil is located near the ignition distrib-
utor (Fig. 22).
Refer to Group 8D, Ignition System for additional
information.
MALFUNCTION INDICATOR LAMPÐPCM OUTPUT
The Malfunction Indicator Lamp (formerly referred
to as the Check Engine Lamp) illuminates on the in-
strument panel each time the ignition key is turned
on. It will stay on for three seconds as a bulb test.
If the powertrain control module (PCM) receives an
incorrect signal, or no signal from certain sensors or
emission related systems, the lamp is turned on. This
is a warning that the PCM has recorded a system or
sensor malfunction. In some cases, when a problem is
declared, the PCM will go into a limp-in mode. This
is an attempt to keep the system operating. It signals
an immediate need for service.
The lamp can also be used to display a Diagnostic
Trouble Code (DTC). Cycle the ignition switch On-
Off-On-Off-On within three seconds and any codes
stored in the PCM memory will be displayed. This is
done in a series of flashes representing digits. Refer
to On-Board Diagnostics in the General Diagnosis
section of this group for more information.
RADIATOR FAN RELAYÐPCM OUTPUT
XJ MODELS ONLY
The electric radiator cooling fan used in XJ models
(equipped with 4.0L engine, heavy duty cooling
and/or air conditioning) is controlled by the power-
train control module (PCM) through radiator fan re-
lay. The relay is energized when coolant temperature
is above 103ÉC (217ÉF). It will then de-energize when
coolant temperature drops to 98ÉC (208ÉF). Refer to
Group 7, Cooling Systems for more information.
The relay is located in the power distribution cen-
ter (PDC) (Fig. 23).
The electric radiator cooling fan is not used on YJ
models.
SCI TRANSMITÐPCM OUTPUT
SCI Transmit is the serial data communication
transmit circuit for the DRB scan tool. The power-
train control module (PCM) transmits data to the
DRB through the SCI Transmit circuit.
SHIFT INDICATORÐPCM OUTPUT
Vehicles equipped with manual transmissions have
an Up-Shift indicator lamp. The lamp is controlled
by the powertrain control module (PCM). The lamp
illuminates on the instrument panel to indicate when
the driver should shift to the next highest gear for
best fuel economy. The PCM will turn the lamp OFF
after 3 to 5 seconds if the shift of gears is not per-
formed. The up-shift light will remain off until vehi-
cle stops accelerating and is brought back to range of
up-shift light operation. This will also happen if ve-
hicle is shifted into fifth gear.
The indicator lamp is normally illuminated when
the ignition switch is turned on and it is turned off
when the engine is started up. With the engine run-
ning, the lamp is turned on/off depending upon en-
gine speed and load.
Fig. 23 PDCÐXJ Models
Fig. 22 Ignition CoilÐTypical
14 - 26 FUEL SYSTEMJ

CLEAN AND INSPECTION
(1) Wash all components in clean solvent and dry
with compressed air.
(2) Check for scores, nicks or burrs on the rack pis-
ton finished surface. Slight wear is normal on the
worm gear surfaces.
ASSEMBLE
(1) Install O-ring seal and teflon ring and lubricate
with power steering fluid.
(2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston and
align worm shaft spiral groove with rack piston ball
guide hole (Fig. 33).
WARNING: MAKE SURE ALL RACK PISTON BALLS
ARE REINSTALLED IN THE RACK PISTON. IM-
PROPER INSTALLATION MAY RESULT IN PER-
SONAL INJURY.There are 24 balls in the rack piston circuit,
12 are black and 12 are silver (Chrome). The
black rack piston balls are smaller than the sil-
ver balls. THE BLACK AND SILVER BALLS
MUST BE INSTALLED ALTERNATELY INTO
THE RACK PISTON AND BALL GUIDE. This
procedure will maintain worm shaft preload.
(3) Lubricate and install rack piston balls through
return guide hole while turning wormshaft COUN-
TERCLOCKWISE.
(4) Install remaining balls to guide using grease or
petroleum jelly at each end to hold in place (Fig. 34).
(5) Install guide onto rack piston and return with
clamp and screws. Tighten screws to 58 Nzm (43 in.
lbs.) torque.
(6) Insert Arbor C-4175 (J-21552) into bore of rack
piston. Hold tool tightly against worm shaft while
Fig. 34 Balls in the Return Guide
Fig. 31 Remove and Install Rack Piston
Fig. 32 Remove and Install Seal on Rack Piston
Fig. 33 Installing Balls in Rack Piston
JSTEERING 19 - 31

(7) Raise the key-release lever slightly. Install the
end of the lever spring between the lever and the
boss on the housing (Fig. 27).
(8) Apply chassis lubricant to the wave washer
(Fig. 27). Position it on the threaded pivot post and
resting on the release lever.
(9) Position the shroud on the key/lock cylinder
housing and install the attaching screws. Tighten the
screws to 2 Nzm (18 in. lbs.) torque.Ensure that
the wave washer (Fig. 27) is not displaced whileattaching the shroud to the cylinder housing.
(10) Insert the short, hooked end of the remote rod
in the lock rack.
(11) Install the assembled key/lock cylinder hous-
ing and shroud on the steering column jacket. Install
the attaching screws (Fig. 28). Tighten the screws to
7Nzm (60 in. lbs.) torque.
COLUMN SHIFT OR CONSOLE SHIFT FINAL
ASSEMBLY
(1) 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
(Fig. 29). Force it inward and move the ignition
switch actuator rod up and down to align the compo-
nents. When the components align, the key/lock cyl-
inder will move inward and lock in place.
(2) Install the key warning buzzer switch.
(3) Install the ignition switch, refer to Ignition
Switch ÐAll Models in Group 8D, Ignition.
(4) Install the lower bearing, the adapter, the re-
tainer and spring clip at the lower end of the steer-
ing column.
(5) Install the steering shaft through the lower end
of the steering column and insert it into the upper
bearing.
(6) Position the turn signal switch and wire har-
ness in the cylinder housing. Fold the wires against
the connector. Route the connector down through the
steering column jacket.
(7) Install the windshield wiper wire harness and
switch. Route the wire harness down through steer-
ing column jacket.
Fig. 28 Key/Lock Cylinder Housing Installation
Fig. 26 Key-Release Lever Installation
Fig. 27 Spring Positioning & Wave Washer
Installation
JSTEERING 19 - 57

(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