JEEP CHEROKEE 1994 Service Repair Manual

IGNITION KEY WARNING SWITCH REPLACEMENT
(1) Disconnect negative cable from battery.
(2) Remove horn button with a push and turn mo-
tion.
(3) Remove horn button components (Fig. 1).
(4) Turn key to LOCK position and remove steer-
ing wheel nut and washer.
(5) Scribe an alignment mark on steering wheel in
line with mark already existing on end of steering
column.
(6) Remove vibration damper from steering column
hub, if equipped.
(7) Remove steering wheel using a steering wheel
puller. DO NOT hammer on puller or end of steering
shaft.
WARNING: TO REMOVE THE STEERING SHAFT
SNAP RING IN THE FOLLOWING STEP, THE LOCK-
PLATE MUST BE COMPRESSED. DO NOT AT-
TEMPT TO REMOVE THE LOCKPLATE WITHOUT
COMPRESSOR TOOL C4156 AS THE LOCKPLATE
IS UNDER HEAVY SPRING TENSION.
(8) Compress lockplate with compressor tool
C4156.
(9) Remove steering shaft snap ring (Fig. 2). Dis-
card snap ring. It is not reusable.
(10) Remove compressor tool.
(11) Remove lockplate, cancelling cam, and upper
bearing preload spring.
(12) Remove horn button components from cancel-
ing cam.(13) Remove screw and hazard warning switch
knob.
(14) Remove dimmer switch actuator arm attach-
ing screw (Fig. 3).
(15) Remove turn/hazard switch attaching screws
(Fig. 3).
(16) Unplug wiper switch connector.
(17) Push turn/hazard connector up and out of
Fig. 1 Steering Wheel Removal/Installation
Fig. 2 Lockplate Removal
Fig. 3 Turn/Hazard Switch And Dimmer Actuating
Arm Screws
8U - 4 CHIME/BUZZER WARNING SYSTEMSJ

steering column connector (Fig. 4).
(18) Pry up locking tabs of steering column connec-
tor and remove connector from column bracket.
(19) Pull turn/hazard switch out of the column far
enough to allow access to remaining screws.
(20) Insert ignition key in the lock cylinder and
turn key to ON position.(21) Remove key warning buzzer switch and re-
taining clip with a paper clip. Insert paper clip below
retainer so that retainer is flattened (Fig. 5).
Do not attempt to remove buzzer switch and
clip separately. The clip could fall into the col-
umn jacket.
(22) Reverse the removal procedures to assemble
steering column.
(23) Install steering wheel. Tighten steering wheel
nut to 34 Nzm (25 ft. lbs.) torque.
Fig. 4 Turn/Hazard Switch And Steering Column
Connectors
Fig. 5 Buzzer Switch Removal
JCHIME/BUZZER WARNING SYSTEMS 8U - 5

WIRING DIAGRAMS
CONTENTS
page page
FUSE CHARTS AND RELAY BANKS......... 8
GENERAL INFORMATION.................. 1
SPLICE LOCATIONS..................... 53
WIRING AND COMPONENT IDENTIFICATION . 13WIRING DIAGRAMS XJ.................. 149
WIRING DIAGRAMS XJ RHD............. 271
WIRING DIAGRAMS YJ.................. 73
GENERAL INFORMATION
INDEX
page page
Circuit Identification........................ 2
Component Identification.................... 2
Connector and Terminal Assembly Replacement . . 5
Connector Replacement.................... 4
Connectors.............................. 3
Fusible Link Replacement................... 4
Fusible Links............................. 3
Locating A System........................ 2Secondary Ignition Wiring................... 1
Splice Locations.......................... 2
Symbols, Fuses and Abbreviations............ 6
Terminal Replacement...................... 5
Troubleshooting Wiring Problems.............. 3
Wire Code Identification.................... 2
Wiring Diagram Sheets and Indexes........... 1
Wiring Repair............................ 4
The wiring diagrams contain the latest information
at the time of publication.
Throughout this group references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction Section at the front of
this service manual.
SECONDARY IGNITION WIRING
Secondary ignition wiring is shown in Figures 1
and 2. For additional information on ignition systems
or distributor operation refer to Group 8D Ignition
Systems.
WIRING DIAGRAM SHEETS AND INDEXES
The diagrams are organized to show the basic ve-
hicle and all of its options. Add-on or non-factory op-
tions are not covered. The diagram pages are
identified by a sheet number which is located at the
lower right or left hand corner of each sheet.Page
numbers at the top of each page do not apply to
diagram sheets.
Diagram sheets show all information relating to
the system. This includes feeds, grounds, switch in-
ternal circuity, connectors, splices, and pin identifica-
tion for controllers and modules. All components,switches, and relays are shown in the at rest position
with the key removed from the ignition and the doors
closed.
In certain instances a wire may be referenced to
another sheet. When this happens, the wire will be
identified as to where it is going.
The index used for the diagrams is located at the
beginning of the section. The main system and all re-
lated components are covered.
Fig. 1 Secondary Ignition Wiring 2.5L
JWIRING DIAGRAMS 8W - 1

WIRE CODE IDENTIFICATION
Each wire shown in the diagrams contains a code
(Fig. 3) which identifies the main circuit, part of the
main circuit, gauge of wire, and color. The color is
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 4). If the
wire has a tracer and it is a standard color an aster-
isk will follow the main wire color. If the tracer is
non-standard the main wire color will have a slash (/)
after it followed by the tracer color.
CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric
code to identify the wire and its function. To identify
which circuit code applies to a system, refer to the
Circuit Identification Code Chart. This chart shows
the main circuits only and does not show the second-
ary codes that may apply to some models.
LOCATING A SYSTEM
To locate a system or component in the diagrams,
refer to the alphabetical index at the front of the di-
agrams. Determine the diagram sheet number. Sheet
numbers are located at the lower right or left handcorner of each sheet.Page numbers at the top of
the page do not apply to diagram sheets.
The index identifies the main system and all com-
ponents that relate to that system. There are also
sections of the index that identify specific compo-
nents only (for example modules, lamps, etc.). Refer
to a components name in the index if you are unclear
as to what a system may be called.
Diagram sheets are arranged starting with the bat-
tery and fuses. Then working into charging, starting,
and ignition systems. After this they start at the
front of the vehicle and work to rear. The diagrams
end with connector identification pages.
COMPONENT IDENTIFICATION
When looking for a components location in the vehicle
refer to the Component Identification section index.
This section shows the wire harness routing and the
components location in the vehicle. When using this sec-
tion refer to the wiring diagrams for the general loca-
tion of the component. Then use the component
identification index to locate the proper figure number.
SPLICE LOCATIONS
Splice locations are indicated in the diagrams by a
diamond with a splice circuit code within it (Fig. 5
example 1). If there is more than one splice per cir-
cuit a small box will be connected to it with the
splice number in it (Fig. 5 example 2).
To locate a splice in the wiring harness determine
the splice number from the wiring diagrams then re-
fer to the splice location index. This section shows
the general location of the splice in the harness.
Fig. 2 Secondary Ignition Wiring 4.0L
Fig. 3 Wire Color Code Identification
Fig. 4 Wire Color Code Chart
8W - 2 WIRING DIAGRAMSJ

CONNECTORS
The connectors shown in the diagram sheets are
viewed from the terminal end unless otherwise speci-
fied. For viewing bulkhead, powertrain control module,
and transmission control module connectors refer to the
rear of the wiring diagrams. This area shows major con-
nectors and identifies pin and cavity information.
The connectors shown in the diagrams are identi-
fied in two ways. The first is an actual view of the
connector. This view shows the connector and which
cavity the wire is in.
The second way is with the use of arrows to indicate
the connector. This is done when the connector is to
large to be shown on the diagram page. A box placed
next to the connector identifies the connector and the
cavity the wire is in. In certain instances there may be
more than one connector in the same location. When
this happens the connector identification box will have a
number placed in it. Refer to the rear of the diagrams
for a complete pin out of the connector.
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below.(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit as the problem area. Refer to the
wiring diagrams fuse application chart for circuit
identification.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step check for
proper operation of all items on the circuit repaired.
Refer to the wiring diagram fuse application chart for
circuit identification.
FUSIBLE LINKS
Vehicle wiring harnesses are equipped with fusible
links to protect against harness damage in the event
of a short in the system. Fusible links are color coded
to indicate wire gauge and size. Refer to the fusible
link chart for color and gauge identification (Fig. 6).
Fig. 5 Wiring Splice Examples
Fig. 6 Fusible Link Chart
JWIRING DIAGRAMS 8W - 3

FUSIBLE LINK REPLACEMENT
CAUTION: Do not replace blown fusible links with a
standard wire. Only use fusible type wire with hypa-
lon insulation or damage to the electrical system
could occur. Also make sure correct gauge of wir-
ing is used. Refer to the wiring diagrams for proper
gauge and color.
When a fusible link blows it is important to find
out what the problem is. They are placed in the elec-
trical system for protection against shorts to ground.
This can be caused by a component failure or various
wiring failures.Do not just replace the fusible
link to correct the problem.
When diagnosing a faulty fusible link it is impor-
tant to check the wire carefully. In some instances
the link may be blown and it will not show through
the insulation, the wire should be checked over its
entire length for internal breaks.
(1) Disconnect battery negative cable.
(2) Cut out the blown portion of the fusible link.
(3) Strip 1 inch of insulation from each end of the
existing fusible link.
(4) Place a piece of heat shrink tubing over one
side of the fusible link. Make sure the tubing will be
long enough to cover and seal the entire repair area.
(5) Cut a replacement piece of fusible link approx-
imately two inches longer than the piece removed.
(6) Remove one inch of insulation from each end of
the replacement fusible link.
(7) Spread the strands of wire apart on each of the
exposed wires (Fig. 7 example 1).
(8) Push the two ends of the wire together until
the strands of wire are close to the insulation (Fig. 7
example 2).
(9) Twist the wires together (Fig. 7 example 3).
(10) Solder the wires together using rosin core type
solder only.Do not use acid core type solder.
(11) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(12) Secure the fusible link to the existing ones to
prevent chafing or damage to the insulation.
(13) Connect battery and test affected systems.
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wir-
ing diagrams. The wires must also be held securely
in place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.(4) Spread the strands of the wire apart on each of
the exposed wires (Fig. 7 example 1).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex-
ample 2).
(6) Twist the wires together (Fig. 7 example 3).
(7) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(8) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation.
(10) Connect battery and test affected systems.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector to be repaired from its
mating half.
(3) Remove connector locking wedge (Fig. 8).
(4) Position the connector locking finger away from
the terminal while pulling on the wire to remove the
terminal from the connector (Fig. 9).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin
out identification refer to the wiring diagrams.
(8) Insert the connector locking wedge into the re-
paired connector.
(9) Connect connector to its mating half.
Fig. 7 Wire Repair
8W - 4 WIRING DIAGRAMSJ

(10) Connect battery and test affected systems.
CONNECTOR AND TERMINAL ASSEMBLY
REPLACEMENT
(1) Disconnect Battery.
(2) Disconnect the connector being repaired from
its mating half.
(3) Cut off the existing wire connector directly be-
hind the insulator and remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side about
1/2 inch apart (Fig. 10).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair (allow extra length
for soldered connections). Check that the overall
length is the same as the original (Fig. 10).
(7) Remove 1 inch of insulation from each wire.(8) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each of
the exposed wires (Fig. 7 example 1).
(10) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex-
ample 2).
(11) Twist the wires together (Fig. 7 example 3).
(12) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Reconnect the repaired connector.
(17) Connect battery and test affected systems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half.
(3) Remove connector locking wedge (Fig. 8).
(4) Position the connector locking finger away from
the terminal while pulling on the wire to remove the
terminal from the connector (Fig. 9).
(5) Cut the wire 6 inches from the back of the con-
nector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assembly
that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and re-
move 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
Fig. 8 Connector Locking Wedge Tab (Typical)
Fig. 9 Connector Locking Finger and Locking
Wedge (Typical)
Fig. 10 Stagger Cutting Wires
JWIRING DIAGRAMS 8W - 5

(10) Spread the strands of the wire apart on each
of the exposed wires (Fig. 7 example 1).
(11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex-
ample 2).
(12) Twist the wires together (Fig. 7 example 3).
(13) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge and recon-
nect the connector to its mating half.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.(18) Connect battery and test affected systems.
SYMBOLS, FUSES AND ABBREVIATIONS
Various symbols are used throughout the wiring di-
agrams. These symbols can be identified by referring
to the symbol identification chart (Fig. 11).
Certain abbreviations are also used in the dia-
grams. These have been developed in such a way
that there meaning should be clear. For fuse block,
relay bank, and power distribution center informa-
tion refer to the fuse charts and relay bank index.
CAUTION: When replacing a blown fuse it is impor-
tant to replace it with a fuse having the correct am-
perage rating. The use of a fuse with a rating other
than indicated may result in an electrical overload.
If a proper rated fuse continues to blow, it indicates
a problem that should be corrected.
8W - 6 WIRING DIAGRAMSJ

Fig. 11 Symbol Identification
JWIRING DIAGRAMS 8W - 7