cooling JEEP CHEROKEE 1994 Service Workshop Manual

INSTALLATION
(1) Install coolant temperature sensor into the
thermostat housing. Tighten to 28 Nzm (21 ft. lbs.)
torque.
(2) Connect the wire connector.
(3) Fill the cooling system. Refer to group 7, Cool-
ing System.
DISTRIBUTOR
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing.
The seal is not serviceable.
The camshaft position sensor is located in the dis-
tributor on all engines (Fig. 9).
Refer to Fig. 9 for an exploded view of the distrib-
utor.
REMOVALÐ2.5L ENGINE
(1) Disconnect the negative battery cable at the
battery.
(2) Disconnect coil secondary cable at coil.
(3) Remove distributor cap from distributor (2
screws). Do not remove cables from cap.
(4) Disconnect the distributor wiring harness from
the main engine harness.
(5) Scribe a mark on the distributor housing in
line with the tip of the rotor. Note the position of the
rotor and distributor housing. This is in relation tothe surrounding engine components as reference
points for installing the distributor.
(6) Remove the distributor holddown bolt and
clamp.
(7) Remove the distributor from engine by lifting
straight up. Remove and discard old distributor-to-
engine block gasket. Note that the rotor will rotate
slightly in a counterclockwise direction while lifting
up the distributor. Note this position after removal.
INSTALLATIONÐ2.5L ENGINE
ENGINE NOT ROTATED AFTER REMOVAL
This procedure assumes that the engine was not ro-
tated with distributor out of engine.
(1) Clean the distributor mounting hole area of the
engine block.
(2) Install a new distributor-to-engine block gas-
ket.
There is a fork on the distributor housing where
the housing seats against the engine block. The slot
in the fork aligns with the distributor holddown bolt
hole in the engine block. The distributor is correctly
installed when the rotor is correctly positioned. This
is with the slot in the fork aligned with the hold-
down bolt hole in the cylinder block. Because of the
fork on the distributor housing, initial ignition tim-
ing is not adjustable (the distributor cannot be rotat-
ed).
(3) Position the distributor shaft in the cylinder
block. If the engine was not rotated while the distrib-
utor was removed, perform the following:
²Align the rotor tip with the scribe mark on the
distributor housing during removal. Turn the rotor
approximately 1/8-turn counterclockwise past the
scribe mark.
CAUTION: Be sure that the distributor shaft fully
engages into the oil pump drive gear shaft. It may
be necessary to slightly rotate (bump) the engine.
This is done while applying downward hand force
on the distributor body. It should fully engage the
distributor shaft with the oil pump drive gear shaft.
²Slide the distributor shaft down into the engine.
It may be necessary to move the rotor and shaft
(slightly) to engage the distributor shaft with the slot
in the oil pump shaft. The same may have to be done
to engage the distributor gear with the camshaft
gear. However, the rotor should align with the scribe
mark when the distributor shaft is down in place.
²Install the distributor holddown clamp and bolt.
Tighten the bolt to 23 Nzm (17 ft. lbs.) torque.
(4) Install the distributor cap (with the ignition ca-
bles) on the distributor housing (Fig. 10). Tighten
distributor cap holddown screws to 3 Nzm (26 in. lbs.)
torque.
(5) Connect the distributor wiring harness to the
main engine harness.
Fig. 9 DistributorÐ2.5L/4.0L EnginesÐTypical
JIGNITION SYSTEMS 8D - 23

The camshaft position sensor is located in the dis-
tributor on all engines (Fig. 9).
Refer to figure 9 for an exploded view of the dis-
tributor.
(1) Disconnect the negative battery cable at bat-
tery.
(2) On XJ models equipped with A/C, remove the
electrical cooling fan and shroud assembly from the
radiator. This will provide room to turn the engine
with a socket and ratchet using the vibration damper
bolt.
(3) Scribe a mark on the distributor housing. Do
this below the left side of (past) the number one
spark plug cable post of the distributor cap. This will
be used as a reference for #1 cylinder firing position
(Fig. 14).
(4) Remove the distributor cap from distributor (2
screws).
(5) Turn the engine in a clockwise direction until
the rotor is approaching the scribe mark on the dis-
tributor housing. Then slowly turn the engine until
the timing mark on the crankshaft vibration damper
lines up with zero on the front cover timing scale
(Fig. 15).
The timing mark is on the edge of the vibra-
tion damper closest to the engine front cover.
(6) Align the trailing edge of the rotor blade with
the scribe mark on the distributor housing (Fig. 16).
(7) Remove the distributor holddown bolt and
clamp.
(8) Remove the distributor from the engine by lift-
ing straight up. Remove and discard old distributor-
to-engine block gasket. Note that the rotor willrotate slightly in a counterclockwise direction while
lifting up the distributor. Note this position after re-
moval.
INSTALLATIONÐ4.0L ENGINE
(1) Clean the distributor mounting area of the cyl-
inder block.
(2) Install a replacement distributor-to-engine
block gasket.
(3) Using a flat blade screwdriver, turn the oil
pump gear shaft. Do this until the slot is slightly
past the 11 o'clock position (Fig. 17).
Fig. 13 Distributor Rotor PositionÐ2.5L EngineFig. 14 Mark Distributor Housing
Fig. 15 Align Timing Marks
JIGNITION SYSTEMS 8D - 25

The oil pump shaft is located down in the distribu-
tor hole.
(4) Install the rotor.
(5) Without engaging the distributor gear into the
cam gear, position the distributor into the hole in the
engine block. Be sure the distributor gasket is in-
stalled.
(6) Visually line up the holddown ear of the dis-
tributor housing with the holddown clamp hole (Fig.
18).
(7) Turn the rotor to the 4 o'clock position (Fig.
19).
(8) Slide the distributor down into the block until
it seats. Keep the holddown ear aligned to the hole
in the block.
(9) The rotor should be in the 5 o'clock position.
This is with the trailing edge of rotor blade lined up
with scribe mark on distributor housing (number one
spark plug cable post location).(10) Install the distributor holddown clamp bolt
and tighten to 23 Nzm (17 ft. lbs.) torque.
(11) Install the distributor cap and connect the dis-
tributor electrical connector.
(12) Install electrical cooling fan and shroud if ap-
plicable.
(13) Connect battery cable to battery.
IGNITION COIL
The ignition coil is an epoxy filled type. If the coil
is replaced, it must be replaced with the same type.
Fig. 16 Align Rotor Trailing Edge With Scribe Mark
Fig. 17 Align Oil Pump Gear ShaftÐ4.0L Engine
Fig. 18 Distributor InstallationÐTypical
Fig. 19 Rotor Alignment
8D - 26 IGNITION SYSTEMSJ

WIRING DIAGRAMS XJ
INDEX
Wiring Diagram Name Sheet Number
A/C Compressor Clutch Relay...................3,69
A/C Compressor Clutch........................69
A/C Heater Blower Motor.......................70
A/C Low Pressure Switch.......................69
A/C Mode Select Switch........................70
A/C Thermostat..............................69
ABS Diode.................................33
ABS Green Indicator Lamp......................57
ABS Hydraulic Actuation Unit.....................33
ABS #1 Relay.............................3,31
ABS #2 Relay.............................3,31
ABS Pump Motor............................30
ABS Red Indicator Lamp.......................57
Ambient Temperature Sensor.....................53
Antenna...................................71
Antenna Mast...............................71
Anti-Lock Brake Control Module Connector...........109
Anti-Lock Braking System...............29,30,31,32,33
ABS Diode...............................33
ABS Relays...............................31
Anti-Lock Pump Motor.......................30
Anti-Lock Brake System Module.........29,30,31,32,33
Data Link Connector.........................32
G Sensor................................30
Hydraulic Actuation Unit......................33
Left Front Wheel Sensor......................29
Left Rear Wheel Sensor.......................29
Pedal Travel Sensor.........................30
Right Front Wheel Sensor.....................29
Right Rear Wheel Sensor......................29
Anti-Lock Brake System Module...........29,30,31,32,33
Anti-Lock Pump Motor.........................30
Anti-Lock Relay..............................31
Ashtray Lamp...............................48
Automatic Shut Down Relay..................3,12,17
Automatic Transmission Control System (2.5L).........27
Front Axle Lock-Up Switch.....................27
EMCC Relay..............................27
EMCC Solenoid............................27
Back-Up Lamp Switch.........................25
Ballast Resistor..............................89
Battery..................................1,7,8
Blower Motor.............................68,70
Blower Resistors...........................68,70
Blower Switch............................68,70
Body Ground...............................44
Brake Warning Switch.........................67
Bulkhead Disconnect.................101,102,103,104
Camshaft Position Sensor.....................11,20
Cargo Lamp................................50
Center High Mounted Stop Lamp..................98
Charging System 2.5L..........................5
Generator.................................5Wiring Diagram Name Sheet Number
Charging System 4.OL..........................6
Generator.................................6
Chime Module..............................74
Ignition Key Warning Switch....................74
Seat Belt Switch...........................74
Cigar Lighter...............................37
Cigar Lighter Lamp...........................48
Circuit Breakers
In Line Circuit Breaker........................2
Trailer Tow In-Line Circuit Breaker................97
Windshield Wiper Circuit Breaker...............63,64
Connectors
Anti-Lock Brake Control Module Connector.........109
Data Link Connector...................16,18,25,32
Instrument Cluster Connector................55,108
Main Body Connectors.......................112
Power Mirror Connector......................110
Powertrain Control Module Connector.............111
Remote Keyless Entry Module Connector...........114
Steering Column Connector...................106
Telltale Connector........................56,107
Trailer Tow Connector........................93
Transmission Control Module Connector...........105
Cooling Fan Relay...........................3,23
Courtesy Lamp..............................49
Crankshaft Position Sensor....................11,20
Data Link Connector....................16,18,25,32
Daytime Running Lamp Module (DRL)...............38
Daytime Running Lamp System...................38
Diode,ABS.................................33
Distributor Ignition Coil.......................16,18
Dome Lamp................................51
Dome And Courtesy Lamps..................49,50,51
Cargo Lamp..............................50
Dome Lamp..............................51
Dome/Reading Lamp.........................51
Glove Box Lamp...........................49
Left Courtesy Lamp.........................49
Reading Lamp.............................51
Right Courtesy Lamp........................49
Vanity Lamps.............................51
Dome Reading Lamp..........................51
Door Jamb Switch System....................75,76
Left Front Door Jamb Switch...................75
Left Rear Door Jamb Switch...................75
Liftgate Switch............................76
Right Front Door Jamb Switch..................76
Right Rear Door Jamb Switch..................76
EMCC Relay...............................3,27
EMCC Solenoid..............................27
Engine Block Coolant Heater/Cigar Lighter............37
Cigar Lighter..............................37
Engine Block Coolant Heater....................37
JWIRING DIAGRAMS 8W - 149

Wiring Diagram Name Sheet Number
Fuse #15...............................1,41
Fuse #17...........................2,10,55,74
Fuse #18...............................1,66
Fuse #19.............................1,41,47
Gauges
Engine Coolant Temperature Gauge...........59,60,61
Engine Oil Pressure Gauge.................59,60,61
Fuel Gauge...........................59,60,61
G Sensor..................................30
Generator.................................5,6
Glove Box Lamp.............................49
Hazard Flasher............................35,46
Headlamp Delay Module........................43
Headlamp Dimmer Switch.......................41
Headlamp Switch...........................41,42
Fog Lamp Illumination........................42
Fog Lamp Switch...........................42
Headlamp Dimmer Switch.....................41
Headlamp Switch...........................41
Headlamps...............................39,40
Heat Mode Select Switch.......................68
Heated Oxygen Sensor.......................13,21
Heated Rear Window..........................66
Relay...................................66
Grid...................................66
Switch..................................66
Heated Rear Window Switch Lamp.................47
Heater A/C Panel Lamp........................47
Heater and A/C System......................69,70
A/C Mode Selector Switch.....................70
A/C Compressor Clutch.......................69
A/C Compressor Clutch Relay...................69
A/C Heater Blower Motor......................70
A/C Thermostat............................69
A/C Low Pressure Switch.....................69
Blower Resistor............................70
Blower Switch.............................70
Powertrain Control Module.....................69
Heat Mode Select Switch.......................68
Heater Blower Motor..........................68
Heater,Engine Block...........................37
Heater System..............................68
Blower Resistor............................68
Blower Switch.............................68
Heater Blower Motor.........................68
Heater Mode Select Switch....................68
Heavy Duty Cooling 4.OL.......................23
Fan Control Relay...........................23
Powertrain Control Module.....................23
Radiator Fan Motor.........................23
High Beam Indicator Lamp..................59,60,61
High Beam Relay............................40
Hi-Line Instrument Cluster.......................61
Horn Brush/Slip Ring..........................34
Horn Relay................................34
Horn Switch................................34
Horns....................................34
Hydraulic Actuation Unit, ABS....................33Wiring Diagram Name Sheet Number
Idle Air Control Motor.......................15,22
Ignition Key Warning Switch.....................74
Ignition Switch..............................2,9
Ignition System............................9,10
Injectors................................15,22
In Line Circuit Breaker..........................2
Instrument Cluster............................55
Powertrain Control Module.....................55
Washer Fluid Level Switch.....................55
Instrument Cluster (Hi-Line)......................61
Instrument Cluster (Lo-Line).....................60
Instrument Cluster (Standard)....................59
Instrument Cluster Connector..................55,108
Instrument Cluster Printed Circuit Board (W/ABS).......57
Instrument Cluster Printed Circuit Board (W/O ABS)......58
Instrument Cluster Indicators.....................56
Instrument Panel Ground.......................62
Instrument Panel Illumination...................47,48
Ashtray Lamp.............................48
Cigar Lighter Lamp..........................48
Fog Lamp Illumination........................47
Heater A/C Panel Lamp.......................47
Heater Rear Window Switch Lamp................47
Rear Wiper Wash Switch Lamp..................47
Transfer Case Lamp.........................48
Transmission Range Switch Lamp................48
Intake Air Temperature Sensor..................14,19
Intermittent Front Wipers/Washers.................64
Intermittent Wiper Module.......................64
Lamps
ABS Green Indicator Lamp.....................57
ABS Red Indicator Lamp......................57
Ashtray Lamp.............................48
Cargo Lamp..............................50
Center High Mounted Stop Lamps................98
Cigar Lighter Lamp..........................48
Dome Lamp..............................51
Dome/Reading Lamp.........................51
Fog Lamp Illumination........................47
4WD Indicator Lamp.....................26,57,58
Full Time Indicator Lamp....................57,58
Glove Box Lamp...........................49
Heated Rear Window Switch Lamp...............47
Heater A/C Panel Lamp.......................47
High Beam Indicator Lamp.................59,60,61
Indicator Lamp 4WD.......................57,58
Instrument Cluster Illumination Lamps.........59,60,61
Left Back-Up Lamp........................91,93
Left Courtesy Lamp.........................49
Left Fog Lamp.............................39
Left Headlamp.............................39
Left Park/Turn Signal Lamp....................39
Left Side Marker Lamp (Front)..................39
Left Side Marker Lamp (Rear)................91,93
Left Tail/Stop Lamp.......................91,93
Left Turn Indicator Lamp..................59,60,61
Left Turn Lamp (Amber)....................91,93
Left Vanity Lamp...........................51
JWIRING DIAGRAMS 8W - 151

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 Diagram Name Sheet Number
Throttle Position Sensor....................14,19
Vehicle Speed Sensor......................11,20
Speakers................................71,72
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
Speedometer...........................59,60,61
Splices
Splice A3...............................1,41
Splice A11...............................5,6
Splice A11-1..............................78
Splice A11-2..............................97
Splice A14.............................12,17
Splice A21............................2,12,17
Splice A21-1.............................2,10
Splice A38..............................2,10
Splice A142............................15,22
Splice A142-1...........................15,22
Splice A142-2.....................5,6,15,16,18,22
Splice C7................................70
Splice C15...............................66
Splice C43.............................68,70
Splice C90...............................69
Splice E2................................47
Splice F12...........................16,18,69
Splice F34...............................41
Splice F85.............................37,71
Splice F87...............................54
Splice G7..............................11,20
Splice K4..............................14,19
Splice K4-1.............................14,19
Splice K6..............................14,19
Splice K7..............................11,20
Splice K22...............................19
Splice K29...............................46
Splice L10.............................92,96
Splice L39...............................40
Splice L50.............................91,95
Splice L60.............................92,96
Splice L90.............................91,95
Splice L90-1..............................40
Splice L90-2............................92,96
Splice L90-3............................91,93
Splice M1..............................51,53
Splice M1-1..............................49
Splice M2................................50
Splice M2-1..............................49
Splice M2-2............................50,75
Splice M2-3............................51,54
Splice Q1................................80
Splice P2................................86
Splice P34...............................86
Splice P79...............................73
Splice Z0.................................5
Splice Z1..............................51,54Wiring Diagram Name Sheet Number
Splice Z1-1...............................44
Splice Z1-2...............................42
Splice Z1-3...............................62
Splice Z1-4.............................63,64
Splice Z1-5.............................44,66
Splice Z1-6.............................91,93
Splice Z1-7.............................92,96
Splice Z1-10..............................40
Splice Z1-11..............................33
Splice Z1-12..............................34
Splice Z1-13..............................73
Splice Z1-14..............................97
Splice Z11.............................16,18
Splice Z12...............................31
Splice Z12-1............................13,21
Splice 117.............................92,96
Splice 205...............................32
Splice 235...............................33
Splice 236...............................32
Splice 465...............................38
Standard Instrument Cluster Printed Circuit Board.......59
Steering Column Connector.....................106
Stop Lamp Relay............................97
Stop/Turn Hazard Systems.....................45,46
Hazard Flasher.............................46
Hazard Switch.............................46
Powertrain Control Module.....................45
Stop Lamp Switch..........................46
Turn and Hazard Flasher Switch.................46
Turn Signal Flasher..........................45
Switches
A/C Low Pressure Switch.....................69
A/C Mode Select Switch......................70
Back-Up Lamp Switch........................25
Blower Switch...........................68,70
Brake Warning Switch........................67
Engine Cooling Temperature Switch...............24
Engine Oil Pressure Switch....................24
Fog Lamp Switch...........................42
Front Axle Switch.........................26,27
Hazard Switch.............................46
Headlamp Dimmer Switch.....................41
Headlamp Switch..........................1,41
Heat Mode Select Switch......................68
Heated Rear Window Switch....................66
Horn Switch..............................34
Ignition Key Warning Switch....................74
Ignition Switch............................2,9
Left Door Lock Switch.......................85
Left Front Door Jamb Switch...................75
Left Front Door Window Switch.................87
Left Power Seat Switch.......................77
Left Rear Door Jamb Switch...................75
Left Rear Door Window Switch..................82
Liftgate Switch............................76
Park Brake Switch..........................67
Park/Neutral Position Switch....................7
Power Mirror Switch Assembly..................73
8W - 154 WIRING DIAGRAMSJ

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

can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a lo-
cating dowel is recommended during assembly to pre-
vent smearing the material off location.
ENGINE PERFORMANCE
To provide best vehicle performance and lowest ve-
hicle emissions, it is most important that the tune-up
be done accurately. Use the specifications listed on
the Vehicle Emission Control Information label
found on the engine compartment hood.
(1) Test battery specific gravity. Add water, if nec-
essary. Clean and tighten battery connections.
(2) Test cranking amperage draw (refer to Group
8B, Battery/Starter Service for the proper proce-
dures).
(3) Tighten the intake manifold bolts (refer to
Group 11, Exhaust System and Intake Manifold for
the proper specifications).
(4) Perform cylinder compression test:
(a) Check engine oil level and add oil, if neces-
sary.
(b) Drive the vehicle until engine reaches normal
operating temperature.
(c) Select a route free from traffic and other
forms of congestion, observe all traffic laws and
briskly accelerate through the gears several times.
The higher engine speed may help clean out valve
seat deposits which can prevent accurate compres-
sion readings.
CAUTION: DO NOT overspeed the engine.
(d) Remove all spark plugs from engine. As
spark plugs are being removed, check electrodes for
abnormal firing indicators - fouled, hot, oily, etc.
Record cylinder number of spark plug for future
reference.
(e) Disconnect coil wire from distributor and se-
cure to good ground to prevent a spark from start-
ing a fire.
(f) Be sure throttle blades are fully open during
the compression check.
(g) Insert compression gage adaptor into the
No.1 spark plug hole. Crank engine until maxi-
mum pressure is reached on gauge. Record this
pressure as No.1 cylinder pressure.
(h) Repeat Step 4g for all remaining cylinders.
(i) Compression should not be less than 689 kPa
(100 psi) and not vary more than 172 kPa (25 psi)
from cylinder to cylinder.
(j) If cylinder(s) have abnormally low compres-
sion pressures, repeat steps 4a through 4h.
(k) If the same cylinder(s) repeat an abnormally
low reading, it could indicate the existence of a
problem in the cylinder.
The recommended compression pressures are
to be used only as a guide to diagnosing engineproblems. An engine should NOT be disassem-
bled to determine the cause of low compression
unless some malfunction is present.
(5) Clean or replace spark plugs as necessary. Ad-
just gap (refer to Group 8D, Ignition System for gap
adjustment and torque).
(6) Test resistance of spark plug cables (refer to
Group 8D, Ignition System).
(7) Inspect the primary wire. Test coil output volt-
age, primary and secondary resistance. Replace parts
as necessary (refer to Group 8D, Ignition System and
make necessary adjustment).
(8) Set ignition timing to specifications (refer to
Specification Label on engine compartment hood).
(9) Perform a combustion analysis.
(10) Test fuel pump for pressure and vacuum (refer
to Group 14, Fuel System for the proper specifica-
tions).
(11) Inspect air filter element (refer to Group 0,
Lubrication and Maintenance for the proper proce-
dure).
(12) Inspect crankcase ventilation system (refer to
Group 0, Lubrication and Maintenance for the proper
procedure).
(13) For emission controls refer to Group 25, Emis-
sion Controls System for service procedures.
(14) Inspect and adjust accessory belt drives (refer
to Group 7, Cooling System for the proper adjust-
ments).
(15) Road test vehicle as a final test.
HONING CYLINDER BORES
Before honing, stuff plenty of clean shop towels un-
der the bores and over the crankshaft to keep abra-
sive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). 20-60 strokes, de-
pending on the bore condition, will be sufficient to
provide a satisfactory surface. Using honing oil
C-3501-3880 or a light honing oil available from ma-
jor oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
9 - 2 ENGINESJ

(a) Align the transmission torque converter
housing with the engine.
(b) Loosely install the converter housing lower
bolts and install the next higher bolt and nut on
each side.
(c) Tighten all 4 bolts finger-tight.
(5) Install the engine support cushions (if re-
moved).
(6) Lower the engine and engine support cushions
onto the engine compartment brackets.
(7) Remove the engine lifting device.
(8) Raise the vehicle.
(9) If equipped with an automatic transmission:
(a) Install the converter-to-drive plate bolts. En-
sure the installation reference marks are aligned.
Tighten the bolts to 54 Nzm (40 ft. lbs.) torque.
(b) Install the converter-housing access cover.
(c) Install the exhaust pipe support.
(10) Install the remaining converter or flywheel
housing bolts.
(11) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(12) Tighten the engine support cushing through-
bolt nuts.
(13) Install the remaining flywheel/converter hous-
ing bolts. Tighten the bolts to 38 Nzm (28 ft. lbs.)
torque.
(14) Connect the exhaust pipe to the manifold.
(15) Install the oil filter.
(16) Lower the vehicle.
(17) Connect the coolant hoses and tighten the
clamps.
(18) If equipped with power steering:
(a) Remove the protective caps
(b) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 Nzm (38 ft. lbs.)
torque.
(c) Fill the pump reservoir with fluid.
(19) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
(20) Install the fan shroud and radiator/condenser
(if equipped with air conditioning).
(21) Connect the radiator hoses.
(22) Connect the automatic transmission fluid
cooler pipes, if equipped.
(23) Connect the oxygen sensor wire connector.
(24) Connect the throttle valve rod and retainer.
Connect the throttle cable and install the rod. Install
the throttle valve rod spring.
(25) Connect the speed control cable, if equipped.
(26) Connect the fuel supply and return lines to
the throttle body.
(27) Connect all the vacuum hoses and wire con-
nectors.
(28) Connect the service valves to the A/C com-
pressor ports, if equipped with air conditioning.(29) Fill the power steering reservoir.
(30) Connect the battery cables.
(31) Install the hood.
(32) Install the air cleaner.
(33) Start the engine and inspect for leaks.
(34) Fill the cooling system.
(35) Stop the engine and check the fluid levels.
Add fluid, as required.
ENGINE ASSEMBLYÐYJ VEHICLES
REMOVAL
(1) Place a protective cloth over the windshield
frame. Raise the hood and rest it on the windshield
frame (Fig. 19).
(2) Disconnect the battery cable clamps and re-
move the battery.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND
CAP.
(3) Remove the radiator drain cock and radiator
cap to drain the coolant. DO NOT waste usable cool-
ant. If the solution is clean, drain the coolant into a
clean container for reuse.
(4) Disconnect the wire connectors from the gener-
ator.
(5) Disconnect the ignition coil and distributor
wire connectors.
(6) Disconnect the oil pressure sender wire connec-
tor.
Fig. 19 Hood on Windshield Frame
9 - 16 2.5L ENGINEJ