ECU JEEP CHEROKEE 1995 Service Owners Manual

MULTI-PORT FUEL INJECTION (MFI)ÐCOMPONENT REMOVAL/INSTALLATION
INDEX
page page
Accelerator Pedal and Throttle Cable........... 58
Air Cleaner Element....................... 59
Air Cleaner Housing....................... 58
Air Conditioning (A/C) Clutch Relay............ 58
Automatic Shutdown (ASD) Relay............. 59
Brake Switch............................ 59
Camshaft Position Sensor................... 60
Crankshaft Position Sensor.................. 60
Engine Coolant Temperature Sensor........... 60
Fuel Filter............................... 60
Fuel Injector............................. 60
Fuel Pressure Regulator.................... 61
Fuel Pump Module........................ 61
Fuel Pump Relay......................... 61
Fuel Rail Assembly........................ 62
Fuel System Pressure Release Procedure....... 62
Fuel Tank Pressure Relief/Rollover Valve........ 62Fuel Tanks.............................. 62
Fuel Tubes/Lines/Hoses and Clamps........... 62
Idle Air Control (IAC) Motor.................. 62
Ignition Coil............................. 62
Intake Manifold........................... 63
Intake Manifold Air Temperature Sensor......... 60
Manifold Absolute Pressure (Map) Sensor....... 63
Oxygen (O2S) Sensor...................... 63
Park Neutral Switch....................... 63
Power Steering Pressure SwitchÐ2.5L
Engine Only............................ 63
Powertrain Control Module (PCM)............. 64
Quick-Connect Fittings..................... 64
Throttle Body............................ 64
Throttle Position Sensor (TPS)............... 65
Torque Converter Clutch Relay............... 65
Vehicle Speed Sensor...................... 66
ACCELERATOR PEDAL AND THROTTLE CABLE
Refer to the Accelerator Pedal and Throttle Cable
section of this group for removal/installation proce-
dures.
AIR CONDITIONING (A/C) CLUTCH RELAY
The A/C clutch relay is located in the power distri-
bution center (PDC) (Figs. 1 or 2). For location of this
relay within the PDC, refer to label on PDC cover.
AIR CLEANER HOUSING
REMOVAL
(1) Unlock clean air hose clamp (Figs. 3 or 4) at air
cleaner cover. To unlock the clamp, attach adjustablepliers to clamp and rotate pliers as shown in figure
5. Remove clean air hose at cover.
(2) Disconnect vacuum lines at air cleaner housing.
(3) YJ Models: Release the three over-center type
clamps securing the housing to the housing bracket.
XJ Models: Remove the housing cover and remove air
cleaner element. Remove two bolts and one nut.
(4) Release the air cleaner housing from the ambi-
ent air inlet and remove housing from vehicle.
INSTALLATION
(1) Position air cleaner housing to body and ambi-
ent air inlet.
(2) YJ Models: Lock the three over-center type
clamps securing the housing to the housing bracket.
XJ Models: Install two bolts and one nut to housing.
Install air cleaner element and cover.
(3) Install vacuum lines to housing.
Fig. 1 PDCÐYJ Models
Fig. 2 PDCÐXJ Models
14 - 58 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATIONJ

INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Intake
Manifold for removal/installation procedures.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The MAP sensor is located on the dash panel near
the rear of the engine cylinder head (valve) cover
(Fig. 15).
REMOVAL
(1) Disconnect the MAP sensor electrical connector
(Fig. 15).
(2) Disconnect the MAP sensor vacuum supply
hose (Fig. 15).
(3) Remove the MAP sensor mounting bolts and re-
move MAP sensor.
INSTALLATION
(1) Install MAP sensor to dash panel and secure
with mounting bolts.
(2) Install the MAP sensor vacuum supply hose.
(3) Connect the MAP sensor electrical connector.
OXYGEN (O2S) SENSOR
The O2S sensor is installed in the exhaust down
pipe just below the exhaust manifold flange (Fig. 16).
REMOVAL
WARNING: THE EXHAUST MANIFOLD BECOMES
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Raise and support the vehicle.
(2) Separate the electrical connectors.
(3) Remove the O2S sensor from the exhaust man-
ifold. Snap-On oxygen sensor wrench (number YA
8875) may be used for removal and installation.
INSTALLATION
Threads of new factory oxygen sensors are coated
with anti-seize compound to aid in removal.
(1) Install the O2S sensor into the exhaust mani-
fold and tighten to 30 Nzm (22 ft. lbs.) torque.
(2) Connect the O2S sensor wire connector to the
main harness.
(3) Lower the vehicle.
PARK NEUTRAL SWITCH
Refer to Group 21, Transmissions for park neutral
switch service.
POWER STEERING PRESSURE SWITCHÐ2.5L
ENGINE ONLY
The power steering pressure switch is installed in
the power steering high-pressure hose (Figs. 17 or
18).
REMOVAL
(1) Disconnect the electrical connector from the
power steering pressure switch.
Fig. 15 MAP SensorÐTypical
Fig. 16 Oxygen SensorÐTypical
Fig. 17 Power Steering Pressure SwitchÐYJ Models
JFUEL SYSTEM COMPONENT REMOVAL/INSTALLATION 14 - 63

(4) Remove bearing spacer, races and thrust bear-
ing (Fig. 21).
(5) Remove O-ring seal.
(6) Remove retaining snap ring.
(7) Remove needle bearing, dust seal and lip seal
with tool C-4177 and handle C-4171 (Fig. 22).
ASSEMBLE
CAUTION: Needle bearing must be installed with
identification on bearing facing tool to prevent dam-
age to bearing.(1) Install needle bearing into adjuster plug with
tool C-4177 and handle C-4171.
(2) Apply white petroleum grease on lip seal. In-
stall lip seal into adjuster plug with tool C-4177 and
handle C-4171.
(3) Apply white petroleum grease to dust seal cav-
ity and install dust seal into adjuster plug with tool
C-4177 and handle C-4171.
(4) Install retainer snap ring.
(5) Install O-ring seal to adjuster plug.
(6) Install large bearing race, thrust bearing, small
bearing race and bearing spacer to adjuster plug.
(7) Install thrust washer bearing retainer to ad-
juster plug (Fig. 23).
CAUTION: When installing adjuster plug, care
should be taken NOT to cut the seals.
(8) Install adjuster plug into housing with Spanner
Wrench C-4381.
(9) Adjust bearing preload, refer to Thrust Bearing
Preload Adjustment.
(10) Install adjuster plug lock nut, and using a
punch (drift) in a notch, tighten securely (Fig. 24).
Hold adjuster plug to maintain alignment of the
marks.
(11) Adjust pitman shaft. Refer to Over-Center Ad-
justment.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
VALVE REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
Fig. 21 Adjustment Plug Components
Fig. 22 Needle Bearing Removal
Fig. 23 Install Retainer
19 - 30 STEERINGJ

(2) Remove two screws retaining the interlock
mechanism to the column (Fig. 3). Unsnap the mech-
anism from column.
(3) Remove the center console and related trim.
Refer to Group 23, Body.
(4) Disconnect the cable eyelet from the bellcrank
(Fig. 4).
(5) Disconnect and remove the cable from the shift
bracket.
(6) Remove the accelerator pedal (the cable routes
under the pedal), refer to Group 14, Fuel Systems.
Release the cable from the accelerator pedal clip.
Move the carpet as necessary to remove the cable.INSTALLATION/ADJUSTMENT
(1) Snap the cable base assembly into the large
square opening in the steering column (Fig. 4).
(2) Secure the plastic base with two (2) self tap-
ping screws (Fig. 3).
Fig. 1 Ignition Interlock Cable Routing
Fig. 2 Ignition Key Cylinder Actuation
Fig. 3 Interlock Mechanism on Column
19 - 56 STEERINGJ

(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.
(8) Align the turn signal switch in the housing and
secure the switch with the attaching screws. Tighten
the screws to 4 Nzm (35 in. lbs.) torque.
(9) Install the dimmer switch actuator arm.
Tighten the attaching screws to 4 Nzm (35 in. lbs.)
torque.
(10) If equipped, install the cruise control wire har-
ness. Install the turn signal stalk by pushing it
straight into the column.
(11) Position the thrust washer, the upper bearing
preload spring and the canceling cam on the steering
shaft (Fig. 18).
(12) Place the turn signal switch in the neutral
(OFF) position and install the hazard warning switch
knob.
(13) Position the lockplate on the steering shaft.
Install a replacement lockplate retaining snap ring
on the sleeve of the Lock Plate Compressor C-4156.
Install the tool on the steering shaft (Fig. 19).
(14) Compress the lockplate with the compressor
tool and position the retaining snap ring in the steer-
ing shaft groove.
(15) Ensure that the retaining snap ring is com-
pletely seated in the groove before removing the tool.
Remove the tool and install the lockplate cover.(16) Install the steering wheel. Refer to the instal-
lation procedure. Tighten the steering wheel retain-
ing nut to 34 Nzm (25 ft. lbs.) torque.
(17) If removed, install the steering column in the
vehicle. Refer to the installation procedure.
(18) If disconnected, connect the battery negative
cable and, if equipped, reset the clock
Fig. 17 Key/Lock Cylinder InstallationFig. 18 Canceling Cam Position
Fig. 19 Lockplate Snap Ring Installation
JSTEERING 19 - 65

(7) Disconnect transfer case shift linkage at trans-
fer case.
(8) Disconnect vehicle speed sensor wires and
transfer case vent hose.
(9) Remove slave cylinder from clutch housing.
(10) Disconnect transmission shift lever as follows:
(a) Lower transmission-transfer case assembly
approximately 7-8 cm (3 in.) for access to shift le-
ver.
(b) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 6). Move boot upward on shift lever for
access to retainer that secures lever in shift tower.
(c) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers. Turn retainer counterclockwise to release it.
(d) Lift lever and retainer out of shift tower (Fig.
6).Do not remove the shift lever from the
floorpan boots. Leave the lever in place for
later transmission installation.
(11) Mark front and rear propeller shafts for in-
stallation alignment (Fig. 7). Then remove both
shafts.
(12) Remove crankshaft position position sensor
(Figs. 8, 9).
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission re-
moval. The sensor can easily be damaged if left in
place during removal operations.
(13) Unclip wire harnesses from transmission and
transfer case.
(14) Remove slave cylinder from clutch housing.
(15) Support transmission with transmission jack.
(16) Remove nuts attaching transfer case to trans-
mission and remove transfer case.
(17) Secure transmission to jack with safety
chains.
(18) Remove clutch housing brace rod.(19) Remove clutch housing-to-engine bolts.
(20) Pull transmission jack rearward until input
shaft clears clutch. Then slide transmission out from
under vehicle.
Fig. 6 Removing/Installing Shift Lever
Fig. 7 Marking Propeller Shaft And Axle Yokes
Fig. 8 Crankshaft Position Sensor (2.5L)
Fig. 9 Crankshaft Position Sensor (4.0L)
21 - 4 AX 4/5 MANUAL TRANSMISSIONJ

(21) Remove clutch release bearing, release fork
and retainer clip.
(22) Remove clutch housing from transmission.
TRANSMISSION INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft. lbs.) torque.
(2) Lubricate contact surfaces of release fork pivot
ball stud and release fork with high temp grease.
Then install release bearing, fork and retainer clip.
(3) Mount transmission on transmission jack.
(4) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar high temp
grease.
(5) Align transmission input shaft, release bearing,
and clutch disc splines. Then slide transmission into
place.
(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure the
housing is properly seated on engine block be-
fore tightening bolts.
(7) Lower transmission approximately 7-8 cm (3
in.) for access to shift tower. Be sure transmission is
in first or third gear.
(8) Reach up and around transmission and insert
shift lever in shift tower. Press lever retainer down-
ward and turn it clockwise to lock it in place. Then
install lever dust boot on shift tower.
(9) Install slave cylinder in clutch housing.
(10) Align and install transfer case on and trans-
mission. Tighten transfer case-to-transmission nuts
to 35 Nzm (26 ft. lbs.) torque.
(11) Connect transfer case vent hose and shift link-
age. Check and adjust linkage if necessary.
(12) Connect transfer case vent hose.
(13) Secure wire harnesses in clips/tie straps on
transmission and transfer case.
(14) Connect backup light switch wires.
(15) Connect vehicle speed sensor wires.
(16) Install and connect crankshaft position sensor.
(17) Install rear crossmember (Fig. 5). On XJ,
tighten crossmember-to-frame bolts to 41 Nzm (31 ft.
lbs.) torque. Then tighten transmission-to-rear sup-
port bolts/nuts to 45 Nzm (33 ft. lbs.) torque. On YJ,
tighten bolts/nuts to indicated torque (Fig. 5).
(18) Remove jack stand.
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) Install skid plate, if equipped. Tighten bolts to
42 Nzm (31 ft. lbs.) torque. Tighten stud nuts to 17
Nzm (150 in. lbs.) torque.
(21) Top off transmission and transfer case lubri-
cant levels.
(22) Lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING AND FRONT BEARING
RETAINER REMOVAL
(1) Drain transmission lubricant.
(2) Remove release bearing and lever.
(3) Remove clutch housing bolts and remove hous-
ing.
(4) On 2-wheel drive models, remove vehicle speed
sensor, speedometer adapter and speedometer driven
gear. Then remove extension housing seal (Fig. 1).
(5) Remove detent spring and ball. Remove detent
plug (Fig. 2) and remove detent spring and ball with
pencil magnet.
Fig. 1 Removing 2-Wheel Drive Extension Housing
Seal
Fig. 2 Detent Ball Plug Location
JAX 4/5 MANUAL TRANSMISSION 21 - 5

ASSEMBLING OUTPUT SHAFT, INPUT SHAFT
AND COUNTER GEAR
(1) If front bearing was removed from input shaft,
press new bearing on shaft (Fig. 43).(2) Secure front bearing with thickest snap ring
that will fit in groove (Fig. 43).
(3) Press front bearing on counter gear. Secure
bearing with thickest snap ring that will fit in ring
groove (Fig. 44).
(4) Install new oil seals in front bearing retainer
and adapter (Fig. 45). Bearing retainer seal depth is
11.2 - 12.1 mm (0.441 - 0.480 in.).
(5) Install reverse shaft and shaft retaining pin in
adapter. Then install access hole plug with torx bit
(Fig. 46).
(6) Lubricate transmission components with speci-
fied gear lubricant.
(7) Assemble 1-2 and 3-4 synchronizer hubs,
sleeves, springs and key inserts (Fig. 47).
(8) Assemble and install third gear, needle bearing,
synchronizer ring, 3-4 synchronizer and snap ring on
output shaft (Fig. 48). Use thickest snap ring that
fits in shaft groove.
Fig. 43 Installing Front Bearing And Snap Ring
Fig. 44 Installing Counter Gear Front Bearing And
Snap Ring
JAX 4/5 MANUAL TRANSMISSION 21 - 17

(6) On XJ, remove rear crossmember. On YJ, re-
move skid plate (Fig. 1).
(7) Disconnect transmission shift linkage, speed-
ometer cable, transfer case vacuum lines and clutch
hydraulic lines.
(8) Lower transmission-transfer case assembly no
more than 7.6 cm (3 in.) for access to shift lever.
(9) Reach up and around transmission case and
unseat shift lever dust boot from transmission shift
tower (Fig. 2). Move boot upward on shift lever for
access to lever retainer.
(10) Disengage shift lever as follows:
(a) Reach up and around transmission case and
press shift lever retainer downward with your fin-
gers.
(b) Turn retainer counterclockwise to release it.
(c) Lift lever and retainer out of shift tower (Fig.
2).It is not necessary to remove shift lever
from floorpan boot. Simply leave lever in
place for later installation.(11) Mark front and rear propeller shafts for in-
stallation alignment (Fig. 2). Then remove both
shafts.
(12) Remove crankshaft position sensor (Fig. 4).
(13) Disconnect transmission and transfer case
vent hoses.
(14) Remove slave cylinder from clutch housing.
(15) Remove wire harnesses from clips/tie straps
on transmission and transfer case.
(16) Support transmission-transfer case assembly
with transmission jack. Secure assembly to jack with
safety chains.
(17) Reposition adjustable jack stand under engine.
Be sure to place wood block between jack and oil
pan.
(18) Remove clutch housing brace rod.
(19) Remove clutch housing-to-engine bolts and re-
move transmission-transfer case assembly.
(20) Remove bolts attaching transmission to trans-
fer case and separate components.
(21) Remove release bearing, fork and retainer
clip.
(22) Remove clutch housing from transmission.
TRANSMISSION INSTALLATION
(1) Install clutch housing on transmission. Tighten
housing bolts to 37 Nzm (27 ft-lbs) torque.
(2) Lubricate contact surfaces of release fork, lever
and pivot ball stud. Then install bearing, fork and
clip in clutch housing.
(3) Mount transmission on transmission jack. Se-
cure transmission with safety chains.
(4) Lightly lubricate pilot bearing and transmis-
sion input shaft splines with Mopar high tempera-
ture grease.
(5) Align transmission input shaft and clutch disc
splines and install transmission.
Fig. 2 Removing/Installing Shift Lever
Fig. 3 Marking Propeller Shaft And Axle Yoke
Fig. 4 Crankshaft Position Sensor Location
21 - 36 AX 15 MANUAL TRANSMISSIONJ

(6) Install and tighten clutch housing-to-engine
bolts to 38 Nzm (28 ft. lbs.) torque.Be sure housing
is properly seated on engine before tightening
bolts.
(7) Lower transmission no more than 7.6 cm (3 in.)
for access to the shift tower.
(8) Reach up and around the transmission and in-
sert shift lever in shift tower. Press lever retainer
downward and turn it clockwise to lock it in place.
Then install lever dust boot on shift tower.
(9) Install and connect crankshaft position sensor.
(10) Align and install transfer case on transmis-
sion. Tighten transfer case attaching nuts to 35 Nzm
(26 ft. lbs.) torque.
(11) Connect transfer case vacuum and vent hoses.
(12) Install and connect transfer case shift linkage.
Check and adjust linkage if necessary.
(13) Secure wire harnesses to clips/tie straps on
transmission and transfer case.
(14) Connect backup light switch wires.
(15) Install clutch slave cylinder.
(16) Connect vehicle speed sensor wires.
(17) On XJ, install rear crossmember and attach
cushion and bracket. Tighten crossmember-to-frame
bolts to 41 Nzm (30 ft. lbs.) torque. Tighten transmis-
sion-to-rear cushion and bracket bolts/nuts to 45 Nzm
(33 ft. lbs.) torque.
(18) On YJ, install rear cushion and bracket and
skid plate. Tighten attaching bolts/nuts to indicated
torque (Fig. 1).
(19) Align and install front/rear propeller shafts.
Tighten shaft U-joint clamp bolts to 19 Nzm (170 in.
lbs.) torque.
(20) On XJ, install skid plate if removed. Tighten
bolts to 42 Nzm (31 ft. lbs.) torque. Tighten stud nuts
to 17 Nzm (150 in. lbs.) torque.
(21) Top off transmission and transfer lubricant
levels.
(22) Remove supports and lower vehicle.
TRANSMISSION DISASSEMBLY AND OVERHAUL
ADAPTER HOUSING REMOVAL
(1) Remove release bearing, release lever and re-
lease fork from clutch housing. Then remove clutch
housing from transmission.
(2) Remove backup light switch. Then remove
drain plug (Fig. 1) and drain transmission lubricant
into pan.
(3) Remove shift tower bolts and remove tower
from adapter or extension housing (Fig. 2).
(4) Remove gasket from shift tower (Fig. 3).
Fig. 1 Drain Plug And Backup Light Switch Location
Fig. 2 Shift Tower Removal/Installation
Fig. 3 Shift Tower Gasket Removal/Installation
JAX 15 MANUAL TRANSMISSION 21 - 37