light JEEP CHEROKEE 1995 Service Repair Manual

INTERIOR LIGHTING
INDEX
page page
Cargo Lamp and Dome Lamp................. 1
Chime/Buzzer Module....................... 2
Diagram Index............................ 2
General Information........................ 1
Glove Box Lamp........................... 1Ignition Switch Lamp........................ 1
Instrument Panel Illumination Lamps............ 1
Reading Lamps........................... 1
Underhood Lamp.......................... 1
Visor Vanity Mirror Lamps.................... 1
GENERAL INFORMATION
Circuit M1 supplies power to the glove box lamp,
dome lamp, reading lamps, cargo lamp and vanity
lamps. Circuit M1 is protected by fuse 16 in the
Power Distribution Center (PDC).
Circuit E2 supplies power for the instrument panel
illumination lamps.
INSTRUMENT PANEL ILLUMINATION LAMPS
Circuit E2 from the headlamp switch splices to
supply power to the following illumination lamps:
²Ash receiver lamp
²Cigar lighter lamp
²Transmission range indicator lamp
²Transfer case range indicator lamp
²A/C-Heater switch lamp
²Heated rear window switch lamp
²Rear wiper switch lamp
²Fog lamp switch lamp
Fuse 25 in the fuse block protects circuit E2. Cir-
cuit Z1 provides ground for all of the illumination
lamps except for the cigar lighter lamp. The cigar
lighter lamp is case grounded.
HELPFUL INFORMATION
Circuit E2 also supplies power to the radio, LCD
relay and the illumination lamps in the instrument
cluster.
IGNITION SWITCH LAMP
Circuit M50 supplies voltage to the ignition switch
lamp. Circuit Z1 provides ground for the lamp.
GLOVE BOX LAMP
Circuit M1 from fuse 16 in the Power Distribution
Center (PDC) powers the glove box lamp. A case
grounded switch, in series after the lamp, closes
when the glove box door is opened. The switch com-
pletes a path to ground on circuit Z1.
CARGO LAMP AND DOME LAMP
Circuit M1 from fuse 16 in the Power Distribution
Center (PDC) supplies power to the cargo lamp anddome lamp. The M1 circuit is HOT at all times. The
ground path for the lamp is provided in three differ-
ent ways.
One way is through the door jamb switches. Circuit
M2 connects to the door jamb switches to the dome
lamp and cargo lamp. The switches are connected to
ground circuit Z1. When a door is opened, the
plunger in the switch closes, completing a path to
ground.
The second way is through the liftgate switch. Cir-
cuit G71 connects to circuit M2 at the cargo lamp
connector. Circuit G71 connects to the liftgate switch.
The liftgate switch connects to ground circuit Z1.
When the lift gate opens, the plunger in the switch
closes, completing a path to ground.
The third ground path is through the headlamp
switch. Circuit M2 is spliced in with the headlamp
switch. When the operator turns the headlamp
switch to the dome lamp ON position, a ground path
is provided through the switch.
READING LAMPS
Circuit M1 from fuse 16 in the Power Distribution
Center (PDC) supplies power to the reading lamps.
Circuit M1 is HOT at all times. When the operator
depresses the reading lamp, the reading lamp switch
closes and supplies ground on circuit Z1.
VISOR VANITY MIRROR LAMPS
Circuit M1 from fuse 16 in the Power Distribution
Center (PDC) supplies power to the vanity lamps.
Circuit M1 is HOT at all times. When the vanity
lamps switch closes, voltage flows to vanity mirror
lamps. The vanity mirror is case grounded.
UNDERHOOD LAMP
Circuit A7 from fuse 16 in the Power Distribution
Center (PDC) supplies battery voltage for the under-
hood lamp. A mercury switch, in series after the
lamp, connects the lamp to ground on circuit Z1.
When the hood is raised, mercury inside the switch
moves to a position where it connects circuit M1 to
ground circuit Z1, illuminating the lamp.
J8W-44 INTERIOR LIGHTINGÐXJ-RHD 8W - 44 - 1

CHIME/BUZZER MODULE
The buzzer or optional chime module sounds an au-
dible warning tone. The tone sounds for seat belt
warning and when the ignition key is in the ignition
switch while the drivers door is open. The tone also
sounds when the ignition key is in the ON position
while the drivers side seat belt is not buckled. Lastly,
the tone sounds when the headlamps are ON when
the ignition is OFF. Refer to Group 8U for system op-
eration.
When the ignition switch is in the RUN or START
position, fuse F87 from fuse 26 in the fuse block sup-
plies power to the chime/buzzer module. Circuit A21
from the ignition switch supplies power to fuse 26.
Circuit L7 from fuse 9 in the fuse block also sup-
plies power to the chime/buzzer module. Circuit A3
from fuse 5 in the Power Distribution Center (PDC)
powers fuse 9.
When the parking lamps or headlamps are ON, the
headlamp switch connects circuit G26 with the driv-
ers side door jamb switch. Circuit G26 also connects
to the key-in switch. Circuit M11 connects the key-in
switch to the chime module and the headlamp
switch.
If the headlamps are ON, and the drivers door
opens, ground for the chime/buzzer is on circuit C26
from the headlamp switch through the door jamb
switch to circuit Z1.
If the headlamps are OFF with the key in the ig-
nition while the drivers side door is open, ground for
the chime/buzzer is supplied through the key-in
switch. The ground path is over circuit M11, through
the closed key-in switch to circuit C26. From circuit
C26, the ground path continues through the drivers
door jamb switch to circuit Z1.
Circuit G11 from the buzzer powers the seat belt
warning lamp in the instrument cluster. Circuit Z1
at the instrument cluster provides ground for the
lamp.Circuit G10 from the buzzer connects to the seat
belt switch. When the seat belt switch closes a path
to ground is completed on circuit Z1 and the tone
sounds momentarily.
Circuit Z1 also grounds the chime buzzer module.
HELPFUL INFORMATION
Circuit F87 also powers the instrument cluster and
the headlamp delay module.
DIAGRAM INDEX
Component Page
Cargo Lamp............................8W-44-6
Chime/Buzzer Module......................8W-44-3
Courtesy Lamps.........................8W-44-5
Dome Lamp............................8W-44-6
Door Jamb Switches......................8W-44-7
Fuse 3 (PDC)...........................8W-44-6
Fuse 5 (PDC).........................8W-44-5, 8
Fuse 6 (PDC)...........................8W-44-6
Fuse 9 (Fuse Block).....................8W-44-3, 8
Fuse 16 (PDC)........................8W-44-4, 6
Fuse 25 (Fuse Block)......................8W-44-8
Fuse 26 (Fuse Block)......................8W-44-3
Glove Box Lamp and Switch.................8W-44-5
Headlamp Switch....................8W-44-3, thru 8
Headlamp Delay Module....................8W-44-3
Ignition Switch..........................8W-44-3
Instrument Cluster......................8W-44-3, 9
Instrument Panel Illumination Lamps..........8W-44-8, 9
Key-In Switch...........................8W-44-4
Liftgate Switch..........................8W-44-6
Reading Lamps..........................8W-44-6
Seat Belt Switch.........................8W-44-3
Telltale Connector (Instrument Cluster)...........8W-44-3
Time Delay Relay........................8W-44-4
Underhood Lamp.........................8W-44-4
8W - 44 - 2 8W-44 INTERIOR LIGHTINGÐXJ-RHDJ

FRONT LIGHTING
INDEX
page page
Diagram Index............................ 3
Dimming Module........................... 1
Fog Lamps............................... 2
Headlamp Delay Module..................... 1Headlamp Relay........................... 1
Headlamps............................... 1
Parking Lamps............................ 2
HEADLAMPS
The headlamp switch has three positions: ON,
PARK (parking lamps) and OFF. Circuit A3 from fuse
12 in the PDC connects to the headlamp switch and
feeds circuit L7 through fuse 9 in the fuse block. Cir-
cuit L7 connects to the headlamp switch.
Circuit A3 also splices to feed circuit L11 through
fuse 10 in the fuse block. Circuit L11 connects to the
dimmer switch circuitry in the multi-function switch.
The headlamp switch has an internal circuit
breaker that connects circuit A3 to circuit F34. Cir-
cuit F34 connects to the headlamp relay.
HEADLAMP RELAY
When the headlamp switch is in the ON position it
connects circuit A3 from fuse 5 in the Power Distri-
bution Center (PDC) to circuit F34. Circuit A3 is
HOT at all times.
Circuit F34 supplies battery voltage to the coil and
contact sides of the headlamp relay. Circuit Z1 sup-
plies ground for the relay. When voltage is present on
circuit F34, the relay contacts close and connect cir-
cuit F39 to circuit F34.
Circuit F39 powers the headlamps through the
dimmer switch circuitry in the multi-function switch.
HEADLAMP SWITCH IN OFF OR PARKING
LAMP POSITION
Circuit L11 connects to the dimmer switch portion
of the multi-function switch. Circuit L11 supplies
power for the high beams on circuit L3 when the op-
erator flashes the headlamps with the turn signal
stalk of the multi-function switch.
HEADLAMP SWITCH IN ON POSITION
When the headlamp switch is in the ON position,
circuit A3 from fuse 12 in the Power Distribution
Center (PDC) connects to circuit F34. Circuit F34
connects to circuit F39 through the headlamp relay.
Circuit F39 feeds circuit L4 through the headlamp
dimmer switch circuitry in the multi-function switch.
Circuit L4 powers the low beam of the headlamps.
When the operator selects high beam operation
with the turn signal stalk of the multi-functionswitch, circuit L11 connects to the L3 circuit. Circuit
L3 powers high beam operation.
HEADLAMP GROUND
Circuit Z1 provides ground for both the right and
left headlamps. Circuit Z1 also supplies ground the
fog lamps, if equipped.
HELPFUL INFORMATION
²Check fuse 5 in the PDC.
²The headlamp switch has an internal circuit
breaker.
²Circuit L7 is double crimped at the headlamp
switch and branches to the chime module.
HEADLAMP DELAY MODULE
When the operator turns off the ignition switch and
the headlamp switch, the headlamp delay module
powers the headlamps for approximately 45 seconds.
When the ignition switch is in the RUN position,
circuit A21 powers circuit F87 through fuse 17 in the
fuse block. Circuit F87 supplies the IGNITION ON/
OFF signal to the headlamp delay module. Circuit Z1
provides ground for the module.
When the headlamp delay module activates, it con-
nects circuit X4 from fuse 5 in the fuse block to cir-
cuit F34. Circuit F34 connects to the circuit F39
through the headlamp relay. Circuit F39 powers the
headlamps through the headlamp dimmer switch cir-
cuit L4.
HELPFUL INFORMATION
Circuit A7 from fuse 3 in the PDC supplies voltage
to the fuse block bus bar that powers circuit X4
through the fuse in cavity 5.
DIMMING MODULE
Some vehicles are equipped with a dimming mod-
ule. The module is powered by the dimming relay.
In the RUN position, the ignition switch connects
circuit A1 from fuse 6 in the Power Distribution Cen-
ter (PDC) to circuit A38. Circuit A38 powers circuit
L170 through fuse 20 in the fuse block. Circuit L170
supplies power to the dimming relay.
When the headlamps are ON, circuit L90 from the
headlamp switch energizes the dimming relay. When
J8W-50 FRONT LIGHTINGÐXJ-RHD 8W - 50 - 1

energized, the relay supplies power to the dimming
module on a branch of circuit A38. Circuit Z1 pro-
vides ground for the dimming relay.
The dimming module connects to the headlamp
dimmer switch on circuits L3 and L4.
PARKING LAMPS
Circuit A3 from fuse 5 in the Power Distribution
Center (PDC) connects to a bus bar in the fuse block
which feeds circuit L7. Fuse 9 in the fuse block pro-
tects circuit L7.
The headlamp switch has three positions: ON,
PARK (parking lamps) and OFF, plus a dimmer
switch. When the headlamp switch is in the PARK or
ON position, the switch connects circuit L7 to circuit
L90. From the headlamp switch, circuit L90 branches
to power the front parking lamps and rear tail
lamps, side marker lamps, and rear license plate
lamps.
GROUND CIRCUIT
Circuit Z1 provides a ground for the parking lamps
and side marker lamps. The Z1 circuit also provide
ground for the headlamps.
HELPFUL INFORMATION
²Check fuse 5 in PDC.
²Check fuse 9 in the fuse block.
²When the headlamp switch is in the PARK or ON
position, the dimmer circuit, L7, also connects to cir-
cuit E2. Circuit E2 continues through fuse 25 in the
fuse block. Circuit E2 powers the illumination lamps.
FOG LAMPS
The fog lamps are controlled by the fog lamp
switch and fog lamp relay. The fog lamps operate
only when the headlamp switch is in the ON posi-
tion, and the operator has selected low-beam opera-
tion. When the headlamps are in high-beam
operation, the fog lamps will not operate.
Circuit F39 from fuse 13 in the Power Distribution
Center (PDC) supplies voltage to the contact side of
the park lamp relay.
When the fog lamp switch closes, it connects circuit
F34 from the headlamp relay to L35. Circuit L35
supplies power to the coil side of the fog lamp relay
and energizes the relay. Ground for the coil side of
the fog lamp relay is provided on circuit Z1.
When fog lamp relay energizes, it connects circuit
F39 to circuit 117. Circuit 117 supplies power to the
fog lamps. Circuit Z1 provides ground for the fog
lamps.
If the high beam lamps are ON, the dimmer switch
does not power circuit L4 and the fog lamp relay
opens. When the relay opens, battery voltage is re-
moved from the fog lamps.
8W - 50 - 2 8W-50 FRONT LIGHTINGÐXJ-RHDJ

DIAGRAM INDEX
Component Page
Chime/Buzzer Module......................8W-50-6
Dimming Module.........................8W-50-9
Dimming Relay..........................8W-50-8
Fog Lamp Relay........................8W-50-10
Fog Lamp Switch........................8W-50-10
Fuse 5 (Fuse Block).......................8W-50-7
Fuse 5 (PDC).........................8W-50-4, 8
Fuse 6 (PDC).........................8W-50-6, 8
Fuse 7 (PDC)..........................8W-50-10
Fuse 9 (Fuse Block).......................8W-50-4
Fuse 10 (Fuse Block)......................8W-50-7
Fuse 11 (Fuse Block)......................8W-50-8
Fuse 13 (PDC).........................8W-50-10
Fuse 20 (Fuse Block)......................8W-50-8
Fuse 26 (Fuse Block)......................8W-50-6
Headlamp Delay Module....................8W-50-7
Headlamp Dimmer Switch.................8W-50-4, 7
Headlamp Switch.....................8W-50-4, 7, 9
Headlamp Relay.........................8W-50-9
Ignition Switch........................8W-50-6, 8
Instrument Cluster........................8W-50-5
Left Fog Lamp.........................8W-50-10
Left Headlamp..........................8W-50-5
Left Marker Lamp........................8W-50-5
Left Tail, Stop and Turn Signal Lamp............8W-50-5
Overhead Console......................8W-50-4, 8
Right Fog Lamp........................8W-50-10
Right Headlamp.........................8W-50-5
Right Tail, Stop and Turn Signal Lamp...........8W-50-5
Telltale Connector (Instrument Cluster)...........8W-50-9
J8W-50 FRONT LIGHTINGÐXJ-RHD 8W - 50 - 3

REAR LIGHTING
TAIL LAMPS AND REAR LICENSE PLATE LAMPS
Circuit A3 from fuse 5 in the Power Distribution
Center (PDC) connects to a bus bar in the fuse block
which feeds circuit L7. Fuse 9 in the fuse block pro-
tects circuit L7.
The headlamp switch has three positions: ON,
PARK (parking lamps) and OFF, plus a dimmer
switch. When the headlamp switch is in the PARK or
ON position, the switch connects circuit L7 to circuit
L90. From the headlamp switch, circuit L90 branches
to power the front parking lamps and rear tail
lamps, side marker lamps, and rear license plate
lamps.
GROUND CIRCUIT
Circuit Z1 provides a ground for the parking lamps,
tail lamps, and rear license plate lamps.
HELPFUL INFORMATION
²Check fuse 5 in PDC.
²Check fuse 9 in the fuse block.
²When the headlamp switch is in the PARK or ON
position, circuit L7 also connects to circuit E2. Cir-
cuit E2 continues through fuse 25 in the fuse block.
Circuit E2 powers the illumination lamps.
STOP LAMPS AND CHMSL LAMPS
Circuit L9 from fuse 4 in the Power Distribution
Center (PDC) connects to the stop lamp switch.
When the operator depresses the brake pedal, the
stop lamp switch closes and connects circuit L9 to
circuit L50. Circuit L50 connects to the stop lamps
and center high mounted stop lamps (CHMSL). Cir-
cuit Z1 provides a ground for the stop lamps.
HELPFUL INFORMATION
²Check fuses 13 in the PDC.
²Check for continuity across the stop lamp switch
when it is closed.
BACK-UP LAMPS
In the START or RUN position, the ignition switch
connects circuit A1 from fuse 6 in the Power Distri-
bution Center (PDC) to circuit A21. Circuit A21 feeds
a bus bar in the PDC that powers circuit F12
through fuse 11.
Circuit F12 supplies power to the back-up lamp
switch. On automatic transmission equipped vehicles,
the back-up lamp switch is part of an assembly that
includes the PARK/NEUTRAL position switch. When
the operator puts the transmission in REVERSE, the
back-up lamp switch connects circuit F12 to circuit
L10. Circuit L10 feeds the back-up lamps. Circuit Z1
provides ground for the back-up lamps.
HELPFUL INFORMATION
²Check fuses 6 and 11 in the PDC.
²Check for continuity across the back-up lamp
switch when it is closed.
DIAGRAM INDEX
Component Page
Center High Mounted Stop Lamps (CHMSL).......8W-51-3
Fuse 4 (PDC)...........................8W-51-3
Fuse 5 (PDC)...........................8W-51-2
Fuse 6 (Fuse Block).......................8W-51-2
Fuse 6 (PDC)...........................8W-51-2
Fuse 9 (Fuse Block).......................8W-51-2
Headlamp Switch.........................8W-51-2
Ignition Switch..........................8W-51-2
Left Back-Up Lamp.......................8W-51-4
Left Side Marker Lamp.....................8W-51-4
Left Tail/Stop Lamp.......................8W-51-4
Left Turn Signal Lamp.....................8W-51-4
License Plate Lamp.......................8W-51-3
Park/Neutral Position Switch.................8W-51-2
Right Back-Up Lamp......................8W-51-5
Right Side Marker Lamp....................8W-51-5
Right Tail/Stop Lamp......................8W-51-4
Right Turn Signal Lamp....................8W-51-5
Stop Lamp Switch........................8W-51-3
J8W-51 REAR LIGHTINGÐXJ-RHD 8W - 51 - 1

Fig. 1 Front End Lighting Connectors
J8W-90 CONNECTOR LOCATIONSÐXJ-RHD 8W - 90 - 3

Fig. 1 Front End Lighting Splices XJ-RHD
Fig. 2 Engine Compartment Splices, Left Side XJ-RHD
J8W-95 SPLICE LOCATIONSÐXJ-RHD 8W - 95 - 3

ENGINES
CONTENTS
page page
LUBRICATION SYSTEM................... 37
LUBRICATION SYSTEM................... 79
2.5L ENGINE SERVICE PROCEDURES....... 134.0L ENGINE SERVICE PROCEDURES....... 55
ENGINE DIAGNOSIS...................... 5
STANDARD SERVICE PROCEDURES......... 1
STANDARD SERVICE PROCEDURES
INDEX
page page
Engine Performance........................ 2
Form-In-Place Gaskets...................... 1
Honing Cylinder Bores...................... 2
Hydrostatic Lock........................... 4Measuring with Plastigage.................... 3
Repair Damaged or Worn Threads............. 4
Service Engine Assembly (Short Block).......... 4
FORM-IN-PLACE GASKETS
There are several places where form-in-place gas-
kets are used on the engine.DO NOT use form-in-
place gasket material unless specified.Care
must be taken when applying form-in-place gaskets.
Bead size, continuity and location are of great impor-
tance. Too thin a bead can result in leakage while too
much can result in spill-over. A continuous bead of
the proper width is essential to obtain a leak-free
joint.
Two types of form-in-place gasket materials are
used in the engine area (Mopar Silicone Rubber Ad-
hesive Sealant and Mopar Gasket Maker). Each have
different properties and cannot be used interchange-
ably.
MOPAR SILICONE RUBBER ADHESIVE
SEALANT
Mopar Silicone Rubber Adhesive Sealant, normally
black in color, is available in 3 ounce tubes. Moisture
in the air causes the sealant material to cure. This
material is normally used on flexible metal flanges.
It has a shelf life of a year and will not properly cure
if over aged. Always inspect the package for the ex-
piration date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normally red in color, is
available in 6 cc tubes. This anaerobic type gasket
material cures in the absence of air when squeezedbetween smooth machined metallic surfaces. It will
not cure if left in the uncovered tube. DO NOT use
on flexible metal flanges.
SURFACE PREPARATION
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some in-
stances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
Scrape or wire brush all gasket surfaces to remove
all loose material. Inspect stamped parts to ensure
gasket rails are flat. Flatten rails with a hammer on
a flat plate, if required. Gasket surfaces must be free
of oil and dirt. Make sure the old gasket material is
removed from blind attaching holes.
GASKET APPLICATION
Assembling parts using a form-in-place gasket re-
quires care.
Mopar Silicone Rubber Adhesive Sealant should be
applied in a continuous bead approximately 3 mm
(0.12 inch) in diameter. All mounting holes must be
circled. For corner sealing,a3or6mm(1/8 or 1/4
inch) drop is placed in the center of the gasket con-
tact area. Uncured sealant may be removed with a
shop towel. Components should be torqued in place
while the sealant is still wet to the touch (within 10
JENGINES 9 - 1

minutes). The use of a locating dowel is recom-
mended during assembly to prevent smearing the
material off location.
Mopar Gasket Maker should be applied sparingly
to one gasket surface. The sealant diameter should
be 1.00 mm (0.04 inch) or less. Be certain the mate-
rial surrounds each mounting hole. Excess material
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 ab-
normal firing indicatorsÐfouled, 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 maximum
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 engine
problems. 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) Perform a combustion analysis.
(9) Test fuel pump for pressure (refer to Group 14,
Fuel System for the proper specifications).
(10) Inspect air filter element (refer to Group 0,
Lubrication and Maintenance for the proper proce-
dure).
(11) Inspect crankcase ventilation system (refer to
Group 0, Lubrication and Maintenance for the proper
procedure).
(12) For emission controls refer to Group 25, Emis-
sion Controls System for service procedures.
(13) Inspect and adjust accessory belt drives (refer
to Group 7, Cooling System for the proper adjust-
ments).
(14) 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.
9 - 2 ENGINESJ