dash panel JEEP CHEROKEE 1995 Service User Guide

CLUTCH HYDRAULIC LINKAGE INSTALLATION
(1) Be sure reservoir cover on clutch master cylin-
der is tight to avoid spills.
(2) Position clutch linkage components in vehicle.
Work connecting line and slave cylinder downward
past engine and adjacent to clutch housing.
(3) Position clutch master cylinder on dash panel
(Fig. 12).
(4) Attach clutch master cylinder push rod to pin
on clutch pedal. Secure rod with new clip if neces-
sary.
(5) Install and tighten clutch master cylinder at-
taching nuts to 23-34 Nzm (200-300 in. lbs.) torque.
(6) Raise vehicle.
(7) Insert slave cylinder push rod through clutch
housing opening and into release lever. Be sure cap
on end of rod is securely engaged in lever. Check this
before installing cylinder attaching nuts.
(8) Install and tighten slave cylinder attaching
nuts to 23-34 Nzm (200-300 in. lbs.) torque.
(9) Secure clutch fluid line in body clips.
(10) Lower vehicle.
(11) Connect clutch pedal position switch wires.
CLUTCH FLUID LEVEL
The clutch fluid reservoir, master cylinder, slave
cylinder and fluid lines are prefilled with fluid at the
factory during assembly operations.
The hydraulic system should not require additional
fluid under normal circumstances. In fact,the reser-
voir fluid level will actually increase as normal
clutch wear occurs. For this reason, it is impor-
tant to avoid overfilling, or removing fluid from
the reservoir.
Fig. 9 Slave Cylinder Attachment
Fig. 10 Clutch Master Cylinder And Push Rod
Attachment (Left Hand Drive Models)
Fig. 11 Clutch Master Cylinder Location (Right Hand
Drive Models)
Fig. 12 Clutch Master Cylinder Mounting (Typical)
6 - 14 CLUTCH SERVICEJ

ignition switch to ON. Lamp should light. If OK, go
to next step. If not OK, replace bulb.
(3) Turn ignition switch to OFF. Disconnect battery
negative cable. Unplug cluster connector B. Check for
continuity between cavity 2 (cavity 15 - RHD) of clus-
ter connector B and a good ground. There should be
no continuity. If OK, go to next step. If not OK, re-
pair short circuit to PCM as required.
(4) Check continuity between cavity 2 (cavity 15 -
RHD) of cluster connector B and cavity 32 of PCM
connector. There should be continuity. If not OK, re-
pair open circuit to PCM as required.
SEAT BELT REMINDER LAMP
(1) Refer to Group 8U - Chime/Buzzer Warning
Systems to check chime/buzzer module operation. If
OK, go to next step. If not OK, replace chime/buzzer
module.
(2) Disconnect battery negative cable. Remove in-
strument cluster bezel and cluster assembly. Unplug
cluster (tell-tale) connector B. Check for continuity
between cavity 16 (cavity 1 - RHD) of cluster connec-
tor B and a good ground. There should be continuity.
If OK, plug cluster connector B back into cluster and
go to next step. If not OK, repair open circuit to
ground as required.
(3) Connect battery negative cable. Install a
jumper wire between a 12-volt battery feed and cav-
ity 15 (cavity 2 - RHD) of cluster connector B. Lamp
should light. If OK, go to next step. If not OK, re-
place bulb.
(4) Disconnect battery negative cable. Unplug
chime/buzzer module from fuseblock module (connec-
tor near fuseblock module - RHD). Unplug cluster
connector B. Check for continuity between cavity 15
(cavity 2 - RHD) of cluster connector B and a good
ground. There should be no continuity. If OK, go to
next step. If not OK, repair short circuit to chime/
buzzer module as required.
(5) Check continuity between cavity 15 (cavity 2 -
RHD) of cluster connector B and cavity for terminal
A3 of chime/buzzer module (Fig. 7) in fuseblock mod-
ule (connector near fuseblock module - RHD). There
should be continuity. If not OK, repair open circuit to
chime/buzzer module as required.
TURN SIGNAL INDICATOR LAMPS
(1) Disconnect battery negative cable. Remove in-
strument cluster bezel and cluster assembly. Probe
cavity A3 of cluster connector A. Check for continuity
to a good ground. There should be continuity. If OK,
go to next step. If not OK, repair open circuit to
ground.
(2) Connect battery negative cable. Install a
jumper wire from cavity A2 (left indicator) or cavity
B6 (cavity B7 - RHD)(right indicator) of cluster con-
nector A to a 12-volt battery feed. Lamp should light.
If OK, continue to next step. If not OK, replace bulb.(3) Disconnect battery negative cable. Check for
continuity between cavity A2 (left indicator) or cavity
B6 (cavity B7 - RHD)(right indicator) of cluster con-
nector A and cavity A1 (cavity 11 - RHD)(left front
turn signal) or cavity F2 (cavity 10 - RHD)(right
front turn signal) of bulkhead disconnect (dash to in-
strument panel connector B - RHD). There should be
continuity. If OK, refer to Group 8J - Turn Signal
and Hazard Warning Systems for further diagnosis.
If not OK, repair open circuit as required.
UPSHIFT INDICATOR LAMP
(1) Disconnect battery negative cable. Unplug PCM
connector. Connect battery negative cable. Turn igni-
tion switch to ON. Install a jumper wire from cavity
54 of PCM connector (Fig. 5) to a good ground. Lamp
should light. Remove jumper from ground. Lamp
should go off. If OK, refer to Powertrain Diagnostic
Procedures manual to diagnose PCM. If not OK, turn
ignition switch to OFF and go to next step.
(2) Disconnect battery negative cable. Remove in-
strument cluster bezel and cluster assembly. Install a
jumper wire from cavity 7 of cluster (tell-tale) con-
nector B to a good ground. Connect battery negative
cable. Turn ignition switch to ON. Lamp should light.
If OK, go to next step. If not OK, replace bulb.
(3) Turn ignition switch to OFF. Disconnect battery
negative cable. Unplug cluster connector B. Check for
continuity between cavity 7 of cluster connector B
and a good ground. There should be no continuity. If
OK, go to next step. If not OK, repair short circuit as
required.
(4) Check for continuity between cavity 7 of cluster
connector B and cavity 54 of PCM connector. There
should be continuity. If not OK, repair open circuit as
required.
Fig. 7 Chime/Buzzer Module Receptacle
JINSTRUMENT PANEL AND GAUGESÐXJ 8E - 15

(9) Apply a rubberized undercoating material to
the splash panel screws.
RADIO REMOVE/INSTALL - YJ
(1) Disconnect battery negative cable.
(2) Remove center cluster bezel attaching screws
(Fig. 17).
(3) Remove radio bezel.
(4) Remove radio attaching screws.
(5) Disconnect radio antenna cable.
(6) Disconnect radio wire harness.
(7) Remove radio.
(8) Reverse removal procedures to install.
SPEAKERS REMOVE/INSTALL - YJ
INSTRUMENT PANEL - YJ
RIGHT SIDE
The speaker is located behind grille panel at right
end of the instrument panel.
(1) Reach up behind instrument panel and remove
4 stamped nuts holding the speaker in place.
(2) Disconnect speaker electrical connector and re-
move speaker.
LEFT SIDE
The speaker is located behind grille panel at left
end of the dash panel.
(1) Remove nuts that attach the park brake assem-
bly mounting studs to the dash panel. The nuts are
accessible from the engine compartment (Fig. 18).
CAUTION: If vehicle is equipped with a rear window
wiper, there is a ground wire attached to top of bolt
that attaches the park brake assembly to the instru-
ment panel.
(2) Remove bolt that attaches the park brake as-
sembly to the instrument panel and allow assembly
to fall out of the way.
(3) Reach up behind instrument panel and remove
4 stamped nuts holding speaker in place.
(4) Disconnect speaker electrical connector and re-
move speaker.
(5) Reverse removal procedures to install.
SOUND BAR - YJ
(1) Pull sound bar padding away from bar on the
passenger side (Fig. 19).
(2) Disconnect speaker harness connector located
on the passenger side at the sound bar.
Fig. 16 Disconnect Antenna Lead - XJ
Fig. 17 Center Cluster Bezel Remove/Install - YJ
Fig. 18 Park Brake Assembly - YJ
JAUDIO SYSTEMS 8F - 9

for pin 2 (Fig. 6). If OK, go to next step. If not OK,
see diagnosis for Stop Lamp Switch.
(4) Connect a jumper wire between servo harness
connector cavity for pin 2 and pin 2 of the servo.
Check for battery voltage at pins 1, 3 and 4 of the
servo. If OK, go to next step. If not OK, replace the
servo.
(5) Turn ignition switch to OFF position. Check for
continuity between servo harness connector cavity for
pin 1 and a good ground. There should be continuity.
If not OK, repair open circuit to ground as required.
POWERTRAIN CONTROL MODULE
(1) Disconnect 60-way connector from the PCM, lo-
cated on the dash panel near the wiper motor in the
engine compartment (Fig. 7).(2) Connect negative lead of voltmeter to a good
body ground near the module.
(3) For the following tests, the ignition switch
must be in the ON position. See Fig. 8 for controller
terminal locations. Touch the positive lead of the
voltmeter to the terminal in cavity number 33. With
the speed control switch in the OFF position, the
voltmeter should read zero volts. With the speed con-
trol switch in the ON position, the voltmeter should
read battery voltage. If not, repair the main harness
as necessary.
(4) Touch the positive lead of the voltmeter to the
terminal in cavity number 53. As in step (3), the volt-
meter should read zero volts with the switch in the
OFF position, and battery voltage with the switch in
the ON position.
(5) Touch the positive lead of the voltmeter to the
terminal in cavity number 48. With the speed control
switch in the OFF position, the voltmeter should
Fig. 4 Speed Control Servo - LHD
Fig. 5 Speed Control Servo - RHD
Fig. 6 Servo Harness Connector
Fig. 7 Powertrain Control Module
JVEHICLE SPEED CONTROL SYSTEM 8H - 7

DAYTIME RUNNING LIGHTS (CANADA ONLY)ÐXJ
SERVICE INFORMATION
The Daytime Running Lights (Headlamps) System
is installed on vehicles manufactured for sale in Can-
ada only. The headlamps are illuminated when the
ignition switch is turned to the ON position. The
DRL module receives a vehicle-moving signal from
the vehicle speed sensor. This provides a constant
headlamps-oncondition as long as the vehicle is
moving. The lamps are illuminated at less than 50
percent of normal intensity.
DRL MODULE REPLACEMENTÐXJ
REMOVAL
The Daytime Running Lights (DRL) module is lo-
cated on the right fender inner panel adjacent to the
dash panel (Fig. 24).
(1) Disconnect the wire harness connector from the
module.
(2) Remove the screws that attach the module to
the fender inner panel.
(3) Remove the module from the fender inner
panel.
INSTALLATION
(1) Position the module on the right fender inner
panel.
(2) Install the attaching screws. Tighten the
screws securely.(3) Connect the wire harness connector to the mod-
ule.
Fig. 24 Daytime Running Lights (DRL) Module
JLAMPSÐXJ VEHICLES 8L - 15

CONNECTOR LOCATIONS
GENERAL INFORMATION
This section provides illustrations identifying com-
ponent and connector locations in the vehicle. A con-nector index is provided. Use the wiring diagrams in
each section for connector number identification. Re-
fer to the index for the proper figure number.
CONNECTOR LOCATIONS
Connector # Color Location Fig.
C101......BK ...Front of Left Fender Side Shield . . .1, 2
C102......BK ...Bottom Right of Radiator Closure
Panel....................8
C103......BK ...Near Left Side of Radiator......2,8
C104......BK ...Left Fender Side Shield
C105......BK ...Bottom of Left Fender Side Shield . . .2
C106......BK ...Left Fender Side Shield, Near PCM .1, 2
C107......BK ...OnABSPump Motor...........2
C108......BK ...Right Rear Corner of Engine
Compartment.............2,3
C109......BK ...Center of Dash Panel.........1,4
C110......BK ...Center of I.P., Below ABS Control
Module...............13, 14
C111......BK ...Left of Steering Column.........14
C112......BK ...AtABSControl Module.........13
C113......BK ...InHarness, Near ABS Control
Module.................13
C114......BK ...Center of I.P., Below ABS Control
Module.................14
C115......BK ...Near ABS Control Module.......14
C116......BK ...Below ABS Control Module.......14
C117......BK ...Rear of Intake Manifold........6,7
C118......BK ...OnThrottle Body............6,7
C119......BK ...Bottom Left Front of Cylinder
Block..................6,7
C120......BK ...OnThrottle Body............6,7
C121......GY ...Rear of Intake Manifold........6,7
C122......BK ...AtThermostat Housing........6,7
C123......BK ...Injector No. 1..............6,7
C124......BK ...Injector No. 2..............6,7
C125......BK ...Injector No. 3..............6,7
C126......BK ...Injector No. 4..............6,7
C127......BK ...Injector No. 5................7
C128......BK ...Injector No. 6................7
C129......GN ...Center of Dash Panel.........1,4
C130......BK ...Below Brake Master Cylinder.....1,2
C131......BK ...Distributor................6,7
C132......GN ...Lower Right Side of I.P.
C133......BK ...Right of Blower Motor..........4
C134......GY ...Right of Blower Motor..........4
C135......GY ...Right of Blower Motor..........4
C136......BR ...OnWasher Fluid Reservoir......1,4
C137......BK ...Under Side of Hood..........1,4
C138......BK ...Left of Blower Motor...........4
C139......BK ...Bottom of Washer Fluid Reservoir .3, 4
C140......BK ...Bottom of Washer Fluid Reservoir .3, 4
C141......BK ...InFront of Washer Fluid Reservoir .1, 4
C142......BK ...Between PDC and Blower Motor . .1, 4Connector # Color Location Fig.
C143......BK ...Bottom Front of Right Fender
Side Shield..............1,3
C144......BK ...Front of Right Fender Side Shield . .1, 3
C145......BK ...Front of Right Fender Side Shield . .1, 3
C146......BK ...Right Side of Grille Opening.....1,3
C147......BK ...Below Distributor..............7
C148......BK ...Right Side of Engine..........6,7
C149......BK ...Rear of Generator...........5,6
C150......BK ...Right Rear of Engine...........7
C151......BK ...Right Fender Side Shield.......1,4
C152......GY ...Behind Power Steering Pump......6
C153......BK ...Right Side of Transmission.......21
C154......BK ...Left Side of Radiator Closure Panel . .8
C155......BK ...Left Rear of Radiator Closure Panel . .8
C156......BK ...Behind Lens.................8
C157......BK ...Behind Left Headlamp...........8
C158......BK ...Behind Lens.................8
C159......BK ...Center of Grille Opening.........8
C160......BK ...Behind Lens.................8
C161......BK ...Behind Right Headlamp..........8
C162......BK ...Behind Lens.................8
C163......BK ...Center of Grille Opening.........8
C164......BK ...Right Center of Engine Compartment
C201......BK ...Below Left Side of I.P.........9,14
C202......LG ...Behind Left Kick Panel.........14
C203......BK ...Behind Left Kick Panel.........14
C204......GY ...Behind Left Kick Panel.........14
C205......BK ...Bottom Right of I.P............12
C206......BK ...Bottom Right of I.P............12
C207......BK ...Behind Headlamp Switch........10
C208......BK ...Bottom Right of I.P............12
C209......BK ...OnI.P.Right of Steering Column . . .10
C210......BK ...OnI.P.Right of Steering Column . . .10
C211......BK ...Rear of Radio...............11
C212......BR ...Center of I.P.................10
C213......BK ...Center of I.P.................10
C214......GY ...Right Side of I.P..............13
C215......BK ...Right Side of I.P..............13
C216......GY ...Glove Box.................10
C217......BK ...Bottom Right of I.P............11
C218......RD ...Right Side of I.P...........13, 17
C219......BK ...Bottom Right of I.P............11
C220......BK ...Right Side of I.P..............13
C221......BK ...Right Corner of I.P............13
C222......LG ...Right Corner of I.P............13
C223......BK ...Right Front of Steering Column....14
C224......BK ...Right Front of Steering Column....14
C225......NAT...Below Steering Column.........14
J8W-90 CONNECTOR LOCATIONSÐXJ VEHICLES 8W - 90 - 1

SPLICE LOCATIONS
GENERAL INFORMATION
This section provides illustrations identifying the
general location of the splices in this vehicle. A splice
index is provided. Use the wiring diagrams in each
section for splice number identification. Refer to the
index for the proper splice number.
SPLICE LOCATIONS
Splice
NumberLocations Fig.
S101 Near Generator T/O..................4
S102 Near Bulkhead T/O...................2
S103 Near Bulkhead T/O...................2
S104 Near Bulkhead T/O...................2
S105 Near Bulkhead T/O...................2
S106 Near Bulkhead T/O...................1
S107 Near Wiper Motor T/O................1
S108 Near Wiper Motor T/O................1
S109 Near Wiper Motor T/O................1
S110 Center of Dash Panel Near Grommet.......1
S111 Near T/O for ABS Diode...............7
S112 Near T/O for Map Sensor..............1
S113 Near T/O for Injector #5 and #6..........4
S114 Near T/O for Injector #5 and #6..........4
S115 Near T/O for Injector #5 and #6..........4
S116 Near T/O for Injector #5 and #6..........4
S117 Near T/O for Map Sensor..............1
S118 Near T/O for Map Sensor..............1
S119 Near Distributor T/O..................1
S120 Between Distributor T/O and Underhood
Lamp T/O.......................1
S121 Between Distributor T/O and Underhood
Lamp T/O.......................1
S122 Between Distributor T/O and Underhood
Lamp T/O.......................1
S123 RT Side of Cowl Panel................1
S124 RT Side of Cowl Panel................1
S125 Near T/O for PDC...................1
S126 Near T/O for Oil Pressure Switch..........5
S127 Near Generator T/O..................5
S128 LT Side of Grille Panel................3
S129 LT Side of Grille Panel................3
S130 Center of Grille Panel.................3
S201 Near Body Harness Connector T/O.........6
S202 Near Body Harness Connector T/O.........6
S203 Near Body Harness Connector T/O.........6
S204 Near Relay Center...................6
S205 Near T/O for Headlamp Switch...........6Splice
NumberLocations Fig.
S206 Near T/O for Telltale..................6
S207 Near T/O for Cluster..................6
S208 Near T/O for Cluster..................6
S209 Right Side of Cluster.................6
S210 Right Side of Cluster.................6
S211 Near Instrument Panel Ground T/O........6
S212 Near Wiper Switch T/O................6
S213 Near Antenna T/O...................7
S214 Near Blower Resistor T/O..............7
S215 Right Side of Instrument Panel...........7
S301 In Left Rear Door T/O.................8
S302 Near Left C-Pillar....................8
S303 Near Left C-Pillar....................8
S304 Near Left C-Pillar....................8
S305 Near Left C-Pillar....................8
S306 Near Left C-Pillar....................8
S307 Left Rear Wheel Well................10
S308 Left Rear Wheel Well................10
S309 Near Left Rear Door T/O...............8
S310 Near Left Rear Door T/O...............8
S311 Left Side of Floor Tunnel...............9
S312 Top of Floor Tunnel..................9
S313 In Power Mirror Switch T/O.............9
S314 Right A- Pillar.....................11
S315 Near RT Vanity Mirror T/O.............11
S316 Near RT Vanity Mirror T/O.............11
S317 In Trailer Tow Harness Near Grommet......14
S318 In Trailer Tow Harness Near Grommet......14
S319 In Liftgate.......................13
S320 Right A-Pillar.....................11
S321 In Left Front Door..................12
S401 In Left Rear Tail Lamp..........Not Shown
S402 In Right Rear Tail Lamp.........Not Shown
S403 In Left Rear Tail Lamp..........Not Shown
S404 In Right Rear Tail Lamp.........Not Shown
J8W-95 SPLICE LOCATIONSÐXJ VEHICLES 8W - 95 - 1

CONNECTOR LOCATIONS
GENERAL INFORMATION
This section provides illustrations identifying com-
ponent and connector locations in the vehicle. A con-nector index is provided. Use the wiring diagrams in
each section for connector number identification. Re-
fer to the index for the proper figure number.
CONNECTOR LOCATIONS
Connector # Color Location Fig.
C101......BK ...Front Left of Engine Compartment . .2
C102......BK ...InFront of Washer Fluid Reservoir . .2
C103......BK ...Bottom of Washer Fluid Reservoir . .2
C104......BK ...Bottom of Washer Fluid Reservoir . .2
C105......BK ...TopofWasher Fluid Reservoir.....2
C106......BK ...TopofRadiator Fan Housing......2
C107......BK ...Left Fender Side Shield.........2
C108......BK ...Left Fender Side Shield.........2
C109......BK ...Near Air Cleaner..............2
C110......BK ...Left Corner of Engine Compartment .2
C111......BK ...Rear of Intake Manifold.........4
C112......BK ...OnThrottle Body.............4
C113......BK ...OnThrottle Body.............4
C114......BK ...Rear of Intake Manifold.........4
C115......GN ...Lower Right of I.P.
C116......BK ...Near ABS Control Module
C117......GN ...Center of Dash Panel...........2
C118......BK ...Injector No. 6...............4
C119......BK ...Injector No. 5...............4
C120......BK ...Injector No. 4...............4
C121......BK ...Injector No. 3...............4
C122......BK ...Injector No. 2...............4
C123......BK ...Injector No. 1...............4
C124......BK ...OnEngine, Behind Power
Steering Pump.............4
C125......BK ...OnThermostat Housing.........4
C126......BK ...OnABSControl Module.........7
C127......BK ...Near ABS Control Module........7
C128......BK ...Near Distributor..............4
C129......BK ...Near Center of Dash Panel.......3
C130......GY ...Near Center of Dash Panel.......3
C131......BK ...Near Left Kick Panel
C132......BK ...OnSteering Column...........6
C133......BK ...Near Center of Dash Panel.......3
C134......BK ...Center of Dash Panel...........3
C135......BK ...Below Brake Master Cylinder......3
C136......BK ...Right Corner of Engine Compartment .3
C137......BK ...Right Side of Hood............3
C138......BK ...Near ABS Control Module
C139......BK ...Near ABS Control Module........7
C140......GY ...Near ABS Control Module........7
C141......GN ...Near ABS Control Module........7
C142......BK ...Right Fender Side Shield........3
C143......BK ...Right Fender Side Shield........3
C144......BK ...Right Fender Side Shield........3
C145......BK ...Right Fender Side Shield........3
C146......BK ...Below Battery................3
C147......BK ...Rear of Battery...............5
C148......BK ...AtStarter Motor..............4
C149......BK ...Right Side of Engine Near Distributor .4
C150......BK ...Rear of Generator.............4
C151......BK ...Rear of Generator.............5Connector # Color Location Fig.
C152......BK ...Behind Lens................1
C153......BK ...Left Rear of Radiator Closure Panel .1
C154......BK ...Behind Lens................1
C155......BK ...Behind Lens................1
C156......BK ...Behind Lens................1
C157......BK ...Center of Grille Opening.........1
C158......BK ...Center of Grille Opening.........1
C159......BK ...Behind Lens................1
C160......BK ...Behind Lens................1
C201......GY ...Center Bottom of I.P............8
C202......WT ...Center Bottom of I.P............8
C203......BK ...Behind Right Kick Panel........12
C204......BK ...Right Side of I.P.
C205......BK ...Left Rear of I.P...............8
C206......BK ...Left Rear of I.P...............8
C207......BK ...Near Right Kick Panel..........7
C208......GN ...Near Right Kick Panel..........7
C209......RD ...Behind Right Kick Panel........12
C210......BK ...Behind Fender Side Shield
C211......BK ...Near Right Kick Panel..........7
C212......BK ...Near Right Kick Panel
C213......BK ...Rear of Headlamp Switch.......10
C214......BK ...Rear of I.P., Right of Steering
Column..................9
C215......BK ...Rear of I.P., Right of Steering
Column..................9
C216......BK ...Rear of I.P., Right of Steering
Column.................9
C217......RD ...Rear of I.P., Right of Steering
Column..................9
C218......BK ...Below Stop Lamp Switch........7
C219......BK ...Rear of I.P., Right of Steering
Column.................9
C220......NAT ..Rear of I.P. Cluster...........10
C221......BK ...Rear of I.P. Cluster...........10
C222......NAT ..Rear of I.P., Left of Steering Column .9
C223......BK ...Rear of I.P., Left of Steering Column .9
C224......BK ...Rear of I.P., Left of Steering Column .9
C225......BK ...Rear of I.P., Left of Steering Column .9
C226......BK ...OnSteering Column...........6
C227......BK ...Near ABS Control Module........7
C228......WT ...Center of I.P.
C229......BK ...Center of I.P.
C230......BK ...OnSteering Column...........6
C231......BK ...OnSteering Column...........6
C232......BK ...OnSteering Column...........6
C233......BK ...Center Bottom of I.P............8
C234......BK ...Rear of I.P., Above Ash Receiver . . .8
C235......BK ...Rear of Radio...............9
C236......BR ...Rear of A/C-Heater Controls.....10
C237......BK ...Center Bottom of I.P............8
C238......BK ...Near ABS Control Module........7
J8W-90 CONNECTOR LOCATIONSÐXJ-RHD 8W - 90 - 1

(6) Remove upper radiator support retaining bolts
and remove radiator support.
(7) Remove the fan shroud (Fig. 13) and electric
cooling fan.
(8) Disconnect the transmission fluid cooler tubing
(automatic transmission).
(9) Disconnect radiator fan switch wire connector.
(10)Vehicles with Air Conditioning:
(a) Discharge the A/C condenser.
(b) Remove the service valves and cap the com-
pressor ports.
(11) Remove the radiator or radiator and con-
denser (if equipped with A/C).
(12) Remove the fan assembly from the idler pul-
ley.
(13) Disconnect the heater hoses at the engine
thermostat housing and water pump (Figs. 13 and
14).
(14) Disconnect the throttle linkages (Fig. 15).
(15) Disconnect the speed control cable (if
equipped)Ð(Fig. 15).(16) Disconnect the line pressure cable (if equipped
with automatic transmission).
(17) Disconnect injection system wire harness con-
nector at the dash panel.
(18) Disconnect the distributor electrical connec-
tion and the oil pressure switch connector.
(19) Perform the Fuel System Pressure Release
procedure (refer to Group 14, Fuel System).
(20) Disconnect the quick-connect fuel lines at the
fuel rail and return line by squeezing the two retain-
ing tabs against the fuel tube (Fig. 15). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(21) Remove the fuel line bracket from the intake
manifold.
(22) Remove the air cleaner assembly (Fig. 16).
(23) Remove the power brake vacuum check valve
from the booster, if equipped.
(24) If equipped with power steering (Fig. 16):
(a) Disconnect the hoses from the fittings at the
steering gear.
(b) Drain the pump reservoir.
(c) Cap the fittings on the hoses and steering
gear to prevent foreign objects from entering the
system.
(25) Identify, tag and disconnect all necessary wire
connectors and vacuum hoses.
(26) Raise and support the vehicle.
(27) Disconnect the wires from the starter motor
solenoid.
(28) Remove the starter motor.
Fig. 13 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Heater hoses
Fig. 14 Heater Hoses (RH Drive Vehicle)
Fig. 15 Accelerator Cable, Speed Control Cable,
Automatic Transmission Control Cable & Quick-
Connect Fuel Lines
9 - 60 4.0L ENGINEJ

(29) Disconnect the exhaust pipe from the mani-
fold.
(30) Disconnect the engine speed sensor wire con-
nection.
(31) Remove the exhaust pipe support.
(32) Remove the flywheel and converter housing
access cover.
(33)Vehicles with Automatic Transmission:
(a) Mark the converter and drive plate location.
(b) Remove the converter-to-drive plate bolts.
(34) Remove the upper flywheel and converter
housing bolts and loosen the bottom bolts.
(35) Remove the engine mount cushion-to-engine
compartment bracket bolts.
(36) Lower the vehicle.
(37) Attach a lifting device to the engine.
(38) Raise the engine off the front supports.
(39) Place a support or floor jack under the con-
verter (or flywheel) housing.
(40) Remove the remaining converter (or flywheel)
housing bolts.
(41) Lift the engine out of the engine compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the flywheel.
(1) Attach a lifting device to the engine and lower
the engine into the engine compartment. For easier
installation, it may be necessary to remove the en-
gine mount cushions from the engine mount bracket
as an aide in alignment of the engine to the trans-
mission.
(2)Vehicles with Manual Transmission:
(a) Insert the transmission shaft into the clutch
spline.
(b) Align the flywheel housing with the engine.(c) Install and tighten the flywheel housing lower
bolts finger tight.
(3)Vehicles with Automatic Transmission:
(a) Align the transmission torque converter hous-
ing 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.
(4) Install the engine mount cushions (if removed).
(5) Lower the engine and engine mount cushions
onto the engine compartment brackets. Install the
bolts and finger tighten the nuts.
(6) Remove the engine lifting device.
(7) Raise and support the vehicle.
(8) Install the remaining flywheel and converter
housing bolts. Tighten all bolts to 38 Nzm (28 ft. lbs.)
torque.
(9)Vehicles with Automatic Transmission:
(a) Install the converter-to-drive plate bolts.
(b) Ensure the installation reference marks are
aligned.
(10) Install the flywheel and converter housing ac-
cess cover.
(11) Install the exhaust pipe support and tighten
the screw.
(12) Tighten the engine mount-to-bracket bolts.
(13) Connect the engine speed sensor wire connec-
tions and tighten the screws.
(14) Connect the exhaust pipe to the manifold.
(15) Install the starter motor and connect the ca-
ble.
(16) Connect the wires to the starter motor sole-
noid.
(17) Lower the vehicle.
(18) Connect all the vacuum hoses and wire con-
nectors identified during engine removal.
(19) 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.
(20) Install the power brake vacuum check valve to
the booster, if equipped.
(21) Connect the fuel inlet and return hoses at the
fuel rail. Verify that the quick-connect fitting assem-
bly fits securely over the fuel lines by giving the fuel
lines a firm tug.
(22) Install the fuel line bracket to the intake man-
ifold.
(23) Connect the distributor electrical connector
and oil pressure switch connector.
(24) Connect the injection system wire harness
connector on the dash panel.
(25) Connect the line pressure cable (if equipped
with automatic transmission).
Fig. 16 Air Cleaner Assembly & Power Steering
Pump
J4.0L ENGINE 9 - 61