lock JEEP CHEROKEE 1995 Service Repair 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

CAMSHAFT POSITION SENSOR
For removal/installation procedures, refer to Group
8D, Ignition System. See Camshaft Position Sensor.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
The intake manifold air temperature sensor is in-
stalled into the intake manifold plenum (Figs. 7 or
8).
REMOVAL
(1) Disconnect the electrical connector from the
sensor.
(2) Remove the sensor from the intake manifold.
INSTALLATION
(1) Install the sensor into the intake manifold.
Tighten the sensor to 28 Nzm (20 ft. lbs.) torque.
(2) Connect the electrical connector to the sensor.
CRANKSHAFT POSITION SENSOR
For description, operation and removal/installation
procedures, refer to Group 8D, Ignition Systems in
this manual.
ENGINE COOLANT TEMPERATURE SENSOR
The coolant temperature sensor is installed in the
thermostat housing (Fig. 9).
REMOVAL
(1) Drain cooling system until the coolant level is
below the cylinder head. Observe theWARNINGSin
Group 7, Cooling.
(2) Disconnect the coolant temperature sensor wire
connector.
(3) Remove the sensor from the thermostat hous-
ing (Fig. 9).
INSTALLATION
(1) Install coolant temperature sensor into the cyl-
inder block. 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.
FUEL FILTER
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
FUEL INJECTOR
REMOVAL
(1) Remove the fuel rail. Refer to Fuel Rail Re-
moval in this section.
(2) Remove the clip(s) that retain the fuel injec-
tor(s) to the fuel rail (Figs. 10 or 11).
INSTALLATION
(1) Install the fuel injector(s) into the fuel rail as-
sembly and install retaining clip(s).
(2) If the same injector(s) is being reinstalled, in-
stall new o-ring(s).
(3) Install fuel rail. Refer to Fuel Rail Installation
in this section.
(4) Start engine and check for fuel leaks.
Fig. 7 Sensor LocationÐ2.5L Engine
Fig. 8 Sensor LocationÐ4.0L Engine
Fig. 9 Engine Coolant Temperature SensorÐTypical
14 - 60 FUEL SYSTEM COMPONENT REMOVAL/INSTALLATIONJ

POWER STEERING PUMP
Hydraulic pressure is provided for operation of the
power steering gear by a belt driven power steering
pump. The power steering pump is a constant flow
rate and displacement, vane-type pump. The internal
parts in the housing operate submerged in fluid. The
flow control orifice is part of the high pressure line
fitting. The pressure relief valve inside the flow con-
trol valve limits the pump pressure.
Power steering pumps have different pres-
sure rates and are not interchangeable with
other pumps.
The power steering pump is connected to the steer-
ing gear via high pressure and return hose. The
pump shaft has a pressed-on drive pulley that is belt
driven by the crankshaft pulley (Fig. 3).
XJ vehicles with 2.5L engines and all YJ vehicles:
The reservoir is mounted at the front left side of the
engine compartment. XJ vehicles equipped with a
4.0L engine have the reservoir attached to the pump
body with spring clips.
STEERING COLUMNS
Two general types of steering columns are installed
on Jeep vehicles: a fixed, non-tilt column and a tilt
column (Fig. 4).
The ignition key/lock cylinder is located in the
steering column. When the key/lock cylinder is
turned to the LOCK position, the ignition switch and
steering shaft cannot be operated. For vehicles withan automatic transmission, the lock mechanism also
prevents operation of the gear shift mechanism.
The center, slip-type intermediate shaft is attached
to the steering gear and steering column shaft with
universal joints.
Both types of steering columns have anti-theft pro-
visions. They are energy-absorbing.
Fig. 2 Ratio Code Location
Fig. 3 TC Series Pump With Integral Reservoir
Fig. 4 Steering Columns
19 - 2 STEERINGJ

(2) Be sure tool and pulley remain aligned and
NOT cocked with the pump shaft.
(3) Press the pulley on flush with end of pump
shaft (Fig. 7).
(4) Install power steering pump. Refer to Pump
Replacement in this section.
With Serpentine Belts; Run engine until warm (5
min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.).Be
careful that pulley does not contact mounting
bolts.
RESERVOIR REPLACEMENT
REMOVAL
(1) Remove power steering pump. Refer to Pump
Replacement in this section.
(2) Clean exterior of pump with solvent.
(3) Clamp the pump body in a soft jaw vice.
(4) Pry up tab and slide the retaining clip off (Fig.
8).
(5) Remove fluid reservoir from pump body. Re-
move and discard O-ring seal (Fig. 9).
INSTALLATION
(1) Lubricate new O-ring Seal with Mopar Power
Steering Fluid or equivalent.
(2) Install O-ring seal in housing.
(3) Install reservoir onto housing.
(4) Slide and tap in reservoir retainer clips until
tab locks to housing.
(5) Install power steering pump. Refer to Pump
Replacement in this section.
FLOW CONTROL VALVE FITTING O-RING SEAL
REMOVAL
(1) Clean area around fitting to prevent dirt from
entering pump. Remove pressure hose from pump fit-
ting.
Fig. 6 Install Drive PulleyÐTypical
Fig. 7 Pump Shaft Location
Fig. 8 Remove Reservoir ClipsÐTypical
Fig. 9 Remove ReservoirÐTypical
19 - 14 STEERINGJ

(2) Remove fitting from pump housing (Fig. 10).
Prevent flow control valve and spring from
sliding out of housing bore.
(3) Remove and discard O-ring seal.
INSTALLATION
(1) If necessary, clean and install flow control valve
and spring in pump housing bore.Be sure the hex
nut end of the valve is facing in toward pump.
(2) Install O-ring seal onto fitting (Fig. 10).
(3) Install flow control valve in pump housing and
tighten to 75 Nzm (55 ft. lbs.) torque.
(4) Install pressure hose to valve.
POWER STEERING PUMPÐINITIAL OPERATION
CAUTION: The fluid level should be checked with
engine off to prevent injury from moving compo-
nents. Use only Mopar Power Steering Fluid. Do not
use automatic transmission fluid. Do not overfill.
Wipe filler cap clean, then check the fluid level.
The dipstick should indicate FULL COLD when the
fluid is at normal temperature 21ÉC to 27ÉC (70ÉF to
80ÉF).
(1) Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two (2) minutes.
(2) Start the engine and let run for a few seconds.
Then turn the engine off.
(3) Add fluid if necessary. Repeat the above proce-
dure until the fluid level remains constant after run-
ning the engine.
(4) Raise the front wheels off the ground.
(5) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
stops.
(6) Add power steering fluid if necessary.
(7) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
(8) Stop the engine. Check the fluid level and refill
as required.
(9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
cedure.
Fig. 10 Flow Control Valve Fitting
JSTEERING 19 - 15

²SECOND - over-center preload adjustment
WORM THRUST BEARING PRELOAD
ADJUSTMENT
(1) Remove adjuster plug locknut (Fig. 8).
(2) Turn the adjuster in with Spanner Wrench
C-4381. Tighten the plug and thrust bearing in the
housing until firmly bottomed in housing.
(3) Place an index mark on the housing even with
one of the holes in adjuster plug (Fig. 9).(4) Measure back (counterclockwise) 13 mm (0.50
in) and mark housing (Fig. 10).
(5) Rotate adjustment cap back (counterclockwise)
with spanner wrench until hole is aligned with the
second mark (Fig. 11).
(6) Install and tighten locknut to 109 Nzm (80 ft.
lbs.) torque. Be sure adjustment cap does not turn
while tightening the locknut.
OVER-CENTER ADJUSTMENT
(1) Rotate the stub shaft from stop to stop and
count the number of turns.
Fig. 10 Remarking The Housing
Fig. 11 Aligning To The Second Mark
Fig. 8 Loosening the Adjuster Plug Locknut
Fig. 9 Alignment Marking On Housing
JSTEERING 19 - 25

(2) Starting at either stop turn the stub shaft back
1/2 the total number of turns. This is the center of
the gear travel (Fig. 12).
(3) Turn the pitman shaft adjuster screw back
(COUNTERCLOCKWISE) until extended, then turn
back in (CLOCKWISE) one full turn.
(4) Place the torque wrench in the vertical position
on the stub shaft. Rotate the wrench 45 degrees each
side of the center and record the highest rotational
torque on center (Fig. 13).
(5) Turn the adjuster in until torque to turn stub
shaft is 0.6 to 1.2 Nzm (6.0 to 10.0 in. lbs.) more than
reading in Step 4.
(6) Prevent the adjuster screw from turning while
tightening adjuster lock nut. Tighten the adjuster
lock nut to 49 Nzm (36 ft. lbs.).
GEAR DISASSEMBLY INFORMATION
CAUTION: Cleanliness is extremely important when
repairing a power steering gear. Keep the bench,
tools and components clean at all times. Thor-
oughly clean the exterior of the gear with cleaning
solvent before disassembly. Drain as much of the
fluid as possible. Use protective vise jaws at all
times when clamping components. During assem-
bly, lubricate all components with power steering
fluid except where noted (Fig. 14).
Fig. 12 Steering Gear Centered
Fig. 13 Checking Over-center Rotation Torque
19 - 26 STEERINGJ

PITMAN SHAFT AND SIDE COVER REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman arm from steering gear. Refer
to Pitman Arm Removal in the Steering Linkage sec-
tion.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
²Clean exposed end of pitman shaft and housing.
²Clean pitman shaft spline with a wire brush.
(1) Remove preload adjuster nut.
(2) Rotate stub shaft with socket to center gear.
Remove side cover bolts.
(3) Remove side cover, gasket and pitman shaft as
an assembly.
(4) Remove pitman shaft from the side cover (Fig.
15).
ASSEMBLE
(1) Install pitman shaft to side cover by screwing
shaft in until it fully seats to side cover.
(2) Install preload adjuster nut.Do not tighten
nut until after pitman shaft adjustment has
been made.(3) Install gasket to side cover and bend tabs
around edges of side cover.
(4) Install pitman shaft assembly and side cover to
housing.
(5) Install side cover bolts and tighten to 60 Nzm
(44 ft. lbs.).
(6) Adjust pitman shaft, refer to Over-Center Ad-
justment.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this Group.
HOUSING END PLUG
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
(2) Remove pitman arm from steering gear. Refer
to Steering Linkage in this Group.
(3) Rotate stub shaft back and forth to drain power
steering fluid.
DISASSEMBLE
²Rotate stub shaft back and forth to drain fluid
(1) Rotate retaining ring until one end is under the
hole in the housing. Unseat and force ring from
groove (Fig. 16).
(2) Rotate stub shaft slowly COUNTER-CLOCK-
WISE to remove end plug out from housing (Fig. 17).
Fig. 15 Side Cover and Pitman Shaft
Fig. 16 End Plug Retaining Ring
19 - 28 STEERINGJ

CAUTION: Do not turn stub shaft any farther than
necessary. The recirculating balls will drop out of
the rack piston circuit and fall inside the rack pis-
ton chamber.
(3) Remove O-ring seal (Fig. 17).
ASSEMBLE
²Lubricate O-ring seal with power steering fluid
(1) Install O-ring into housing.
(2) Install plug, tap lightly with a plastic mallet to
seat it.
(3) Install retaining ring with open end 25 mm (1
inch) from access hole (Fig. 18).
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.(2) Install pitman arm onto steering gear. Refer to
Steering Linkage in this Group.
ADJUSTER PLUG ASSEMBLY REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove adjuster plug lock nut from housing.
(2) Remove adjuster plug from housing with Span-
ner Wrench C-4381 (Fig. 19).
(3) Remove thrust washer bearing retainer from
adjuster plug with screwdriver (Fig. 20).
Fig. 17 End Plug Components
Fig. 18 Installing The Retaining Ring
Fig. 19 Remove/Install Adjustment Plug
Fig. 20 Remove Retainer
JSTEERING 19 - 29

(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