electrical JEEP CHEROKEE 1995 Service Workshop Manual

POWER WINDOWS
CONTENTS
page page
DIAGNOSIS............................. 1
GENERAL INFORMATION.................. 1SERVICE PROCEDURES................... 7
GENERAL INFORMATION
Power door windows are optional equipment on XJ
(Cherokee) models. The power windows operate only
with the ignition switch in the ON position. This
group covers diagnosis and service of the electrical
components peculiar to the power window system.
For service of mechanical components such as the
regulator, lift plate or window tracks refer to Group
23 - Body Components.
Following are general descriptions of the major
components in the power window system. Refer to
Group 8W - Wiring Diagrams for complete circuit de-
scriptions and diagrams.
POWER WINDOW SWITCH
Both front and rear door windows can be raised or
lowered electrically by operating the four two-way
switches on the driver's door panel. A single two-way
switch on each passenger's door panel operates only
the window on that passenger's door. The switches
cannot be repaired. If faulty, they must be replaced.
POWER WINDOW MOTOR
A permanent magnet reversible motor moves the
window regulator through a cable and drum operat-ing mechanism. A positive and negative battery con-
nection to the two motor terminals will cause the
motor to rotate in one direction. Reversing current
through these same two connections will cause the
motor to rotate in the opposite direction. In addition,
each power window motor is equipped with an inte-
gral automatic re-setting circuit breaker to protect
the motor from overloads. The power window motor
and regulator assembly cannot be repaired. If faulty,
the entire assembly must be replaced.
CIRCUIT BREAKER
An automatic re-setting circuit breaker in the fuse-
block module is used to protect the power window
system circuit. The circuit breaker can protect the
system from a short circuit, and can also protect the
system from an overload condition caused by an ob-
structed or stuck window glass or regulator. The cir-
cuit breaker can not be repaired. If faulty, it must be
replaced.
DIAGNOSIS
It is necessary that the window be free to slide up
and down for the power window system to function
properly. If the window is not free to move up and
down, the motor will overload and trip the circuit
breaker. To determine if the glass is free, disconnect
regulator plate from the glass and slide window up
and down by hand.
An alternate method is to shake the glass in the
door, with the glass positioned between the up and
down stop positions. Check that the glass can be
moved slightly from side to side, front to rear, and up
and down. Then check that window is not boundtight in the tracks. If window is free, proceed with di-
agnosis that follows. If window is not free, refer to
Group 23 - Body Components for service procedures.
CIRCUIT BREAKER
Locate correct circuit breaker in fuseblock module.
Pull out slightly, but be sure that circuit breaker ter-
minals still contact terminals in fuseblock module.
Turn ignition switch to ON position. Connect ground
wire of voltmeter to a good ground. With probe of
voltmeter positive lead, check both terminals of cir-
cuit breaker for battery voltage. If only one terminal
JPOWER WINDOWS 8S - 1

the following procedures to reduce the possibility of
electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume
that it is.
(1) Always touch a known good ground before han-
dling the part. This should be repeated while han-
dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written diagnostic
procedure.
(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part from its protective pack-
ing until it is time to install the part.
(5) Before removing the part from its package,
ground the package to a known good ground on the
vehicle.
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
²Jumper Wire - This is a test wire used to connect
two points of a circuit. It can be used to bypass an
open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A
LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN
A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a circuit.
Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-
megohm or greater impedance.
²Ohmmeter - Used to check the resistance between
two points of a circuit. Low or no resistance in a
circuit means good continuity.CAUTION: - Most of the electrical components used
in today's vehicle are Solid State. When checking
resistance in these circuits use a meter with a 10-
megohm or greater impedance. In addition, make
sure the power is disconnected from the circuit.
Circuits that are powered up by the vehicle electrical
system can cause damage to the equipment and
provide false readings.
²Probing Tools - These tools are used for probing
terminals in connectors (Fig. 7). Select the proper size
tool from Special Tool Package 6807, and insert it into
the terminal being tested. Use the other end of the
tool to insert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused by
faulty electrical connections or wiring. It is also pos-
sible for a sticking component or relay to cause a
problem. Before condemning a component or wiring
assembly check the following items.
²Connectors are fully seated
²Spread terminals, or terminal push out
²Terminals in the wiring assembly are fully seated
into the connector/component and locked in position
²Dirt or corrosion on the terminals. Any amount of
corrosion or dirt could cause an intermittent problem
²Damaged connector/component casing exposing the
item to dirt and moisture
²Wire insulation that has rubbed through causing a
short to ground
²Wiring broke inside of the insulation
TROUBLESHOOTING TESTS
Before beginning any tests on a vehicle's electrical
system, use the Wiring Diagrams and study the cir-
cuit. Also refer to the Troubleshooting Wiring Prob-
lems section in this section.
TESTING FOR VOLTAGE
(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 8).
Fig. 6 Electrostatic Discharge Symbol
Fig. 7 Probing Tool
8W - 4 WIRING DIAGRAMSÐGENERAL INFORMATIONJ

(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half.
(3) Remove connector locking wedge, if required
(Fig. 14).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Figs. 15 and 16).
(5) Cut the wire 6 inches from the back of the
connector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assembly
that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and
remove 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one side
of the wire. Make sure the tubing will be long enough
to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11
example 2).
(12) Twist the wires together (Fig. 11 example 3).(13) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if re-
quired, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect the battery, and test all affected sys-
tems.
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove the
protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 18).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(8) Re-connect the battery, and test affected sys-
tems.Fig. 17 Stagger Cutting Wires (Typical)
Fig. 18 Diode Identification
8W - 8 WIRING DIAGRAMSÐGENERAL INFORMATIONJ

WIRING DIAGRAMS
CONTENTS
page page
8W-01 GENERAL INFORMATIONÐWIRING
DIAGRAMS.................... 8W-01-1
8W-10 FUSE/FUSE BLOCK........... 8W-10-1
8W-11 POWER DISTRIBUTION........ 8W-11-1
8W-15 GROUND DISTRIBUTION....... 8W-15-1
8W-20 CHARGING SYSTEM.......... 8W-20-1
8W-21 STARTING SYSTEM........... 8W-21-1
8W-30 FUEL/IGNITION.............. 8W-30-1
8W-31 TRANSMISSION CONTROLS.... 8W-31-1
8W-32 ANTI-LOCK BRAKES.......... 8W-32-1
8W-33 VEHICLE SPEED CONTROL..... 8W-33-1
8W-40 INSTRUMENT CLUSTER....... 8W-40-1
8W-41 HORN/CIGAR LIGHTER......... 8W-41-1
8W-42 AIR CONDITIONING/HEATER.... 8W-42-1
8W-44 INTERIOR LIGHTING.......... 8W-44-1
8W-47 AUDIO SYSTEM.............. 8W-47-18W-48 HEATED REAR WINDOW....... 8W-48-1
8W-49 OVERHEAD CONSOLE......... 8W-49-1
8W-50 FRONT LIGHTING............. 8W-50-1
8W-51 REAR LIGHTING............. 8W-51-1
8W-52 TURN SIGNALS.............. 8W-52-1
8W-53 WIPERS..................... 8W-53-1
8W-54 TRAILER TOW................ 8W-54-1
8W-60 POWER WINDOWS.......... 8W-60-1
8W-61 POWER DOOR LOCKS......... 8W-61-1
8W-62 POWER MIRRORS............ 8W-62-1
8W-63 POWER SEAT................ 8W-63-1
8W-70 SPLICE INFORMATION........ 8W-70-1
8W-80 CONNECTOR PIN OUTS....... 8W-80-1
8W-90 CONNECTOR LOCATIONS...... 8W-90-1
8W-95 SPLICE LOCATIONS........... 8W-95-1
HOW TO USE THIS GROUP
The purpose of this group is to show the electrical
circuits in a clear, simple fashion and to make trou-
bleshooting easier. Components that work together
are shown together. All electrical components used in
a specific system are shown on one diagram. The feed
for a system is shown at the top of the page. All
wires, connectors, splices, and components are shown
in the flow of current to the bottom of the page. Wir-
ing which is not part of the circuit represented is ref-
erenced to another page/section, where the complete
circuit is shown. In addition, all switches, compo-
nents, and modules are shown in theat rest posi-
tion with the doors closed and the key removed
from the ignition.
If a component is part of several different circuits,
it is shown in the diagram for each. For example, the
headlamp switch is the main part of the exterior
lighting, but it also affects the interior lighting and
the chime warning system.
It is important to realize that no attempt is
made on the diagrams to represent components
and wiring as they appear on the vehicle. For
example, a short piece of wire is treated the
same as a long one. In addition, switches and
other components are shown as simply as pos-
sible, with regard to function only.
The wiring diagram show circuits for all wheel-
bases. If there is a difference in systems or compo-
nents between wheel-bases, an identifier is placed
next to the component.
SECTION IDENTIFICATION
Sections in Group 8W are organized by sub-sys-
tems. The sections contain circuit operation descrip-
tions, helpful information, and system diagrams. The
intention is to organize information by system, con-
sistently from year to year.
CONNECTOR LOCATIONS
Section 8W-90 contains Connector Location illus-
trations. The illustrations contain the connector
number and component identification. Connector Lo-
cation charts in Section 8W-90 reference the illustra-
tion number for components and connectors.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the number on the Diagram
pages.
SPLICE LOCATIONS
Splice Location charts in Section 8W-70 show the
entire splice, and provide references to other sections
the splice serves.
Section 8W-95 contains illustrations that show the
general location of the splices in each harness. The
illustrations show the splice by number, and provide
a written location.
JWIRING DIAGRAMSÐXJ VEHICLES 8W - 1 - 1

ANTI-LOCK BRAKES
INDEX
page page
ABS Power Relay.......................... 1
ABS Pump Motor Relay..................... 1
ABS Warning Lamp........................ 2
Acceleration Switch......................... 1
Brake Switch Input......................... 2
Data Link Connector........................ 2Diagram Index............................ 3
General Information........................ 1
Hydraulic Control Unit....................... 2
Pump Motor Speed Sensor................... 2
Wheel Speed Sensors...................... 1
GENERAL INFORMATION
Three fuses supply power for the Anti-Lock Brake
System (ABS); fuses 8 and 10 in the Power Distribu-
tion Center (PDC) and fuse 7 in the fuse block. Fuses
8 and 10 in the PDC are connected directly to battery
voltage and are HOT all times. Fuse 7 in the fuse
block is HOT when the ignition switch is the RUN
Position.
In the RUN position, the ignition switch connects
circuit A1 from fuse 6 in the PDC with circuit A38.
Circuit A38 connects to a bus bar in the fuse block.
The bus bar feeds circuit B236 through fuse 7. Fuse 7
is a 2 amp fuse.
Circuit B236 connects to the coil side of the ABS
power relay and cavity 53 of the ABS control module.
Circuit Z1 provides ground for the ABS control mod-
ule. Circuit Z1 connects to cavities 1 and 19 of the
ABS control module.
Refer to group 5, Brakes for operational descrip-
tions of ABS system components.
WHEEL SPEED SENSORS
The all wheel anti-lock system uses four wheel
speed sensors; one for each wheel. Each sensor con-
verts wheel speed into an electrical signal that it
transmits to the ABS control module. A pair of
twisted wires connect to each sensor to provide sig-
nals to the ABS control module.
Circuits B6 and B7 provide signals to ABS control
module from right front wheel speed sensor. Circuit
B6 which provides the LOW signal connects to cavity
29 of the ABS control module. Circuit B7 connects to
cavity 47 of the module and provides the HIGH sig-
nal.
Circuits B8 and B9 provide signals to ABS control
module from left front wheel speed sensor. Circuit B8,
which provides the LOW signal, connects to cavity 30
of the ABS control module. Circuit B9 connects to
cavity 48 of the module and provides the HIGH sig-
nal.
Circuits B1 and B2 provide signals to ABS control
module from right rear wheel speed sensor. Circuit
B1 which provides the LOW signal connects to cavity45 of the ABS control module. Circuit B2 connects to
cavity 27 of the module and provides the HIGH sig-
nal.
Circuits B4 and B3 provide signals to ABS control
module from left rear wheel speed sensor. Circuit B3,
which provides the LOW signal, connects to cavity 28
of the ABS control module. Circuit B4 connects to
cavity 46 of the module and provides the HIGH sig-
nal.
ACCELERATION SWITCH
During four-wheel drive operation, the acceleration
(G) switch provides deceleration data to the ABS con-
trol module. Refer to Group 5, Brakes for additional
information.
Circuits B515, B516, and B517 connect the accel-
eration sensor to the ABS control module. Circuits
B515 and B516 provide switch states while circuit
B517 provides ground. At the ABS control module
circuit B515 connects to cavity 25, circuit B516 con-
nects to cavity 43 and circuit B517 connects to cavity
26.
ABS POWER RELAY
The ABS power relay is located in the power distri-
bution center (PDC). When the ABS module grounds
the ABS power relay on circuit B207, the relay
switches to connect circuit A20 from PDC fuse 10 to
circuit B235. Circuit B236 from fuse 7 in the fuse
block splices to feed the coil side of the ABS power
relay. Circuit B207 connects to cavity 34 of the ABS
control module.
Circuit B235 is double crimped at the ABS power
relay. One branch of circuit B235 supplies power to
the coil side of the ABS pump motor relay. The other
branch of circuit B235 splices to cavities 3 and 33 of
the ABS control module and to the hydraulic control
unit.
ABS PUMP MOTOR RELAY
The ABS pump motor relay in the power distribu-
tion center (PDC) supplies voltage to the ABS pump
motor. When the ABS power relay energizes, circuit
B235 supplies battery voltage to the coil side of the
J8W-32 ANTI-LOCK BRAKESÐXJ VEHICLES 8W - 32 - 1

WIRING DIAGRAMS
CONTENTS
page page
8W-01 GENERAL INFORMATIONÐWIRING
DIAGRAMS...................... 8W-01-1
8W-10 FUSE/FUSE BLOCK........... 8W-10-1
8W-11 POWER DISTRIBUTION........ 8W-11-1
8W-15 GROUND DISTRIBUTION....... 8W-15-1
8W-20 CHARGING SYSTEM.......... 8W-20-1
8W-21 STARTING SYSTEM........... 8W-21-1
8W-30 FUEL/IGNITION.............. 8W-30-1
8W-31 TRANSMISSION CONTROLS.... 8W-31-1
8W-32 ANTI-LOCK BRAKES........... 8W-32-1
8W-33 VEHICLE SPEED CONTROL..... 8W-33-1
8W-40 INSTRUMENT CLUSTER....... 8W-40-1
8W-41 HORN/CIGAR LIGHTER........ 8W-41-1
8W-42 AIR CONDITIONING/HEATER.... 8W-42-1
8W-44 INTERIOR LIGHTING.......... 8W-44-1
8W-47 AUDIO SYSTEM.............. 8W-47-18W-48 HEATED REAR WINDOW....... 8W-48-1
8W-49 OVERHEAD CONSOLE.......... 8W-49-1
8W-50 FRONT LIGHTING............ 8W-50-1
8W-51 REAR LIGHTING............. 8W-51-1
8W-52 TURN SIGNALS.............. 8W-52-1
8W-53 WIPERS.................... 8W-53-1
8W-54 TRAILER TOW................ 8W-54-1
8W-60 POWER WINDOWS............ 8W-60-1
8W-61 POWER DOOR LOCKS......... 8W-61-1
8W-62 POWER MIRRORS............ 8W-62-1
8W-63 POWER SEAT................ 8W-63-1
8W-70 SPLICE INFORMATION........ 8W-70-1
8W-80 CONNECTOR PIN OUTS....... 8W-80-1
8W-90 CONNECTOR LOCATIONS...... 8W-90-1
8W-95 SPLICE LOCATIONS........... 8W-95-1
HOW TO USE THIS GROUP
The purpose of this group is to show the electrical
circuits in a clear, simple fashion and to make trou-
bleshooting easier. Components that work together
are shown together. All electrical components used in
a specific system are shown on one diagram. The feed
for a system is shown at the top of the page. All
wires, connectors, splices, and components are shown
in the flow of current to the bottom of the page. Wir-
ing which is not part of the circuit represented is ref-
erenced to another page/section, where the complete
circuit is shown. In addition, all switches, compo-
nents, and modules are shown in theat rest posi-
tion with the doors closed and the key removed
from the ignition.
If a component is part of several different circuits,
it is shown in the diagram for each. For example, the
headlamp switch is the main part of the exterior
lighting, but it also affects the interior lighting and
the chime warning system.
It is important to realize that no attempt is
made on the diagrams to represent components
and wiring as they appear on the vehicle. For
example, a short piece of wire is treated the
same as a long one. In addition, switches and
other components are shown as simply as pos-
sible, with regard to function only.
The wiring diagram show circuits for all wheel-
bases. If there is a difference in systems or compo-
nents between wheel-bases, an identifier is placed
next to the component.
SECTION IDENTIFICATION
Sections in Group 8W are organized by sub-sys-
tems. The sections contain circuit operation descrip-
tions, helpful information, and system diagrams. The
intention is to organize information by system, con-
sistently from year to year.
CONNECTOR LOCATIONS
Section 8W-90 contains Connector Location illus-
trations. The illustrations contain the connector
number and component identification. Connector Lo-
cation charts in Section 8W-90 reference the illustra-
tion number for components and connectors.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the number on the Diagram
pages.
SPLICE LOCATIONS
Splice Location charts in Section 8W-70 show the
entire splice, and provide references to other sections
the splice serves.
Section 8W-95 contains illustrations that show the
general location of the splices in each harness. The
illustrations show the splice by number, and provide
a written location.
JWIRING DIAGRAMSÐXJ-RHD 8W - 1 - 1

ANTI-LOCK BRAKES
INDEX
page page
ABS Power Relay.......................... 1
ABS Pump Motor Relay..................... 1
ABS Warning Lamp........................ 2
Acceleration Switch......................... 1
Brake Pedal Travel Sensor................... 2
Brake Switch Input......................... 2Data Link Connector........................ 2
Diagram Index............................ 3
General Information........................ 1
Hydraulic Control Unit....................... 2
Pump Motor Speed Sensor................... 2
Wheel Speed Sensors...................... 1
GENERAL INFORMATION
Three fuses supply power for the Anti-Lock Brake
System (ABS); fuses 6 and 10 in the Power Distribu-
tion Center (PDC) and fuse 2 in the fuse block. Fuses
6 and 10 in the PDC are connected directly to battery
voltage and are HOT all times. Fuse 2 in the fuse
block is HOT when the ignition switch is the RUN
Position.
In the RUN position, the ignition switch connects
circuit A1 from fuse 6 in the PDC with circuit A38.
Circuit A38 connects to a bus bar in the fuse block.
The bus bar feeds circuit B236 through fuse 2. Fuse
2 is a 2 amp fuse.
Circuit B236 connects to the coil side of the ABS
power relay and cavity 53 of the ABS control module.
Circuit Z1 provides ground for the ABS control
module. Circuit Z1 connects to cavities 1 and 19 of
the ABS control module.
Refer to group 5, Brakes for operational descrip-
tions of ABS system components.
WHEEL SPEED SENSORS
The all wheel anti-lock system uses four wheel
speed sensors; one for each wheel. Each sensor con-
verts wheel speed into an electrical signal that it
transmits to the ABS control module. A pair of
twisted wires connect to each sensor to provide sig-
nals to the ABS control module.
Circuits B6 and B7 provide signals to ABS control
module from the right front wheel speed sensor. Cir-
cuit B6 which provides the LOW signal connects to
cavity 29 of the ABS control module. Circuit B7 con-
nects to cavity 47 of the module and provides the
HIGH signal.
Circuits B8 and B9 provide signals to ABS control
module from the left front wheel speed sensor. Cir-
cuit B8, which provides the LOW signal, connects to
cavity 30 of the ABS control module. Circuit B9 con-
nects to cavity 48 of the module and provides the
HIGH signal.
Circuits B1 and B2 provide signals to ABS control
module from the right rear wheel speed sensor. Cir-
cuit B1 which provides the LOW signal connects tocavity 45 of the ABS control module. Circuit B2 con-
nects to cavity 27 of the module and provides the
HIGH signal.
Circuits B4 and B3 provide signals to ABS control
module from the left rear wheel speed sensor. Circuit
B3, which provides the LOW signal, connects to cav-
ity 28 of the ABS control module. Circuit B4 connects
to cavity 46 of the module and provides the HIGH
signal.
ACCELERATION SWITCH
During four-wheel drive operation, the acceleration
switch provides deceleration data to the ABS control
module. Refer to Group 5, Brakes for additional in-
formation.
Circuits B515, B516, and B517 connect the acceler-
ation sensor to the ABS control module. Circuits
B515 and B516 provide switch states while circuit
B517 provides ground. At the ABS control module cir-
cuit B515 connects to cavity 25, circuit B516 connects
to cavity 43 and circuit B517 connects to cavity 26.
ABS POWER RELAY
The ABS power relay is located in the power distri-
bution center (PDC). When the ABS module grounds
the ABS power relay on circuit B207, the relay
switches to connect circuit A20 from PDC fuse 10 to
circuit B235. Circuit B236 from fuse 7 in the fuse
block splices to feed the coil side of the ABS power
relay. Circuit B207 connects to cavity 34 of the ABS
control module.
Circuit B235 is double crimped at the ABS power
relay. One branch of circuit B235 supplies power to
the coil side of the ABS pump motor relay. The other
branch of circuit B235 splices to cavities 3 and 33 of
the ABS control module and to the hydraulic control
unit.
ABS PUMP MOTOR RELAY
The ABS pump motor relay in the power distribu-
tion center (PDC) supplies voltage to the ABS pump
motor. When the ABS power relay energizes, circuit
B235 supplies battery voltage to the coil side of the
J8W-32 ANTI-LOCK BRAKESÐXJ-RHD 8W - 32 - 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

CAUTION: When disconnecting the cruise control
connector at the throttle body, DO NOT pry the con-
nector off with pliers or screwdriver. Use finger
pressure only. Prying the connector off could break
it.
(9) Disconnect the electrical connectors. Pull the
harnesses away from the manifold.
²The throttle position sensor.
²The idle speed control motor.
²The coolant temperature sensor at the thermostat.
²The manifold air temperature sensor at the intake
manifold.
²The fuel injectors.
²The oxygen sensor.
(10) Disconnect the crankcase ventilation (CCV)
vacuum hose and manifold absolute pressure (MAP)
sensor vacuum hose connector at the intake mani-
fold.
(11) Disconnect vacuum hose from vacuum port on
the intake manifold.
(12) Disconnect CCV hose at the cylinder head
cover (Fig. 12).
(13) Remove the molded vacuum harness.
(14) Disconnect the vacuum brake booster hose at
the intake manifold.
(15) Remove bolts 2 through 5 securing the intake
manifold to the cylinder head (Fig. 11). Slightly
loosen bolt No.1 and nuts 6 and 7.
(16) Remove the intake manifold and gaskets.
Drain the coolant from the manifold.
CLEANING
Clean the intake manifold and cylinder head mat-
ing surfaces.DO NOT allow foreign material to
enter either the intake manifold or the ports in
the cylinder head.
INSTALLATION
(1) Install the new intake manifold gasket over the
locating dowels.
(2) Position the manifold in place and finger
tighten the mounting bolts.
(3) Tighten the fasteners in sequence and to the
specified torque (Fig. 11).
²Fastener No.1ÐTighten to 41 Nzm (30 ft. lbs.)
torque.
²Fasteners Nos.2 through 7ÐTighten to 31 Nzm (23
ft. lbs.) torque.
(4) Connect the fuel return and supply tube to the
connector next to the fuel rail. Push them into the
fitting until a click is heard. Verify that the connec-
tions are complete.
²First, ensure only the retainer tabs protrude from
the connectors.
²Second, pull out on the fuel tubes to ensure they
are locked in place.
(5) Connect the molded vacuum hoses to the vac-
uum port on the intake manifold and the cylinder
head cover.
(6) Connect the electrical connectors.
²The throttle position sensor.
²The automatic idle speed control motor.
²The coolant temperature sensor at the thermostat
housing.
²The fuel injectors.
²The air manifold temperature sensor.
²The oxygen sensor.
(7) Connect the CCV vacuum hose and MAP sen-
sor vacuum hose connectors to the throttle body.
(8) Install the power steering pump and bracket
assembly to the water pump and intake manifold.
(9) Connect the accelerator cable and cruise control
cable to the holddown bracket and the throttle arm.
CAUTION: Ensure that the accessory drive belt is
routed correctly. Failure to do so can cause the wa-
ter pump to turn in the opposite direction resulting
in engine overheating. Refer to Group 7, Cooling
System for the proper procedure.
(10) Tension the accessory drive belt. Refer to
Group 7, Cooling System for the proper procedure.
(11) Connect the air inlet hose to the throttle body
and the air cleaner.
(12) Connect the battery negative cable.
(13) Start the engine and check for leaks.
INTAKE MANIFOLDÐ4.0L ENGINE
The intake and engine exhaust manifolds on the
4.0L engine must be removed and installed together.
The two manifolds use a common gasket at the cyl-
inder head.
REMOVAL
(1) Disconnect the battery negative cable.
Fig. 12 Crankcase Ventilation (CCV) Hose (2.5L
Engine)
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDJ