oil JEEP WRANGLER 1994 Workshop Manual

MULTI-PORT FUEL INJECTION (MFI)ÐCOMPONENT REMOVAL/INSTALLATION
INDEX
page page
Accelerator Pedal and Throttle Cable......... 54
Air Cleaner Housing...................... 54
Air Conditioning (A/C) Clutch Relay........... 54
Air Filter............................... 54
Automatic Shut Down (ASD) Relay........... 54
Brake Switch............................ 54
Camshaft Position Sensor.................. 54
Crankshaft Position Sensor................. 55
Engine Coolant Temperature Sensor.......... 55
Fuel Filter.............................. 55
Fuel Injector............................ 55
Fuel Pump Module....................... 56
Fuel Pump Relay........................ 56
Fuel Rail Assembly....................... 56
Fuel System Pressure Release Procedure...... 56
Fuel Tank Pressure Relief/Rollover Valve...... 56
Fuel Tanks............................. 56Fuel Tubes/Lines/Hoses and Clamps.......... 56
Idle Air Control (IAC) Motor................. 56
Ignition Coil............................. 57
Intake Air Temperature Sensor.............. 54
Intake Manifold.......................... 57
Manifold Absolute Pressure (MAP) Sensor..... 57
Oxygen (O2S) Sensor..................... 57
Park Neutral Switch....................... 58
Power Steering Pressure SwitchÐ2.5L
Engine Only........................... 58
Powertrain Control Module (PCM)............ 58
Quick-Connect Fittings..................... 59
Throttle Body............................ 59
Throttle Position Sensor (TPS).............. 59
Torque Converter Clutch Relay.............. 60
Vehicle Speed Sensor..................... 60
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 Dis-
tribution Center (PDC) (Figs. 1 or 2). For location of
this relay within the PDC, refer to label on PDC
cover.
AIR CLEANER HOUSING
Refer to Group 25, Emission Control System.
AIR FILTER
Refer to Group 25, Emission Control System.
AUTOMATIC SHUT DOWN (ASD) RELAY
The ASD relay is located in the Power Distribution
Center (Figs. 1 or 2) (PDC). For location of this relay
within the PDC, refer to label on PDC cover.
BRAKE SWITCH
Refer to Group 5, Brakes for removal/installation
procedures.
CAMSHAFT POSITION SENSOR
For removal/installation procedures, refer to Group
8D, Ignition System. See Camshaft Position Sensor.
INTAKE AIR TEMPERATURE SENSOR
The intake manifold air temperature sensor is in-
stalled into the intake manifold plenum (Figs. 3 or
4).
Fig. 1 PDCÐYJ Models
Fig. 2 PDCÐXJ Models
14 - 54 FUEL SYSTEMJ

REMOVAL
(1) Disconnect the electrical connector from the
IAC motor.
(2) Remove IAC motor torx head mounting bolts.
(3) Remove IAC motor.
INSTALLATION
(1) Install IAC motor into throttle body and
tighten retaining bolts.
(2) Connect electrical connector to IAC motor.
IGNITION COIL
Refer to Group 8D, Ignition Systems for removal/
installation procedures.
INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Intake
Manifold for removal/installation procedures.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The MAP sensor is located on the dash panel near
the rear of the engine cylinder head (valve) cover
(Fig. 9).
REMOVAL
(1) Disconnect the MAP sensor electrical connector
(Fig. 9).
(2) Disconnect the MAP sensor vacuum supply
hose (Fig. 9).
(3) Remove the MAP sensor mounting bolts and
remove MAP sensor.
INSTALLATION
(1) Install MAP sensor to dash panel and secure
with mounting bolts.
(2) Install the MAP sensor vacuum supply hose.
(3) Connect the MAP sensor electrical connector.
OXYGEN (O2S) SENSOR
The O2S sensor is installed in the exhaust down
pipe just below the exhaust manifold flange (Fig. 10).
REMOVAL
WARNING: THE EXHAUST MANIFOLD BECOMES
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Raise and support the vehicle.
(2) Separate the electrical connectors.
(3) Remove the O2S sensor from the exhaust man-
ifold. Snap-On oxygen sensor wrench (number YA
8875) may be used for removal and installation.
INSTALLATION
Threads of new factory oxygen sensors are coated
with anti-seize compound to aid in removal.
(1) Install the O2S sensor into the exhaust mani-
fold and tighten to 30 Nzm (22 ft. lbs.) torque.
(2) Connect the O2S sensor wire connector to the
main harness.
Fig. 8 Idle Air Control
MotorÐRemoval/InstallationÐTypical
Fig. 9 MAP SensorÐTypical
Fig. 10 Oxygen SensorÐTypical
JFUEL SYSTEM 14 - 57

Fig. 43 Auxiliary Air-To-Oil CoolerÐXJ Models
Fig. 44 Condenser Mounting BoltsÐYJ Models
7 - 30 COOLING SYSTEMJ

Fig. 3 Test Positive Battery Cable Resistance
(Typical)
Fig. 4 Test Ground Circuit Resistance
Fig. 5 Test Starter Motor Ground (Typical)
Fig. 6 Continuity Test Between Solenoid Terminal
and Field Coil Terminal
JBATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 11

Fig. 10 Rotor InspectionÐTypical
Fig. 11 Ignition CoilÐTypical
JIGNITION SYSTEMS 8D - 11

Fig. 15 Coil TerminalsÐTypical
Fig. 16 PCM 60-Way Connector
Fig. 17 Special Jumper Ground-to-Coil Negative
Terminal
JIGNITION SYSTEMS 8D - 13

Fig. 17 Align Oil Pump Gear ShaftÐ4.0L Engine
Fig. 18 Distributor InstallationÐTypical
Fig. 19 Rotor Alignment
8D - 26 IGNITION SYSTEMSJ

Wiring Diagram Name Sheet Number
A/C Compressor Clutch........................45
A/C Compressor Clutch Relay....................45
A/C Heater Blower Motor.......................46
A/C Low Pressure Switch.......................45
A/C Mode Selector Switch.......................46
A/C System.............................45, 46
A/C Thermostat..............................45
Antenna Mast...............................47
Ashtray Illumination Lamp.......................26
Automatic Shut Down Relay......................9
Back-up Lamp Switch.........................16
Battery....................................6
Blower Motor............................44, 46
Blower Resistor...........................44, 46
Blower Switch............................44, 46
Body Ground...............................59
Brake Warning Switch.........................42
Camshaft Position Sensor.......................12
Cargo Lamp................................30
Charging System.............................5
Generator.................................5
Check Engine Indicator Lamp..................39, 40
Chime Module..............................43
Chime Module Connector.......................71
Cigar Lighter...............................58
Circuit Breakers
Windshield Wiper Circuit Breaker...............2,33
Connectors
Chime Module Connector......................71
Dash to Instrument Panel Connector A.............64
Dash to Instrument Panel Connector B.............65
Dash to Instrument Panel Connector C.............66
Data Link Connector.........................10
Instrument Cluster Connector 16 Way...........37, 69
Main Body Connector 1.......................70
Power Mirror Connector......................61
Powertrain Control Module Connector..............73
Steering Column Connector 11 Way...............67
Telltale Connector........................38, 68
Transmission Control Module Connector............72
Transmission Data Link Connector................17
Coolant Temperature Switch......................16
Crankshaft Position Sensor......................12
Dash to Instrument Panel Connector A..............64
Dash to Instrument Panel Connector B..............65
Dash to Instrument Panel Connector C..............66
Data Link Connector..........................10
Distributor Ignition Coil........................10
Dome Lamp................................31
Dome and Courtesy Lamps.................29, 30, 31
Cargo Lamp..............................30
Dome Lamp..............................31

Fig. 2 Timing Case Cover Oil Seal Removal
9 - 26 2.5L ENGINEJ

Fig. 12 Oil Pump Gear Slot Alignment
Fig. 13 Distributor Rotor Pre-Positioning
Fig. 14 Correct Rotor Position
9 - 30 2.5L ENGINEJ