catalytic converter JEEP XJ 1995 Service And User Guide

INSTALLATION
(1) Assemble exhaust pipe to manifold and cata-
lytic converter loosely to permit proper alignment of
all parts.
(2) Use a new clamp and tighten the nuts to 61
Nzm (45 ft. lbs.) torque.
(3) Connect the exhaust pipe to the engine exhaust
manifold. Install a new seal between the exhaust
manifold and the exhaust pipe (4.0L engine, only).
Tighten the nuts to 31 Nzm (23 ft. lbs.) torque (Fig.
1).
(3) Install the rear crossmember. Tighten the
crossmember-to-sill bolts to 41 Nzm (30 ft. lbs.)
torque. Remove the support from the transmission.
(4) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 48
Nzm (35 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
EXHAUST PIPEÐYJ VEHICLES
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve lu-
bricant (Fig. 4). Allow 5 minutes for penetration.(3) Remove the oxygen sensor from the exhaust
pipe (Fig. 2).
(4) Disconnect the exhaust pipe from the engine
exhaust manifold.
(5) Disconnect the exhaust pipe from the catalytic
converter and slide the pipe out of the transmission
torque arm insulator (Fig. 5). Remove the exhaust
pipe.
INSTALLATION
(1) Slide the exhaust pipe into the transmission
torque arm insulator and onto the catalytic converter
(Fig. 5).
(2) Clean the mating surface of the engine exhaust
manifold flange.
(3) Connect the exhaust pipe to the engine exhaust
manifold using new nuts. DO NOT tighten the nuts.
(4) Align the exhaust pipe.
(5) Use a new clamp at the exhaust pipe to cata-
lytic converter connection and tighten the nuts to 61
Nzm (45 ft. lbs.) torque.
(6) Tighten the exhaust pipe-to-engine exhaust
manifold nuts to 31 Nzm (23 ft. lbs.) torque.
(7) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 48
Nzm (35 ft. lbs.) torque.
(8) Lower the vehicle.
(9) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
CATALYTIC CONVERTER
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
Fig. 4 Exhaust Pipe-to-Engine Exhaust Manifold
Bolts and Nuts
Fig. 5 Exhaust Pipe-to-Catalytic Converter
ConnectionÐYJ Vehicles
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

(2) Remove the clamp from the catalytic converter
and muffler connection (Fig. 6).
(3) Heat the catalytic converter and muffler con-
nection with an oxyacetylene torch until the metal
becomes cherry red.
(4) While the metal is still cherry red, twist the
muffler assembly back and forth to separate it from
the catalytic converter.
(5) Disconnect the exhaust pipe from the catalytic
converter (Figs. 3 and 5). If needed, heat up the pipes
to separate.
INSTALLATION
(1) Connect the catalytic converter to the exhaust
pipe (Figs. 3 and 5). Use a new clamp and tighten
the nuts to 61 Nzm (45 ft. lbs.) torque.
(2) Install the muffler onto the catalytic converter
until the alignment tab is inserted into the align-
ment slot.
(3) Install a new clamp at the muffler and catalytic
converter connection (Fig. 6). Tighten the clamp nuts
to 61 Nzm (45 ft. lbs.) torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND EXHAUST TAILPIPEÐXJ VEHICLES
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler. Service replacement mufflers and exhaust
tailpipes are either clamped together or welded to-
gether.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front muffler clamp from the cata-
lytic converter and muffler connection (Fig. 6).
(3) Remove the rear exhaust tailpipe hanger clamp
(Fig. 7) and remove the exhaust tailpipe from the
front exhaust tailpipe hanger (Fig. 8).
(4) Heat the catalytic converter-to-muffler connec-
tion with an oxyacetylene torch until the metal be-
comes cherry red.
(5) While the metal is still cherry red, remove the
exhaust tailpipe/muffler assembly from the catalytic
converter.
(6) Remove the exhaust tailpipe from the muffler:
Fig. 6 Catalytic Converter-to-Muffler Connection
Fig. 7 Rear Exhaust Tailpipe Hanger Clamp
Fig. 8 Front Exhaust Tailpipe Hanger
JEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5

²To remove an original equipment exhaust tailpipe/
muffler combination, cut the exhaust tailpipe close to
the muffler. Collapse the part remaining in the muf-
fler and remove.
²To remove a service exhaust tailpipe/muffler com-
bination, apply heat until the metal becomes cherry
red. Remove the exhaust tailpipe/muffler clamp and
twist the exhaust tailpipe out of the muffler.
INSTALLATION
(1) Install the muffler onto the catalytic converter.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly on
the rear exhaust tailpipe hanger. Make sure that the
exhaust tailpipe has sufficient clearance from the
floor pan.
(4) Install the remaining clamps and the front ex-
haust tailpipe hanger.
(5) Tighten the nuts on the muffler-to-catalytic
converter clamp to 61 Nzm (45 ft. lbs.) torque (Fig. 6).
Tighten the nuts on the rear exhaust tailpipe clamp
to 14 Nzm (10 ft. lbs.) torque (Fig. 7).
(6) Lower the vehicle.
(7) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND EXHAUST TAILPIPEÐYJ VEHICLES
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler. Service replacement mufflers and exhaust
tailpipes are clamped together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise the vehicle and support the rear of the
vehicle by the side rails and allow the axle to hang
free.
(2) Remove the front muffler clamp from the cata-
lytic converter and muffler connection (Fig. 6).
(3) Remove the exhaust tailpipe hanger/bracket
(Fig. 9).
(4) Remove the exhaust tailpipe from the front ex-
haust tailpipe hanger (Fig. 10).
(5) Heat the converter-to-muffler connection with
an oxyacetylene torch until the metal becomes cherry
red.
(6) While the metal is still cherry red, place a
block of wood against the front of the muffler and
drive the muffler rearward to disengage.
(7) Remove the exhaust tailpipe/muffler assembly.
(8) Remove the exhaust tailpipe from the muffler:²To remove an original equipment exhaust tailpipe/
muffler combination, cut the exhaust tailpipe close to
the muffler. Collapse the part remaining in the muf-
fler and remove.
²To remove a service exhaust tailpipe/muffler com-
bination, remove the exhaust tailpipe/muffler clamp.
Heat the exhaust tailpipe-to-muffler connection with
an oxyacetylene torch until the metal becomes cherry
red. While the metal is still cherry red, twist the ex-
haust tailpipe out of the muffler.
Fig. 9 Rear Exhaust Tailpipe Hanger/Bracket
Fig. 10 Front Exhaust Tailpipe Hanger
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLDJ

INSTALLATION
(1) Install the muffler onto the catalytic converter
outlet. Ensure that the locator on the converter
aligns with the notch on the muffler, if so equipped.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the muffler
outlet. Ensure that the locator on the exhaust
tailpipe aligns with the notch on the muffler, if so
equipped. Install the clamp and tighten the nuts fin-
ger tight.
(3) Install the front exhaust tailpipe supports and
the rear exhaust tailpipe hanger. Ensure that the ex-
haust tailpipe has sufficient clearance from the floor
pan and shields.
(4) Tighten the nuts on the muffler-to-catalytic
converter and the muffler-to-exhaust tailpipe clamps
to 61 Nzm (45 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and contact with the body panels and shields.
ENGINE EXHAUST MANIFOLDÐ2.5L ENGINE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove all components attached to the intake
manifold.
(3) Raise the vehicle.
(4) Disconnect the exhaust pipe from the engine
exhaust manifold.
(5) Lower the vehicle.
(6) Remove fasteners 2 through 5 and remove the
intake manifold (Fig. 11).
(7) Remove fasteners 1, 6 and 7 and remove the
engine exhaust manifold (Fig. 11).
CLEANING
Clean the intake and engine exhaust manifolds and
cylinder head mating surfaces.DO NOT allow for-eign material to enter either the intake mani-
fold or the ports in the cylinder head.
INSTALLATION
(1) Install a new intake manifold gasket over the
alignment dowels on the cylinder head.
(2) Install the engine exhaust manifold assembly.
Exhaust manifold must be centrally located
over the end studs and spacer (Fig. 11).
(3) Tighten bolt No.1 to 41 Nzm (30 ft. lbs.) torque
(Fig. 11).
(4) Install the intake manifold on the cylinder
head dowels (Fig. 11).
(5) Install bolts 2 through 5 (Fig. 11). Tighten
these bolts to 31 Nzm (23 ft. lbs.) torque.
(6) Install new engine exhaust manifold spacers
over the engine exhaust manifold mounting studs in
the cylinder head (Fig. 11).
(7) Tighten nuts 6 and 7 to 31 Nzm (23 ft. lbs.)
torque (Fig. 11).
(8) Install all components to the intake manifold.
(9) Raise the vehicle.
(10) Connect the exhaust pipe to the engine ex-
haust manifold. Tighten the bolts to 31 Nzm (23 ft.
lbs.) torque.
(11) Lower the vehicle.
(12) Connect the battery negative cable.
(13) Start the engine and check for leaks.
ENGINE EXHAUST MANIFOLDÐ4.0L ENGINE
The intake and engine exhaust manifolds on the
4.0L engine must be removed and installed together.
The manifolds use a common gasket at the cylinder
head.
Refer to Intake ManifoldÐ4.0L Engine in this sec-
tion for the proper removal and installation proce-
dures.
INTAKE MANIFOLDÐ2.5L ENGINE
REMOVAL
(1) Disconnect the battery negative cable.
(2) Remove the air inlet hose from the throttle
body and air cleaner.
(3) Loosen the accessory drive belt tension and re-
move the belt from the power steering pump.
(4) Remove the power steering pump and brackets
from the water pump and intake manifold. Support
power steering pump and bracket with mechanics
wire attached to the radiator upper crossmember.
(5) Remove the fuel tank filler cap to relieve the
fuel tank pressure.
(6) Install the fuel tank filler cap.
(7) Disconnect fuel supply and return tube from
the fuel rail (refer to Group 14, Fuel System - Quick
Connect Fittings).
(8) Disconnect the accelerator cable from the throt-
tle body and the holddown bracket.
Fig. 11 Intake/Engine Exhaust Manifold Installation
(2.5L Engine)
JEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7

POWER STEERING PUMP
INDEX
page page
Drive Pulley Replacement................... 13
Flow Control Valve Fitting O-Ring Seal......... 14
Power Steering PumpÐInitial Operation........ 15
Pressure and Return Hose Replacement........ 11Pump Replacement........................ 12
Reservoir Replacement..................... 14
Service Information........................ 11
SERVICE INFORMATION
The power steering pump internal components are
not serviced or adjusted. If a malfunction or an inter-
nal fluid leak occurs, the complete unit must be re-
placed. A reservoir, cap, and O-ring seal kit are the
only service components available.
PRESSURE AND RETURN HOSE REPLACEMENT
Cap hose open ends and pump/steering gear fit-
tings to prevent entry of foreign material.
WARNING: POWER STEERING FLUID (AND PUMP
COMPONENTS) AND THE EXHAUST SYSTEM CAN
BE EXTREMELY HOT IF THE ENGINE HAS BEEN
RECENTLY OPERATING. DO NOT START THE EN-
GINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW THE HOSES TO TOUCH A
HOT EXHAUST MANIFOLD OR THE CATALYTIC
CONVERTER.
REMOVAL
(1) Remove fasteners from hose retaining brackets
at all locations.
(2) If applicable, remove pressure sensor from
pressure hose (Fig. 1, 2).
(3) Disconnect pressure and return hose from the
steering gear. Drain the fluid from pump and reser-
voir (Fig. 1, 2, 3).
(4) Disconnect pressure and return hose from the
pump. Remove hoses from vehicle (Fig. 1, 2, 3).
INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.
(2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or kinks.The
hose must be kept away from exhaust system
components.Do not distort hose tube ends by bend-
ing, kinking or over tightening.
(3) If applicable, install and tighten pressure sen-
sor to 28 Nzm (252 in. lbs.) torque (Fig. 1, 2).
(4) When used, the protective foam sleeves must be
properly positioned on the hose to prevent chafing.
Fig. 1 Power Steering HoseÐYJ
JSTEERING 19 - 11

(12) Install transfer case on transmission. Tighten
attaching nuts to 47 Nzm (35 ft. lbs.) torque if case
has 3/8 studs, or 35 Nzm (26 ft. lbs.) if case has 5/16
studs.
(13) Install rear crossmember and attach transmis-
sion rear support to crossmember.
(14) Remove transmission jack.
(15) Connect vehicle speed sensor wires.
(16) Install inspection cover on converter housing.(17) Install exhaust pipes and support brackets, if
removed.
(18) Install starter motor.
(19) Connect wires to park/neutral position switch.
(20) Connect gearshift and linkage and throttle ca-
ble.
(21) Connect transfer case shift linkage.
(22) Connect propeller shafts to transfer case
yokes.
(23) Connect front exhaust pipes and catalytic con-
verter support bracket bolts (if removed).
(24) Install skid plate, rear cushion and bracket, if
removed.
(25) Fill transfer case to bottom edge of fill plug
hole with Mopar Dexron II.
(26) Lower vehicle and fill transmission to correct
level with ATF Plus, type 7176 fluid.
(27) Install fan shroud and bolts (if removed).
(28) Check and adjust gearshift cable or linkage if
necessary. Then check and adjust throttle valve cable
if necessary.
Fig. 8 Transmission Attachment
Fig. 9 Transmission Cooler Line Location And
Identification
21 - 118 30RH/32RH TRANSMISSION REMOVAL AND INSTALLATIONJ

BUMPERÐXJ, LIFTGATE LICENSE PLATE
SCREW ANCHOR.....................23-65
BUMPERÐXJ, REAR SEATBACK LATCH
STRIKER...........................23-84
BUMPERS......................13-16,13-5
BUS, CCD; FUEL/IGNITION (XJ).......8W-30-5
BUSHING AND PISTON CLEARANCE,
AW-4 .............................21-339
BUSHING REPLACEMENT, AXLE......2-12,2-34
BUSHING REPLACEMENT, LEAF SPRING
EYE; FRONT SUSPENSION AND AXLE.....2-17
BUSHING REPLACEMENT, LEAF SPRING
EYE; REAR SUSPENSION AND AXLES . . . 3-5,3-7
BUSHINGS, CLUTCH AND BRAKE PEDAL . . . 0-22
BUZZER, COMBINATION; INTERIOR
LIGHTING (YJ)....................8W-44-1
BUZZER MODULE.................8U-1,8U-2
BUZZER MODULE SCHEMATIC - YJ.......8U-4
CABLE, ACCELERATOR PEDAL AND
THROTTLE.....................14-17,14-58
CABLE ADJUSTMENT, PARK INTERLOCK . 21-195
CABLE ADJUSTMENT, SHIFT...........21-195
CABLE ADJUSTMENT, TRANSMISSION
THROTTLE.........................21-194
CABLE ADJUSTMENT, TRANSMISSION
THROTTLE VALVE....................21-71
CABLE ADJUSTMENT (XJ), PARK
INTERLOCK........................21-101
CABLE ADJUSTMENT (XJ), SHIFT.......21-100
CABLE ADJUSTMENT (XJ/YJ), THROTTLE
VALVE..............................21-101
CABLE REMOVE/INSTALL, SERVO.......8H-10
CABLE REPLACEMENT, TRANSMISSION
THROTTLE.........................21-193
CABLE REPLACEMENT (XJ), PARKING
BRAKE REAR.........................5-67
CABLE REPLACEMENT (YJ), PARKING
BRAKE FRONT........................5-67
CABLE REPLACEMENT (YJ), PARKING
BRAKE REAR.........................5-68
CABLE REPLACEMENTÐXJ, LATCH
RELEASE...........................23-11
CABLE RESISTANCE, SPARK PLUG......8D-14
CABLE, SERVO.......................8H-1
CABLE, SPEEDOMETER.................0-33
CABLE TENSIONER ADJUSTMENT
(XJ/YJ), PARKING BRAKE...............5-69
CABLE TENSIONER REPLACEMENT (XJ),
PARKING BRAKE......................5-66
CABLE, THROTTLE...................14-17
CABLE/LINKAGE ADJUSTMENT,
GEARSHIFT.........................21-71
CABLES, DISTRIBUTOR CAP AND
ROTOR, IGNITION.....................0-20
CABLES, SPARK PLUG SECONDARY.....8D-14,
8D-24
CABLES, VENT DOOR CONTROL.........24-32
CALIBRATION, COMPASS...............8C-5
CALIPER ASSEMBLY...................5-50
CALIPER CLEANING AND INSPECTION.....5-50
CALIPER DISASSEMBLY................5-48
CALIPER INSTALLATION................5-51
CALIPER OPERATION AND WEAR
COMPENSATION......................5-45
CALIPER REMOVAL....................5-48
CAMSHAFT......................9-32,9-74
CAMSHAFT PIN REPLACEMENT......9-34,9-75
CAMSHAFT POSITION SENSOR; FUEL
SYSTEM............................14-60
CAMSHAFT POSITION SENSOR;
FUEL/IGNITION (XJ)................8W-30-3
CAMSHAFT POSITION SENSOR;
FUEL/IGNITION (YJ)................8W-30-3
CAMSHAFT POSITION SENSOR;
IGNITION SYSTEMS..............8D-17,8D-2
CAMSHAFT POSITION SENSOR;
FUEL/IGNITION (XJ-RHD)............8W-30-3
CAMSHAFT POSITION SENSOR TEST;
FUEL SYSTEM.......................14-46
CAMSHAFT POSITION SENSOR TEST;
IGNITION SYSTEMS
...................8D-6
CAMSHAFT POSITION SENSORÐPCM
INPUT
.............................14-22
(CANADA ONLY)ÐXJ, DAYTIME
RUNNING LIGHTS
....................8L-15
(CANADA ONLY)ÐYJ, DAYTIME
RUNNING LIGHTS
....................8L-30
CANISTER, EVAP
..................25-4,25-7CAP AND ROTOR, IGNITION CABLES,
DISTRIBUTOR........................0-20
CAP, DISTRIBUTOR....................8D-7
CAP, FUEL TANK FILLER TUBE;
EMISSION CONTROL SYSTEMS......25-4,25-7
CAP, FUEL TANK FILLER TUBE; FUEL
SYSTEM............................14-13
CAP, RADIATOR PRESSURE.............7-25
CAPACITIES, COOLING SYSTEM..........7-45
CAPACITIES, FLUID.....................0-3
CAPACITIES, FUEL TANK..........14-13,14-67
CAPACITY TEST, FUEL PUMP............14-7
CAR REPLACEMENT, PITMAN SHAFT
SEALSÐIN.........................19-23
CARDAN (CV), DOUBLE................16-11
CARDAN, SINGLE....................16-10
CARGO BARRIERÐXJ................23-101
CARGO LAMP AND DOME LAMP;
INTERIOR LIGHTING (XJ-RHD)........8W-44-1
CARGO LAMP, COURTESY LAMPS AND
DOME LAMP; INTERIOR LIGHTING (XJ) . 8W-44-1
CARGO LAMPÐXJ...................23-94
CARPET/MATÐXJ, FRONT.............23-99
CARPET/MATÐXJ, REAR.............23-100
CARPETÐYJ.......................23-156
CARPETS AND FLOOR MATSÐXJ.......23-99
CARRIERÐYJ, EXTERNAL SPARE/
WHEEL TIRE.......................23-133
CASE (4WD VEHICLES), TRANSFER........0-24
CASE ASSEMBLY, TRANSFER....21-294,21-319
CASE CHANGES, TRANSFER...........21-307
CASE CLEANING AND INSPECTION,
TRANSMISSION.....................21-125
CASE COVER OIL SEAL REPLACEMENT,
TIMING.........................9-30,9-73
CASE COVER, TIMING..............9-31,9-72
CASE DISASSEMBLY AND OVERHAUL,
TRANSFER...................21-289,21-310
CASE IDENTIFICATION, TRANSFER.....21-284,
21-307
CASE INSTALLATION, TRANSFER . 21-288,21-309
CASE LUBRICANT AND FILL LEVEL,
TRANSFER.........................21-284
CASE, NP231 TRANSFER.......21-283,21-305
CASE, NP242 TRANSFER.......21-307,21-331
CASE OVERHAUL, FIRST-REVERSE
BRAKE PISTON AND TRANSMISSION....21-247
CASE REMOVAL, TRANSFER.....21-287,21-309
CASE SKID PLATE, TRANSFER......13-15,13-3
CASE SPECIFICATIONS, TRANSMISSION/
TRANSFER.........................21-333
CATALYTIC CONVERTER............11-1,11-4
CATALYTIC CONVERTOR................25-1
CAUTIONS, AND WARNINGS, NOTES;
WIRING DIAGRAMSÐGENERAL
INFORMATION (XJ)...................8W-1
CCD BUS; FUEL/IGNITION (XJ)........8W-30-5
CENTER HIGH MOUNTED STOP LAMP
(CHMSL)ÐXJ.......................8L-12
CENTER HIGH MOUNTED STOP LAMP
(CHMSL)ÐYJ.......................8L-28
CERTIFICATION LABEL, VEHICLE SAFETY . Intro.-4
CHAIN AND SPROCKETS, TIMING....9-31,9-73
CHANGE AND FILTER REPLACEMENT,
ENGINE OIL
..........................0-16
CHANGE, LUBRICANT; FRONT
SUSPENSION AND AXLE
................2-23
CHANGE, LUBRICANT; REAR
SUSPENSION AND AXLES
...........3-13,3-31
CHANGE, REFILLING AFTER OVERHAUL
OR FLUID/FILTER
..............21-100,21-182
CHANGES AND PARTS
INTERCHANGEABILITY, TRANSMISSION
. . . 21-67
CHANGES, TRANSFER CASE
...........21-307
CHANNEL REPLACEMENTÐYJ, DOOR
FRAME GLASS
......................23-142
CHARGING, BATTERY
..................8A-7
CHARGING REFRIGERANT SYSTEM
......24-11
CHARGING SYSTEM; BATTERY/
STARTING/CHARGING SYSTEMS
DIAGNOSTICS
.......................8A-17
CHARGING SYSTEM; CHARGING
SYSTEM (XJ)
.....................8W-20-1
CHARGING SYSTEM; CHARGING
SYSTEM (XJ-RHD)
.................8W-20-1
CHARGING SYSTEM; CHARGING
SYSTEM (YJ)
.....................8W-20-1CHARGING SYSTEM INDICATOR LAMP;
INSTRUMENT CLUSTER (XJ).........8W-40-3
CHARGING SYSTEM SPECIFICATIONS....8A-23
CHARGING TIME TABLE, BATTERY........8A-8
CHART, MAIN BEARING FITTING......9-48,9-90
CHART, XJ PERFORMANCE
TEMPERATURE AND PRESSURE.........24-13
CHART, YJ PERFORMANCE
TEMPERATURE AND PRESSURE.........24-13
CHARTÐAX 15 MANUAL
TRANSMISSION, SELECTIVE SNAP
RING.............................21-334
CHARTS, BRAKELINE..................5-12
CHARTS, DIAGNOSIS GUIDES...........21-77
CHARTS, GEARTRAIN OPERATION AND
APPLICATION.......................21-169
CHARTS, INSPECTION AND DIAGNOSIS.....6-4
CHASSIS AND BODY COMPONENTS.......0-28
CHASSIS COMPONENT AND WHEEL
BEARING LUBRICANTS.................0-28
CHECK VALVE TEST, POWER BOOSTER.....5-9
CHECKING FLUID LEVEL AND
CONDITION........................21-182
CHECKS, PRELIMINARY.................7-5
CHIME/BUZZER MODULE; INTERIOR
LIGHTING (XJ)....................8W-44-2
CHIME/BUZZER MODULE; INTERIOR
LIGHTING (XJ-RHD)................8W-44-2
CHMSL LAMPS, STOP LAMPS; REAR
LIGHTING (XJ)....................8W-51-1
CHMSL LAMPS, STOP LAMPS; REAR
LIGHTING (XJ-RHD)................8W-51-1
CHMSL LAMPS, STOP LAMPS; REAR
LIGHTING (YJ)....................8W-51-1
(CHMSL)ÐXJ, CENTER HIGH MOUNTED
STOP LAMP.........................8L-12
(CHMSL)ÐYJ, CENTER HIGH MOUNTED
STOP LAMP.........................8L-28
CIGAR LIGHTER; HORN/CIGAR LIGHTER . . . 8E-1
CIGAR LIGHTER; HORN/CIGAR LIGHTER
(YJ).............................8W-41-1
CIGAR LIGHTER; INSTRUMENT CLUSTER
(XJ).............................8W-40-1
CIRCUIT IDENTIFICATION; WIRING
DIAGRAMSÐGENERAL INFORMATION
(XJ)...............................8W-1
CIRCUIT REMOVE/INSTALL, PRINTED....8E-19,
8E-40
CIRCUIT SENSEÐPCM INPUT, IGNITION . . 14-23
CIRCUIT VOLTAGE, OPEN...............8A-6
CLAMPS, FUEL TUBES/LINES/HOSES . 14-62,14-9
CLASSIFICATION OF LUBRICANTS.........0-2
CLASSIFICATIONS AND RATINGS,
BATTERY...........................8A-23
CLEANER, AIR.......................14-29
CLEANER ELEMENT, AIR; EMISSION
CONTROL SYSTEMS...................25-7
CLEANER ELEMENT, AIR; FUEL SYSTEM . . 14-59
CLEANER ELEMENT, AIR; LUBRICATION
AND MAINTENANCE...................0-18
CLEANER HOUSING, AIR...............14-58
CLEANING AND INSPECTION, CALIPER....5-50
CLEANING AND INSPECTION, GEAR......19-42
CLEANING AND INSPECTION,
TRANSMISSION CASE................21-125
CLEANING OF TIRES...................22-2
CLEANING/INSPECTION; FRONT
SUSPENSION AND AXLE
................2-37
CLEANING/INSPECTION; REAR
SUSPENSION AND AXLES
...............3-20
CLEANING/REVERSE FLUSHING,
COOLING SYSTEM
....................7-22
CLEARANCE AND RAMP ANGLE,
GROUND
............................0-11
CLEARANCE, AW-4 BUSHING AND
PISTON
...........................21-339
CLOCKSPRING
.......................19-51
CLUSTER AND GAUGE HOUSINGSÐYJ,
INSTRUMENT
......................23-151
CLUSTER ASSEMBLY REMOVE/INSTALL
. . 8E-17,
8E-35
CLUSTER BEZELÐXJ, INSTRUMENT
.....23-80
CLUSTER BEZELÐYJ, INSTRUMENT
....23-151
CLUSTER CONNECTORS (RHD)
.........8E-11
CLUSTER, GAUGE PACKAGE
.......8E-31,8E-43
CLUSTER GROUND; INSTRUMENT
CLUSTER (XJ)
.....................8W-40-3
4 INDEXJ
Description Group-Page Description Group-Page Description Group-Page

CONTENTS; INSTRUMENT PANEL AND
GAUGESÐXJ........................8E-24
CONTENTS; LAMPS...................8L-19
CONTINUITY (LEFT POSITION), POWER
MIRROR SWITCH.....................8T-3
CONTINUITY, POWER SEAT SWITCH......8R-2
CONTINUITY (RIGHT POSITION), POWER
MIRROR SWITCH.....................8T-3
CONTINUITY TESTS, IGNITION SWITCH . . . 8D-30
CONTROL AND DISPLAY SYMBOLS,
INTERNATIONAL VEHICLE.............Intro.-5
CONTROL AND DISPLAY SYMBOLS,
VEHICLE.........................Intro.-10
CONTROL CABLES, VENT DOOR.........24-32
CONTROL DIAGNOSTIC TROUBLE CODE,
SPEED..............................8H-5
CONTROL, FUEL PUMP ELECTRICAL......14-5
CONTROL (IAC) MOTOR, IDLE AIR; FUEL
SYSTEM............................14-62
CONTROL (IAC) MOTOR, IDLE AIR;
FUEL/IGNITION (XJ)................8W-30-2
CONTROL (IAC) MOTOR, IDLE AIR;
FUEL/IGNITION (YJ)................8W-30-2
CONTROL (IAC) MOTOR, IDLE AIR;
FUEL/IGNITION (XJ-RHD)............8W-30-2
CONTROL (IAC) MOTORÐPCM OUTPUT,
IDLE AIR...........................14-27
CONTROL INFORMATION (VECI) LABEL,
VEHICLE EMISSION....................25-1
CONTROL MODULE (PCM) 60-WAY
CONNECTOR, POWERTRAIN............14-40
CONTROL MODULE (PCM),
POWERTRAIN; EMISSION CONTROL
SYSTEMS...........................25-7
CONTROL MODULE (PCM),
POWERTRAIN; FUEL SYSTEM......14-20,14-64
CONTROL MODULE (PCM),
POWERTRAIN; IGNITION SYSTEMS......8D-11,
8D-23,8D-5
CONTROL MODULE, POWERTRAIN . . . 8H-1,8H-7
CONTROL MODULE (TCM) SERVICE,
TRANSMISSION.....................21-183
CONTROL MODULE, TRANSMISSION;
TRANSMISSION CONTROLS (XJ-RHD) . . 8W-31-1
CONTROL MODULEÐ4.0L ENGINE ONLY,
TRANSMISSION; TRANSMISSION
CONTROLS (XJ)...................8W-31-1
CONTROL MOTOR TEST, IDLE AIR.......14-49
CONTROL PANEL LAMP, ACCESSORY
LAMP AND HEATER; INTERIOR
LIGHTING (YJ)....................8W-44-1
CONTROL REPLACEMENT, HEATER.......24-32
CONTROL REPLACEMENT, HEATER AND
A/C................................24-23
CONTROL SERVO REMOVE/INSTALL,
SPEED..............................8H-9
CONTROL SERVO, SPEED..........8H-1,8H-6
CONTROL SWITCH REMOVE/INSTALL,
SPEED..............................8H-9
CONTROL SWITCH, SPEED.........8H-1,8H-6
CONTROL SYSTEM, EMISSION...........0-20
CONTROL SYSTEM, EVAP
(EVAPORATION)......................25-4
CONTROL SYSTEM MAINTENANCE,
EMISSION............................0-4
CONTROL THERMOSTAT, TEMPERATURE . . 24-34
CONTROL, THERMOSTATIC.............24-16
CONTROL UNIT (ECU), ELECTRONIC......5-34
CONTROL UNIT (HCU), HYDRAULIC.......5-33
CONTROL UNIT, HYDRAULIC; ANTI-LOCK
BRAKES (XJ)......................8W-32-2
CONTROL UNIT, HYDRAULIC; ANTI-LOCK
BRAKES (XJ-RHD).................8W-32-2
CONTROL UNIT, HYDRAULIC; ANTI-LOCK
BRAKES (YJ)......................8W-32-2
CONTROL VALVE FITTING O-RING SEAL,
FLOW..............................19-14
CONTROL, VEHICLE SPEED; VEHICLE
SPEED CONTROL (XJ)..............8W-33-1
CONTROL, VEHICLE SPEED; VEHICLE
SPEED CONTROL (XJ-RHD)..........8W-33-1
CONTROLÐPCM INPUT, SPEED
.........14-25
CONTROLÐPCM OUTPUT, SPEED
.......14-29
CONTROLS AND COMPONENTS,
TRANSMISSION
......................21-67
CONTROLS, EMISSION
.................25-4
CONTROLSÐPCM INPUT, AIR
CONDITIONING (A/C)
..................14-21CONTROLSÐXJ VEHICLES, AIR
CONDITIONING......................24-15
CONTROLSÐYJ VEHICLES, AIR
CONDITIONING......................24-16
CONVERSION FORMULAS AND
EQUIVALENT VALUES...............Intro.-11
CONVERSION, METRIC..............Intro.-16
CONVERSION, METRIC AND ENGLISH/
SAE .............................Intro.-11
CONVERTER, CATALYTIC............11-1,11-4
CONVERTER CLUTCH RELAY TEST,
TORQUE............................14-48
CONVERTER CLUTCH RELAY, TORQUE....14-65
CONVERTER CLUTCH RELAYÐPCM
OUTPUT, TORQUE....................14-29
CONVERTER CLUTCH (TCC) SOLENOID
AND RELAY, TORQUE; FUEL/IGNITION
(XJ).............................8W-30-4
CONVERTER CLUTCH (TCC) SOLENOID
AND RELAY, TORQUE; TRANSMISSION
CONTROLS (YJ)...................8W-31-1
CONVERTER CLUTCH (TCC) SOLENOID
AND RELAYÐ2.5L ENGINE ONLY,
TORQUE; TRANSMISSION CONTROLS
(XJ).............................8W-31-1
CONVERTER DIAGNOSIS, TORQUE . 21-86,21-87,
21-88
CONVERTER HOUSING LEAK DIAGNOSIS . . 21-75
CONVERTER INSTALLATION,
TRANSMISSION.....................21-117
CONVERTER INSTALLATION,
TRANSMISSION AND TORQUE.........21-199
CONVERTER REMOVAL, TRANSMISSION . 21-115
CONVERTER REMOVAL, TRANSMISSION
AND TORQUE......................21-198
CONVERTER STALL TEST..............21-74
CONVERTER STALL TEST, TORQUE.....21-178
CONVERTER STATOR CLUTCH
INSPECTION, TORQUE................21-199
CONVERTER, TORQUE...........21-167,21-67
CONVERTERÐPUMP SEALÐDRIVE
PLATE SERVICE.....................21-116
CONVERTOR, CATALYTIC................25-1
COOLANT............................7-20
COOLANT RESERVE/OVERFLOW SYSTEM . . 7-24
COOLANT ROUTING, SYSTEM.............7-1
COOLANT TEMPERATURE GAUGE,
ENGINE; INSTRUMENT CLUSTER (XJ) . . 8W-40-1
COOLANT TEMPERATURE SENSOR.......25-7
COOLANT TEMPERATURE SENSOR,
ENGINE; FUEL SYSTEM................14-60
COOLANT TEMPERATURE SENSOR,
ENGINE; FUEL/IGNITION (XJ).........8W-30-3
COOLANT TEMPERATURE SENSOR,
ENGINE; FUEL/IGNITION (YJ).........8W-30-3
COOLANT TEMPERATURE SENSOR,
ENGINE; IGNITION SYSTEMS.......8D-19,8D-5
COOLANT TEMPERATURE SENSOR,
ENGINE; FUEL/IGNITION (XJ-RHD).....8W-30-3
COOLANT TEMPERATURE SENSOR TEST,
ENGINE; FUEL SYSTEM................14-46
COOLANT TEMPERATURE SENSOR TEST,
ENGINE; IGNITION SYSTEMS............8D-9
COOLANT TEMPERATURE SENSORÐ
PCM INPUT, ENGINE
..................14-23
COOLANT TEMPERATURE WARNING
LAMP, ENGINE; INSTRUMENT
CLUSTER (XJ)
.....................8W-40-1
COOLANT TEMPERATURE WARNING
LAMP, ENGINE; INSTRUMENT
CLUSTER (XJ-RHD)
................8W-40-1
COOLER FLOW TESTING,
TRANSMISSION
.....................21-113
COOLER LINE AND FITTING SERVICE,
TRANSMISSION
.....................21-111
COOLER LINE FITTINGS, TRANSMISSION
. 21-197
COOLER REVERSE FLUSHING,
TRANSMISSION
.....................21-114
COOLER SERVICE, TRANSMISSION
.....21-196
COOLERS, TRANSMISSION OIL
..........7-36
COOLING FANÐXJ MODELS WITH 4.0L
6-CYLINDER ENGINE, AUXILIARY
ELECTRIC
...........................7-35
COOLING SYSTEM; COOLING SYSTEM
......7-1
COOLING SYSTEM; HEATING AND AIR
CONDITIONING
......................24-10
COOLING SYSTEM CAPACITIES
..........7-45COOLING SYSTEM CLEANING/REVERSE
FLUSHING...........................7-22
COOLING SYSTEM COMPONENTS.........7-1
COOLING SYSTEM DIAGNOSIS............7-6
COOLING SYSTEM, DRAINING...........7-21
COOLING SYSTEM, ENGINE.............0-18
COOLING SYSTEM FANS................7-32
COOLING SYSTEM FOR LEAKS, TESTING . . . 7-22
COOLING SYSTEM HOSES..............7-32
COOLING SYSTEM, REFILLING...........7-21
CORE AND HOUSING, HEATER..........24-33
CORE, HEATER......................24-26
COURTESY LAMPS AND DOME LAMP,
CARGO LAMP; INTERIOR LIGHTING
(XJ).............................8W-44-1
COURTESY LAMPS AND DOME LAMPS;
INTERIOR LIGHTING (YJ)............8W-44-1
COURTESY LAMPS, READING...........8C-1
COVER AND DISC INSTALLATION,
CLUTCH.............................6-10
COVER AND DISC REMOVAL, CLUTCH.....6-10
COVER AND DISC RUNOUT, CLUTCH.......6-3
COVER AND FRAMEÐXJ, BUCKET
SEATBACK..........................23-81
COVER, ENGINE CYLINDER HEAD....9-22,9-64
COVER, FRAME CROSSMEMBER........13-16
COVER OIL SEAL REPLACEMENT,
TIMING CASE....................9-30,9-73
COVER REPLACEMENT, PITMAN SHAFT
AND SIDE..........................19-28
COVER, TIMING CASE..............9-31,9-72
COVERÐXJ, BUCKET SEAT CUSHION....23-81
COVERÐXJ, PARKING BRAKE HANDLE . . . 23-94
COVERÐXJ, REAR SEAT CUSHION......23-82
COVERÐXJ, REAR SEATBACK..........23-84
COVERSÐXJ, B/C-PILLAR AND
LIFTGATE PILLAR TRIM...............23-88
COWL GRILLE AND SCREENÐXJ........23-12
COWL GRILLE AND SCREENÐYJ.......23-109
COWL WEATHERSTRIP SEAL/
CROSSMEMBER AIR DEFLECTORÐXJ....23-11
COWL WEATHERSTRIP SEALÐYJ......23-109
CRANKCASE VENTILATION SYSTEM;
EMISSION CONTROL SYSTEMS..........25-5
CRANKCASE VENTILATION SYSTEM;
LUBRICATION AND MAINTENANCE........0-19
CRANKING SPECIFICATIONS, 2.5L
STARTING SYSTEM COLD..............8A-23
CRANKING SPECIFICATIONS, 4.0L
STARTING SYSTEM COLD..............8A-23
CRANKSHAFT MAIN BEARINGS......9-45,9-87
CRANKSHAFT POSITION SENSOR; FUEL
SYSTEM............................14-60
CRANKSHAFT POSITION SENSOR;
FUEL/IGNITION (XJ)................8W-30-3
CRANKSHAFT POSITION SENSOR;
FUEL/IGNITION (YJ)................8W-30-3
CRANKSHAFT POSITION SENSOR;
IGNITION SYSTEMS..............8D-17,8D-3
CRANKSHAFT POSITION SENSOR;
FUEL/IGNITION (XJ-RHD)............8W-30-3
CRANKSHAFT POSITION SENSOR TEST;
FUEL SYSTEM.......................14-47
CRANKSHAFT POSITION SENSOR TEST;
IGNITION SYSTEMS...................8D-7
CRANKSHAFT POSITION SENSORÐPCM
INPUT.............................14-22
CROSSMEMBER COVER, FRAME........13-16
CROSSMEMBERÐXJ, RADIATOR
SUPPORT...........................23-6
CUSHION AND COVERÐXJ, BUCKET
SEAT ..............................23-81
CUSHION COVERÐXJ, REAR SEAT......23-82
CUSHIONÐXJ, REAR SEAT.............23-82
CUT-OFF SWITCH, LOW-PRESSURE
HIGH-PRESSURE................24-15,24-16
CYCLING CLUTCH SWITCH, FIN
SENSING......................24-15,24-31
CYLINDER AND COMBINATION VALVE
INSTALLATION (WITH ABS), MASTER.....5-20
CYLINDER AND COMBINATION VALVE
REMOVAL (WITH ABS), MASTER.........5-17
CYLINDER BENCH BLEEDING, MASTER
....5-21
CYLINDER BLOCK
.................9-49,9-91
CYLINDER BORES, HONING
..............9-2
CYLINDER, CLUTCH MASTER
............0-22
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST
........................9-6
6 INDEXJ
Description Group-Page Description Group-Page Description Group-Page