tow JEEP XJ 1995 Service And Service Manual

IGNITION SWITCH TEST
Refer to Group 8D - Ignition Systems for testing
and service of this component.
PARK/NEUTRAL POSITION SWITCH TEST
Refer to Group 21 - Transmission and Transfer
Case for testing and service of this component.
2.5L STARTER NOISE DIAGNOSIS
See Starter Noise Diagnosis chart. If the complaint
is similar to Conditions 1 and 2 in chart, correction
can be achieved by shimming starter according to the
following procedures:
Disconnect the battery negative cable to pre-
vent inadvertent starting of engine.
(1) If the complaint is similar to Condition 1, the
starter must be moved toward the flywheel/drive
plate ring gear by removing shims (Fig. 11).
Shim thickness is 0.381 mm (0.015 in.) and
shims may be stacked if required.
(2) If the complaint is similar to Condition 2, the
starter must be moved away from the flywheel/drive
plate ring gear. This is done by installing shim(s)
across both mounting pads. More than one shim may
be required.
This is generally a condition that causes bro-
ken flywheel/drive plate ring gear teeth or bro-
ken starter housings.
STARTER NOISE DIAGNOSIS
Fig. 11 Starter Shim
8A - 16 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICSJ

(8) If voltage is not present at supply wire, check
for voltage at pin-7 of powertrain control module
(PCM) 60-way connector. Leave the PCM connector
connected for this test.
(9) If voltage is still not present, perform vehicle
test using the DRB scan tool.
(10) If voltage is present at pin-7, but not at the
supply wire:
(a) Check continuity between the supply wire.
This is checked between the distributor connector
and pin-7 at the PCM. If continuity is not present,
repair the harness as necessary.
(b) Check for continuity between the camshaft
position sensor output wire and pin-44 at the PCM.
If continuity is not present, repair the harness as
necessary.
(c) Check for continuity between the ground cir-
cuit wire at the distributor connector and ground.
If continuity is not present, repair the harness as
necessary.
(11) While observing the voltmeter, crank the en-
gine with ignition switch. The voltmeter needle
should fluctuate between 0 and 5 volts while the en-
gine is cranking. This verifies that the camshaft po-
sition sensor in the distributor is operating properly
and a sync pulse signal is being generated.
If sync pulse signal is not present, replacement of
the camshaft position sensor is necessary.
For removal or installation of ignition system com-
ponents, refer to the Component Removal/Installa-
tion section of this group.
For system operation and component identification,
refer to the Component Identification/System Opera-
tion section of this group.
CRANKSHAFT POSITION SENSOR TEST
To perform a complete test of this sensor and its
circuitry, refer to the DRB scan tool. Also refer to the
appropriate Powertrain Diagnostics Procedures man-
ual. To test the sensor only, refer to the following:
The sensor is located on the transmission bellhous-
ing at the left/rear side of the engine block (Figs. 2, 3
or 4).
(1) Near the rear of the intake manifold, discon-
nect sensor pigtail harness connector from main wir-
ing harness.
(2) Place an ohmmeter across terminals B and C
(Fig. 5). Ohmmeter should be set to 1K-to-10K scale
for this test. The meter reading should be open (no
resistance). Replace sensor if a low resistance is indi-
cated.
For removal or installation of ignition system com-
ponents, refer to the Component Removal/Installa-
tion section of this group.DISTRIBUTOR CAP
INSPECTION
Remove the distributor cap and wipe it clean with
a dry lint free cloth. Visually inspect the cap for
cracks, carbon paths, broken towers, or damaged ro-
tor button (Figs. 6 and 7). Also check for white depos-
its on the inside (caused by condensation entering
the cap through cracks). Replace any cap that dis-
plays charred or eroded terminals. The inside flat
surface of a terminal end (faces toward rotor) will in-
dicate some evidence of erosion from normal opera-
tion. Examine the terminal ends for evidence of
mechanical interference with the rotor tip.
If replacement of the distributor cap is necessary,
transfer spark plug cables from the original cap to
the new cap. This should be done one cable at a time.
Each cable is installed onto the tower of the new cap
that corresponds to its tower position on the original
Fig. 2 Crankshaft Position SensorÐ2.5L 4-Cyl.
EngineÐTypical
Fig. 3 Crankshaft Position SensorÐ4.0L 6-Cyl.
EngineÐAll Except YJ models With Auto. Trans.
JIGNITION SYSTEMS 8D - 7

cap. Fully seat the cables onto the towers. If neces-
sary, refer to the engine Firing Order diagrams (Figs.
8or9).
DISTRIBUTOR ROTOR
Visually inspect the rotor (Fig. 10) for cracks, evi-
dence of corrosion, or the effects of arcing on the
metal tip. Also check for evidence of mechanical in-
terference with the cap. Some charring is normal on
the end of the metal tip. The silicone-dielectric-var-
nish-compound applied to the rotor tip for radio in-
terference noise suppression, will appear charred.
This is normal.Do not remove the charred com-
pound.Test the spring for insufficient tension. Re-
place a rotor that displays any of these adverse
conditions.
DRB SCAN TOOL
For operation of the DRB scan tool, refer to the ap-
propriate Powertrain Diagnostic Procedures service
manual.
Fig. 4 Crankshaft Position SensorÐ4.0L 6-Cyl.
EngineÐYJ models With Auto. Trans.
Fig. 5 Crankshaft Position Sensor Connector
Fig. 6 Cap InspectionÐExternalÐTypical
Fig. 7 Cap InspectionÐInternalÐTypical
Fig. 8 Firing OrderÐ2.5L 4-Cylinder Engine
8D - 8 IGNITION SYSTEMSJ

IGNITION COIL
To perform a complete test of the ignition coil and
its circuitry, refer to the DRB scan tool. Also refer tothe appropriate Powertrain Diagnostics Procedures
manual. To test the coil only, refer to the following:
The ignition coil (Fig. 11) is designed to operate
without an external ballast resistor.
Inspect the ignition coil for arcing. Test the coil ac-
cording to coil tester manufacturer's instructions.
Test the coil primary and secondary resistance. Re-
place any coil that does not meet specifications. Refer
to the Ignition Coil Resistance chart.
If the ignition coil is being replaced, the secondary
spark plug cable must also be checked. Replace cable
if it has been burned or damaged.
Arcing at the tower will carbonize the cable nipple,
which if it is connected to a new ignition coil, will
cause the coil to fail.
If the secondary coil cable shows any signs of dam-
age, it should be replaced with a new cable and new
terminal. Carbon tracking on the old cable can cause
arcing and the failure of a new ignition coil.
ENGINE COOLANT TEMPERATURE SENSOR TEST
For an operational description, diagnosis and re-
moval/installation procedures, refer to Group 14,
Fuel System.
IGNITION COIL RESISTANCE
Fig. 9 Firing OrderÐ4.0L 6-Cylinder Engine
Fig. 10 Rotor InspectionÐTypical
Fig. 11 Ignition CoilÐTypical (4.0L Shown)
JIGNITION SYSTEMS 8D - 9

IGNITION SECONDARY CIRCUIT DIAGNOSIS
CHECKING FOR SPARK
CAUTION: When disconnecting a high voltage cable
from a spark plug or from the distributor cap, twist
the rubber boot slightly (1/2 turn) to break it loose
(Fig. 12). Grasp the boot (not the cable) and pull it
off with a steady, even force.
(1) Disconnect the ignition coil secondary cable
from center tower of the distributor cap. Hold the ca-
ble terminal approximately 12 mm (1/2 in.) from a
good engine ground (Fig. 13).
WARNING: BE VERY CAREFUL WHEN THE ENGINE
IS CRANKING. DO NOT PUT YOUR HANDS NEAR
THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR
LOOSE FITTING CLOTHING.
(2) Rotate (crank) the engine with the starter mo-
tor and observe the cable terminal for a steady arc. If
steady arcing does not occur, inspect the secondary
coil cable. Refer to Spark Plug Cables in this group.
Also inspect the distributor cap and rotor for cracksor burn marks. Repair as necessary. If steady arcing
occurs, connect ignition coil cable to the distributor
cap.
(3) Remove a cable from one spark plug.
(4) Using insulated pliers, hold the cable terminal
approximately 12 mm (1/2 in.) from the engine cylin-
der head or block while rotating the engine with the
starter motor. Observe the spark plug cable terminal
for an arc. If steady arcing occurs, it can be expected
that the ignition secondary system is operating cor-
rectly.(note that if the ignition coil cable is re-
moved for this test, instead of a spark plug
cable, the spark intensity will be much higher.)
If steady arcing occurs at the spark plug cables, but
the engine will not start, connect the DRB scan tool.
Refer to the Powertrain Diagnostic Procedures ser-
vice manual.
FAILURE TO START TEST
To prevent unnecessary diagnostic time and wrong
test results, the previous Checking For Spark test
should be performed prior to this test.
WARNING: SET PARKING BRAKE OR BLOCK THE
DRIVE WHEELS BEFORE PROCEEDING WITH THIS
TEST.
(1) Unplug the ignition coil harness connector at
the coil (Fig. 14).
(2) Connect a set of small jumper wires (18 gauge
or smaller) between the disconnected harness termi-
nals and the ignition coil terminals. To determine po-
larity at connector and coil, refer to the Wiring
Diagrams section.
(3) Attach one lead of a voltmeter to the positive
(12 volt) jumper wire. Attach the negative side of
voltmeter to a good ground. Determine that sufficient
battery voltage (12.4 volts) is present for the starting
and ignition systems.
Fig. 12 Cable Removal
Fig. 13 Checking for SparkÐTypical
Fig. 14 Coil Harness ConnectorÐTypical (4.0L
Shown)
8D - 10 IGNITION SYSTEMSJ

temperature ranges. This depends upon the thick-
ness and length of the center electrodes porcelain in-
sulator.)
SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center
electrode insulator that also appears blistered (Fig.
25). The increase in electrode gap will be consider-
ably in excess of 0.001 inch per 1000 miles of opera-
tion. This suggests that a plug with a cooler heat
range rating should be used. Over advanced ignition
timing, detonation and cooling system malfunctions
can also cause spark plug overheating.
SPARK PLUG SECONDARY CABLES
TESTING
Spark plug cables are sometimes referred to as sec-
ondary ignition cables or secondary wires. The cables
transfer electrical current from the distributor to in-
dividual spark plugs at each cylinder. The spark plug
cables are of nonmetallic construction and have a
built in resistance. The cables provide suppression of
radio frequency emissions from the ignition system.Check the high-tension cable connections for good
contact at the ignition coil, distributor cap towers
and spark plugs. Terminals should be fully seated.
The terminals and spark plug covers should be in
good condition. Terminals should fit tightly to the ig-
nition coil, distributor cap and spark plugs. The
spark plug cover (boot) of the cable should fit tight
around the spark plug insulator. Loose cable connec-
tions can cause corrosion and increase resistance, re-
sulting in shorter cable service life.
Clean the high tension cables with a cloth moist-
ened with a nonflammable solvent and wipe dry.
Check for brittle or cracked insulation.
When testing secondary cables for damage with an
oscilloscope, follow the instructions of the equipment
manufacturer.
If an oscilloscope is not available, spark plug cables
may be tested as follows:
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
With the engine not running, connect one end of a
test probe to a good ground. Start the engine and run
the other end of the test probe along the entire
length of all spark plug cables. If cables are cracked
or punctured, there will be a noticeable spark jump
from the damaged area to the test probe. The cable
running from the ignition coil to the distributor cap
can be checked in the same manner. Cracked, dam-
aged or faulty cables should be replaced with resis-
tance type cable. This can be identified by the words
ELECTRONIC SUPPRESSION printed on the cable
jacket.
Use an ohmmeter to test for open circuits, exces-
sive resistance or loose terminals. Remove the dis-
tributor cap from the distributor.Do not remove
cables from cap.Remove cable from spark plug.
Connect ohmmeter to spark plug terminal end of ca-
ble and to corresponding electrode in distributor cap.
Resistance should be 250 to 1000 Ohms per inch of
cable. If not, remove cable from distributor cap tower
and connect ohmmeter to the terminal ends of cable.
If resistance is not within specifications as found in
the Spark Plug Cable Resistance chart, replace the
cable. Test all spark plug cables in this manner.
Fig. 24 Preignition Damage
Fig. 25 Spark Plug Overheating
SPARK PLUG CABLE RESISTANCE
8D - 14 IGNITION SYSTEMSJ

To test ignition coil-to-distributor cap cable, do not
remove the cable from the cap. Connect ohmmeter to
rotor button (center contact) of distributor cap and
terminal at ignition coil end of cable. If resistance is
not within specifications as found in the Spark Plug
Cable Resistance chart, remove the cable from the
distributor cap. Connect the ohmmeter to the termi-
nal ends of the cable. If resistance is not within spec-
ifications as found in the Spark Plug Cable
Resistance chart, replace the cable. Inspect the igni-
tion coil tower for cracks, burns or corrosion.
For removal and installation of spark plug cables,
refer to Spark Plug Secondary Cables in the Compo-
nent Removal/Installation section.
THROTTLE POSITION SENSOR TEST
For an operational description, diagnosis and re-
moval/installation procedures, refer to Group 14,
Fuel System.
OXYGEN (O2S) SENSOR TESTS
For an operational description, diagnosis or remov-
al/ installation procedures, refer to Group 14, Fuel
Systems.
ON-BOARD DIAGNOSTICS
FOR CERTAIN IGNITION SYSTEM
COMPONENTS
The powertrain control module (PCM) performs an
On-Board Diagnostic (OBD) check for certain ignition
system components on all vehicles. This is done by
setting a diagnostic trouble code (DTC).
A DTC can be obtained in two different ways. One
of the ways is by connecting the DRB scan tool to the
data link connector. This connector is located in the
engine compartment (Figs. 26 or 27). Refer to the ap-
propriate Powertrain Diagnostic Procedures service
manual for operation of the DRB scan tool. The other
way is to cycle the ignition key and observe the mal-
function indicator lamp (MIL). The MIL lamp is dis-
played on the instrument panel as the CHECK
ENGINE lamp (Figs. 28 or 29). This lamp will flash
a numeric code. If a numeric code number 11 (for the
crankshaft position sensor) or 42 (for the ASD relay)
is observed, a problem has been found in the ignition
system.
Note that the CHECK ENGINE lamp will illumi-
nate initially for approximately two seconds each
time the ignition key is turned to the ON position.
This is done for a bulb test.
Fig. 26 Data Link ConnectorÐXJ ModelsÐTypical
Fig. 27 Data Link ConnectorÐYJ ModelsÐTypical
JIGNITION SYSTEMS 8D - 15

When installing new cables, make sure a positive
connection is made. A snap should be felt when a
good connection is made between the plug cable and
the distributor cap tower.THROTTLE POSITION SENSOR (TPS)
For an operational description, diagnosis and re-
moval/installation procedures, refer to Group 14,
Fuel System.
Fig. 22 Engine Firing OrderÐ4.0L 6-Cylinder EngineFig. 21 Engine Firing OrderÐ2.5L 4-Cylinder Engine
JIGNITION SYSTEMS 8D - 25

(a) With lock cylinder and ignition switch in
Lock position, insert lock cylinder into ignition
switch until it bottoms.(b) Insert ignition key into lock cylinder. While
gently pushing lock cylinder in toward ignition
switch, rotate ignition key to end of travel.
(6) Install retaining screw into bracket and lock
cylinder. Tighten screw to 36.5 Nzm (2664 in. lbs.)
torque.
(7) Install steering column covers. Tighten screws
to2Nzm (17 in. lbs.) torque.
(8) If vehicle is equipped with a tilt steering col-
umn, install tilt lever.
(9) Connect negative cable to battery.
(10) Check for proper operation of halo light, shift
lock (if applicable), and column lock. Also check for
proper operation of ignition switch accessory, lock,
off, run, and start positions.
Fig. 10 Ignition Switch Mounting PadFig. 8 Key Cylinder Removal
Fig. 9 Ignition Switch View From Column
8D - 28 IGNITION SYSTEMSJ

spring loaded to release when the key is released.
The maximum voltage drop between any two con-
nected terminals should not exceed 12.5 millivolts
per amp. For example: If a 10 amp load is drawn
through the switch, maximum voltage drop should be
10 x 0.0125 or 0.125 volt.
INSTALLATION/ADJUSTMENT
(1) Place the key lock switch in the ACCESSORY
position.
(2) Place the slider bar (in the ignition switch)
(Fig. 12) into the ACCESSORY detent position.
(3) Connect the wiring to the switch as follows: In-
stall the non-black (colored) connector first and then
the black (colored) connector to the ignition switch.
One connector will interlock the other connector.
(4) Slip the remote actuator rod into the access
hole on the switch (Fig. 12). Install the switch to the
steering column. Be careful not to move the slider
bar (on the switch) out of the ACCESSORY detent
position. Remove the ignition switch actuator rod se-
curing-tape from steering column.
(5) Install the two ignition switch-to-steering col-
umn screws finger tight.Do not tighten screws at
this time.
(6) Adjust ignition switch as follows:
(a) Non-tilt steering column: While holding key
lock switch in ACCESSORY position, gently slide
ignition switchup(towards steering wheel). This
will remove slack from switch. Tighten attaching
screws. Do not allow the ignition switch to move
from the ACCESSORY detent position.
(b) Tilt steering column: While holding the key
lock switch in the ACCESSORY position, gently
slide the ignition switchdown(away from steering
wheel) to remove slack from switch. Tighten at-
taching screws. Do not allow the ignition switch to
move from the ACCESSORY detent position.
Because the ignition switch and the headlamp dim-
mer switch share the same two mounting screws, oneof the screws must be removed from the ignition
switch. This must be doneafterthe ignition switch
has been adjusted andbeforethe dimmer switch
has been installed. Remove one screw.Do notre-
move the stud/nut.
(7) Install the headlamp dimmer switch as follows:
Slip switch into actuator rod and position over the ig-
IGNITION SWITCH CONTINUITY TESTS
Fig. 13 Ignition Switch Terminals/Circuits
8D - 30 IGNITION SYSTEMSJ