tow JEEP XJ 1995 Service And Workshop Manual

nition switch. Install screws finger tight. Remove the
dimmer switch actuator rod securing-tape from steer-
ing column.
(8) Adjust dimmer switch as follows: Depress the
switch slightly and insert a 3/32-inch drill bit into
the adjustment hole (Fig. 11). This is done to prevent
horizontal switch movement.
(9) Move switch toward steering wheel to remove
any lash from switch actuator rod. Tighten dimmer
and ignition switch fasteners to 4 Nzm (35 in. lbs.)
torque.(10) Install the windshield wiper intermittent con-
trol module and its bracket (if equipped).
(11) Install the negative battery cable.
Test dimmer switch. Test ignition switch operation
in all switch positions. If equipped with a tilt steer-
ing column, test operation of dimmer switch and ig-
nition switch in all tilt positions.
Fig. 14 Detent PositionsÐNon-Tilt Steering Column
Fig. 15 Detent PositionsÐTilt Steering Column
JIGNITION SYSTEMS 8D - 31

TURN SIGNAL INDICATOR LAMPS
(1) Disconnect battery negative cable. Remove left
instrument cluster bezel and main cluster assembly.
Probe cavity 20 of cluster connector. Check for conti-
nuity to a good ground. There should be continuity. If
OK, go to next step. If not OK, repair open circuit to
ground.
(2) Connect battery negative cable. Install a
jumper wire from cavity 18 (left indicator) or cavity 7
(right indicator) of cluster connector to a 12-volt bat-
tery feed. Lamp should light. If OK, continue to next
step. If not OK, replace bulb.
(3) Disconnect battery negative cable. Check for
continuity between cavity 18 (left indicator) or cavity
7 (right indicator) of cluster connector and cavity H
(left front turn signal) or cavity J (right front turn
signal) of steering column wiring connector. There
should be continuity. If OK, refer to Group 8J - Turn
Signal and Hazard Warning Systems for further di-
agnosis. If not OK, repair open circuit as required.
UPSHIFT INDICATOR LAMP
(1) Disconnect battery negative cable. Unplug PCM
connector. Connect battery negative cable. Turn igni-
tion switch to ON. Install a jumper wire from cavity
54 of PCM connector (Fig. 5) to a good ground. Lamp
should light. Remove jumper from ground. Lamp
should go off. If OK, refer to Powertrain Diagnostic
Procedures manual to diagnose PCM. If not OK, turn
ignition switch to OFF and go to next step.
(2) Disconnect battery negative cable. Remove left
instrument cluster bezel and main cluster assembly.
Install a jumper wire from cavity 5 of cluster connec-
tor to a good ground. Connect battery negative cable.
Turn ignition switch to ON. Lamp should light. If
OK, go to next step. If not OK, replace bulb.
(3) Turn ignition switch to OFF. Disconnect battery
negative cable. Unplug cluster connector. Check for
continuity between cavity 5 of cluster connector and
a good ground. There should be no continuity. If OK,
go to next step. If not OK, repair short circuit as re-
quired.(4) Check for continuity between cavity 5 of cluster
connector and cavity 54 of PCM connector. There
should be continuity. If not OK, repair open circuit as
required.
CLUSTER ILLUMINATION LAMPS
(1) Check fuse 10 in fuseblock module. If OK, go to
next step. If not OK, replace fuse.
(2) Turn park lamps on at headlamp switch. Rotate
panel dimmer switch thumb-wheel to HI position,
just before interior lamps detent. Check for battery
voltage at fuse 10 in fuseblock module. Rotate panel
dimmer thumb-wheel towards LO position while ob-
serving test voltmeter. Reading should go from bat-
tery voltage to zero volts. If OK, go to next step. If
not OK, repair open circuit to headlamp switch or re-
fer to Group 8L - Lamps to diagnose headlamp
switch.
(3) Disconnect battery negative cable. Remove left
or center instrument cluster bezel and main or gauge
package cluster assembly. Unplug cluster connector.
Connect battery negative cable. Turn park lamps on
at headlamp switch. Rotate panel dimmer thumb-
wheel to HI position, just before interior lamps de-
tent. Check for battery voltage at cavity 21 of main
cluster connector, or cavity 7 of gauge package clus-
ter connector. If OK, go to next step. If not OK, re-
pair open circuit to fuse as required.
(4) Turn park lamps off. Disconnect battery nega-
tive cable. Remove fuse 10 from fuseblock module.
Probe cavity 21 of main cluster connector, or cavity 7
of gauge package cluster connector. Check for conti-
nuity to a good ground. There should be no continu-
ity. If OK, go to next step. If not OK, repair short
circuit as required.
(5) Probe cavity 20 of main cluster connector, or
cavities 1 and 13 of gauge package cluster connector.
Check for continuity to ground. There should be con-
tinuity. If not OK, repair open circuit as required.
8E - 34 INSTRUMENT PANEL AND GAUGESÐYJJ

SERVICE PROCEDURES
CLUSTER ASSEMBLY REMOVE/INSTALL
MAIN CLUSTER
(1) Disconnect battery negative cable.
(2) Remove 6 screws from left instrument cluster
bezel (Fig. 8).
(3) Slide bezel toward steering wheel.
(4) Remove 3 screws holding right side switch
panel (Fig. 9).
(5) Remove 3 screws holding left side switch bezel.
(6) Remove 2 screws holding cluster in place.
(7) Lift up top of cluster. Roll cluster out between
steering column and instrument panel far enough to
reach connector located behind tachometer.
(8) Disconnect cluster connector and remove clus-
ter (Fig. 10).
(9) Reverse removal procedures to install.
Fig. 8 Left Cluster Bezel Remove/Install
Fig. 9 Main Cluster Remove/Install
JINSTRUMENT PANEL AND GAUGESÐYJ 8E - 35

(5) To remove plate, slide it toward bottom of hous-
ing (Fig. 19).
(6) Remove all lamp holders from printed circuit.
(7) Remove printed circuit including connector.
(8) Reverse removal procedures to install.
GAUGE PACKAGE CLUSTER
(1) Remove gauge package cluster as described in
Cluster Remove/Install.
(2) Remove gauge package lens and mask as de-
scribed in Gauges Remove/Install.
(3) Remove all gauge attaching screws from rear of
cluster housing (Fig. 20).
(4) Remove screw holding the cluster connector re-
taining plate to the housing.
(5) To remove plate, slide it toward the bottom of
the housing (Fig. 21).(6) Remove all lamp holders from the printed cir-
cuit.
(7) Remove printed circuit including connector.
(8) Reverse removal procedures to install.
Fig. 20 Gauge Package Printed Circuit Remove/Install
Fig. 19 Cluster Connector Retaining Plate
Fig. 21 Cluster Connector Retaining Plate
JINSTRUMENT PANEL AND GAUGESÐYJ 8E - 41

HEADLAMP OR PANEL DIMMER SWITCH
REMOVE/INSTALL
(1) Disconnect battery negative cable.
(2) Remove 6 screws from left instrument cluster
bezel (Fig. 22).
(3) Slide bezel toward steering wheel.
(4) Apply upward force to the bezel and downward
force to the indicator panel. This will release the in-
dicator panel holding tabs (Fig. 23).
(5) Remove the bezel from the instrument panel.
(6) Remove the headlamp or panel dimmer switch
retaining screws (Fig. 24).
(7) Disconnect the headlamp/panel dimmer switch
wire harness connector.
(8) Remove the headlamp/panel dimmer switch
from the instrument panel cavity.
(9) Reverse removal procedures to install.
Fig. 22 Left Cluster Bezel Remove/Install
Fig. 23 Indicator Panel Holding Tabs
Fig. 24 Headlamp/Panel Dimmer Switch Remove/
Install
8E - 42 INSTRUMENT PANEL AND GAUGESÐYJJ

WARNING: THE USE OF VEHICLE SPEED CON-
TROL IS NOT RECOMMENDED WHEN DRIVING
CONDITIONS DO NOT PERMIT MAINTAINING ACONSTANT SPEED, SUCH AS IN HEAVY TRAFFIC
OR ON ROADS THAT ARE WINDING, ICY, SNOW
COVERED, OR SLIPPERY.
DIAGNOSIS
Before beginning diagnosis, perform a vehicle road
test to verify reports of speed control system mal-
function. The road test should include attention to
the speedometer. Speedometer operation should be
smooth and without flutter at all speeds.
Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-
tem. The cause of any speedometer problems should
be corrected before proceeding. Refer to Group 8E -
Instrument Panel and Gauges for speedometer diag-
nosis.
If a road test verifies a system problem and the
speedometer operates properly, check for:
(1) Loose or corroded electrical connections at the
servo. Corrosion should be removed from electricalterminals and a light coating of Mopar MultiPurpose
Grease, or equivalent, applied.
(2) Correct installation of the vacuum check valve
in the hose from servo to vacuum source. The word
VAC on the valve must point toward the vacuum
source.
(3) Loose or leaking vacuum hoses or connections.
(4) Secure attachment of both ends of the speed
control servo cable.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals, or seals. If
these components are damaged, intermittent or
complete system failure may occur.
Fig. 1 Vehicle Speed Control System
8H - 2 VEHICLE SPEED CONTROL SYSTEMJ

TURN SIGNAL AND HAZARD WARNING SYSTEMS
CONTENTS
page page
DIAGNOSIS............................. 3
GENERAL INFORMATION.................. 1SERVICE PROCEDURES................... 5
GENERAL INFORMATION
Following are general descriptions of the major
components in the XJ (Cherokee)/YJ (Wrangler)
model turn signal and hazard warning systems. Refer
to Group 8W - Wiring Diagrams for complete circuit
descriptions and diagrams.
TURN SIGNAL SYSTEM
With the ignition switch in the ON or ACCESSORY
position and the turn signal switch lever (YJ) or
multi-function switch control lever (XJ) moved up
(right turn) or down (left turn), the turn signal sys-
tem is activated.
When the turn signal system is activated, the se-
lected (right or left) turn signal indicator lamp, front
park/turn signal lamp and rear tail/stop/turn signal
lamp bulb filaments will flash. With the headlamp
switch in the OFF position, the turn and front side
marker lamps flash in unison. With the headlamp
switch in the ON position, the turn and front side
marker lamps flash alternately.
HAZARD WARNING SYSTEM
The hazard warning is activated by a switch button
located below the ignition lock cylinder (YJ) or on the
top of the steering column (XJ) between the steering
wheel and the instrument panel. The hazard warning
flasher (YJ) or combination flasher (XJ) receives bat-
tery feed at all times, and the system is functional
regardless of ignition switch position. The hazard
warning switch button is identified with a double
triangle. On YJ models, push the switch button in to
activate the hazard warning system and pull the
button out to turn system off. On XJ models, push in
on the switch button to latch the switch and activate
the hazard warning system, and push in on the
switch button again to unlatch the switch and turn
the system off.
When the hazard warning system is activated, all
(right and left) turn signal indicator, front park/turn
signal lamp and rear tail/stop/turn signal lamp bulb
filaments will flash.
TURN SIGNAL FLASHER (YJ ONLY)
The turn signal flasher is located in the fuseblock
module. It contains one fixed contact point and one
contact point attached to a flexible bimetal arm. The
contact points are normally closed. When a turn sig-
nal is activated, current flows through the flasher. As
current flows through the bimetal arm it heats and
flexes to pull the contact points open, stopping cur-
rent flow. As the bimetal arm cools it straightens,
until the contact points close and the cycle repeats.
The standard flasher is designed to handle the cur-
rent flow requirements of the factory installed light-
ing. If supplemental lighting is added to the turn
signal circuits such as when towing a trailer with
lights, the current flow through the flasher increases.
This causes the flash rate to increase. It is recom-
mended that the standard flasher be replaced with a
heavy-duty (hazard warning) flasher when supple-
mental lighting is added.
However, when a turn signal bulb fails with a stan-
dard flasher, the remaining bulbs in that circuit will
light, but not flash. This will give the driver an indi-
cation to check the turn signal bulbs. Because a
heavy-duty flasher has different internal circuitry, a
failed bulb will not prevent the remaining bulbs in
the circuit from flashing. Therefore, it is recom-
mended that an occasional visual inspection of exte-
rior turn signal lamp operation be performed when a
heavy-duty flasher is installed.
HAZARD WARNING FLASHER (YJ ONLY)
The hazard warning flasher is located in the fuse-
block module. The hazard warning flasher contains
two normally open contact points mounted to two
flexible arms. A bimetal strip is attached between the
two arms. When the hazard warning is activated,
current flows through the flasher. As the current
flows through the bimetal strip it heats and pulls the
flexible arms together until the contact points close,
JTURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1

allowing current flow to the lamps. As the bimetal
strip cools, the contact points are pushed open and
the cycle repeats.
COMBINATION FLASHER (XJ ONLY)
The combination flasher functions as both the turn
signal and hazard warning flasher on XJ models. The
combination flasher is a smart relay that is located in
the relay center under the lower instrument panel
and inboard of the steering column. The combination
flasher can not be repaired. If faulty, it must be
replaced.
The combination flasher is designed to handle the
current flow requirements of the factory installed
lighting. If supplemental lighting is added to the turn
signal circuits such as when towing a trailer with
lights, the combination flasher will automatically
compensate. This allows the flash rate to remain the
same, regardless of electrical load increases. However,
if a bulb fails in the turn signal or hazard warning
circuits, the flash rate of the remaining bulbs in that
circuit will increase to 120 flashes per minute or
higher.
TURN SIGNAL/HAZARD WARNING SWITCH
(YJ ONLY)
The turn signal and hazard warning switches are
combined into a single unit mounted within the upper
steering column bowl and beneath the steering wheel.
The turn signal lever on the left side of the steering
column is moved up or down to select the right or left
turn signal switch position. The turn signals will only
operate with the ignition switch in the ACCESSORY
or ON position.
The hazard warning button on the right side of the
steering column is pushed in to turn the hazard
warning system on, or pulled out to turn the system
off. The hazard warning system will operate regard-
less of ignition switch position. The turn signal/haz-
ard warning switch can not be repaired. If faulty, the
entire unit must be replaced.
MULTI-FUNCTION SWITCH (XJ ONLY)
The multi-function switch assembly (Fig. 1) is
mounted to the left side of the steering column. This
switch contains electrical circuitry for the following
functions:²turn signals
²hazard warning
²headlamp beam selection
²headlamp optical horn
²windshield wipers
²windshield washers.
The information contained in this group addresses
only the switch functions for the turn signal and
hazard warning circuits. For information relative to
other switch functions, refer to the appropriate group.
However, the multi-function switch can not be re-
paired. If any function of the switch is faulty, the
entire switch assembly must be replaced.
TURN SIGNAL INDICATOR LAMPS
These lamps are located in the instrument cluster.
They flash with the exterior turn signal lamps to give
the driver a visual indication that a turn signal or the
hazard warning circuit is operating. For diagnosis
and service of this component, refer to Group 8E -
Instrument Panel and Gauges.
TURN SIGNAL LAMPS
The exterior lamps included in the turn signal and
hazard warning circuits include: the front park/turn
signal, and the rear tail/stop/turn signal. For diagno-
sis and service of these lamps, refer to Group 8L -
Lamps.
Fig. 1 Multi-Function Switch
8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMSJ

(15) Remove turn/hazard switch attaching screws.
(16) Remove 6 housing screws (Fig. 10).
(17) Slide housing toward steering wheel.
(18) Remove cover under column.
(19) If vehicle is equipped with a column shift,
remove PRNDL cable clip (Fig. 11).(20) Remove 2 nuts holding steering column
bracket to brake sled (Fig. 12).
(21) Remove 4 bolts holding steering column
bracket to column.
(22) Loosen column brace mounting nut at drivers
side kick panel. This will allow column to drop.
(23) Push turn/hazard connector up and out of
steering column connector (Fig. 13).
Fig. 10 Instrument Housing Remove/Install
Fig. 11 PRNDL Cable Clip Remove/Install
Fig. 12 Lower Steering Column
Fig. 13 Turn/Hazard Switch and Steering Column
Connectors
JTURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7

(2) Reservoir filler neck is held in reservoir by a
grommet. Remove reservoir filler neck (Fig. 17) by
pulling sharply away from reservoir.
(3) Remove 2 reservoir mounting screws.
(4) Raise vehicle on hoist and remove left front in-
ner wheelhouse splash shield.
(5) Disconnect hose(s) from washer pump(s) and
drain solvent from reservoir into a clean container
for re-use.
(6) Disconnect wiring from pump(s) and fluid level
sensor (if equipped).
(7) Remove washer pumps from reservoir by pull-
ing out of grommets.
(8) To remove reservoir, slide slightly towards rear
of vehicle to release hook (Fig. 17) from inner fender
slot. Then lower front of reservoir and slide unit for-
ward to remove.(9) Reverse removal procedures to install. Use new
grommets when installing washer pumps.
Fig. 16 Washer Pumps (LHD)
Fig. 17 Washer Reservoir and Pumps (RHD)
JWIPER AND WASHER SYSTEMS - XJ 8K - 9