radiator JEEP XJ 1995 Service And Manual Online

(a) Check movement of release shift handle but-
ton (floor shift) or release lever (column shift). You
should not be able to press button inward or move
column lever.
(b) Turn ignition switch to On position.
(c) Press floor shift lever release button or move
column lever. Then shift into Neutral. If cable ad-
justment is correct, ignition switch can not be
turned to Lock position. Perform same check with
transmission in D range.
(7) Move shift lever back to Park and check igni-
tion switch operation. You should be able to turn
switch to Lock position and shift lever release button/
lever should not move.
TRANSMISSION COOLER SERVICE
Main Cooler
The transmission main cooler is located in the ra-
diator. The main cooler can be flushed when neces-
sary, however, the cooler is not a repairable
component. If the cooler is damaged, plugged, or
leaking, the radiator will have to be replaced.
Auxiliary Cooler
The auxiliary cooler is mounted in front of the ra-
diator at the driver side of the vehicle (Fig. 48). The
cooler can be flushed when necessary, while mountedin the vehicle. The cooler can also be removed for ac-
cess, repair, or replacement as needed.
The main and auxiliary coolers should both be
flushed whenever a transmission or converter clutch
malfunction generates sludge, debris, or particles of
clutch friction material.
Cooler Service
The main cooler (and radiator) and the auxiliary
cooler can be removed for service or access to other
components. Auxiliary cooler removal requires that
Fig. 47 Park Lock Cable Attachment
Fig. 48 Auxiliary Cooler Mounting (Left Hand Drive)
21 - 196 AW-4 IN-VEHICLE SERVICEJ

the front bumper and radiator support be removed
for access to the cooler lines and attaching bracket.
REVERSE FLUSHING MAIN AND AUXILIARY
COOLERS AND COOLER LINES
Reverse flushing the cooler and lines will prevent
sludge and particles from flowing back into the
transmission after repair. The flushing procedure ap-
plies to standard (in-radiator) coolers and auxiliary
coolers equally.
Pressure equipment is preferred for reverse flush-
ing. However, reverse flushing can be performed us-
ing hand operated equipment as described in the
following procedure.
(1) Disconnect cooler lines at transmission and at
auxiliary cooler (Figs. 48 and 49).
(2) Position drain pan under cooler line to catch
material flushed through coolers and lines.
(3) Reverse flush each cooler using hand operated
suction gun filled with mineral spirits. Insert gun
nozzle (or hose) into cooler inlet (return) line. Then
force mineral spirits through into line and through
cooler.
(4) Continue reverse flushing until fluid exiting in-
let (pressure) line is clear and free of debris/residue.
(5) Replace radiator if fluid cannot be pumped
through main cooler. Replace auxiliary cooler if leaks
are evident, or if fluid cannot be pumped through it.
(6) Clear flushing materials from coolers and lines
with short pulses of compressed air. Insert air gun
nozzle into cooler inlet (return) line and continue
short pulses of air until all fluid is cleared from
cooler and lines.(7) Pump one quart of fresh automatic transmis-
sion fluid through cooler and lines before reconnect-
ing cooler lines.
FLOW TESTING TRANSMISSION MAIN
COOLER
Cooler flow is checked by measuring the amount of
fluid flow through the cooler in a 20 second time pe-
riod. The test is performed with the engine running
and transmission in neutral. Fluid is then pumped
through the cooler by the transmission oil pump.
(1) Disconnect cooler inlet line at transmission fit-
ting.
(2) Securely attach hose to end of inlet line and po-
sition line in a one quart test container.
(3) Add extra quart of fluid to transmission.
(4) Use stopwatch to check flow test time.
(5) Shift transmission into neutral and set parking
brake.
(6) Start and run engine at curb idle speed and im-
mediately note cooler flow. Approximately one quart
of fluid should flow into test container in 20 second
period.
(7) If cooler flow is intermittent, flows less than
one quart in 20 seconds, or does not flow at all,
cooler is faulty and must be replaced.
TRANSMISSION COOLER LINE FITTINGS
Quick connect fittings are used at the transmission
cooler line connections. The fitting seals and guides
are serviceable.
Replace the seals and guides whenever the fittings
exhibit leakage, or will not properly snap into place.
Fig. 49 Auxiliary Cooler Mounting (Right Hand Drive)
JAW-4 IN-VEHICLE SERVICE 21 - 197

EXTERIOR COMPONENTS
INDEX
page page
Air Exhaust GrilleÐXJ...................... 25
Battery TrayÐXJ.......................... 14
Body Side Molding/CladdingÐXJ.............. 20
Body Stripes/DecalsÐXJ.................... 21
Brush GuardÐXJ.......................... 3
Cowl Grille and ScreenÐXJ................. 12
Cowl Weatherstrip Seal/Crossmember Air
DeflectorÐXJ........................... 11
Dash Panel Insulator PanelÐXJ.............. 12
Drip Rail MoldingÐXJ...................... 25
Exterior NameplatesÐXJ................... 26
External MirrorsÐXJ....................... 27
Front FenderÐXJ......................... 14
Fuel Filler Door BumpersÐXJ................ 27Fuel Filler Nozzle/TubeÐXJ................. 26
Grille and Grille Opening Panel (GOP)ÐXJ....... 3
Hood AdjustmentÐXJ...................... 10
Hood Hinge ReplacementÐXJ............... 10
Hood Latch ReplacementÐXJ................ 11
Hood Latch Striker ReplacementÐXJ.......... 11
HoodÐXJ................................ 7
Latch Release Cable ReplacementÐXJ......... 11
Luggage RackÐXJ........................ 28
Quarter Window AppliqueÐXJ................ 25
Radiator Support CrossmemberÐXJ............ 6
Rear Wheelhouse Flares and LinersÐXJ........ 19
Safety Latch Striker ReplacementÐXJ.......... 11
BRUSH GUARDÐXJ
REMOVAL
(1) Remove the bolts and washers that attach the
brush guard (Fig. 1) to the side sills.(2) Remove the nuts and washers that the attach
brush guard to the bumper. Remove the brush guard
from the bumper.INSTALLATION
(1) Position and support the brush guard on the
bumper. Install the attaching washers and nuts.
Do not tighten the nuts until the brush guard
is properly positioned on the vehicle and
aligned.
(2) Install the bolts and washers to attach the
brush guard to side sills.
(3) Align the brush guard and tighten the bolts.
GRILLE AND GRILLE OPENING PANEL (GOP)ÐXJ
REMOVAL
(1) Remove the screws and grille (Fig. 2) from the
grille opening panel (GOP).
(2) Remove the screws, side marker lenses and the
headlamp bezels from the grille opening panel (GOP)
(Fig. 3).
(3) Remove the headlamps and park/turn signal
lamps from the GOP (Fig. 4).
(4) Open the hood.
(5) Remove the nuts that attach the grille opening
panel (GOP) to the bracket on radiator support cross-
member.
Fig. 1 Brush Guard Removal/Installation
JEXTERIOR COMPONENTSÐXJ 23 - 3

RADIATOR SUPPORT CROSSMEMBERÐXJ
REMOVAL
(1) Remove the grille opening panel (GOP).
(2) For 2.5L engines, remove the power steering
pump reservoir from the left filler panel (Fig. 9).
(3) Remove the radiator support crossmember and
radiator from the front of vehicle (Fig. 10).(4) If additional disassembly is required, remove
the horns, baffle braces and the wire harnesses from
the baffles (Fig. 11).
Fig. 10 Radiator Support Crossmember & Modular Radiator
Fig. 9 P/S Pump Reservoir Removal/Installation
Fig. 11 Horns, Baffle Braces & Wire Harnesses
23 - 6 EXTERIOR COMPONENTSÐXJJ

INSTALLATION
(1) If removed, install the horns, baffle braces and
the wire harnesses on the baffles (Fig. 11).
(2) Position the radiator and the radiator support
crossmember at the front of vehicle (Fig. 10). Install
and tighten screws to 9 Nzm (76 in-lbs) torque.
(3) For 2.5L engines, install the power steering
pump reservoir on the left filler panel (Fig. 9).
(4) Install the grille opening panel (GOP).
HOODÐXJ
The hood service procedures included in this sec-
tion include:
²Hood removal and installation.
²Hood adjustment.
²HingeÐlatchÐstriker service (Fig. 12).
²Latch release cable service.
JEXTERIOR COMPONENTSÐXJ 23 - 7

(2) Install the hinge nuts on the studs. Tighten the
restraint cable nut to 4 Nzm (38 in-lbs) torque.
Tighten the remaining nuts to 9 Nzm (77 in-lbs)
torque.
If a replacement hinge seal is being installed,
position it around the hinge arm, force it
against the hinge base.
(3) Position the hinge seal around the hinge arm
and on hinge base.
(4) Install the hood.
(5) Adjust the hood as necessary.
HOOD LATCH REPLACEMENTÐXJ
REMOVAL
(1) Remove the screw that attaches the latch to the
hood inner panel (Fig. 15).
(2) Disconnect the latch from the hood and latch
connecting rod. Remove the latch from the hood.
INSTALLATION
(1) Connect the latch to the latch connecting rod
and position it on the hood inner panel.
(2) Install the screw that attaches the latch to the
hood inner panel.
(3) Tighten the screw to 9 Nzm (77 in-lbs) torque.
(4) Test the operation of the latch release cable and
latch.
HOOD LATCH STRIKER REPLACEMENTÐXJ
REMOVE
(1) Remove the grille opening panel (GOP).
(2) Remove the screws that attach the striker to
the radiator baffle (Fig. 19).
(3) Remove the striker and shims from the baffle.
INSTALLATION
(1) Position the shims and striker on the radiator
baffle and install the screws.
(2) Tighten the screws to 21 Nzm (15 ft-lbs) torque.
(3) Test the striker/hood alignment by opening and
closing the hood several times. Adjust the striker, if
necessary.
LATCH RELEASE CABLE REPLACEMENTÐXJ
REMOVAL
(1) Drill out the bellcrank to hood rivet heads and
remove the rivets (Fig. 14).
(2) Disconnect the bellcrank from the latch rod and
the latch release cable. Remove the bellcrank from
the hood.
(3) Disconnect the latch release cable from the
clips on the hood.
(4) Remove the left cowl side trim panel.
(5) Remove the cable bracket screws from the cowl
side panel.(6) Pull the cable through the dash panel and re-
move it from under the instrument panel.
INSTALLATION
(1) Insert the replacement cable end through the
hole in the dash panel into the engine compartment.
(2) Pull the cable forward and seat the grommet in
the dash panel.
(3) Position the cable bracket on the cowl side
panel and install the screws. Tighten the screws to
13 Nzm (111 in-lbs) torque.
(4) Install the left cowl side trim panel.
(5) Connect the cable and latch rod to the
bellcrank.
(6) Position the bellcrank on the hood and install
the rivets.
(7) Attach the cable to the clips.
(8) Test release the cable for proper operation.
SAFETY LATCH STRIKER REPLACEMENTÐXJ
REMOVAL
(1) Remove the striker screws from the radiator
support crossmember (Fig. 21).
(2) Remove the striker from the crossmember.
INSTALLATION
(1) Position the striker on the radiator support
crossmember and install the screws. Tighten the
screws to 9 Nzm (77 in-lbs) torque.
(2) Test the safety latch operation.
COWL WEATHERSTRIP SEAL/CROSSMEMBER AIR
DEFLECTORÐXJ
WEATHERSTRIP SEAL REPLACEMENT
(1) Pry upward along the length of seal (Fig. 22).
(2) Detach the seal retainers from the cowl panel.
(3) Remove the seal from cowl panel.
Fig. 21 Hood Safety Latch StrikerÐ2.5L Engine
(Typical)
JEXTERIOR COMPONENTSÐXJ 23 - 11

EXTERIOR COMPONENTS
INDEX
page page
Battery TrayÐYJ......................... 110
Body Side Step MoldingÐYJ................ 115
Body Stripes/DecalsÐYJ................... 116
Cowl Grille and ScreenÐYJ................ 109
Cowl Weatherstrip SealÐYJ................ 109
Exterior Nameplates (Adhesive-Backed)ÐYJ.... 120
External Spare/Wheel Tire CarrierÐYJ........ 133
Fender FlareÐYJ........................ 114
Fender Inner Splash ShieldsÐYJ............. 116
Fender Splash ApronsÐYJ................. 115
FendersÐYJ............................ 110
Fuel Filler Protector/NozzleÐYJ............. 121
Half Metal Door Mirror (External)ÐYJ......... 121
Hard Top Liftgate GlassÐYJ................ 124
Hard Top RepairÐYJ..................... 127
Hard Top Roof VentÐYJ................... 127
Hard TopÐYJ........................... 126Hood AlignmentÐYJ...................... 107
Hood Insulator PanelÐYJ.................. 107
Hood Safety LatchÐYJ.................... 109
HoodÐYJ.............................. 107
Liftgate Glass Weatherstrip Seal ReplacementÐYJ. 125
Radiator Grille AppliqueÐYJ................ 104
Soft Top Service InformationÐYJ............. 127
Soft Top ServiceÐYJ..................... 129
Sport BarÐYJ........................... 132
Tailgate AdjustmentÐYJ................... 121
Tailgate HingeÐYJ....................... 121
Tailgate Latch and Release HandleÐYJ........ 122
Tailgate Latch StrikerÐYJ.................. 123
Tailgate Lock CylinderÐYJ................. 122
Tailgate Weatherstrip SealÐYJ.............. 123
TailgateÐYJ............................ 121
Wheelhouse Splash LinersÐYJ.............. 115
RADIATOR GRILLE APPLIQUEÐYJ
REMOVAL
(1) Raise the hood.
(2) Remove the headlamp bezels (Fig. 1).(3) Remove the headlamp bulb retainer screws
(Fig. 2).
(4) Disconnect and remove the headlamps and
buckets as a unit (Fig. 2).
Fig. 1 Grille Applique, Headlamp Bezel and Grille Panel
23 - 104 EXTERIOR COMPONENTSÐYJJ

(5) Remove the parking lamp retaining screws
(Fig. 2).
(6) Disconnect the wire harness connectors and re-
move the parking lamps (Fig. 2).
(7) Remove the front crossmember cover.
(8) Remove the retaining screws and the bumper
inserts at the top of the grille panel (Fig. 1).
(9) Detach the grille applique from the grille panel
(Fig. 1).
(10) Remove the double faced foam adhesive tape
at the bottom of the grille applique (Fig. 1).
INSTALLATION
(1) Install double faced foam tape at the bottom,
interior side of the grille applique (Fig. 1).
(2) Position the grille applique over the grille panel
and press inward along the bottom where the tape is
located (Fig. 1).
(3) Install the grille applique retaining screws and
the bumper inserts (Fig. 1).
(4) Connect the wire harness connectors and posi-
tion the headlamp buckets and headlamps in the
grille panel (Fig. 2).
(5) Install the headlamp bulb retainer and the
screws (Fig. 1). Tighten the screws to 2 Nzm (18 in-
lbs) torque.
(6) Install the headlamp bezels and the retaining
screws (Fig. 1). Tighten the screws securely.
(7) Connect the wire harness connectors and in-
stall the parking lamps.
(8) Install the parking lamp retaining screws.
Tighten the screws to 2 Nzm (18 in-lbs) torque.
(9) Close the hood.
(10) Install the front crossmember cover.
RADIATOR GRILLE PANEL
REMOVAL
(1) Remove the front crossmember cover.
(2) Remove the screws and washers, and separate
the radiator and shroud from the grille panel (Fig. 3).(3) If equipped, remove the retaining bolts and
separate the A/C condenser from the grille panel
(Fig. 4).
(4) Remove the retaining screws and the P/S fluid
reservoir from the grille panel (Fig. 5).
Fig. 2 Front LampsFig. 3 Radiator and Shroud
Fig. 4 Radiator and Shroud
Fig. 5 P/S Fluid Reservoir
JEXTERIOR COMPONENTSÐYJ 23 - 105

(5) Remove the retaining screws and the air intake
adapters from the grille panel (Fig. 6).
(6) Remove the bolts and washers that attach the
grille panel to the fenders (Fig. 7).
(7) Remove the bolts, washers and spacers that at-
tach the grille panel to the front crossmember (Fig.
8).
(8) Remove the nuts that attach the radiator sup-
port rods to the front brackets (Fig. 9). Remove the
rods from the brackets.
(9) Tilt the grille panel forward and disconnect the
head lamp, turn signal and marker lamp wire har-
ness connectors.
(10) For vehicles equipped with A/C, discharge the
A/C system. Disconnect the high pressure hose at the
sight glass connection and at the compressor. Cap thehose and fittings to prevent foreign material entry. If
necessary, refer to Group 24ÐHeating And Air Con-
ditioning.
(11) Remove the grille panel from the vehicle (Fig.
8).
(12) If a replacement radiator grille panel will be
installed, remove the grille applique (Fig. 8) and
transfer the lamps, the headlamp buckets and the re-
taining brackets.
Fig. 7 Grille Panel Front Bolt
Fig. 8 Radiator Grille Applique and Grille Panel
Fig. 6 Air Intake and Radiator Baffle Adapters
23 - 106 EXTERIOR COMPONENTSÐYJJ

INSTALLATION
(1) Position the grille panel on the vehicle.
(2) Connect the marker, park and headlamp wire
harness connectors.
(3) Connect the radiator support rods with the re-
taining brackets (Fig. 9).
(4) Attach the grille panel to the front crossmem-
ber.
(5) Install the grille panel-to-front fender bolts
(Fig. 7). Tighten the retaining screws to 27 Nzm (20
ft-lbs) torque.
(6) Install the air intake adapters on the grille
panel (Fig. 6). Tighten the retaining screws to 3 Nzm
(25 in-lbs) torque.
(7) Install the P/S fluid reservoir on the grille
panel (Fig. 5). Tighten the retaining screws to 8 Nzm
(72 in-lbs) torque.
(8) If equipped, install the A/C condenser on the
grille panel (Fig. 4). Tighten the retaining screws to 2
Nzm (20 in-lbs) torque. Connect the high pressure
hose at the sight glass connection and at the com-
pressor.
(9) Install the radiator and shroud on the grille
panel (Fig. 3). Tighten the retaining screws to 15
Nzm (132 in-lbs) torque.
(10) Install the front crossmember cover.
(11) If removed, install the grille applique (Fig. 8).
(12) Evacuate and charge the A/C system.
HOODÐYJ
REMOVAL
(1) Raise and support the hood.
(2) Disconnect the underhood lamp wire harness
connector (Fig. 10).(3) Mark the position of the hinges on the hood for
installation alignment reference (Fig. 11).
(4) Remove the hinge attaching screws and remove
the hood (Fig. 11).
(5) If the hood must be replaced, remove and
transfer the insulator panel, hinges, latches,
bumpers, brackets, footman loop, hood lamp, support
rod, and safety latch to the replacement hood (Fig.
12).
INSTALLATION
(1) Position the hood on the vehicle and install the
hinge attaching screws.
(2) Align the hinges with the installation reference
marks on the hood and tighten the hinge screws se-
curely.
(3) Connect the underhood lamp wire harness con-
nector (Fig. 10).
(4) Close the hood.
HOOD ALIGNMENTÐYJ
The hood hinge attaching screw holes are oversized
to facilitate hood adjustment movement.
(1) Loosen the hinge attaching screws.
(2) Move the hood in the direction(s) required for
correct alignment.
(3) Tighten the hinge attaching screws.
HOOD INSULATOR PANELÐYJ
REMOVAL
(1) Raise and support the hood.
(2) Remove the insulator panel retainers (Fig. 13).
(3) Remove the insulator panel from the hood.
INSTALLATION
(1) Position the insulator panel on the hood.
(2) Install the insulator panel retainers.
(3) Remove the support rod and close the hood.
Fig. 9 Radiator Support Rods
Fig. 10 Underhood Lamp
JEXTERIOR COMPONENTSÐYJ 23 - 107