fuel filter JEEP XJ 1995 Service And Repair Manual
[x] Cancel search | Manufacturer: JEEP, Model Year: 1995, Model line: XJ, Model: JEEP XJ 1995Pages: 2158, PDF Size: 81.9 MB
Page 24 of 2158
37,500 MILES (60 000 KM) OR AT 30 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Drain and refill manual transmission.
45,000 MILES (72 500 KM) OR AT 36 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Inspect brake linings.
²Flush and replace engine coolant, regardless of
mileage.
52,500 MILES (84 500 KM) OR AT 42 MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Flush and replace engine coolant if not done at 36
months.
60,000 MILES (96 500 KM) OR AT 48 MONTHS
²Replace air cleaner element.
²Replace distributor cap and rotor.
²Replace ignition wires.
²Replace spark plugs.
²Adjust or replace drive belts.
²Change engine oil.
²Replace engine oil filter.
²Replace fuel filter. (See Note #1)
²Lubricate steering linkage.
²Drain and refill automatic transmission.
²Drain and refill transfer case.
67,500 MILES (108 500 KM) OR AT 54
MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Inspect brake linings.
75,000 MILES (120 500 KM) OR AT 60
MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Drain and refill manual transmission.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
82,500 MILES (133 000 KM) OR AT 66
MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
90,000 MILES (145 000 KM) OR AT 72
MONTHS
²Replace air cleaner element.
²Replace spark plugs.
²Adjust drive belts.
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Inspect brake linings.
²Drain and refill automatic transmission.
²Drain and refill transfer case.
97,500 MILES (157 000 KM) OR AT 78
MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
105,000 MILES (169 000 KM) OR AT 84
MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
112,500 MILES (181 000 KM) OR AT 90
MONTHS
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Inspect brake linings.
²Drain and refill manual transmission.
²Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
change.
120,000 MILES (193 000 KM) OR AT 96
MONTHS
²Replace air cleaner element.
²Replace distributor cap and rotor.
²Lubricate steering linkage.
²Drain and refill automatic transmission.
²Drain and refill transfer case.
²Replace ignition wires.
²Replace spark plugs.
²Adjust or replace drive belts.
²Change engine oil.
²Replace engine oil filter.
²Replace fuel filter. (See note #1)
JLUBRICATION AND MAINTENANCE 0 - 5
Page 26 of 2158
²Drain and refill automatic transmission fluid.
²Change front and rear axle fluid.*
²Replace air cleaner element.
²Replace distributor cap and rotor.
²Replace ignition wires.
²Adjust or replace drive belts.
²Replace fuel filter. See note #1.
²Inspect brake linings.
²Drain and refill transfer case.
63,000 MILES (102 000KM)
²Change engine oil.
²Replace engine oil filter.
66,000 MILES (105 600KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
69,000 MILES (110 000KM)
²Change engine oil.
²Replace engine oil filter.
72,000 MILES (115 200KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Drain and refill Manual transmission fluid.
²Drain and refill automatic transmission.
²Change front and rear axle fluid.*
²Inspect brake linings.
75,000 MILES (120 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x2).
²Inspect air cleaner element, replace as necessary.
78,000 MILES (125 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
81,000 MILES (130 000KM)
²Change engine oil.
²Replace engine oil filter.
²Flush and replace engine coolant.
84,000 MILES (134 400KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Drain and refill automatic transmission fluid.
²Change front and rear axle fluid.*
²Inspect brake linings.
87,000 MILES (140 000KM)
²Change engine oil.
²Replace engine oil filter.
90,000 MILES (144 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Replace spark plugs.
²Drain and refill Manual transmission fluid.
²Replace air cleaner element.
²Adjust drive belts.
²Drain and refill transfer case fluid.
93,000 MILES (149 000KM)
²Change engine oil.
²Replace engine oil filter.
96,000 MILES (154 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Drain and refill automatic transmission fluid.
²Change front and rear axle fluid.*
²Inspect brake linings.
99,000 MILES (158 400KM)
²Change engine oil.
²Replace engine oil filter.
102,000 MILES (163 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
105,000 MILES (168 000KM)
²Change engine oil.
²Replace engine oil filter.
²Inspect air cleaner element, replace as necessary.
²Lubricate steering linkage (4x2).
108,000 MILES (172 800KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
²Drain and refill Manual transmission fluid.
²Drain and refill automatic transmission fluid.
²Change front and rear axle fluid.*
²Inspect brake linings.
111,000 MILES (177 600KM)
²Change engine oil.
²Replace engine oil filter.
²Flush and replace engine coolant.
114,000 MILES (182 400KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage (4x4).
117,000 MILES (187 200KM)
²Change engine oil.
²Replace engine oil filter.
JLUBRICATION AND MAINTENANCE 0 - 7
Page 27 of 2158
120,000 MILES (192 000KM)
²Change engine oil.
²Replace engine oil filter.
²Lubricate steering linkage.
²Replace spark plugs.
²Drain and refill automatic transmission fluid.
²Change front and rear axle fluid.*
²Inspect brake linings.
²Replace air cleaner element.
²Replace distributor cap and rotor.
²Replace ignition wires.
²Adjust or replace drive belts.
²Replace fuel filter. See note #1.²Drain and refill transfer case fluid.
NOTE 1:Not required for California vehicles, rec-
ommended for proper vehicle performance.
* Off-highway operation, trailer towing, taxi, limou-
sine, bus, snow plowing, or other types of commercial
service or prolonged operation with heavy loading,
especially in hot weather, require front and rear axle
service indicated witha*inScheduleÐB. Perform
these services if you usually operate your vehicle un-
der these conditions.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
0 - 8 LUBRICATION AND MAINTENANCEJ
Page 34 of 2158
ENGINE MAINTENANCE
INDEX
page page
Accessory Drive Belt....................... 21
Air Cleaner Element....................... 18
Air-Conditioner Compressor.................. 21
Battery................................. 20
Crankcase Ventilation System................ 19
Emission Control System................... 20
Engine Break-In.......................... 15
Engine Cooling System..................... 18
Engine Oil.............................. 15Engine Oil Change and Filter Replacement...... 16
Engine Oil Filter.......................... 17
Engine Supports.......................... 21
Exhaust System.......................... 21
Fuel Filter............................... 19
Fuel Usage StatementÐGas Engines.......... 19
Ignition Cables, Distributor Cap and Rotor....... 20
Rubber and Plastic Component Inspection....... 20
Spark Plugs............................. 20
ENGINE BREAK-IN
CAUTION: Wide open throttle operation in low
gears, before engine break-in period is complete,
can damage engine.
After first starting a new engine, allow it to idle for
15 seconds before shifting into a drive gear. Also:
²Drive the vehicle at varying speeds less than 88
km/h (55 mph) for the first 480 km (300 miles).
²Avoid fast acceleration and sudden stops.
²Do not drive at full-throttle for extended periods of
time.
²Do not drive at constant speeds.
²Do not idle the engine excessively.
A special break-in engine oil is not required. The
original engine oil installed is a high quality, energy
conserving lubricant. Special break-in oils are not
recommended. These oils could interfere with the
normal piston ring seating process.
New engines tend to consume more fuel and oil un-
til after the break-in period has ended.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE IR-
RITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER.
DO NOT WASH SKIN WITH GASOLINE, DIESEL
FUEL, THINNER, OR SOLVENTS, HEALTH PROB-
LEMS CAN RESULT.
DO NOT POLLUTE, DISPOSE OF USED ENGINE
OIL PROPERLY. CONTACT YOUR DEALER OR GOV-
ERNMENT AGENCY FOR LOCATION OF COLLEC-
TION CENTER IN YOUR AREA.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase lu-
bricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied or an oil that conforms to the API Service Grade
SH or SH/CD. MOPAR provides engine oils that con-
form to all of these service grades.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity grade of engine oil. SAE 30 specifies a single
viscosity engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range. Select an engine oil that is best
suited to your particular temperature range and vari-
ation (Fig.1).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommeded for
gasoline engines. They are designated as either EN-
ERGY CONSERVING or ENERGY CONSERVING
II.
Fig. 1 Temperature/Engine Oil Viscosity
JLUBRICATION AND MAINTENANCE 0 - 15
Page 37 of 2158
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used en-
gine oil after it has been drained from a vehicle en-
gine. Refer to the WARNING listed above.
ENGINE COOLING SYSTEM
WARNINGS AND PRECAUTIONS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN.
DISPOSE OF GLYCOL BASE COOLANT PROP-
ERLY, CONTACT YOUR DEALER OR GOVERNMENT
AGENCY FOR LOCATION OF COLLECTION CENTER
IN YOUR AREA.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE, PER-
SONAL INJURY CAN RESULT.
AVOID RADIATOR COOLING FAN WHEN ENGINE
COMPARTMENT RELATED SERVICE IS PER-
FORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Do not use straight antifreeze as engine
coolant, inadequate engine running temperatures
can result.
Do not operate vehicle without proper concentra-
tion of recommended ethylene glycol coolant, high
running temperatures and cooling system corrosion
can result.
The engine cooling system will develop internal
pressure of 97 to 123 kPa (14 to 18 psi) at normal op-
erating temperature. Allow the vehicle approximately
one half hour to cool off before opening the cooling
system. As an indicator of pressure, squeeze the up-
per radiator hose between index finger and thumb. If
it collapses with little effort the system would have
low internal pressure and should be safe to open to
the first safety notch of the radiator cap. Refer to
Group 7, Cooling System.
COOLING SYSTEM INSPECTION
Coolant level should be inspected when other en-
gine compartment service is performed or when cool-
ant leak is suspected. With the engine at normal
operating temperature, observe the coolant level in
thecoolant recovery bottle. The coolant level mustbe at least above the ADD mark and preferably at
the FULL mark. Add coolant to the coolant recovery
bottleonly, if necessary.
Cooling system freeze protection should be tested
at the onset of the winter season or every 12 months.
Service is required if coolant is low, contaminated,
rusty or freeze protection is inadequate. To properly
test cooling system, see Group 7, Cooling System.
The cooling system factory fill is a mixture of 50%
Ethylene Glycol based antifreeze and 50% water. Us-
ing a suitable hydrometer, measure antifreeze con-
centration in the radiator when the engine is cool. If
the cooling system has recently been serviced, allow
coolant to circulate for at least 20 minutes before
taking hydrometer reading. Properly mixed coolant
will protect the cooling system to -37ÉC (-35ÉF). If the
freeze protection is above -28ÉC (-20ÉF), drain enough
coolant from the cooling system to allow room to add
antifreeze to achieve adequate protection. A mix table
on the coolant container indicates the amount of an-
tifreeze required to winterize the cooling system
based on the capacity, see Capacity Chart in General
Information section of this group.
ANTIFREEZE SPECIFICATION
Chrysler Corporation recommends the use of Mo-
par Antifreeze/Coolant or a high quality, ethylene
glycol base antifreeze/coolant, with a silicate inhibi-
tor.
COOLING SYSTEM SERVICE
The cooling system should be drained, flushed and
filled with the proper coolant mixture at the inter-
vals described in the Lubrication and Maintenance
Schedules. Refer to General Information section of
this group. For proper service instructions see Group
7, Cooling System.
AIR CLEANER ELEMENT
The air cleaner element should be serviced at the
intervals described in the Lubrication and Mainte-
nance Schedules sections of this group. Additional in-
formation can be found in Group 14, Fuel System
and Group 25, Emission System. Inspect all air
cleaner hoses or tubes for damage or leaks when
other engine compartment service is performed. Re-
place faulty components.
FILTER ELEMENT SERVICE/REPLACEMENT
CAUTION: The air cleaner cover must be installed
properly for the emissions system and engine con-
troller to function correctly.
Do not immerse paper air filter element in clean-
ing solvents, damage can result.
(1) Remove the air cleaner cover from the body/
housing (Fig. 9).
0 - 18 LUBRICATION AND MAINTENANCEJ
Page 38 of 2158
(2) Remove the air cleaner element from the body/
housing.
(3) Hold a shop light on throttle body side of ele-
ment. Inspect air intake side of element. If element
is saturated with oil or light is not visible, replace fil-
ter. If element is saturated with oil, perform crank-
case ventilation system tests.
(4) Wash the air cleaner cover and body/housing
(Fig. 10) with cleaning solvent and wipe dry.
(5) Install the air cleaner element and attach the
cover to the body/housing.
CRANKCASE VENTILATION SYSTEM
All Jeep 2.5L and 4.0L engines are equipped with a
crankcase ventilation (CCV) system. Refer to Group
25 Emissions, for additional information.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag-
nostic and service procedures refer to Group 14, Fuel
System.
FUEL USAGE STATEMENTÐGAS ENGINES
Jeep vehicles are designed to meet all emission reg-
ulations and provide excellent fuel economy using
high quality unleaded gasoline. Only use unleaded
gasolines having a minimum posted octane of 87.
If a Jeep vehicle develops occasional light spark
knock (ping) at low engine speeds, this is not harm-
ful. However,continued heavy knock at high
speeds can cause damage and should be
checked immediately.
In addition to using unleaded gasoline with the
proper octane rating,those that contain deter-
gents, corrosion and stability additives are rec-
ommended.Using gasolines that have these
additives will help improve fuel economy, reduce
emissions and maintain vehicle performance.
Poor quality gasolinecan cause problems such
as hard starting, stalling and stumble. If these prob-
lems occur, use another brand of gasoline before con-
sidering servicing the vehicle.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
materials that contain oxygen such as alcohol, MTBE
and ETBE. The type and amount of oxygenate used
in the blend is important. The following are generally
used in gasoline blends:
ETHANOL
Ethanol (Ethyl or Grain Alcohol) properly blended,
is used as a mixture of 10 percent ethanol and 90
percent gasoline.Gasoline with ethanol may be
used in your vehicle.
METHANOL
CAUTION: Do not use gasolines containing metha-
nol. Use of methanol/gasoline blends may result in
starting and driveability problems. In addition, dam-
age may be done to critical fuel system compo-
nents.
Methanol (Methyl or Wood Alcohol) is used in a va-
riety of concentrations blended with unleaded gaso-
Fig. 9 Air Cleaner & Filter ElementÐ2.5L and 4.0L
Engines
Fig. 10 Air Cleaner Body/Housing & Cover
JLUBRICATION AND MAINTENANCE 0 - 19
Page 275 of 2158
nostic Procedures manual for diagnostic information
and operation of the DRB scan tool.
To test operation of the fan relay only, refer to Re-
laysÐOperation/Testing. This can be found in Group
14, Fuel Systems.
REMOVAL
The auxiliary cooling fan is attached to the radia-
tor upper crossmember behind the radiator.
(1) Remove the two fan mounting bolts from radi-
ator upper crossmember (Fig. 43).
(2) Disconnect the electric fan connector.
(3) Lift fan straight up and out of vehicle.
INSTALLATION
(1) Align lower retaining tabs of fan shroud with
slots in bracket at bottom of radiator. Push fan down
into position.
(2) Tighten the mounting bolts to 4 Nzm (31 in.
lbs.) torque.
(3) Connect auxiliary cooling fan electrical connec-
tor.
TRANSMISSION OIL COOLERS
WATER-TO-OIL COOLER
All models equipped with an automatic transmis-
sion are equipped with a transmission oil cooler
mounted internally within the radiator tank. This in-
ternal cooler is supplied as standard equipment on
all models equipped with an automatic transmission.
Transmission oil is cooled when it passes through
this separate cooler. In case of a leak in the internalradiator mounted transmission oil cooler, engine cool-
ant may become mixed with transmission fluid or
transmission fluid may enter engine cooling system.
Both cooling system and transmission should be
drained and inspected if the internal radiator
mounted transmission cooler is leaking.
Also refer to the section on Transmission Air-to-Oil
Coolers. This auxiliary air-to-oil cooler is an option
on most engine packages.
REPLACING WATER-TO-OIL COOLER IN
RADIATOR SIDE TANK
The internal transmission oil cooler located within
the radiator is not serviceable. If it requires service,
the radiator must be replaced.
Once the repaired or replacement radiator has
been installed, fill the cooling system and inspect for
leaks. Refer to the Refilling Cooling System and Test-
ing Cooling System For Leaks sections in this group.
If the transmission operates properly after repairing
the leak, drain the transmission and remove the
transmission oil pan. Inspect for sludge and/or rust.
Inspect for a dirty or plugged inlet filter. If none of
these conditions are found, the transmission and
torque convertor may not require reconditioning. Re-
fer to Group 21 for automatic transmission servicing.
AIR-TO-OIL COOLER
An auxiliary air-to-oil transmission oil cooler is
available with most engine packages.
On XJ and YJ models, the cooler is located in front
of the radiator or A/C condenser (if equipped) and be-
hind the grill (Figs. 44, 45 or 46). It is mounted to
the front frame crossmember.
Fig. 43 Auxiliary Cooling FanÐRemove/InstallÐ
Typical
Fig. 44 Auxiliary Air-To-Oil CoolerÐYJ Models
7 - 36 COOLING SYSTEM SERVICE PROCEDURESJ
Page 362 of 2158
(5) Probe cavity B1 of cluster connector A. Check
for continuity to a good ground. There should be no
continuity. If OK, go to next step. If not OK, repair
short circuit as required.
(6) Still probing cavity B1 of cluster connector A,
check for continuity to cavity B of sending unit body
half connector. There should be continuity. If OK, re-
place gauge. If not OK, repair open circuit as re-
quired.
OIL PRESSURE GAUGE
The diagnosis found here addresses an inoperative
gauge condition. If the problem being diagnosed is re-
lated to gauge accuracy, be certain to confirm that
problem is with gauge and not with engine oiling sys-
tem performance. Actual engine oil pressure should
be checked with a test gauge and compared to gauge
readings before you proceed with gauge diagnosis.
Refer to Group 9 - Engines for more information.
(1) Turn ignition switch to ON. Disconnect oil pres-
sure sending unit connector. The sending unit (Fig. 3)
is located on right side of engine block. On 2.5L en-
gine, it is just forward of ignition distributor and just
to the rear of generator mounting bracket. On 4.0L
engine, it is just to the rear of ignition distributor
and above oil filter adapter. The gauge needle should
move to high end of gauge scale. If OK, go to next
step. If not OK, go to step 3.
(2) Install a jumper wire from sending unit wiring
to ground. The gauge needle should move to low end
of gauge scale. If OK, replace sending unit. If not
OK, remove jumper wire and go to next step.
(3) Turn ignition switch to OFF. Disconnect battery
negative cable. Remove instrument cluster bezel and
cluster assembly. Disconnect instrument cluster con-
nector A.
(4) Probe cavity B7 (cavity B8 - RHD) of cluster
connector A. Check for continuity to a good ground.
There should be no continuity. If OK, go to next step.
If not OK, repair short circuit as required.(5) Still probing cavity B7 (cavity B8 - RHD) of
cluster connector A, check for continuity to sending
unit wire connector. There should be continuity. If
OK, replace gauge. If not OK, repair open circuit as
required.
SPEEDOMETER/ODOMETER
The diagnosis found here addresses an inoperative
gauge condition. If the problem being diagnosed is re-
lated to gauge accuracy, be certain to confirm that
problem is with gauge and not with incorrect speed-
ometer pinion, axle ratio or tire size. Refer to Group
21 - Transmission and Transfer Case for more infor-
mation.
(1) Perform vehicle speed sensor test as described
in the appropriate Powertrain Diagnostic Procedures
manual. If OK, go to next step. If not OK, replace ve-
hicle speed sensor.
(2) Disconnect battery negative cable. Unplug vehi-
cle speed sensor, PCM, and daytime running lamp
module connectors. Remove instrument cluster bezel
and cluster assembly. Disconnect instrument cluster
connector A.
(3) Probe cavity A5 (cavity B6 - RHD) of cluster
connector A. Check for continuity to a good ground.
There should be no continuity. If OK, go to next step.
If not OK, repair short circuit as required.
(4) Still probing cavity A5 (cavity B6 - RHD) of
cluster connector A, check for continuity to cavity 1 of
vehicle speed sensor connector (Fig. 4). There should
be continuity. If OK, replace speedometer/odometer. If
not OK, repair open circuit as required.
TACHOMETER
(1) With engine running, check for tachometer sig-
nal at pin 43 of PCM connector (Fig. 5). See Tachom-
eter Calibration chart in Specifications. If OK, go to
next step. If not OK, replace PCM.
Fig. 2 Fuel Gauge Sending Unit ConnectorFig. 3 Oil Pressure Switch/Sending Unit - Typical
8E - 6 INSTRUMENT PANEL AND GAUGESÐXJJ
Page 370 of 2158
(2) Disconnect battery negative cable. Remove in-
strument cluster bezel and cluster assembly. Unplug
cluster connector A. Connect battery negative cable.
Turn headlamps on and select high beam. Check for
battery voltage at cavity A4 of cluster connector A. If
OK, replace indicator bulb. If not OK, repair circuit
to headlamp dimmer (multi-function) switch as re-
quired.
LOW FUEL WARNING LAMP
(1) Check that fuel gauge is operating as designed.
See Fuel Gauge Calibration chart in Specifications. If
OK, go to next step. If not OK, see Fuel Gauge in
this section for diagnosis.
(2) With at least 10 gallons of fuel in fuel tank, un-
plug fuel tank sending unit connector. Turn ignition
switch to ON and wait 10 seconds. Lamp (LED)
should light. Reconnect fuel tank sending unit and
wait 20 seconds. Lamp (LED) should go off. If not
OK, replace low fuel warning lamp module.
LOW OIL PRESSURE WARNING LAMP
The diagnosis found here addresses an inoperative
lamp condition. If the problem being diagnosed is re-
lated to lamp accuracy, be certain to confirm that
problem is with lamp and not with engine oiling sys-
tem. Actual engine oil pressure should be checked
with a test gauge before you proceed with lamp diag-
nosis. Refer to Group 9 - Engines for more informa-
tion.
(1) Turn ignition switch to ON. Lamp should light.
Start engine. Lamp should go off. If not OK, turn en-
gine off and go to next step.
(2) Unplug connector at oil pressure switch (Fig.
3). The switch is located on right side of engine block.
On 2.5L engine, it is just forward of ignition distrib-
utor and just to the rear of generator mounting
bracket. On 4.0L engine, it is just to the rear of igni-
tion distributor and above oil filter adapter. Install a
jumper wire from connector to a good ground. Turn
ignition switch to ON. Lamp should light. Unplug
jumper wire. Lamp should go out. If OK, replace oil
pressure switch. If not OK, go to next step.
(3) Turn ignition switch to OFF. Disconnect battery
negative cable. Remove instrument cluster bezel and
cluster assembly. Install a jumper wire from cavity
B7 (cavity B8 - RHD) of cluster connector A to a good
ground. Connect battery negative cable and turn ig-
nition switch to ON. Lamp should light. If OK, go to
next step. If not OK, replace lamp bulb.
(4) Turn ignition switch to OFF. Disconnect battery
negative cable. Unplug instrument cluster connector
A. Check continuity between cavity B7 (cavity B8 -
RHD) of cluster connector A and a good ground.
There should be no continuity. If OK, go to next step.
If not OK, repair short circuit as required.
(5) Check continuity between cavity B7 (cavity B8
- RHD) of cluster connector A and oil pressure switchconnector. There should be continuity. If not OK, re-
pair open circuit as required.
LOW WASHER FLUID WARNING LAMP
(1) Unplug washer fluid level switch connector.
Turn ignition switch to ON. Check for battery voltage
at connector cavity A. If OK, turn ignition switch to
OFF and go to next step. If not OK, repair open cir-
cuit to fuse F6 in PDC.
(2) Install a jumper wire from cavity A to cavity B
of washer fluid level switch connector. Turn ignition
switch to ON. Lamp should light. Unplug jumper and
lamp should go OFF. If OK, replace washer fluid
level switch. If not OK, go to next step.
(3) Turn ignition switch to OFF. Disconnect battery
negative cable. Remove instrument cluster bezel and
cluster assembly. Unplug instrument cluster (tell-
tale) connector B. Check continuity between cavity 16
(cavity 1 - RHD) of cluster connector B and a good
ground. There should be continuity. If OK, plug clus-
ter connector B back into cluster and go to next step.
If not OK, repair open circuit to ground as required.
(4) Connect battery negative cable. Install a
jumper wire from a 12-volt battery feed to cavity 1
(cavity 16 - RHD) of cluster connector B. Lamp
should light. If OK, go to next step. If not OK, re-
place bulb.
(5) Disconnect battery negative cable. Unplug clus-
ter connector B. Check continuity between cavity 1
(cavity 16 - RHD) of cluster connector B and a good
ground. There should be no continuity. If OK, go to
next step. If not OK, repair short circuit to switch as
required.
(6) Check continuity between cavity 1 (cavity 16 -
RHD) of cluster connector B and cavity B of washer
fluid level switch connector. There should be continu-
ity. If not OK, repair open circuit to switch as re-
quired.
MALFUNCTION INDICATOR LAMP
The diagnosis found here addresses an inoperative
lamp condition. If the lamp comes on and stays on
with engine running, refer to Group 14 - Fuel System
for diagnosis. If no fuel or emission system problem
is found, the following procedure will help locate a
short or open in the lamp circuit.
(1) Disconnect battery negative cable. Unplug PCM
connector. Install a jumper wire from cavity 32 of
PCM connector (Fig. 5) to a good ground. Connect
battery negative cable. Turn ignition switch to ON.
Lamp should light. Remove jumper wire and lamp
should go OFF. If OK, refer to Powertrain Diagnostic
Procedures to check PCM. If not OK, go to next step.
(2) Turn ignition switch to OFF. Disconnect battery
negative cable. Remove instrument cluster bezel and
cluster assembly. Install a jumper wire from cavity 2
(cavity 15 - RHD) of cluster (tell-tale) connector B to
a good ground. Connect battery negative cable. Turn
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Page 384 of 2158
continuity. If OK, go to next step. If not OK, repair
circuit to ground as required.
(4) Remove center instrument cluster bezel and
gauge package cluster assembly. Disconnect cluster
connector.
(5) Probe cavity 6 of cluster connector. Check for
continuity to a good ground. There should be no con-
tinuity. If OK, go to next step. If not OK, repair short
circuit as required.
(6) Still probing cavity 6 of cluster connector, check
for continuity to cavity 2 of sending unit wiring body
half connector. There should be continuity. If OK, re-
place gauge. If not OK, repair open circuit as re-
quired.
OIL PRESSURE GAUGE
The diagnosis found here addresses an inoperative
gauge condition. If the problem being diagnosed is re-
lated to gauge accuracy, be certain to confirm that
problem is with gauge and not with engine oiling sys-
tem performance. Actual engine oil pressure should
be checked with a test gauge and compared to gauge
readings before you proceed with gauge diagnosis.
Refer to Group 9 - Engines for more information.
(1) Turn ignition switch to ON. Disconnect oil pres-
sure sending unit connector. The sending unit (Fig. 3)
is located on right side of engine block. On 2.5L en-
gine, it is just forward of ignition distributor and just
to the rear of generator mounting bracket. On 4.0L
engine, it is just to the rear of ignition distributor
and above oil filter adapter. The gauge needle should
move to high end of gauge scale. If OK, go to next
step. If not OK, go to step 3.
(2) Install a jumper wire from sending unit wiring
to ground. The gauge needle should move to low end
of gauge scale. If OK, replace sending unit. If not
OK, remove jumper wire and go to next step.(3) Turn ignition switch to OFF. Disconnect battery
negative cable. Remove center instrument cluster be-
zel and gauge package cluster assembly. Disconnect
cluster connector.
(4) Probe cavity 9 of cluster connector. Check for
continuity to a good ground. There should be no con-
tinuity. If OK, go to next step. If not OK, repair short
circuit as required.
(5) Still probing cavity 9 of cluster connector, check
for continuity to sending unit wire connector. There
should be continuity. If OK, replace gauge. If not OK,
repair open circuit as required.
SPEEDOMETER/ODOMETER
The diagnosis found here addresses an inoperative
gauge condition. If the problem being diagnosed is re-
lated to gauge accuracy, be certain to confirm that
problem is with gauge and not with incorrect speed-
ometer pinion, axle ratio or tire size. Refer to Group
21 - Transmission and Transfer Case for more infor-
mation.
(1) Perform vehicle speed sensor test as described
in the appropriate Powertrain Diagnostic Procedures
manual. If OK, go to next step. If not OK, replace ve-
hicle speed sensor.
(2) Disconnect battery negative cable. Unplug vehi-
cle speed sensor, PCM, and daytime running lamp
module connectors. Remove left instrument cluster
bezel and main cluster assembly. Disconnect cluster
connector.
(3) Probe cavity 13 of cluster connector. Check for
continuity to a good ground. There should be no con-
tinuity. If OK, go to next step. If not OK, repair short
circuit as required.
(4) Still probing cavity 13 of cluster connector,
check for continuity to cavity 1 of vehicle speed sen-
sor connector (Fig. 4). There should be continuity. If
OK, replace speedometer/odometer. If not OK, repair
open circuit as required.
Fig. 2 Fuel Gauge Sending Unit ConnectorFig. 3 Oil Pressure Sending Unit - Typical
8E - 28 INSTRUMENT PANEL AND GAUGESÐYJJ