molex connectors JEEP XJ 1995 Service And Repair Manual

WIRING DIAGRAMSÐGENERAL INFORMATION
INDEX
page page
Circuit Identification......................... 1
Connector and Terminal Replacement........... 7
Connector Replacement..................... 6
Connectors............................... 2
Diode Replacement........................ 8
Electrostatic Discharge (ESC) Sensitive Devices . . . 2
General Information......................... 1
Intermittent and Poor Connections.............. 4
Notes, Cautions, and Warnings................ 1Symbols................................. 2
Take Outs................................ 2
Terminal Replacement....................... 8
Terminal/Connector RepairÐMolex Connectors.... 6
Troubleshooting Tests....................... 4
Troubleshooting Tools....................... 4
Troubleshooting Wiring Problems.............. 5
Wire Code Identification..................... 1
Wiring Repair............................. 6
GENERAL INFORMATION
This Group is divided into three stand alone sec-
tions; XJ, YJ, and XJ Right Hand Drive (XJ-RHD).
Separate circuit descriptions and wiring diagrams are
provided for each vehicle. Each section contains a
Contents list for the wiring diagrams and circuit de-
scriptions for that vehicle.
The complete XJ circuit descriptions and diagrams
are printed first, followed by those for the YJ and
then the XJ-RHD. The heading at the top of each
page identifies the vehicle covered in the section.
NOTES, CAUTIONS, and WARNINGS
Throughout this group additional important infor-
mation is presented in three ways; Notes, Cautions,
and Warnings.
NOTESare used to help describe how switches or
components operate to complete a particular circuit.
They are also used to indicate different conditions
that may appear on the vehicle. For example, an
up-to and after condition.
CAUTIONSare used to indicate information that
could prevent making an error that may damage the
vehicle.
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
ALWAYS WEAR SAFETY GLASSES FOR EYE PRO-
TECTION.
USE SAFETY STANDS ANYTIME A PROCEDURE RE-
QUIRES BEING UNDER A VEHICLE.
BE SURE THAT THE IGNITION SWITCH ALWAYS IS
IN THE OFF POSITION, UNLESS THE PROCEDURE
REQUIRES IT TO BE ON.SET THE PARKING BRAKE WHEN WORKING ON
ANY VEHICLE. AN AUTOMATIC TRANSMISSION
SHOULD BE IN PARK. A MANUAL TRANSMISSION
SHOULD BE IN NEUTRAL.
OPERATE THE ENGINE ONLY IN A WELL-VENTI-
LATED AREA.
KEEP AWAY FROM MOVING PARTS WHEN THE EN-
GINE IS RUNNING, ESPECIALLY THE FAN AND BELTS.
TO PREVENT SERIOUS BURNS, AVOID CONTACT
WITH HOT PARTS SUCH AS THE RADIATOR, EX-
HAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CON-
VERTER, AND MUFFLER.
DO NOT ALLOW FLAME OR SPARKS NEAR THE
BATTERY. GASES ARE ALWAYS PRESENT IN AND
AROUND THE BATTERY.
ALWAYS REMOVE RINGS, WATCHES, LOOSE
HANGING JEWELRY, AND LOOSE CLOTHING.
WIRE CODE IDENTIFICATION
Each wire shown in the diagrams contains a code
(Fig. 1) which identifies the main circuit, part of the
main circuit, gauge of wire, and color. The color is
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 2).
CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric
code to identify the wire and its function (Fig. 3). To
identify which circuit code applies to a system, refer
to the Circuit Identification Code Chart. This chart
shows the main circuits only and does not show the
secondary codes that may apply to some models.
JWIRING DIAGRAMSÐGENERAL INFORMATION 8W - 1

WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wiring
diagrams. The wires must also be held securely in
place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one side
of the wire. Make sure the tubing will be long enough
to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11
example 2).
(6) Twist the wires together (Fig. 11 example 3).
(7) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation.
(10) Connect battery and test all affected systems.
TERMINAL/CONNECTOR REPAIRÐMOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 12).(4) Using special tool 6742, release the locking fin-
gers on the terminal (Fig. 13).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the connector or terminal as
necessary.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component.
(3) Remove connector locking wedge, if required
(Fig. 14).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 15, and Fig. 16).
Fig. 10 Testing for Voltage DropFig. 11 Wire Repair
Fig. 12 Molex Connector Repair
8W - 6 WIRING DIAGRAMSÐGENERAL INFORMATIONJ

CLUSTER GROUND; INSTRUMENT
CLUSTER (XJ-RHD)................8W-40-2
CLUSTER ILLUMINATION LAMPS . . 8E-16,8E-26,
8E-34,8E-4
CLUSTER, INSTRUMENT; INSTRUMENT
CLUSTER (XJ).....................8W-40-1
CLUSTER, INSTRUMENT; INSTRUMENT
CLUSTER (XJ-RHD)................8W-40-1
CLUSTER, INSTRUMENT; INSTRUMENT
CLUSTER (YJ).....................8W-40-1
CLUSTER (LHD), HIGH-LINE GAUGE.......8E-9
CLUSTER (LHD), TELL-TALE............8E-10
CLUSTER, LOW-LINE GAUGE............8E-8
CLUSTER, MAIN.....................8E-30
CLUSTERS, INSTRUMENT..........8E-24,8E-1
CLUTCH, A/C COMPRESSOR............24-15
CLUTCH AND BRAKE PACK
REQUIREMENTS, AW-4...............21-341
CLUTCH AND BRAKE PEDAL BUSHINGS . . . 0-22
CLUTCH ASSEMBLY, COMPRESSOR......24-20
CLUTCH COMPONENT LUBRICATION......6-10
CLUTCH COMPONENTS..................6-1
CLUTCH, COMPRESSOR...............24-16
CLUTCH CONTAMINATION...............6-3
CLUTCH COVER AND DISC
INSTALLATION........................6-10
CLUTCH COVER AND DISC REMOVAL.....6-10
CLUTCH COVER AND DISC RUNOUT.......6-3
CLUTCH DIAGNOSIS.....................6-3
CLUTCH DISC AND PLATE THICKNESS,
AW-4 .............................21-338
CLUTCH FLUID LEVEL..................6-14
CLUTCH HOUSING MISALIGNMENT........6-4
CLUTCH HOUSING REPLACEMENT........6-13
CLUTCH HYDRAULIC LINKAGE
INSTALLATION........................6-14
CLUTCH HYDRAULIC LINKAGE REMOVAL . . 6-13
CLUTCH INSPECTION, TORQUE
CONVERTER STATOR................21-199
CLUTCH LINKAGE FLUID.................6-1
CLUTCH MASTER CYLINDER............0-22
CLUTCH MISALIGNMENT................6-3
CLUTCH OPERATION....................6-2
CLUTCH OVERHAUL, DIRECT..........21-228
CLUTCH OVERHAUL, OVERDRIVE
PLANETARY GEAR...................21-218
CLUTCH OVERHAUL, SUN GEAR AND
NO. 1 ONE-WAY....................21-238
CLUTCH PEDAL INSTALLATION..........6-15
CLUTCH PEDAL REMOVAL..............6-15
CLUTCH RELAY, A/C COMPRESSOR . 24-15,24-16
CLUTCH RELAY, AIR CONDITIONING
(A/C)..............................14-58
CLUTCH RELAY TEST, TORQUE
CONVERTER........................14-48
CLUTCH RELAY, TORQUE CONVERTER....14-65
CLUTCH RELAYÐPCM OUTPUT, AIR
CONDITIONING (A/C)..................14-26
CLUTCH RELAYÐPCM OUTPUT, TORQUE
CONVERTER........................14-29
CLUTCH SAFETY PRECAUTIONS..........6-10
CLUTCH SERVICE
.....................6-10
CLUTCH SWITCH, FIN SENSING
CYCLING
......................24-15,24-31
CLUTCH (TCC) SOLENOID AND RELAY,
TORQUE CONVERTER; FUEL/IGNITION
(XJ)
.............................8W-30-4
CLUTCH (TCC) SOLENOID AND RELAY,
TORQUE CONVERTER; TRANSMISSION
CONTROLS (YJ)
...................8W-31-1
CLUTCH (TCC) SOLENOID AND
RELAYÐ2.5L ENGINE ONLY, TORQUE
CONVERTER; TRANSMISSION
CONTROLS (XJ)
...................8W-31-1
CLUTCHÐLOW-REVERSE DRUMÐREAR
SUPPORT OVERHAUL, OVERRUNNING
. . . 21-125
CODE DECODING, VEHICLE
...........Intro.-5
CODE DESIGNATIONS, VEHICLE
........Intro.-1
CODE (DTC), DIAGNOSTIC TROUBLE
.....14-54
CODE, GENERATOR DIAGNOSTIC
TROUBLE
...........................8A-22
CODE IDENTIFICATION, WIRE; WIRING
DIAGRAMSÐGENERAL INFORMATION
(XJ)
...............................8W-1
CODE PLATE, VEHICLE
...............Intro.-4
CODE, SPEED CONTROL DIAGNOSTIC
TROUBLE
...........................8H-5CODES AND DIMENSIONS,
DESIGNATIONS, LABELS/PLATES.......Intro.-1
COIL, EVAPORATOR..................24-30
COIL, IGNITION; FUEL SYSTEM.........14-62
COIL, IGNITION; FUEL/IGNITION (XJ) . . . 8W-30-2
COIL, IGNITION; FUEL/IGNITION (YJ) . . . 8W-30-2
COIL, IGNITION; IGNITION SYSTEMS....8D-22,
8D-4,8D-9
COIL, IGNITION; FUEL/IGNITION
(XJ-RHD).........................8W-30-2
COIL RESISTANCE, IGNITION............8D-9
COIL SPRING........................2-14
COILÐPCM OUTPUT, IGNITION.........14-28
COLD CRANKING SPECIFICATIONS, 2.5L
STARTING SYSTEM...................8A-23
COLD CRANKING SPECIFICATIONS, 4.0L
STARTING SYSTEM...................8A-23
COLUMN ASSEMBLY REPLACEMENT.....19-52
COLUMN COMPONENT SERVICE........19-54
COLUMN GENERAL SERVICEÐXJ,
STEERING..........................19-47
COLUMN, NON-TILT STEERING..........19-60
COLUMN REPLACEMENT..............19-58
COLUMN, TILT STEERING..............19-66
COLUMNÐXJ, STEERING..............19-78
COLUMNÐYJ, STEERING.........19-58,19-78
COMBINATION BUZZER; INTERIOR
LIGHTING (YJ)....................8W-44-1
COMBINATION FLASHER; TURN SIGNALS
(XJ).............................8W-52-1
COMBINATION VALVE..................5-34
COMBINATION VALVE INSTALLATION
(WITH ABS), MASTER CYLINDER.........5-20
COMBINATION VALVE REMOVAL (WITH
ABS), MASTER CYLINDER..............5-17
COMBINATION VALVE REPLACEMENT
(NON-ABS)..........................5-16
COMBUSTION PRESSURE LEAKAGE
TEST, CYLINDER.......................9-6
COMBUSTION PRESSURE LEAKAGE
TEST DIAGNOSIS, CYLINDER.............9-7
COMFORT SWITCH, TRANSMISSION;
TRANSMISSION CONTROLS (XJ-RHD) . . 8W-31-1
COMPASS...........................8C-1
COMPASS/DISPLAY SELF-DIAGNOSTIC
TEST...............................8C-2
COMPASS/THERMOMETER DIAGNOSIS....8C-4
COMPENSATION, CALIPER OPERATION
AND WEAR..........................5-45
COMPONENTSÐYJ, EVAPORATIVE
HOUSING............................24-6
COMPONENTSÐYJ, INSTRUMENT
PANEL............................23-152
COMPONENTSÐYJ VEHICLES, BODY....23-102
COMPRESSION PRESSURE TEST,
CYLINDER............................9-5
COMPRESSOR.......................24-19
COMPRESSOR, A/C; AIR CONDITIONING/
HEATER (YJ)......................8W-42-2
COMPRESSOR, AIR-CONDITIONER........0-21
COMPRESSOR CLUTCH...............24-16
COMPRESSOR CLUTCH, A/C............24-15
COMPRESSOR CLUTCH ASSEMBLY......24-20
COMPRESSOR CLUTCH RELAY, A/C . 24-15,24-16
COMPRESSOR SERVICE...............24-19
CONDENSER, A/C
....................24-34
CONDENSER FILTER DRIERÐ2.5L
ENGINES
...........................24-27
CONDENSERÐ4.0L ENGINES
...........24-28
CONDITION, CHECKING FLUID LEVEL
....21-182
CONDITIONING (A/C) CLUTCH RELAY,
AIR
...............................14-58
CONDITIONING (A/C) CLUTCH
RELAYÐPCM OUTPUT, AIR
............14-26
CONDITIONING (A/C) CONTROLSÐPCM
INPUT, AIR
.........................14-21
CONDITIONING, AIR
..................24-37
CONDITIONING CONTROLSÐXJ
VEHICLES, AIR
......................24-15
CONDITIONING CONTROLSÐYJ
VEHICLES, AIR
......................24-16
CONDITIONING, HEATER AND AIR; AIR
CONDITIONING/HEATER (YJ)
.........8W-42-2
CONDITIONING OPERATION, AIR; AIR
CONDITIONING/HEATER (XJ)
.........8W-42-2
CONDITIONING OPERATION, AIR; AIR
CONDITIONING/HEATER (XJ-RHD)
.....8W-42-2CONDITIONING PERFORMANCE TESTS,
AIR ...............................24-12
CONDITIONING SCHEMATICÐXJ, AIR.....24-5
CONDITIONING TEST PROCEDURES,
HEATING AND AIR....................24-15
CONDITIONS, NORMAL OPERATING........5-3
CONNECTING ROD BEARING FITTING
CHART..........................9-41,9-83
CONNECTING RODS, PISTONS.......9-39,9-81
CONNECTIONS, INTERMITTENT AND
POOR; WIRING DIAGRAMSÐGENERAL
INFORMATION (XJ)...................8W-4
CONNECTIONS, RADIO ILLUMINATION
RELAY..............................8F-4
CONNECTIONS, STARTER RELAY........8A-15
CONNECTOR, ABS DIAGNOSTIC.......5-35,5-3
CONNECTOR AND TERMINAL
REPLACEMENT; WIRING DIAGRAMSÐ
GENERAL INFORMATION (XJ)...........8W-7
CONNECTOR, DATA LINK; ANTI-LOCK
BRAKES (XJ)......................8W-32-2
CONNECTOR, DATA LINK; ANTI-LOCK
BRAKES (XJ-RHD).................8W-32-2
CONNECTOR, DATA LINK; ANTI-LOCK
BRAKES (YJ)......................8W-32-2
CONNECTOR, DATA LINK; FUEL/IGNITION
(XJ).............................8W-30-5
CONNECTOR, DATA LINK; FUEL/IGNITION
(YJ).............................8W-30-5
CONNECTOR, DATA LINK;
TRANSMISSION CONTROLS (XJ-RHD) . . 8W-31-1
CONNECTOR, DATA LINK; FUEL/IGNITION
(XJ-RHD)..........................8W-30-4
CONNECTOR LOCATIONS; CONNECTOR
LOCATIONS (XJ)...................8W-90-1
CONNECTOR LOCATIONS; CONNECTOR
LOCATIONS (XJ-RHD)...............8W-90-1
CONNECTOR LOCATIONS; CONNECTOR
LOCATIONS (YJ)...................8W-90-1
CONNECTOR LOCATIONS; CONNECTOR
PIN OUTS (XJ)....................8W-80-1
CONNECTOR LOCATIONS; CONNECTOR
PIN OUTS (XJ-RHD)................8W-80-1
CONNECTOR LOCATIONS; CONNECTOR
PIN OUTS (YJ)....................8W-80-1
CONNECTOR LOCATIONS; WIRING
DIAGRAMS (XJ)......................8W-1
CONNECTOR LOCATIONS; WIRING
DIAGRAMS (XJ-RHD)..................8W-1
CONNECTOR LOCATIONS; WIRING
DIAGRAMS (YJ)......................8W-1
CONNECTOR, POWERTRAIN CONTROL
MODULE (PCM) 60-WAY...............14-40
CONNECTOR REPLACEMENT; WIRING
DIAGRAMSÐGENERAL INFORMATION
(XJ)...............................8W-6
CONNECTORÐPCM INPUT, DATA LINK . . . 14-22
CONNECTORÐPCM OUTPUT, DATA LINK . . 14-27
CONNECTORS; WIRING DIAGRAMSÐ
GENERAL INFORMATION (XJ)...........8W-2
CONNECTORS (RHD), CLUSTER.........8E-11
CONNECTORS, TERMINAL/CONNECTOR
REPAIRÐMOLEX; WIRING
DIAGRAMSÐGENERAL INFORMATION
(XJ)...............................8W-6
CONSOLE, OVERHEAD; OVERHEAD
CONSOLE (XJ)....................8W-49-1
CONSOLE, OVERHEAD; OVERHEAD
CONSOLE (XJ-RHD)................8W-49-1
CONSOLE REMOVE/INSTALL, OVERHEAD . . . 8C-6
CONSOLE SHIFT, DISASSEMBLYÐ
COLUMN OR........................19-60
CONSOLEÐXJ, FULL FLOOR...........23-95
CONSOLEÐXJ, MINI-FLOOR............23-94
CONSOLEÐXJ, OVERHEAD; BODY
COMPONENTSÐXJ VEHICLES..........23-93
CONSOLEÐXJ, OVERHEAD; LAMPS......8L-17
CONSOLESÐYJ, FLOOR..............23-155
CONTACT PATTERN ANALYSIS,
BACKLASH; FRONT SUSPENSION AND
AXLE...............................2-45
CONTACT PATTERN ANALYSIS,
BACKLASH; REAR SUSPENSION AND
AXLES
..............................3-27
CONTACT/CLOCKSPRING, HORN
.........8G-4
CONTAMINATED BRAKELINING
............5-7
CONTAMINATION, BRAKE FLUID
.......5-10,5-7
CONTAMINATION, CLUTCH
...............6-3
JINDEX 5
Description Group-Page Description Group-Page Description Group-Page

RELAY TESTING, AUTOMATIC
SHUTDOWN (ASD)...................14-46
RELAY TESTING, FUEL PUMP...........14-47
RELAY, TORQUE CONVERTER CLUTCH....14-65
RELAY, TORQUE CONVERTER CLUTCH
(TCC) SOLENOID; FUEL/IGNITION (XJ) . . 8W-30-4
RELAY, TORQUE CONVERTER CLUTCH
(TCC) SOLENOID; TRANSMISSION
CONTROLS (YJ)...................8W-31-1
RELAY, TURN SIGNAL; TURN SIGNALS
(XJ-RHD).........................8W-52-1
RELAY, UNLOCK; POWER DOOR LOCKS
(XJ).............................8W-61-1
RELAY, UNLOCK; POWER DOOR LOCKS
(XJ-RHD).........................8W-61-1
RELAYÐ2.5L ENGINE ONLY, TORQUE
CONVERTER CLUTCH (TCC)
SOLENOID; TRANSMISSION
CONTROLS (XJ)...................8W-31-1
RELAYÐPCM OUTPUT, AIR
CONDITIONING (A/C) CLUTCH..........14-26
RELAYÐPCM OUTPUT, AUTO
SHUTDOWN (ASD)...................14-26
RELAYÐPCM OUTPUT, FUEL PUMP......14-27
RELAYÐPCM OUTPUT, RADIATOR FAN . . . 14-28
RELAYÐPCM OUTPUT, TORQUE
CONVERTER CLUTCH.................14-29
RELAYS, POWER LOCK/UNLOCK.........8P-1
RELAY/TIMER, DEFOGGER..............8N-1
RELAY/TIMER REMOVE/INSTALL,
DEFOGGER..........................8N-4
RELEASE AND LOCK HANDLEÐYJ,
FULL-METAL DOOR LATCH INSIDE.......23-137
RELEASE AND LOCK RODSÐXJ, DOOR
INSIDE LATCH.......................23-50
RELEASE BEARING REPLACEMENT.......6-11
RELEASE CABLE REPLACEMENTÐXJ,
LATCH .............................23-11
RELEASE HANDLEÐYJ, FULL-METAL
DOOR LATCH EXTERNAL..............23-140
RELEASE HANDLEÐYJ, TAILGATE LATCH . 23-122
RELEASE PROCEDURE, FUEL PRESSURE . . . 14-6
RELEASE PROCEDURE, FUEL SYSTEM
PRESSURE.........................14-62
RELIEF/ROLLOVER VALVE, FUEL TANK
PRESSURE....................14-16,14-62
RELIEF/ROLLOVER VALVE, PRESSURE . 25-6,25-7
REMINDER INDICATOR (SRI) LAMP,
SERVICE............................25-1
REMOTE GARAGE DOOR OPENER
STORAGE...........................8C-1
REMOTE KEYLESS ENTRY MODULE;
POWER DOOR LOCKS (XJ)...........8W-61-1
REMOVAL, ACCELERATION SWITCH.......5-39
REMOVAL AND INSTALLATION,
30RH/32RH TRANSMISSION...........21-115
REMOVAL AND INSTALLATION, AW-4
TRANSMISSION.....................21-198
REMOVAL, BRAKE PEDAL...............5-31
REMOVAL, BRAKELIGHT SWITCH.........5-32
REMOVAL, CALIPER...................5-48
REMOVAL, CLUTCH COVER AND DISC.....6-10
REMOVAL, CLUTCH HYDRAULIC
LINKAGE............................6-13
REMOVAL, CLUTCH PEDAL..............6-15
REMOVAL, DIFFERENTIAL; FRONT
SUSPENSION AND AXLE................2-34
REMOVAL, DIFFERENTIAL; REAR
SUSPENSION AND AXLES...............3-18
REMOVAL, DISC BRAKESHOE............5-46
REMOVAL, DRUM BRAKESHOE...........5-55
REMOVAL, FRONT WHEEL SENSOR.......5-38
REMOVAL (NON-ABS), MASTER
CYLINDER...........................5-15
REMOVAL, REAR WHEEL SENSOR........5-38
REMOVAL, ROTOR....................5-51
REMOVAL, TRANSFER CASE.....21-287,21-309
REMOVAL, TRANSMISSION........21-35,21-3
REMOVAL, TRANSMISSION AND
CONVERTER.......................21-115
REMOVAL, TRANSMISSION AND
TORQUE CONVERTER................21-198
REMOVAL, TRANSMISSION VALVE BODY
. 21-186
REMOVAL, VALVE BODY
..............21-104
REMOVAL, WHEEL CYLINDER
...........5-57
REMOVAL (WITH ABS), MASTER
CYLINDER AND COMBINATION VALVE
.....5-17
REMOVAL (XJ), HCU
...................5-41REMOVAL (XJ MODELS), ECU...........5-40
REMOVAL (XJ), SHIFT LEVER....21-286,21-309
REMOVAL (XJ WITH ABS), POWER
BRAKE BOOSTER.....................5-24
REMOVAL (XJ WITH FULL CONSOLE),
PARKING BRAKE LEVER................5-63
REMOVAL (XJ WITH MINI CONSOLE),
PARKING BRAKE LEVER................5-62
REMOVAL (XJ WITHOUT ABS), POWER
BRAKE BOOSTER.....................5-29
REMOVAL (XJ WITHOUT CONSOLE),
PARKING BRAKE LEVER................5-64
REMOVAL (YJ), HCU...................5-44
REMOVAL (YJ), PARKING BRAKE PEDAL . . . 5-66
REMOVAL (YJ), POWER BRAKE
BOOSTER............................5-30
REMOVAL (YJ), SHIFT LEVER..........21-286
REMOVAL/DISASSEMBLY, PINION;
FRONT SUSPENSION AND AXLE..........2-36
REMOVAL/DISASSEMBLY, PINION; REAR
SUSPENSION AND AXLES...............3-19
REMOVAL/INSTALLATION, COMPONENT;
EMISSION CONTROL SYSTEMS..........25-7
REMOVAL/INSTALLATION, COMPONENT;
IGNITION SYSTEMS..................8D-17
REMOVAL/INSTALLATION, MULTI-PORT
FUEL INJECTION (MFI)ÐCOMPONENT....14-58
REMOVAL/INSTALLATION (YJ MODELS),
ECU ................................5-41
REMOVAL/INSTALLATIONÐXJ, DOOR....23-35
REMOVE/INSTALL - XJ, ANTENNA........8F-8
REMOVE/INSTALL - XJ, MULTI-
FUNCTION SWITCH....................8J-5
REMOVE/INSTALL - XJ, RADIO...........8F-6
REMOVE/INSTALL - XJ, SOUND BAR......8F-8
REMOVE/INSTALL - XJ, SPEAKERS........8F-6
REMOVE/INSTALL - YJ, ANTENNA.......8F-10
REMOVE/INSTALL - YJ, RADIO...........8F-9
REMOVE/INSTALL - YJ, SOUND BAR.....8F-10
REMOVE/INSTALL - YJ, SPEAKERS........8F-9
REMOVE/INSTALL - YJ, TURN
SIGNAL/HAZARD WARNING SWITCH......8J-5
REMOVE/INSTALL, AIRBAG MODULE.....8M-3
REMOVE/INSTALL, BATTERY.............8B-1
REMOVE/INSTALL, CLUSTER ASSEMBLY . . 8E-17,
8E-35
REMOVE/INSTALL, DEFOGGER
RELAY/TIMER........................8N-4
REMOVE/INSTALL, DEFOGGER SWITCH....8N-4
REMOVE/INSTALL, GAUGES.......8E-17,8-E39
REMOVE/INSTALL, HEADLAMP OR
PANEL DIMMER SWITCH..............8E-42
REMOVE/INSTALL, HEADLAMP SWITCH . . . 8E-19
REMOVE/INSTALL, HORN...............8G-3
REMOVE/INSTALL, HORN SWITCH........8G-3
REMOVE/INSTALL, INSTRUMENT PANEL . . 8E-20
REMOVE/INSTALL, KEYLESS ENTRY
MODULE...........................8P-10
REMOVE/INSTALL, LIFTGATE WASHER
NOZZLE............................8K-24
REMOVE/INSTALL, LIFTGATE WIPER
ARM ..............................8K-17
REMOVE/INSTALL, LIFTGATE WIPER
MOTOR........................8K-20,8K-6
REMOVE/INSTALL, LIFTGATE WIPER/
WASHER SWITCH................8K-24,8K-8
REMOVE/INSTALL, OVERHEAD CONSOLE . . . 8C-6
REMOVE/INSTALL, POWER LOCK
MOTOR.............................8P-8
REMOVE/INSTALL, POWER LOCK
SWITCH.............................8P-8
REMOVE/INSTALL, POWER LOCK/
UNLOCK RELAY......................8P-12
REMOVE/INSTALL, POWER MIRROR......8T-4
REMOVE/INSTALL, POWER MIRROR
SWITCH.............................8T-4
REMOVE/INSTALL, POWER SEAT
ADJUSTER/MOTORS...................8R-3
REMOVE/INSTALL, POWER SEAT
SWITCH
............................8R-3
REMOVE/INSTALL, POWER WINDOW
MOTOR
.............................8S-7
REMOVE/INSTALL, POWER WINDOW
SWITCH
.............................8S-7
REMOVE/INSTALL, PRINTED CIRCUIT
....8E-19,
8E-40
REMOVE/INSTALL, READING/COURTESY
LAMP BULB
.........................8C-8REMOVE/INSTALL, SERVO CABLE.......8H-10
REMOVE/INSTALL, SPEED CONTROL
SERVO.............................8H-9
REMOVE/INSTALL, SPEED CONTROL
SWITCH............................8H-9
REMOVE/INSTALL, STARTER RELAY.......8B-6
REMOVE/INSTALL, SUNGLASSES
STORAGE BIN........................8C-7
REMOVE/INSTALL, VACUUM RESERVOIR . . 8H-10
REMOVE/INSTALL, WASHER PUMP......8K-24
REMOVE/INSTALL, WASHER PUMP/
RESERVOIR..........................8K-8
REMOVE/INSTALL, WINDSHIELD WIPER
ARM ..............................8K-17
REMOVE/INSTALL, WINDSHIELD WIPER
BLADE.............................8K-17
REMOVE/INSTALL, WINDSHIELD WIPER
LINKAGE AND PIVOTS................8K-17
REMOVE/INSTALL, WINDSHIELD WIPER
MOTOR........................8K-19,8K-6
REMOVE/INSTALL, WINDSHIELD
WIPER/WASHER SWITCH..........8K-20,8K-7
REMOVE/INSTALLÐ2.5L, STARTER.......8B-4
REMOVE/INSTALLÐ4.0L, STARTER.......8B-5
REMOVE/INSTALLÐLEFT-HAND DRIVE,
GENERATOR.........................8B-6
REMOVE/INSTALLÐRIGHT-HAND DRIVE,
GENERATOR.........................8B-7
REMOVEÐINSTALL, AIRBAG MODULE....19-49
REPAIR DAMAGED OR WORN THREADS....9-4
REPAIR PRODUCTSÐXJ, AFTERMARKET
PAINT AND TRIM...................23-159
REPAIR PRODUCTSÐYJ, AFTERMARKET
PAINT AND TRIM...................23-160
REPAIR, WIRING; WIRING DIAGRAMSÐ
GENERAL INFORMATION (XJ)...........8W-6
REPAIRING LEAKS....................22-3
REPAIRÐMOLEX CONNECTORS,
TERMINAL/CONNECTOR; WIRING
DIAGRAMSÐGENERAL INFORMATION
(XJ)...............................8W-6
REPAIRÐXJ, STATIONARY GLASS
WATER LEAK DETECTION..............23-76
REPAIRÐYJ, HARD TOP..............23-127
REPAIRÐYJ, STATIONARY GLASS
WATER LEAK DETECTION.............23-150
REPAIRS, FRAME....................13-13
REPAIRS, REAR WINDOW GLASS GRID;
REAR WINDOW DEFOGGER.............8N-3
REPLACEÐCYLINDER HEAD NOT
REMOVED, VALVE COMPONENT......9-23,9-65
REPLACEMENTÐXJ, BACK-UP/REAR
TURN SIGNAL/TAIL LAMP BULB
.........8L-12
REPLACEMENTÐXJ, DOME LAMP
.......8L-17
REPLACEMENTÐXJ, DOOR HINGE/
HINGE PIN
..........................23-52
REPLACEMENTÐXJ, DOOR RESTRAINT
. . . 23-41
REPLACEMENTÐXJ, DRL MODULE
......8L-15
REPLACEMENTÐXJ, FOG LAMP
..........8L-9
REPLACEMENTÐXJ, FOG LAMP SWITCH
. 8L-10
REPLACEMENTÐXJ, FRONT PARK/TURN
SIGNAL LAMP BULB
...................8L-9
REPLACEMENTÐXJ, HEADLAMP BULB
....8L-7
REPLACEMENTÐXJ, HEADLAMP DELAY
MODULE
...........................8L-14
REPLACEMENTÐXJ, HOOD HINGE
.......23-10
REPLACEMENTÐXJ, HOOD LATCH
.......23-11
REPLACEMENTÐXJ, HOOD LATCH
STRIKER
...........................23-11
REPLACEMENTÐXJ, INTERIOR
REARVIEW MIRROR SUPPORT
BRACKET
...........................23-68
REPLACEMENTÐXJ, LATCH RELEASE
CABLE
.............................23-11
REPLACEMENTÐXJ, LIFTGATE SUPPORT
ROD BALL STUD
.....................23-63
REPLACEMENTÐXJ, SAFETY LATCH
STRIKER
...........................23-11
REPLACEMENTÐXJ, SIDE MARKER
LAMP BULB
.........................8L-10
REPLACEMENTÐXJ, UNDERHOOD LAMP
. 8L-13
REPLACEMENTÐXJ, UNDERHOOD LAMP
BULB
..............................8L-13
REPLACEMENTÐXJ VEHICLES, DRIVE
AXLE ASSEMBLY; FRONT SUSPENSION
AND AXLE
...........................2-23
JINDEX 23
Description Group-Page Description Group-Page Description Group-Page

TAILGATE LATCH STRIKERÐYJ........23-123
TAILGATE LOCK CYLINDERÐYJ........23-122
TAILGATE WEATHERSTRIP SEALÐYJ....23-123
TAILGATEÐYJ......................23-121
TAILPIPEÐXJ VEHICLES, MUFFLER AND
EXHAUST............................11-5
TAILPIPEÐYJ VEHICLES, MUFFLER AND
EXHAUST............................11-6
TAKE OUTS; WIRING DIAGRAMSÐ
GENERAL INFORMATION (XJ)...........8W-2
TANK CAPACITIES, FUEL..........14-13,14-67
TANK FILLER TUBE CAP, FUEL;
EMISSION CONTROL SYSTEMS......25-4,25-7
TANK FILLER TUBE CAP, FUEL; FUEL
SYSTEM............................14-13
TANK FILLER TUBE, NO-LEAD FUEL......14-13
TANK, FUEL.........................14-13
TANK PRESSURE RELIEF/ROLLOVER
VALVE, FUEL...................14-16,14-62
TANK SKID PLATE, FUEL...........13-15,13-3
TANK SUPPORT STRAP, FUEL............13-4
TANKS, FUEL...................14-13,14-62
TAPPETS, HYDRAULIC.............9-24,9-66
TELL-TALE CLUSTER (LHD)............8E-10
TEMPERATURE AND PRESSURE CHART,
XJ PERFORMANCE...................24-13
TEMPERATURE AND PRESSURE CHART,
YJ PERFORMANCE...................24-13
TEMPERATURE CONTROL THERMOSTAT . . 24-34
TEMPERATURE GAUGE, ENGINE
COOLANT; INSTRUMENT CLUSTER
(XJ).............................8W-40-1
TEMPERATURE SENSOR, COOLANT.......25-7
TEMPERATURE SENSOR, ENGINE
COOLANT; FUEL SYSTEM..............14-60
TEMPERATURE SENSOR, ENGINE
COOLANT; FUEL/IGNITION (XJ).......8W-30-3
TEMPERATURE SENSOR, ENGINE
COOLANT; FUEL/IGNITION (YJ).......8W-30-3
TEMPERATURE SENSOR, ENGINE
COOLANT; IGNITION SYSTEMS.....8D-19,8D-5
TEMPERATURE SENSOR, ENGINE
COOLANT; FUEL/IGNITION (XJ-RHD) . . . 8W-30-3
TEMPERATURE SENSOR, INTAKE AIR;
FUEL/IGNITION (XJ)................8W-30-4
TEMPERATURE SENSOR, INTAKE AIR;
FUEL/IGNITION (YJ)................8W-30-4
TEMPERATURE SENSOR, INTAKE AIR;
FUEL/IGNITION (XJ-RHD)............8W-30-4
TEMPERATURE SENSOR, INTAKE
MANIFOLD AIR; FUEL SYSTEM..........14-60
TEMPERATURE SENSOR, INTAKE
MANIFOLD AIR; IGNITION SYSTEMS . 8D-23,8D-5
TEMPERATURE, SENSOR RESISTANCE
(OHMS)ÐCOOLANT TEMPERATURE
SENSOR/MANIFOLD AIR...............14-46
TEMPERATURE SENSOR TEST, ENGINE
COOLANT; FUEL SYSTEM..............14-46
TEMPERATURE SENSOR TEST, ENGINE
COOLANT; IGNITION SYSTEMS..........8D-9
TEMPERATURE SENSOR TEST, INTAKE
MANIFOLD AIR; FUEL SYSTEM
..........14-46
TEMPERATURE SENSOR TEST, INTAKE
MANIFOLD AIR; IGNITION SYSTEMS
.....8D-11
TEMPERATURE SENSOR/MANIFOLD AIR
TEMPERATURE, SENSOR RESISTANCE
(OHMS)ÐCOOLANT
..................14-46
TEMPERATURE SENSORÐPCM INPUT,
ENGINE COOLANT
....................14-23
TEMPERATURE SENSORÐPCM INPUT,
INTAKE MANIFOLD AIR
................14-22
TEMPERATURE WARNING LAMP, ENGINE
COOLANT; INSTRUMENT CLUSTER
(XJ)
.............................8W-40-1
TEMPERATURE WARNING LAMP, ENGINE
COOLANT; INSTRUMENT CLUSTER
(XJ-RHD)
.........................8W-40-1
TENSION, DRIVE BELT
.................7-45
TENSION SPECIFICATIONS, BELT
.........7-38
TENSIONER ADJUSTMENT (XJ/YJ),
PARKING BRAKE CABLE
................5-69
TENSIONER REPLACEMENT (XJ),
PARKING BRAKE CABLE
................5-66
TENSIONERÐXJ MODELS WITH RIGHT
HAND DRIVE, AUTOMATIC BELT
..........7-42
TENSIONÐEXCEPT RIGHT HAND DRIVE
(RHD), BELT
.........................7-38TENSIONÐEXCEPT RIGHT HAND DRIVE
(RHD) MODELS, BELT..................7-45
TENSIONÐRIGHT HAND DRIVE (RHD),
BELT ...............................7-38
TERMINAL REPLACEMENT; WIRING
DIAGRAMSÐGENERAL INFORMATION
(XJ)...............................8W-8
TERMINAL REPLACEMENT, CONNECTOR;
WIRING DIAGRAMSÐGENERAL
INFORMATION (XJ)...................8W-7
TERMINAL/CONNECTOR REPAIRÐ
MOLEX CONNECTORS; WIRING
DIAGRAMSÐGENERAL INFORMATION
(XJ)...............................8W-6
TEST, AUTOMATIC SHUTDOWN (ASD)
RELAY..............................8D-6
TEST, CAMSHAFT POSITION SENSOR;
FUEL SYSTEM.......................14-46
TEST, CAMSHAFT POSITION SENSOR;
IGNITION SYSTEMS...................8D-6
TEST, COMPASS/DISPLAY SELF-
DIAGNOSTIC.........................8C-2
TEST, CONVERTER STALL..............21-74
TEST, CRANKSHAFT POSITION SENSOR;
FUEL SYSTEM.......................14-47
TEST, CRANKSHAFT POSITION SENSOR;
IGNITION SYSTEMS...................8D-7
TEST, CYLINDER COMBUSTION
PRESSURE LEAKAGE...................9-6
TEST, CYLINDER COMPRESSION
PRESSURE...........................9-5
TEST DIAGNOSIS, CYLINDER
COMBUSTION PRESSURE LEAKAGE........9-7
TEST, ENGINE COOLANT TEMPERATURE
SENSOR; FUEL SYSTEM................14-46
TEST, ENGINE COOLANT TEMPERATURE
SENSOR; IGNITION SYSTEMS...........8D-9
TEST, EXTENDED IDLE SWITCH.........14-48
TEST, FUEL INJECTOR.................14-51
TEST, FUEL PRESSURE LEAK DOWN......14-8
TEST, FUEL PUMP CAPACITY............14-7
TEST, FUEL SYSTEM PRESSURE....14-51,14-6
TEST, HYDRAULIC PRESSURE....21-177,21-72
TEST, IDLE AIR CONTROL MOTOR.......14-49
TEST, INTAKE MANIFOLD AIR
TEMPERATURE SENSOR; FUEL
SYSTEM............................14-46
TEST, INTAKE MANIFOLD AIR
TEMPERATURE SENSOR; IGNITION
SYSTEMS..........................8D-11
TEST, MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR; FUEL SYSTEM.........14-47
TEST, MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR; IGNITION SYSTEMS.....8D-11
TEST, MANUAL SHIFTING.............21-177
TEST, MASTER CYLINDER/POWER
BOOSTER............................5-8
TEST, OXYGEN SENSOR (O2S) HEATING
ELEMENT...........................14-48
TEST, POWER BOOSTER CHECK VALVE.....5-9
TEST, POWER BOOSTER VACUUM.........5-9
TEST PROCEDURES, HEATING AND AIR
CONDITIONING......................24-15
TEST, REFRIGERANT SERVICE AND
PERFORMANCE......................24-11
TEST, STARTER MOTOR RELAY.........14-51
TEST, THROTTLE POSITION SENSOR.....8D-15
TEST, THROTTLE POSITION SENSOR
(TPS)..............................14-48
TEST, TORQUE CONVERTER CLUTCH
RELAY
.............................14-48
TEST, TORQUE CONVERTER STALL
.....21-178
TEST, VACUUM SUPPLY
................8H-6
TEST, VEHICLE SPEED SENSOR
.........14-48
TESTING, AUTOMATIC SHUTDOWN
(ASD) RELAY
........................14-46
TESTING COOLING SYSTEM FOR LEAKS
. . . 7-22
TESTING, FUEL PUMP RELAY
...........14-47
TESTING, INTERMITTENT WIPE SWITCH
. . 8K-15
TESTING, NON-INTERMITTENT WIPE
SWITCH
............................8K-14
TESTING PROCEDURESÐXJ, MULTI-
FUNCTION SWITCH
....................8L-4
TESTING REFRIGERANT, LEAK
..........24-11
TESTING, ROAD
.......................5-5
TESTING SPECIFICATIONS, 2.5L
STARTER AND SOLENOID
..............8A-23TESTING SPECIFICATIONS, 4.0L
STARTER AND SOLENOID..............8A-23
TESTING, TRANSMISSION COOLER
FLOW.............................21-113
TESTS, AIR CONDITIONING
PERFORMANCE......................24-12
TESTS, IGNITION SWITCH CONTINUITY . . . 8D-30
TESTS, OXYGEN (O2S) SENSOR........8D-15
TESTS, SYSTEM......................8N-1
TESTS, TROUBLESHOOTING; WIRING
DIAGRAMSÐGENERAL INFORMATION
(XJ)...............................8W-4
TESTS, WATER PUMP..................7-13
THERMOMETER......................8C-1
THERMOMETER DIAGNOSIS.............8C-2
THERMOSTAT........................7-17
THERMOSTAT, TEMPERATURE CONTROL . . 24-34
THERMOSTATIC CONTROL.............24-16
THICKNESS, AW-4 CLUTCH DISC AND
PLATE ............................21-338
THICKNESS, DISC BRAKE ROTOR........5-52
THIS GROUP, HOW TO USE; WIRING
DIAGRAMS (XJ)......................8W-1
THIS GROUP, HOW TO USE; WIRING
DIAGRAMS (XJ-RHD)..................8W-1
THIS GROUP, HOW TO USE; WIRING
DIAGRAMS (YJ)......................8W-1
THREAD NOTATIONÐSAE AND METRIC . Intro.-13
THREADS, REPAIR DAMAGED OR WORN....9-4
THROTTLE BODY.................14-33,14-64
THROTTLE CABLE....................14-17
THROTTLE CABLE, ACCELERATOR
PEDAL........................14-17,14-58
THROTTLE CABLE ADJUSTMENT,
TRANSMISSION.....................21-194
THROTTLE CABLE REPLACEMENT,
TRANSMISSION.....................21-193
THROTTLE POSITION SENSOR;
FUEL/IGNITION (XJ)................8W-30-4
THROTTLE POSITION SENSOR;
FUEL/IGNITION (YJ)................8W-30-4
THROTTLE POSITION SENSOR; IGNITION
SYSTEMS...........................8D-5
THROTTLE POSITION SENSOR;
FUEL/IGNITION (XJ-RHD)............8W-30-4
THROTTLE POSITION SENSOR TEST.....8D-15
THROTTLE POSITION SENSOR (TPS);
FUEL SYSTEM.......................14-65
THROTTLE POSITION SENSOR (TPS);
IGNITION SYSTEMS..................8D-25
THROTTLE POSITION SENSOR (TPS)
SERVICE..........................21-193
THROTTLE POSITION SENSOR (TPS)
TEST..............................14-48
THROTTLE POSITION SENSOR
(TPS)ÐPCM INPUT...................14-25
THROTTLE VALVE CABLE ADJUSTMENT,
TRANSMISSION......................21-71
THROTTLE VALVE CABLE ADJUSTMENT
(XJ/YJ)............................21-101
THROUGH DEEP WATER PUDDLES,
BRAKES DO NOT HOLD AFTER
DRIVING.............................5-7
TIE ROD ......................19-16,19-19
TIGHTENING, WHEEL NUT..........5-54,5-59
TILT STEERING COLUMN..............19-66
TIME LAG TEST.....................21-178
TIME TABLE, BATTERY CHARGING........8A-8
TIMING CASE COVER..............9-31,9-72
TIMING CASE COVER OIL SEAL
REPLACEMENT...................9-30,9-73
TIMING CHAIN AND SPROCKETS.....9-31,9-73
TIMING, IGNITION....................8D-11
TIMING, VALVE...................9-30,9-71
TIPS, TRANSMISSION ASSEMBLY......21-155
TIRE AND WHEEL BALANCE.............22-6
TIRE AND WHEEL RUNOUT.............22-8
TIRE CARRIERÐYJ, EXTERNAL
SPARE/WHEEL......................23-133
TIRE INFLATION PRESSURES............22-2
TIRE NOISE OR VIBRATION.............22-4
TIRE PROBLEMS, WHEEL................5-7
TIRE WEAR PATTERNS
.................22-4
TIRES; LUBRICATION AND
MAINTENANCE
.......................0-32
TIRES; WHEELS AND TIRES
.............22-1
TIRES, CLEANING OF
..................22-2
TIRES, REPLACEMENT
.................22-2
JINDEX 29
Description Group-Page Description Group-Page Description Group-Page