ignition JEEP YJ 1995 Service And Repair Manual

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

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

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

²Do not allow passengers to ride in a vehicle being
towed.
²Always observe state and local laws regarding tow-
ing regulations.²Do not tow a vehicle in a manner that could jeop-
ardize the safety of the operator, pedestrians or other
motorists.
²Do not attach tow chains, T-hooks, J-hooks, or a
tow sling to a bumper, steering linkage, drive shafts
or a non-reinforced frame hole.
GROUND CLEARANCE AND RAMP ANGLE
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehicle should be raised until lifted wheels
are a minimum 100 mm (4 in) from the ground. Be
sure there is adequate ground clearance at the oppo-
site end of the vehicle, especially when towing over
rough terrain or steep rises in the road. If necessary,
remove the wheels from the lifted end of the vehicle
and lower the vehicle closer to the ground, to in-
crease the ground clearance at the opposite end of
the vehicle. Install lug nuts on wheel attaching studs
to retain brake drums.
FLAT-BED TOWING RAMP ANGLE
If a vehicle with flat-bed towing equipment is used,
the approach ramp angle should not exceed 15 de-
grees.
TWO-WHEEL-DRIVE VEHICLE TOWINGÐXJ
Chrysler Corporation recommends that a vehicle be
towed with the rear end lifted, whenever possible.
TOWING-REAR END LIFTED (SLING-TYPE)
CAUTION: Do not use steering column lock to se-
cure steering wheel during towing operation.
2WD XJ vehicles can be towed with the front
wheels on the surface for extended distances at
speeds not exceeding 48 km/h (30 mph).
(1) Attach J-hooks around the axle shaft tube out-
board of the shock absorber.
(2) Place the sling crossbar under and forward of
the bumper.
(3) Attach safety chains around the frame rails.
(4) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(5) Secure steering wheel in the straight ahead po-
sition with a clamp device designed for towing.
(6) Verify that steering components are in good
condition.
(7) Shift the transmission to NEUTRAL.
Fig. 3 Correct Vehicle Lifting LocationsÐTypical
Fig. 4 Tow Vehicles With Approved Equipment.
JLUBRICATION AND MAINTENANCE 0 - 11

TOWING-FRONT END LIFTED (SLING-TYPE)
CAUTION: Many vehicles are equipped with air
dams, spoilers, and/or ground effect panels. To
avoid component damage, a wheel-lift towing vehi-
cle or a flat-bed hauling vehicle is recommended.
If a 2WD XJ vehicle cannot be towed with the rear
wheels lifted, it can be towed with the front wheels
lifted.
(1) Attach a J-hook to the disabled vehicle at the
left side of the axle.
(2) Position the sling crossbar close to the J-hook
and below the front bumper.
(3) Secure a chain to the right side of vehicle by
placing it over the axle shaft tube and attaching it to
a structural member (Fig. 5).
(4) Attach the safety chains to the vehicle.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
2WD-AUTOMATIC TRANSMISSION
Provided the transmission is operable, tow only in
NEUTRALat speeds not to exceed 30 mph (50
km/h) and distances less than 15 miles (25km/h).
If the vehicle is to be towed more than 15 miles,
the propeller shaft should be disconnected or place
tow dollies under rear wheels.
2WD-MANUAL TRANSMISSION
To reduce the possible damage of transmission com-
ponents, the propeller shaft must be removed or
place tow dollies under the rear wheels before tow-
ing. Refer to Propeller Shafts, Group 16 for proper
removal procedure.
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysler Corporation recommends that a vehicle be
transported on a flat-bed device. A Wheel-lift or
Sling-type device can be used provided all the wheels
are lifted off the ground using tow dollies.
TOWING-REAR END LIFTED (SLING-TYPE)
4WD XJ VEHICLES
(1) Raise the front of the vehicle off the ground
and install tow dollies under front wheels.
(2) Attach J-hooks around the rear axle shaft tube
outboard of the shock absorber.
(3) Place the sling crossbar under and forward of
the bumper.
(4) Attach safety chains around the frame rails.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(6) Secure steering wheel in the straight ahead po-
sition with a clamp device designed for towing.
(7) Shift the transfer case to NEUTRAL.
4WD YJ VEHICLES
Use Wheel-Lift equipment and Tow Dollies
when towing from the rear end of the vehicle.
TOWING-FRONT END LIFTED (SLING-TYPE)
4WD XJ VEHICLES
(1) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(2) Attach a J-hook to the disabled vehicle at the
left side of front the axle.
(3) Position the sling crossbar close to the J-hook
and below the front bumper (Fig. 6).
(4) Secure a chain to the right side of vehicle by
placing it over the axle shaft tube and attaching it to
a structural member
(4) Attach the safety chains to the vehicle.
(5) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(6) Shift transfer case to NEUTRAL.
Fig. 5 Sling-Type, Front-End Towing (XJ Rear View)
Fig. 6 Sling-Type, Front-End Towing (XJ Front View)
0 - 12 LUBRICATION AND MAINTENANCEJ

4WD YJ VEHICLES
(1) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
CAUTION: Use tow chains with T-hooks for con-
necting to the disabled vehicle's frame rails. Never
use J-hooks.
(2) Attach the T-hooks to the slots in the front end
of each frame rail (Fig. 7).
(3) Position each safety chain over the top of each
front spring and inboard of each front spring shackle.
(4) Double wrap each chain.
(5) Position the sling crossbar under the front
bumper.
(6) Turn the ignition switch to the OFF position to
unlock the steering wheel.
(7) Shift the transfer case to NEUTRAL.
TOWING WHEN KEYS ARE NOT AVAILABLE
When the vehicle is locked and keys are not avail-
able, use a flat bed hauler. A Wheel-lift or Sling-type
device can be used provided all the wheels are lifted
off the ground using tow dollies (Fig. 8).
EMERGENCY TOW HOOKS
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.
Some Jeep vehicles are equipped with front and
rear emergency tow hooks (Fig. 9). The tow hooks
should be used forEMERGENCYpurposes only.CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
FLAT TOWING (4 TIRES/WHEELS ON
SURFACE)
Tow a vehicle in this manner only when all four
wheels will freely rotate. Prepare the vehicle accord-
ing to the following procedures.
2WD VEHICLES
(1) Mark the drive shaft and the axle drive pinion
gear shaft yoke for installation alignment reference.
(2) Remove the drive shaft. Install a protective cov-
ering over the drive shaft U-joints to retain them as-
sembled and protected.
Fig. 7 Sling-Type, Front-End Towing (YJ Vehicles)
Fig. 8 Sling-Type, Front-End Towing With Rear
Wheels On A Tow Dolly
Fig. 9 Emergency Front Tow HooksÐXJ & YJ
Vehicles
JLUBRICATION AND MAINTENANCE 0 - 13

(3) Cover the open end of the transmission exten-
sion housing.
4WD VEHICLESÐXJ
(1) Shift transfer case lever to NEUTRAL.
(2) Place ignition switch in the unlocked position.
4WD VEHICLESÐYJ
CAUTION: Follow these steps to be certain that the
transfer case is fully in N (NEUTRAL) and that the
axle is completely disengaged before flat towing to
prevent damage to internal parts.
(1) Shift transfer case into 2H and check that the
4WD light goes out.
(2) Start engine and drive the vehicle 3 mm (10 ft.)
rearward and then 3 mm (10 ft.) forward to make
sure the axle is disengaged.(3) Shift transmission to Neutral.
(4) Turn off engine with the ignition key in the un-
locked OFF position.
(5) Shift transfer case lever from 2H to N (NEU-
TRAL) position.
(6) Shift manual transmission into gear or auto-
matic transmission into P (PARK).
WARNING: WITH THE TRANSFER CASE IN NEU-
TRAL POSITION, THE VEHICLE COULD ROLL UN-
EXPECTEDLY. THE PARKING BRAKE SHOULD
ALWAYS BE APPLIED BEFORE THE TOW BAR IS
ATTACHED.
(7) Attach vehicle to the tow vehicle with tow bar.
CAUTION: Do not use a bumper mounted clamp-on
tow bar, damage to bumper face bar may occur.
0 - 14 LUBRICATION AND MAINTENANCEJ

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

line. You may encounter fuels containing 3 percent or
more methanol along with other alcohols called cosol-
vents.
Problems that are the result of using methanol/gas-
oline blends are not the responsibility of Chrysler
Corporation. They may not be covered by the vehicle
warranty.
MTBE/ETBE
Gasoline and MTBE (Methyl Tertiary Butyl Ether)
blends are a mixture of unleaded gasoline and up to
15 percent MTBE. Gasoline and ETBE (Ethyl Ter-
tiary Butyl Ether) are blends of gasoline and up to
17 percent ETBE. Gasoline blended with MTBE or
ETBE may be used.
CLEAN AIR GASOLINE
Many gasolines are now being blended that con-
tribute to cleaner air, especially in those areas of the
country where air pollution levels are high. These
new blends provide a cleaner burning fuel and some
are referred to asReformulated Gasoline.
In areas of the country where carbon monoxide lev-
els are high, gasolines are being treated with oxygen-
ated materials such as MTBE, ETBE and ethanol.
Chrysler Corporation supports these efforts toward
cleaner air and recommends the use of these gaso-
lines as they become available.
IGNITION CABLES, DISTRIBUTOR CAP AND
ROTOR
Inspect and test ignition cables, distributor cap and
rotor when the spark plugs are replaced. Oil and
grime should be cleaned from the ignition cables and
distributor cap to avoid possible spark plug fouling.
Mopar Foamy Engine Degreaser or equivalent is rec-
ommended for cleaning the engine compartment. For
proper service and diagnostic procedures refer to
Group 8D, Ignition System.
IGNITION TIMING
The ignition timing for 2.5L and 4.0L engines is
not adjustable. Refer to the specifications listed on
the engine Emission Control Information Label. Re-
fer to Group 25, Emission Control Systems for addi-
tional information.
SPARK PLUGS
Ignition spark plugs should be replaced at the
mileage interval described in the Lubrication and
Maintenance Schedules. Refer to the General Infor-
mation section of this group. For proper service pro-
cedures refer to Group 8D, Ignition Systems.
BATTERY
WARNING: WEAR SAFETY GLASSES, RUBBER
GLOVES AND PROTECTIVE CLOTHING WHEN HAN-DLING/SERVICING A BATTERY. THE BATTERY
ELECTROLYTE CONTAINS SULFURIC ACID AND
WILL CAUSE HARM IF IT CONTACTS SKIN, EYES
OR CLOTHING. IT WILL ALSO DAMAGE PAINTED
(AS WELL AS UN-PAINTED) SURFACES OF A VEHI-
CLE. IF SULFURIC ACID CONTACTS ANY OF
THESE, FLUSH IMMEDIATELY WITH LARGE
AMOUNTS OF WATER. IF SULFURIC ACID CON-
TACTS SKIN OR EYES, GET IMMEDIATE MEDICAL
ATTENTION. DO NOT SMOKE IN THE VICINITY OF A
BATTERY. KEEP OPEN FLAMES AND SPARKS
AWAY FROM BATTERY FILLER CAPS BECAUSE
EXPLOSIVE GAS IS ALWAYS PRESENT.
Inspect battery tray, hold down and terminal con-
nections when other under hood service is performed.
For proper diagnostic procedures refer to Group 8A,
Battery/Starting/Charging System Diagnostics. For
service and cleaning procedures refer to Group 8B,
Battery/Starter Service.
Care should be taken when disposing a bat-
tery after removal from a vehicle. Lead-acid
batteries are highly poisonous and, when indis-
criminately disposed, could create a problem
for the environment. Contact the applicable lo-
cal city or county government agency to deter-
mine where automobile (lead-acid) batteries
can be properly disposed in the local area.
RUBBER AND PLASTIC COMPONENT INSPECTION
CAUTION: Plastic hoses or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds.
Position plastic or rubber components away from
moving parts in engine compartment or under vehi-
cle, or damage will result.
Do not allow rubber engine mounts or other com-
ponents to become oil contaminated, repair cause
of oil contamination and clean area.
All rubber and plastic components should be in-
spected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deteriora-
tion of rubber components, Chrysler Corporation rec-
ommends Mopar Foamy Engine Degreaser or
equivalent be used to clean engine compartment of
oil and road grime.
EMISSION CONTROL SYSTEM
Inspect all emission control components and hoses
when other under hood service is performed. Refer to
emission system Vacuum Hose Label located on the
inside of the hood in the engine compartment and
Group 25, Emission Control Systems for proper ser-
vice procedures.
0 - 20 LUBRICATION AND MAINTENANCEJ

(5) Inspect the reservoir rubber diaphragm seal for
cracks, cuts and distortion.
(6) Inspect the brake fluid tubing fittings and the
master cylinder housing for indications of fluid leak-
age. Repair as necessary.
(7) Install the brake fluid reservoir cover.
ANTI-LOCK BRAKE SYSTEMÐXJ VEHICLES
The anti-lock brake system fluid reservoir for XJ
Vehicles is located in the engine compartment at the
left side of the dash panel.
(1) Turn the ignition switch ON and allow the
pump motor to operate until it automatically de-en-
ergizes.
(2) Clean the cover before removing it.
CAUTION: Over-filling could cause fluid overflow
and possible reservoir damage when the pump mo-
tor energizes.
(3) The brake fluid level should be no lower than
the ADD indicator on the side of the reservoir (Fig.
8). If not, add brake fluid as necessary. Raise the
fluid level to the FULL indicator only. Do not over-fill
the reservoir.
(4) Turn the ignition switch OFF.
BRAKE SYSTEM INSPECTION
A brake system inspection should be included with
all brake service procedures, and also each time the
vehicle is lubricated.
(1) Inspect the brake pads and linings for excessive
wear, cracks, charred surfaces and broken rivets.
(2) Inspect brake pads and linings for contamina-
tion from brake fluid, and/or other fluids.
(3) Replace the brake pads linings if they are worn
to within 0.78 mm (1/32 in) of the rivet head.
(4) Operate the rear brake self-adjuster lever and
pivot. Test the operation of the self-adjuster screw for
ease of movement.
(5) Inspect the self-adjuster components for wear
or damage.
(6) Inspect the disc brake caliper dust boot for
damage and indications of brake fluid leakage. In-
spect the bushings and pins for corrosion, tears and a
binding condition.
(7) Pull the rear wheel cylinder dust boot back to
expose the wheel cylinder housing. Inspect for fluid
leaks. Inspect the pistons and cylinder bores.
(8) Inspect the brake differential warning valve
and housing for indications of leakage.
BRAKE FLUID HOSES/TUBING
The rubber brake fluid hoses should be inspected
for:
²Correct length
²Severe surface cracking
²Swelling
²Pulling
²Scuffing
²Excessively worn areas
If the hose has cracks or abrasions in the rub-
ber cover, the hose should be replaced.
(1) Inspect all the hoses for kinks, a distorted con-
dition and fluid leakage.
(2) Inspect the hose and tubing routing under the
vehicle. Verify that no hose/tubing is rubbing against
any exhaust or other underbody components.
PARKING BRAKE
(1) Engage the parking brake pedal and then re-
lease it.
(2) Test it for smooth operation and vehicle-holding
capability.
(3) Inspect the parking brake cables.
(4) With the parking brake released, the rear
wheels should
rotate without restriction. Adjust the parking brake
cable tension, if necessary (Fig. 9 and 10).
(5) Repair any parking brake malfunctions.
BRAKE OPERATIONAL TEST
(1) Drive the vehicle and test for proper brake ac-
tion.
Fig. 7 Reservoir Fluid LevelÐYJ (2.5L)
Fig. 8 Reservoir Fluid LevelÐYJ-XJ and Anti-Lock
Brake System
JLUBRICATION AND MAINTENANCE 0 - 31