1994 JEEP CHEROKEE Power steering

ROUTINE SERVICE
The following routine vehicle service is highly rec-
ommended on a monthly basis.
TIRESÐInspect the tires for unusual wear/damage
and determine if the inflation pressure is acceptable
for the vehicle load.
BATTERYÐInspect and clean the terminals.
Tighten the terminals, if necessary.
FLUIDSÐDetermine if the coolant, brake fluid,
power steering, automatic transmission, and clutch
fluid level are acceptable. Add fluid, if necessary.
LIGHTS/ELECTRICALÐTest all the electrically
operated systems in the vehicle for proper operation.
It is also recommended that the engine oil level
and the windshield washer fluid level be deter-
mined (and corrected) during each fuel fill-up.
FUEL REQUIREMENTS
All Jeeptengines require the use of unleaded gas-
oline. In addition, the fuel must have a minimum oc-
tane rating of 87.
CAUTION: UNLEADED FUEL ONLY must be used in
vehicles equipped with a catalyst emission control
system. All vehicles have reminders printed on the
instrument panel (Fig. 1) and on the fuel filler door
(Fig. 2). Vehicles also have fuel filler tubes that are
designed to accept only the small-diameter un-
leaded gasoline nozzles. It is illegal to defeat the
design of an unleaded fuel filler tube.
CLASSIFICATION OF LUBRICANTS
Lubricating fluids and chassis component lubri-
cants are classified and graded according to stan-
dards recommended by the:
²Society of Automotive Engineers (SAE),²American Petroleum Institute (API), and
²National Lubricating Grease Institute (NLGI).
ENGINE OIL
SAE VISCOSITY GRADE
An SAE viscosity grade is used to specify viscosity
of engine oil. SAE 30 specifies a single viscosity en-
gine oil. Engine oils also have multiple viscosities
(Fig. 3).
The viscosity grade of an oil is an indicator of its
thickness or flow capability. The lower the number,
the better the flow. The second viscosity grade num-
ber (without a W suffix) is the warm/hot-temperature
viscosity. The viscosity increases with engine temper-
ature. With a single viscosity grade, the oil viscosity
is valid only for one narrow temperature range.
Fig. 1 Unleaded Fuel Only RemindersÐFuel Gauge
Fig. 2 Unleaded Fuel Only ReminderÐFuel Filler
Door
Fig. 3 SAE Oil Viscosity Grade & API Service Grade
0 - 2 LUBRICATION AND MAINTENANCEJ

MAINTENANCE SCHEDULES
INTRODUCTION
Chrysler Corporation has compiled recommended
lubrication and maintenance schedules and proce-
dures to help reduce premature wear or failure over
a broad range of operating conditions.
SEVERE SERVICE MAINTENANCE
If the vehicle is involved with a severe driving con-
dition, after each 4 800-km (3,000-miles)/3-month in-
terval. A severe driving condition includes:
²frequent short trip driving less than 24 km (15
miles);
²frequent driving in a dusty environment;
²trailer towing;
²extensive engine idling;
²sustained high-speed operation;
²desert operation;
²frequent starting and stopping;
²cold-climate operation;
²off-road driving; or
²commercial service.
MAINTENANCE SCHEDULES
AT EACH STOP FOR FUEL
²Check engine oil level, add as required.
²
Check windshield washer solvent and add if required.
ONCE A MONTH
²Check tire pressure and look for unusual wear or
damage.
²Inspect battery and clean and tighten terminals as
required.
²Check electrolyte level and add water as needed.
²Check fluid levels of coolant reservoir, power steer-
ing and transmission and add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check rubber seals on each side of the radiator for
proper fit.
7,500 MILES (12 000 KM) OR AT 6 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Rotate Tires.
15,000 MILES (24 000 KM) OR AT 12 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.²Check fluid level in battery.
²Rotate Tires.
22,500 MILES (36 000 KM) OR AT 18 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Rotate Tires.
30,000 MILES (48 000 KM) OR AT 24 MONTHS
²Replace air cleaner filter.
²Replace spark plugs.
²Adjust drive belt.
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Check fluid level in battery.
²Drain and refill automatic transmission.
²Drain and refill transfer case.
²Rotate Tires.
37,500 MILES (60 000 KM) OR AT 30 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Drain and refill manual transmission.
²Rotate Tires.
45,000 MILES (72 500 KM) OR AT 36 MONTHS
²Check engine coolant level, hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Check fluid level in battery.
²Rotate Tires.
52,500 MILES (84 500 KM) OR AT 42 MONTHS
²Flush and replace engine coolant.
²Check engine coolant system hoses and clamps.
²Change engine oil.
²Replace engine oil filter.
²Check exhaust system.
²Lubricate steering linkage (4x4 models).
²Lubricate propeller shaft universal joints.
²Rotate Tires.
JLUBRICATION AND MAINTENANCE 0 - 5

CHASSIS AND BODY COMPONENTS
INDEX
page page
Body Components........................ 34
Chassis Component and Wheel Bearing
Lubricants............................ 30
Front Wheel Bearings..................... 31
Headlamps............................. 35Manual Steering GearÐYJ Vehicles.......... 32
Power Brake System...................... 32
Power Steering System.................... 31
Steering Linkage and Ball Studs............. 30
Tires.................................. 34
CHASSIS COMPONENT AND WHEEL BEARING
LUBRICANTS
The chassis component and wheel bearing lubri-
cants that are recommended for Jeeptvehicles are
identified by the NLGI Certification Symbol (Fig. 1).
The symbol contains a coded designation that identi-
fies the usage and quality of the lubricant.
The letterGdesignates wheel bearing lubricant.
LetterLdesignates chassis lubricant. When the let-
ters are combined the lubricant can be used for dual
applications. The suffix lettersCandBdesignate the
level of the lubricant for the application. The letterC
represents level available for wheel bearing lubricant
(G) and the letterBrepresents level available for
chassis lubricant (L).
STEERING LINKAGE AND BALL STUDS
RECOMMENDED MAINTENANCE
The general condition of the steering linkage (Fig.
2) should be inspected and the ball studs should be
lubricated:
²2WD vehicles Ð after each 24 000-km (15,000-
miles) or six-months interval of vehicle operation has
elapsed; or
²4WD vehicles Ð after each 12 000-km (7,500-
miles) or six-months interval of vehicle operation has
elapsed.
LUBRICANT SPECIFICATION
Steering linkage should be lubricated with a dual-
purpose, lithium-base lubricant that is identified as
NLGI GC-LB lubricant.
INSPECTION/LUBRICATION
(1) Inspect the steering linkage. Examine the tie
rods and the drag link for bending, and the ball
studs for looseness and excessive wear.
(2) Replace, as necessary, all torn/ruptured ball-
stud seals and damaged/defective steering linkage
components.
CAUTION: Use care to prevent lubricant from con-
tacting the brake rotors.
(3) Lubricate the ball studs:
²clean the tips of the Zerk type lubrication fittings
on the tie-rod and drag-link ball-stud ends to avoid
lubricant contamination;
²lubricate the ball studs with high quality, dual-
purpose, lithium base chassis/wheel bearing lubri-
cant (NLGI GC-LB lubricant);
²cease the lubricant pressure when lubricant begins
to freely exit the base of the seal, or if the seal be-
gins to expand; and
²wipe the excess lubricant from the exterior sur-
faces of the ball joints and the adjacent surfaces.
Fig. 1 NLGI Lubricant Container Certification/
Identification Symbol
Fig. 2 Steering Components (XJ)ÐTypical
0 - 30 LUBRICATION AND MAINTENANCEJ

FRONT WHEEL BEARINGS
Only 2WD XJ vehicles are equipped with front
wheel bearings. XJ vehicles have semi-floating axle
shafts and axle shaft bearings that are lubricated via
differential lube oil.
RECOMMENDED MAINTENANCEÐ2WD XJ
VEHICLES
The front wheel bearings should be lubricated (re-
packed) at the same time as front brake pad/caliper
service is conducted.
LUBRICANT SPECIFICATION
Wheel bearings should be lubricated with a lubri-
cant that is identified as NLGI GC-LB lubricant.
INSPECTION/LUBRICATION
(1) Remove the wheel/tire and the disc brake cali-
per.Do not disconnect the caliper brake fluid
hose unless the caliper must also be removed for
maintenance. Support the caliper with a hanger
to prevent brake fluid hose damage.
(2) Remove the dust cap, the cotter pin, the nut re-
tainer, the adjustment nut, and the thrust washer
from the spindle (Fig. 3). Discard the cotter pin.
(3) Remove the wheel outer bearing from the hub.
(4) Remove the wheel hub/disc brake rotor from
the spindle.
(5) Remove the seal and the inner wheel bearing
from the hub cavity.
(6) After removal, inspect both front wheel bearing
races for indications of pitting, brinelling and exces-
sive heat.
(7) Wipe the spindle clean and apply a small
amount of chassis/wheel bearing lubricant (NLGI
GC-LB lubricant) to prevent rust. Wipe the wheel
hub cavity clean.
CAUTION: Do not over-fill the wheel hub cavity with
lubricant. Excessive lubricant can cause overheat-ing and bearing damage. Also, excessive lubricant
can be forced out of the wheel hub cavity and con-
taminate the brake rotor/pads.
(8) Partially fill the wheel hub cavity with chassis/
wheel bearing lubricant (NLGI GC-LB lubricant).
(9) Pack the wheel bearings with chassis/wheel
bearing lubricant (NLGI GC-LB lubricant). Ensure
that sufficient lubricant is forced between the bear-
ing rollers.
(10) Install the wheel inner bearing in the wheel
hub and install a replacement seal.
(11) Clean the disc brake rotor contact surfaces, if
necessary.
(12) Install the wheel hub/disc brake rotor on the
spindle.
(13) Install the wheel outer bearing, the thrust
washer, and the spindle nut.
(14) Tighten the spindle nut with 28 NIm (21 ft.
lbs.) torque while rotating the disc brake rotor to
seat the bearings.
(15) Loosen the spindle nut 1/2 turn. While rotat-
ing the disc brake rotor, tighten the spindle nut with
2NIm (19 in. lbs.) torque.
(16) Install the nut retainer and a replacement cot-
ter pin.
(17) Clean the dust cap and apply wheel bearing
lubricant to the inside surface.Do not fill the dust
cap with lubricant.
(18) Install the dust cap.
(19) Install the disc brake caliper.
POWER STEERING SYSTEM
RECOMMENDED MAINTENANCE
The condition of power steering system should be
inspected and the fluid level checked. Add fluid as
necessary.
FLUID SPECIFICATION
Jeeptpower steering systems require MOPAR
Power Steering Fluid, or an equivalent product.
The original power steering fluid installed in
Jeeptvehicles includes black-light leak detec-
tion dye.
INSPECTION
Inspect the power steering system (Figs. 4 and 5)
for the sources of fluid leaks, steering gear housing
cracks and ensure that the steering gear is securely
attached to the vehicle frame rail. Inspect the steer-
ing damper for leaks and loose connections.
FLUID LEVEL
The fluid level dipstick is attached to the reservoir
cap (Fig. 6). The fluid level in the reservoir can be
determined with the fluid either hot or cold.
(1) Remove the cap from the reservoir.
Fig. 3 2WD Front Wheel BearingsÐXJ Vehicles
JLUBRICATION AND MAINTENANCE 0 - 31

(2) Depending on fluid temperature, if the level is
below the FULL HOT mark or the FULL COLD
mark on the dipstick, add power steering fluid.
(3) Install the cap on the reservoir.
MANUAL STEERING GEARÐYJ VEHICLES
RECOMMENDED MAINTENANCE
The manual steering gear should be inspected for
damage at the same time as the engine oil is
changed and the oil filter is replaced. Repair as nec-essary (refer to Group 19ÐSteering for additional in-
formation and service procedures).
POWER BRAKE SYSTEM
RECOMMENDED MAINTENANCE
The condition of the brake system should be in-
spected and the fluid level in the master cylinder
should be checked each time the brake system is ser-
viced. Add brake fluid and repair as necessary.
In addition, the brake system should be operation-
ally tested periodically to ensure that it is function-
ing normally.
FLUID SPECIFICATION
Jeeptpower brake systems require MOPAR
Heavy-Duty Brake Fluid, or an equivalent product
identified as conforming to FMVSS No. 116, DOT-3
and SAE J-1703 specifications.
Usenew brake fluid onlywhen adding fluid to
the reservoir, to fill the brake system. Never use re-
claimed fluid.
BRAKE FLUID LEVEL
STANDARD POWER BRAKE SYSTEM
(1) Clean the cover and the sides of the brake fluid
reservoir.
(2) Detach the bail retainer from the reservoir
cover and remove the cover from the reservoir.
(3) The brake fluid level should be 6 mm (1/4 in)
below the rim of each reservoir well for XJ and YJ
Vehicles (Fig. 7). If not, add brake fluid as necessary.
(4) Inspect the reservoir cover bail retainer for ten-
sion and the cover for proper fit. The cover should fit
tight and have a good seal.
Fig. 4 Power Steering SystemÐXJ Vehicles
Fig. 5 Power Steering SystemÐYJ Vehicles
Fig. 6 Power Steering Fluid Reservoir
DipstickÐTypical
0 - 32 LUBRICATION AND MAINTENANCEJ

TOE POSITIONÐYJ VEHICLES
The wheel toe position should be the final front
wheel alignment adjustment. In all instances follow
the equipment manufacturer's recommended proce-
dure.
(1) Secure the steering wheel with the front wheels
in the straight-ahead position. For vehicles equipped
with power steering, start the engine before straight-
ening the wheels.(2) Loosen the adjustment sleeve clamp bolts on
the tie rod (Fig. 6).
YJ Vehicles
The tie rod and adjustment sleeve have both
right and left hand threads to provide equal ad-
justment for each wheel.
(3) After the adjustment is completed, position the
tie rod adjustment sleeve clamp bolts as shown.
(4) Tighten the adjustment sleeve clamp bolts to
27 Nzm (20 ft. lbs.) torque.
(5) The steering wheel can be centered by the drag
link. Complete the adjustment. Position the drag link
clamp bolts as shown. Tighten the bolts to 49 Nzm
(36 ft. lbs.) torque.
Fig. 6 Steering Linkage
ALIGNMENT SPECIFICATIONSÐXJ VEHICLES
ALIGNMENT SPECIFICATIONSÐYJ VEHICLES
JFRONT SUSPENSION AND AXLE 2 - 9

MULTI-PORT FUEL INJECTION (MFI)ÐCOMPONENT DESCRIPTION/SYSTEM
OPERATION
INDEX
page page
Air Conditioning (A/C) Clutch RelayÐPCM Output.24
Air Conditioning (A/C) ControlsÐPCM Input.... 19
Auto Shut Down (ASD) RelayÐPCM Output.... 24
Automatic Shut Down (ASD) SenseÐPCM Input . 19
Battery VoltageÐPCM Input................ 19
Brake SwitchÐPCM Input.................. 20
Camshaft Position SensorÐPCM Input........ 20
Crankshaft Position SensorÐPCM Input....... 20
Data Link ConnectorÐPCM Input............ 20
Data Link ConnectorÐPCM Output........... 24
EMR LampÐPCM Output.................. 24
Engine Coolant Temperature SensorÐPCM Input . 21
Extended Idle SwitchÐPCM Input............ 21
Fuel InjectorsÐPCM Output................ 25
Fuel Pressure Regulator................... 30
Fuel Pump RelayÐPCM Output............. 25
Fuel Rail............................... 30
General Information....................... 17
Generator FieldÐPCM Output............... 25
Generator LampÐPCM Output.............. 25
Idle Air Control (IAC) MotorÐPCM Output...... 25
Ignition Circuit SenseÐPCM Input............ 21
Ignition CoilÐPCM Output.................. 26Intake Air Temperature SensorÐPCM Input.... 20
Malfunction Indicator LampÐPCM Output...... 26
Manifold Absolute Pressure (MAP) SensorÐ
PCM Input............................ 21
Open Loop/Closed Loop Modes of Operation . . . 27
Overdrive/Override Switch.................. 22
Oxygen (O2S) SensorÐPCM Input........... 22
Park/Neutral SwitchÐPCM Input............. 22
Power Ground........................... 22
Power Steering Pressure SwitchÐPCM Input . . . 22
Powertrain Control Module (PCM)............ 18
Radiator Fan RelayÐPCM Output............ 26
SCI ReceiveÐPCM Input.................. 22
SCI TransmitÐPCM Output................. 26
Sensor ReturnÐPCM Input................. 23
Shift IndicatorÐPCM Output................ 26
Speed ControlÐPCM Input................. 23
Speed ControlÐPCM Output................ 27
TachometerÐPCM Output.................. 27
Throttle Body............................ 29
Throttle Position Sensor (TPS)ÐPCM Input..... 23
Torque Converter Clutch RelayÐPCM Output . . . 27
Vehicle Speed SensorÐPCM Input........... 23
GENERAL INFORMATION
All 2.5L 4 cylinder and 4.0L 6 cylinder engines are
equipped with sequential Multi-Port Fuel Injection
(MFI). The MFI system provides precise air/fuel ra-
tios for all driving conditions.
The Powertrain Control Module (PCM) operates
the fuel system. The PCM was formerly referred to
as the SBEC or engine controller. The PCM is a pre-
programmed, dual microprocessor digital computer.
It regulates ignition timing, air-fuel ratio, emission
control devices, charging system, speed control, air
conditioning compressor clutch engagement and idle
speed. The PCM can adapt its programming to meet
changing operating conditions.
Powertrain Control Module (PCM) Inputsrep-
resent the instantaneous engine operating conditions.
Air-fuel mixture and ignition timing calibrations for
various driving and atmospheric conditions are pre-
programmed into the PCM. The PCM monitors and
analyzes various inputs. It then computes engine fuel
and ignition timing requirements based on these in-
puts. Fuel delivery control and ignition timing will
then be adjusted accordingly.
Other inputs to the PCM are provided by the brake
light switch, air conditioning select switch and the
speed control switches. All inputs to the PCM are
converted into signals.
Electrically operated fuel injectors spray fuel in
precise metered amounts into the intake port directlyabove the intake valve. The injectors are fired in a
specific sequence by the PCM. The PCM maintains
an air/fuel ratio of 14.7 to 1 by constantly adjusting
injector pulse width. Injector pulse width is the
length of time that the injector opens and sprays fuel
into the chamber. The PCM adjusts injector pulse
width by opening and closing the ground path to the
injector.
Manifold absolute pressure (air density) and engine
rpm (speed) are the primary inputs that determine
fuel injector pulse width. The PCM also monitors
other inputs when adjusting air-fuel ratio.
Inputs That Effect Fuel Injector Pulse Width
²Exhaust gas oxygen content
²Engine coolant temperature
²Manifold absolute pressure (MAP)
²Engine speed
²Throttle position
²Battery voltage
²Air conditioning selection
²Transmission gear selection (automatic transmis-
sions only)
²Speed control
The powertrain control module (PCM) adjusts igni-
tion timing by controlling ignition coil operation. The
ignition coil receives battery voltage when the igni-
tion key is in the run or starter position. The PCM
provides a ground for the ignition coil. The coil dis-
JFUEL SYSTEM 14 - 17

OVERDRIVE/OVERRIDE SWITCH
On vehicles equipped with overdrive, the power-
train control module (PCM) regulates the 3-4 over-
drive up-shift and down-shift through the overdrive
solenoid.
Refer to Group 21 for more information.
OXYGEN (O2S) SENSORÐPCM INPUT
The O2S sensor is located in the exhaust down pipe
(Fig. 11). It provides an input voltage to the power-
train control module (PCM) relating the oxygen con-
tent of the exhaust gas. The PCM uses this
information to fine tune the air-fuel ratio by adjust-
ing injector pulse width.
The O2S sensor produces voltages from 0 to 1 volt.
This voltage will depend upon the oxygen content of
the exhaust gas in the exhaust manifold. When a
large amount of oxygen is present (caused by a lean
air-fuel mixture), the sensor produces a low voltage.
When there is a lesser amount present (rich air-fuel
mixture) it produces a higher voltage. By monitoring
the oxygen content and converting it to electrical
voltage, the sensor acts as a rich-lean switch.
The oxygen sensor is equipped with a heating ele-
ment that keeps the sensor at proper operating tem-
perature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into closed loop operation sooner.
In Closed Loop operation, the powertrain control
module (PCM) monitors the O2S sensor input (along
with other inputs). It then adjusts the injector pulse
width accordingly. During Open Loop operation, the
PCM ignores the O2S sensor input and adjusts injec-
tor pulse width to a preprogrammed value (based on
other sensor inputs).
PARK/NEUTRAL SWITCHÐPCM INPUT
The park/neutral switch is located on the transmis-
sion housing and provides an input to the powertrain
control module (PCM). This will indicate that the au-
tomatic transmission is in Park, Neutral or a drivegear selection. This input is used to determine idle
speed (varying with gear selection), fuel injector
pulse width and ignition timing advance. Refer to
Group 21, Transmissions, for testing, replacement
and adjustment information.
POWER GROUND
The power ground is used to control ground circuits
for the following powertrain control module (PCM)
loads:
²Generator Field Winding
²8 volt (PCM) power supply
²Fuel Injectors
²Ignition Coil
POWER STEERING PRESSURE SWITCHÐPCM
INPUT
A pressure sensing switch is included in the power
steering system (mounted on the high-pressure line).
This switch will be on vehicles equipped with a 2.5L
engine and power steering. The switch (Fig. 12 YJ
Models or Fig. 13 XJ Models) provides an input to
the PCM. This input is provided during periods of
high pump load and low engine rpm; such as during
parking maneuvers. The PCM will then increase the
idle speed through the idle air control (IAC) motor.
This is done to prevent the engine from stalling un-
der the increased load.
When steering pump pressure exceeds 1896 kPa6
172 kPa (275625 psi) the PCM will increase the en-
gine idle speed. This will prevent the engine from
stalling.
SCI RECEIVEÐPCM INPUT
SCI Receive is the serial data communication re-
ceive circuit for the DRB scan tool. The powertrain
control module (PCM) receives data from the DRB
through the SCI Receive circuit.
Fig. 11 Heated Oxygen Sensor LocationÐTypical
Fig. 12 Power Steering Pump Pressure SwitchÐYJ
Models
14 - 22 FUEL SYSTEMJ