1994 JEEP CHEROKEE transmission

INSTALLATION
(1) Position the camshaft position sensor in the
distributor housing. Place the wire harness grommet
into the opening in the distributor housing.
(2) Install retaining arm and retaining screw.
(3) Install distributor shaft into distributor hous-
ing. Make sure the upper thrust washer is installed
on the shaft.
(4) Position thrust washer and drive gear on dis-
tributor shaft.
(5) Note the previousCAUTIONand install dis-
tributor drive gear roll pin.
(6) Install rotor.
(7) Install distributor.
CRANKSHAFT POSITION SENSOR
The crankshaft position sensor is mounted in thetransmission bellhousing at the left/rear side of the
engine block (Figs. 5, 6 or 7).
On all 2.5L and 4.0L engines (except YJ models
with an automatic transmission and 4.0L engine) the
sensor is attached with two bolts. The 2.5L engine,
when equipped with an automatic transmission, will
have the sensor mounted with two nuts.
On YJ models with a 4.0L engine and automatic
transmission, the sensor uses a single slotted hole to
adjust its depth. A paper/cardboard type spacer with
self-adhesive (Fig. 7) is attached to the bottom of the
sensor to set this depth. After the engine has been
started (and after sensor installation), this temporary
spacer will be sheared off. New factory replacement
sensors are equipped with this spacer. If the original
sensor is to be reinstalled, such as with transmission
and/or flywheel removal, a new spacerMUSTbe in-
stalled.
Fig. 3 Distributor GearÐRemoval/Installation
Fig. 4 Camshaft Position Sensor
Fig. 5 Crankshaft Position SensorÐ2.5L
EngineÐTypical
Fig. 6 Crankshaft Position SensorÐ4.0L EngineÐAll
Except YJ models With Automatic Transmission
JIGNITION SYSTEMS 8D - 21

REMOVALÐALL ENGINES
(1) Near the rear of the intake manifold, discon-
nect the pigtail harness (on the sensor) from the
main electrical harness.
(2) Remove the nut holding sensor wire clip to fuel
rail mounting stud.
(3) Depending upon application, remove either the
sensor mounting bolt(s) or nuts.
(4) Remove the sensor.
(5) Remove clip from sensor wire harness.
INSTALLATIONÐALL EXCEPT YJ MODELS
WITH 4.0L ENGINE AND AUTOMATIC
TRANSMISSION
(1) Install the sensor flush against the opening in
the transmission housing.
(2) Install and tighten the two sensor mounting
bolts (or nuts) to 19 Nzm (14 ft. lbs.) torque.
CAUTION: On some models, two bolts used to se-
cure the sensor to the transmission. These bolts
are specially machined to correctly space the unit
to the flywheel. Do not attempt to install any other
bolts.
(3) Connect the electrical connector to the sensor.
(4) Install clip on sensor wire harness.
(5) Install clip over fuel rail mounting stud. Install
clip mounting nut.
INSTALLATIONÐYJ MODELS WITH 4.0L
ENGINE AND AUTOMATIC TRANSMISSION
(1) Be sure the paper/cardboard spacer (Fig. 7) has
been installed to the bottom of the new sensor.If original sensor is being reinstalled (such as with
transmission or flywheel removal), clean bottom of
the sensor before installation. Obtain a new spacer
and remove the paper backing. Install the self-adhe-
sive side to bottom of sensor. This spacerMUSTbe
installed. If spacer is not installed, sensor will be
damaged when engine is started.
(2) Position sensor to transmission bellhousing and
install mounting bolt finger tight.
(3) Gently seat (push down) the sensor until the
paper spacer contacts the outer edge of the flywheel.
(4) Tighten sensor mounting bolt (Fig. 7) to 17-
to-21 Nzm (13-to-16 ft. lbs.) torque.
(5) Connect the electrical connector to sensor.
(6) Install the clip to sensor wire harness.
(7) Install clip over fuel rail mounting stud. Install
clip mounting nut.
ENGINE COOLANT TEMPERATURE SENSOR
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR. RE-
FER TO GROUP 7, COOLING.
REMOVAL
The sensor is installed in the thermostat housing
(Fig. 8).
(1) Drain cooling system until the coolant level is
below the cylinder head. For cooling system draining,
refer to Group 7, Cooling.
(2) Disconnect the coolant temperature sensor wire
connector.
(3) Remove the sensor from the thermostat hous-
ing (Fig. 8).
Fig. 7 Crankshaft Position SensorÐ4.0L EngineÐYJ
models With Automatic Transmission
Fig. 8 Coolant Temperature SensorÐTypical
8D - 22 IGNITION SYSTEMSJ

other side. When coolant temperature is too high the
switch closes providing a path to ground, and the indi-
cator bulb lights.
TACHOMETER
The tachometer displays the engine speed (RPM).
With the engine running, the tachometer receives an
engine speed signal from the Powertrain Control
Module pin 43 (values shown in Specifications chart).
SPEEDOMETER/ODOMETER SYSTEM
The speedometer/odometer system consists of an elec-
tric speedometer and pushbutton reset odometer
mounted in the cluster. The system also includes the
wire harness from the cluster to the vehicle speed sen-
sor at the transmission, and the adapter and pinion in
the transmission. A signal is sent from a transmission
mounted vehicle speed sensor to the speedometer/odom-
eter circuitry through the wiring harness. Refer to
Group 21 - Transmission for selecting the proper pinion,
and selecting and indexing the proper adapter.
FUEL GAUGE
The fuel gauge pointer position is controlled by a
magnetic field created by electrical current flow through
the coils within the gauge. A change in current flow will
change the magnetic field which changes the pointer po-
sition. The fuel level sender is a variable resistor that
changes electrical resistance with a change of the level
of fuel in the tank (values shown in Specifications
chart).
LOW FUEL WARNING LAMP
The low fuel warning lamp will light when the fuel
level falls below approximately 4 gallons. A low fuel
warning module controls when the lamp will light.
When the module senses 66.5 ohms or less from the
fuel level sender for 10 continuous seconds, the lamp
will light. The lamp will remain on until the module
senses 63.5 ohms or more from the fuel level sender
for 20 continuous seconds.
UPSHIFT INDICATOR LAMP
Vehicles equipped with manual transmissions have an
optional upshift indicator lamp. The lamp is controlled
by the Powertrain Control Module. The lamp lights to
indicate when the driver should shift to the next high-
est gear for best fuel economy. The Powertrain Control
Module will turn the lamp off after 3 to 5 seconds if the
upshift is not performed. The lamp will remain off until
the vehicle stops accelerating and is brought back to the
range of lamp operation or shifted into another gear.
The indicator lamp is normally illuminated when
the ignition switch is turned ON and is turned off
when the engine is started. The lamp will be lighted
during engine operation according to engine speed
and load.
BRAKE INDICATOR LAMP
The brake indicator lamp warns the driver that the
parking brake is applied or that hydraulic pressure in
the split brake system is unequal.
Voltage is supplied through the brake indicator
bulb to 3 switches. A path to ground for the current
is available if:
²The brake warning switch is closed (with unequal
brake system hydraulic pressures), or
²
The ignition switch is in the START position (to test
the bulb), or
²The park brake switch is closed (with the parking
brake applied).
ANTI-LOCK BRAKE SYSTEM (ABS) INDICATOR
LAMP
The anti-lock brake system (ABS) lamp lights to in-
dicate a system self-check is in process at vehicle
start-up. If light remains on after start-up or comes
on and stays on while driving, it may indicate that
the ABS system has detected a malfunction or has
become inoperative.
4WD INDICATOR LAMP
COMMAND-TRAC 4WD
The PART TIME lamp lights when the vehicle is en-
gaged in four-wheel drive mode. Voltage is supplied to
one side of the indicator bulb. A switch in the transfer
case area is connected to the other side of the indicator
bulb. When the switch is closed, a path to ground is pro-
vided and the indicator bulb lights.
SELECT-TRAC 4WD
The four-wheel drive icon or FULL TIME lamp
lights when the vehicle is engaged in full time four-
wheel drive mode. The PART TIME lamp lights when
the vehicle is in part time four-wheel drive mode.
Voltage is supplied to one side of the indicators.
Switches in the transfer case area are connected to
the other side of the indicator bulbs. When a switch
is closed, a path to ground is provided and the indi-
cator bulb lights.
MALFUNCTION INDICATOR LAMP (CHECK ENGINE)
The Malfunction Indicator Lamp (Check Engine)
lights each time the ignition switch is turned ON and
stays on for 3 seconds as a bulb test.
If the PCM receives an incorrect signal or no signal
from certain sensors or emission related systems the
lamp is turned on (pin 32 of PCM). This is a warning
that the PCM has recorded a system or sensor mal-
function. In some cases when a diagnostic trouble
code is declared the PCM will go into a limp-in mode
in an attempt to keep the system operating. It sig-
nals an immediate need for service.
The lamp also can be used to display diagnostic
trouble codes (DTC). Cycle the ignition switch ON,
OFF, ON, OFF, ON within 5 seconds. This will allow
any trouble codes stored in the PCM memory to be
displayed in a series of flashes representing digits.
8E - 2 XJ INSTRUMENT PANEL AND GAUGESJ

(3) Pull cable and clip through hole in the mount-
ing bezel and remove indicator.
(4) Install indicator and cluster.
(5) To adjust indicator, place transmission in PARK.(6) Align pointer on indicator with PARK position.
(7) Install clip to steering column shroud.
(8) Move transmission shift lever to check proper
alignment.
Fig. 5 Printed Circuit Removal/Installation
Fig. 6 Cluster Connector Retaining StrapFig. 7 Printed Circuit And Cluster Connector
JXJ INSTRUMENT PANEL AND GAUGES 8E - 7

INSTRUMENT PANEL AND GAUGESÐYJE
CONTENTS
page page
GAUGE PACKAGE DIAGNOSIS............ 22
GAUGE PACKAGE GENERAL INFORMATION . 22
GAUGE PACKAGE SERVICE PROCEDURES . . 24
INSTRUMENT CLUSTER DIAGNOSIS....... 14INSTRUMENT CLUSTER GENERAL INFORMATION.14
INSTRUMENT CLUSTER SERVICE PROCEDURES.. 17
SPECIFICATIONS....................... 27
INSTRUMENT CLUSTER GENERAL INFORMATION
SPEEDOMETER/ODOMETER SYSTEM
The speedometer/odometer system consists of an
electric speedometer and pushbutton reset odometer
mounted in the cluster. The system also includes the
wire harness from the cluster to the vehicle speed
sensor at the transmission, and the adapter and pin-
ion in the transmission. A signal is sent from a
transmission mounted vehicle speed sensor to the
speedometer/odometer circuitry through the wiring
harness. Refer to Group 21 - Transmission for select-
ing the proper pinion, and selecting and indexing the
proper adapter.
TACHOMETER
The tachometer displays the engine speed (RPM).
With the engine running, the tachometer receives anengine speed signal from the Powertrain Control
Module pin 43 (values shown in Specifications chart).
INDICATOR LAMPS
The Brake, Upshift (2.5L with 5 speed transmis-
sion except California), and Malfunction Indicator
(Check Engine) lamps are located in the indicator
lamp panel above the steering column. The lamps
share a common battery feed connection through the
ignition switch and fuse #9.
The turn signals, high beam indicator, seat belt re-
minder, hazard lamp, master lighting and illumina-
tion bulbs are supplied battery voltage through
various switches and share a common ground.
INSTRUMENT CLUSTER DIAGNOSIS
INDEX
page page
Brake Indicator Lamp...................... 16
DiagnosingÐAll Lamps Out................. 16
Instrument Panel Illumination Lamps.......... 16
Malfunction Indicator Lamp (Check Engine)..... 16Seat Belt Reminder Lamp................... 16
Speedometer............................ 14
Tachometer............................. 14
Upshift Indicator Lamp..................... 16
SPEEDOMETER
(1) Raise vehicle.
(2) Disconnect the vehicle speed sensor connector.
(3) Connect a voltmeter between the black wire
pin of the connector and ground.
(4) Turn the ignition switch to the ON position.
(5) Check for approximately 5 volts. If OK, per-
form vehicle speed sensor test. Refer to the appropri-
ate Powertrain Diagnostic Procedures manual. If not
OK, continue with step 6.
(6) Turn ignition switch to OFF position.(7) Check continuity between vehicle speed sensor
connector and terminal 13 of instrument cluster con-
nector. If OK, replace speedometer. If not OK, repair
open circuit.
TACHOMETER
(1) Tachometer input is from the Powertrain Con-
trol Module (PCM) pin 43. Use the DRB scan tool to
perform actuator test. If OK, continue with step 2. If
not, replace PCM.
(2) Check for continuity between cluster connector
pin 12 and PCM pin 43. If OK, replace tachometer. If
not, repair open circuit.
8E - 14 YJ INSTRUMENT PANEL AND GAUGESJ

DIAGNOSINGÐALL LAMPS OUT
(1) Inspect fuse #9. Replace as required.
(2) Measure voltage at instrument cluster connec-
tor terminal 20. Meter should read zero ohms. If not,
repair open to ground.
UPSHIFT INDICATOR LAMP
Vehicles equipped with manual transmissions have
an optional upshift indicator lamp. The lamp is con-
trolled by the PCM. The lamp lights to indicate when
the driver should shift to the next highest gear for best
fuel economy. The PCM will turn the lamp off after 3 to
5 seconds if the upshift is not performed. The lamp will
remain off until the vehicle stops accelerating and is
brought back to the range of lamp operation or shifted
into another gear.
The indicator lamp is normally illuminated when
the ignition switch is turned ON and it is turned off
when the engine is started. The lamp will be lighted
during engine operation according to engine speed
and load.
(1) Turn ignition switch to ON.
(2) Ground pin 2 of cluster connector. Lamp should
light. If not, replace bulb. If OK, continue with step 3.
(3) Turn ignition switch to OFF. Check for conti-
nuity between cluster connector pin 2 and pin 54 of
the PCM. If not, repair open. If OK, refer to DRB
scan tool actuator test of upshift indicator.
BRAKE INDICATOR LAMP
The brake indicator is a dual function lamp. It will in-
dicate an unequal pressure condition in the split brake
hydraulic system and it also will indicate when the park-
ing brake is engaged. Separate switches are used for each
indicator lamp function. A switch mounted on the brake
pedal assembly will close a ground circuit whenever the
parking brakes are applied. A second switch is installed
in the brake hydraulic lines near the master cylinder. If
the switch is balanced by equal pressure on both ends of
the switch valve, the valve remains centered and the
lamp remains off. If the valve is shifted by unequal pres-
sure between the front or rear brake hydraulic systems,
the lamp circuit is connected to ground. To make sure
the brake lamp is functional before the vehicle is driven,
it is illuminated through a ground circuit when the igni-
tion switch is turned to the START position.
(1) Turn ignition switch to ON.
(2) Ground pin 1 of the cluster connector. Lamp
should light. If not, replace bulb. If OK, continue
with step 3.
(3) Turn ignition switch to OFF. Check for continuity to
park brake switch and brake warning switch.
MALFUNCTION INDICATOR LAMP (CHECK ENGINE)
The Malfunction Indicator Lamp (Check Engine) il-
luminates each time the ignition switch is turned
ON and stays on for 3 seconds as a bulb test.If the PCM receives an incorrect signal or no signal
from certain sensors or emission related systems the
lamp is turned on (pin 32 of PCM). This is a warning
that the PCM has recorded a system or sensor mal-
function. In some cases when a diagnostic fault is de-
clared the PCM will go into a limp-in mode in an
attempt to keep the system operating. It signals an
immediate need for service.
The lamp also can be used to display diagnostic
trouble codes (DTC). Cycle the ignition switch ON,
OFF, ON, OFF, ON within 5 seconds. This will allow
any DTC's stored in the PCM memory to be dis-
played in a series of flashes representing digits.
(1) Turn ignition switch to ON.
(2) Ground pin 4 of cluster connector. Lamp should
light. If not, replace bulb. If OK, continue with step 3.
(3) Turn ignition switch to OFF. Check for conti-
nuity between cluster connector pin 4 and PCM cav-
ity 32. If OK, replace PCM. If not, repair open.
SEAT BELT REMINDER LAMP
Apply 12 volts to terminal 16 of cluster connector.
Lamp should light. If not, replace bulb. If OK, check
wiring for an open to buzzer module. Refer to Group
8U - Chime/Buzzer Warning Systems.
INSTRUMENT PANEL ILLUMINATION LAMPS
The instrument panel illumination lamps share
two common connections. There is a splice after fuse
#10 that connects the lamps to battery feed. There is
also a splice that connects all lamps to ground. Be-
cause they share these common connection points in
a parallel circuit, the illumination lamps will all
come on at the same time. It also means one or more
lamps can be out without affecting the operation of
the other lamps.
On the battery side of the circuit, the headlamp
switch illumination rheostat/switch and panel lamps
fuse receive battery feed in series from the park/tail
fuse. In the park lamp position, the headlamp switch
completes the circuit from the park/tail fuse to the il-
lumination rheostat/switch and panel lamps fuse.
The illumination rheostat contains a variable resis-
tor that allows the driver to vary illumination inten-
sity from off to full brightness.
DIAGNOSIS
(1) Turn parking lamps ON.
(2) Check fuse #10. Replace as required.
(3) Measure voltage at battery side of fuse #10
with rheostat turned counterclockwise to clockwise
(LO to HI). Meter should read zero volts to battery
voltage. If not, replace headlamp switch.
(4) Measure resistance at ground side of fuse #10
with parking lamps OFF. Meter should read almost
zero ohms (except bulb filament). If not, repair open
to ground. If zero ohms, 12 volt supply wire from fuse
is shorted to ground, repair short.
8E - 16 YJ INSTRUMENT PANEL AND GAUGESJ

(4) Slide speed switch to RESUME/ACCEL and
hold it there. Vehicle should accelerate.
(5) Release speed switch back to ON. Vehicle will
hold the new faster speed, if SET speed button has
been pressed.
(6) Tap brake pedal. Vehicle will decelerate.
If vehicle has a manual transmission, repeat test,
but depress the clutch pedal.
(7) Slide speed switch momentarily RESUME/AC-
CEL. Vehicle will accelerate to former set speed.
(8) While cruising, accelerate, then remove foot
from accelerator. Vehicle will coast back to set speed.
(9) While speed control is engaged, tap SET but-
ton. Vehicle speed will increase 2 mph for each time
SET button is tapped.
Fig. 6 Vacuum Gauge Test
8H - 8 VEHICLE SPEED CONTROL SYSTEMJ

CONNECTORS
The connectors shown in the diagram sheets are
viewed from the terminal end unless otherwise speci-
fied. For viewing bulkhead, powertrain control module,
and transmission control module connectors refer to the
rear of the wiring diagrams. This area shows major con-
nectors and identifies pin and cavity information.
The connectors shown in the diagrams are identi-
fied in two ways. The first is an actual view of the
connector. This view shows the connector and which
cavity the wire is in.
The second way is with the use of arrows to indicate
the connector. This is done when the connector is to
large to be shown on the diagram page. A box placed
next to the connector identifies the connector and the
cavity the wire is in. In certain instances there may be
more than one connector in the same location. When
this happens the connector identification box will have a
number placed in it. Refer to the rear of the diagrams
for a complete pin out of the connector.
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below.(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit as the problem area. Refer to the
wiring diagrams fuse application chart for circuit
identification.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step check for
proper operation of all items on the circuit repaired.
Refer to the wiring diagram fuse application chart for
circuit identification.
FUSIBLE LINKS
Vehicle wiring harnesses are equipped with fusible
links to protect against harness damage in the event
of a short in the system. Fusible links are color coded
to indicate wire gauge and size. Refer to the fusible
link chart for color and gauge identification (Fig. 6).
Fig. 5 Wiring Splice Examples
Fig. 6 Fusible Link Chart
JWIRING DIAGRAMS 8W - 3