1994 JEEP CHEROKEE warning

REMOVAL
(1) Disconnect the electrical connector from the
sensor.
(2) Remove the sensor from the intake manifold.
INSTALLATION
(1) Install the sensor into the intake manifold.
Tighten the sensor to 28 Nzm (20 ft. lbs.) torque.
(2) Connect the electrical connector to the sensor.
CRANKSHAFT POSITION SENSOR
For description, operation and removal/installation
procedures, refer to Group 8D, Ignition Systems in
this manual.
ENGINE COOLANT TEMPERATURE SENSOR
The coolant temperature sensor is installed in the
thermostat housing (Fig. 5).
REMOVAL
(1) Drain cooling system until the coolant level is
below the cylinder head. Observe theWARNINGSin
Group 7, Cooling.(2) Disconnect the coolant temperature sensor wire
connector.
(3) Remove the sensor from the thermostat hous-
ing (Fig. 5).
INSTALLATION
(1) Install coolant temperature sensor into the cyl-
inder block. Tighten to 28 Nzm (21 ft. lbs.) torque.
(2) Connect the wire connector.
(3) Fill the cooling system. Refer to Group 7, Cool-
ing System.
FUEL FILTER
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
FUEL INJECTOR
REMOVAL
(1) Remove the fuel rail. Refer to Fuel Rail Re-
moval in this section.
(2) Remove the clip(s) that retain the fuel injec-
tor(s) to the fuel rail (Fig. 6).
Fig. 3 Sensor LocationÐ2.5L Engine
Fig. 4 Sensor LocationÐ4.0L Engine
Fig. 5 Engine Coolant Temperature SensorÐTypical
Fig. 6 Injector Retaining Clips
JFUEL SYSTEM 14 - 55

INSTALLATION
(1) Install the fuel injector(s) into the fuel rail as-
sembly and install retaining clip(s).
(2) Install fuel rail. Refer to Fuel Rail Installation
in this section.
(3) Start engine and check for fuel leaks.
FUEL PUMP MODULE
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
FUEL PUMP RELAY
The Fuel Pump relay is located in the Power Dis-
tribution Center (PDC) (Figs. 1 or 2). For location of
this relay within the PDC, refer to label on PDC
cover.
FUEL RAIL ASSEMBLY
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE (EVEN WITH THE ENGINE
OFF) OF APPROXIMATELY 131-269 KPA (19-39
PSI). THIS PRESSURE MUST BE RELEASED BE-
FORE SERVICING THE FUEL RAIL.
(1) Remove fuel tank filler tube cap.
(2) Disconnect the negative battery cable from bat-
tery.
(3) Perform the Fuel System Pressure Release Pro-
cedure as described in the Fuel Delivery System sec-
tion of this Group.
(4) Remove and numerically attach a tag (if fuel
injector is not already tagged), the injector harness
connectors. Do this at each injector (Fig. 7).
(5) Disconnect vacuum line from fuel pressure reg-
ulator (Fig. 7).
(6) Disconnect fuel supply line from fuel rail and
the fuel return line from fuel pressure regulator (Fig.7). Refer to Fuel Tubes/Lines/Hoses and Clamps, or
Quick-Connect Fittings. These can both be found in
the Fuel Delivery section of this group.
(7) Remove fuel rail mounting bolts.
On models with automatic transmissions, it may be
necessary to remove automatic transmission throttle
line pressure cable (and bracket). This will aid in fuel
rail assembly removal.
(8) Remove fuel rail by gently rocking until all the
fuel injectors are out of the intake manifold.
INSTALLATION
(1) Position tips of all fuel injectors into the corre-
sponding injector bore in the intake manifold. Seat
injectors into manifold.
(2) Tighten fuel rail mounting bolts to 27 Nzm (20
ft. lbs.) torque.
(3) Connect injector harness connectors to appro-
priate (tagged) injector.
(4) Connect both fuel lines to fuel rail.
(5) Connect vacuum supply line to fuel pressure
regulator.
(6) Install protective cap to pressure test port fit-
ting.
(7) Install fuel tank cap.
(8) Connect negative battery cable to battery.
(9) Start engine and check for fuel leaks.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF)
OF APPROXIMATELY 100 KPA (14.5 PSI). BEFORE
SERVICING THE FUEL PUMP, FUEL LINES, FUEL
FILTER OR FUEL INJECTOR, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
Refer to the Fuel Delivery System section of this
group. See Fuel Pressure Release procedure.
FUEL TANKS
Refer to the Fuel Tank section of this group for re-
moval/installation procedures.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
Refer to the Fuel Tank section of this group for re-
moval/installation procedures.
FUEL TUBES/LINES/HOSES AND CLAMPS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures. Also refer
to Quick-Connect Fittings in the Fuel Delivery sec-
tion of this group.
IDLE AIR CONTROL (IAC) MOTOR
The IAC motor is mounted to the throttle body ad-
jacent to the throttle position sensor (Fig. 8).
Fig. 7 Fuel Injector HarnessÐTypical
14 - 56 FUEL SYSTEMJ

REMOVAL
(1) Disconnect the electrical connector from the
IAC motor.
(2) Remove IAC motor torx head mounting bolts.
(3) Remove IAC motor.
INSTALLATION
(1) Install IAC motor into throttle body and
tighten retaining bolts.
(2) Connect electrical connector to IAC motor.
IGNITION COIL
Refer to Group 8D, Ignition Systems for removal/
installation procedures.
INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Intake
Manifold for removal/installation procedures.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
The MAP sensor is located on the dash panel near
the rear of the engine cylinder head (valve) cover
(Fig. 9).
REMOVAL
(1) Disconnect the MAP sensor electrical connector
(Fig. 9).
(2) Disconnect the MAP sensor vacuum supply
hose (Fig. 9).
(3) Remove the MAP sensor mounting bolts and
remove MAP sensor.
INSTALLATION
(1) Install MAP sensor to dash panel and secure
with mounting bolts.
(2) Install the MAP sensor vacuum supply hose.
(3) Connect the MAP sensor electrical connector.
OXYGEN (O2S) SENSOR
The O2S sensor is installed in the exhaust down
pipe just below the exhaust manifold flange (Fig. 10).
REMOVAL
WARNING: THE EXHAUST MANIFOLD BECOMES
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Raise and support the vehicle.
(2) Separate the electrical connectors.
(3) Remove the O2S sensor from the exhaust man-
ifold. Snap-On oxygen sensor wrench (number YA
8875) may be used for removal and installation.
INSTALLATION
Threads of new factory oxygen sensors are coated
with anti-seize compound to aid in removal.
(1) Install the O2S sensor into the exhaust mani-
fold and tighten to 30 Nzm (22 ft. lbs.) torque.
(2) Connect the O2S sensor wire connector to the
main harness.
Fig. 8 Idle Air Control
MotorÐRemoval/InstallationÐTypical
Fig. 9 MAP SensorÐTypical
Fig. 10 Oxygen SensorÐTypical
JFUEL SYSTEM 14 - 57

POWER STEERING PUMP
INDEX
page page
Drive Pulley Replacement.................. 11
Flow Control Valve Fitting O-Ring Seal........ 12
Power Steering PumpÐInitial Operation....... 13
Pressure and Return Hose Replacement........ 9Pump Replacement....................... 10
Reservoir Replacement.................... 12
Service Information........................ 9
SERVICE INFORMATION
The power steering pump internal components are
not serviced or adjusted. If a malfunction or an inter-
nal fluid leak occurs, the complete unit must be re-
placed. A reservoir, cap, and O-ring seal kit are the
only service components available.
PRESSURE AND RETURN HOSE REPLACEMENT
Cap hose open ends and pump/steering gear fit-
tings to prevent entry of foreign material.
WARNING: POWER STEERING FLUID (AND PUMP
COMPONENTS) AND THE EXHAUST SYSTEM CAN
BE EXTREMELY HOT IF THE ENGINE HAS BEEN
RECENTLY OPERATING. DO NOT START THE EN-
GINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW THE HOSES TO TOUCH A
HOT EXHAUST MANIFOLD OR THE CATALYTIC
CONVERTER.
REMOVAL
(1) Remove fasteners from hose retaining brackets
at all locations.(2) If applicable, remove pressure sensor from
pressure hose (Fig. 1, 2).
(3) Disconnect pressure and return hose from the
steering gear. Drain the fluid from pump and reser-
voir (Fig. 1, 2, 3).
(4) Disconnect pressure and return hose from the
pump. Remove hoses from vehicle (Fig. 1, 2, 3).
INSTALLATION
(1) Wipe hose ends, pump and gear unions clean.
(2) Connect hose at steering gear and pump. Route
hose while avoiding extreme bends or kinks.The
hose must be kept away from exhaust system
components.Do not distort hose tube ends by bend-
ing, kinking or over tightening.
(3) If applicable, install and tighten pressure sen-
sor to 28 Nzm (252 in. lbs.) torque (Fig. 1, 2).
(4) When used, the protective foam sleeves must be
properly positioned on the hose to prevent chafing.
(5) Tighten fittings at pump and gear to 35 Nzm
(25 ft. lbs.) torque.
(6) Install clamps on return hose on gear, pump
and reservoir.
Fig. 1 Power Steering Hose YJ
JSTEERING 19 - 9

CLEAN AND INSPECTION
(1) Wash all components in clean solvent and dry
with compressed air.
(2) Check for scores, nicks or burrs on the rack pis-
ton finished surface. Slight wear is normal on the
worm gear surfaces.
ASSEMBLE
(1) Install O-ring seal and teflon ring and lubricate
with power steering fluid.
(2) Install worm shaft to rack piston outside of
housing. Fully seat worm shaft to rack piston and
align worm shaft spiral groove with rack piston ball
guide hole (Fig. 33).
WARNING: MAKE SURE ALL RACK PISTON BALLS
ARE REINSTALLED IN THE RACK PISTON. IM-
PROPER INSTALLATION MAY RESULT IN PER-
SONAL INJURY.There are 24 balls in the rack piston circuit,
12 are black and 12 are silver (Chrome). The
black rack piston balls are smaller than the sil-
ver balls. THE BLACK AND SILVER BALLS
MUST BE INSTALLED ALTERNATELY INTO
THE RACK PISTON AND BALL GUIDE. This
procedure will maintain worm shaft preload.
(3) Lubricate and install rack piston balls through
return guide hole while turning wormshaft COUN-
TERCLOCKWISE.
(4) Install remaining balls to guide using grease or
petroleum jelly at each end to hold in place (Fig. 34).
(5) Install guide onto rack piston and return with
clamp and screws. Tighten screws to 58 Nzm (43 in.
lbs.) torque.
(6) Insert Arbor C-4175 (J-21552) into bore of rack
piston. Hold tool tightly against worm shaft while
Fig. 34 Balls in the Return Guide
Fig. 31 Remove and Install Rack Piston
Fig. 32 Remove and Install Seal on Rack Piston
Fig. 33 Installing Balls in Rack Piston
JSTEERING 19 - 31

turning the stub shaft COUNTERCLOCKWISE.
²The rack piston will be forced onto the tool and
hold the rack piston balls in place.
(7) Install the races and thrust bearing to worm
shaft (Fig. 35).
(8) Install worm shaft to housing.
(9) Install valve. Refer to Valve Replacement in
this section.
(10) Install rack piston to worm shaft from tool,
compress seals.
²Hold Arbor tightly against worm shaft and turn
stub shaft CLOCKWISE until rack piston is seated
on worm shaft.
WARNING: MAKE SURE ALL RACK PISTON BALLS
ARE REINSTALLED IN THE RACK PISTON. IM-
PROPER INSTALLATION MAY RESULT IN PER-
SONAL INJURY.
(11) Install rack piston plug and tighten to 150
Nzm (111 ft. lbs.) torque.
(12) Install housing end plug. Refer to Housing
End Plug Replacement in this section.
(13) Install pitman shaft and side cover. Refer to
Side Cover and Pitman Shaft Replacement in this
section.
(14) Adjust steering gear. Refer to Steering Gear
Adjustments in this section.
INSTALL
(1) Install steering gear. Refer to Power Steering
Gear Replacement in this section.
PITMAN SHAFT SEALS AND BEARING
REPLACEMENT
REMOVE
(1) Remove steering gear from vehicle. Refer to
Power Steering Gear Replacement in this section.
DISASSEMBLE
(1) Remove pitman arm from gear. Refer to Pit-
man Arm Removal in Steering Linkage.
(2) Clean exposed end of pitman shaft and housing.
Use a wire brush to clean the shaft splines.
(3) Remove retaining ring with snap ring pliers
(Fig. 36).
CAUTION: Use care not to score the housing bore
when prying out seals and washers.
(4) Remove backup washer and double lip seal
with screwdriver.
(5) Remove backup washer and single lip seal with
screwdriver.
(6) Inspect the housing for burrs and remove if
necessary.
(7) Remove needle bearing from side cover area of
housing (Fig. 37).
ASSEMBLE
(1) Install needle bearing into housing (Fig. 38).
(2) Install single lip seal with Installer or a suit-
able size socket (Fig. 39).
(3) Coat the double lip seal and washer with
grease.
(4) Install the backup washer.
(5) Install the double lip seal.
(6) Install the backup washer.
Fig. 36 Pitman Shaft Seals
Fig. 35 Worm Shaft and Bearing
19 - 32 STEERINGJ

NON-TILT STEERING COLUMN
DISASSEMBLYÐCOLUMN OR CONSOLE SHIFT
Steering column removal from the vehicle is not
necessary for;
²Lockplate cover
²Lockplate
²Steering shaft retaining ring
²Canceling cam
²Turn signal switch
²Upper bearing preload spring
²Ignition key/lock cylinder service
The steering column must be removed from
the vehicle to service any other component.
(1) If the column is removed for service, fabricate a
support fixture to clamp it in a vise (Fig. 1).
(2) Remove the steering wheel. Refer to the re-
moval procedure.
(3) Remove the lockplate cover.
WARNING: THE LOCKPLATE RETAINS A VERY
STRONG, SPRING FORCE. DO NOT ATTEMPT TO
REMOVE THE STEERING SHAFT RETAINING SNAP
RING WITHOUT USING LOCKPLATE COMPRESSOR
C-4156 (J23653-B).
(4) Compress the lockplate with Compressor
C-4156 (J-23653-B) and release the steering shaft re-
taining snap ring (Fig. 2).
(5) Remove the lockplate compressor tool and the
retaining snap ring. Discard the snap ring.CAUTION: When the steering shaft retaining snap
ring is removed, the steering shaft is no longer re-
tained within the column.
(6) Remove the lockplate, canceling cam, upper
bearing preload spring, and the thrust washer from
the steering column/shaft (Fig. 3).
Fig. 2 Retaining Snap Ring Removal
Fig. 3 Steering Column Disassembly
Fig. 1 Steering Column Support Fixture
19 - 50 STEERINGJ

(7) Remove the hazard warning switch knob. Press
the knob inward and remove it from the column by
turning it counterclockwise.
(8) Remove the turn signal/wiper/cruise control
stalk by pulling it out straight from the column.
Wiper must be in the off position.
(9) Disconnect the turn signal wire harness con-
nector from the bracket.
CAUTION: Wrap tape around the turn signal
switch wire harness connector (Fig. 4) to prevent it
from becoming entangled during removal.
(10) Remove the turn signal switch retaining
screws (Fig. 5), dimmer switch actuator arm, to re-
move the switch. Guide the switch straight up and
out of the steering column.
(11) Remove the wiper switch wire harness and all
the other wire harnesses located within the steering
column.
(12) Insert the ignition switch key into the key/
lock cylinder and turn to the ON position.
CAUTION: Do not attempt to remove the key warn-
ing buzzer switch and contacts separately. If sepa-
rated, the contacts can detach and drop into the
steering column.
(13) Remove the key warning buzzer switch and
contacts as a unit (Fig. 6). Use needle-nose pliers or
a paper clip bent at a right angle (90 degrees).
(14) Turn ignition key/lock cylinder to the ON po-
sition. Insert a thin screwdriver into the slot adjacent
to the switch attaching screw boss (right-hand slot).Depress the spring latch located at the bottom of the
slot to release the key/lock cylinder. Remove the key/
lock cylinder. (Fig. 7).
(15) Remove the ignition switch and the dimmer
switch (Fig. 8) from the lower end of the steering col-
umn.
Proceed to Column Shift Disassembly Proce-
dure or Console Shift Disassembly Procedure.
Fig. 4 Taped Turn Signal Switch Wire Harness
Connector
Fig. 5 Turn Signal Switch Retaining Screw
Fig. 6 Key Warning Buzzer/Contacts Removal
JSTEERING 19 - 51