1994 JEEP CHEROKEE ignition

Wiring Diagram Name Sheet Number
Throttle Position Sensor....................14,19
Vehicle Speed Sensor......................11,20
Speakers................................71,72
Left Front Door Speaker......................71
Left Instrument Panel Speaker..................71
Left Liftgate Speaker.........................72
Right Front Door Speaker.....................72
Right Instrument Panel Speaker.................72
Right Liftgate Speaker........................72
Speedometer...........................59,60,61
Splices
Splice A3...............................1,41
Splice A11...............................5,6
Splice A11-1..............................78
Splice A11-2..............................97
Splice A14.............................12,17
Splice A21............................2,12,17
Splice A21-1.............................2,10
Splice A38..............................2,10
Splice A142............................15,22
Splice A142-1...........................15,22
Splice A142-2.....................5,6,15,16,18,22
Splice C7................................70
Splice C15...............................66
Splice C43.............................68,70
Splice C90...............................69
Splice E2................................47
Splice F12...........................16,18,69
Splice F34...............................41
Splice F85.............................37,71
Splice F87...............................54
Splice G7..............................11,20
Splice K4..............................14,19
Splice K4-1.............................14,19
Splice K6..............................14,19
Splice K7..............................11,20
Splice K22...............................19
Splice K29...............................46
Splice L10.............................92,96
Splice L39...............................40
Splice L50.............................91,95
Splice L60.............................92,96
Splice L90.............................91,95
Splice L90-1..............................40
Splice L90-2............................92,96
Splice L90-3............................91,93
Splice M1..............................51,53
Splice M1-1..............................49
Splice M2................................50
Splice M2-1..............................49
Splice M2-2............................50,75
Splice M2-3............................51,54
Splice Q1................................80
Splice P2................................86
Splice P34...............................86
Splice P79...............................73
Splice Z0.................................5
Splice Z1..............................51,54Wiring Diagram Name Sheet Number
Splice Z1-1...............................44
Splice Z1-2...............................42
Splice Z1-3...............................62
Splice Z1-4.............................63,64
Splice Z1-5.............................44,66
Splice Z1-6.............................91,93
Splice Z1-7.............................92,96
Splice Z1-10..............................40
Splice Z1-11..............................33
Splice Z1-12..............................34
Splice Z1-13..............................73
Splice Z1-14..............................97
Splice Z11.............................16,18
Splice Z12...............................31
Splice Z12-1............................13,21
Splice 117.............................92,96
Splice 205...............................32
Splice 235...............................33
Splice 236...............................32
Splice 465...............................38
Standard Instrument Cluster Printed Circuit Board.......59
Steering Column Connector.....................106
Stop Lamp Relay............................97
Stop/Turn Hazard Systems.....................45,46
Hazard Flasher.............................46
Hazard Switch.............................46
Powertrain Control Module.....................45
Stop Lamp Switch..........................46
Turn and Hazard Flasher Switch.................46
Turn Signal Flasher..........................45
Switches
A/C Low Pressure Switch.....................69
A/C Mode Select Switch......................70
Back-Up Lamp Switch........................25
Blower Switch...........................68,70
Brake Warning Switch........................67
Engine Cooling Temperature Switch...............24
Engine Oil Pressure Switch....................24
Fog Lamp Switch...........................42
Front Axle Switch.........................26,27
Hazard Switch.............................46
Headlamp Dimmer Switch.....................41
Headlamp Switch..........................1,41
Heat Mode Select Switch......................68
Heated Rear Window Switch....................66
Horn Switch..............................34
Ignition Key Warning Switch....................74
Ignition Switch............................2,9
Left Door Lock Switch.......................85
Left Front Door Jamb Switch...................75
Left Front Door Window Switch.................87
Left Power Seat Switch.......................77
Left Rear Door Jamb Switch...................75
Left Rear Door Window Switch..................82
Liftgate Switch............................76
Park Brake Switch..........................67
Park/Neutral Position Switch....................7
Power Mirror Switch Assembly..................73
8W - 154 WIRING DIAGRAMSJ

WIRING DIAGRAMS XJ-RHD
INDEX
Wiring Diagram Name Sheet Number
A/C Compressor Clutch........................45
A/C Compressor Clutch Relay....................45
A/C Heater Blower Motor.......................46
A/C Low Pressure Switch.......................45
A/C Mode Selector Switch.......................46
A/C System.............................45, 46
A/C Thermostat..............................45
Antenna Mast...............................47
Ashtray Illumination Lamp.......................26
Automatic Shut Down Relay......................9
Back-up Lamp Switch.........................16
Battery....................................6
Blower Motor............................44, 46
Blower Resistor...........................44, 46
Blower Switch............................44, 46
Body Ground...............................59
Brake Warning Switch.........................42
Camshaft Position Sensor.......................12
Cargo Lamp................................30
Charging System.............................5
Generator.................................5
Check Engine Indicator Lamp..................39, 40
Chime Module..............................43
Chime Module Connector.......................71
Cigar Lighter...............................58
Circuit Breakers
Windshield Wiper Circuit Breaker...............2,33
Connectors
Chime Module Connector......................71
Dash to Instrument Panel Connector A.............64
Dash to Instrument Panel Connector B.............65
Dash to Instrument Panel Connector C.............66
Data Link Connector.........................10
Instrument Cluster Connector 16 Way...........37, 69
Main Body Connector 1.......................70
Power Mirror Connector......................61
Powertrain Control Module Connector..............73
Steering Column Connector 11 Way...............67
Telltale Connector........................38, 68
Transmission Control Module Connector............72
Transmission Data Link Connector................17
Coolant Temperature Switch......................16
Crankshaft Position Sensor......................12
Dash to Instrument Panel Connector A..............64
Dash to Instrument Panel Connector B..............65
Dash to Instrument Panel Connector C..............66
Data Link Connector..........................10
Distributor Ignition Coil........................10
Dome Lamp................................31
Dome and Courtesy Lamps.................29, 30, 31
Cargo Lamp..............................30
Dome Lamp..............................31Wiring Diagram Name Sheet Number
Dome/Reading Lamp.........................31
Glove Box Lamp...........................29
Reading Lamp.............................31
Vanity Lamps.............................31
Dome/Reading Lamp..........................31
Door Jamb Switch System....................49, 50
Left Front Door Jamb Switch...................50
Left Rear Door Jamb Switch...................50
Liftgate Switch............................46
Right Front Door Jamb Switch..................49
Right Rear Door Jamb Switch..................49
Electronic Fuel Injection
Ignition System................9,10,11,12,13,14
Automatic Shut Down Relay.....................9
Camshaft Position Sensor.....................12
Crankshaft Position Sensor.....................12
Data Link Connector.........................10
Distributor Ignition Coil.......................10
Engine Coolant Temperature Sensor...............11
Fuel Injectors.............................14
Fuel Pump Relay............................9
Heated Oxygen Sensor.......................13
Idle Air Control Motor........................14
Intake Air Temp Sensor.......................11
Map Sensor..............................11
Powertrain Control Module........9,10,11,12,13,14
Throttle Position (Sensor).....................11
Engine Block Heater...........................58
Engine Coolant Temperature Sensor................11
Engine Coolant Temperature Switch.................15
Engine Oil Pressure and Temperature System..........15
Engine Oil Pressure Switch......................15
Engine Starter System..........................6
Battery..................................6
Engine Starter Motor.........................6
Engine Starter Relay..........................6
Fan Control Relay...........................3,7
Fog Lamp Illumination Lamp.....................20
Fog Lamp Relay.............................21
Fog Lamp Switch............................20
4WD Select Trac Indicator Lamp................39, 40
Front Axle Switch............................16
Front End Lighting.........................21, 22
Fog Lamp Relay...........................21
Left Fog Lamp.............................21
Left Headlamp.............................21
Left Park/Turn Signal Lamp....................21
Left Side Marker Lamp.......................21
Right Fog Lamp............................22
Right Headlamp............................22
Right Park/Turn Signal Lamp...................22
Right Side Marker Lamp......................22
Front Wipers/Washer - Intermittent..............33, 34
JWIRING DIAGRAMS 8W - 271

Wiring Diagram Name Sheet Number
Front Washer Pump.........................34
Front Wiper Motor..........................34
Intermittent Wiper Module.....................33
Park Switch..............................34
Washer Fluid Level Switch.....................33
Washer Switch............................33
Windshield Wiper/Washer Circuit Breaker...........33
Wiper/Washer Switch........................33
Fuel Gauge Sensor...........................54
Fuel Injectors...............................14
Fuel Pump.................................54
Fuel Pump Module...........................54
Fuel Pump Relay............................3,9
Fuel Tank System............................54
Full Time Indicator Lamp.....................39, 40
Fuse Application Chart........................1,2
Fuse Panel..............................62, 63
Fuses
Fuse #2.............................2,4,60
Fuse #4..........................2,33,44,46
Fuse #5.............................1,4,27
Fuse #6.............................1,4,51
Fuse #9...............................1,19
Fuse #10..............................1,19
Fuse #13............................2,47,58
Fuse #14.........................2,23,33,60
Fuse #19............................2,33,35
Fuse #25............................1,19,25
Fuse #26..........................1,8,37,43
F1 ...................................3,4
F2 ...................................3,9
F3 ...................................3,17
F4 ...................................3,4
F5 .................................3,6,17
F6 .................................3,9,10
F7 .....................................3
F8 ...................................3,4
F9 .....................................3
F10 ...................................3,4
F11 ...................................3,4
F12 ...................................3,4
F13 ...................................3,4
F14 ...................................3,4
F15 ...................................3,4
F16 ...................................3,4
Generator..................................5
Glove Box Lamp.............................29
Hazard Flasher..............................32
Headlamp Dimmer Switch.......................19
Headlamp Switch...........................1,19
Headlamp Switch System.....................19, 20
Fog Lamp Illumination........................20
Fog Lamp Switch...........................20
Headlamp Dimmer Switch.....................19
Headlamp Switch...........................19
Headlamps..............................21, 22
Heated Oxygen Sensor.........................13
Heated Rear Window..........................60Wiring Diagram Name Sheet Number
Relay...................................60
Switch..................................60
Switch Illumination..........................25
Heater A/C Panel Lamp........................25
Heater and A/C System......................45, 46
A/C Compressor Clutch.......................45
A/C Compressor Clutch Relay...................45
A/C Heater Blower Motor......................46
A/C Low Pressure Switch.....................45
A/C Mode Selector Switch.....................46
A/C Thermostat............................45
Blower Resistor............................46
Blower Switch.............................46
Powertrain Control Module.....................45
Heater System..............................44
Blower Resistor............................44
Blower Switch.............................44
Heater Blower Motor.........................44
Heat Mode Select Switch......................44
Heater Blower Motor..........................44
Heater Element..............................52
Heavy Duty Cooling (4.0L).......................7
Fan Control Relay...........................7
Powertrain Control Module.....................7
Radiator Fan Motor..........................7
High-Beam Indicator Lamp......................41
Horn System...............................27
Horn Brush/Slip Ring........................27
Horn Relay...............................27
Horn Switch..............................27
Left Side Horn.............................27
Right Side Horn............................27
Idle Air Control Motor.........................14
Ignition Key Warning Switch.....................43
Ignition Switch...............................8
Ignition System..............................8
Instrument Cluster............................37
Instrument Cluster Connector.....................37
Instrument Cluster Connector 16 Way...............69
Instrument Cluster Indicator Printed Circuit Board.......40
Instrument Cluster Printed Circuit Board (Standard)......41
Instrument Panel Ground.......................32
Instrument Panel Illumination..................25, 26
Heated Rear Window Switch Illumination...........25
Heater A/C Panel Lamp.......................25
Rear Wiper/Wash Switch Lamp..................26
Transfer Case Lamp.........................26
Transmission Range Lamp.....................26
Intake Air Temp Sensor........................11
Intermittent Front Wipers/Washers...............33, 34
Intermittent Wiper Module.......................33
Lamps
Ashtray Illumination Lamp.....................26
Back-Up Lamp..........................55, 56
Cargo Lamp..............................30
Check Engine Indicator Lamp................39, 40
Cigar Lighter Illumination......................58
Dome Lamp..............................31
8W - 272 WIRING DIAGRAMSJ

Wiring Diagram Name Sheet Number
Fuel Pump Relay..........................3,9
Heated Rear Window Relay....................60
Horn Relay...............................27
LCD Illumination Relay.......................57
Right Front Door Jamb Switch....................49
Right Rear Door Jamb Switch....................49
Right Speaker...............................48
Seat Belt Switch.............................43
Seat Belt Indicator Lamp.....................39, 40
Sensors
Camshaft Position Sensor.....................12
Crankshaft Position Sensor.....................12
Engine Coolant Temperature Sensor...............11
Fuel Gauge Sensor..........................54
Heated Oxygen Sensor.......................13
Intake Air Temperature Sensor..................11
Map Sensor..............................11
Throttle Position Sensor......................11
Vehicle Speed Sensor........................16
Speakers, Radio...........................47, 48
Splices
Splice A3..............................1,19
Splice A11................................5
Splice A14................................9
Splice A21................................9
Splice A21-1............................8,43
Splice A48.............................2,33
Splice A142..............................14
Splice A142-1.............................14
Splice A142-2.........................5,10,14
Splice C7................................46
Splice C15...............................52
Splice C15-1..............................52
Splice C43............................44, 46
Splice C90...............................45
Splice E2................................25
Splice F12...............................10
Splice F85.............................47, 58
Splice G7.............................12, 16
Splice K4................................11
Splice K4-1...............................11
Splice K6................................11
Splice K7................................12
Splice K22...............................11
Splice K29................................9
Splice L3................................21
Splice L90...............................55
Splice L90-1..............................22
Splice L90-2..............................56
Splice L90-3..............................55
Splice M1................................31
Splice M1-1..............................29
Splice M2................................30
Splice M2-1..............................29
Splice M2-2..............................30
Splice P79...............................51
Splice V32...............................53
Splice Z1-1...............................59Wiring Diagram Name Sheet Number
Splice Z1-2...............................20
Splice Z1-3...............................32
Splice Z1-4...............................28
Splice Z1-5............................59, 60
Splice Z1-6...............................55
Splice Z1-7...............................56
Splice Z1-10..............................22
Splice Z1-13..............................51
Splice Z1-14...............................7
Splice Z1-15..............................59
Splice Z1-16..............................16
Splice Z11...............................10
Splice Z12-1..............................13
Splice 117...............................21
Starter System...............................6
Battery..................................6
Engine Starter Motor.........................6
Engine Starter Relay..........................6
Steering Column Connector 11 Way................67
Stop Lamp Switch............................24
Stop/Turn and Hazard System..................23, 24
Hazard Flasher.............................24
Hazard Switch.............................24
Stop Lamp Switch..........................24
Turn and Hazard Flasher Switch.................24
Turn Signal Flasher..........................23
Switches
A/C Low Pressure Switch.....................45
A/C Mode Selector Switch.....................46
Back-Up Lamp Switch........................16
Blower Switch..........................44, 46
Brake Warning Switch........................42
Engine Coolant Temperature Switch...............15
Engine Oil Pressure Switch....................15
Fog Lamp Switch...........................20
Front Axle Switch...........................16
Hazard Switch.............................24
Headlamp Dimmer Switch.....................19
Headlamp Switch.........................1,19
Heated Rear Window Switch....................60
Heat Mode Select Switch......................44
Horn Switch..............................27
Ignition Key Warning Switch....................43
Ignition Switch.............................8
Left Front Door Jamb Switch...................50
Left Rear Door Jamb Switch...................50
Liftgate Switch............................50
Oil Pressure Switch.........................15
Park Brake Switch..........................42
Park Switch (Wiper).........................34
Power Mirror Switch.........................51
Rear Wiper/Washer Switch.....................35
Reed Switch..............................18
Right Front Door Jamb Switch..................49
Right Rear Door Jamb Switch..................49
Seat Belt Switch...........................43
Stop Lamp Switch..........................24
Transmission Range Switch....................17
8W - 274 WIRING DIAGRAMSJ

can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a lo-
cating dowel is recommended during assembly to pre-
vent smearing the material off location.
ENGINE PERFORMANCE
To provide best vehicle performance and lowest ve-
hicle emissions, it is most important that the tune-up
be done accurately. Use the specifications listed on
the Vehicle Emission Control Information label
found on the engine compartment hood.
(1) Test battery specific gravity. Add water, if nec-
essary. Clean and tighten battery connections.
(2) Test cranking amperage draw (refer to Group
8B, Battery/Starter Service for the proper proce-
dures).
(3) Tighten the intake manifold bolts (refer to
Group 11, Exhaust System and Intake Manifold for
the proper specifications).
(4) Perform cylinder compression test:
(a) Check engine oil level and add oil, if neces-
sary.
(b) Drive the vehicle until engine reaches normal
operating temperature.
(c) Select a route free from traffic and other
forms of congestion, observe all traffic laws and
briskly accelerate through the gears several times.
The higher engine speed may help clean out valve
seat deposits which can prevent accurate compres-
sion readings.
CAUTION: DO NOT overspeed the engine.
(d) Remove all spark plugs from engine. As
spark plugs are being removed, check electrodes for
abnormal firing indicators - fouled, hot, oily, etc.
Record cylinder number of spark plug for future
reference.
(e) Disconnect coil wire from distributor and se-
cure to good ground to prevent a spark from start-
ing a fire.
(f) Be sure throttle blades are fully open during
the compression check.
(g) Insert compression gage adaptor into the
No.1 spark plug hole. Crank engine until maxi-
mum pressure is reached on gauge. Record this
pressure as No.1 cylinder pressure.
(h) Repeat Step 4g for all remaining cylinders.
(i) Compression should not be less than 689 kPa
(100 psi) and not vary more than 172 kPa (25 psi)
from cylinder to cylinder.
(j) If cylinder(s) have abnormally low compres-
sion pressures, repeat steps 4a through 4h.
(k) If the same cylinder(s) repeat an abnormally
low reading, it could indicate the existence of a
problem in the cylinder.
The recommended compression pressures are
to be used only as a guide to diagnosing engineproblems. An engine should NOT be disassem-
bled to determine the cause of low compression
unless some malfunction is present.
(5) Clean or replace spark plugs as necessary. Ad-
just gap (refer to Group 8D, Ignition System for gap
adjustment and torque).
(6) Test resistance of spark plug cables (refer to
Group 8D, Ignition System).
(7) Inspect the primary wire. Test coil output volt-
age, primary and secondary resistance. Replace parts
as necessary (refer to Group 8D, Ignition System and
make necessary adjustment).
(8) Set ignition timing to specifications (refer to
Specification Label on engine compartment hood).
(9) Perform a combustion analysis.
(10) Test fuel pump for pressure and vacuum (refer
to Group 14, Fuel System for the proper specifica-
tions).
(11) Inspect air filter element (refer to Group 0,
Lubrication and Maintenance for the proper proce-
dure).
(12) Inspect crankcase ventilation system (refer to
Group 0, Lubrication and Maintenance for the proper
procedure).
(13) For emission controls refer to Group 25, Emis-
sion Controls System for service procedures.
(14) Inspect and adjust accessory belt drives (refer
to Group 7, Cooling System for the proper adjust-
ments).
(15) Road test vehicle as a final test.
HONING CYLINDER BORES
Before honing, stuff plenty of clean shop towels un-
der the bores and over the crankshaft to keep abra-
sive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). 20-60 strokes, de-
pending on the bore condition, will be sufficient to
provide a satisfactory surface. Using honing oil
C-3501-3880 or a light honing oil available from ma-
jor oil distributors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
9 - 2 ENGINESJ

ENGINE DIAGNOSIS
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine tune-ups.
These malfunctions may be classified as either per-
formance (e.g., engine idles rough and stalls) or me-
chanical (e.g., a strange noise).
Refer to the Service DiagnosisÐPerformance chart
and the Service DiagnosisÐMechanical chart for pos-
sible causes and corrections of malfunctions. Refer to
Group 14, Fuel System for the fuel system diagnosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can
not be isolated with the Service Diagnosis charts. In-
formation concerning additional tests and diagnosis
is provided within the following diagnosis:
²Cylinder Compression Pressure Test.
²Cylinder Combustion Pressure Leakage Test.
²Engine Cylinder Head Gasket Failure Diagnosis.
²Intake Manifold Leakage Diagnosis.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A DI-
RECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
METHOD 1
(1) Start the engine.
(2) Open the acetylene valve of an oxyacetylene
torch. DO NOT ignite.
(3) Pass the torch tip over the exposed gasket area
(EDGE) between the manifold and the engine cylin-
der head.
(4) If the engine speed increases, the manifold has
an air leak.
METHOD 2
(1) Start the engine.
(2) Apply engine oil to the exposed gasket area
(EDGE) between the manifold and the engine cylin-
der head.
(3) If oil is forced into the manifold and if smoke is
visible from the exhaust tailpipe, the manifold has
an air leak.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Clean the spark plug recesses with compressed
air.
(2) Remove the spark plugs.
(3) Secure the throttle in the wide-open position.
(4) Disconnect the ignition coil.
(5) Insert a compression pressure gauge and rotate
the engine with the engine starter motor for three
revolutions.
(6) Record the compression pressure on the 3rd
revolution. Continue the test for the remaining cyl-
inders.
Refer to Engine Specifications for the correct en-
gine compression pressures.
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS
A leaking engine cylinder head gasket usually re-
sults in loss of power, loss of coolant and engine mis-
firing.
An engine cylinder head gasket leak can be located
between adjacent cylinders or between a cylinder and
the adjacent water jacket.
²An engine cylinder head gasket leaking between
adjacent cylinders is indicated by a loss of power
and/or engine misfire.
²An engine cylinder head gasket leaking between a
cylinder and an adjacent water jacket is indicated by
coolant foaming or overheating and loss of coolant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders; follow the proce-
dures outlined in Cylinder Compression Pressure
Test. An engine cylinder head gasket leaking be-
tween adjacent cylinders will result in approximately
a 50-70% reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE
TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A DI-
RECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
Remove the radiator cap.
Start the engine and allow it to warm up until the
engine thermostat opens.
If a large combustion/compression pressure leak ex-
ists, bubbles will be visible in the coolant.
If bubbles are not visible, install a radiator pres-
sure tester and pressurize the coolant system.
JENGINES 9 - 5

(a) Align the transmission torque converter
housing with the engine.
(b) Loosely install the converter housing lower
bolts and install the next higher bolt and nut on
each side.
(c) Tighten all 4 bolts finger-tight.
(5) Install the engine support cushions (if re-
moved).
(6) Lower the engine and engine support cushions
onto the engine compartment brackets.
(7) Remove the engine lifting device.
(8) Raise the vehicle.
(9) If equipped with an automatic transmission:
(a) Install the converter-to-drive plate bolts. En-
sure the installation reference marks are aligned.
Tighten the bolts to 54 Nzm (40 ft. lbs.) torque.
(b) Install the converter-housing access cover.
(c) Install the exhaust pipe support.
(10) Install the remaining converter or flywheel
housing bolts.
(11) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(12) Tighten the engine support cushing through-
bolt nuts.
(13) Install the remaining flywheel/converter hous-
ing bolts. Tighten the bolts to 38 Nzm (28 ft. lbs.)
torque.
(14) Connect the exhaust pipe to the manifold.
(15) Install the oil filter.
(16) Lower the vehicle.
(17) Connect the coolant hoses and tighten the
clamps.
(18) If equipped with power steering:
(a) Remove the protective caps
(b) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 Nzm (38 ft. lbs.)
torque.
(c) Fill the pump reservoir with fluid.
(19) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
(20) Install the fan shroud and radiator/condenser
(if equipped with air conditioning).
(21) Connect the radiator hoses.
(22) Connect the automatic transmission fluid
cooler pipes, if equipped.
(23) Connect the oxygen sensor wire connector.
(24) Connect the throttle valve rod and retainer.
Connect the throttle cable and install the rod. Install
the throttle valve rod spring.
(25) Connect the speed control cable, if equipped.
(26) Connect the fuel supply and return lines to
the throttle body.
(27) Connect all the vacuum hoses and wire con-
nectors.
(28) Connect the service valves to the A/C com-
pressor ports, if equipped with air conditioning.(29) Fill the power steering reservoir.
(30) Connect the battery cables.
(31) Install the hood.
(32) Install the air cleaner.
(33) Start the engine and inspect for leaks.
(34) Fill the cooling system.
(35) Stop the engine and check the fluid levels.
Add fluid, as required.
ENGINE ASSEMBLYÐYJ VEHICLES
REMOVAL
(1) Place a protective cloth over the windshield
frame. Raise the hood and rest it on the windshield
frame (Fig. 19).
(2) Disconnect the battery cable clamps and re-
move the battery.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND
CAP.
(3) Remove the radiator drain cock and radiator
cap to drain the coolant. DO NOT waste usable cool-
ant. If the solution is clean, drain the coolant into a
clean container for reuse.
(4) Disconnect the wire connectors from the gener-
ator.
(5) Disconnect the ignition coil and distributor
wire connectors.
(6) Disconnect the oil pressure sender wire connec-
tor.
Fig. 19 Hood on Windshield Frame
9 - 16 2.5L ENGINEJ

(14) Install the remaining flywheel housing bolts.
Tighten the bolts to 38 Nzm (28 ft. lbs.) torque.
(15) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(16) Install the oil filter.
(17) Lower the vehicle.
(18) Connect the coolant hoses and tighten the
clamps.
(19) If equipped with power steering:
(a) Remove the protective caps
(b) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 Nzm (38 ft. lbs.)
torque.
(c) Fill the pump reservoir with fluid.
(20) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
(21) Tighten the serpentine drive belt according to
the specifications listed in Group 7, Cooling System.
(22) Install the fan shroud and radiator.
(23) Connect the radiator hoses.
(24) Connect the heater hoses.
(25) Connect the throttle valve rod and retainer.
(26) Connect the throttle cable and install the rod.
(27) Install the throttle valve rod spring.
(28) Connect the speed control cable, if equipped.
(29) Connect the oxygen sensor wire connector.
(30) Install the vacuum hose and check valve on
the brake booster.
(31) Connect the coolant temperature sensor wire
connector.
(32) Connect the idle speed actuator wire connec-
tor.
(33) Connect the fuel inlet and return hoses at the
fuel rail. Verify that the quick-connect fitting assem-
bly fits securely over the fuel lines by giving the fuel
lines a firm tug.
(34) Install the fuel line bracket to the intake
manifold.
(35) Connect all fuel injection wire connections.
(36) Install the engine ground strap.
(37) Connect the ignition coil wire connector.
(38) Remove the coolant temperature sending unit
to permit air to escape from the block. Fill the cool-
ing system with coolant. Install the coolant tempera-
ture sending unit when the system is filled.
(39) Install the battery and connect the battery ca-
bles.
(40) Install the air cleaner bonnet to the throttle
body.
(41) Install the air cleaner.
(42) Lower the hood and secure in place.
(43) Start the engine and inspect for leaks.
(44) Stop the engine and check the fluid levels.
Add fluid, as required.ENGINE CYLINDER HEAD COVER
A cured gasket is part of the engine cylinder head
cover.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect the Crankcase Ventilation (CCV)
vacuum hose from engine cylinder head cover (Fig.
1).
(3) Disconnect the fresh air inlet hose from the en-
gine cylinder head cover (Fig. 1).
(4) Remove the engine cylinder head cover mount-
ing bolts.
(5) Remove the engine cylinder head cover.
CLEANING
Remove any original sealer from the cover sealing
surface of the engine cylinder head and clean the
surface using a fabric cleaner.
Remove all residue from the sealing surface using
a clean, dry cloth.
INSPECTION
Inspect the engine cylinder head cover for cracks.
Replace the cover, if cracked.
The original grey gasket material should NOT be
removed. If sections of the gasket material are miss-
ing or are compressed, replace the engine cylinder
head cover. However, sections with minor damage
such as small cracks, cuts or chips may be repaired
with a hand held applicator. The new material must
be smoothed over to maintain gasket height. Allow
the gasket material to cure prior to engine cylinder
head cover installation.
INSTALLATION
(1) If a replacement cover is installed, transfer the
CCV valve grommet the oil filler cap from the origi-
nal cover to the replacement cover.
(2) Install engine cylinder head cover. Tighten the
mounting bolts to 10 Nzm (85 in. lbs.) torque.
Fig. 1 Engine Cylinder Head Cover
9 - 18 2.5L ENGINEJ