1994 JEEP CHEROKEE stop start

Wiring Diagram Name Sheet Number
License Lamp...........................91,95
Low Washer Indicator Lamp..................57,58
Malfunction Indicator Lamp..................57,58
Maintenance Required Indicator Lamp...........57,58
Park Brake Indicator Lamp.....................58
Reading Lamp.............................51
Rear Wiper/Wash Switch Lamp..................47
Right Back-Up Lamp.......................92,96
Right Courtesy Lamp........................49
Right Fog Lamp............................40
Right Headlamp............................40
Right Park/Turn Signal Lamp...................40
Right Side Marker Lamp (Front).................40
Right Side Marker (Rear)....................92,96
Right Tail/Stop Lamp......................92,96
Right Turn Indicator Lamp.................59,60,61
Right Turn Lamp (Amber)...................92,96
Right Vanity Lamp..........................51
Seat Belt Warning Indicator Lamp..............57,58
Transfer Case Lamp.........................48
Transmission Range Switch Lamp................48
Underhood Lamp...........................34
Upshift Indicator Lamp.....................57,58
Vanity Lamps...........................51,53
L.C.D. Illumination Relay........................52
Left Front Door Connector And Door Lock Switch
Function Chart.............................87
Left Front Door Connector and Widow Lift Switch
Function Chart.............................87
Left Front Door Jamb Switch.....................75
Left Front Door Lock Motor......................86
Left Front Door Speaker........................71
Left Front Wheel Sensor........................29
Left Instrument Panel Speaker....................71
Left Liftgate Speaker..........................72
Left Power Seat Motor Assembly..................77
Left Power Seat Switch........................77
Left Rear Door Connector and Window Lift Switch
Function Chart.............................88
Left Rear Door Jamb Switch.....................75
Left Rear Door Window Switch...................82
Left Rear Wheel Sensor........................29
Left Turn Relay..............................97
Liftgate Switch..............................76
Liftgate Lock motor...........................86
Lo-Line Instrument Cluster Printed Circuit Board........60
Low Fuel Warning Module...................59,60,61
Low Washer Indicator Lamp...................57,58
Main Body Connectors........................112
Maintenance Required Indicator Lamp.............57,58
Malfunction Indicator Lamp....................57,58
Map Sensor..............................14,19
Modules
Anti-Lock Brake System Module.........29,30,31,32,33
Chime Module.............................74
Daytime Running Lamp Module.................38
Headlamp Delay Module......................43
Intermittent Wiper Module.....................64Wiring Diagram Name Sheet Number
Low Fuel Warning Module.................59,60,61
Powertrain Control Module. . . .11,12,13,14,15,16,17, 18,19,
20,21,22,23,35,36,45,55,69
Remote Keyless Entry Module...................28
Transmission Control Module.................25,26
Motors
ABS Pump Motor...........................30
A/C Heater Blower Motor......................70
Engine Starter Motor........................7,8
Front Wiper Motor........................63,64
Heater Blower Motor.........................68
Idle Air Control Motor......................15,22
Left Front Door Lock Motor....................86
Left Front Door Window Motor..................81
Left Power Mirror..........................73
Left Power Seat Motor Assembly................77
Left Rear Door Lock Motor....................86
Left Rear Door Window Motor..................82
Liftgate Lock Motor.........................86
Radiator Fan Motor.........................23
Rear Wiper Motor..........................65
Right Front Door Lock Motor...................86
Right Front Door Window Motor.................81
Right Power Mirror.........................73
Right Rear Door Lock Motor...................86
Right Rear Door Window Motor.................82
Oil Pressure Switch...........................24
Overhead Console System.....................53,54
Ambient Temperature Sensor...................53
Overhead Console..........................53
Vanity Lamps.............................53
Park Brake Switch............................67
Park Brake Indicator Lamp......................58
Parking Brake Switch..........................67
Park Lamp Relay.............................39
Park/Neutral Position Switch......................7
Pedal Travel Sensor...........................30
Power Distribution Center....................1,2,3,4
Power Distribution Center Application Chart............4
Power Distribution Center Identification...............3
Power Door Locks......................83,84,85,86
Left Door Lock Switch.......................85
Left Front Door Lock Motor....................86
Left Rear Door Lock Motor....................86
Liftgate Lock Motor.........................86
Power Door Lock Relay.......................83
Power Door Unlock Relay.....................83
Right Door Lock Switch......................85
Right Front Door Lock Motor...................86
Right Rear Door Lock Motor...................86
Power Door Lock Relay........................83
Power Door Unlock Relay.......................83
Power Mirror Connector.......................110
Power Mirror Connector and Switch Function Chart......88
Power Mirror Switch Assembly...................73
Power Mirror System..........................73
Left Power Mirror..........................73
Power Mirror Switch Assembly..................73
8W - 152 WIRING DIAGRAMSJ

Wiring Diagram Name Sheet Number
Right Power Mirror.........................73
Power Mirrors.............................73
Power Seat..............................77,78
Left Power Seat Motor Assembly................77
Left Power Seat Switch.......................78
Power Steering Pressure Switch...................15
Powertrain Control Module......11,12,13,14,15,16,17,18,19,
20,21,22,23,35,36,45,55,69
Powertrain Control Module (PCM) Connector..........111
Power Windows.......................79,80,81,82
Left Front Door Window Motor..................81
Left Rear Door Window Motor..................82
Left Rear Door Window Switch..................82
Power Window Switch.......................79
Right Front Door Window Switch................81
Right Front Door Window Motor.................81
Right Rear Door Window Motor.................82
Right Rear Door Window Switch.................82
Power Window Switch.........................79
Printed Circuit Boards.................57,58,59,60,61
Pumps
Front Washer...........................63,64
Rear Washer..............................65
Radiator Fan Motor...........................23
Radio....................................71
Antenna Mast.............................71
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
Reading Lamps..............................51
Rear Lighting...................91,92,93,94,95,96,97
Left Back-Up Lamp........................91,93
Left Side Marker Lamp (Rear)................91,93
Left Tail/Stop Lamp.......................91,93
Left Turn Lamp (Amber)....................91,93
Left Turn Relay............................97
License Lamp...........................91,95
Right Back-Up Lamp.......................92,96
Right Side Marker Lamp (Rear)...............92,96
Right Tail/Stop Lamp......................92,96
Right Turn Lamp (Amber)...................92,96
Right Turn Relay...........................97
Stop Lamp Relay...........................97
Trailer Tow Connector........................93
Trailer Tow In-Line Circuit Breaker................97
Rear Lighting With Trailer Tow............93,94,95,96,97
Rear Lighting Without Trailer Tow................91,92
Rear Washer Pump...........................65
Rear Wiper Motor............................65
Rear Wiper/Washer Motor.......................65
Rear Washer Pump...........................65
Rear Wiper Motor............................65
Rear Wiper/Washer Switch......................65
Rear Wiper/Washer Switch Lamp..................47
Reed Switch................................26Wiring Diagram Name Sheet Number
Relays
ABS #1 Relay............................3,31
ABS #2 Relay............................3,31
A/C Compressor Clutch Relay..................3,69
Automatic Shut Down Relay.................3,12,17
Cooling Fan Relay...........................3
EMCC Relay.............................3,27
Engine Starter Relay.......................3,7,8
Fan Control Relay...........................23
Fuel Pump Relay........................3,12,17
Heated Rear Window Relay....................66
High Beam Relay...........................40
Horn Relay...............................34
L.C.D. Illumination Relay......................52
Left Turn Relay............................97
Park Lamp Relay...........................39
Power Door Lock Relay.......................83
Power Door Unlock Relay.....................83
Right Turn Relay...........................97
Stop Lamp Relay...........................97
Relay Center Identification......................113
Remote Keyless Entry System....................28
Remote Keyless Entry Module...................28
Remote Keyless Entry Module Connector...........114
Resistor,Ballast..............................39
Resistor,Blower..............................68
Right Front Door Jamb Switch....................76
Right Front Door Speaker.......................72
Right Front Door Window Switch..................81
Right Front Wheel Sensor.......................29
Right Front Door Connector and Door Lock Switch
Function Chart.............................87
Right Front Door Lock Motor.....................86
Right Instrument Panel Speaker...................72
Right Liftgate Speaker.........................72
Right Front Door Window Connector and Window Lift
Switch Function Chart........................87
Right Rear Door Jamb Switch....................76
Right Rear Door Window Connector and Window Lift
Function Chart.............................88
Right Rear Wheel Sensor.......................29
Right Turn Relay.............................97
Seat Belt Switch.............................74
Seat Belt Warning Indicator Lamp................57,58
Sensors
Ambient Temperature Sensor...................53
Camshaft Position Sensor...................11,20
Crankshaft Position Sensor...................11,20
Engine Coolant Temperature Sensor.............14,19
G Sensor................................30
Heated Oxygen Sensor.....................13,21
Intake Air Temperature Sensor................14,19
Left Front Wheel Sensor......................29
Left Rear Wheel Sensor.......................29
MAP Sensor............................14,19
Pedal Travel Sensor.........................30
Right Front Wheel Sensor.....................29
Right Rear Wheel Sensor......................29
JWIRING DIAGRAMS 8W - 153

Wiring Diagram Name Sheet Number
Dome/Reading Lamp.........................31
Fog Lamps............................21, 22
Fog Lamp Illumination Lamp...................20
4WD Select Trac Indicator Lamp..............39, 40
Front Headlamps.........................21, 22
Full Time Indicator Lamp...................39, 40
Glove Box Lamp...........................29
Heated Rear Window Lamp....................25
Heater A/C Panel Lamp.......................25
High-Beam Indicator Lamp.....................41
Instrument Cluster Illumination Lamps.............41
Left Backup Lamp..........................55
Left Fog Lamp.............................21
Left Headlamp.............................21
Left Park/Turn Signal Lamp....................21
Left Side Marker...........................55
Left Side Marker Lamp (Front)..................21
Left Tail/Stop Lamp.........................55
Left Turn Indicator Lamp......................41
Left Turn Lamp (Amber)......................55
License Lamp.............................55
Low Washer Indicator Lamp.................39, 40
Maintenance Required Indicator Lamp...........39, 40
Malfunction Indicator Lamp..................39, 40
Park Brake Indicator Lamp.....................40
Park/Turn Signal Lamps....................21, 22
Reading Lamp.............................31
Rear Wiper/Wash Switch Lamp..................26
Right Back-up Lamp.........................56
Right Fog Lamp............................22
Right Headlamp............................22
Right Park/Turn Signal Lamp...................22
Right Side Marker..........................56
Right Side Marker Lamp (Front).................22
Right Tail/Stop Lamp........................56
Right Turn Indicator Lamp.....................41
Right Turn Lamp (Amber).....................56
Seat Belt Indicator Lamp...................39, 40
Side Marker Lamps (Front)..................21, 22
Transfer Case Lamp.........................26
Transmission Range Lamp.....................26
Underhood Lamp...........................28
Upshift Indicator Lamp.....................39, 40
Vanity Lamps.............................31
LCD Illumination Relay.........................57
Left Front Door Jamb Switch.....................50
Left Rear Door Jamb Switch.....................50
Left Speakers............................47, 48
Liftgate Switch..............................50
Low Washer Indicator Lamp...................39, 40
Main Body Connector 1........................70
Maintenance Required Indicator Lamp............39, 40
Map Sensor................................11
Modules
Chime Module.............................43
Fuel Pump Module..........................54
Intermittent Wiper Module.....................33
Powertrain Control Module . .7, 9, 10, 11, 12, 13, 14, 45, 53Wiring Diagram Name Sheet Number
Transmission Control Module.................17, 18
Motors
A/C Heater Blower Motor......................46
Engine Starter Motor.........................6
Front Wiper Motor..........................34
Heater Blower Motor.........................44
Idle Air Control Motor........................14
Radiator Fan Motor..........................7
Rear Wiper Motor..........................36
Oil Pressure and Temperature System...............15
Coolant Temperature Switch....................15
Oil Pressure Switch.........................15
Park Brake Indicator Lamp......................40
Park Brake Switch............................42
Power Distribution Center........................1
Power Distribution Center Application Chart............4
Power Distribution Center Identification...............3
Power Mirror Connector........................61
Power Mirror Switch Assembly...................51
Power Mirrors............................51, 52
Heater Element............................52
Left Power Mirror..........................52
Right Power Mirror.........................52
Powertrain Control Module . . .7, 9, 10, 11, 12, 13, 14, 45, 53
Powertrain Control Module Connector...............73
Pumps
Front Washer.............................34
Rear Washer..............................35
Fuel...................................54
Radiator Fan Motor............................7
Radio.................................47, 48
Antenna Mast.............................47
Left Instrument Panel Speaker..................47
Left Liftgate Speaker.........................48
Radio..................................47
Right Instrument Panel Speaker.................48
Right Liftgate Speaker........................48
Rear Lighting............................55, 56
Left Back-Up Lamp..........................55
Left Side Marker...........................55
Left Tail/Stop Lamp.........................55
Left Turn Lamp (Amber)......................55
License Lamp.............................55
Right Back-Up Lamp.........................56
Right Side Marker..........................56
Right Tail/Stop Lamp........................56
Right Turn Lamp (Amber).....................56
Rear Wiper/Washer.........................35, 36
Rear Washer Pump.........................35
Rear Wiper Motor..........................36
Rear Wiper/Washer Switch.....................35
Reading Lamps..............................31
Relays
A/C Compressor Clutch Relay.................3,45
Automatic Shut Down Relay...................3,9
Engine Starter Relay........................3,6
Fan Control Relay.........................3,7
Fog Lamp Relay...........................21
JWIRING DIAGRAMS 8W - 273

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

(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

(17) Tighten the serpentine drive belt according to
the specifications listed in Group 7, Cooling System.
(18) Install the fan shroud and radiator (refer to
Group 7, Cooling System for the proper procedure).
(19) Connect the radiator hoses.
(20) Connect the throttle valve rod and retainer.
(21) Connect the throttle cable and install the rod.
(22) Install the throttle valve rod spring.
(23) Connect the speed control cable, if equipped.
(24) Connect the oxygen sensor wire connector.
(25) Install the vacuum hose and check valve on
the brake booster.
(26) Connect the coolant temperature sensor wire
connector.
(27) Connect the idle speed actuator wire connec-
tor.
(28) 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.
(29) Install the fuel line bracket to the intake
manifold.
(30) Connect all fuel injection wire connections.
(31) Install the engine ground strap.
(32) Connect the ignition coil wire connector.
(33) 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.
(34) 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.
(35) Install the battery and connect the battery ca-
bles.
(36) Install the air cleaner bonnet to the throttle
body.
(37) Install the air cleaner.
(38) Lower the hood and secure in place.
(39) Start the engine and inspect for leaks.
(40) 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 and oil filler cap from the orig-
inal cover to the replacement cover.
(2) Install engine cylinder head cover. Tighten the
mounting bolts to 10 Nzm (85 in. lbs.) torque.
(3) Connect the CCV hoses (Fig. 1).
(4) Connect negative cable to battery.
ROCKER ARMS
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Remove the engine cylinder head cover.
(2) Remove the capscrews at each bridge and pivot
assembly (Fig. 2). Alternately loosen the capscrews
one turn at a time to avoid damaging the bridges.
Fig. 1 Engine Cylinder Head Cover
J4.0L ENGINE 9 - 59

(3) Using a brass punch and a hammer, install
lock ring. Carefully tap lock ring clockwise until it
seats against stop on fuel tank.
(4) Connect fuel supply and return hoses to fittings
on fuel pump module. Tighten hose clamps.
(5) Connect fuel pump module electrical harness
connector to main harness connector.
(6) Lower vehicle.
(7) Fill fuel tank. Install fuel tank cap.
(8) Connect negative battery cable.
(9) Start vehicle and inspect for leaks.
REMOVALÐYJ MODELS
The fuel tank must be removed to remove the fuel
pump module.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE FUEL PUMP MODULE,
THE FUEL SYSTEM PRESSURE MUST BE RE-
LEASED. REFER TO THE FUEL PRESSURE RE-
LEASE PROCEDURE IN THIS GROUP.
WARNING: EXTINGUISH ALL TOBACCO SMOKING
PRODUCTS BEFORE SERVICING THE FUEL SYS-
TEM. KEEP OPEN FLAME AWAY FROM FUEL SYS-
TEM COMPONENTS.
(1) Remove negative battery cable.
(2) Remove fuel filler cap. Perform the Fuel Pres-
sure Release Procedure as outlined in this group.
(3) Remove fuel tank. Refer to Fuel Tank Remov-
alÐYJ Models.
(4) Remove fuel pump module assembly.
(5) Remove mounting screws. Lift assembly and
gasket out of fuel tank. Discard old gasket (Fig. 4).
(6) Remove and discard fuel pump inlet filter.DISASSEMBLYÐYJ MODELS
(1) Remove and discard fuel pump inlet filter (Fig.
5).
The wire terminals to the fuel pump motor are dif-
ferent in size and cannot be connected to the wrong
terminal.
(2) Disconnect fuel pump terminal wires from
pump.
(3) Remove fuel pump outlet hose and clamp (Fig.
6). Replace the hose if it shows any signs of fatigue
or failure.
(4) Remove fuel pump top mounting bracket nut
(Fig. 6). Remove fuel pump.
ASSEMBLYÐYJ MODELS
Whenever the fuel pump is replaced, the fuel pump
inlet filter (sock) must also be replaced.
(1) Place fuel pump top mounting bracket over top
of pump.
(2) Position fuel pump into lower bracket. Slide
stud of top bracket through hole in fuel pump side
bracket. Tighten fuel pump top mounting nut.
Fig. 4 Fuel Pump ModuleÐRemove/InstallÐYJ
Models
Fig. 5 Fuel Pump ModuleÐYJ Models
Fig. 6 Fuel Pump Removal/InstallationÐYJ Models
14 - 4 FUEL SYSTEMJ