(3) Attach catalytic converter, muffler or tailpipe
insulator to support hanger to insulator.
FUEL AND BRAKE FLUID TUBE RETAINER CLIP
REMOVAL
(1) Remove the fuel/brake fluid tubes from clip
grooves.
(2) As applicable, pry serrated clip outward and re-
move it from frame rail hole, or remove stand-off
bracket screw.
INSTALLATION
(1) Position clip at the frame/panel hole.
(2) As applicable, force serrated clip inward and
seat it against the frame/panel, or install the stand-
off bracket screw.
(3) Insert fuel/brake fluid tubes in clip grooves and
press inward to seat them.
FUEL FILTER BRACKET
REMOVAL
(1) Remove screws that attach fuel filter bracket to
frame rail.
(2) Remove the screw from fuel filter bracket
clamp.
(3) Remove the clamp and fuel filter from bracket.
(4) Remove the bracket from filter.
INSTALLATION
(1) Position fuel filter bracket on filter.
(2) Position clamp on bracket and install screw.
Tighten screw to 8 Nzm (74 in-lbs) torque.(3) Position fuel filter bracket on frame rail.
(4) Install the screws that attach bracket to frame
rail. Tighten screws to 42 Nzm (31 ft-lbs) torque.
FUEL FILLER HOSE SPLASH SHIELDÐXJ
VEHICLES
REMOVAL
(1) Remove the screws that attach fuel filler hose
splash shield to wheelhouse panel and frame rail.
(2) Remove the hose splash shield from wheelhouse
panel and frame rail (Fig. 7).
INSTALLATION
(1) Position fuel filler hose splash shield at wheel-
house panel and frame rail.
(2) Install screws to attach splash shield to wheel-
house panel and frame rail.
FUEL TANK SUPPORT STRAP
SERVICE INFORMATION
XJ fuel tank support straps are attached to the un-
Fig. 4 Fuel and Brake Tube Serrated/Bracket-Type
Retainer ClipsÐXJ Vehicles
Fig. 5 Fuel Filter Bracket Removal/Installation
Fig. 6 Fuel Filter Bracket Clamp
Removal/Installation
23 - 86 BODY COMPONENTSÐXJ VEHICLESJ
A blue wire (without a connector) located under in-
strument panel near fuse panel is available for
trailer electric brake control unit.
The stop lamp and turn signal plug-in relays are
located behind left quarter trim panel.
HITCH REMOVALÐXJ VEHICLES
An XJ class III, weight-distributing/equalizer type
hitch is comprised of:
²a towing tube with a ball mount receptacle, and²various reinforcement/support brackets that are at-
tached to the vehicle frame sills and rear crossmem-
ber with bolts.
(1) If necessary, remove the trailer tow wire har-
ness connector from the hitch.
(2) Support the hitch.
(3) Remove the bolts that attach the towing tube
to the frame sills and reinforcement bracket. If
equipped, remove the fuel tank skid plate.
Fig. 14 Equalizer Type HitchÐXJ Vehicles
Fig. 12 Class III Trailer Tow Wire Harness and
ConnectorsFig. 13 Class III Trailer Tow Wire Harness Plug-In
Relays
JBODY COMPONENTSÐXJ VEHICLES 23 - 89
COMPONENT REMOVAL/INSTALLATION
INDEX
page page
Air Cleaner Housing....................... 8
Air Filter................................ 9
Coolant Temperature Sensor................. 9
EVAP Canister........................... 9Fuel Tank Filler Tube Cap.................. 9
Oxygen (O2S) Sensor...................... 9
Powertrain Control Module (PCM)............. 9
Pressure Relief/Rollover Valve................ 9
AIR CLEANER HOUSING
REMOVAL
(1) Unlock clean air hose clamp (Figs. 3 or 4) at
air cleaner cover. To unlock the clamp, attach adjust-
able pliers to clamp and rotate pliers as shown in fig-
ure 3. Remove clean air hose at cover.
(2) Disconnect vacuum lines at air cleaner hous-
ing.
(3) YJ Models: Release the three over-center type
clamps securing the housing to the housing bracket.
XJ Models: Remove the housing cover and remove
air filter. Remove two bolts and one nut.
(4) Release the air cleaner housing from the ambi-
ent air inlet and remove housing from vehicle.
INSTALLATION
(1) Position air cleaner housing to body and ambi-
ent air inlet.
(2) YJ Models: Lock the three over-center type
clamps securing the housing to the housing bracket.
XJ Models: Install two bolts and one nut to housing.Fig. 3 Air CleanerÐXJ ModelsÐTypical
Fig. 4 Air CleanerÐYJ ModelsÐTypical
Fig. 5 Clamp Removal
25 - 8 EMISSION CONTROL SYSTEMSJ
VARIATION, DISC BRAKE ROTOR
THICKNESS..........................5-31
VEHICLE CODE DECODING............INTRO.-3
VEHICLE CODE PLATE................INTRO.-2
VEHICLE CONTROL AND DISPLAY
SYMBOLS........................INTRO.-7
VEHICLE CONTROL AND DISPLAY
SYMBOLS, INTERNATIONAL.........INTRO.-3
VEHICLE DESIGNATION CODES........INTRO.-1
VEHICLE DESIGNATIONS.............INTRO.-1
VEHICLE DIMENSION DATA....INTRO.-3,INTRO.-4
VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL............25-1
VEHICLE, ENGINE STARTER MOTOR
TEST PROCEDURES ON................8A-9
VEHICLE, GEAR ADJUSTMENTS IN........19-37
VEHICLE, GENERATOR TEST
PROCEDURES ON....................8A-14
VEHICLE IDENTIFICATION NUMBER (VIN)
DECODING.......................INTRO.-2
VEHICLE IDENTIFICATION NUMBER (VIN)
PLATE...........................INTRO.-1
VEHICLE LOAD DATA................INTRO.-3
VEHICLE LOAD DATA, XJ.............INTRO.-5
VEHICLE RESPONSE IN ANTILOCK MODE.....5-3
VEHICLE SAFETY CERTIFICATION LABEL . INTRO.-1
VEHICLE SPEED CONTROL SYSTEM
ELECTRICAL TESTS...................8H-5
VEHICLE SPEED SENSOR................14-60
VEHICLE SPEED SENSOR TEST; FUEL
SYSTEM............................14-45
VEHICLE SPEED SENSOR TEST;
VEHICLE SPEEDCONTROL SYSTEM.......8H-5
VEHICLE SPEED SENSORÐPCM INPUT....14-23
VEHICLE VIBRATION....................22-9
VENT DOOR CONTROL CABLES...........24-39
VENT, HARD TOP ROOF................23-165
VENT WINDOW, FRONT DOOR............23-50
VENT WINDOW GLASS, FULL-METAL
DOOR............................23-177
VENT WINDOW GLASSÐXJ VEHICLES,
REAR QUARTER.....................23-80
VENTILATION, FRESH AIR...............24-39
VENTILATION SYSTEM, CRANKCASE;
EMISSIONCONTROL SYSTEMS...........25-5
VENTILATION SYSTEM, CRANKCASE;
LUBRICATIONAND MAINTENANCE........0-17
VIBRATION; FRONT SUSPENSION AND AXLE . 2-17
VIBRATION; PROPELLER SHAFTS..........16-3
VIBRATION; REAR SUSPENSION AND AXLES . . 3-8
VIBRATION DAMPER; ENGINES........9-26,9-67
VIBRATION DIAGNOSIS; WHEELS AND
TIRES.........................22-9,22-10
VIBRATION, DRIVELINE..................16-3
VIBRATION, TIRE NOISE OR..............22-4
VIBRATION TYPES......................22-9
VIBRATION, VEHICLE....................22-9
VISUAL INSPECTION...................14-32
VOLTAGE, BATTERY OPEN CIRCUIT.........8A-4
VOLTAGE DROP METHOD, STARTER
FEED CIRCUITTESTS -.................8A-9
VOLTAGE SPECIFICATIONS, OUTPUT.......8B-12
VOLTAGE TEST, BATTERY OPEN CIRCUIT....8A-3
VOLTAGEÐPCM INPUT, BATTERY.........14-19
VOLTMETER...........................8E-1
VOLTMETER INOPERATIVE................8E-3
VOLTMETER, OPERATIONAL CHECK.......8A-15
WARNING INOPERATIVE, LOW FUEL........8E-4
WARNING LAMP, LOW FUEL..............8E-2
WARNING LIGHT DISPLAY, ABS............5-3
WARNING LIGHT DISPLAY, BRAKE..........5-4
WARNING LIGHTS, BRAKE.................5-1
WARNING SWITCH REPLACEMENT,
IGNITION KEY........................8U-4
WASHER, DIAGNOSING INTERMITTENT
WINDSHIELD........................8K-12
WASHER, DIAGNOSING NON-
INTERMITTENTWINDSHIELD............8K-12
WASHER, DIAGNOSING REAR WIPER.......8K-6
WASHER INDICATOR INOPERATIVE, LOW....8E-4
WASHER (INTERMITTENT), DIAGNOSING
WINDSHIELD
.........................8K-4
WASHER, INTERMITTENT WIPER
.........8K-20
WASHER (NON-INTERMITTENT),
DIAGNOSINGWINDSHIELD
..............8K-4
WASHER NOZZLE REPLACEMENT
.........8K-13WASHER PUMP REPLACEMENT . . 8K-2 8K-6,8K-11
WASHER PUMP REPLACEMENT, REAR.....8K-13
WASHER PUMP REPLACEMENTÐRIGHT
HAND DRIVE.........................8K-3
WASHER, STANDARD WIPER............8K-19
WASHERS, WINDSHIELD WIPERS..........8A-1
WASHER/THRUST PLATE SPECIFICATIONS,
30RH/32RH SNAP RING/THRUST.......21-322
WATER LEAK DETECTION AND REPAIR,
FIXEDGLASS..................23-83,23-189
WATER PUMPS.....................7-9,7-10
WATER PUMP TESTS.....................7-9
WATERDAM, FULL-METAL DOOR.........23-176
WEAR COMPENSATION, CALIPER
OPERATION..........................5-24
WEAR INDICATORS, TREAD...............22-3
WEAR PATTERNS, TIRE..................22-4
WEATHERSTRIP SEAL, COWL...........23-139
WEATHERSTRIP SEAL, LIFTGATE
OPENING...........................23-70
WEATHERSTRIP SEAL REPLACEMENT,
LIFTGATEGLASS....................23-163
WEATHERSTRIP SEAL, TAILGATE........23-161
WEATHERSTRIP SEAL, WINDSHIELD
FRAME............................23-185
WEATHERSTRIP SEAL/CROSSMEMBER
AIRDEFLECTOR, COWL................23-10
WEATHERSTRIP SEALS, DOOR WINDOW
GLASSAND DOOR OPENING............23-62
WEATHERSTRIP SEALS, FULL-METAL
DOOR............................23-180
WHEEL ALIGNMENT, FRONT...............2-5
WHEEL BALANCE, TIRE..................22-6
WHEEL BEARING LUBRICANTS, CHASSIS
COMPONENT.........................0-30
WHEEL BEARINGS, FRONT...............0-31
WHEEL BRAKE COMPONENTS..............5-1
WHEEL CYLINDER INSTALLATION..........5-37
WHEEL CYLINDER OVERHAUL.............5-36
WHEEL CYLINDER REMOVAL.............5-36
WHEEL INSTALLATION...................22-6
WHEEL LUG NUT......................22-11
WHEEL NUT TIGHTENING............5-32,5-37
WHEEL ORNAMENTATION................22-6
WHEEL REPLACEMENT..................22-6
WHEEL RUNOUT, TIRE...................22-8
WHEEL SENSOR AIR GAP ADJUSTMENT....5-49
WHEEL SENSOR INSTALLATION, FRONT.....5-49
WHEEL SENSOR INSTALLATION, REAR......5-50
WHEEL SENSOR REMOVAL, FRONT........5-49
WHEEL SENSOR REMOVAL, REAR.........5-49
WHEEL SPEED SENSOR OPERATION........5-45
WHEEL SPEED SENSORS.................5-41
WHEEL, STEERING.....................19-45
WHEEL/TIRE SIZE AND INPUT SIGNALS......5-3
WHEELHOUSE FLARES AND LINERS, REAR . 23-18
WHEELHOUSE SPLASH LINERS..........23-146
WHEELHOUSE TRIM PANELSÐXJ
VEHICLES,QUARTER.................23-115
WHEELS..............................22-6
WINDOW APPLIQUEÐXJ VEHICLES,
QUARTER..........................23-29
WINDOW DEFOGGER GRID REPAIR, REAR . . . 8N-2
WINDOW DEFOGGER GRID TEST, REAR.....8N-1
WINDOW DEFOGGER, REAR..............8A-1
WINDOW DEFOGGER SWITCH
REPLACEMENT, REAR..................8N-4
WINDOW EXTERIOR MOULDINGS, DOOR . . . 23-61
WINDOW, FRONT DOOR VENT
............23-50
WINDOW GLASS AND DOOR OPENING
WEATHERSTRIP SEALS, DOOR
..........23-62
WINDOW GLASS, FIXED
..........23-73,23-183
WINDOW GLASS, FRONT DOOR
..........23-49
WINDOW GLASS, FULL-METAL DOOR
.....23-178
WINDOW GLASS, FULL-METAL DOOR
VENT
.............................23-177
WINDOW GLASS, HARD TOP QUARTER
. . . 23-188
WINDOW GLASS, REAR DOOR
...........23-52
WINDOW GLASS, REAR DOOR FIXED
......23-53
WINDOW GLASS REGULATOR, FRONT
DOOR
.............................23-48
WINDOW GLASS REGULATOR, FULL-
METAL DOOR
......................23-177
WINDOW GLASS REGULATOR HANDLE,
FULL-METALDOOR
..................23-175WINDOW GLASS REGULATOR, REAR
DOOR
.............................23-51
WINDOW GLASSÐXJ VEHICLES,
LIFTGATE
...........................23-81
WINDOW GLASSÐXJ VEHICLES,
REAR QUARTERVENT
.................23-80
WINDOW GLASS/REAR QUARTER
PLASTIC INSERTÐXJ VEHICLES,
QUARTER
..........................23-80
WINDOW REGULATOR REPLACEMENT
.......8S-9
WINDOW SWITCH, PASSENGER DOOR
......8S-8
WINDOW SWITCH
..............8S-5,8S-6,8S-7
WINDSHIELD FRAME
..................23-184
WINDSHIELD FRAME WEATHERSTRIP
SEAL
.............................23-185
WINDSHIELD GLASS
..................23-185
WINDSHIELD GLASS REPLACEMENT
......23-75
WINDSHIELD REVEAL MOULDING
. . . 23-73,23-183
WINDSHIELD SERVICE INFORMATION
......23-75
WINDSHIELD SIDE MOULDINGÐXJ
VEHICLES
.........................23-114
WINDSHIELD WASHER, DIAGNOSING
INTERMITTENT
......................8K-12
WINDSHIELD WASHER,
DIAGNOSINGNON-INTERMITTENT
.......8K-12
WINDSHIELD WASHER (INTERMITTENT),
DIAGNOSING
.........................8K-4
WINDSHIELD WASHER (NON-
INTERMITTENT),DIAGNOSING
............8K-4
WINDSHIELD WIPER MOTOR
.............8K-2
WINDSHIELD WIPERS, DIAGNOSING
. . 8K-3,8K-11
WIPER ARM AND PIVOT ASSEMBLY
REPLACEMENT,FRONT
.................8K-9
WIPER ARM REPLACEMENT, FRONT
........8K-8
WIPER ARM REPLACEMENT, REAR
........8K-12
WIPER BLADE REPLACEMENT, FRONT
......8K-8
WIPER CONTROL SWITCH REPLACEMENT
. . . 8K-15
WIPER, DIAGNOSING REAR
...............8K-6
WIPER, LIFTGATE
.......................8K-5
WIPER MODULE, INTERMITTENT
..........8K-5
WIPER MOTOR, FRONT
.................8K-10
WIPER MOTOR REPLACEMENT, REAR
.....8K-13
WIPER MOTOR, WINDSHIELD
.............8K-2
WIPER SWITCH REPLACEMENT,
LIFTGATE
............................8K-6
WIPER SWITCH REPLACEMENT,
REAR
..............................8K-13
WIPER SWITCH TESTING
...............8K-19
WIPER SWITCHES, REAR DEFOGGER/
FOGLAMP/REAR
.....................8E-21
WIPER WASHER, DIAGNOSING REAR
.......8K-6
WIPER WASHER, INTERMITTENT
.........8K-20
WIPER WASHER, STANDARD
............8K-19
WIPERS, DIAGNOSING WINDSHIELD
. . 8K-3,8K-11
WIPERS/WASHERS, FRONT
...............8K-1
WIPERS/WASHERS GENERAL INFORMATION,
FRONT
..............................8K-8
WIPER/WASHER, DIAGNOSING REAR
......8K-14
WIPER/WASHER SWITCH TESTING,
REAR
..........................8K-7,8K-14
WIRE CODE IDENTIFICATION
.............8W-2
WIRING AND COMPONENT IDENTIFICATION
. 8W-13
WIRING AND ELECTRICAL CIRCUITS,
ABS SYSTEM
..........................5-4
WIRING DIAGRAM SHEETS AND INDEXES
. . . 8W-1
WIRING DIAGRAMS YJ
.................8W-73
WIRING PROBLEMS, TROUBLESHOOTING
. . . 8W-3
WIRING REPAIR
.......................8W-4
WIRING, SECONDARY IGNITION
...........8W-1
WOODGRAIN MOULDING
................23-19
WOODGRAIN OVERLAY
.................23-22
WORM SHAFT REPLACEMENT, RACK
PISTON
............................19-30
WORN THREADS, REPAIR DAMAGED OR
.....9-4
JINDEX25
Description Group-Page Description Group-Page Description Group-Page