1994 JEEP CHEROKEE run flat

(3) Install new spring nuts on wheel studs.
(4) Install wheel and lower vehicle.
DISC BRAKE ROTOR THICKNESS
Rotor minimum usable thickness is 22.7 mm (0.89
in.). This dimension is either cast, or stamped on the
rotor hub, or outer edge.
Measure rotor thickness at the center of the brake-
shoe contact surface.
Replace the rotor if worn below minimum thick-
ness. Also replace the rotor if refinishing would re-
duce thickness below the allowable minimum.
DISC BRAKE ROTOR RUNOUT
Check rotor lateral runout whenever pedal pulsa-
tion, or rapid, uneven brakelining wear has occurred.
On 4-wheel drive models, the rotor must be se-
curely clamped to the hub to ensure an accurate
runout measurement. Secure the rotor with the
wheel nuts and 4 or 5 large diameter flat washers on
each stud as shown (Fig. 28).
Use a dial indicator to check lateral runout (Fig. 28).
Maximum allowable rotor lateral runout is 0.13
mm (0.005 in.).Check lateral runout with a dial indicator (Fig.
29). Excessive lateral runout will cause brake pedal
pulsation and rapid, uneven wear of the brakeshoes.
Maximum allowable rotor runout for all models is
0.12 mm (0.005 in.).
DISC BRAKE ROTOR THICKNESS VARIATION
Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
Measure rotor thickness at four to six points
around the rotor face. Position the micrometer ap-
proximately 2 cm (3/4 in.) from the rotor outer cir-
cumference for each measurement (Fig. 30).
Thickness should notvaryby more than 0.013 mm
(0.0005 in.) from point-to-point on the rotor. Refinish
or replace the rotor if necessary.
Fig. 27 Rotor And Hub
Fig. 28 Securing4x4Rotor For Lateral Runout Check
Fig. 29 Typical Method Of Checking Rotor Lateral
Runout
Fig. 30 Measuring Rotor Thickness Variation
JBRAKES 5 - 31

CLUTCH SERVICE
INDEX
page page
Clutch Cover and Disc Installation............ 10
Clutch Cover and Disc Removal............. 10
Clutch Fluid Level........................ 14
Clutch Housing Replacement................ 11
Clutch Hydraulic Linkage Installation.......... 12
Clutch Hydraulic Linkage Removal........... 11Clutch Pedal Installation................... 15
Clutch Pedal Removal..................... 15
Clutch Safety Precautions.................. 10
Flywheel Service......................... 15
Pilot Bearing Replacement................. 11
Release Bearing Replacement............... 11
CLUTCH SAFETY PRECAUTIONS
WARNING: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. DUST AND DIRT ON
CLUTCH PARTS USE MAY CONTAIN ASBESTOS FI-
BERS. BREATHING EXCESSIVE CONCENTRATIONS
OF THESE FIBERS CAN CAUSE SERIOUS BODILY
HARM. WEAR A RESPIRATOR DURING SERVICE
AND NEVER CLEAN CLUTCH COMPONENTS WITH
COMPRESSED AIR OR WITH A DRY BRUSH. EI-
THER CLEAN THE COMPONENTS WITH A WATER
DAMPENED RAGS OR USE A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR REMOVING ASBES-
TOS FIBERS AND DUST. DO NOT CREATE DUST
BY SANDING A CLUTCH DISC. REPLACE THE DISC
IF THE FRICTION MATERIAL IS DAMAGED OR
CONTAMINATED. DISPOSE OF ALL DUST AND
DIRT CONTAINING ASBESTOS FIBERS IN SEALED
BAGS OR CONTAINERS. THIS WILL HELP MINIMIZE
EXPOSURE TO YOURSELF AND TO OTHERS. FOL-
LOW ALL RECOMMENDED SAFETY PRACTICES
PRESCRIBED BY THE OCCUPATIONAL SAFETY
AND HEALTH ADMINISTRATION (OSHA) AND THE
ENVIRONMENTAL SAFETY AGENCY (EPA), FOR
THE HANDLING AND DISPOSAL OF PRODUCTS
CONTAINING ASBESTOS.
CLUTCH COVER AND DISC REMOVAL
(1) Remove transmission. Refer to procedures in
Group 21.
(2) If original clutch cover will be reinstalled,
mark position of cover on flywheel for assembly ref-
erence. Use paint or a scriber for this purpose.
(3) If clutch cover is to be replaced, cover bolts can
be removed in any sequence. However, if original
cover will be reinstalled, loosen cover bolts evenly
and in rotation to relieve spring tension equally.
This is necessary avoid warping cover.
(4) Remove cover bolts and remove cover and disc
(Fig. 2).
CLUTCH COVER AND DISC INSTALLATION
(1) Lightly scuff sand flywheel face with 180 grit
emery cloth. Then clean surface with a wax and
grease remover.
(2) Lubricate pilot bearing with Mopar high tem-
perature bearing grease.
(3) Check runout and free operation of new clutch
disc as follows:
(a) Slide disc onto transmission input shaft
splines. Disc should slide freely on splines.
(b) Leave disc on shaft and check face runout
with dial indicator. Check runout at disc hub and
about 6 mm (1/4 in.) from outer edge of facing.
(c) Face runout should not exceed 0.5 mm (0.020
in.). Obtain another clutch disc if runout exceeds
this limit.
(4) Position clutch disc on flywheel. Be sure side of
disc marked flywheel side is positioned against fly-
wheel (Fig. 2). If disc is not marked, be sure flat side
of disc hub is toward flywheel.
(5) Insert clutch alignment tool in clutch disc (Fig.
3).
(6) Insert alignment tool in pilot bearing and posi-
tion disc on flywheel. Be sure disc hub is positioned
correctly. Side of hub marked Flywheel Side should
face flywheel (Fig. 2). If disc is not marked, place flat
side of disc against flywheel.
(7) Position clutch cover over disc and on flywheel
(Fig. 3).
(8) Install clutch cover bolts finger tight.
(9) Tighten cover bolts evenly and in rotation a
few threads at a time.Cover bolts must be tight-
ened evenly and to specified torque to avoid dis-
torting cover. Tightening torques are 31 Nzm (23
ft. lbs.) on 2.5L engines and 54 Nzm (40 ft. lbs.) on
4.0L engines.
(10) Apply light coat of Mopar high temperature
bearing grease to pilot bearing hub and splines of
transmission input shaft.Do not overlubricate
shaft splines. This will result in grease contami-
nation of disc.
(11) Install transmission (Fig. 4). Refer to proce-
dures in Group 21.
6 - 10 CLUTCH SERVICEJ

30RH/32RH IN-VEHICLE SERVICE
INDEX
page page
Checking Fluid Level and Condition........... 96
Front Band Adjustment.................... 99
Gearshift Linkage Adjustment (YJ)............ 96
Governor and Park Gear Service............ 101
Oil Filter Replacement.................... 100
Park Interlock Cable Adjustment (XJ)......... 97
Park Lock Component Replacement......... 102
Park/Neutral Position Switch Service......... 103
Rear Band Adjustment.................... 99
Recommended Fluid...................... 96
Servicing Transmission Cooler Lines and Fittings. 106
Shift Cable Adjustment (XJ)................ 97
Speedometer Service.................... 103
Transmission Cooler Flow Testing........... 106
Transmission Cooler Reverse Flushing....... 105
Transmission Throttle Cable Adjustment (XJ/YJ) . 98
Valve Body Installation................... 101
Valve Body Removal..................... 100
Valve Body Service...................... 100
RECOMMENDED FLUID
The recommended and preferred fluid for 30RH/
32RH transmissions is Mopar ATF Plus, Type 7176.
Mopar Dexron II is acceptable but should only be
used when ATF Plus is not available.
Transmission fluid capacity is approximately 17
pints (7.9 liters). This is the approximate amount of
fluid required to fill the transmission and torque con-
verter after overhaul.
CHECKING FLUID LEVEL AND CONDITION
(1) Position vehicle on flat, level surface. This is
important in obtaining an accurate fluid level check.
(2) To avoid false readings, which could produce
under or over fill condition, do not check level until
fluid is at normal operating temperature.
(3) Shift transmission into Neutral.
(4) Apply parking brakes.
(5) Operate engine at curb idle speed.
WARNING: WHEN PERFORMING UNDERHOOD OP-
ERATIONS WITH THE ENGINE RUNNING, KEEP
YOUR HANDS WELL AWAY FROM HOT OR ROTAT-
ING ENGINE COMPONENTS. DO NOT WEAR
LOOSE ARTICLES OF CLOTHING WHICH COULD
BECOME ENTANGLED IN ENGINE COMPONENTS
OR ACCESSORIES.
(6) Shift transmission through all gear ranges and
back to Neutral (leave engine running).
(7) Clean exterior of dipstick cap and fill tube be-
fore removing transmission dipstick.
(8) Remove dipstick and inspect fluid level.
²Correct level is to FULL mark
²Acceptable level is between ADD and FULL marks
(9) Check fluid condition. Fluid should be dark to
light red in color and free of dirt or debris.
(10) If fluid is discolored or smells burned but
transmission operation was OK, check cooler flow,
flush cooler and lines and change fluid and filter.
Then road test again to confirm proper operation.(11) If fluid is black or dark brown, burned/turned
to sludge, contains large quantities of metal or fric-
tion material particles, transmission will need over-
haul. Especially if problems were evident during
road test and preliminary diagnosis. Fluid cooler
should also be flow tested and flushed if necessary.
GEARSHIFT LINKAGE ADJUSTMENT (YJ)
(1) Check linkage adjustment by starting engine in
Park and Neutral.
(2) Adjustment is OK if engine starts only in park
and Neutral. Adjustment is incorrect if engine starts
in one but not both positions.
(3) If engine starts in any position other than Park
or Neutral, or if engine will not start at all, park/
neutral position switch may be faulty.
(4) Shift transmission into Park.
(5) Raise vehicle.
(6) Check condition of shift rods, bellcrank, bell-
crank brackets and linkage bushings/grommets (Fig.
1). Tighten, repair, replace worn, damaged parts. Do
not attempt adjustment if linkage components are
worn or damaged.
(7) Loosen shift rod trunnion lock bolt or nut. Be
sure upper shift rod slides freely in trunnion (Fig. 1).
Also be sure shift rods and bellcrank rotate freely
and do not bind at any point.
(8) Verify that manual lever is in Park detent
(Fig. 1). Move lever all the way rearward to be sure
it is in Park.
(9) Check for positive engagement of park lock by
attempting to rotate propeller shaft. Shaft will not
turn when park pawl is engaged.
(10) Adjust shift rod trunnion to a obtain free pin
fit in bellcrank arm and tighten trunnion lock bolt or
nut. Prevent shift rod from turning while tightening
bolt or nut. Gearshift linkage lash must be elimi-
nated to obtain proper adjustment. Eliminate lash by
pulling downward on shift rod and pressing upward
on bellcrank.
21 - 96 30RH/32RH IN-VEHICLE SERVICEJ

TIRE NOISE OR VIBRATION
The radial-ply tire on your vehicle is more sensi-
tive to improper mounting, or imbalance.
To determine if tires are the cause of vibration,
drive the vehicle over a smooth road at different
speeds. Note the effect of acceleration and decelera-
tion on noise level. Differential and exhaust noise
will change in intensity as speed varies. Tire noise
will usually remain constant.
TIRE WEAR PATTERNS
Under inflation will increase wear on the shoulders
of the tire. Over inflation will increase wear at the
center of the tread.
Excessive camber causes the tire to run at an angle
to the road. One side of tread is worn more than the
other.
Excessive toe-in or toe-out causes wear on the
tread edges. There is a feathered effect across the
tread (Fig. 7).
Fig. 7 Abnormal Tire Tread Wear Patterns
22 - 4 WHEELS AND TIRESJ

WHEELS
GENERAL INFORMATION
Original equipment wheels are designed for the
specified Maximum Vehicle Capacity.
All models use steel or cast aluminum drop center
wheels. The safety rim wheel (Fig. 1) has raised sec-
tions between the rim flanges and the rim well.
Initial inflation of the tire forces the bead over
these raised sections. In case of tire failure, the
raised sections hold the tire in position on the wheel
until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights and alignment equipment.
WHEEL INSTALLATION
The wheel studs and nuts are designed for specific
applications. They must be replaced with equivalent
parts. Do not use replacement parts of lesser quality
or a substitute design. All aluminum and some steel
wheels have wheel stud nuts which feature an en-
larged nose. This enlarged nose is necessary to en-
sure proper retention of the aluminum wheels.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces.
Ensure wheels are installed with good metal-to-metal
contact. Improper installation could cause loosening
of wheel nuts. This could affect the safety and han-
dling of your vehicle.
To install the wheel, first position it properly on
the mounting surface. All wheel nuts should then be
tightened just snug. Gradually tighten them in se-
quence to 129 Nzm (95 ft. lbs.) torque (Fig. 2).Never
use oil or grease on studs or nuts.
WHEEL REPLACEMENT
Wheels must be replaced if they have:
²Excessive runout²Bent or dented
²Leak air through welds
²Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Original equipment wheels are available through
your dealer. Replacement wheels from any other
source should be equivalent in:
²Load carrying capacity
²Diameter
²Width
²Offset
²Mounting configuration
Failure to use equivalent replacement wheels may
affect the safety and handling of your vehicle. Re-
placement withusedwheels is not recommended.
Their service history may have included severe treat-
ment.
Refer to the Specifications Chart for informa-
tion regarding above requirements.
WHEEL ORNAMENTATION
WARNING: HANDLE ALL WHEEL ORNAMENTATION
WITH EXTREME CARE DURING REMOVAL AND IN-
STALLATION. SHARP EDGES ON THE COVERS OR
CAPS CAN CAUSE PERSONAL INJURY.
TIRE AND WHEEL BALANCE
It is recommended that a two plane dynamic bal-
ancer be used when a wheel and tire assembly re-
quire balancing. Static should be used only when a
two plane balancer is not available.
For static imbalance, find location of heavy spot
causing imbalance. Counter balance wheel directly
opposite the heavy spot. Determine weight required
to counterbalance the area of imbalance. Place half
of this weight on theinnerrim flange and the other
Fig. 2 Lug Nut Tightening Pattern
Fig. 1 Wheel Safety Rim
22 - 6 WHEELS AND TIRESJ

Radial runout of more than 1.5 mm (.060 inch)
measured at the center line of the tread may cause
the vehicle to shake.
Lateral runout of more than 2.0 mm (.080 inch)
measured near the shoulder of the tire may cause the
vehicle to shake.
Sometimes radial runout can be reduced. Relocate
the wheel and tire assembly on the mounting studs
(See Method 1). If this does not reduce runout to an
acceptable level, the tire can be rotated on the wheel.
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
Check accuracy of the wheel mounting surface; ad-
just wheel bearings.
Drive vehicle a short distance to eliminate tire flat
spotting from a parked position.
Make sure all wheel nuts are properly torqued.
Relocate wheel on the mounting, two studs over
from the original position.
Re-tighten wheel nuts until all are properly
torqued, to eliminate brake distortion.
Check radial runout. If still excessive, mark tire
sidewall, wheel, and stud at point of maximum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
Rotating tire on wheel is particularly effective
when there is runout in both tire and wheel.Remove tire from wheel and re-mount wheel on
hub in former position.
Check wheel radial runout (Fig. 9).
²STEEL WHEELS: Radial runout 0.040 in., Lateral
runout 0.045 in.
²ALUMINUM WHEELS: Radial runout 0.030 in.,
Lateral runout 0.035 in.
If point of greatest runout is near original chalk
mark, remount tire 180 degrees. Recheck runout.
VEHICLE VIBRATION
Vehicle vibration can be caused by:
²Tire/wheel unbalance or excessive runout
²Defective tires with extreme tread wear
²Nylon overlay flat spots (performance tires only)
²Incorrect wheel bearing adjustment (if applicable)
²Loose or worn suspension/steering components
²Certain tire tread patterns
²Incorrect drive shaft angles or excessive drive
shaft/yoke runout
²Defective or worn U-joints
²Excessive brake rotor or drum runout
²Loose engine or transmission supports/mounts
²And by engine operated accessories
Refer to the appropriate Groups in this man-
ual for additional information.
VIBRATION TYPES
There are two types of vehicle vibration:
²Mechanical
²Audible.
Mechanical vehicle vibration can be felt through
the seats, floor pan and/or steering wheel.
Audible vehicle vibration is heard above normal
background noise. The sound can be a droning or
drumming noise.Vibrations are sensitive to change in engine
torque, vehicle speed or engine speed.
ENGINE TORQUE SENSITIVE VIBRATION
This vibration can be increased or decreased by:
²Accelerating
²Decelerating
²Coasting
²Maintaining a constant vehicle speed
VEHICLE SPEED SENSITIVE VIBRATION
This vibration condition always occurs at the same
vehicle speed regardless of the engine torque or en-
gine speed.
ENGINE SPEED (RPM) SENSITIVE VIBRATION
This vibration occurs at varying engine speeds. It
can be isolated by increasing or decreasing the en-
gine speed with the transmission in NEUTRAL posi-
tion.
VIBRATION DIAGNOSIS
A vibration diagnosis should always begin with a
10 mile (16 km) trip (to warm the vehicle and tires).
Then a road test to identify the vibration. Corrective
Fig. 9 Checking Wheel Runout
JWHEELS AND TIRES 22 - 9

ILLUMINATION LAMPS, INSTRUMENT
PANEL.............................8E-16
ILLUMINATION, RADIO/CLOCK.............8E-4
ILLUMINATION RELAY, RADIO.............8F-3
INDEX, GROUP; ELECTRICAL..............8A-1
INDEX, GROUP; INSTRUMENT PANEL
AND GAUGES........................8E-1
INDEX; WIRING DIAGRAMS XJ..........8W-149
INDEX; WIRING DIAGRAMS XJ-RHD.....8W-271
INDEX; WIRING DIAGRAMS YJ...........8W-73
INDEXES, WIRING DIAGRAM SHEETS......8W-1
INDICATOR, 4WD......................8E-22
INDICATOR, ANTI-LOCK..................8E-4
INDICATOR (BASE CLUSTER ONLY),
OPERATIONAL CHECK WITH BATTERY....8A-14
INDICATOR BEZEL REPLACEMENT.........8E-17
INDICATOR (CHECK ENGINE) LAMP FOR
DIAGNOSTIC TROUBLE CODES..........8A-19
INDICATOR INOPERATIVE, 4WD............8E-4
INDICATOR INOPERATIVE, BRAKE..........8E-4
INDICATOR INOPERATIVE, COOLANT
TEMPERATURE.......................8E-3
INDICATOR INOPERATIVE, LOW WASHER....8E-4
INDICATOR INOPERATIVE, OIL
PRESSURE..........................8E-3
INDICATOR INOPERATIVE, UPSHIFT........8E-4
INDICATOR LAMP, 4WD..................8E-2
INDICATOR LAMP, ANTI-LOCK BRAKE
SYSTEM (ABS).......................8E-2
INDICATOR LAMP, BRAKE; INSTRUMENT
PANEL AND GAUGESÐXJ...............8E-2
INDICATOR LAMP, BRAKE; INSTRUMENT
PANEL AND GAUGESÐYJ..............8E-16
INDICATOR LAMP (CHECK ENGINE),
MALFUNCTION; INSTRUMENT PANEL
AND GAUGESÐXJ................8E-2,8E-4
INDICATOR LAMP (CHECK ENGINE),
MALFUNCTION; INSTRUMENT PANEL
AND GAUGESÐYJ...................8E-16
INDICATOR LAMP, COOLANT
TEMPERATURE.......................8E-1
INDICATOR LAMPÐPCM OUTPUT,
MALFUNCTION......................14-26
INDICATOR LAMP, UPSHIFT; INSTRUMENT
PANEL AND GAUGESÐXJ...............8E-2
INDICATOR LAMP, UPSHIFT; INSTRUMENT
PANEL AND GAUGESÐYJ..............8E-16
INDICATOR LAMPS....................8E-14
INDICATOR, OIL PRESSURE...............8E-1
INDICATORÐPCM OUTPUT, SHIFT........14-26
INDICATOR REPLACEMENTÐGEAR
SELECTOR...........................8E-6
INDICATOR, SEAT BELT..................8E-4
INDICATOR (SRI) LAMP, SERVICE
REMINDER..........................25-1
INDICATORS INOPERATIVE, GAUGES.......8E-3
INDICATORS, TREAD WEAR...............22-3
INFLATION PRESSURE LABEL, TIRE.....INTRO.-3
INFLATION PRESSURES, TIRE.............22-2
INITIALIZATION, SYSTEM POWER-UP.......5-43
INJECTION (MFI)ÐCOMPONENT
DESCRIPTION/SYSTEM OPERATION,
MULTI-PORT FUEL...................14-17
INJECTION (MFI)ÐCOMPONENT
REMOVAL/INSTALLATION, MULTI-PORT
FUEL..............................14-54
INJECTION (MFI)ÐGENERAL DIAGNOSIS,
MULTI-PORT FUEL...................14-32
INJECTOR DIAGNOSISÐVEHICLE RUNS
ROUGH AND/OR HAS A MISS
...........14-49
INJECTOR, FUEL
.......................14-55
INJECTOR TEST
.......................14-48
INJECTORSÐPCM OUTPUT, FUEL
.........14-25
INNER AXLE SHAFT OIL SEAL
REPLACEMENT
.......................2-33
INNER SCUFF PLATE/COWL SIDE TRIM
PANELÐXJ VEHICLES, FRONT
.........23-114
INNER SPLASH SHIELDS, FENDER
.......23-147
INOPERATIVE, 4WD INDICATOR
............8E-4
INOPERATIVE, ALL GAUGES
.............8E-22
INOPERATIVE, BRAKE INDICATOR
..........8E-4
INOPERATIVE, COOLANT TEMPERATURE
GAUGE
..............................8E-3
INOPERATIVE, COOLANT TEMPERATURE
INDICATOR
..........................8E-3INOPERATIVE, DIAGNOSINGÐTURN
SIGNAL.............................8J-2
INOPERATIVE, DIAGNOSISÐHAZARD
LAMPS..........................8J-1,8J-2
INOPERATIVE, DIAGNOSISÐTURN
SIGNAL.............................8J-1
INOPERATIVE, FUEL GAUGE...............8E-3
INOPERATIVE, GAUGES AND INDICATORS....8E-3
INOPERATIVE, LOW FUEL WARNING........8E-4
INOPERATIVE, LOW WASHER INDICATOR....8E-4
INOPERATIVE, OIL PRESSURE GAUGE......8E-3
INOPERATIVE, OIL PRESSURE
INDICATOR..........................8E-3
INOPERATIVE, ONE GAUGE..............8E-22
INOPERATIVE, SPEEDOMETER/
ODOMETER..........................8E-3
INOPERATIVE, TACHOMETER..............8E-3
INOPERATIVE, UPSHIFT INDICATOR........8E-4
INOPERATIVE, VOLTMETER...............8E-3
INPUT, AIR CONDITIONING (A/C)
CONTROLSÐPCM....................14-19
INPUT, AUTOMATIC SHUT DOWN (ASD)
SENSEÐPCM.......................14-19
INPUT, BATTERY VOLTAGEÐPCM.........14-19
INPUT, BRAKE SWITCHÐPCM............14-20
INPUT, CAMSHAFT POSITION SENSORÐ
PCM...............................14-20
INPUT, CRANKSHAFT POSITION
SENSORÐPCM......................14-20
INPUT, DATA LINK CONNECTORÐPCM.....14-20
INPUT, ENGINE COOLANT TEMPERATURE
SENSORÐPCM......................14-21
INPUT, EXTENDED IDLE SWITCHÐPCM....14-21
INPUT, IGNITION CIRCUIT SENSEÐPCM....14-21
INPUT, INTAKE AIR TEMPERATURE
SENSORÐPCM......................14-20
INPUT, LOSS OF SENSOR.................5-3
INPUT, MANIFOLD ABSOLUTE
PRESSURE (MAP) SENSORÐPCM.......14-21
INPUT, OXYGEN (O2S) SENSORÐPCM.....14-22
INPUT, PARK/NEUTRAL SWITCHÐPCM.....14-22
INPUT, POWER STEERING PRESSURE
SWITCHÐPCM......................14-22
INPUT, SCI RECEIVEÐPCM..............14-22
INPUT, SENSOR RETURNÐPCM..........14-23
INPUT SIGNALS, WHEEL/TIRE SIZE..........5-3
INPUT, SPEED CONTROLÐPCM..........14-23
INPUT, THROTTLE POSITION SENSOR
(TPS)ÐPCM........................14-23
INPUT, VEHICLE SPEED SENSORÐPCM....14-23
INSERTÐXJ VEHICLES, QUARTER
WINDOW GLASS/REAR QUARTER
PLASTIC...........................23-80
INSIDE LATCH RELEASE AND LOCK
RODS, DOOR........................23-57
INSIDE RELEASE AND LOCK HANDLE,
FULL-METAL DOOR LATCH............23-175
INSPECTION AND ADJUSTMENT,
PRELIMINARY......................21-167
INSPECTION AND DIAGNOSIS CHARTS.......6-4
INSPECTION, CALIPER CLEANING..........5-28
INSPECTION, CLEANING....21-13,21-204,21-305
INSPECTION, COMPONENT................5-8
INSPECTION, GEAR CLEANING...........19-40
INSPECTION, PRE-ALIGNMENT.............2-6
INSPECTION, TORQUE CONVERTER
STATOR CLUTCH....................21-189
INSPECTION, TRANSMISSION CASE
CLEANING.........................21-118
INSPECTION, VALVE BODY DISASSEMBLY
. . 21-138
INSPECTION, VISUAL
...................14-32
INSPECTION/MEASUREMENTS, FRAME
.....13-10
INSPECTIONS, STARTER SYSTEM
DIAGNOSTIC
.........................8A-9
INSTALLATION, 30RH/32RH
TRANSMISSION REMOVAL
............21-108
INSTALLATION, ACCELERATION SENSOR
....5-52
INSTALLATION, AW-4 TRANSMISSION
REMOVAL AND
.....................21-189
INSTALLATIONÐAX 15, TRANSMISSION
....21-35
INSTALLATION, BRAKE PEDAL
.............5-66
INSTALLATION, BRAKELIGHT SWITCH
.......5-66
INSTALLATION, CALIPER
.................5-30
INSTALLATION, CLUTCH COVER AND
DISC
...............................6-10INSTALLATION, CLUTCH HYDRAULIC
LINKAGE............................6-12
INSTALLATION, CLUTCH PEDAL............6-15
INSTALLATION, DIFFERENTIAL; FRONT
SUSPENSION AND AXLE................2-43
INSTALLATION, DIFFERENTIAL; REAR
SUSPENSION AND AXLES...............3-24
INSTALLATION, DISC BRAKESHOE..........5-26
INSTALLATION, DRUM BRAKESHOE........5-34
INSTALLATION, FRONT WHEEL SENSOR.....5-49
INSTALLATION, MASTER CYLINDER....5-20,5-50
INSTALLATION, POWER BRAKE
BOOSTER.......................5-23,5-51
INSTALLATION, REAR WHEEL
SENSOR............................5-50
INSTALLATION, RING GEAR...............3-24
INSTALLATION, ROTOR..................5-30
INSTALLATION, TRANSFER CASE . . . 21-276,21-296
INSTALLATION, TRANSMISSION...........21-4
INSTALLATION, TRANSMISSION AND
CONVERTER.......................21-109
INSTALLATION, TRANSMISSION
AND TORQUE CONVERTER............21-190
INSTALLATION, TRANSMISSION VALVE
BODY.............................21-177
INSTALLATION, VALVE BODY............21-101
INSTALLATION, WHEEL..................22-6
INSTALLATION, WHEEL CYLINDER.........5-37
INSTALLATIONÐXJ, HCU.................5-54
INSTALLATION (XJ WITH FULL
CONSOLE), PARKING BRAKE LEVER.......5-60
INSTALLATION (XJ WITH MINI
CONSOLE), PARKING BRAKE LEVER.......5-58
INSTALLATION (XJ WITHOUT CONSOLE),
PARKING BRAKE LEVER................5-60
INSTALLATIONÐYJ, HCU.................5-54
INSTALLATION (YJ), PARKING BRAKE
PEDAL..............................5-61
INSTALLATION/ADJUSTMENT, IGNITION
SWITCH............................8D-31
INSTRUMENT CLUSTER.................8E-15
INSTRUMENT CLUSTER AND GAUGE
HOUSINGS
.........................23-190
INSTRUMENT CLUSTER BEZEL
.....23-91,23-191
INSTRUMENT CLUSTER BULB
REPLACEMENT
......................8E-19
INSTRUMENT CLUSTER DIAGNOSIS;
INSTRUMENT PANEL AND GAUGESÐ
XJ
.................................8E-3
INSTRUMENT CLUSTER DIAGNOSIS;
INSTRUMENT PANEL AND GAUGESÐ
YJ
................................8E-14
INSTRUMENT CLUSTER GAUGES;
INSTRUMENT PANEL AND GAUGESÐ
XJ
................................8E-13
INSTRUMENT CLUSTER GAUGES;
INSTRUMENT PANEL AND GAUGESÐ
YJ
................................8E-27
INSTRUMENT CLUSTER GENERAL
INFORMATION; INSTRUMENT PANEL
AND GAUGESÐXJ
....................8E-1
INSTRUMENT CLUSTER GENERAL
INFORMATION; INSTRUMENT PANEL
AND GAUGESÐYJ
...................8E-14
INSTRUMENT CLUSTER REPLACEMENT;
INSTRUMENT PANEL AND GAUGESÐ
XJ
.................................8E-5
INSTRUMENT CLUSTER REPLACEMENT;
INSTRUMENT PANEL AND GAUGESÐ
YJ
................................8E-17
INSTRUMENT CLUSTER SERVICE
PROCEDURES; INSTRUMENT PANEL
AND GAUGESÐXJ
....................8E-5
INSTRUMENT CLUSTER SERVICE
PROCEDURES; INSTRUMENT PANEL
AND GAUGESÐYJ
...................8E-17
INSTRUMENT CLUSTER/SWITCH/
LIGHTER/RADIO/HEVAC
................23-91
INSTRUMENT CLUSTERS
................8E-10
INSTRUMENT PANEL
.............23-93,23-190
INSTRUMENT PANEL AND GAUGESÐXJ
.....8E-1
INSTRUMENT PANEL AND GAUGESÐYJ
.....8E-1
INSTRUMENT PANEL COMPONENTS
......23-191
INSTRUMENT PANEL GAUGES
............8E-27
12 INDEXJ
Description Group-Page Description Group-Page Description Group-Page

TEMPERATURE SENSOR TEST, ENGINE
COOLANT; FUEL SYSTEM..............14-43
TEMPERATURE SENSOR TEST, ENGINE
COOLANT; IGNITION SYSTEMS..........8D-12
TEMPERATURE SENSOR TEST, INTAKE
AIR ...............................14-43
TEMPERATURE SENSOR TEST, INTAKE
MANIFOLD AIR......................8D-14
TENSION, BELT.......................8B-10
TENSION, DRIVE BELT...............7-33,7-38
TENSIONÐRIGHT HAND DRIVE
(RHD),BELT..........................7-34
TENSION SPECIFICATIONS, BELT...........7-34
TENSIONER REPLACEMENT (XJ), PARKING
BRAKE CABLE........................5-61
TENSIONERÐXJ MODELS, AUTOMATIC
BELT ...............................7-36
TERMINAL ASSEMBLY REPLACEMENT,
CONNECTOR.........................8W-5
TERMINAL REPLACEMENT...............8W-5
TEST, A/C PERFORMANCE................24-8
TEST, ACTUATOR MOTOR STALL...........8P-6
TEST, AIR PRESSURE...................21-73
TEST, ANALYZING THE ROAD.............21-70
TEST, BATTERY LOAD...................8A-4
TEST, BATTERY OPEN CIRCUIT VOLTAGE....8A-3
TEST, CAMSHAFT POSITION SENSOR;
FUEL SYSTEM.......................14-43
TEST, CAMSHAFT POSITION SENSOR;
IGNITION SYSTEMS...................8D-8
TEST, CONVERTER STALL...............21-72
TEST, CRANKSHAFT POSITION SENSOR;
FUEL SYSTEM.......................14-44
TEST, CRANKSHAFT POSITION SENSOR;
IGNITION SYSTEMS...................8D-9
TEST, CYLINDER COMBUSTION
PRESSURE LEAKAGE...................9-6
TEST, CYLINDER COMBUSTION
PRESSURE LEAKAGE DIAGNOSIS..........9-6
TEST, CYLINDER COMPRESSION PRESSURE . . 9-5
TEST, ENGINE COOLANT TEMPERATURE
SENSOR......................8D-12,14-43
TEST, EXTENDED IDLE SWITCH...........14-45
TEST, FUEL PRESSURE LEAK DOWN........14-7
TEST, FUEL PUMP CAPACITY..............14-7
TEST, FUEL SYSTEM PRESSURE......14-5,14-48
TEST, HYDRAULIC PRESSURE......21-71,21-168
TEST, HYDROMETER....................8A-3
TEST, IDLE AIR CONTROL MOTOR........14-46
TEST, INJECTOR.......................14-48
TEST, INTAKE AIR TEMPERATURE SENSOR . . 8D-14,
14-43
TEST, MANIFOLD ABSOLUTE PRESSURE
(MAP) SENSOR.................8D-14,14-44
TEST, MANUAL SHIFTING...............21-168
TEST, MASTER CYLINDER/POWER
BOOSTER............................5-11
TEST, OXYGEN SENSOR (O2S)
HEATING ELEMENT...................14-45
TEST, POWER BOOSTER CHECK VALVE......5-11
TEST, POWER BOOSTER VACUUM..........5-12
TEST PROCEDURES, BATTERY............8A-2
TEST PROCEDURES ON VEHICLE,
ENGINE STARTER MOTOR..............8A-9
TEST PROCEDURES ON VEHICLE,
GENERATOR........................8A-14
TEST, PUMP PRESSURE.................19-3
TEST, REAR WINDOW DEFOGGER GRID.....8N-1
TEST, REFRIGERANT LEAK................24-8
TEST, ROAD; TRANSMISSION AND
TRANSFER CASE.....................21-70
TEST, ROAD; VEHICLE SPEED CONTROL
SYSTEM............................8H-5
TEST SPECIFICATIONS, 30RH/32RH
PRESSURE........................21-323
TEST, SPEED CONTROL SWITCH (TURN
SIGNAL LEVER)......................8H-7
TEST, STARTER MOTOR RELAY...........14-48
TEST, STARTING SYSTEM COLD
CRANKING...........................8A-9
TEST, STOP LAMP SPEED CONTROL
SWITCH
............................8H-7
TEST, THROTTLE POSITION SENSOR
......8D-18
TEST, THROTTLE POSITION SENSOR
(TPS)
..............................14-45
TEST, TIME LAG
......................21-169TEST, TORQUE CONVERTER CLUTCH
RELAY.............................14-45
TEST, TORQUE CONVERTER STALL.......21-169
TEST, VACUUM SUPPLY.................8H-7
TEST, VEHICLE SPEED SENSOR......8H-5,14-45
TESTING, AUTOMATIC SHUTDOWN
(ASD) RELAY........................14-43
TESTING COOLING SYSTEM FOR LEAKS.....7-18
TESTING, FUEL PUMP RELAY............14-44
TESTING GENERAL INFORMATION,
BATTERY............................8A-3
TESTING, IGNITION SWITCH.............8D-30
TESTING, POWER MIRROR SWITCH........8T-2
TESTING, REAR WIPER/WASHER
SWITCH.......................8K-7,8K-14
TESTING, SWITCH; POWER SEATS.........8R-2
TESTING, SWITCH; POWER WINDOWS......8S-5
TESTING, SWITCH; REAR WINDOW
DEFOGGER..........................8N-2
TESTING, TRANSMISSION COOLER FLOW . . 21-106
TESTING, WIPER SWITCH...............8K-19
TESTS - (VOLTAGE DROP METHOD),
STARTER FEED CIRCUIT................8A-9
TESTS, ANTENNA.......................8F-9
TESTS AT POWERTRAIN CONTROL
MODULE, ELECTRICAL.................8H-6
TESTS AT SERVO, ELECTRICAL............8H-5
TESTS, COMPRESSOR VALVE PLATEÐ
LEAK...............................24-8
TESTS, IGNITION SWITCH CONTINUITY....8D-31
TESTS, OXYGEN SENSOR...............8D-19
TESTS, STARTER CONTROL CIRCUIT......8A-11
TESTS, VEHICLE SPEED CONTROL
SYSTEM............................8H-5
TESTS, WATER PUMP....................7-9
THERMOMETER AND SENSOR SYSTEM
REPAIR PROCEDURES.................8C-6
THERMOSTAT..........................7-13
THERMOSTAT, TEMPERATURE CONTROL . . . 24-35
THICKNESS, AW-4 CLUTCH DISC AND
PLATE ............................21-325
THICKNESS, DISC BRAKE ROTOR..........5-31
THICKNESS VARIATION, DISC BRAKE
ROTOR.............................5-31
THIRD GEAR (CONVERTER CLUTCH
ENGAGED), HYDRAULIC FLOW IN.......21-90
THIRD GEAR, HYDRAULIC FLOW IN D
RANGE.............................21-89
THREAD NOTATIONÐSAE AND METRIC . . INTRO.-9
THREADS, REPAIR DAMAGED OR WORN.....9-4
THROTTLE 3-2 DOWNSHIFT, HYDRAULIC
FLOW DURING FULL..................21-92
THROTTLE 3-2 DOWNSHIFT, HYDRAULIC
FLOW DURING PART..................21-91
THROTTLE BODY; FUEL SYSTEM.....14-29,14-59
THROTTLE CABLE.....................14-16
THROTTLE CABLE, ACCELERATOR PEDAL . . 14-16,
14-54
THROTTLE CABLE ADJUSTMENT,
TRANSMISSION.....................21-185
THROTTLE CABLE ADJUSTMENT,
TRANSMISSION......................21-98
THROTTLE CABLE REPLACEMENT,
TRANSMISSION.....................21-184
THROTTLE POSITION SENSOR............8D-6
THROTTLE POSITION SENSOR TEST.......8D-18
THROTTLE POSITION SENSOR (TPS);
FUEL SYSTEM.......................14-59
THROTTLE POSITION SENSOR (TPS);
IGNITION SYSTEMS..................8D-29
THROTTLE POSITION SENSOR (TPS)
SERVICE..........................21-184
THROTTLE POSITION SENSOR (TPS)
TEST..............................14-45
THROTTLE POSITION SENSOR (TPS)Ð
PCM INPUT.........................14-23
THROTTLE VALVE CABLE ADJUSTMENT,
TRANSMISSION......................21-70
TIE ROD ........................19-14,19-17
TIGHTENING, WHEEL NUT............5-32,5-37
TILT STEERING COLUMN................19-59
TIME LAG TEST
......................21-169
TIMING CASE COVER
................9-27,9-67
TIMING CASE COVER OIL SEAL
REPLACEMENT
...................9-26,9-67
TIMING CHAIN AND SPROCKETS
......9-28,9-68TIMING, IGNITION.....................8D-14
TIMING, VALVE.....................9-26,9-66
TIPS, TRANSMISSION ASSEMBLY........21-146
TIRE AND WHEEL BALANCE..............22-6
TIRE AND WHEEL RUNOUT...............22-8
TIRE CARRIER, EXTERNAL SPARE/WHEEL . 23-172
TIRE INFLATION PRESSURE LABEL.....INTRO.-3
TIRE INFLATION PRESSURES.............22-2
TIRE NOISE OR VIBRATION...............22-4
TIRE WEAR PATTERNS..................22-4
TIRES; LUBRICATION AND MAINTENANCE....0-34
TIRES................................22-1
TIRES, CLEANING OF....................22-2
TIRES, REPLACEMENT...................22-2
TIRE/WHEEL HOLDDOWN AND FLOOR
BRACKETS.........................23-128
TOOL, DRB SCAN; COOLING SYSTEM........7-5
TOOL, DRB SCAN; EMISSION CONTROL
SYSTEMS...........................25-2
TOOL, DRB SCAN; FUEL SYSTEM.........14-51
TOOL, DRB SCAN; IGNITION SYSTEMS.....8D-10
TOP REPAIR, HARD...................23-165
TOP ROOF VENT......................23-165
TOP SERVICE............23-164,23-166,23-167
TORQUE; COOLING SYSTEM..............7-39
TORQUE; FUEL SYSTEM................14-62
TORQUE; IGNITION SYSTEMS............8D-33
TORQUE, COLLISION DAMAGE............13-1
TORQUE CONVERSION..............INTRO.-10
TORQUE CONVERTER; TRANSMISSION
AND TRANSFER CASE...........21-66,21-158
TORQUE CONVERTER CLUTCH RELAY......14-60
TORQUE CONVERTER CLUTCH RELAY
TEST..............................14-45
TORQUE CONVERTER CLUTCH RELAYÐ
PCM OUTPUT.......................14-27
TORQUE CONVERTER INSTALLATION,
TRANSMISSION.....................21-190
TORQUE CONVERTER REMOVAL,
TRANSMISSION.....................21-189
TORQUE CONVERTER STALL TEST.......21-169
TORQUE CONVERTER STATOR CLUTCH
INSPECTION.......................21-189
TORQUE SPECIFICATIONS, 30RH/32RH....21-323
TORQUE SPECIFICATIONSÐ AX 15
MANUAL TRANSMISSION.............21-320
TORQUE SPECIFICATIONSÐACCESSORIES . 23-208
TORQUE SPECIFICATIONS, AW-4
.........21-331
TORQUE SPECIFICATIONS, BATTERY
.......8B-10
TORQUE SPECIFICATIONS; BATTERY/
STARTER/GENERATOR SERVICE
.........8B-12
TORQUE SPECIFICATIONS, BRAKE
..........5-67
TORQUE SPECIFICATIONS; CLUTCH
........6-17
TORQUE SPECIFICATIONS; ELECTRICAL
.....8A-8
TORQUE SPECIFICATIONS; ENGINES
....9-49,9-89
TORQUE SPECIFICATIONS; EXHAUST
SYSTEM AND INTAKE MANIFOLD
........11-10
TORQUE SPECIFICATIONS; FRONT
SUSPENSION AND AXLE
................2-47
TORQUE SPECIFICATIONS; HEATING AND
AIR CONDITIONING
...................24-45
TORQUE SPECIFICATIONS; HORNS
.........8G-3
TORQUE SPECIFICATIONS;
INTRODUCTION
...................INTRO.-8
TORQUE SPECIFICATIONS, NP231/NP242
. . 21-331
TORQUE SPECIFICATIONS; PROPELLER
SHAFTS
............................16-14
TORQUE SPECIFICATIONS; REAR
SUSPENSION AND AXLES
...............3-50
TORQUE SPECIFICATIONS, STARTER
MOTOR
............................8B-11
TORQUE SPECIFICATIONS; STEERING
......19-73
TORQUE SPECIFICATIONS XJ
.............8K-7
TORQUE SPECIFICATIONSÐXJ VEHICLES
. . 23-207
TORQUE VALUES, STANDARD
.........INTRO.-9
TOW HOOKÐXJ VEHICLES, REAR
.........23-87
TOW HOOKS
..........................13-14
TOW HOOKS, FRONT
....................13-5
TOWING, JUMP STARTING, HOISTING
.......0-7
TOWING RECOMMENDATIONS
..............0-8
TRACK BAR
....................2-10,2-13,3-6
TRACKS, BUCKET SEAT PLATFORM
.......23-105
TRAC-LOK DIFFERENTIAL
................3-44
JINDEX23
Description Group-Page Description Group-Page Description Group-Page