1994 JEEP WRANGLER Owners Manual

Fig. 31 System SchematicÐYJ Models with 4.0L Engine
14 - 40 FUEL SYSTEMJ

Fig. 32 System SchematicÐXJ Models with 2.5L Engine
JFUEL SYSTEM 14 - 41

Fig. 33 System SchematicÐXJ Models with 4.0L Engine
14 - 42 FUEL SYSTEMJ

AUTOMATIC SHUT DOWN (ASD) RELAY TESTING
To perform a complete test of the ASD relay and
its circuitry, refer to the DRB scan tool and appropri-
ate Powertrain Diagnostics Procedures manual. To
test the relay only, refer to RelaysÐOperation/Test-
ing in this section of the group.
CAMSHAFT POSITION SENSOR TEST
Refer to Group 8D, Ignition Systems, for Camshaft
Position Sensor testing.
ENGINE COOLANT TEMPERATURE SENSOR TEST
To perform a complete test of the engine coolant
temperature sensor and its circuitry, refer to DRB
scan tool and appropriate Powertrain Diagnostics
Procedures manual. To test the sensor only, refer to
the following:
Disconnect wire harness connector from engine
coolant temperature sensor (Fig. 34).
Test the resistance of the sensor with a high input
impedance (digital) volt-ohmmeter. The resistance
should be less than 1000 ohms with the engine at its
correct operating temperature. Refer to the Coolant
Temperature Sensor/Manifold Air Temperature Sen-
sor resistance chart. Replace the sensor if it is not
within the range of resistance specified in the chart.
Test continuity of the wire harness. Do this be-
tween the Powertrain Control Module (PCM) wire
harness connector terminal-2 and the sensor connec-
tor terminal. Also test continuity of wire harness ter-
minal-4 to the sensor connector terminal. Repair the
wire harness if an open circuit is indicated.
INTAKE AIR TEMPERATURE SENSOR TEST
To perform a complete test of the sensor and its cir-
cuitry, refer to DRB scan tool and appropriate Pow-
ertrain Diagnostics Procedures manual. To test the
sensor only, refer to the following:Disconnect the wire harness connector from the in-
take manifold air temperature sensor (Figs. 35 or
36).
Test the resistance of the sensor with an input im-
pedance (digital) volt-ohmmeter. The resistance
should be less than 4000 ohms with the engine at op-
erating temperature. The longer the engine idles, the
warmer the intake manifold temperature will be-
come. Refer to the Coolant Temperature Sensor/Man-
ifold Air Temperature Sensor resistance chart.
Replace the sensor if it is not within the range of re-
sistance specified in the chart.
Test the resistance of the wire harness. Do this be-
tween the Powertrain Control Module (PCM) wire
Fig. 34 Coolant Temperature SensorÐTypical
SENSOR RESISTANCE (OHMS)ÐCOOLANT
TEMPERATURE SENSOR/MANIFOLD AIR TEM-
PERATURE
Fig. 35 Air Temperature SensorÐ2.5L Engine
JFUEL SYSTEM 14 - 43

harness connector terminal-2 and the sensor connec-
tor terminal. Also test terminal-4 to the sensor con-
nector terminal. Repair the wire harness as
necessary if the resistance is greater than 1 ohm.
FUEL PUMP RELAY TESTING
For testing this relay, refer to RelaysÐOperation/
Testing in this section of the group.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
TEST
To perform a complete test of the MAP sensor and
its circuitry, refer to DRB scan tool and appropriate
Powertrain Diagnostics Procedures manual. To test
the sensor only, refer to the following:
Inspect the MAP sensor vacuum hose connections
at the throttle body and sensor. Repair as necessary.
CAUTION: When testing, do not remove the electri-
cal connector from MAP sensor (Fig. 37). Be sure
that the MAP sensor harness wires are not dam-
aged by the test meter probes.Test the MAP sensor output voltage at the MAP
sensor connector between terminals A and B (as
marked on the sensor body) (Fig. 38). With the igni-
tion switch ON and the engine OFF, output voltage
should be 4-to-5 volts. The voltage should drop to 1.5-
to-2.1 volts with a neutral-hot idle speed condition.
Test Powertrain Control Module (PCM) (termi-
nal-5) for the same voltage described above to verify
the wire harness condition. Repair as necessary.
Test MAP sensor supply voltage at sensor connec-
tor between terminals A and C (Fig. 38) with the ig-
nition ON and engine OFF. The voltage should be
approximately 5 volts (60.5V). Five volts (60.5V)
should also be at terminal-6 of the PCM wire harness
connector. Repair or replace the wire harness as nec-
essary.
Test the MAP sensor ground circuit at sensor con-
nector terminal-A (Fig. 38) and PCM connector ter-
minal-4. Repair the wire harness if necessary.
Test the MAP sensor ground circuit at the PCM
connector between terminal-4 and terminal-11 with
an ohmmeter. If the ohmmeter indicates an open cir-
cuit, inspect for a defective sensor ground connection.
Refer to Group 8W, Wiring for location of engine
grounds. If the ground connection is good, replace the
PCM. If terminal-4 has a short circuit to 12 volts,
correct this condition before replacing the PCM.
CRANKSHAFT POSITION SENSOR TEST
Refer to Group 8D, Ignition Systems for test proce-
dures.
Fig. 36 Air Temperature SensorÐ4.0L Engine
Fig. 37 MAP SensorÐTypical
Fig. 38 MAP Sensor Connector TerminalsÐTypical
14 - 44 FUEL SYSTEMJ

EXTENDED IDLE SWITCH TEST
OPTIONAL POLICE PACKAGE ONLY
OPERATION
The extended idle switch is used to raise the en-
gine idle speed to approximately 1000 rpm when the
shifter is in either the Park or Neutral position. A
rocker-type 2-wire switch (extended idle switch) is
mounted to the instrument panel.This switch is
available only with 4.0L engine when supplied
with the optional police package.
TESTING
The extended idle switch will control a ground cir-
cuit going to the powertrain control module (PCM).
When a ground signal (through this switch) has been
received at pin number 10 in the PCM, engine idle
speed will increase.
Bring the engine to normal operating temperature
and turn the extended idle switch to the ON position.
Engine speed should now increase to approximately
1000 rpm when the shifter is in either the Park or
Neutral position. If engine speed does not increase,
apply a good ground to pin number 10 at the PCM
using a small paper clip. Be careful not to damage
the wiring with the paper clip. If the engine speed
now increases, it can be assumed that the PCM is
functioning correctly. Check the instrument panel
mounted switch for a closed ground circuit when in
the ON position. If the engine speed will not increase
after applying a ground to pin number 10, replace
the PCM. Refer to Group 8W, Wiring Diagrams for
circuit and wiring information.
THROTTLE POSITION SENSOR (TPS) TEST
To perform a complete test of the sensor and its cir-
cuitry, refer to DRB scan tool and appropriate Pow-
ertrain Diagnostics Procedures manual. To test the
sensor only, refer to the following:
The throttle position sensor (TPS) can be tested
with a digital voltmeter. The center terminal of the
TPS is the output terminal (Figs. 39 or 40).
With the ignition key in the ON position, back-
probe the TPS connector. Check the TPS output volt-
age at the center terminal wire of the connector.
Check this at idle (throttle plate closed) and at wide
open throttle (WOT). At idle, TPS output voltage
should must be greater than 200 millivolts. At wide
open throttle, TPS output voltage must be less than
4.8 volts. The output voltage should increase gradu-
ally as the throttle plate is slowly opened from idle to
WOT.
TORQUE CONVERTER CLUTCH RELAY TEST
To test the relay only, refer to RelaysÐOperation/
Testing in this section of the group. To test the
torque converter clutch circuit and related compo-nents, refer to the appropriate Powertrain Diagnostic
Procedures manual for operation of the DRB scan
tool.
VEHICLE SPEED SENSOR TEST
To perform a complete test of the sensor and its cir-
cuitry, refer to DRB scan tool and appropriate Pow-
ertrain Diagnostics Procedures manual.
OXYGEN SENSOR (O2S) HEATING ELEMENT TEST
To perform a complete test of the O2S sensor (Fig.
41) and its circuitry, refer to DRB scan tool and ap-
propriate Powertrain Diagnostics Procedures manual.
To test the sensor only, refer to the following:
The oxygen sensor heating element can be tested
with an ohmmeter as follows:
With the sensor at room temperature 25 degrees C
(77 degrees F), disconnect the O2S sensor connector.
Connect the ohmmeter test leads across the white
wire terminals of the sensor connector. Resistance
should be between 5 and 7 ohms. Replace the sensor
if the ohmmeter displays an infinity (open) reading.
Fig. 39 TPS TestingÐ2.5L Engine
Fig. 40 TPS TestingÐ4.0L Engine
JFUEL SYSTEM 14 - 45

IDLE AIR CONTROL MOTOR TEST
Idle Air Control (IAC) Motor operation can be
tested using special exerciser tool number 7558 (Fig.
42).
CAUTION: Proper safety precautions must be taken
when testing the idle air control motor:
²Set the parking brake and block the drive wheels
²Route all tester cables away from the cooling fans,
drive belt, pulleys and exhaust components
²Provide proper ventilation while operating the en-
gine
²Always return the engine idle speed to normal be-
fore disconnecting the exerciser tool
(1) With the ignition OFF, disconnect the IAC mo-
tor wire connector at throttle body (Fig. 42).
(2) Plug the exerciser tool number 7558 harness
connector into the IAC motor.
(3) Connect the red clip of exerciser tool 7558 to
battery positive terminal. Connect the black clip tonegative battery terminal. The red light on the exer-
ciser tool will flash when the tool is properly con-
nected.
(4) Start engine.
When the switch on the tool is in the HIGH or
LOW position, the light on the tool will flash. This
indicates that voltage pulses are being sent to the
IAC stepper motor.
(5) Move the switch to the HIGH position. The en-
gine speed should increase. Move the switch to the
LOW position. The engine speed should decrease.
(a) If the engine speed changes while using the
exerciser tool, the IAC motor is functioning prop-
erly. Disconnect the exerciser tool and connect the
IAC motor wire connector to the stepper motor.
(b) If the engine speed does not change, turn the
ignition OFF and proceed to step (6). Do not discon-
nect exerciser tool from the IAC motor.
(6) Remove the IAC motor from the throttle body.
Do not remove IAC motor housing from throttle
body.
CAUTION: When checking IAC motor operation with
the motor removed from the throttle body, do not
extend the pintle (Fig. 43) more than 6.35 mm (.250
in). If the pintle is extended more than this amount,
it may separate from the IAC motor. The IAC motor
must be replaced if the pintle separates from the
motor.
(7) With the ignition OFF, cycle the exerciser tool
switch between the HIGH and LOW positions. Ob-
serve the pintle. The pintle should move in-and-out
of the motor.
(a) If the pintle does not move, replace the idle
air control motor. Start the engine and test the re-
placement motor operation as described in step (5).
(b) If the pintle operates properly, check the idle
air control motor bore in the throttle body bore for
blockage and clean as necessary. Reinstall the idle
air control motor and retest. If blockage is not
Fig. 41 Oxygen SensorÐTypical
Fig. 42 IAC Motor TestingÐTypical
Fig. 43 Idle Air Control (IAC) Motor Pintle
14 - 46 FUEL SYSTEMJ

found, refer to the DRB scan tool and the appropri-
ate Powertrain Diagnostics Procedures service
manual.
RELAYSÐOPERATION/TESTING
OPERATION
The following operations/tests apply to these
relays only:automatic shut down (ASD), fuel pump
and torque converter clutch. For operations/tests on
all other relays, refer to the appropriate section of
this service manual.
The relay terminal numbers from (Fig. 44) can be
found on the bottom of the relay:
²Terminal number 30 is connected to battery volt-
age and can be switched or B+ (hot) at all times.
²Terminal number 87A is connected (a circuit is
formed) to terminal 30 in the de-energized (normally
OFF) position.
²Terminal number 87 is connected (a circuit is
formed) to terminal 30 in the energized (ON) posi-
tion. Terminal number 87 then supplies battery volt-
age to the component being operated.
²Terminal number 86 is connected to a switched (+)
power source.
²Terminal number 85 is grounded by the power-
train control module (PCM).
TESTING
(1) Remove relay before testing.
(2) Using an ohmmeter, perform a resistance test
between terminals 85 and 86. Resistance value
(ohms) should be 7565 ohms for resistor equipped
relays.
(3) Connect the ohmmeter between terminals num-
ber 87A and 30. Continuity should be present at this
time.
(4) Connect the ohmmeter between terminals num-
ber 87 and 30. Continuity should not be present at
this time.
(5) Use a set of jumper wires (16 gauge or small-
er). Connect one jumper wire between terminal num-
ber 85 (on the relay) to the ground side (-) of a 12
Volt power source.
(6) Attach the other jumper wire to the positive
side (+) of a 12V power source. Do not connect the
jumper wire to relay at this time.
CAUTION: DO NOT ALLOW THE OHMMETER TO
CONTACT TERMINALS 85 OR 86 DURING THESE
TESTS. DAMAGE TO OHMMETER MAY RESULT.
(7) Attach the other jumper wire (12V +) to termi-
nal number 86. This will activate the relay. Continu-
ity should now be present between terminals number
Fig. 44 Relay Terminals
JFUEL SYSTEM 14 - 47