1994 JEEP WRANGLER battery location

INSTALLATIONÐYJ MODELS
(1) Place tank into skid plate. Wrap straps around
tank with strap bolts inserted through holes in skid
plate. Tighten strap nuts to 7.3 Nzm (65 in. lbs.) torque.
(2) Raise skid plate/fuel tank until gauge sender wire
connector can be connected to harness connector.
(3) Finish raising skid plate/fuel tank assembly
into position. Tighten mounting nuts to 16 Nzm (12
ft. lbs.) torque. Remove transmission jack.
(4) Connect fuel fill hose and fill vent hose to filler
neck. Tighten hose clamps.
(5) Connect vent hose to vent tube.
(6) Connect fuel supply hose to the supply tube and
fuel return hose to return tube. Tighten hose clamps.
(7) Install fuel filler neck shroud with push clips.
(8) Lower vehicle.
(9) Fill fuel tank. Install filler cap.
(10) Connect negative battery cable to battery.
(11) Start vehicle and inspect for leaks.
FUEL GAUGE SENDING UNIT
The fuel gauge sending unit is attached to the fuel
pump module. Refer to Fuel Pump Module in the
Fuel Delivery System section of this group.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
The fuel tank is equipped with a pressure relief/
rollover valve (Fig. 8). The dual function valve will
relieve fuel tank pressure and prevent fuel flow
through the fuel tank vent tubes in the event of ac-
cidental vehicle rollover.
The valve consists of a plunger, spring and orifice/
guide plate (Fig. 9). The valve is normally open allowing
fuel vapor to vent to the EVAP canister. Here it is
stored until it can be consumed by the engine (undercontrolled conditions). The plunger seats in the guide
plate at the orifice preventing liquid fuel from reaching
the EVAP canister. This is done if bottom of plunger is
contacted by fuel sloshing in tank when vehicle is cor-
nering.
In the event of accidental vehicle rollover, the valve
is inverted. In this position the plunger is forced
against the guide plate and raw fuel is prevented
from flowing through the valve orifice into the fuel
tank vent tube.
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING THE PRESSURE RELIEF/
ROLLOVER VALVE, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED. REFER TO THE FUEL PRES-
SURE RELEASE PROCEDURE IN THIS GROUP.
(1) Disconnect negative battery cable.
(2) Remove the fuel filler cap and drain fuel tank.
Refer to Fuel Tank Removal.
(3) Remove fuel tank. Refer to Fuel Tank Removal.
(4) The rollover valve is seated in a grommet. Re-
move by prying one side upward and then roll the
grommet out of tank (Fig. 8).
INSTALLATION
(1) Start one side of grommet into opening in fuel
tank. Using finger pressure only, press valve/grom-
met into place.
(2) Install fuel tank. Refer to Fuel Tank Installation.
(3) Fill fuel tank. Install fuel tank filler cap.
(4) Connect negative battery cable.
(5) Start vehicle and check for leaks.
Fig. 8 Valve LocationÐTypical
Fig. 9 Pressure Relief/Rollover Valve Operation
JFUEL SYSTEM 14 - 15

charges when the PCM supplies a ground. By switch-
ing the ground path on and off, the PCM regulates
ignition timing.
The sensors and switches that provide inputs to the
powertrain control module (PCM) comprise the En-
gine Control System. It is also comprised of the PCM
Outputs (engine control devices that the are operated
by the PCM).
SYSTEM DIAGNOSIS
The powertrain control module (PCM) tests many
of its own input and output circuits. If a Diagnostic
Trouble Code (DTC) is found in a major system, this
information is stored in the PCM memory. Refer to
On-Board Diagnostics in the MFI SystemÐGeneral
Diagnosis section of this group for DTC information.
POWERTRAIN CONTROL MODULE (PCM)
The PCM operates the fuel system. The PCM was
formerly referred to as the SBEC or engine control-
ler. The PCM is a pre-programmed, dual micropro-
cessor digital computer. It regulates ignition timing,
air-fuel ratio, emission control devices, charging sys-
tem, speed control, air conditioning compressor
clutch engagement and idle speed. The PCM can
adapt its programming to meet changing operating
conditions.
On XJ models, the PCM is located in the engine
compartment next to the air cleaner (Fig. 1). On YJ
models, the PCM is located in the engine compart-
ment behind the windshield washer fluid reservoir
(Fig. 2).
The PCM receives input signals from various
switches and sensors. Based on these inputs, the
PCM regulates various engine and vehicle operations
through different system components. These compo-
nents are referred to as PCM Outputs. The sensors
and switches that provide inputs to the PCM are con-
sidered PCM Inputs.The PCM adjusts ignition timing based upon in-
puts it receives from sensors that react to: engine
rpm, manifold absolute pressure, coolant tempera-
ture, throttle position, transmission gear selection
(automatic transmission), vehicle speed and the
brake switch.
The PCM adjusts idle speed based on inputs it re-
ceives from sensors that react to: throttle position,
vehicle speed, transmission gear selection, coolant
temperature and from inputs it receives from the air
conditioning clutch switch and brake switch.
Based on inputs that it receives, the PCM adjusts
ignition coil dwell. The PCM also adjusts the gener-
ator charge rate through control of the generator
field and provides speed control operation.
Powertrain Control Module (PCM) Inputs:
²Generator output
²A/C request (if equipped with factory A/C)
²A/C select (if equipped with factory A/C)
²Auto shut down (ASD) sense
²Intake air temperature sensor
²Battery voltage
²Brake switch
²Engine coolant temperature sensor
²Crankshaft position sensor
²Ignition circuit sense (ignition switch in run posi-
tion)
²Manifold absolute pressure sensor
²Overdrive/override switch
²Oxygen sensor
²Park/neutral switch (auto. trans. only)
²SCI receive (DRB scan tool connection)
²Speed control resume switch
²Speed control set switch
²Speed control on/off switch
²Camshaft position sensor signal
²Throttle position sensor
²Vehicle speed sensor
²Sensor return
²Power ground
Fig. 1 PCM LocationÐXJ Models
Fig. 2 PCM LocationÐYJ Models
14 - 18 FUEL SYSTEMJ

AIR CONDITIONING (A/C) CLUTCH RELAYÐPCM
OUTPUT
The powertrain control module (PCM) activates the
A/C compressor through the A/C clutch relay. The
PCM regulates A/C compressor operation by switch-
ing the ground circuit for the A/C clutch relay on
and off. The relay is located in the Power Distribu-
tion Center (PDC) (Figs. 17 or 18). For the location of
the relay within the PDC, refer to label on PDC
cover.
When the PCM receives a request for A/C from A/C
evaporator switch, it will adjust idle air control (IAC)
motor position. This is done to increase idle speed.
The PCM will then activate the A/C clutch through
the A/C clutch relay. The PCM adjusts idle air con-
trol (IAC) stepper motor position to compensate for
increased engine load from the A/C compressor.
By switching the ground path for the relay on and
off, the PCM is able to cycle the A/C compressor
clutch. This is based on changes in engine operating
conditions. If, during A/C operation, the PCM senses
low idle speeds or a wide open throttle condition, itwill de-energize the relay. This prevents A/C clutch
engagement. The relay will remain de-energized un-
til the idle speed increases or the wide open throttle
condition exceeds 15 seconds or no longer exists. The
PCM will also de-energize the relay if coolant tem-
perature exceeds 125ÉC (257ÉF).
AUTO SHUT DOWN (ASD) RELAYÐPCM OUTPUT
The ASD relay is located in the Power Distribution
Center (PDC) (Figs. 17 or 18). For the location of this
relay within the PDC, refer to label on PDC cover.
The ASD supplies battery voltage to the fuel pump,
fuel injector, ignition coil, generator field winding
and oxygen (O2S) sensor heating element. The
ground circuit for the coil in the ASD relay is con-
trolled by the powertrain control module (PCM). The
PCM operates the relay by switching the ground cir-
cuit on and off.
The fuel pump relay is controlled by the PCM
through same circuit that the ASD relay is con-
trolled.
The powertrain control module (PCM) energizes
the fuel pump through the fuel pump relay. (The
PCM was formerly referred to as the SBEC or engine
controller). Battery voltage is applied to the relay
from the ignition switch. The relay is energized when
a ground is provided by the PCM. The relay is lo-
cated in the Power Distribution Center (PDC) (Figs.
17 or 18). For the location of fuel pump relay within
PDC, refer to label on PDC cover.
For the 1994 model year, the ballast resistor and
ballast resistor bypass relay are no longer used to
control the fuel pump circuit.
DATA LINK CONNECTORÐPCM OUTPUT
Refer to the previous paragraphs on Data Link
ConnectorÐPCM Input for information.
EMR LAMPÐPCM OUTPUT
The EMR lamp is not used for the 1994 model
year.
Fig. 16 Vehicle Speed SensorÐTypical
Fig. 17 PDCÐYJ Models
Fig. 18 PDCÐXJ Models
14 - 24 FUEL SYSTEMJ

SPEED CONTROLÐPCM OUTPUT
Speed control operation is regulated by the power-
train control module (PCM). The PCM controls the
vacuum to the throttle actuator through the speed
control vacuum and vent solenoids. Refer to Group
8H for speed control information.
TACHOMETERÐPCM OUTPUT
The powertrain control module (PCM) supplies en-
gine rpm values to the instrument cluster tachome-
ter (if equipped). Refer to Group 8E for tachometer
information.
TORQUE CONVERTER CLUTCH RELAYÐPCM
OUTPUT
ALL 2.5L 4 CYL. WITH 3-SPEED AUTO. TRANS
4.0L 6 CYL. YJ MODELS WITH 3-SPEED AUTO.
TRANS
The transmission mounted torque converter clutch
(TCC) solenoid is used to control the torque con-
verter. The solenoid is controlled through the power-
train control module (PCM) and by the TCC relay.
This relay is used only on vehicles equipped with a
3-speed automatic transmission.
An electrical output signal is sent from the PCM to
the TCC relay after the PCM receives information
from the vehicle speed, MAP, throttle position and
engine coolant temperature sensors. After the TCC
relay receives this necessary information, it will send
a signal to the torque converter clutch solenoid to
control the torque converter.
On YJ models the TCC relay is located in the en-
gine compartment, on the cowl panel and near the
battery (Fig. 24). On XJ models the TCC relay is lo-
cated in the power distribution center (PDC) (Fig.
23).
OPEN LOOP/CLOSED LOOP MODES OF
OPERATION
As input signals to the powertrain control module
(PCM) change, the PCM adjusts its response to the
output devices. For example, the PCM must calculate
different injector pulse width and ignition timing for
idle than it does for wide open throttle (WOT). There
are several different modes of operation that deter-
mine how the PCM responds to the various input sig-
nals.
MODES
²Open Loop
²Closed Loop
During Open Loop modes, the powertrain control
module (PCM) receives input signals and responds
only according to preset PCM programming. Input
from the oxygen (O2S) sensor is not monitored dur-
ing Open Loop modes.
During Closed Loop modes, the PCM will monitor
the oxygen (O2S) sensor input. This input indicates
to the PCM whether or not the calculated injector
pulse width results in the ideal air-fuel ratio. This
ratio is 14.7 parts air-to-1 part fuel. By monitoring
the exhaust oxygen content through the O2S sensor,
the PCM can fine tune the injector pulse width. This
is done to achieve optimum fuel economy combined
with low emission engine performance.
The fuel injection system has the following modes
of operation:
²Ignition switch ON
²Engine start-up (crank)
²Engine warm-up
²Idle
²Cruise
²Acceleration
²Deceleration
²Wide open throttle (WOT)
²Ignition switch OFF
The ignition switch On, engine start-up (crank),
engine warm-up, acceleration, deceleration and wide
open throttle modes are Open Loop modes. The idle
and cruise modes, (with the engine at operating tem-
perature) are Closed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
This is an Open Loop mode. When the fuel system
is activated by the ignition switch, the following ac-
tions occur:
²The powertrain control module (PCM) pre-posi-
tions the idle air control (IAC) motor.
²The PCM determines atmospheric air pressure
from the MAP sensor input to determine basic fuel
strategy.
²The PCM monitors the engine coolant temperature
sensor input. The PCM modifies fuel strategy based
on this input.
Fig. 24 TCC Relay LocationÐYJ Models
JFUEL SYSTEM 14 - 27

DIAGNOSTIC TROUBLE CODE DESCRIPTIONSÐCONTINUED
Diagnostic
Trouble
CodeDRB Scan Tool
DisplayDescription of Diagnostic Trouble Code
41**..........Generator Field Not
Switching ProperlyAn open or shorted condition detected in the generator field control circuit.
42* ..........Auto Shutdown Relay
Control CircuitAn open or shorted condition detected in the auto shutdown relay circuit.
44* ..........Battery Temp Sensor
Volts out of LimitAn open or shorted condition exists in the engine coolant temperature sensor
circuit or a problem exists in the PCM's battery temperature voltage circuit.
46**..........Charging System Voltage
Too HighBattery voltage sense input above target charging voltage during engine
operation.
47**..........Charging System Voltage
Too LowBattery voltage sense input below target charging during engine operation.
Also, no significant change detected in battery voltage during active test of
generator output.
51**.......... O2SSignal Stays Below
Center (Lean)Oxygen sensor signal input indicates lean air/fuel ratio condition during
engine operation.
52**.......... O2SSignal Stays Above
Center (Rich)Oxygen sensor signal input indicates rich air/fuel ratio condition during
engine operation.
53* ..........Internal PCM Failure PCM Internal fault condition detected.
or
PCM Failure SPI
CommunicationsPCM Internal fault condition detected.
54* .......... NoCamSync Signal at
PCMNo fuel sync (camshaft signal) detected during engine cranking.
55* .......... N/ACompletion of diagnostic trouble code display on the Malfunction Indicator
Lamp (Check Engine Lamp).
62* .......... PCMFailure SPI miles not
storedUnsuccessful attempt to update SPI miles in the PCM EEPROM.
63* .......... PCMFailure EEPROM
Write DeniedUnsuccessful attempt to write to an EEPROM location by the PCM.
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as
described in manual and observe code flashed by Check Engine lamp.
** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
JFUEL SYSTEM 14 - 53

INSTALLATION
(1) Install the fuel injector(s) into the fuel rail as-
sembly and install retaining clip(s).
(2) Install fuel rail. Refer to Fuel Rail Installation
in this section.
(3) Start engine and check for fuel leaks.
FUEL PUMP MODULE
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
FUEL PUMP RELAY
The Fuel Pump relay is located in the Power Dis-
tribution Center (PDC) (Figs. 1 or 2). For location of
this relay within the PDC, refer to label on PDC
cover.
FUEL RAIL ASSEMBLY
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE (EVEN WITH THE ENGINE
OFF) OF APPROXIMATELY 131-269 KPA (19-39
PSI). THIS PRESSURE MUST BE RELEASED BE-
FORE SERVICING THE FUEL RAIL.
(1) Remove fuel tank filler tube cap.
(2) Disconnect the negative battery cable from bat-
tery.
(3) Perform the Fuel System Pressure Release Pro-
cedure as described in the Fuel Delivery System sec-
tion of this Group.
(4) Remove and numerically attach a tag (if fuel
injector is not already tagged), the injector harness
connectors. Do this at each injector (Fig. 7).
(5) Disconnect vacuum line from fuel pressure reg-
ulator (Fig. 7).
(6) Disconnect fuel supply line from fuel rail and
the fuel return line from fuel pressure regulator (Fig.7). Refer to Fuel Tubes/Lines/Hoses and Clamps, or
Quick-Connect Fittings. These can both be found in
the Fuel Delivery section of this group.
(7) Remove fuel rail mounting bolts.
On models with automatic transmissions, it may be
necessary to remove automatic transmission throttle
line pressure cable (and bracket). This will aid in fuel
rail assembly removal.
(8) Remove fuel rail by gently rocking until all the
fuel injectors are out of the intake manifold.
INSTALLATION
(1) Position tips of all fuel injectors into the corre-
sponding injector bore in the intake manifold. Seat
injectors into manifold.
(2) Tighten fuel rail mounting bolts to 27 Nzm (20
ft. lbs.) torque.
(3) Connect injector harness connectors to appro-
priate (tagged) injector.
(4) Connect both fuel lines to fuel rail.
(5) Connect vacuum supply line to fuel pressure
regulator.
(6) Install protective cap to pressure test port fit-
ting.
(7) Install fuel tank cap.
(8) Connect negative battery cable to battery.
(9) Start engine and check for fuel leaks.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF)
OF APPROXIMATELY 100 KPA (14.5 PSI). BEFORE
SERVICING THE FUEL PUMP, FUEL LINES, FUEL
FILTER OR FUEL INJECTOR, THE FUEL SYSTEM
PRESSURE MUST BE RELEASED.
Refer to the Fuel Delivery System section of this
group. See Fuel Pressure Release procedure.
FUEL TANKS
Refer to the Fuel Tank section of this group for re-
moval/installation procedures.
FUEL TANK PRESSURE RELIEF/ROLLOVER VALVE
Refer to the Fuel Tank section of this group for re-
moval/installation procedures.
FUEL TUBES/LINES/HOSES AND CLAMPS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures. Also refer
to Quick-Connect Fittings in the Fuel Delivery sec-
tion of this group.
IDLE AIR CONTROL (IAC) MOTOR
The IAC motor is mounted to the throttle body ad-
jacent to the throttle position sensor (Fig. 8).
Fig. 7 Fuel Injector HarnessÐTypical
14 - 56 FUEL SYSTEMJ

(3) Lower the vehicle.
PARK NEUTRAL SWITCH
Refer to Group 21, Transmissions for park neutral
switch service.
POWER STEERING PRESSURE SWITCHÐ2.5L
ENGINE ONLY
The power steering pressure switch is installed in
the power steering high pressure hose (Figs. 11 or
12).
REMOVAL
(1) Disconnect the electrical connector from the
power steering pressure switch.
(2) Place a small container or shop towel beneath
the switch to collect any excess fluid.
(3) Remove the switch.
INSTALLATION
(1) Install the power steering switch.
(2) Connect the electrical connector to the switch.(3) Check power steering fluid and add as neces-
sary.
(4) Start the engine and again check power steer-
ing fluid. Add fluid if necessary.
POWERTRAIN CONTROL MODULE (PCM)
On XJ models, the PCM is located in the engine
compartment next to the air cleaner (Fig. 13). On YJ
models, the PCM is located in the engine compart-
ment behind the windshield washer fluid reservoir
(Fig. 14).
REMOVAL
(1) Disconnect the negative battery cable at the
battery.
(2) YJ Models Only: Remove the windshield
washer fluid tank.
(3) Loosen the 60-Way connector mounting bolt
(Figs. 13 or 14).
(4) Remove the electrical connector by pulling
straight back.
(5) Remove the three PCM mounting bolts.
(6) Remove PCM.
Fig. 11 Power Steering Pressure SwitchÐYJ Models
Fig. 12 Power Steering Pressure SwitchÐXJ Models
Fig. 13 PCM LocationÐXJ Models
Fig. 14 PCM LocationÐYJ Models
14 - 58 FUEL SYSTEMJ

INSTALLATION
(1) After the PCM electrical connector has been
separated from the PCM, inspect the pins for corro-
sion, being spread apart, bent or misaligned. Also in-
spect the pin heights in the connector. If the pin
heights are different, this would indicate a pin has
separated from the connector. Repair as necessary.
(2) Install PCM. Tighten three mounting bolts to 1
Nzm (9 in. lbs.) torque.
(3) Engage 60-way connector into PCM. Tighten
connector mounting bolt to 4 Nzm (35 in. lbs.) torque.
(4) YJ Models: Install windshield washer fluid
tank.
(5) Connect negative cable to battery.
QUICK-CONNECT FITTINGS
Refer to the Fuel Delivery System section of this
group for removal/installation procedures.
THROTTLE BODY
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect air cleaner hose from throttle body.
(3) Disconnect idle air control motor and throttle
position sensor wire connectors.
(4) Disconnect accelerator cable, throttle cable (au-
tomatic transmission) and speed control cable (if
equipped) from throttle arm (Fig. 15).
(5) Remove throttle body mounting bolts, throttle
body and gasket. Discard old gasket (Fig. 16).
INSTALLATION
(1) Install throttle body and new gasket. Tighten
throttle body mounting bolts to 12 Nzm (9 ft. lbs.)
torque.
(2) Connect idle air control motor and throttle po-
sition sensor wire connectors.
(3) Connect throttle linkage to throttle arm.CAUTION: When the automatic transmission throttle
cable is connected, it MUST be adjusted.
(4) If equipped with an automatic transmission,
connect and adjust the transmission line pressure ca-
ble. Refer to Group 21, Transmissions for adjustment
procedure.
(5) Install air cleaner hose to throttle body.
(6) Connect negative battery cable to battery.
THROTTLE POSITION SENSOR (TPS)
The TPS is mounted to the throttle body (Figs. 17
or 18).
REMOVAL
(1) Disconnect TPS electrical connector.
(2) Remove TPS mounting bolts.
(3) Remove TPS.
INSTALLATION
The throttle shaft end of the throttle body slides
into a socket in the TPS (Fig. 19). The TPS must be
installed so that it can be rotated a few degrees. (If
Fig. 16 Throttle
BodyÐRemoval/InstallationÐTypical
Fig. 17 TPS LocationÐ2.5L Engine
Fig. 15 Cables at Throttle Body
JFUEL SYSTEM 14 - 59