1995 JEEP XJ sensor

MALFUNCTION INDICATOR (CHECK ENGINE)
LAMP
The Powertrain Control Module (PCM) provides
ground for the malfunction indicator (Check Engine)
lamp on circuit G3. Circuit G3 connects to cavity 32
of the PCM. Circuit G5 connects to the instrument
cluster and supplies battery voltage for the malfunc-
tion indicator lamp. When illuminated, the malfunc-
tion indicator lamp displays the message CHECK
ENGINE.
For information regarding diagnostic trouble code
access using the malfunction indicator lamp, refer to
Group 14, Fuel Systems.
UP-SHIFT LAMP
On vehicles equipped with a manual transmission,
the Powertrain Control Module (PCM) provides
ground for the Up-Shift lamp on circuit K54. Circuit
G5 provides battery voltage for the lamp.
ABS WARNING LAMP
Circuit G5 provides power for the ABS warning
lamp at the instrument cluster. Ground for the ABS
warning lamp is provided by either the ABS control
module or by the ABS power relay when the relay is
not energized. The ABS control module illuminates
the lamp by providing ground on circuit G19.
Circuit G19 splices to connect to circuit B15
through a diode. When the ABS power relay is not
energized, it connects circuit B15 to circuit Z12. The
ground path for the warning lamp is provided
through the diode to circuit B15, through the ABS
power relay to ground on circuit Z12.
The diode between circuit G19 and B15 prevents
voltage from flowing to the ABS control module when
the ABS power relay switches to supply power on cir-
cuit B15.
BRAKE WARNING LAMP
Circuit G5 provides battery voltage for the brake
warning lamp. Circuit G11 can provide ground for
the lamp in 3 ways. The first ground path is through
the ignition switch when the key is in the START po-
sition.
The second ground path for the brake warning
lamp on circuit G11 is through the case grounded
brake warning switch. When the switch closes it pro-
vides a ground.
The third ground path on circuit G11 is through
the case grounded park brake switch. When the
switch closes it provides ground.
HIGH BEAM INDICATOR LAMP
Circuit G34 supplies power for the high-beam indi-
cator lamp when the operator either flashes the opti-
cal horn (high beams) or selects high beam operation.
Circuit Z1 provides the ground path for the lamp.
Circuit L3 from the headlamp switch powers the
high beam circuits of the headlamps. On vehicles not
equipped with Daytime Running Lamps (DRL), cir-
cuit G34 double crimps to circuit L3 at the bulkhead
connector.
On vehicles equipped with DRL, circuit L3 splices
to the DRL module. The DRL module powers circuit
G34.
TURN SIGNAL INDICATOR LAMPS
Circuit L61 supplies battery voltage to the left turn
signal indicator lamp. The right turn signal indicator
lamp receives battery voltage from circuit L60. The
turn signal/hazard flasher switch powers circuits L60
and L61. Circuit Z1 provides ground for the lamps.
HELPFUL INFORMATION
²If the warning lamps, gauges and indicator lamps
don't operate, check fuse 4 in the PDC and fuse 9 in
the fuse block.
²If the illumination lamps don't operate, check fuse
10 in the fuse block.
DIAGRAM INDEX
Component Page
4WD Switch............................8W-40-9
ABS Control Module......................8W-40-5
Brake Warning Switch.....................8W-40-5
Combination Buzzer.....................8W-40-7, 8
Daytime Running Lamp (DRL) Module.........8W-40-4, 6
Engine Coolant Temperature Sensor...........8W-40-7, 8
Engine Oil Pressure Sensor..................8W-40-9
Fuse 3 (PDC).......................8W-40-3, 7, 8
Fuse 4 (PDC).......................8W-40-4, 7, 8
Fuse 7 (PDC)...........................8W-40-6
Fuse 8 (Fuse Block)...................8W-40-3, 7, 8
Fuse 9 (Fuse Block).......................8W-40-8
Fuse 10 (Fuse Block).................8W-40-3, 7, 10
Gauge Package......................8W-40-7, 8, 9
Headlamp Switch...................8W-40-3, 6, 7, 8
Headlamp Dimmer Switch...................8W-40-6
Ignition Switch......................8W-40-4, 5, 8
Instrument Cluster...................8W-40-3 thru 9
Panel Lamp Dimmer Switch..............8W-40-3, 7, 8
Park Brake Switch........................8W-40-5
Powertrain Control Module.................8W-40-4, 5
8W - 40 - 2 8W-40 INSTRUMENT CLUSTERÐYJ VEHICLESJ

When the park lamp relay energizes, the relay con-
tacts close and connect circuit F81 from fuse 6 in the
fuse block to circuit L36. Circuit L36 connects to the
contact side of the high beam relay. The contacts in
the high beam relay are normally closed. Battery
voltage flows through high beam relay to the fog
lamps on circuit L39. Circuit L39 also splices to the
lamp in the fog lamp switch.
Circuit L3 from the dimmer switch provides power
for the high beams of the headlamps and connects to
Circuit G34. Circuit G34 powers the coil side of the
high beam relay. Circuit Z1 provides ground for the
coil. When the operator selects high beam operation
or flashes the optical horn, circuit G34 energizes the
high beam relay. When energized, the normally
closed contacts in the relay open, shutting off battery
voltage to the fog lamps on circuit L39.
HELPFUL INFORMATION
²Circuit A6 from fuse 3 in the PDC supplies voltage
to the fuse block for fuses in cavities 3 and 6. Fuse 6
in the fuse block protects circuit F81 which powers
the contact side of the park lamp relay.
²In the high beam position, the dimmer switch con-
nects circuit L20 from the headlamp switch to circuit
L3. The headlamp switch connects circuit A3 from
fuse 7 in the PDC with circuit L20. Circuits A3 and
L20 are HOT at all times.
DAYTIME RUNNING LAMP (DRL) MODULEÐ
CANADIAN VEHICLES ONLY
On Canadian vehicles, the low-beam headlamps op-
erate when the ignition switch is in the RUN position
and the headlamp switch is OFF.
When the ignition switch is in the START or RUN
positions, circuit A1 from fuse 4 in the Power Distri-
bution Center (PDC) connects to circuit A21. Circuit
A21 supplies voltage to circuit G5 through fuse 9 in
the fuse block. Circuit G5 splices to supply battery
voltage to the DRL module.
Circuit L20 from the headlamp switch connects to
the DRL module. Circuit L20 is HOT at all times.
The DRL module receives the vehicle speed sensor
input from circuit G7. Circuit G34 from the DRLmodule provides power for the high beam indicator
lamp in the instrument cluster.
Circuit L4 feeds the low beams of the headlamps.
When the headlamp switch is in the OFF position,
the DRL module powers the left and right headlamps
on circuit L4. When the headlamps are ON, the dim-
mer switch powers the low beams on circuit L4.
Circuit L3 feeds the high beams of the headlamps.
When the operator flashes the high beams with the
turn signal stalk, the DRL senses voltage on circuit
L3. When it senses voltage on circuit L3, the DRL
module stops supplying power to the low beams on
circuit L4.
Circuit Z1 provides ground for the DRL module.
Circuit Z1 terminates at the radiator left side sup-
port.
DIAGRAM INDEX
Component Page
Daytime Running Lamp (DRL) Module. . . .8W-50-3, 7, 9, 11
Fog Lamps.............................8W-50-9
Fog Lamp Switch........................8W-50-9
Fuse 3 (PDC)...........................8W-50-3
Fuse 4 (PDC)..........................8W-50-10
Fuse 6 (Fuse Block).......................8W-50-8
Fuse 7 (PDC)........................8W-50-3, 10
Fuse 8 (Fuse Block).......................8W-50-3
Fuse 9 (Fuse Block)......................8W-50-10
Headlamp Switch....................8W-50-3, 8, 10
Headlamp Dimmer Switch.................8W-50-3, 8
High Beam Relay.........................8W-50-9
Ignition Switch.........................8W-50-10
Instrument Cluster..................8W-50-3 thru 10
Left Headlamp.........................8W-50-4, 6
Left Park, Turn Signal Lamp...............8W-50-4, 6
Left Side Marker Lamp...................8W-50-4, 6
Park Lamp Relay.........................8W-50-8
Powertrain Control Module..................8W-50-11
Right Headlamp........................8W-50-5, 7
Right Park, Turn Signal Lamp..............8W-50-5, 7
Right Side Marker Lamp..................8W-50-5, 7
8W - 50 - 2 8W-50 FRONT LIGHTINGÐYJ VEHICLESJ

CONNECTOR LOCATIONS
GENERAL INFORMATION
This section provides illustrations identifying com-
ponent and connector locations in the vehicle. A con-nector index is provided. Use the wiring diagrams in
each section for connector number identification. Re-
fer to the index for the proper figure number.
CONNECTOR LOCATIONS
Connector # . Color . Location Fig.
C101......BK ...RTFender Side Shield..........1
C102......BK ...RTFender Side Shield Under PDC . .1
C103......BK ...RTFender Side Shield..........1
C104......BK ...LTSide of Battery on Cowl Panel . . .1
C105 2.5L . . . NAT . . RT Rear of Engine............3
C105 4.0L . . . NAT . . RT Rear of Engine............4
C106......BK ...AtLamp...................1
C107......NAT ..Center of Cowl Panel Near
Map Sensor...............1
C108......BK ...LTKick Panel Above Park Brake . . .8
C109......BK ...Under Drivers Seat............8
C110......BK ...Under I.P.Front of Floor Tunnel....6
C111......BK ...Under I.P.Front of Floor Tunnel....6
C112......BK ...Under I.P. RT of Stop Lamp Switch .7
C113......BK ...LTFender Side Shield..........1
C114......BK ...LTSide Cowl Panel............1
C115......BK ...LTFender Side Shield..........1
C116......BK ...LTFender Side Shield..........1
C117......BK ...LTFender Side Shield..........1
C118......BK ...Bottom of Washer Reservoir......2
C119......BK ...Near Bulkhead Disconnect
2.5L only..........Not Shown
C120 2.5L . . . BK . . . Rear of Generator.............3
C120 4.0L . . . BK . . . Rear of Generator.............5
C121 2.5L . . . BK . . . RT Rear of Engine............3
C121 4.0L . . . BK . . . Rear of Generator.............4
C122......BK ...OnReceiver/Drier.............4
C123 2.5L . . . BK . . . RT Side of Engine Rear of Distributor .3
C123 4.0L . . . BK . . . RT Side of Engine Rear of Distributor .4
C124 2.5L . . . BK . . . At End of Distributor Pig Tail.....3
C124 4.0L . . . BK . . . At End of Distributor Pig Tail.....4
C125......GY ...RTSide of Transmission........5
C126......BK ...LTRear of Transmission.........5
C127......BK ...TopofFuel Tank..............9
C128......BK ...TopofRear Cross-member.......9
C129......BK ...TopofRear Cross-member.......9
C130 2.5L . . . BK . . . On Thermostat Housing.........3
C130 4.0L . . . BK . . . On Thermostat Housing.........4
C131 2.5L . . . BK . . . LT Side of Engine Bottom of Intake .3
C131 4.0L . . . BK . . . LT Side of Engine Bottom of Intake .4
C132 2.5L . . . BK . . . Injector #1.................3
C132 4.0L . . . BK . . . Injector #1.................4
C133 2.5L . . . BK . . . Injector #2.................3
C133 4.0L . . . BK . . . Injector #2.................4
C134 2.5L . . . BK . . . Injector #3.................3
C134 4.0L . . . BK . . . Injector #3.................4
C135 2.5L . . . BK . . . Injector #4.................3
C135 4.0L . . . BK . . . Injector #4.................4Connector # . Color . Location Fig.
C136......BK ...Injector #5.................4
C137......BK ...Injector #6.................4
C138 2.5L . . . BK . . . Center of Dash Panel...........1
C138 4.0L . . . BK . . . Center of Dash Panel...........1
C139......BK ...Under Bulkhead LT Side of I.P.....1
C140 2.5L . . . GY . . . LT Rear of Intake.............3
C140 4.0L . . . GY . . . LT Rear of Intake.............4
C141 2.5L . . . BK . . . Rear of Throttle Body..........3
C141 4.0L . . . BK . . . Rear of Throttle Body..........4
C142 2.5L . . . BK . . . On Throttle Body.............3
C142 4.0L . . . BK . . . On Throttle Body.............4
C143 2.5L . . . BK . . . Rear of Intake...............3
C143 4.0L . . . BK . . . Rear of Intake...............4
C144......BK ...Above Bulkhead Disconnect.......1
C145......GY ...OnPower Steering Pump........3
C146......BK ...AtHeadlamp..........Not Shown
C147......YL ...AtSide Marker Lamp..........2
C148......BK ...AtPark/Turn Lamp......Not Shown
C149......BK ...RTSide Behind Bumper.........2
C150......BK ...LTSide Behind Bumper.........2
C151......BK ...AtPark/Turn Lamp............2
C152......YL ...AtSide Marker Lamp. . . .Not Shown
C153......BK ...AtHeadlamp................2
C154......BK ...LTFender Side Shield..........2
C155......BK ...Direct Connection to Horn.......2
C156......BK ...Bottom of Washer Reservoir......2
C201......BK ...LTSide of I.P...............7
C202......BK ...OnFuse Block...............7
C203......BK ...LTKick Panel................7
C204......BK ...LTKick Panel................7
C205......BK ...LTSide Kick Panel Under I.P......7
C206......BK ...AtSpeaker...........Not Shown
C207......BK ...LTofSteering Column Rear
of Cluster.................7
C208......BK ...LTSide of Steering Column......7
C209......BK ...Rear of Switch...............7
C210......BK ...Rear of Switch...............7
C211......BK ...Base of Steering Column........7
C212......BK ...AtWiper Motor..............7
C213......BK ...RTofSteering Column Under I.P. . .7
C214......BK ...RTSide of Cluster Bezel . .Not Shown
C215......BK ...Base of Steering Column........7
C216......BK ...Base of Steering Column........7
C217......BK ...RTSide of Brake Pedal Support . . .7
C218......BK ...Base of Steering Column........7
C219......BK ...Rear of Switch...............7
C220......BK ...Rear of Switch...............7
C221......BK ...Rear of Switch...............7
J8W-90 CONNECTOR LOCATIONSÐYJ VEHICLES 8W - 90 - 1

SPLICE LOCATIONS
GENERAL INFORMATION
This section provides illustrations identifying the
general location of the splices in this vehicle. A splice
index is provided. Use the wiring diagrams in each
section for splice number identification. Refer to the
index for the proper splice number.
SPLICE LOCATIONS
Splice
NumberLocations Fig.
S101 Near PDC T/O.....................1
S102 Near T/O for Engine Wiring.............1
S103 RT Dash Panel Near T/o for Ground.......1
S104 Near T/O for MAP Sensor..............1
S105 Near T/O for MAP Sensor..............1
S106 Left Side of MAP Sensor..............1
S107 In ABS Wiring T/O Near Grommet........1
S108 In ABS Wiring T/O Near Grommet........1
S109 Above Brake Booster.................1
S110 Rear of Generator...................3
S111 2.5L RT Side of Valve Cover...............4
S111 4.0L RT Side of Valve Cover...............3
S112 Near T/O for PRNDL Switch............5
S113 Between Inj #2 and Inj #3.............3
S114 Near T/O for Throttle Body Wiring........3
S115 Above Bulkhead Connector.............1
S116 Above Bulkhead Connector.............1
S117 Near Data Link T/O..................1
S118 Near Data Link T/O..................1
S119 Near Data Link T/O..................1
S120 4.0L RT Side of Valve Cover...............3
S121 2.5L RT Side of Valve Cover...............4
S122 Near T/O for RT PK/TURN Lamp.........2
S123 Near T/O for RT Fog Lamp.............2
S124 Near T/O for LT Fog Lamp.............2
S125 Near T/O for LT PK/TURN Lamp.........2Splice
NumberLocations Fig.
S126 Near T/O for Headlamp...............2
S127 Near T/O for Headlamp...............2
S128 Near T/O for Headlamp...............2
S129 Near Horn T/O.....................2
S201 Near T/O for Dimmer Switch............7
S202 Near T/O for Dimmer Switch............7
S203 Near T/O for Dimmer Switch............7
S204 Near T/O for Dimmer Switch............7
S205 Near T/O for Wiper Switch.............7
S206 Near T/O for Wiper Switch.............7
S207 Near Panel Illumination T/O.............7
S208 Near Panel Illumination T/O.............7
S209 Near Panel Illumination T/O.............7
S210 Near Panel Illumination T/O.............7
S211 Near T/O for Ignition Switch............7
S212 Near T/O for Ignition Switch............7
S213 Near T/O for Radio..................6
S301 Near T/O for Park Brake Switch..........8
S302 Near T/O for Park Brake Switch..........8
S303 Near Grommet LT Rear Quarter Panel......8
S304 Near LT Rear Tail Lamp T/O............8
S305 RT Rear Quarter Panel Near Tail Lamp.....8
S306 Near T/O for Dome Lamp.......Not Shown
S307 In CHMSL Jumper Harness......Not Shown
S308 In CHMSL Jumper Harness......Not Shown
J8W-95 SPLICE LOCATIONSÐYJ VEHICLES 8W - 95 - 1

(2) Install the upper inner retainer and bushing on
the top of the damper.
(3) Position the upper damper bracket over the
damper and install the stud nut and bolts.
(4) Tighten the stud nut to 23 Nzm (17 ft. lbs.)
torque. Tighten the bracket bolts to 61 Nzm (45 ft.
lbs.) torque.
(5) Install the bushing, upper outer retainer and
damper nut.
(6) Install the bushing, lower outer retainer and
damper nut.
(7) Tighten the upper and lower damper nuts.
(8) Connect negative cable to battery.
ENGINE ASSEMBLYÐXJ VEHICLES
REMOVAL
(1) Disconnect the battery cables. Remove the bat-
tery.
(2) Mark the hinge locations on the hood panel for
alignment reference during installation. Remove the
engine compartment lamp. Remove the hood.
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) Remove the lower radiator hose.
(5) Remove the upper radiator hose and coolant re-
covery hose (Fig. 15).
(6) Remove the fan shroud (Fig. 15).
(7) Disconnect the transmission fluid cooler tubing
(automatic transmission).
(8) Remove the radiator/condenser (if equipped
with air conditioning).
(9) Remove fan assembly and install a 5/16 x 1/2-
inch SAE capscrew through fan pulley into water
pump flange. This will maintain the pulley and wa-
ter pump in alignment when crankshaft is rotated.
(10) Disconnect the heater hoses (Figs. 16 and 17).
(11) Disconnect the throttle linkages (Fig. 16),
speed control cable (if equipped) and throttle valve
rod.
(12) Disconnect the oxygen sensor wire connector.
(13) Disconnect the wires from the starter motor
solenoid.
(14) Disconnect all fuel injection harness connec-
tions.
(15) Disconnect the quick-connect fuel lines at the
fuel rail and return line by squeezing the two retain-
ing tabs against the fuel tube (Fig. 16). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(16) Remove the fuel line bracket from the intake
manifold.
(17) Remove the air cleaner assembly (Fig. 18).
(18) If equipped with air conditioning, remove the
service valves and cap the compressor ports.
(19) Remove the power brake vacuum check valve
from the booster, if equipped.
(20) If equipped with power steering (Fig. 18):
Fig. 14 Engine Damper
Fig. 15 Upper Radiator Hose, Coolant Recovery
Hose & Fan Shroud
9 - 18 2.5L ENGINEJ

(a) Align the transmission torque converter hous-
ing 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 and converter
housing 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 and con-
denser (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 compres-
sor 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 - 20 2.5L ENGINEJ

(7) Disconnect the wires at the starter motor sole-
noid and injection wire harness connector.
(8) Disconnect the quick-connect fuel lines at the
fuel rail and return line by squeezing the two retain-
ing tabs against the fuel tube (Fig. 20). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(9) Remove the fuel line bracket from the intake
manifold.
(10) Disconnect the engine ground strap.
(11) Remove the air cleaner assembly.
(12) Disconnect the vacuum purge hose at the fuel
vapor canister tee.
(13) Disconnect the idle speed actuator wire con-
nector.
(14) Disconnect the throttle cable and remove it
from the bracket.
(15) Disconnect the throttle rod at the bellcrank.
(16) Disconnect the speed control cable, if
equipped.
(17) Disconnect the oxygen sensor wire connector.
(18) Disconnect the upper and lower radiator hoses
at the radiator.
(19) Disconnect the coolant hoses from the rear of
the intake manifold and thermostat housing.
(20) Disconnect the heater hoses.
(21) Remove the fan shroud screws.
(22) Remove the radiator attaching bolts.
(23) Remove the radiator and fan shroud.
(24) Remove the fan and spacer or Tempatrol fan
assembly.
(25) Install a 5/16 X 1/2-inch SAE capscrew
through fan pulley into water pump flange. This will
maintain the pulley and water pump in alignment
when crankshaft is rotated.
(26) Remove the power brake vacuum check valve
from the booster, if equipped.
(27) If equipped with power steering:(a) Disconnect the hoses from the fittings at the
steering gear.
(b) Drain the pump reservoir.
(c) Cap the fittings on the hoses and steering
gear to prevent foreign objects from entering the
system.
(28) Lift the vehicle and support it with support
stands.
(29) Remove the oil filter.
(30) Remove the starter motor.
(31) Remove the flywheel housing access cover.
(32) Remove the engine support cushion-to-bracket
through bolts.
(33) Disconnect the exhaust pipe from the mani-
fold.
(34) Remove the upper flywheel housing bolts and
loosen the bottom bolts.
(35) Remove the engine shock damper bracket
from the sill.
(36) Lower the vehicle.
(37) Attach a lifting device to the engine.
(38) Raise the engine off the front supports.
(39) Place a support stand under the flywheel
housing.
(40) Remove the remaining flywheel housing bolts.
(41) Lift the engine out of the engine compartment
and install on an engine stand.
(42) Install the oil filter to keep foreign material
out of the engine.
INSTALLATION
(1) Remove the oil filter.
(2) Lift the engine off the stand and lower it into
the engine compartment. For easier installation, it
may be useful to remove the engine support cushions
from the engine support brackets as an aide for
alignment of the engine-to-transmission.
(3) Insert the transmission shaft into the clutch
spline.
(4) Align the flywheel housing with the engine.
(5) Install and finger tighten the flywheel housing
lower bolts.
(6) Install the engine support cushions (if re-
moved).
(7) Remove the support stand from beneath the
flywheel housing.
(8) Lower the engine and engine support cushions
onto the engine compartment brackets. Ensure that
the bolt holes are aligned. Install the bolts and
tighten.
(9) Remove the engine lifting device.
(10) Raise the vehicle.
(11) Attach the engine shock damper bracket to
the sill.
(12) Attach the exhaust pipe to the manifold. In-
stall and tighten the nuts to 31 Nzm (23 ft. lbs.)
torque.
(13) Install the flywheel housing access cover.
Fig. 20 Fuel Line Quick-Connect Couplings
J2.5L ENGINE 9 - 21

(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 man-
ifold.
(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 dark grey gasket material should NOT
be removed. If sections of the gasket material are
missing or are compressed, replace the engine cylin-
der 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 - 22 2.5L ENGINEJ