1995 JEEP XJ brake

ANTI-LOCK BRAKES
GENERAL INFORMATION
Three fuses supply power for the Anti-Lock Brake
System (ABS); fuses 9 and 10 in the PDC and fuse
13 in the fuse block. Fuses 9 and 10 in the Power
Distribution Center (PDC) are connected directly to
battery voltage and are HOT all times. Fuse 13 is
HOT when the ignition switch is the RUN position.
In the RUN position, the ignition switch connects
circuit A1 from fuse 4 in the PDC with circuit A22.
Circuit A22 connects to a bus bar in the fuse block.
The bus bar feeds circuit F15 through fuse 13. Fuse
13 is a 2 amp fuse.
Circuit F15 splices to the coil side of the ABS
power relay and cavity 53 of the ABS control module.
Circuit Z1 provides ground for the ABS control
module. Circuit Z1 connects to cavities 1 and 19 of
the ABS control module.
Refer to group 5, Brakes for operational descrip-
tions of ABS system components.
WHEEL SPEED SENSORS
The all wheel anti-lock system uses four wheel
speed sensors; one for each wheel. Each sensor con-
verts wheel speed into an electrical signal that it
transmits to the ABS control module. A pair of
twisted wires connect to each sensor to provide sig-
nals to the ABS control module.
Circuits B6 and B7 provide signals to ABS control
module from the right front wheel speed sensor. Cir-
cuit B6, which provides the LOW signal, connects to
cavity 29 of the ABS control module. Circuit B7 con-
nects to cavity 47 of the module and provides the
HIGH signal.
Circuits B8 and B9 provide signals to ABS control
module from the left front wheel speed sensor. Cir-
cuit B8, which provides the LOW signal, connects to
cavity 30 of the ABS control module. Circuit B9 con-
nects to cavity 48 of the module and provides the
HIGH signal.
Circuits B1 and B2 provide signals to ABS control
module from the right rear wheel speed sensor. Cir-
cuit B1 which provides the LOW signal, connects to
cavity 27 of the ABS control module. Circuit B2 con-
nects to cavity 45 of the module and provides the
HIGH signal.
Circuits B4 and B3 provide signals to ABS control
module from the left rear wheel speed sensor. Circuit
B3, which provides the LOW signal, connects to cav-
ity 28 of the ABS control module. Circuit B4 connects
to cavity 46 of the module and provides the HIGH
signal.
ACCELERATION SWITCH
During four-wheel drive operation, the acceleration
switch provides deceleration data to the ABS control
module. Refer to Group 5, Brakes for additional in-
formation.
Circuits B21, B22, and B23 connect the accelera-
tion sensor to the ABS control module. Circuits B21
and B22 provide switch states while circuit B23 pro-
vides ground. At the ABS control module circuit B21
connects to cavity 25, circuit B22 connects to cavity
43 and circuit B23 connects to cavity 26.
ABS POWER RELAY
The ABS power relay is located in the Power Dis-
tribution Center (PDC). When the ABS module
grounds the ABS power relay on circuit B20, the re-
lay switches to connect circuit B15 and circuit A20
from PDC fuse 10. Circuit F15 from fuse 13 in the
fuse block splices to feed the coil side of the ABS
power relay. Circuit B20 connects to cavity 34 of the
ABS control module.
Circuit B15 is double crimped at the ABS power re-
lay. One branch of circuit B15 supplies power to the
coil side of the ABS pump motor relay. The other
branch of circuit B15 splices to cavities 3 and 33 of
the ABS control module and to the hydraulic control
unit.
ABS PUMP MOTOR RELAY
The ABS pump motor relay in the Power Distribu-
tion Center (PDC) supplies voltage to the ABS pump
motor. When the ABS power relay energizes, circuit
B15 supplies battery voltage to the coil side of the
ABS pump motor relay. The ABS control module pro-
vides ground for the relay on circuit B116. Circuit
B116 connects to cavity 15 of the ABS control mod-
ule.
When the ABS pump motor energizes, it connects
circuit A10 from PDC fuse 9 to circuit B25. Circuit
B25 supplies battery voltage to the pump motor. Cir-
cuit Z12 provides ground for the pump motor.
PUMP MOTOR SPEED SENSOR
The input from the pump motor speed sensor tells
the ABS control module that the pump is operating.
Circuit B17 and B16 from the control module connect
to the speed sensor.
BRAKE PEDAL TRAVEL SENSOR
The brake pedal travel sensor provides the ABS
control module with data regarding brake pedal posi-
tion. The sensor is a variable resistor that the ABS
J8W-32 ANTI-LOCK BRAKESÐYJ VEHICLES 8W - 32 - 1

module provides voltage to and receives input from.
Circuit B210 from cavity 41 of the ABS control mod-
ule provides voltage to the sensor. Circuit B258 car-
ries the signal from the sensor to cavity 16 of the
ABS module.
BRAKE SWITCH INPUT
Circuit L50 from the stop lamp provides the brake
switch input to the ABS control module. When the
brake pedal is pressed, the stop lamp switch closes to
supply battery voltage from circuit F32 to circuit
L50. Circuit L50 connects to cavity 32 of the ABS
control module. Circuit F32 originates at fuse 3 in
the fuse block.
Circuit A6 from Power Distribution Center (PDC)
fuse 3 supplies voltage to the fuse block for circuit
F32.
HYDRAULIC CONTROL UNIT
When the ABS power relay energizes, two branches
of circuit B15 splice to supply voltage to the isolation
and decay solenoids in the hydraulic control unit.
The hydraulic control unit contains three separate
isolation solenoids and three separate decay sole-
noids. The ABS control module activates the decay
and isolation solenoids by providing separate ground
paths for each.
The ABS module provides a ground path for the
rear isolation solenoid on circuit B251. Circuit B251
connects to cavity 54 of the ABS control module.
For the right front isolation solenoid, the ABS mod-
ule provides a ground path on circuit B249. Circuit
B249 connects to cavity 38 of the ABS control mod-
ule.
On circuit B245, the ABS module provides ground
for the left front isolation solenoid. Circuit B245 con-
nects to cavity 20 of the ABS control module.
The ABS module provides a ground path for the
rear decay solenoid on circuit B254. Circuit B254
connects to cavity 36 of the ABS control module.
For the right front decay solenoid, the ABS module
provides a ground path on circuit B248. Circuit B248
connects to cavity 21 of the ABS control module.
On circuit B243, the ABS module provides ground
for the left decay solenoid. Circuit B243 connects to
cavity 2 of the ABS control module.
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 notenergized, it connects circuit B15 to circuit Z12. The
ground path for the warning lamp is through the di-
ode 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.
DATA LINK CONNECTOR
Circuit D11 from cavity 23 of the ABS control mod-
ule receives data from the DRB scan tool through the
data link connector. The ABS control module trans-
mits data to the scan tool through the connector on
circuit D12. Circuit D12 originates at cavity 42 of the
ABS control module.
Through the data link connector, circuit Z12 pro-
vides ground for the DRB scan tool. Circuit Z12 ter-
minates at the right rear of the dash panel.
Circuit A4 from fuse 8 in the Power Distribution
Center (PDC) supplies power to fuse 16 in the PDC.
Fuse 16 powers circuit M1 which supplies battery
voltage to the scan tool through the diagnostic con-
nector.
HELPFUL INFORMATION
²Check fuses 4, 9 and 10 in the PDC
²Check fuse 13 in the fuse block
DIAGRAM INDEX
Component Page
ABS Power Relay........................8W-32-4
ABS Pump Motor/Sensor...................8W-32-5
ABS Warning Lamp.......................8W-32-4
ABS Control Module..................8W-32-3 thru 7
ABS Pump Motor Relay....................8W-32-5
Brake Pedal Travel Sensor...................8W-32-6
Data Link Connector......................8W-32-6
Fuse 1 Fuse Block........................8W-32-4
Fuse 3 Fuse Block........................8W-32-6
Fuse 3 (PDC)...........................8W-32-6
Fuse 4 (PDC)...........................8W-32-4
Fuse 8 (PDC)...........................8W-32-6
Fuse 10 (PDC)..........................8W-32-4
Fuse 12 Fuse Block.......................8W-32-4
Fuse 12 (PDC)..........................8W-32-6
Fuse 13 (PDC)..........................8W-32-4
Hydraulic Actuation Unit....................8W-32-3
Ignition Switch..........................8W-32-4
Powertrain Control Module (PCM)..............8W-32-6
Stop Lamp Switch........................8W-32-6
Wheel Speed Sensors......................8W-32-7
8W - 32 - 2 8W-32 ANTI-LOCK BRAKESÐYJ VEHICLESJ

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

REAR LIGHTING
TAIL LAMPS AND LICENSE PLATE LAMPS
Circuit A6 in the Power Distribution Center (PDC)
connects to a bus bar in the fuse block. The fuse
block bus bar powers circuit F33. Circuit F33 con-
nects to the headlamp switch. Fuse 3 in the PDC
protects circuit A3. Fuse 8 in the fuse block protects
circuit F33.
The headlamp switch has three positions: ON,
PARK (parking lamps) and OFF, plus a dimmer
switch. When the headlamp switch is in the PARK or
ON position, the switch connects circuit F33 to cir-
cuit L7. From the headlamp switch, circuit L7
branches to power the front parking lamps and rear
tail and license plate lamps. The lamps are case
grounded.
HELPFUL INFORMATION
²If the vehicle is equipped with factory installed fog
lamps, circuit L7 splices to feed the park lamp relay.
²Jumper harnesses connect the tail, stop, turn sig-
nal lamp to the body harness.
²Check fuse 3 in the PDC.
²Check fuse 8 in the fuse block.
²Circuit L7 also feeds the radio, if equipped.
STOP LAMPS AND CHMSL LAMPS
Circuit A6 from fuse 3 in the Power Distribution
Center (PDC) supplies voltage to the fuse block bus
bar. The bus bar powers circuit F32 through fuse 3 in
the fuse block. Circuit F32 connects to the stop lamp
switch.
When the operator depresses the brake pedal, the
stop lamp switch closes, and connects circuit F32 to
circuit L50. Circuit L50 connects to the CHMSL
lamps and turn signal/hazard flasher. Circuit Z1 pro-
vides ground for the CHMSL lamps. The turn signal/
hazard flasher supplies current to the L62 and L63
circuits. Circuit L62 powers the right stop lamp. Cir-
cuit L63 powers the left stop lamp. The stop lamps
are case grounded.
HELPFUL INFORMATION
²Circuits L50 and Z1 pass through contacts in the
rear door before reaching the CHMSL lamps.
²Check fuse 3 in the PDC.²Check fuse 3 in the fuse block.
²Check for continuity across the stop lamp switch
when it is closed.
²If the vehicle is equipped with anti-lock brakes,
circuit L50 connects to the ABS module.
BACK-UP LAMPS
In the START or RUN position, the ignition switch
connects circuit A1 from fuse 4 in the Power Distri-
bution Center (PDC) to circuit A21. Circuit A21 feeds
a bus bar in the fuse block that powers circuit G5
through fuse 9.
Circuit G5 splices to supply power to the back-up
lamp switch. On automatic transmission vehicles, the
back-up lamp switch is part of an assembly that in-
cludes the PARK/NEUTRAL position switch.
When the operator puts the transmission in Re-
verse, the back-up lamp switch connects circuit G5 to
circuit L1. Circuit L1 feeds the case grounded
back-up lamps.
HELPFUL INFORMATION
²Check fuse 4 in the PDC.
²Check fuse 9 in the fuse block.
²Check for continuity across the back-up lamp
switch when it is closed.
DIAGRAM INDEX
Component Page
ABS Control Module......................8W-51-3
Back-Up Lamps..........................8W-51-4
Back-Up Lamp Switch.....................8W-51-2
Center High Mounted Stop Lamps (CHMSL).......8W-51-3
Fuse 3 (Fuse Block).......................8W-51-2
Fuse 3 (PDC)...........................8W-51-2
Fuse 4 (PDC)...........................8W-51-2
Fuse 9 (Fuse Block).......................8W-51-2
Fuse 8 (Fuse Block).......................8W-51-2
Headlamp Switch.........................8W-51-2
Ignition Switch..........................8W-51-2
Powertrain Control Module..................8W-51-3
Stop Lamp Switch........................8W-51-3
Tail, Stop, and Turn Signal Lamps.............8W-51-4
J8W-51 REAR LIGHTINGÐYJ VEHICLES 8W - 51 - 1

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

(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