1995 JEEP XJ clutch

CAUTION: Do not use water, or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air can distort, or crack the
gear and flywheel.TORQUE SPECIFICATIONS
JCLUTCH SERVICE 6 - 17

(10) Check and adjust automatic transmission
fluid level (if equipped).
COOLING SYSTEM HOSES
Rubber hoses route coolant to and from the radia-
tor, intake manifold and heater core. All XJ models
equipped with air conditioning have a coolant control
valve. This is located in-line with the heater core in-
let and outlet hoses. It controls coolant flow to the
heater core when the air conditioning system is in
operation.
Radiator lower hoses are spring-reinforced to pre-
vent collapse from water pump suction at moderate
and high engine speeds.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (FIG. 36). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS. AL-
WAYS WEAR SAFETY GLASSES WHEN SERVICING
CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 37). If re-
placement is necessary, use only an original equip-
ment clamp with matching number or letter.
Inspect the hoses at regular intervals. Replace
hoses that are cracked, feel brittle when squeezed, or
swell excessively when the system is pressurized.
For all vehicles: In areas where specific routing
clamps are not provided, be sure that hoses are posi-
tioned with sufficient clearance. Check clearance
from exhaust manifolds and pipe, fan blades, drive
belts and sway bars. Improperly positioned hoses can
be damaged, resulting in coolant loss and engine
overheating.Ordinary worm gear type hose clamps (when
equipped) can be removed with a straight screw-
driver or a hex socket.To prevent damage to
hoses or clamps, the hose clamps should be
tightened to 4 Nzm (34 in. lbs.) torque. Do not
over tighten hose clamps.
When performing a hose inspection, inspect the ra-
diator lower hose for proper position and condition of
the internal spring.
COOLING SYSTEM FANS
Also refer to either the Viscous Fan Drive and/or
the Auxiliary Electric Cooling FanÐXJ Models With
4.0L Engine sections for additional information.
All models are equipped with a mechanical temper-
ature controlled fan. This thermal viscous fan drive
(Fig. 38) is a torque-and-temperature-sensitive clutch
unit. It automatically increases or decreases fan
speed to provide proper engine cooling. XJ models
equipped with a 4.0L 6-cylinder engine may also
have an auxiliary electrical cooling fan. This is with
models that have air conditioning and/or heavy duty
cooling.
REMOVAL
Some engines have the mechanical fan/viscous fan
drive assembly mounted directly to the water pump
hub (Fig. 38). It may also be mounted to a hub/bear-
ing attached to an aluminum bracket on the right
front side of engine (Fig. 39).
(1) Loosen but do not remove at this time, the four
fan hub mounting nuts (Figs. 38 or 39).
Fig. 36 Hose Clamp ToolÐTypical
Fig. 37 Clamp Number/Letter Location
7 - 32 COOLING SYSTEM SERVICE PROCEDURESJ

STARTING SYSTEM
GENERAL INFORMATION
The starting system (Fig. 1) consists of:
²ignition switch
²starter relay
²park/neutral position switch (automatic transmis-
sion)
²wiring harness and connections
²battery
²starter with an integral solenoid.
Following is a general description of the major
starting system components. Refer to Group 8W -
Wiring Diagrams for complete circuit descriptions
and diagrams.
These components form 2 separate circuits. A high-
amperage feed circuit that feeds the starter up to
300+ amps, and a low-amperage control circuit that
operates on less than 20 amps.
Battery voltage is supplied through the low-amper-
age control circuit to the coil battery terminal of the
starter relay when the ignition switch is turned to
the START position.
If the vehicle is equipped with an automatic trans-
mission, the park/neutral position switch provides a
ground path to the starter relay coil ground terminal.
This switch provides ground only with the transmis-
sion in NEUTRAL or PARK. If the vehicle is
equipped with a manual transmission, the starter re-
lay coil ground terminal is always grounded.
With the starter relay coil now energized, the nor-
mally open relay contacts close. The relay contacts
connect the relay common feed terminal to the relay
normally open terminal. The closed relay contacts en-
ergize the starter solenoid coil windings.
The energized solenoid coils pull-in and hold-in the
solenoid plunger. The solenoid plunger pulls the shiftlever in the starter. This engages the starter overrun-
ning clutch and pinion gear with the flywheel/drive
plate ring gear.
As the solenoid plunger reaches the end of its
travel, the solenoid contact disc completes the high-
amperage starter feed circuit. Current now flows be-
tween the solenoid battery terminal and the starter
motor, energizing the starter.
Once the engine starts, the overrunning clutch pro-
tects the starter from damage by allowing the starter
pinion gear to spin faster than the pinion shaft.
When the driver releases the ignition switch to the
ON position the starter relay coil is de-energized.
This causes the relay contacts to open. When the re-
lay contacts open, the starter solenoid coil is de-ener-
gized.
When the solenoid coil is de-energized, the solenoid
plunger return spring returns the plunger to its re-
laxed position. This causes the contact disc to open
the starter feed circuit, and the shift lever to disen-
gage the overrunning clutch and pinion gear from the
ring gear.
The starter motor and solenoid are serviced only as
a complete assembly. If either component fails, the
entire assembly must be replaced.
DIAGNOSIS
Before removing any unit from the starting system
for repair, perform the following inspections:
INSPECTION
BATTERY INSPECTION
To determine condition of the battery, see Battery
in this group.
WIRING INSPECTION
Inspect wiring for damage. Inspect all connections
at:
²starter solenoid
²park/neutral position switch (automatic transmis-
sion)
²ignition switch
²starter relay
²battery (including all ground connections).
Clean, tighten and repair all connections as re-
quired.
SOLENOID, RELAY AND SWITCH INSPECTIONS
Inspect the solenoid, relay and ignition switch to
determine their condition. Also, if equipped with au-
tomatic transmission, inspect condition of the park/
neutral position switch. Testing information can be
found in the following pages.
Fig. 1 Starting System Components (Typical)
JBATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 11

CAUTION: Be certain that battery cables are con-
nected to the correct battery terminals. Reverse po-
larity can damage electrical components.
(12) Place oiled felt washer on battery positive ter-
minal post.
(13) Install and tighten battery positive cable ter-
minal clamp. Then install and tighten negative cableterminal clamp. Both cable clamp bolts require
torque of 8.5 Nzm (75 in. lbs.).
(14) Apply a thin coating of petroleum jelly or
chassis grease to cable terminals and battery posts.
STARTER AND STARTER RELAY
GENERAL INFORMATION
This section covers starter and starter relay service
procedures only. For diagnostic procedures, refer to
Group 8A - Battery/Starting/Charging Systems Diag-
nostics. Service procedures for other starting system
components can be found as follows:
²battery - see Battery, in this group
²ignition switch - refer to Group 8D - Ignition Sys-
tems
²park/neutral position switch (automatic transmis-
sion) - refer to Group 21 - Transmission and Transfer
Case
²wiring harness and connectors - refer to Group 8W
- Wiring Diagrams.
STARTER
The starter motor incorporates several features to
create a reliable, efficient, compact and lightweight
unit. A planetary gear system (intermediate trans-
mission) is used between the electric motor and pin-
ion gear. This feature makes it possible to reduce the
dimensions of the starter. At the same time, it allows
higher armature rotational speed and delivers in-
creased torque through the pinion gear to the fly-
wheel or drive plate ring gear.
The use of a permanent magnet field also reduces
starter size and weight. This field consists of six
high-strength permanent magnets. The magnets are
aligned according to their polarity and are perma-
nently fixed in the starter field frame.
The starter motors for all engines are activated by
a solenoid mounted to the overrunning clutch hous-
ing. However, the starter motor/solenoid are serviced
only as a complete assembly. If either component
fails, the entire assembly must be replaced.
This unit is highly sensitive to hammering, shocks
and external pressure.
CAUTION: The starter motor MUST NOT BE
CLAMPED in a vise by the starter field frame. Doing
so may damage the magnets. It may be clamped by
the mounting flange ONLY.CAUTION: Do not connect starter motor incorrectly
when tests are being performed. The permanent
magnets may be damaged and rendered unservice-
able.
STARTER RELAY
The starter relay is an International Standards Or-
ganization (ISO) type relay, and is located in the
Power Distribution Center (PDC). Refer to underside
of PDC cover for relay location.
STARTER REMOVE/INSTALLÐ2.5L
XJ MODELS
(1) Disconnect battery negative cable.
(2) Remove exhaust clamp from bracket (Fig. 11).
(3) Remove nut and bolt from forward end of brace
rod (automatic transmission only).
Fig. 11 Exhaust Clamp and Brace Remove (XJÐ
2.5L)
8B - 4 BATTERY/STARTER/GENERATOR SERVICEJ

POWER DISTRIBUTION
GENERAL INFORMATION
This section covers the Power Distribution Center
(PDC) and all circuits involved with it. For additional
information on system operation, refer to the appro-
priate section of the wiring diagrams.
DIAGRAM INDEX
Component Page
A/C Compressor Clutch Relay..............8W-11-3, 11
ABS Control Module.....................8W-11-6, 7
ABS Power Relay......................8W-11-3, 6
ABS Pump Motor Relay..................8W-11-3, 7
Automatic Shut Down Relay................8W-11-3, 9
Chime/Buzzer Module..................8W-11-10, 14
Circuit Breaker Cavity 16 (Fuse Block)..........8W-11-13
Combination Flasher......................8W-11-17
Daytime Running Lamp Module.............8W-11-5, 10
Diode D101............................8W-11-6
Engine Starter Motor Relay................8W-11-3, 4
Fuel Pump Relay.......................8W-11-3, 8
Fuse 1 (PDC)..........................8W-11-13
Fuse 3 (PDC)..........................8W-11-12
Fuse 4 (Fuse Block)......................8W-11-14
Fuse 4 (PDC)..........................8W-11-15
Fuse 5 (PDC)..........................8W-11-14
Fuse 6 (PDC)....................8W-11-4, 7, 10, 15
Fuse 7 (Fuse Block).......................8W-11-7
Fuse 7 (PDC)...........................8W-11-4
Fuse 8 (PDC)...........................8W-11-7
Fuse 9 (Fuse Block)......................8W-11-12
Fuse 9 (PDC)..........................8W-11-13
Fuse 10 (PDC)........................8W-11-6, 8
Fuse 11 (Fuse Block).....................8W-11-13
Fuse 11 (PDC).........................8W-11-10
Fuse 12 (PDC).........................8W-11-15Component Page
Fuse 13 (PDC)..........................8W-11-4
Fuse 14 (PDC)..........................8W-11-8
Fuse 15 (Fuse Block).....................8W-11-14
Fuse 15 (PDC)..........................8W-11-8
Fuse 16 (PDC).........................8W-11-12
Fuse 17 (Fuse Block).....................8W-11-10
Headlamp Delay Module.................8W-11-10, 14
Headlamp Switch........................8W-11-14
Headlamp Dimmer Switch..................8W-11-14
Horn Rear Window Relay..................8W-11-17
Horn Relay............................8W-11-17
Ignition Switch...................8W-11-4, 7, 10, 15
In-Line Circuit Breaker (Stop Lamp Relay)........8W-11-13
LCD Illumination Relay....................8W-11-17
Overhead Console.....................8W-11-10, 14
Powertrain Control Module..........8W-11-4, 5, 8, 9, 11
Power Distribution Center...................8W-11-2
Power Door Lock Relay...................8W-11-16
Power Door Unlock Relay..................8W-11-16
Radiator Fan Control Relay................8W-11-3, 11
Remote Keyless Entry Module.............8W-11-10, 12
Relay Center...........................8W-11-16
Telltale Connector (I.P. Cluster)..........8W-11-6, 10, 12
Torque Converter Clutch (TCC) Relay...........8W-11-15
Transmission Control Module...............8W-11-5, 8
J8W-11 POWER DISTRIBUTIONÐXJ VEHICLES 8W - 11 - 1

FUEL/IGNITION
INDEX
page page
Automatic Shut Down (ASD) Relay............. 1
Battery Feed.............................. 1
Brake Switch Input......................... 5
Camshaft Position Sensor.................... 3
CCDBus ................................ 5
Crankshaft Position Sensor................... 3
Data Link Connector........................ 5
Diagram Index Ð2.5L Engine.................. 6
Diagram Index Ð4.0L Engine.................. 6
Engine Coolant Temperature Sensor............ 3
Extended Idle Switch....................... 5
Fuel Injectors............................. 1
Fuel Pump Module......................... 2
Fuel Pump Relay.......................... 2
Heated Oxygen Sensor...................... 3Idle Air Control (IAC) Motor................... 2
Ignition Coil.............................. 2
Ignition Switch............................ 1
Intake Air Temperature Sensor................ 4
Malfunction Indicator Lamp (MIL)............... 5
Manifold Absolute Pressure Sensor............. 4
Park/Neutral Position Switch.................. 4
Power (Device) Ground...................... 5
Power Steering Pressure Switch............... 5
Tachometer Signal......................... 5
Throttle Position Sensor..................... 4
Torque Converter Clutch (TCC) Solenoid and
Relay................................. 4
Upshift Lamp............................. 5
Vehicle Speed Sensor....................... 2
IGNITION SWITCH
Circuit A1 from fuse 11 in the power distribution
center (PDC), supplies battery voltage to the ignition
switch. Depending upon position, the ignition switch
powers circuits A21, A38, A41, or A48.
START POSITION
In the START position, the ignition switch connects
circuit A1 to circuit A41. Circuit A41 connects to the
coil side of the starter motor relay.
Additionally in the START position, the case
grounded ignition switch provides ground for the
brake lamp switch and the warning lamps in the
instrument cluster.
START OR RUN POSITION
In the START or RUN position, the ignition switch
connects circuit A1 to circuit A21. Circuit A21 splices
to power fuse 17 in the fuse block and the coil side of
the Automatic Shut Down (ASD) relay and the fuel
pump relay.
RUN (ONLY) POSITION
When the ignition switch is in the RUN position, it
connects circuit A1 to circuit A38. Circuit A22 splices
to power fuses 1 and 7 in the fuse block.
²Fuse 1 powers the rear wiper system on circuit
V15.
²Fuse 7 feeds the Anti-Lock Brake System (ABS) on
circuit 236.
ACCESSORY OR RUN POSITIONS
In the ACCESSORY or RUN positions, the ignition
switch connects circuit A1 to circuit A48. Circuit A48
connects to a bus bar in the fuse block that feeds
fuses 2, 5, and 8.
AUTOMATIC SHUT DOWN (ASD) RELAY
When the ignition switch is in either the START or
RUN positions, it connects circuit A1 from fuse 6 in
the Power Distribution Center (PDC) to circuit A21.
Circuit A21 supplies battery voltage to the coil side of
the Automatic Shut Down (ASD) relay. The Power-
train Control Module (PCM) provides ground for the
relay on circuit K51. Circuit K51 connects to cavity 51
of the PCM.
When the PCM grounds the ASD relay, contacts
inside the relay close and connect circuit A18 from
fuse 14 in the PDC to circuit A142. Circuit A142
splices to the generator field terminal, fuel injectors,
and ignition coil. Circuit A142 also connects to cavity
57 of the PCM.
HELPFUL INFORMATION
²Along with supplying voltage to the coil side of the
ASD relay, circuit A21 also supplies voltage to the coil
side of the fuel pump relay.
BATTERY FEED
Circuit A14 from fuse 2 in the Power Distribution
Center (PDC) supplies battery voltage to cavity 3 of
the powertrain control module.
HELPFUL INFORMATION
Circuit A14 also supplies power to the contact sides
of the fuel pump relay and fuse F2 in the PDC. Fuse
F2 powers circuit A18 which supplies voltage to the
contact side of the automatic shut down relay.
FUEL INJECTORS
When the Automatic Shut Down (ASD) relay con-
tacts close, they connect circuits A14 and A142. Cir-
J8W-30 FUEL/IGNITIONÐXJ VEHICLES 8W - 30 - 1

The PCM provides a ground for the engine coolant
temperature sensor signal (circuit K2) through circuit
K4. Circuit K4 connects to cavity 4 of the PCM con-
nector.
HELPFUL INFORMATION
Circuit K4 splices to supply ground for the signals
from the following:
²Heated oxygen sensor
²Camshaft position sensor
²Crankshaft position sensor
²Intake air temperature sensor
²Throttle position sensor
²Manifold absolute pressure sensor
²Engine coolant temperature sensor
²Vehicle speed sensor
THROTTLE POSITION SENSOR
From the Powertrain Control Module (PCM), cir-
cuit K6 supplies 5 volts to the throttle position sen-
sor (TPS). Circuit K6 connects to cavity 6 of the
PCM.
Circuit K22 delivers the TPS signal to the PCM.
Circuit K22 connects to cavity 22 of the PCM.
The PCM provides a ground for the throttle posi-
tion sensor signal (circuit K22) through circuit K4.
Circuit K4 connects to cavity 4 of the PCM.
HELPFUL INFORMATION
Refer to Group 14 for throttle position sensor oper-
ation.
Circuit K6 splices to supply 5 volts to the manifold
absolute pressure sensor.
On vehicles equipped with the 4.0L engine and au-
tomatic transmission, circuit K22 splices to the
transmission control module.
Circuit K4 splices to supply ground for the signals
from the following:
²Heated oxygen sensor
²Camshaft position sensor
²Crankshaft position sensor
²Intake air temperature sensor
²Throttle position sensor
²Manifold absolute pressure sensor
²Engine coolant temperature sensor
²Vehicle speed sensor
MANIFOLD ABSOLUTE PRESSURE SENSOR
From the Powertrain Control Module (PCM), cir-
cuit K6 supplies 5 volts to the manifold absolute
pressure (MAP) sensor. Circuit K6 connects to cavity
6 of the PCM.
Circuit K1 delivers the MAP signal to the PCM.
Circuit K1 connects to cavity 1 of the PCM.
The PCM provides a ground for the MAP sensor
signal (circuit K1) through circuit K4. Circuit K4 con-
nects to cavity 4 of the PCM.
HELPFUL INFORMATION
Refer to Group 14 for MAP sensor operation.
Circuit K6 splices to supply 5 volts to the throttle
position sensor.
Circuit K4 splices to supply ground for the signals
from the following:
²Heated oxygen sensor
²Camshaft position sensor
²Crankshaft position sensor
²Intake air temperature sensor
²Throttle position sensor
²Manifold absolute pressure sensor
²Engine coolant temperature sensor
²Vehicle speed sensor
INTAKE AIR TEMPERATURE SENSOR
The intake air temperature sensor provides an in-
put to the Powertrain Control Module (PCM) on cir-
cuit K21. Circuit K21 connects to cavity 21 of the
PCM.
From circuit K21, the intake air temperature sen-
sor draws voltage from the PCM. The sensor is a
variable resistor. As intake air temperature changes,
the resistance in the sensor changes, causing a
change in current draw.
The PCM provides a ground for the intake air tem-
perature sensor signal (circuit K21) through circuit
K4. Circuit K4 connects to cavity 4 of the PCM.
HELPFUL INFORMATION
Circuit K4 splices to supply ground for the signals
from the following:
²Heated oxygen sensor
²Camshaft position sensor
²Crankshaft position sensor
²Intake air temperature sensor
²Throttle position sensor
²Manifold absolute pressure sensor
²Engine coolant temperature sensor
²Vehicle speed sensor
PARK/NEUTRAL POSITION SWITCH
When closed, the case-grounded park/neutral posi-
tion switch provides a ground path on circuit T41 for
the coil side of the starter motor relay. Circuit A41
from the ignition switch provides battery voltage to
the coil side of the relay.
Circuit T41 splices to cavity 30 of the PCM. The
park/neutral position switch provides an input to the
Powertrain Control Module (PCM).
TORQUE CONVERTER CLUTCH (TCC) SOLENOID
AND RELAY
The TCC solenoid is only used on 2.5L engines
with the three-speed automatic transmissions. The
Powertrain Control Module (PCM) operates the TCC
solenoid by energizing the TCC relay.
8W - 30 - 4 8W-30 FUEL/IGNITIONÐXJ VEHICLESJ

Circuit T17 from fuse 3 in the power distribution
center supplies voltage to the coil and contact sides
of the TCC relay. When the PCM provides a ground
path on circuit K54 for the coil side of the relay, the
relay contacts close.
When the relay contacts close, they connect circuit
T17 with circuit T22. Circuit T22 supplies battery
voltage to the case grounded TCC solenoid. Circuit
K54 connects to PCM cavity 54.
HELPFUL INFORMATION
²In the RUN or START position, the ignition switch
connects circuit A1 from fuse 4 in the PDC to circuit
A21.
UPSHIFT LAMP
On vehicles equipped with a manual transmission,
the PCM grounds the up-shift lamp on circuit K54.
Circuit K54 connects to cavity 54 of the PCM.
POWER STEERING PRESSURE SWITCH
The PCM supplies voltage to the power steering
pressure switch on circuit K10. Circuit Z12 provides
ground for the switch. When the switch closes, volt-
age flows through the switch to ground on circuit
Z12. The switch closes during periods of high power
steering pump load and low engine speed; such as
parking maneuvers.
Circuit K10 connects to cavity 10 of the PCM. Cir-
cuit Z12 terminates at the right rear of the engine.
TACHOMETER SIGNAL
The PCM supplies the signal for the tachometer on
circuit G21. Circuit G21 connects to cavity 43 of the
PCM.
MALFUNCTION INDICATOR LAMP (MIL)
The PCM provides ground for the instrument clus-
ter malfunction indicator lamp on circuit G3. The
MIL displays the message CHECK ENGINE when il-
luminated. Circuit F87 provides voltage for the lamp.
DATA LINK CONNECTOR
Circuit F12 supplies battery voltage to the data
link connector. Circuit F12 originates at fuse 11 in
the Power Distribution Center.
Circuit D20 connects to cavity 45 of the PCM. Cir-
cuit D20 is the SCI receive circuit for the PCM.
Circuit D21 connects to cavity 25 of the PCM. Cir-
cuit D21 is the SCI transmit circuit for the PCM.
Circuit Z11 provides ground for the data link con-
nector. Circuit Z11 terminates at the right rear of the
engine. Circuit Z11 also connects to cavity 5 of the
PCM.
HELPFUL INFORMATION
²Circuit Z1 also supplies a ground for the PCM
high current drivers.
²If the system loses ground for the Z11 circuits at
the right rear of the engine, the vehicle will not op-
erate. Check the connection at the ganged-ground cir-
cuit eyelet.
²Circuit F12 splices to supply battery voltage to the
vehicle speed control switch, back-up lamp switch,
A/C compressor clutch relay, windshield washer fluid
level sensor and radiator fan relay (4.0L engines).
BRAKE SWITCH INPUT
Circuit K29 provides the brake switch input to the
PCM. Circuit V40 connects to cavity 29 of the PCM.
POWER (DEVICE) GROUND
Circuit Z12 connects to cavities 11 and 12 of the
PCM. The Z12 circuit provides ground for PCM inter-
nal drivers that operate high current devices like the
injectors and ignition coil.
Internal to the PCM, the power (device) ground cir-
cuit connects to the PCM sensor return circuit (from
circuit K4).
HELPFUL INFORMATION
²The grounding point for circuit Z12 is the right
rear of the engine.
²If the system loses ground for the Z12 circuits at
the rear of the engine, the vehicle will not operate.
Check the connection at the ganged-ground circuit
eyelet.
²On vehicles equipped with the 4.0L engine and au-
tomatic transmission, circuit Z12 splices to provide
ground for the transmission control module.
EXTENDED IDLE SWITCH
On Police Package vehicles, an optional extended
idle switch provides an input to the Powertrain Con-
trol Module (PCM) on circuit K10. Circuit K10 con-
nects to cavity 10 of the PCM. Circuit F60 supplies
battery voltage to the extended idle switch. Circuit
Z1 grounds the switch.
CCD BUS
On vehicles equipped with the 4.0L engine, circuits
D1 and D2 connect the Powertrain Control Module
(PCM) to the CCD Bus. Circuit D1 connects to cavity
26 of the PCM. Circuit D2 connects to cavity 46 of
the PCM. Circuits D1 and D2 are a twisted pair of
wires.
J8W-30 FUEL/IGNITIONÐXJ VEHICLES 8W - 30 - 5