1995 JEEP YJ tire type

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

temperature ranges. This depends upon the thick-
ness and length of the center electrodes porcelain in-
sulator.)
SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center
electrode insulator that also appears blistered (Fig.
25). The increase in electrode gap will be consider-
ably in excess of 0.001 inch per 1000 miles of opera-
tion. This suggests that a plug with a cooler heat
range rating should be used. Over advanced ignition
timing, detonation and cooling system malfunctions
can also cause spark plug overheating.
SPARK PLUG SECONDARY CABLES
TESTING
Spark plug cables are sometimes referred to as sec-
ondary ignition cables or secondary wires. The cables
transfer electrical current from the distributor to in-
dividual spark plugs at each cylinder. The spark plug
cables are of nonmetallic construction and have a
built in resistance. The cables provide suppression of
radio frequency emissions from the ignition system.Check the high-tension cable connections for good
contact at the ignition coil, distributor cap towers
and spark plugs. Terminals should be fully seated.
The terminals and spark plug covers should be in
good condition. Terminals should fit tightly to the ig-
nition coil, distributor cap and spark plugs. The
spark plug cover (boot) of the cable should fit tight
around the spark plug insulator. Loose cable connec-
tions can cause corrosion and increase resistance, re-
sulting in shorter cable service life.
Clean the high tension cables with a cloth moist-
ened with a nonflammable solvent and wipe dry.
Check for brittle or cracked insulation.
When testing secondary cables for damage with an
oscilloscope, follow the instructions of the equipment
manufacturer.
If an oscilloscope is not available, spark plug cables
may be tested as follows:
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
With the engine not running, connect one end of a
test probe to a good ground. Start the engine and run
the other end of the test probe along the entire
length of all spark plug cables. If cables are cracked
or punctured, there will be a noticeable spark jump
from the damaged area to the test probe. The cable
running from the ignition coil to the distributor cap
can be checked in the same manner. Cracked, dam-
aged or faulty cables should be replaced with resis-
tance type cable. This can be identified by the words
ELECTRONIC SUPPRESSION printed on the cable
jacket.
Use an ohmmeter to test for open circuits, exces-
sive resistance or loose terminals. Remove the dis-
tributor cap from the distributor.Do not remove
cables from cap.Remove cable from spark plug.
Connect ohmmeter to spark plug terminal end of ca-
ble and to corresponding electrode in distributor cap.
Resistance should be 250 to 1000 Ohms per inch of
cable. If not, remove cable from distributor cap tower
and connect ohmmeter to the terminal ends of cable.
If resistance is not within specifications as found in
the Spark Plug Cable Resistance chart, replace the
cable. Test all spark plug cables in this manner.
Fig. 24 Preignition Damage
Fig. 25 Spark Plug Overheating
SPARK PLUG CABLE RESISTANCE
8D - 14 IGNITION SYSTEMSJ

The high-line cluster includes the following gauges:
²coolant temperature gauge
²fuel gauge
²oil pressure gauge
²speedometer/odometer
²tachometer
²trip odometer
²voltmeter.
The high-line cluster includes provisions for the fol-
lowing indicator lamps:
²anti-lock brake system lamp
²brake warning lamp
²four-wheel drive indicator lamps
²headlamp high beam indicator lamp
²low fuel warning lamp
²low washer fluid warning lamp
²malfunction indicator (Check Engine) lamp
²seat belt reminder lamp
²turn signal indicator lamps
²upshift indicator lamp.
GAUGES
With the ignition switch in the ON or START posi-
tion, voltage is supplied to all gauges through the in-
strument cluster gauge area printed circuit. With the
ignition switch in the OFF position, voltage is not
supplied to the gauges. A gauge pointer may remain
within the gauge scale after the ignition switch is
OFF. However, the gauges do not accurately indicate
any vehicle condition unless the ignition switch is
ON.
All gauges except the odometer are air core mag-
netic units. Two fixed electromagnetic coils are lo-
cated within the gauge. These coils are wrapped at
right angles to each other around a movable perma-
nent magnet. The movable magnet is suspended
within the coils on one end of a shaft. The gauge nee-
dle is attached to the other end of the shaft.
One of the coils has a fixed current flowing through
it to maintain a constant magnetic field strength.
Current flow through the second coil changes, which
causes changes in its magnetic field strength. The
current flowing through the second coil can be
changed by:
²a variable resistor-type sending unit (fuel level,
coolant temperature, or oil pressure)
²changes in electrical system voltage (voltmeter)
²electronic control circuitry (speedometer/odometer,
tachometer).
The gauge needle moves as the movable permanent
magnet aligns itself to the changing magnetic fields
created around it by the electromagnets.
COOLANT TEMPERATURE GAUGE
The coolant temperature gauge gives an indication
of engine coolant temperature. The coolant tempera-
ture sending unit is a thermistor that changes elec-
trical resistance with changes in engine coolanttemperature. High sending unit resistance causes
low coolant temperature readings. Low resistance
causes high coolant temperature readings.
The gauge will read at the high end of the scale
when the ignition switch is turned to the START po-
sition. This is caused by the bulb test circuit wiring
provision. The same wiring is used for the high-line
cluster with a coolant temperature gauge and the
low-line cluster with a coolant temperature warning
lamp. Sending unit resistance values are shown in a
chart in Specifications.
FUEL GAUGE
The fuel gauge gives an indication of the level of
fuel in the fuel tank. The fuel gauge sending unit has
a float attached to a swing-arm in the fuel tank. The
float moves up or down within the fuel tank as fuel
level changes. As the float moves, an electrical con-
tact on the swing-arm wipes across a resistor coil,
which changes sending unit resistance. High sending
unit resistance causes low fuel level readings. Low
resistance causes high fuel level readings. Sending
unit resistance values are shown in a chart in Spec-
ifications.
OIL PRESSURE GAUGE
The oil pressure gauge gives an indication of en-
gine oil pressure. The combination oil pressure send-
ing unit contains a flexible diaphragm. The
diaphragm moves in response to changes in engine
oil pressure. As the diaphragm moves, sending unit
resistance increases or decreases. High resistance on
the gauge side of the sending unit causes high oil
pressure readings. Low resistance causes low oil
pressure readings. Sending unit resistance values are
shown in a chart in Specifications.
SPEEDOMETER/ODOMETER
The speedometer/odometer gives an indication of
vehicle speed and travel distance. The speedometer
receives a vehicle speed pulse signal from the Vehicle
Speed Sensor (VSS). An electronic integrated circuit
contained within the speedometer reads and analyzes
the pulse signal. It then adjusts the ground path re-
sistance of one electromagnet in the gauge to control
needle movement. It also sends signals to an electric
stepper motor to control movement of the odometer
number rolls. Frequency values for the pulse signal
are shown in a chart in Specifications.
The VSS is mounted to an adapter near the trans-
mission (two-wheel drive) or transfer case (four-wheel
drive) output shaft. The sensor is driven through the
adapter by a speedometer pinion gear. The adapter
and pinion vary with transmission, transfer case,
axle ratio and tire size. Refer to Group 21 - Trans-
mission and Transfer Case for more information.
8E - 2 INSTRUMENT PANEL AND GAUGESÐXJJ

The two pivot cranks are joined by a connecting link,
and a drive link connects the motor crank to the drive
link near the left pivot. Pressed-in plastic bushings in
the ends of the links can be replaced if worn or dam-
aged.
WINDSHIELD WIPER MOTOR
The two-speed permanent magnet wiper motor has
an integral transmission and park switch. The motor
is mounted to the engine side of the cowl panel with
a reinforcement/stud plate and a rubber-isolated
mounting bracket. The wiper motor output shaft
passes through the cowl panel into the cowl plenum
area, where a crank arm attached to the output shaft
drives the wiper drive link.
Wiper speed is controlled by current flow to the ap-
propriate set of brushes. The wiper motor completes
its wipe cycle when the switch is turned OFF, and
parks the blades in the lowest portion of the wipe
pattern. The wiper motor assembly can not be re-
paired. If faulty, the entire motor assembly must be
replaced. The crank arm, mounting bracket, and re-
inforcement/stud plate are available for service.
LIFTGATE WIPER MOTOR
The liftgate wiper motor contains integral elec-
tronic controls and a transmission to provide three
operating modes:
²intermittent wipe with a fixed 5 to 8 second delay
between wipes
²constant wipe that operates when the liftgate
washer is operated
²a park mode that runs the motor until the wiper
blade reaches the park position after the liftgate
wiper switch or ignition switch is turned OFF.
The liftgate wiper motor can not be repaired. If
faulty, the entire assembly must be replaced.
WINDSHIELD WIPER/WASHER SWITCH
Controls for the windshield wiper and washer sys-
tems are contained in the multi-function switch con-
trol lever. The multi-function switch is mounted on
the left side of the steering column between the
steering wheel and the instrument panel. This switch
also controls many other functions. The multi-func-
tion switch can not be repaired. If any function of the
switch is faulty, the entire switch must be replaced.
LIFTGATE WIPER/WASHER SWITCH
The single two-function switch on the instrument
panel right of the steering column controls the lift-
gate wiper and washer functions. The rocker-type
switch features a detent in the WIPE position, but
only momentary contact in the WASH position. Both
the liftgate wiper and liftgate washer motors will op-
erate continuously for as long as the switch is held in
the WASH position. The switch can not be repaired;
if faulty, it must be replaced.
INTERMITTENT WIPE MODULE
In addition to low and high speed, the optional inter-
mittent wipe system has a delay mode. The delay mode
has a range of 2 to 15 seconds. The length of the delay
is selected with a variable resistor in the wiper (multi-
function) switch and is accomplished by electronic cir-
cuitry within the intermittent wipe module. If the
washer knob is depressed while the wiper (multi-func-
tion) switch is in the OFF position, the intermittent
wipe module will operate the wiper motor for approxi-
mately 2 wipes and automatically turn the motor off.
The intermittent wipe module is mounted to the
lower instrument panel, behind the knee blocker and
near the steering column with a hook and loop fas-
tener patch. The module can not be repaired.
WINDSHIELD WASHER NOZZLES
The two fluidic washer nozzles are riveted into
openings in the cowl grille panel below the wind-
shield and are not adjustable. Washer fluid is fed to
the nozzles through hoses clipped to the underside of
the cowl grille panel. The nozzles can not be repaired
and, if faulty, should be replaced.
LIFTGATE WASHER NOZZLE
The single liftgate washer nozzle snaps into place
on the liftgate wiper arm. Washer fluid is fed to the
nozzle from the washer reservoir in the engine com-
partment. A liftgate washer hose system is routed
through the body of the vehicle with the body wiring
harness from the reservoir to the liftgate. The fluid
passes through a nipple on the liftgate wiper motor
output shaft bezel to a hose clipped to the underside
of the wiper arm. The nozzle can not be repaired and,
if faulty, should be replaced.
WASHER RESERVOIR
The washer solvent reservoir is mounted to the left
front inner fender shield near the cowl panel. The
same reservoir is used for both the standard front
and optional liftgate washer systems. It also has a
provision for a low washer fluid level sensor. Refer to
Group 8E - Instrument Panel and Gauges for diagno-
sis and service of the sensor. The reservoir and filler
cap are available for service.
WASHER PUMPS
The washer pump and motor are press-fit into a
rubber grommet near the bottom of the washer res-
ervoir. Vehicles with the optional liftgate wiper/
washer system have two pumps installed in the
single reservoir. A permanently lubricated and sealed
motor is coupled to a rotor-type pump. Washer fluid
is gravity fed from the reservoir to the pump. The
pump then pressurizes the fluid and forces it through
the plumbing to the nozzles when the motor is ener-
gized. The pump and motor can not be repaired. If
faulty, the entire assembly must be replaced.
8K - 2 WIPER AND WASHER SYSTEMS - XJJ

The liftgate wiper motor can not be repaired. If
faulty, the entire assembly must be replaced.
WINDSHIELD WIPER/WASHER SWITCH
Controls for the windshield wiper and washer sys-
tems are contained in the turn signal switch lever.
The turn signal switch lever is mounted on the left
side of the steering column between the steering
wheel and the instrument panel. The wiper/washer
switch can not be repaired. If any function of the
switch is faulty, the entire switch must be replaced.
LIFTGATE WIPER/WASHER SWITCH
The single two-function switch on the instrument
panel right of the steering column controls the lift-
gate wiper and washer functions. The rocker-type
switch features a detent in the WIPE position, but
only momentary contact in the WASH position. Both
the liftgate wiper and liftgate washer motors will op-
erate continuously for as long as the switch is held in
the WASH position. The switch can not be repaired;
if faulty, it must be replaced.
INTERMITTENT WIPE MODULE
In addition to low and high speed, the optional in-
termittent wipe system has a delay mode. The delay
mode has a range of 2 to 15 seconds. The length of
the delay is selected with a variable resistor in the
wiper switch and is accomplished by electronic cir-
cuitry within the intermittent wipe module. If the
washer knob is depressed while the wiper switch is
in the OFF position, the intermittent wipe module
will operate the wiper motor for approximately 2
wipes and automatically turn the motor off.
The intermittent wipe module is mounted to a
bracket behind the lower instrument panel, near the
steering column with a hook and loop fastener patch.
The module can not be repaired.
WINDSHIELD WASHER NOZZLES
The two fluidic washer nozzles are screwed into
openings in the cowl panel below the windshield and
are not adjustable. Washer fluid is fed to the nozzles
through hoses underneath the cowl panel. The noz-
zles can not be repaired and, if faulty, should be re-
placed.
LIFTGATE WASHER NOZZLE
The single liftgate washer nozzle is installed
through the liftgate glass and secured with a nut on
the inside of the glass. Washer fluid is fed to the noz-
zle from the washer reservoir in the engine compart-
ment. A liftgate washer hose system is routed
through the body of the vehicle with the body wiring
harness from the reservoir to the liftgate. The nozzle
can not be repaired and, if faulty, should be replaced.
WASHER RESERVOIR
The washer solvent reservoir is mounted with a
bracket to the left front inner fender shield near the
cowl panel. The same reservoir is used for both the
standard front and optional liftgate washer systems.
The reservoir and filler cap are available for service.
WASHER PUMPS
The washer pump and motor are press-fit into a
rubber grommet near the bottom of the washer res-
ervoir. Vehicles with the optional liftgate wiper/
washer system have two pumps installed in the
single reservoir. A permanently lubricated and sealed
motor is coupled to a rotor-type pump. Washer fluid
is gravity fed from the reservoir to the pump. The
pump then pressurizes the fluid and forces it through
the plumbing to the nozzles when the motor is ener-
gized. The pump and motor can not be repaired. If
faulty, the entire assembly must be replaced.
JWIPER AND WASHER SYSTEMS - YJ 8K - 11

WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wiring
diagrams. The wires must also be held securely in
place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one side
of the wire. Make sure the tubing will be long enough
to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11
example 2).
(6) Twist the wires together (Fig. 11 example 3).
(7) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation.
(10) Connect battery and test all affected systems.
TERMINAL/CONNECTOR REPAIRÐMOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 12).(4) Using special tool 6742, release the locking fin-
gers on the terminal (Fig. 13).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the connector or terminal as
necessary.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component.
(3) Remove connector locking wedge, if required
(Fig. 14).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 15, and Fig. 16).
Fig. 10 Testing for Voltage DropFig. 11 Wire Repair
Fig. 12 Molex Connector Repair
8W - 6 WIRING DIAGRAMSÐGENERAL INFORMATIONJ

(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the re-
paired connector, if required.
(9) Connect connector to its mating half/component.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector (that is to be repaired)
from its mating half/component.
(3) Cut off the existing wire connector directly be-
hind the insulator. Remove six inches of tape from the
harness.
(4) Stagger cut all wires on the harness side at 1/2
inch intervals (Fig. 17).(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 17).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one side
of the wire. Be sure the tubing will be long enough to
cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(10) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11
example 2).
(11) Twist the wires together (Fig. 11 example 3).
(12) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
Fig. 13 Using Special Tool 6742
Fig. 14 Connector Locking Wedge Tab (Typical)
Fig. 15 Terminal Removal
Fig. 16 Terminal Removal Using Special Tool
JWIRING DIAGRAMSÐGENERAL INFORMATION 8W - 7

(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half.
(3) Remove connector locking wedge, if required
(Fig. 14).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Figs. 15 and 16).
(5) Cut the wire 6 inches from the back of the
connector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assembly
that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and
remove 1 inch of insulation.
(9) Place a piece of heat shrink tubing over one side
of the wire. Make sure the tubing will be long enough
to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11
example 2).
(12) Twist the wires together (Fig. 11 example 3).(13) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if re-
quired, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect the battery, and test all affected sys-
tems.
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove the
protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 18).
(4) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(8) Re-connect the battery, and test affected sys-
tems.Fig. 17 Stagger Cutting Wires (Typical)
Fig. 18 Diode Identification
8W - 8 WIRING DIAGRAMSÐGENERAL INFORMATIONJ