1995 JEEP YJ light

INTERIOR LIGHTING
INDEX
page page
Accessory Lamp and Heater Control Panel Lamp . . 1
Combination Buzzer........................ 1
Courtesy Lamps and Dome Lamps............. 1
Diagram Index............................ 2General Information........................ 1
Transmission Range Lamp................... 1
Underhood Lamp.......................... 1
GENERAL INFORMATION
Circuit M1 supplies power to the underhood lamp,
dome lamp, right courtesy lamp and left courtesy
lamp. Fuse 12 in the Power Distribution Center
(PDC) protects circuit M1. Circuit A4 from fuse 8 in
the PDC supplies voltage to fuse 12 and circuit M1.
Fuse 12 is referred to as the Ignition Off Draw (IOD)
fuse.
COURTESY LAMPS AND DOME LAMPS
Circuit M1 supplies battery voltage to the dome
lamps and the right and left courtesy lamps. Circuit
M2 provides ground for the lamps through either the
case grounded door jamb switches or through the
dimmer switch to circuit Z1.
In the ON position, the dimmer switch connects
circuit M2 to ground on circuit Z1. When a door
opens, the case grounded door jamb switch closes and
provides ground for the lamps on circuit M2.
HELPFUL INFORMATION
²Circuit M1 also supplies voltage for radio memory,
underhood lamp and the ABS data link connector.
UNDERHOOD LAMP
Circuit M1 supplies battery voltage for the under-
hood lamp. A mercury switch in series after the lamp
connects the lamp to ground on circuit Z1. When the
hood is raised, mercury inside the switch moves to a
position where it connects circuit M1 to circuit Z1, il-
luminating the lamp. The underhood lamp is wired
in parallel with other components on circuit M1.
ACCESSORY LAMP AND HEATER CONTROL PANEL
LAMP
Circuit E1 from the dimmer switch supplies bat-
tery voltage to fuse 10 in the fuse block when the
dimmer switch is in the LOW or ON position. Fuse
10 protects circuit E2 which supplies power to the
heater control panel lamp and the accessory lamp.
Circuit Z1 provides ground for each lamp.
TRANSMISSION RANGE LAMP
Circuit E1 from the dimmer switch supplies bat-
tery voltage to fuse 10 in the fuse block when thedimmer switch is in the LOW or ON positions. Fuse
10 protects circuit E2 which supplies power to the
transmission range lamp. The lamp is case grounded.
COMBINATION BUZZER
The combination buzzer module sounds an audible
warning tone. The tone sounds for seat belt warning
and when the key is in the ignition switch while the
drivers door is open. The tone also sounds when the
ignition switch is in the ON position while the driv-
ers side seat belt is not buckled. Refer to Group 8U
for buzzer operation.
Fuses 3 and 9 in the fuse block protect the combi-
nation buzzer. Fuse 3 powers circuit F32 which con-
nects to the buzzer. Circuit A6 from fuse 3 in the
Power Distribution Center (PDC) supplies power to
the fuse block for circuit F32.
Circuit G5 from fuse 9 also provides voltage to the
combination buzzer when the ignition switch is in
the START or RUN position. The ignition switch con-
nects circuit A1 from fuse 4 in the PDC to circuit
A21. Circuit A21 connects to the fuse block.
When the key-in switch closes, it connects circuit
G26 to circuit G16. Circuit G16 connects to the driv-
ers side door jamb switch. When the drivers side door
is open and the key-in switch is closed, the case
grounded door jamb switch closes and supplies
ground for the buzzer. Circuit G26 from the combina-
tion buzzer connects to the key-in switch.
Circuit G13 form the buzzer powers the seat belt
warning lamp in the instrument cluster. Circuit Z1
at the instrument cluster provides ground for the
lamp.
Circuit G10 from the buzzer connects to the seat
belt switch. When the seat belt is unlatched, the seat
belt switch closes providing ground on circuit Z1.
Circuit Z1 also grounds the combination buzzer
module.
HELPFUL INFORMATION
²Circuit F32 also powers the stop lamp switch.
²Circuit G5 also provides power for the instrument
cluster gauges and warning lamps, heated rear win-
dow relay and A/C compressor clutch relay. On Cana-
J8W-44 INTERIOR LIGHTINGÐYJ VEHICLES 8W - 44 - 1

dian vehicles, circuit G5 also powers the Daytime
Running Lamps (DRL) module.DIAGRAM INDEX
Component Page
Combination Buzzer.......................8W-44-5
Courtesy Lamps.........................8W-44-4
Dome Lamps...........................8W-44-4
Door Jamb Switches......................8W-44-4
Fuse 3 (Fuse Block).......................8W-44-5
Fuse 3 (PDC).........................8W-44-3, 5
Fuse 4 (PDC)...........................8W-44-5
Fuse 8 (Fuse Block).......................8W-44-3
Fuse 8 (PDC)...........................8W-44-4
Fuse 9 (Fuse Block).......................8W-44-5
Fuse 10 (Fuse Block)......................8W-44-3
Fuse 12 (PDC)..........................8W-44-4
Headlamp Switch.........................8W-44-3
Ignition Switch..........................8W-44-5
Illumination Lamps.......................8W-44-3
Key-In Switch...........................8W-44-5
Panel Lamp Dimmer Switch................8W-44-3, 4
Seat Belt Switch.........................8W-44-5
Underhood Lamp.........................8W-44-4
8W - 44 - 2 8W-44 INTERIOR LIGHTINGÐYJ VEHICLESJ

FRONT LIGHTING
INDEX
page page
Daytime Running Lamp (DRL) ModuleÐCanadian
Vehicles Only........................... 2
Diagram Index............................ 2
Fog Lamps............................... 1Headlamps............................... 1
Parking Lamps............................ 1
HEADLAMPS
The headlamp switch has three positions: ON,
PARK (parking lamps) and OFF. Two circuits, L2 and
L20, connect the headlamp switch to the headlamp
dimmer/optical horn switch. The dimmer switch feeds
the low and high beams of the headlamps.
HEADLAMP SWITCH IN OFF OR PARKING
LAMP POSITION
Circuit A3 from fuse 7 in the Power Distribution
Center (PDC) supplies battery voltage to the head-
lamp switch. The headlamp switch has an internal
circuit breaker that connects circuit A3 to circuit
L20. The switch connects circuit A3 to circuit L2
when the headlamps are ON.
Circuit L20 connects to the dimmer switch. Circuit
L20 powers the high beams of the head lamps on cir-
cuit L3 when the operator flashes the headlamps
with the turn signal stalk.
HEADLAMP SWITCH IN ON POSITION
When the headlamp switch is in the ON position,
the A3 circuit from the PDC connects to circuit L2.
Circuit L2 connects to circuit L4 through the dimmer
switch. Circuit L4 powers the low beam of the head-
lamps.
When the operator selects high beam operation
with the turn signal stalk, the dimmer switch con-
nects circuit L20 to circuit L3. Circuit L3 supplies
battery voltage to the high beams.
HEADLAMP GROUND
Although circuit Z1 provides ground for both the
right and left headlamps, it has different termination
points for each. For the right headlamp, the Z1 cir-
cuit terminates at the radiator right support. For the
left headlamp, the Z1 circuit terminates at the left
radiator support.
HELPFUL INFORMATION
²Check fuse 7 in the PDC.
²The headlamp switch has an internal circuit
breaker.
²For the left front parking lamp, turn signal, side
marker lamp, headlamp, and fog lamp, circuit Z1 ter-
minates at the left radiator support.²For the right front parking lamp, turn signal, side
marker lamp, headlamp, and fog lamp, circuit Z1 ter-
minates at the right radiator support.
PARKING LAMPS
Circuit A6 from fuse 3 in the Power Distribution
Center (PDC) connects to the fuse block bus bar that
powers circuit F33. Fuse 8 in the fuse block protects
circuit F33. Circuit F33 connects to the headlamp
switch.
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, rear tail
lamps, and side marker lamps. Circuit L7 also pow-
ers the park lamp relay, if equipped with fog lamps.
GROUND CIRCUIT
²For the left front parking lamp, turn signal, side
marker lamp, headlamp, and fog lamp, circuit Z1 ter-
minates at the left radiator support.
²For the right front parking lamp, turn signal, side
marker lamp, headlamp, and fog lamp, circuit Z1 ter-
minates at the right radiator support.
HELPFUL INFORMATION
²Check fuse 3 in the PDC.
²Check fuse 8 in the fuse block.
²Circuit L7 also feeds the radio, if equipped.
FOG LAMPS
The fog lamps are controlled by the fog lamp
switch and two relays. The fog lamps operate only
when the headlamp switch is in the ON position, and
the operator has selected low-beam operation. When
the headlamps are in high-beam operation, the fog
lamps will not operate.
When the headlamps or parking lamps are ON, cir-
cuit L7 from the headlamp switch supplies battery
voltage to the coil side of the park lamp relay. When
the operator presses the fog lamp switch, it provides
ground for the coil side of the park lamp relay. This
energizes the relay.
J8W-50 FRONT LIGHTINGÐYJ VEHICLES 8W - 50 - 1

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

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 # . Color . Location Fig.
C222......BK ...Rear of Switch...............6
C223......BK ...Rear of HVAC Switch...........6
C224......BK ...Rear of Radio...............6
C225......BK ...Rear Center of I.P.............6
C226......BK ...Rear of Glove Box LT Side.......6
C227......BK ...Under I.P Right Side...........6
C228......BK ...AtSpeaker...........Not Shown
C229......BK ...RTSide of HVAC Housing.......6
C230......BK ...RTSide of HVAC Housing.......6
C231......BK ...RTKick Panel.............6,7
C232......BK ...TopofI.P.Center Support.......7
C233......BK ...TopofI.P.Center Support.......7
C301......RD ...LTKick Panel................8
C302......BK ...AtBuckle..................8
C303......BK ...LTRear Quarter Panel..........8
C304......BK ...LTRear Quarter Panel..........8
C305......BK ...RTRear Quarter Panel..........8
C306......BK ...AtMotor............Not Shown
C307......BK ...LTSide of I.P. at Lamp.........6
C308......BK ...RTSide of I.P. at Lamp.........7
C309......BK ...AtCHMSL Lamp.......Not Shown
C310......BK ...AtCHMSL Lamp.......Not Shown
C401......BK ...TopofFuel Tank..............9Connector # . Color . Location Fig.
C402......BK ...RTSide of Axle........Not Shown
C403......BK ...RTSide of Roll Bar............8
C404......GY ...LTSide Front of Transmission.....5
C405......BK ...RTSide of Transmission........5
D101............ABSDiode Under I.P.Front of
Floor Tunnel...............6
D201............Taped In Harness Near Wiper
Switch T/O................6
G101............Left of Battery on Dash Panel.....1
G102............Center of Dash Panel...........1
G103 2.5L . .......Rear of Distributor............3
G103 4.0L . .......Rear of Generator.............4
G104 2.5L . .......RTSide of Engine.............3
G104 4.0L . .......RtSide of Engine.............4
G105............RTSide Radiator Closure Panel....2
G106............LTSide Radiator Closure Panel....2
G107............RTSide of Dash Panel.........1
G108 2.5L . .......RTRear of Engine............3
G108 4.0L . .......RTRear of Engine............4
G201.............AtCigar Lighter..............6
G202.............Rear of Radio...............6
8W - 90 - 2 8W-90 CONNECTOR LOCATIONSÐYJ VEHICLESJ

ENGINES
CONTENTS
page page
LUBRICATION SYSTEM................... 37
LUBRICATION SYSTEM................... 79
2.5L ENGINE SERVICE PROCEDURES....... 134.0L ENGINE SERVICE PROCEDURES....... 55
ENGINE DIAGNOSIS...................... 5
STANDARD SERVICE PROCEDURES......... 1
STANDARD SERVICE PROCEDURES
INDEX
page page
Engine Performance........................ 2
Form-In-Place Gaskets...................... 1
Honing Cylinder Bores...................... 2
Hydrostatic Lock........................... 4Measuring with Plastigage.................... 3
Repair Damaged or Worn Threads............. 4
Service Engine Assembly (Short Block).......... 4
FORM-IN-PLACE GASKETS
There are several places where form-in-place gas-
kets are used on the engine.DO NOT use form-in-
place gasket material unless specified.Care
must be taken when applying form-in-place gaskets.
Bead size, continuity and location are of great impor-
tance. Too thin a bead can result in leakage while too
much can result in spill-over. A continuous bead of
the proper width is essential to obtain a leak-free
joint.
Two types of form-in-place gasket materials are
used in the engine area (Mopar Silicone Rubber Ad-
hesive Sealant and Mopar Gasket Maker). Each have
different properties and cannot be used interchange-
ably.
MOPAR SILICONE RUBBER ADHESIVE
SEALANT
Mopar Silicone Rubber Adhesive Sealant, normally
black in color, is available in 3 ounce tubes. Moisture
in the air causes the sealant material to cure. This
material is normally used on flexible metal flanges.
It has a shelf life of a year and will not properly cure
if over aged. Always inspect the package for the ex-
piration date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normally red in color, is
available in 6 cc tubes. This anaerobic type gasket
material cures in the absence of air when squeezedbetween smooth machined metallic surfaces. It will
not cure if left in the uncovered tube. DO NOT use
on flexible metal flanges.
SURFACE PREPARATION
Parts assembled with form-in-place gaskets may be
disassembled without unusual effort. In some in-
stances, it may be necessary to lightly tap the part
with a mallet or other suitable tool to break the seal
between the mating surfaces. A flat gasket scraper
may also be lightly tapped into the joint but care
must be taken not to damage the mating surfaces.
Scrape or wire brush all gasket surfaces to remove
all loose material. Inspect stamped parts to ensure
gasket rails are flat. Flatten rails with a hammer on
a flat plate, if required. Gasket surfaces must be free
of oil and dirt. Make sure the old gasket material is
removed from blind attaching holes.
GASKET APPLICATION
Assembling parts using a form-in-place gasket re-
quires care.
Mopar Silicone Rubber Adhesive Sealant should be
applied in a continuous bead approximately 3 mm
(0.12 inch) in diameter. All mounting holes must be
circled. For corner sealing,a3or6mm(1/8 or 1/4
inch) drop is placed in the center of the gasket con-
tact area. Uncured sealant may be removed with a
shop towel. Components should be torqued in place
while the sealant is still wet to the touch (within 10
JENGINES 9 - 1

minutes). The use of a locating dowel is recom-
mended during assembly to prevent smearing the
material off location.
Mopar Gasket Maker should be applied sparingly
to one gasket surface. The sealant diameter should
be 1.00 mm (0.04 inch) or less. Be certain the mate-
rial surrounds each mounting hole. Excess material
can easily be wiped off. Components should be
torqued in place within 15 minutes. The use of a lo-
cating dowel is recommended during assembly to pre-
vent smearing the material off location.
ENGINE PERFORMANCE
To provide best vehicle performance and lowest ve-
hicle emissions, it is most important that the tune-up
be done accurately. Use the specifications listed on
the Vehicle Emission Control Information label found
on the engine compartment hood.
(1) Test battery specific gravity. Add water, if nec-
essary. Clean and tighten battery connections.
(2) Test cranking amperage draw (refer to Group
8B, Battery/Starter Service for the proper proce-
dures).
(3) Tighten the intake manifold bolts (refer to
Group 11, Exhaust System and Intake Manifold for
the proper specifications).
(4) Perform cylinder compression test:
(a) Check engine oil level and add oil, if neces-
sary.
(b) Drive the vehicle until engine reaches normal
operating temperature.
(c) Select a route free from traffic and other
forms of congestion, observe all traffic laws and
briskly accelerate through the gears several times.
The higher engine speed may help clean out valve
seat deposits which can prevent accurate compres-
sion readings.
CAUTION: DO NOT overspeed the engine.
(d) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for ab-
normal firing indicatorsÐfouled, hot, oily, etc.
Record cylinder number of spark plug for future
reference.
(e) Disconnect coil wire from distributor and se-
cure to good ground to prevent a spark from start-
ing a fire.
(f) Be sure throttle blades are fully open during
the compression check.
(g) Insert compression gage adaptor into the
No.1 spark plug hole. Crank engine until maximum
pressure is reached on gauge. Record this pressure
as No.1 cylinder pressure.
(h) Repeat Step 4g for all remaining cylinders.
(i) Compression should not be less than 689 kPa
(100 psi) and not vary more than 172 kPa (25 psi)
from cylinder to cylinder.(j) If cylinder(s) have abnormally low compres-
sion pressures, repeat steps 4a through 4h.
(k) If the same cylinder(s) repeat an abnormally
low reading, it could indicate the existence of a
problem in the cylinder.
The recommended compression pressures are
to be used only as a guide to diagnosing engine
problems. An engine should NOT be disassem-
bled to determine the cause of low compression
unless some malfunction is present.
(5) Clean or replace spark plugs as necessary. Ad-
just gap (refer to Group 8D, Ignition System for gap
adjustment and torque).
(6) Test resistance of spark plug cables (refer to
Group 8D, Ignition System).
(7) Inspect the primary wire. Test coil output volt-
age, primary and secondary resistance. Replace parts
as necessary (refer to Group 8D, Ignition System and
make necessary adjustment).
(8) Perform a combustion analysis.
(9) Test fuel pump for pressure (refer to Group 14,
Fuel System for the proper specifications).
(10) Inspect air filter element (refer to Group 0,
Lubrication and Maintenance for the proper proce-
dure).
(11) Inspect crankcase ventilation system (refer to
Group 0, Lubrication and Maintenance for the proper
procedure).
(12) For emission controls refer to Group 25, Emis-
sion Controls System for service procedures.
(13) Inspect and adjust accessory belt drives (refer
to Group 7, Cooling System for the proper adjust-
ments).
(14) Road test vehicle as a final test.
HONING CYLINDER BORES
Before honing, stuff plenty of clean shop towels un-
der the bores and over the crankshaft to keep abra-
sive materials from entering the crankshaft area.
(1) Used carefully, the Cylinder Bore Sizing Hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Deglazing of the cylinder walls may be done if
the cylinder bore is straight and round. Use a cylin-
der surfacing hone, Honing Tool C-3501, equipped
with 280 grit stones (C-3501-3810). 20-60 strokes, de-
pending on the bore condition, will be sufficient to
provide a satisfactory surface. Using honing oil
C-3501-3880 or a light honing oil available from ma-
jor oil distributors.
9 - 2 ENGINESJ