1995 JEEP YJ wheel

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

INSTRUMENT CLUSTER
INSTRUMENT CLUSTER
The instrument cluster contains the gauges and
warning lamps. All gauges have magnetic move-
ments.
When the ignition switch is in either the START or
RUN position, circuit A1 from fuse 4 in the Power
Distribution Center (PDC) connects to circuit A21.
Circuit A21 powers fuse 9 in the fuse block. Fuse 9
powers circuit G5. One branch of circuit G5 connects
directly to the combination buzzer. The other branch
of circuit G5 splices to power the gauges, speedome-
ter, tachometer, voltmeter, indicator lamps, and
warning lamps in the instrument cluster.
When the parking lamps or headlamps are ON, the
headlamp switch connects circuit F33 to circuit L7.
Circuit L7 splices to the dimmer switch. Circuit E1
from the dimmer switch powers fuse 10 in the fuse
block when the parking lamps or headlamps are ON.
Circuit E2 from fuse 10 in the fuse block feeds the
illumination lamps in the instrument cluster.
Circuit Z1 provides ground the instrument cluster
illumination lamps, gauges and warning lamps.
HELPFUL INFORMATION
²Circuit G5 also powers the heated rear window,
A/C compressor clutch relay. On Canadian vehicles,
circuit G5 powers the Daytime Running Lamps
(DRL) module.
²Circuit F33 originates at fuse 8 in the fuse block.
Circuit A6 from fuse 3 in the PDC powers fuse 8 in
the fuse block.
ENGINE COOLANT TEMPERATURE GAUGE
Circuit G20 connects the engine coolant tempera-
ture gauge to the engine coolant temperature sensor.
The sensor is a variable resistor and case grounded
to the engine. Circuit G5 connects to the instrument
cluster and supplies voltage for the gauge.
The gauge uses two coils. The first coil has fixed
current flowing through it to maintain magnetic field
strength. Circuit Z1 provides ground for the fixed
current coil. The current level passing through the
second coil is controlled by the variable resistor in
the engine coolant temperature sender. The changing
current varies the magnetic field in the second coil.
Refer to group 8E, Instrument Panel and Gauges
for gauge operation.
FUEL GAUGE
Circuit G4 connects the fuel level sensor to the fuel
gauge in the instrument cluster. Circuit G5 supplies
voltage to the fuel gauge. The fuel level sensor draws
voltage from circuit G5 through the fuel gauge on cir-
cuit G4.The gauge uses two coils. The first coil has fixed
current flowing through it to maintain magnetic field
strength. Circuit Z1 provides ground for the fixed
current coil. The current level passing through the
second coil is controlled by the variable resistor in
the fuel level sensor. The changing current varies the
magnetic field in the second coil.
Circuit Z2 provides the ground path for the fuel
level sensor.
Refer to group 8E, Instrument Panel and Gauges
for gauge operation.
OIL PRESSURE GAUGE
The case grounded oil pressure sending unit is a
variable resistor. The sending unit connects to the oil
pressure gauge on circuit G60.
Circuit G5 connects to the instrument cluster and
supplies battery voltage to the oil pressure gauge.
The gauge uses two coils. The first coil has fixed cur-
rent flowing through it to maintain magnetic field
strength. Circuit Z1 provides ground for the fixed
current coil. The current level passing through the
second coil is controlled by the variable resistor in
the oil pressure sending unit. The changing current
varies the magnetic field in the second coil.
Refer to group 8E, Instrument Panel and Gauges
for gauge operation.
TACHOMETER
The Powertrain Control Module (PCM) provides
the tachometer signal to the electronic tachometer on
circuit G21. Circuit G21 originates at cavity 43 of the
PCM. Circuit Z1 provides ground for the tachometer's
internal logic circuits.
SPEEDOMETER
The electronic speedometer and odometer receive a
signal from the vehicle speed sensor on circuit G7.
Circuit G5 connects to the instrument cluster and
supplies battery voltage to the speedometer. Circuit
Z1 provides ground for the speedometer internal logic
circuits.
Circuit G7 splices to connect to the Powertrain
Control Module (PCM) and if equipped, the Daytime
Running Lamps (DRL) module.
FOUR-WHEEL DRIVE (4WD) INDICATOR LAMP
When the 4WD switch closes, circuit Z1 provides
ground for the 4WD indicator lamp in the instrument
panel. Circuit G5 connects to the instrument cluster
and supplies battery voltage to the 4WD indicator
lamp. Circuit G1 connects the indicator lamp to the
4WD switch.
J8W-40 INSTRUMENT CLUSTERÐYJ VEHICLES 8W - 40 - 1

HORN/CIGAR LIGHTER
HORN
The horn system uses a switch and horn relay. The
horn switch is in the center of the steering wheel.
Circuit A4 from fuse 8 in the Power Distribution
Center (PDC) feeds circuit F31 through fuse 15 in
the PDC. Circuit F31 is HOT at all times and powers
the coil and contact sides of the horn relay.
When the case grounded horn switch is pressed,
circuit X3 provides ground for the coil side of the re-
lay and the contacts close. When the contacts close,
circuit X2 supplies voltage to the horn. Circuit Z1
provides ground for the horn.
HELPFUL INFORMATION
²The horn switch is grounded to the steering wheel.
²Circuit F31 is double crimped at the coil side of
the horn relay.
²Check fuse 8 in the PDC and fuse 15 in the fuse
block.
CIGAR LIGHTER
In the ACCESSORY or RUN position, the ignition
switch supplies voltage to fuse 7 in the fuse block on
circuit A31. Fuse 7 feeds circuit F30 which connects
to the cigar lighter. When the lighter is depressed,
the contacts inside of the lighter element close and
voltage flows to ground on circuit Z1.
HELPFUL INFORMATION
²In the ACCESSORY or RUN position, the ignition
switch connects circuit A1 from fuse 4 in the PDC
with circuit A31.
²Circuit F30 also powers the radio and radio relay.
DIAGRAM INDEX
Component Page
Cigar Lighter...........................8W-41-3
Fuse 4 (PDC)...........................8W-41-3
Fuse 8 (PDC)...........................8W-41-2
Fuse 11 (PDC)..........................8W-41-2
Fuse 7 (Fuse Block).......................8W-41-3
Horn.................................8W-41-2
Horn Relay.............................8W-41-2
Horn Switch............................8W-41-2
Ignition Switch..........................8W-41-3
J8W-41 HORN/CIGAR LIGHTERÐYJ VEHICLES 8W - 41 - 1

(a) Disconnect the power steering 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 material from entering the
system.
(21) Disconnect the coolant hoses from the rear of
the intake manifold.
(22) Identify, tag and disconnect all necessary wire
connectors and vacuum hoses.
(23) Raise the vehicle.
(24) Remove the oil filter.
(25) Remove the starter motor.
(26) Disconnect the exhaust pipe from the exhaust
manifold.
(27) Remove the flywheel and converter housing
access cover.
(28) If equipped with an automatic transmission,
mark the converter and drive plate location in refer-
ence to each other and remove the converter-to-drive
plate bolts.(29) Remove the upper flywheel and converter
housing bolts and loosen the bottom bolts.
(30) Remove the engine support cushion-to-engine
compartment bracket bolts.
(31) Remove the engine shock damper bracket
from the sill.
(32) Lower the vehicle.
(33) Attach a lifting device to the engine.
(34) Raise the engine slightly off the front sup-
ports.
(35) Place a support stand under the converter or
flywheel housing.
(36) Remove the remaining bottom converter or
flywheel housing bolts.
(37) Lift the engine out of the engine compartment
and install on an engine stand.
(38) 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) If equipped with a manual transmission:
(a) Insert the transmission shaft into the clutch
spline.
(b) Align the flywheel housing with the engine.
(c) Install and tighten the flywheel housing lower
bolts finger tight.
(4) If equipped with an automatic transmission:
Fig. 16 Heater Hoses (LH Drive Vehicles), Throttle
Linkage & Quick-Connect Fuel Lines
Fig. 17 Heater Hoses (RH Drive Vehicle)
Fig. 18 Air Cleaner and Power Steering Pump
J2.5L ENGINE 9 - 19

(a) Align the transmission torque converter hous-
ing with the engine.
(b) Loosely install the converter housing lower
bolts and install the next higher bolt and nut on
each side.
(c) Tighten all 4 bolts finger-tight.
(5) Install the engine support cushions (if re-
moved).
(6) Lower the engine and engine support cushions
onto the engine compartment brackets.
(7) Remove the engine lifting device.
(8) Raise the vehicle.
(9) If equipped with an automatic transmission:
(a) Install the converter-to-drive plate bolts. En-
sure the installation reference marks are aligned.
Tighten the bolts to 54 Nzm (40 ft. lbs.) torque.
(b) Install the converter-housing access cover.
(c) Install the exhaust pipe support.
(10) Install the remaining converter or flywheel
housing bolts.
(11) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(12) Tighten the engine support cushing through-
bolt nuts.
(13) Install the remaining flywheel and converter
housing bolts. Tighten the bolts to 38 Nzm (28 ft. lbs.)
torque.
(14) Connect the exhaust pipe to the manifold.
(15) Install the oil filter.
(16) Lower the vehicle.
(17) Connect the coolant hoses and tighten the
clamps.
(18) If equipped with power steering:
(a) Remove the protective caps
(b) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 Nzm (38 ft. lbs.)
torque.
(c) Fill the pump reservoir with fluid.
(19) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
(20) Install the fan shroud and radiator and con-
denser (if equipped with air conditioning).
(21) Connect the radiator hoses.
(22) Connect the automatic transmission fluid
cooler pipes, if equipped.
(23) Connect the oxygen sensor wire connector.
(24) Connect the throttle valve rod and retainer.
Connect the throttle cable and install the rod. Install
the throttle valve rod spring.
(25) Connect the speed control cable, if equipped.
(26) Connect the fuel supply and return lines to
the throttle body.
(27) Connect all the vacuum hoses and wire con-
nectors.
(28) Connect the service valves to the A/C compres-
sor ports, if equipped with air conditioning.(29) Fill the power steering reservoir.
(30) Connect the battery cables.
(31) Install the hood.
(32) Install the air cleaner.
(33) Start the engine and inspect for leaks.
(34) Fill the cooling system.
(35) Stop the engine and check the fluid levels.
Add fluid, as required.
ENGINE ASSEMBLYÐYJ VEHICLES
REMOVAL
(1) Place a protective cloth over the windshield
frame. Raise the hood and rest it on the windshield
frame (Fig. 19).
(2) Disconnect the battery cable clamps and re-
move the battery.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(3) Remove the radiator drain cock and radiator
cap to drain the coolant. DO NOT waste usable cool-
ant. If the solution is clean, drain the coolant into a
clean container for reuse.
(4) Disconnect the wire connectors from the gener-
ator.
(5) Disconnect the ignition coil and distributor wire
connectors.
(6) Disconnect the oil pressure sender wire connec-
tor.
Fig. 19 Hood on Windshield Frame
9 - 20 2.5L ENGINEJ

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

(14) Install the remaining flywheel housing bolts.
Tighten the bolts to 38 Nzm (28 ft. lbs.) torque.
(15) Install the starter motor and connect the ca-
ble. Tighten the bolts to 45 Nzm (33 ft. lbs.) torque.
(16) Install the oil filter.
(17) Lower the vehicle.
(18) Connect the coolant hoses and tighten the
clamps.
(19) If equipped with power steering:
(a) Remove the protective caps
(b) Connect the hoses to the fittings at the steer-
ing gear. Tighten the nut to 52 Nzm (38 ft. lbs.)
torque.
(c) Fill the pump reservoir with fluid.
(20) Remove the pulley-to-water pump flange
alignment capscrew and install the fan and spacer or
Tempatrol fan assembly.
(21) Tighten the serpentine drive belt according to
the specifications listed in Group 7, Cooling System.
(22) Install the fan shroud and radiator.
(23) Connect the radiator hoses.
(24) Connect the heater hoses.
(25) Connect the throttle valve rod and retainer.
(26) Connect the throttle cable and install the rod.
(27) Install the throttle valve rod spring.
(28) Connect the speed control cable, if equipped.
(29) Connect the oxygen sensor wire connector.
(30) Install the vacuum hose and check valve on
the brake booster.
(31) Connect the coolant temperature sensor wire
connector.
(32) Connect the idle speed actuator wire connec-
tor.
(33) Connect the fuel inlet and return hoses at the
fuel rail. Verify that the quick-connect fitting assem-
bly fits securely over the fuel lines by giving the fuel
lines a firm tug.
(34) Install the fuel line bracket to the intake man-
ifold.
(35) Connect all fuel injection wire connections.
(36) Install the engine ground strap.
(37) Connect the ignition coil wire connector.
(38) Remove the coolant temperature sending unit
to permit air to escape from the block. Fill the cool-
ing system with coolant. Install the coolant tempera-
ture sending unit when the system is filled.
(39) Install the battery and connect the battery ca-
bles.
(40) Install the air cleaner bonnet to the throttle
body.
(41) Install the air cleaner.
(42) Lower the hood and secure in place.
(43) Start the engine and inspect for leaks.
(44) Stop the engine and check the fluid levels.
Add fluid, as required.ENGINE CYLINDER HEAD COVER
A cured gasket is part of the engine cylinder head
cover.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect the Crankcase Ventilation (CCV)
vacuum hose from engine cylinder head cover (Fig.
1).
(3) Disconnect the fresh air inlet hose from the en-
gine cylinder head cover (Fig. 1).
(4) Remove the engine cylinder head cover mount-
ing bolts.
(5) Remove the engine cylinder head cover.
CLEANING
Remove any original sealer from the cover sealing
surface of the engine cylinder head and clean the
surface using a fabric cleaner.
Remove all residue from the sealing surface using
a clean, dry cloth.
INSPECTION
Inspect the engine cylinder head cover for cracks.
Replace the cover, if cracked.
The original dark grey gasket material should NOT
be removed. If sections of the gasket material are
missing or are compressed, replace the engine cylin-
der head cover. However, sections with minor damage
such as small cracks, cuts or chips may be repaired
with a hand held applicator. The new material must
be smoothed over to maintain gasket height. Allow
the gasket material to cure prior to engine cylinder
head cover installation.
INSTALLATION
(1) If a replacement cover is installed, transfer the
CCV valve grommet the oil filler cap from the origi-
nal cover to the replacement cover.
(2) Install engine cylinder head cover. Tighten the
mounting bolts to 10 Nzm (85 in. lbs.) torque.
Fig. 1 Engine Cylinder Head Cover
9 - 22 2.5L ENGINEJ