1995 JEEP YJ service

LAMPS
CONTENTS
page page
BULB APPLICATIONÐYJ VEHICLES......... 32
GENERAL INFORMATION................. 19INTERIOR LAMPS....................... 31
SERVICE PROCEDURES.................. 22
GENERAL INFORMATION
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush and coat the inside of the socket lightly with
Mopar Multi-Purpose Grease or equivalent.
DIAGNOSTIC PROCEDURESÐYJ
When a vehicle experiences problems with the
headlamp system, verify the condition of the batteryconnections, charging system, headlamp bulbs, wire
connectors, relay, high beam dimmer switch and
headlamp switch. Refer to Group 8W, Wiring Dia-
grams for component locations and circuit informa-
tion.
Always begin any diagnosis by testing all of the
fuses and circuit breakers in the system. Refer to
Group 8W, Wiring Diagrams.
JLAMPSÐYJ VEHICLES 8L - 19

SERVICE PROCEDURES
INDEX
page page
Back-Up/Rear Turn Signal/Tail Lamp Bulb
ReplacementÐYJ....................... 28
Center High Mounted Stop Lamp (CHMSL)ÐYJ . . 28
Daytime Running Lights (Canada Only)ÐYJ..... 30
Drl Module ReplacementÐYJ................ 30
Fog Lamp ReplacementÐYJ................. 25
Fog Lamp Switch ReplacementÐYJ........... 26
Fog LampsÐYJ.......................... 23
Front Park/Turn Signal Lamp Bulb ReplacementÐ
YJ ................................... 25
Headlamp Alignment PreparationÐYJ.......... 22Headlamp AlignmentÐYJ................... 22
Headlamp Bulb ReplacementÐYJ............. 23
Headlamp Dimmer Switch ReplacementÐYJ..... 26
Headlamp SwitchÐYJ...................... 26
Headlamp/Fog Lamp Adjustment Using Alignment
ScreenÐYJ............................ 23
Side Marker Lamp Bulb ReplacementÐYJ....... 25
Underhood Lamp Bulb ReplacementÐYJ....... 29
Underhood Lamp ReplacementÐYJ........... 29
Underhood Lamp Service InformationÐYJ....... 28
HEADLAMP ALIGNMENTÐYJ
Headlamps can be aligned using the screen method
provided in this section. Alignment Tool C4466-A or
equivalent can also be used. Refer to instructions
provided with the tool for proper procedures.The
preferred headlamp alignment setting is 0 for
the left/right adjustment and 1(down for the
up/down adjustment.
HEADLAMP ALIGNMENT PREPARATIONÐYJ
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Correct defective components that could hinder
proper headlamp alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is not heavily loaded.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
Fig. 1 Headlamp Alignment ScreenÐTypical
8L - 22 LAMPSÐYJ VEHICLESJ

(9) Raise and support the A/C evaporator housing
(Fig. 13).
(10) Install the evaporator housing-to-instrument
panel screws and evaporator support bracket screw.
BACK-UP/REAR TURN SIGNAL/TAIL LAMP BULB
REPLACEMENTÐYJ
REMOVAL
(1) Remove the lens retaining screws from the tail
lamp housing (Fig. 15).
(2) Separate the lens from the tail lamp housing.
(3) Remove the bulb from the lamp socket.
INSTALLATION
(1) Install a replacement bulb in the lamp socket.
(2) Position the lens on the lamp housing.
(3) Install the lens retaining screws. Tighten the
screws securely.
CENTER HIGH MOUNTED STOP LAMP (CHMSL)Ð
YJ
The CHMSL is mounted on top of a bracket that
attaches to the spare tire carrier (Fig. 16).
(1) Remove the CHMSL lens (Fig. 17).
(2) Remove CHMSL lamp housing (Fig. 18)(5) Replace bulbs if necessary.
To install, reverse removal procedure.
UNDERHOOD LAMP SERVICE INFORMATIONÐYJ
When equipped, the underhood lamp is installed on
the hood right, rear inner panel (Fig. 19). The lamp
is illuminated when the hood is opened. The switch
Fig. 15 Back-up/Rear Turn Signal/Tail Lamp Bulb
Replacement
Fig. 16 Center High Mounted Stop Lamp (CHMSL) Bracket Assembly
8L - 28 LAMPSÐYJ VEHICLESJ

INTERIOR LAMPS
INDEX
page page
Dome/Courtesy Lamp Service InformationÐYJ . . . 31
Dome/Courtesy Lamp Trouble DiagnosisÐYJ.... 31Hardtop Dome/Cargo Lamp Bulb ReplacementÐYJ
Vehicles............................... 31
DOME/COURTESY LAMP SERVICE
INFORMATIONÐYJ
The dome/cargo and underpanel courtesy lamps are
controlled via ON/OFF switches. The ON/OFF
switches are in the lamp ground circuits. Voltage via
the dome/courtesy lamp fuse is applied directly to the
lamp bulbs. When either door is opened, the door pil-
lar switch contacts close and provide a direct path to
vehicle body ground.
The dome/cargo and underpanel courtesy lamps
can also be turned on via the interior lamp illumina-
tion rheostat.
DOME/COURTESY LAMP TROUBLE DIAGNOSISÐ
YJ
ALL LAMPS INOPERATIVE FROM INTERIOR
LAMP ILLUMINATION RHEOSTAT
(1) Rotate the interior lamp illumination rheostat
in an upward direction. The lamps should light. If
not OK, remove, inspect and test the dome lamp
fuse. Replace if bad.
(2) If the fuse is OK, repair the open circuit in the
wire harness to vehicle body ground.
(3) If lamp still does not light, replace the switch.
ONE LAMP INOPERATIVE
(1) Measure the resistance across the bulb holder
terminals. The ohmmeter should indicate zero ohms.
If not, replace the bulb.
(2) Measure the voltage between the voltage side
of the bulb holder and vehicle body ground. The volt-
meter should indicate battery voltage. If not, repair
the open circuit in the wire harness to the splice.
LAMPS INOPERATIVE WITH ONE OR MORE
DOORS OPENED
(1) Remove the inoperative switch from the door
pillar and connect the switch wire directly to ground.
The lamp should light.(2) If not, check for an open circuit in black
(ground) wire. Repair as necessary. If lamps still do
not light, replace the switch.
HARDTOP DOME/CARGO LAMP BULB
REPLACEMENTÐYJ VEHICLES
REMOVAL
(1) Remove the dome/cargo lamp lens by squeezing
it at both sides. This will separate the lens retainer
tabs from the lamp housing shoulders (Fig. 1).
(2) Remove the lens from the lamp housing.
(3) Pull the bulb straight out to remove from the
bulb holder.
INSTALLATION
(1) Insert the replacement bulb in the bulb holder.
(2) Position lens at the lamp housing and force it
into the housing until the retainer tabs are seated.
Fig. 1 Hardtop Dome/Cargo Lamp
JLAMPSÐYJ VEHICLES 8L - 31

BULB APPLICATIONÐYJ VEHICLES
GENERAL INFORMATION
The following Bulb Application Table lists the lamp
title on the left side of the column and trade number
or part number on the right.
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the Bulb Applica-
tion Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
oily surfaces. Bulb life will be reduced.
EXTERIOR LAMPSÐYJ
Back-up .................................................................1156
Center High Mounted Stoplamp ..........................912
Fog ............................................................................H3
Front Side Marker .................................................194
Headlamp/Sealed Beam....................................H6054
Park/Turn Signal..................................................3157
Tail/Stop ................................................................1157
INTERIOR LAMPSÐYJ
Service procedures for most of the lamps in the in-
strument panel, Instrument cluster and switches are
located in Group 8E, Instrument Panel and Gauges.
Some components have lamps that can only be ser-
viced by an Authorized Service Center (ASC) after
the component is removed from the vehicle. Contact
local dealer for location of nearest ASC.Dome/Cargo .........................................................212-2
Glove Compartment ...............................................194
Under Hood ............................................................105
Underpanel Courtesy...............................................89
INDICATOR LAMPS
Service procedures for most of the lamps in the in-
strument panel, instrument cluster and switches are
located in Group 8E, Instrument Panel and Gauges.
A/C Control ...............................................................74
Anti-lock Brake ........................................................74
Ash Receiver .........................................................1891
Brake Warning .........................................................74
Cigar Lighter ............................................................53
Fasten Seat Belts ....................................................74
Four Wheel Drive ....................................................74
Generator ................................................................194
Hazard.......................................................................74
Heater Control .......................................................194
High Beam..............................................................194
Illumination ............................................................194
Low Coolant..............................................................74
Radio ......................................................................ASC
Rocker Switch...........................................................74
Seat Belt ...................................................................74
Shift ...........................................................................74
Turn Signal.............................................................194
8L - 32 LAMPSÐYJ VEHICLESJ

RESTRAINT SYSTEMS
CONTENTS
page page
AIRBAG SYSTEM......................... 1
DIAGNOSIS............................. 2GENERAL INFORMATION.................. 1
SERVICE PROCEDURES................... 2
AIRBAG SYSTEM
WARNING: THIS AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX MECHANICAL UNIT. BEFORE ATTEMPT-
ING TO REMOVE OR INSTALL THE AIRBAG SYS-
TEM OR RELATED STEERING WHEEL AND
STEERING COLUMN COMPONENTS YOU MUST
FIRST DISARM THE AIRBAG FIRING MECHANISM.
FAILURE TO DO SO COULD RESULT IN ACCIDEN-
TAL DEPLOYMENT AND POSSIBLE PERSONAL IN-
JURY.
WARNING: THE AIRBAG MODULE INFLATOR/SEN-
SOR ASSEMBLY CONTAINS SODIUM AZIDE AND
POTASSIUM NITRATE. THESE MATERIALS ARE
POISONOUS AND EXTREMELY FLAMMABLE. CON-
TACT WITH ACID, WATER OR HEAVY METALS MAY
PRODUCE HARMFUL AND IRRITATING GASES (SO-
DIUM HYDROXIDE IS FORMED IN THE PRESENCE
OF MOISTURE) OR COMBUSTIBLE COMPOUNDS.
DO NOT ATTEMPT TO DISMANTLE THE MODULE
OR TAMPER WITH ITS ARMING LEVER. DO NOT
PUNCTURE, INCINERATE, OR BRING INTO CON-
TACT WITH ELECTRICITY. DO NOT STORE AT TEM-
PERATURES EXCEEDING 200ÉF.WARNING: REPLACE AIRBAG SYSTEM COMPO-
NENTS WITH PARTS SPECIFIED IN THE CHRYSLER
MOPAR PARTS CATALOG ONLY. IT IS OF PARTICU-
LAR IMPORTANCE THAT ANY COMPONENTS USED
IN THIS MECHANICALLY-FIRED AIRBAG SYSTEM
NOT BE MIXED WITH COMPONENTS FROM AN
ELECTRICALLY-FIRED AIRBAG SYSTEM. SUBSTI-
TUTE PARTS MAY APPEAR THE SAME, BUT INTER-
NAL DIFFERENCES MAY RESULT IN INFERIOR
OCCUPANT PROTECTION.
WARNING: THE FASTENERS, SCREWS, AND
BOLTS, ORIGINALLY USED FOR THE AIRBAG COM-
PONENTS, HAVE SPECIAL COATINGS AND ARE
SPECIFICALLY DESIGNED FOR THE AIRBAG SYS-
TEM. THEY MUST NEVER BE REPLACED WITH ANY
SUBSTITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
SPECIFIED IN THE CHRYSLER MOPAR PARTS CAT-
ALOG.
GENERAL INFORMATION
The airbag system is a standard equipment safety
device on XJ (Cherokee) models. It is designed to pro-
tect the driver from serious injury, caused by a fron-
tal impact of the vehicle. If the airbag module
assembly is defective and non-deployed, refer to
Chrysler Corporation current return list for proper
handling procedures.
Following are general descriptions of the major
components in the airbag system.AIRBAG MODULE
The airbag module protective cover is the only vis-
ible part of the system. The module is mounted di-
rectly to the steering wheel. Under the airbag
module cover, the airbag cushion and its supporting
components are contained. The airbag module con-
tains a housing to which the cushion and impact sen-
sor/inflator assembly are attached and sealed. The
airbag module is non-serviceable, and must be re-
placed if deployed or damaged in any way.
The impact sensor/inflator assembly is mounted to
the back of the module. The inflator seals the hole in
JRESTRAINT SYSTEMS 8M - 1

the airbag cushion so it can discharge the gas it pro-
duces directly into the cushion. The protective cover
is fitted to the front of the airbag module and forms
a decorative cover in the center of the steering wheel.
Upon airbag deployment, this cover will split hori-
zontally.
STORAGE
The airbag module must be stored in its original,
special container until used for service. Also, it must
be stored in a clean, dry environment; away from
sources of extreme heat, sparks, and high electrical
energy. Always place or store the module on a surface
with the trim cover facing up to minimize movement
in case of accidental deployment.
IMPACT SENSOR/INFLATOR ASSEMBLY
The impact sensor/inflator assembly is mounted to
the back of the airbag module. It seals the hole in
the steering wheel side of the airbag cushion so that
gas produced in the inflator can be discharged di-
rectly into the cushion.
The impact sensor provides verification of the di-
rection and severity of the impact. A spherical sens-
ing mass housed in a cylinder will move forward and
rotate a D-shaft when the vehicle is subjected to a
frontal impact of sufficient severity. Airbag inflation
is designed to occur at a precisely calibrated vehicle
deceleration force, and is not linked to vehicle road
speed.The D-shaft retains two spring-loaded firing pins.
When a firing pin is released by the D-shaft, it
strikes and ignites a primer. The primer then reacts
with the pelletized, solid generant contained in the
inflator to produce the nitrogen gas that inflates the
airbag cushion.
ARMING/DISARMING MECHANISM
The steering wheel hub incorporates an airbag
arming/disarming mechanism and a specially de-
signed nut-blocker. The nut-blocker serves as a safety
to prevent removal of the airbag module until the
unit has been disarmed. A removable plastic cover
plug on the top, outer hub of the steering wheel al-
lows access to the arming screw.
When the airbag module is disarmed, the arming
screw extends upward from the steering wheel hub.
This will prevent installation of the plastic cover
plug. Also, the nut-blocker is retracted to allow ac-
cess to the two upper airbag module mounting nuts.
When the airbag module is armed, the plastic cover
plug will install flush with the outer surface of the
steering wheel hub. In addition, the nut-blocker will
prevent access to the two upper airbag module
mounting nuts.
DIAGNOSIS
This mechanical airbag system can not be diag-
nosed or repaired. The only serviced component is
the airbag module assembly. If the airbag module isdamaged in any way or deployed, it must be re-
placed.
SERVICE PROCEDURES
AIRBAG SYSTEM SERVICE (DEPLOYED)
Any vehicle which is to be returned to use after an
airbag deployment, must have the airbag module re-
placed. This is a one-time component and cannot be
reused.
AIRBAG MODULE HANDLING
UNDEPLOYED
At no time should any source of electricity be per-
mitted near the inflator on the back of the module.
When carrying an undeployed module, the trim cover
should be pointed away from the body to minimizeinjury in the event of accidental deployment. If the
module is placed on a bench or other surface, the
plastic trim cover should be face up to minimize
movement in case of accidental deployment.
In addition, the airbag module should be disarmed
whenever the steering wheel or steering column re-
quires service or removal. Failure to observe this
warning could result in accidental airbag deployment
and possible personal injury. Refer to Group 19 -
Steering for more service procedures on steering
wheel and steering column.
8M - 2 RESTRAINT SYSTEMSJ

REAR WINDOW DEFOGGER
CONTENTS
page page
DIAGNOSIS............................. 1
GENERAL INFORMATION.................. 1SERVICE PROCEDURES................... 3
GENERAL INFORMATION
The electrically-heated rear window defogger is an
available option on XJ (Cherokee), and YJ (Wrangler)
models equipped with the hardtop roof option. Fol-
lowing are general descriptions of the major compo-
nents in the rear window defogger system. Refer to
Group 8W - Wiring Diagrams for complete circuit de-
scriptions and diagrams.
REAR WINDOW GLASS GRID
The heated rear window glass has two electrically-
conductive vertical bus bars and a series of horizon-
tal grid lines made of a silver-ceramic material,
which is baked on and bonded to the inside surface of
the glass. The grid lines and bus bars comprise a
parallel electrical circuit.
When the rear window defogger switch is placed in
the ON position, current is directed to the rear win-
dow grid lines through the bus bars. The grid lines
heat the rear window to clear the surface of fog or
snow. Circuit protection for the heated grid circuit is
provided by fuse 18 (XJ) or fuse 6 (YJ) in the fuse-
block module.
The grid lines and bus bars are highly resistant to
abrasion. However, it is possible for an open to occur
in an individual grid line resulting in no current flow
through the line. The grid lines can be damaged or
scraped off with sharp instruments. Care should be
taken in cleaning the glass or removing foreign ma-
terials, decals or stickers. Normal glass cleaning sol-
vents or hot water used with rags or toweling is
recommended.A repair kit is available to repair the grid lines and
bus bars, or to reinstall the heated glass pigtail
wires.
DEFOGGER SWITCH
The rear window defogger switch is mounted in the
instrument panel left of the steering column for XJ,
or right of the steering column for YJ. The switch cir-
cuit is protected by fuse 8 (XJ) or fuse 9 (YJ) in the
fuseblock module. Actuating the switch energizes the
relay and electronic timer. A light-emitting diode
(LED) in the switch (XJ), or a indicator lamp in the
switch (YJ), illuminates to indicate when the system
is turned on. The defogger switch can not be re-
paired. If faulty, the switch must be replaced.
DEFOGGER RELAY/TIMER
The defogger relay/timer is located in the relay cen-
ter on XJ models, or taped to the instrument panel
wiring harness behind the parking brake pedal in the
left cowl side area on YJ models. When the rear de-
fogger switch is actuated, the rear defogger relay is
energized. This causes current to flow through the
grid circuit for approximately 10 minutes, or until
the rear window defogger switch or ignition switch
are turned off.
DIAGNOSIS
SYSTEM TESTS
Electrically-heated rear window defogger operation
can be confirmed in the following manner:
(1) Turn the ignition switch to the ON position.
(2) Turn rear window defogger control switch ON.
(3) Monitor vehicle voltmeter. With the control
switch ON, a distinct needle deflection should be
noted.(4) The rear window defogger operation can be
checked by feeling the glass. A distinct difference in
temperature between the grid lines and adjacent
clear glass can be detected within 3 to 4 minutes of
operation.
(5) Using a DC voltmeter, contact terminal A (Fig.
1) (passenger side) with the negative lead, and termi-
JREAR WINDOW DEFOGGER 8N - 1