1995 JEEP YJ service

POWER MIRRORS
CONTENTS
page page
DIAGNOSIS............................. 1
GENERAL INFORMATION.................. 1SERVICE PROCEDURES................... 4
GENERAL INFORMATION
Power outside rear view mirrors are an available
option on XJ (Cherokee) models. Following are gen-
eral descriptions of the major components in the
power mirror system. Refer to Group 8W - Wiring Di-
agrams for complete circuit descriptions and dia-
grams.
POWER MIRROR
The power mirrors are connected to battery feed at
all times. Each mirror head contains two electric mo-
tors, two drive mechanisms and the mirror glass.
One motor and drive controls mirror up-and-down
movement, and the other controls right-and-left
movement.
The mirror glass is the only serviced replacement
part for the power mirror assembly. If any other com-ponent of the mirror unit is faulty or damaged, the
entire assembly must be replaced.
POWER MIRROR SWITCH
Both the right and left mirror are controlled by a
multi-function switch located on the front of the cen-
ter console storage compartment, directly below the
armrest. The selector switch is moved right (right
mirror control), left (left mirror control), or center to
turn power mirrors off. Then one of four directional
control buttons is depressed to control movement of
the selected mirror up, down, right, or left. The
power mirror switch is serviced only as a complete
unit.
DIAGNOSIS
POWER MIRROR SYSTEM
(1) Check fuse 16 in Power Distribution Center
(PDC) and fuse 9 in fuseblock module. If OK, go to
next step. If not OK, replace fuse.
(2) Check for battery voltage at fuse 9 in fuseblock
module. If OK, go to next step. If not OK, repair cir-
cuit to fuse 16 in PDC.
(3) Remove power mirror switch from the center
console. See Power Mirror Switch Remove/Install.
(4) Disconnect wiring harness connector from
switch. Check for battery voltage at pink wire. If OK,
go to next step. If not OK, repair circuit to fuse 9 in
fuseblock module.
(5) Check for continuity between black wire in
switch harness connector and a good ground. There
should be continuity. If OK, go to next step. If not
OK, repair circuit to ground.
(6) Check switch continuity as shown in the Mirror
Switch Continuity charts. If OK, go to next step. If
not OK, replace switch.(7) See Power Mirror Switch illustration. Connect
a jumper wire from mirror switch connector cavity
for pin E to cavity for pin F. Now connect a second
jumper from connector cavity for pin G to each of the
following pin cavities: A, B, C, then D. In each case,
the selected mirror head should move. If OK, replace
switch. If not OK, go to next step.
(8) Remove door trim panel and unplug power mir-
ror connector inside door. Connect one jumper wire to
a good ground and a second jumper wire to a battery
feed. Connect other ends of jumpers to the mirror
side of connector in door (refer to Group 8W - Wiring
Diagrams for connector cavity identification). Mirror
head should move in each of the four directions. If
OK, repair wiring between mirror switch and door
connectors. If not OK, replace mirror.
JPOWER MIRRORS 8T - 1

SERVICE PROCEDURES
POWER MIRROR SWITCH REMOVE/INSTALL
(1) Disconnect battery negative cable.
(2) Using a wide flat-bladed tool, pry the switch
housing away from the center console (Fig. 1).
(3) Disconnect switch connector and remove
switch.
(4) Reverse removal procedures to install.
POWER MIRROR REMOVE/INSTALL
(1) Remove interior door latch release assembly
and control panel retaining screws (Fig. 2).(2) Disconnect control linkage and wire harness
connector.
(3) Remove latch release and control panel assem-
bly.
(4) Remove armrest lower retaining screws.
(5) Swing armrest downward to a vertical position.
This is necessary to disconnect the armrest from the
upper retainer clip (Fig. 3).
(6) Pull the armrest straight out from the trim
panel.
(7) Remove the trim panel with a wide flat-bladed
tool (Fig. 4). To aid in removal of the trim panel,
start at the bottom of the panel.
Fig. 1 Power Mirror Switch Remove/Install
Fig. 2 Door Control Panel Remove/Install
Fig. 3 Armrest Retainer Clip
Fig. 4 Trim Panel Remove
8T - 4 POWER MIRRORSJ

CHIME/BUZZER WARNING SYSTEMS
CONTENTS
page page
DIAGNOSIS............................. 2
GENERAL INFORMATION.................. 1SERVICE PROCEDURES................... 4
GENERAL INFORMATION
This group covers the buzzer warning system,
which is standard equipment on XJ (Cherokee)/YJ
(Wrangler) models. The system provides an audible
warning to the driver when it monitors the following
conditions:
²key is in ignition switch with the driver's door
open
²head or park lamps are on with driver's door open
(XJ only)
²driver's seat belt is not buckled with ignition
switch in ON position.
Following are general descriptions of the major
components in the buzzer warning system. Refer to
Group 8W - Wiring Diagrams for complete circuit de-
scriptions and diagrams.
BUZZER MODULE
The buzzer module is located in the fuseblock mod-
ule under the left end of the instrument panel. It re-
ceives battery voltage at all times from (fuse 15 - XJ,
fuse 3 - YJ) the fuseblock module. It also receives a
second battery feed (fuse 17 - XJ, fuse 9 - YJ) when
the ignition switch is in the ON or START position.
Other inputs to the module include the driver's door
jamb switch, the driver's seat belt switch, the ignition
key-in switch, and the headlamp switch (XJ only). The
only output of the module is a timed 4 to 8 second feed
to the seat belt reminder lamp in the message center of
the instrument cluster. The timer function begins after
the ignition switch is turned to the ON position.
The buzzer module can not be repaired. If faulty, it
must be replaced.
DRIVER'S DOOR JAMB SWITCH
The driver's door jamb switch is mounted to the
driver's door hinge pillar. The switch closes a path to
ground for the buzzer module through the key-in
switch or headlamp switch (XJ only) when the driv-
er's door is opened, and opens when the driver's door
is closed. This switch can not be repaired. If faulty, it
must be replaced.
IGNITION KEY-IN SWITCH
XJ MODELS
The key-in switch is integral to the ignition switch,
which is mounted on the right side of the steering col-
umn. It closes a path to ground for the buzzer module
when the ignition key is inserted in the ignition lock cyl-
inder and the driver's door jamb switch is closed (door
open). The switch opens when the key is removed from
the ignition lock cylinder. This switch can not be re-
paired. If faulty, the entire ignition switch must be re-
placed. Refer to Group 8D - Ignition Systems for service
procedures.
YJ MODELS
The key-in switch is mounted within the steering col-
umn in the lock cylinder housing. It closes a path to
ground for the buzzer module when the ignition key is
inserted in the ignition lock cylinder and the driver's
door jamb switch is closed (door open). The switch opens
when the key is removed from the ignition lock cylinder.
This switch is available for service replacement. Refer
to Group 19 - Steering for service procedures.
HEADLAMP SWITCH (XJ ONLY)
The headlamp switch is located in the instrument
panel. It closes a path to ground for the buzzer module
when the park or headlamps are on and the driver's
door jamb switch is closed (door open). The switch opens
the ground path when the park and headlamps are
turned off. The headlamp switch can not be repaired. If
faulty, it must be replaced. Refer to Group 8E - Instru-
ment Panel and Gauges for service procedures.
DRIVER'S SEAT BELT SWITCH
The driver's seat belt switch is integral to the driv-
er's seat belt buckle-half assembly. The switch is nor-
mally closed, providing a ground path to the buzzer
module. When the tip-half of the seat belt is inserted
into the seat belt buckle, the switch opens the buzzer
module ground path. The seat belt switch can not be
repaired. If faulty, the entire driver's seat belt buck-
le-half must be replaced. Refer to Group 23 - Body
Components for service procedures.
JCHIME/BUZZER WARNING SYSTEMS 8U - 1

SERVICE PROCEDURES
Service procedures for components of the buzzer
system can be found in the appropriate group as fol-
lows:
²driver's door jamb switch - refer to Group 8L -
Lamps
²ignition key-in switch (XJ) - refer to Group 8D -
Ignition Systems²ignition key-in switch (YJ) - refer to Group 19 -
Steering
²headlamp switch - refer to Group 8E - Instrument
Panel and Gauges
²driver's seat belt switch - refer to Group 23 - Body
Components.
BUZZER MODULE SCHEMATIC - XJBUZZER MODULE SCHEMATIC - YJ
8U - 4 CHIME/BUZZER WARNING SYSTEMSJ

WIRING DIAGRAMSÐGENERAL INFORMATION
INDEX
page page
Circuit Identification......................... 1
Connector and Terminal Replacement........... 7
Connector Replacement..................... 6
Connectors............................... 2
Diode Replacement........................ 8
Electrostatic Discharge (ESC) Sensitive Devices . . . 2
General Information......................... 1
Intermittent and Poor Connections.............. 4
Notes, Cautions, and Warnings................ 1Symbols................................. 2
Take Outs................................ 2
Terminal Replacement....................... 8
Terminal/Connector RepairÐMolex Connectors.... 6
Troubleshooting Tests....................... 4
Troubleshooting Tools....................... 4
Troubleshooting Wiring Problems.............. 5
Wire Code Identification..................... 1
Wiring Repair............................. 6
GENERAL INFORMATION
This Group is divided into three stand alone sec-
tions; XJ, YJ, and XJ Right Hand Drive (XJ-RHD).
Separate circuit descriptions and wiring diagrams are
provided for each vehicle. Each section contains a
Contents list for the wiring diagrams and circuit de-
scriptions for that vehicle.
The complete XJ circuit descriptions and diagrams
are printed first, followed by those for the YJ and
then the XJ-RHD. The heading at the top of each
page identifies the vehicle covered in the section.
NOTES, CAUTIONS, and WARNINGS
Throughout this group additional important infor-
mation is presented in three ways; Notes, Cautions,
and Warnings.
NOTESare used to help describe how switches or
components operate to complete a particular circuit.
They are also used to indicate different conditions
that may appear on the vehicle. For example, an
up-to and after condition.
CAUTIONSare used to indicate information that
could prevent making an error that may damage the
vehicle.
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
ALWAYS WEAR SAFETY GLASSES FOR EYE PRO-
TECTION.
USE SAFETY STANDS ANYTIME A PROCEDURE RE-
QUIRES BEING UNDER A VEHICLE.
BE SURE THAT THE IGNITION SWITCH ALWAYS IS
IN THE OFF POSITION, UNLESS THE PROCEDURE
REQUIRES IT TO BE ON.SET THE PARKING BRAKE WHEN WORKING ON
ANY VEHICLE. AN AUTOMATIC TRANSMISSION
SHOULD BE IN PARK. A MANUAL TRANSMISSION
SHOULD BE IN NEUTRAL.
OPERATE THE ENGINE ONLY IN A WELL-VENTI-
LATED AREA.
KEEP AWAY FROM MOVING PARTS WHEN THE EN-
GINE IS RUNNING, ESPECIALLY THE FAN AND BELTS.
TO PREVENT SERIOUS BURNS, AVOID CONTACT
WITH HOT PARTS SUCH AS THE RADIATOR, EX-
HAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CON-
VERTER, AND MUFFLER.
DO NOT ALLOW FLAME OR SPARKS NEAR THE
BATTERY. GASES ARE ALWAYS PRESENT IN AND
AROUND THE BATTERY.
ALWAYS REMOVE RINGS, WATCHES, LOOSE
HANGING JEWELRY, AND LOOSE CLOTHING.
WIRE CODE IDENTIFICATION
Each wire shown in the diagrams contains a code
(Fig. 1) which identifies the main circuit, part of the
main circuit, gauge of wire, and color. The color is
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 2).
CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric
code to identify the wire and its function (Fig. 3). To
identify which circuit code applies to a system, refer
to the Circuit Identification Code Chart. This chart
shows the main circuits only and does not show the
secondary codes that may apply to some models.
JWIRING DIAGRAMSÐGENERAL INFORMATION 8W - 1

through this switch to circuit Q22. The Q22 circuit
then goes to the right rear window motor.
Ground for the window motor is supplied on the
Q12 circuit back to the right rear door switch. Circu-
ity internal to the switch then passes the ground to
circuit Q28. Circuit Q28 goes from the right rear door
switch to the master switch. A bus bar, internal to
the switch, connects the Q28 circuit to the Z1 circuit.
For window UP operation the circuits are reversed.
Circuits Q28 and Q12 are the feeds, and circuits Q22,
Q33 and Q18 are the grounds.
If the switch is being operated from the RIGHT
REAR door, and the operator is requesting window
DOWN operation, power is supplied on the Q1 circuit
from the driver's master switch circuit through the
switch to the Q22 circuit.
Ground for the motor is supplied on the Q12 circuit
through the switch and back to the master switch on
circuit Q28. A bus bar, internal to the switch, con-
nects the Q28 circuit to the Z1 circuit.
For window UP operation, the circuits are reversed.
Circuit Q12 is the power and circuit Q22 is the
ground.HELPFUL INFORMATION
²When the ignition switch is in the RUN position, it
connects circuit A1 from fuse 11 in the Power Distri-
bution Center (PDC) to circuit A38.
²Refer to the appropriate group of the Service Man-
ual for test procedures.
DIAGRAM INDEX
Component Page
Circuit Breaker (Fuse Block Cavity 6)............8W-60-3
Fuse 6 (PDC)...........................8W-60-3
Ignition Switch..........................8W-60-3
Power Window Door Switches................8W-60-4
Power Window Master Switch................8W-60-3
Power Window Motors.....................8W-60-4
8W - 60 - 2 8W-60 POWER WINDOWSÐXJ VEHICLESJ

Ground for the window motor is supplied on the
Q12 circuit back to the right rear door switch. Circu-
ity internal to the switch then passes the ground to
circuit Q28. Circuit Q28 goes from the right rear door
switch to the master switch. A bus bar, internal to
the switch, connects the Q28 circuit to the Z1 circuit.
For window UP operation the circuits are reversed.
Circuits Q28 and Q12 are the feeds, and circuits Q22,
Q33 and Q18 are the grounds.
If the switch is being operated from the RIGHT
REAR door, and the operator is requesting window
DOWN operation, power is supplied on the Q1 circuit
from the driver's master switch circuit through the
switch to the Q22 circuit.
Ground for the motor is supplied on the Q12 circuit
through the switch and back to the master switch on
circuit Q28. A bus bar, internal to the switch, con-
nects the Q28 circuit to the Z1 circuit.For window UP operation, the circuits are reversed.
Circuit Q12 is the power and circuits Q22 and Q18
are the ground.
HELPFUL INFORMATION
Refer to the appropriate group of the Service Man-
ual for test procedures.
DIAGRAM INDEX
Component Page
Fuse 6 (PDC)...........................8W-60-3
Fuse 12 (Fuse Block)......................8W-60-3
Ignition Switch..........................8W-60-3
Power Window Door Switches................8W-60-4
Power Window Master Switch................8W-60-3
Power Window Motors.....................8W-60-4
8W - 60 - 2 8W-60 POWER WINDOWSÐXJ-RHDJ

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