1995 JEEP YJ automatic transmission

REAR LIGHTING
TAIL LAMPS AND REAR LICENSE PLATE LAMPS
Circuit A3 from fuse 5 in the Power Distribution
Center (PDC) connects to a bus bar in the fuse block
which feeds circuit L7. Fuse 9 in the fuse block pro-
tects circuit L7.
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 L7 to circuit
L90. From the headlamp switch, circuit L90 branches
to power the front parking lamps and rear tail
lamps, side marker lamps, and rear license plate
lamps.
GROUND CIRCUIT
Circuit Z1 provides a ground for the parking lamps,
tail lamps, and rear license plate lamps.
HELPFUL INFORMATION
²Check fuse 5 in PDC.
²Check fuse 9 in the fuse block.
²When the headlamp switch is in the PARK or ON
position, circuit L7 also connects to circuit E2. Cir-
cuit E2 continues through fuse 25 in the fuse block.
Circuit E2 powers the illumination lamps.
STOP LAMPS AND CHMSL LAMPS
Circuit L9 from fuse 4 in the Power Distribution
Center (PDC) connects to the stop lamp switch.
When the operator depresses the brake pedal, the
stop lamp switch closes and connects circuit L9 to
circuit L50. Circuit L50 connects to the stop lamps
and center high mounted stop lamps (CHMSL). Cir-
cuit Z1 provides a ground for the stop lamps.
HELPFUL INFORMATION
²Check fuses 13 in the PDC.
²Check for continuity across the stop lamp switch
when it is closed.
BACK-UP LAMPS
In the START or RUN position, the ignition switch
connects circuit A1 from fuse 6 in the Power Distri-
bution Center (PDC) to circuit A21. Circuit A21 feeds
a bus bar in the PDC that powers circuit F12
through fuse 11.
Circuit F12 supplies power to the back-up lamp
switch. On automatic transmission equipped vehicles,
the back-up lamp switch is part of an assembly that
includes the PARK/NEUTRAL position switch. When
the operator puts the transmission in REVERSE, the
back-up lamp switch connects circuit F12 to circuit
L10. Circuit L10 feeds the back-up lamps. Circuit Z1
provides ground for the back-up lamps.
HELPFUL INFORMATION
²Check fuses 6 and 11 in the PDC.
²Check for continuity across the back-up lamp
switch when it is closed.
DIAGRAM INDEX
Component Page
Center High Mounted Stop Lamps (CHMSL).......8W-51-3
Fuse 4 (PDC)...........................8W-51-3
Fuse 5 (PDC)...........................8W-51-2
Fuse 6 (Fuse Block).......................8W-51-2
Fuse 6 (PDC)...........................8W-51-2
Fuse 9 (Fuse Block).......................8W-51-2
Headlamp Switch.........................8W-51-2
Ignition Switch..........................8W-51-2
Left Back-Up Lamp.......................8W-51-4
Left Side Marker Lamp.....................8W-51-4
Left Tail/Stop Lamp.......................8W-51-4
Left Turn Signal Lamp.....................8W-51-4
License Plate Lamp.......................8W-51-3
Park/Neutral Position Switch.................8W-51-2
Right Back-Up Lamp......................8W-51-5
Right Side Marker Lamp....................8W-51-5
Right Tail/Stop Lamp......................8W-51-4
Right Turn Signal Lamp....................8W-51-5
Stop Lamp Switch........................8W-51-3
J8W-51 REAR LIGHTINGÐXJ-RHD 8W - 51 - 1

STARTING SYSTEM
STARTING SYSTEM
AUTOMATIC TRANSMISSIONS
Circuit A0 from the battery is double crimped at
the positive battery post. One branch of circuit A0
(battery positive cable) connects to the engine starter
motor. The other A0 branch supplies voltage to the
bus bar in the Power Distribution Center (PDC).
The PDC supplies battery voltage to the engine
starter motor solenoid on circuit T40 when the coil
side of the engine starter motor relay energizes. Cir-
cuit A1 from the fuse 4 in the PDC supplies battery
voltage to the contact side of the starter motor relay.
The ignition switch supplies battery voltage to the
coil side of the starter motor relay on circuit A41
when the key is moved to the START position and
the Park/Neutral position switch is closed. Ground
for the coil side of the starter motor relay is supplied
by the case grounded Park/Neutral position switch.
Circuit T41 connects the coil side of the relay to the
Park/Neutral position switch.
When the starter motor relay energizes and the
contacts close, circuit T40 supplies battery voltage to
the starter motor solenoid. Circuit A0 from the bat-
tery supplies voltage to the starter motor when the
solenoid energizes.
MANUAL TRANSMISSIONS
Circuit A0 from the battery is double crimped at
the positive battery post. One branch of circuit A0
(battery positive cable) connects to the battery
starter motor. The other A0 branch supplies voltage
to the bus bar in the Power Distribution Center
(PDC).The PDC supplies battery voltage to the engine
starter motor solenoid on circuit T40 when the coil
side of the engine starter motor relay energizes. Cir-
cuit A1 from the fuse 4 in the PDC supplies battery
voltage to the contact side of the starter motor relay.
The ignition switch supplies battery voltage to the
coil side of the starter motor relay on circuit A41
when the key is moved to the START position. Cir-
cuit T41 from the coil side of the relay connects to a
Z2 jumper wire in the back-up lamp switch. Circuit
Z2 provides ground for the starter motor relay.
When the starter motor relay energizes and the
contacts close, circuit T40 supplies battery voltage to
the starter motor solenoid. Circuit A0 from the bat-
tery supplies voltage to the starter motor when the
solenoid energizes.
HELPFUL INFORMATION
²The Park/Neutral switch closes when the trans-
mission is in either the PARK or NEUTRAL posi-
tions.
²Circuit T41 also connects to cavity 30 of the Pow-
ertrain Control Module (PCM). This input tells the
PCM the operator is starting the vehicle.
DIAGRAM INDEX
Component Page
Engine Starter Motor......................8W-21-2
Engine Starter Motor Relay..................8W-21-2
Ignition Switch..........................8W-21-2
Park/Neutral Position Switch.................8W-21-2
Power Distribution Center (PDC)...............8W-21-2
Powertrain Control Module (PCM)..............8W-21-2
Fuse 4 (PDC)...........................8W-21-2
J8W-21 STARTING SYSTEMÐYJ VEHICLES 8W - 21 - 1

TRANSMISSION CONTROLS
TORQUE CONVERTER CLUTCH (TCC) SOLENOID
AND RELAY
The TCC solenoid is only used on three-speed au-
tomatic transmissions. The Powertrain Control Mod-
ule (PCM) operates the TCC solenoid by energizing
the TCC relay.
Circuit G50 from fuse 5 in the Power Distribution
Center (PDC) supplies voltage to the coil side of the
TCC relay. When the PCM provides a ground path on
circuit K54, the relay contacts close.
When the relay contacts close, they connect circuit
A14 from fuse 1 in the PDC with circuit T22. Circuit
T22 supplies battery voltage to the case grounded
TCC solenoid. Circuit K54 connects to PCM cavity
54.
HELPFUL INFORMATION
²In the RUN or START position, the ignition switch
connects circuit A1 from fuse 4 in the PDC to circuit
A21.
²Circuit A21 powers fuse 5 in the fuse block.
²Circuit G50 also connects to the engine data link
connector, Automatic Shut Down (ASD) relay, and
fuel pump relay.
UPSHIFT LAMP
On vehicles equipped with a manual transmission,
the PCM grounds the up-shift lamp on circuit K54.
Circuit K54 connects to cavity 54 of the PCM.
DIAGRAM INDEX
Component Page
Fuse 1 (PDC)...........................8W-31-2
Fuse 4 (PDC)...........................8W-31-2
Fuse 5 (Fuse Block).......................8W-31-2
Ignition Switch..........................8W-31-2
Instrument Cluster........................8W-31-2
Powertrain Control Module (PCM)..............8W-31-2
TCC Relay.............................8W-31-2
TCC Solenoid...........................8W-31-2
J8W-31 TRANSMISSION CONTROLSÐYJ VEHICLES 8W - 31 - 1

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

INSTALLATIONÐYJ VEHICLES
(1) If the engine support bracket was removed, po-
sition the bracket onto the block and install the at-
taching bolts (Fig. 9). Tighten the bolts to 62 Nzm (46
ft. lbs.) torque.
(2) Place the support cushion on the support cush-
ion bracket (Fig. 9). Install the support cushion re-
taining bolts and nuts. Tighten the bolts and nuts to
52 Nzm (38 ft. lbs.) torque.
(3) Install the through bolt and the retaining nut
(Fig. 9). Tighten the through bolt nut to 69 Nzm (51
ft. lbs.) torque.
(4) Remove the engine support.
(5) Lower the vehicle.
(6) Connect negative cable to battery.
ENGINE MOUNTÐREAR
A resilient rubber cushion supports the transmis-
sion at the rear between the transmission extension
housing and the rear support crossmember or skid
plate.
REMOVALÐXJ VEHICLES
(1) Disconnect negative cable from battery.
(2) Raise the vehicle and support the transmission.
(3) Remove the nuts holding the support cushion to
the crossmember (Figs. 10 and 11). Remove the cross-
member.
(4)MANUAL TRANSMISSION:
(a) Remove the support cushion nuts and remove
the cushion.
(b) If necessary, remove the bolts holding the
transmission support bracket to the transmission
(Fig. 10). Remove the bracket.
(5)AUTOMATIC TRANSMISSION:
(a) Remove the support cushion bolts and remove
the cushion and the transmission support bracket.(b) If necessary on 2WD vehicles, remove the
bolts holding the transmission support adaptor
bracket to the transmission (Fig. 11). Remove the
adaptor bracket.
INSTALLATIONÐXJ VEHICLES
(1)MANUAL TRANSMISSION:
(a) If removed, position the transmission support
bracket to the transmission and install the bolts.
Tighten the bolts to 43 Nzm (32 ft. lbs.) torque.
(b) Position the support cushion onto the trans-
mission support bracket. Install and tighten the
nuts to 46 Nzm (34 ft. lbs.) torque.
(2)AUTOMATIC TRANSMISSION:
(a) If removed, position the transmission support
adaptor bracket (2WD vehicles) to the transmission
and install the bolts. Tighten the bolts to 75 Nzm
(55 ft. lbs.) torque.
(b) Position the transmission support bracket
and support cushion to the transmission and install
the bolts. Tighten the bolts to 75 Nzm (55 ft. lbs.)
torque.
(3) Position the crossmember onto the support
cushion studs and install the nuts. Tighten the nuts
to 22 Nzm (192 in. lbs.) torque.
(4) Install the crossmember to sill bolts and
tighten to 41 Nzm (30 ft. lbs.) torque.
Fig. 10 Rear MountÐXJ Vehicles (Manual
Transmission)
Fig. 11 Rear MountÐXJ Vehicles (Automatic
Transmission)
9 - 16 2.5L ENGINEJ

(5) Remove the transmission support.
(6) Lower the vehicle.
(7) Connect negative cable to battery.
REMOVALÐYJ VEHICLES
(1) Disconnect negative cable from battery.
(2) Raise the vehicle and support the transmission.
(3) Remove the nuts holding the support cushion to
the skid plate (Figs. 12 and 13).
(4) Remove the skid plate bolts and the skid plate.
(5)MANUAL TRANSMISSION:
(a) Remove the bolts holding the support cushion
and torque arm bracket to the transmission (Fig.
12).
(b) Remove the support cushion and torque arm
bracket.
(6)AUTOMATIC TRANSMISSION:
(a) Remove the bolts and nuts holding the sup-
port cushion to the torque arm bracket (Fig 13).
Remove the support cushion.
(b) Remove the bolts holding the torque arm
bracket to the transmission (Fig. 13). Remove the
torque arm bracket.
INSTALLATIONÐYJ VEHICLES
(1)MANUAL TRANSMISSION:
(a) Position the torque arm bracket and support
cushion to the transmission and install the bolts
(Fig. 12).
(b) Tighten the bolts to 54 Nzm (40 ft. lbs.)
torque.
(2)AUTOMATIC TRANSMISSION:
(a) Position the torque arm bracket to the trans-
mission and install the bolts. Tighten the bolts to
54 Nzm (40 ft. lbs.) torque.
(b) Position the support cushion to the torque
arm bracket and install the bolts and nuts. Tighten
the nuts to 54 Nzm (40 ft. lbs.) torque.(3) Position the skid plate to the studs of the sup-
port cushion and install the nuts (Figs. 12 and 13).
Tighten the stud nuts to 54 Nzm (40 ft. lbs.) torque.
(4) Install the skid plate bolts to the sill and
tighten to 88 Nzm (65 ft. lbs.) torque.
(5) Remove the transmission support.
(6) Lower the vehicle.
(7) Connect negative cable to battery.
ENGINE DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the top and bottom damper nuts (Fig.
14).
(3) Remove the outer retainers and bushings (Fig.
14).
(4) Remove the top damper bracket nut and bolts
(Fig. 14).
(5) Remove the bracket, inner retainers, bushings
and the damper (Fig. 14).
INSTALLATION
(1) Install the damper on the lower bracket with
the lower inner retainer and bushing in place.
Fig. 12 Rear MountÐYJ Vehicles (Manual
Transmission)
Fig. 13 Rear MountÐYJ Vehicles (Automatic
Transmission)
J2.5L ENGINE 9 - 17

(2) Install the upper inner retainer and bushing on
the top of the damper.
(3) Position the upper damper bracket over the
damper and install the stud nut and bolts.
(4) Tighten the stud nut to 23 Nzm (17 ft. lbs.)
torque. Tighten the bracket bolts to 61 Nzm (45 ft.
lbs.) torque.
(5) Install the bushing, upper outer retainer and
damper nut.
(6) Install the bushing, lower outer retainer and
damper nut.
(7) Tighten the upper and lower damper nuts.
(8) Connect negative cable to battery.
ENGINE ASSEMBLYÐXJ VEHICLES
REMOVAL
(1) Disconnect the battery cables. Remove the bat-
tery.
(2) Mark the hinge locations on the hood panel for
alignment reference during installation. Remove the
engine compartment lamp. Remove the hood.
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) Remove the lower radiator hose.
(5) Remove the upper radiator hose and coolant re-
covery hose (Fig. 15).
(6) Remove the fan shroud (Fig. 15).
(7) Disconnect the transmission fluid cooler tubing
(automatic transmission).
(8) Remove the radiator/condenser (if equipped
with air conditioning).
(9) Remove fan assembly and install a 5/16 x 1/2-
inch SAE capscrew through fan pulley into water
pump flange. This will maintain the pulley and wa-
ter pump in alignment when crankshaft is rotated.
(10) Disconnect the heater hoses (Figs. 16 and 17).
(11) Disconnect the throttle linkages (Fig. 16),
speed control cable (if equipped) and throttle valve
rod.
(12) Disconnect the oxygen sensor wire connector.
(13) Disconnect the wires from the starter motor
solenoid.
(14) Disconnect all fuel injection harness connec-
tions.
(15) 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. 16). Pull the fuel
tube and retainer from the quick-connect fitting (re-
fer to Group 14, Fuel System for the proper proce-
dure).
(16) Remove the fuel line bracket from the intake
manifold.
(17) Remove the air cleaner assembly (Fig. 18).
(18) If equipped with air conditioning, remove the
service valves and cap the compressor ports.
(19) Remove the power brake vacuum check valve
from the booster, if equipped.
(20) If equipped with power steering (Fig. 18):
Fig. 14 Engine Damper
Fig. 15 Upper Radiator Hose, Coolant Recovery
Hose & Fan Shroud
9 - 18 2.5L ENGINEJ

(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