Jeep Cherokee (XJ): Removal and installation

Automatic shutdown (asd) relay

The ASD relay is located in the Power Distribution Center (PDC) (Fig. 23). Refer to label on PDC cover for relay location.

REMOVAL

(1) Remove PDC cover.

(2) Remove relay from PDC.

(3) Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay.

(4) Check for pin height (pin height should be the same for all terminals within the PDC connector).

Repair if necessary before installing relay.

INSTALLATION

(1) Install relay to PDC.

(2) Install cover to PDC.

Fig. 23 Power Distribution Center (PDC)

1 - POWER DISTRIBUTION CENTER (PDC)

Fuel pump relay

The fuel pump relay is located in the Power Distribution Center (PDC) (Fig. 23). Refer to label on PDC cover for relay location.

REMOVAL

(1) Remove PDC cover.

(2) Remove relay from PDC.

(3) Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay.

(4) Check for pin height (pin height should be the same for all terminals within the PDC connector).

Repair if necessary before installing relay.

INSTALLATION

(1) Install relay to PDC.

(2) Install cover to PDC.

Throttle body

A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the Powertrain Control Module (PCM).

REMOVAL

(1) Remove air cleaner tube at throttle body.

(2) Disconnect throttle body electrical connectors at MAP sensor, IAC motor and TPS (Fig. 24) or (Fig.

25).

Fig. 24 Throttle Body and Sensor Locations-4.0L Engine

1 - MOUNTING BOLTS (4)
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.

(3) Remove all control cables from throttle body (lever) arm. Refer to the Accelerator Pedal and Throttle Cable section of this group for additional information.

(4) Remove four throttle body mounting bolts.

(5) Remove throttle body from intake manifold.

(6) Discard old throttle body-to-intake manifold gasket.

INSTALLATION

(1) Clean mating surfaces of throttle body and intake manifold.

(2) Install new throttle body-to-intake manifold gasket.

(3) Install throttle body to intake manifold.

(4) Install four mounting bolts. Tighten bolts to 11 N·m (100 in. lbs.) torque.

(5) Install control cables.

(6) Install electrical connectors.

(7) Install air cleaner at throttle body.

Fig. 25 Throttle Body and Sensor Locations-2.5L Engine

1 - IDLE AIR CONTROL MOTOR
2 - IAT SENSOR
3 - THROTTLE BODY
4 - THROTTLE POSITION SENSOR
5 - MAP SENSOR
6 - IDLE AIR CONTROL PASSAGE INLET
7 - THROTTLE BODY MOUNTING BOLTS (4)

Throttle position sensor (TPS)

The TPS is mounted to the throttle body (Fig. 24) or (Fig. 25).

REMOVAL

(1) Remove air cleaner tube at throttle body.

(2) Disconnect TPS electrical connector.

(3) Remove TPS mounting screws (Fig. 26).

(4) Remove TPS.

INSTALLATION

The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 27). The TPS must be installed so that it can be rotated a few degrees. (If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs).

The TPS will be under slight tension when rotated.

(1) Install TPS and retaining screws.

(2) Tighten screws to 7 N·m (60 in. lbs.) torque.

(3) Connect TPS electrical connector to TPS.

(4) Manually operate throttle (by hand) to check for any TPS binding before starting engine.

(5) Install air cleaner tube to throttle body.

Idle air control (IAC) motor

The IAC motor is located on the side of the throttle body (Fig. 24) or (Fig. 25).

Fig. 26 TPS Mounting Screws

1 - MOUNTING SCREWS
2 - TPS

Fig. 27 Throttle Position Sensor-Installation

1 - TANGS
2 - THROTTLE SHAFT
3 - THROTTLE BODY
4 - TPS

REMOVAL

(1) Remove air cleaner tube at throttle body.

(2) Disconnect electrical connector from IAC motor.

(3) Remove two mounting bolts (screws) (Fig. 28).

(4) Remove IAC motor from throttle body.

INSTALLATION

(1) Install IAC motor to throttle body.

(2) Install and tighten two mounting bolts (screws) to 7 N·m (60 in. lbs.) torque.

(3) Install electrical connector.

(4) Install air cleaner tube to throttle body.

Fig. 28 Mounting Bolts (Screws)-IAC Motor

1 - IDLE AIR CONTROL MOTOR
2 - MOUNTING SCREWS

Manifold absolute pressure (map) sensor

The MAP sensor is mounted to the side of the throttle body (Fig. 24) or (Fig. 25). An L-shaped rubber fitting is used to connect the MAP sensor to throttle body (Fig. 29).

Fig. 29 MAP Sensor Mounting

1 - THROTTLE BODY
2 - MAP SENSOR
3 - RUBBER FITTING
4 - MOUNTING SCREWS (2)

REMOVAL

(1) Remove air cleaner intake tube at throttle body.

(2) Remove two MAP sensor mounting bolts (screws) (Fig. 29).

(3) While removing MAP sensor, slide the rubber L-shaped fitting (Fig. 29) from throttle body.

(4) Remove rubber L-shaped fitting from MAP sensor.

INSTALLATION

(1) Install rubber L-shaped fitting to MAP sensor.

(2) Position sensor to throttle body while guiding rubber fitting over throttle body vacuum nipple.

(3) Install MAP sensor mounting bolts (screws).

Tighten screws to 3 N·m (25 in. lbs.) torque.

(4) Install air cleaner intake tube.

Powertrain control module (PCM)

The PCM is located in the engine compartment next to the air cleaner assembly (Fig. 30).

Fig. 30 PCM Location

1 - (3) 32-WAY CONNECTORS
2 - PCM

REMOVAL

To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors.

(1) Disconnect negative battery cable at battery.

(2) Remove cover over electrical connectors. Cover snaps onto PCM.

(3) Carefully unplug the three 32-way connectors (Fig. 31) from PCM.

(4) Remove three PCM mounting bolts and remove PCM from vehicle.

INSTALLATION

(1) Install PCM and mounting bolts to vehicle.

(2) Tighten bolts to 4 N·m (35 in. lbs.).

(3) Check pin connectors in the PCM and the three 32-way connectors for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors.

Fig. 31 PCM Mounting

1 - PCM
2 - L. F. FENDER
3 - PCM MOUNTING BOLTS (3)

(4) Install three 32-way connectors.

(5) Install cover over electrical connectors. Cover snaps onto PCM.

(6) Install battery cable.

(7) Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage.

Power steering pressure switch- 2.5L engine

This switch is not used with 4.0L six-cylinder engines.

The power steering pressure switch is installed in the power steering high-pressure hose (Fig. 32).

REMOVAL

(1) Disconnect electrical connector from power steering pressure switch.

(2) Place a small container or shop towel beneath switch to collect any excess fluid.

(3) Remove switch. Use back-up wrench on power steering line to prevent line bending

INSTALLATION

(1) Install power steering switch into power steering line.

(2) Tighten to 14-22 N·m (124-195 in. lbs.) torque.

(3) Connect electrical connector to switch.

(4) Check power steering fluid and add as necessary.

Fig. 32 Power Steering Pressure Switch

1 - POWER STEERING PRESSURE SWITCH
2 - ELECTRICAL CONNECTOR
3 - POWER STEERING PUMP

(5) Start engine and again check power steering fluid. Add fluid if necessary.

Oxygen sensor

REMOVAL

Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system. This fresh air is supplied to the sensor through its pigtail wiring harness.

Refer to (Fig. 33), (Fig. 34), (Fig. 35) or (Fig. 36) for O2S (oxygen sensor) location.

WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR.

(1) Raise and support vehicle.

(2) Disconnect wire connector from O2S sensor.

CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor.

(3) Remove O2S sensor with an oxygen sensor removal and installation tool.

(4) Clean threads in exhaust pipe using appropriate tap.

Fig. 33 Front Oxygen Sensor-4.0L-Federal Emissions

1 - 1/1 O2S

Fig. 34 Oxygen Sensors-4.0L-California Emissions

1 - 1/1 O2S
2 - 2/1 O2S
3 - 2/2 O2S
4 - 1/2 O2S

Fig. 35 Front Oxygen Sensor-2.5L-Federal Emissions

1 - 1/1 O2S

Fig. 36 Rear Oxygen Sensor-2.5L/4.0L-Federal Emissions

1 - 1/2 O2S

INSTALLATION

Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor.

(1) Install O2S sensor. Tighten to 30 N·m (22 ft.

lbs.) torque.

(2) Connect O2S sensor wire connector.

(3) Lower vehicle.

Air cleaner element (filter)

REMOVAL

(1) Unlock air tube clamp (Fig. 37) at air cleaner cover. To unlock clamp, attach adjustable pliers to clamp and rotate pliers as shown in (Fig. 38).

(2) Remove air tube at cover.

(3) Pry back three clips retaining air cleaner cover to air cleaner housing.

(4) Remove housing cover and remove air cleaner element.

(5) Clean inside of housing before replacing element.

Fig. 37 Air Cleaner Housing and Element (Filter)

1 - COVER
2 - AIR TUBE
3 - CLAMPS (2)
4 - HOUSING
5 - CLIPS (3)
6 - ELEMENT (FILTER)

INSTALLATION

(1) Install air cleaner element into housing.

(2) Install air cleaner cover to housing (three clips). Be sure cover is properly seated to air cleaner housing.

(3) Install air tube and clamp to cover. Compress clamp snugly with adjustable pliers as shown in (Fig.

39).

Fig. 38 Clamp Removal

1 - CLAMP
2 - ADJUSTABLE PLIERS
3 - REMOVAL

Fig. 39 Clamp Installation

1 - CLAMP
2 - ADJUSTABLE PLIERS

Engine coolant temperature sensor

WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR.

REFER TO GROUP 7, COOLING.

The coolant temperature sensor is installed in the thermostat housing (Fig. 40).

REMOVAL

(1) Partially drain cooling system until coolant level is below cylinder head. Observe the WARNINGS in Group 7, Cooling.

Fig. 40 Engine Coolant Temperature Sensor-Typical

1 - THERMOSTAT
2 - ENGINE COOLANT TEMPERATURE SENSOR
3 - ELECTRICAL CONNECTOR

(2) Disconnect coolant temperature sensor wire connector.

(3) Remove sensor from thermostat housing.

INSTALLATION

(1) Apply sealant to sensor threads (new replacement sensors will have sealant already applied).

(2) Install coolant temperature sensor into thermostat housing. Tighten to 11 N·m (8 ft. lbs.) torque.

(3) Connect wire connector.

(4) Fill cooling system. Refer to Group 7, Cooling System.

Intake manifold air temperature sensor

The intake manifold air temperature (IAT) sensor is installed into intake manifold plenum near throttle body (Fig. 41) or (Fig. 42).

REMOVAL

(1) Disconnect electrical connector from IAT sensor.

(2) Remove sensor from intake manifold.

INSTALLATION

(1) Install IAT sensor into intake manifold.

Tighten sensor to 28 N·m (20 ft. lbs.) torque.

(2) Connect electrical connector to sensor.

Fig. 41 IAT Sensor Location-4.0L Engine

1 - MOUNTING BOLTS (4)
2 - THROTTLE BODY
3 - IAC MOTOR
4 - ELEC. CONN.
5 - TPS
6 - MAP SENSOR
7 - ELEC. CONN.
8 - IAT SENSOR
9 - ELEC. CONN.

Fig. 42 IAT Sensor Location-2.5L Engine

1 - ELECTRICAL CONNECTOR
2 - INTAKE MANIFOLD TEMPERATURE SENSOR
3 - FUEL INJECTOR

Vehicle speed sensor

The Vehicle Speed Sensor (VSS) is located on the speedometer pinion gear adapter. If equipped with 4WD, this adapter is located on the transfer case extension (left side) (Fig. 43). If equipped with 2WD, this adapter is located on the extension housing of the transmission (left side).

Fig. 43 VSS Location-4WD Shown

1 - SENSOR ELECTRICAL CONNECTOR
2 - SLIDE TAB
3 - 4WD TRANSFER CASE EXTENSION
4 - VEHICLE SPEED SENSOR
5 - RELEASE LOCK

REMOVAL

(1) Raise and support vehicle.

(2) Disconnect electrical connector from sensor by pushing slide tab (Fig. 43). After slide tab has been positioned, push in on secondary release lock (Fig. 43) on side of connector and pull connector from sensor.

(3) Remove sensor mounting bolt (Fig. 44).

(4) Remove sensor (pull straight out) from speedometer pinion gear adapter (Fig. 44). Do not remove gear adapter from transmission.

INSTALLATION

(1) Clean inside of speedometer pinion gear adapter before installing speed sensor.

(2) Install sensor into speedometer gear adapter and install mounting bolt. Before tightening bolt, verify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter.

(3) Tighten sensor mounting bolt to 2.2 N·m (20 in.

lbs.) torque.

(4) Connect electrical connector to sensor.

Fig. 44 VSS Removal/Installation

1 - ELECTRICAL CONNECTOR
2 - SENSOR MOUNTING BOLT
3 - O-RING
4 - SPEEDOMETER PINION GEAR
5 - SPEEDOMETER PINION GEAR ADAPTER
6 - O-RING
7 - VEHICLE SPEED SENSOR