GROUP TAB LOCATOR

IN Introduction 8O Power Distribution Systems

INa Introduction 8P Power Lock Systems

0 Lubrication and Maintenance 8Q Vehicle Theft/Security Systems

0a Lubrication and Maintenance 8Qa Vehicle Theft/Security Systems

2 Suspension 8R Power Seats Systems

3 Differential and Driveline 8S Power Window Systems

5 Brakes 8T Power Mirror Systems

5a Brakes 8U Chime/Buzzer Warning Systems

6 Clutch 8V Overhead Console Systems

6a Clutch 8W Wiring Diagrams

7 Cooling System 9 Engine

7a Cooling System 9a Engine

8A Battery 11 Exhaust System and Intake Manifold

8B Starting System 11a Exhaust System and Intake Manifold

8Ba Starting Systems 13 Frame and Bumpers

8C Charging System 13a Frame and Bumpers

8Ca Charging System 14 Fuel System

8D Ignition System 14a Fuel System–2.5L Diesel Engine

8E Instrument Panel Systems 19 Steering

8Ea Instrument Panel Systems 19a Steering

8F Audio Systems 21 Transmission and Transfer Case

8G Horn Systems 21a Transmission and Transfer Case

8H Vehicle Speed Control System 22 Tires and Wheels

8Ha Vehicle Speed Control System 23 Body

8J Turn Signal and Hazard Warning Systems 24 Heating and Air Conditioning

8K Wiper and Washer Systems 24a Heating and Air Conditioning

8L Lamps 25 Emission Control Systems

8La Lamps 25a Emission Control System

8M Passive Restraint Systems Service Manual Comment Forms

8N Electrically Heated Systems

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 XJ INTRODUCTION 1

INTRODUCTION
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION FASTENER USAGE . . . . . . . . . . . . . . . . . . . . . . . . 3

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . 1 THREADED HOLE REPAIR . . . . . . . . . . . . . . . . . . 3
VEHICLE SAFETY CERTIFICATION LABEL . . . . . . 2 METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 6
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . . 2 TORQUE REFERENCES. . . . . . . . . . . . . . . . . . . . . 6
FASTENER IDENTIFICATION . . . . . . . . . . . . . . . . . 3

DESCRIPTION AND OPERATION • Vehicle Safety Certification Label.

• Frame rail.
VEHICLE IDENTIFICATION NUMBER To protect the consumer from theft and possible
The Vehicle Identification Number (VIN) plate is fraud the manufacturer is required to include a
located on the lower windshield fence near the left Check Digit at the ninth position of the Vehicle Iden-
A-pillar. The VIN contains 17 characters that provide tification Number. The check digit is used by the
data concerning the vehicle. Refer to the VIN decod- manufacturer and government agencies to verify the
ing chart to determine the identification of a vehicle. authenticity of the vehicle and official documenta-
The Vehicle Identification Number is also tion. The formula to use the check digit is not
imprinted on the: released to the general public.
• Body Code Plate.

VEHICLE IDENTIFICATION NUMBER DECODING CHART

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating F = 4001-5000 lbs.
5 Vehicle Line F= Cherokee 4X4 (LHD)
N = Cherokee 4X4 (RHD)
B = Cherokee 4X2 (RHD)
T = Cherokee 4X2 (LHD)
6 Series 2 = SE
6 = Sport/Classic
7 = Limited
7 Body Style 7 = 2dr Sport Utility
8 = 4dr Sport Utility
8 Engine P = 2.5L Gasoline
S = 4.0L Gasoline
9 Check Digit
10 Model Year Y=2000
11 Assembly Plant L = Toledo #1
12 thru 17 Vehicle Build Sequence

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 2 INTRODUCTION XJ
DESCRIPTION AND OPERATION (Continued)

VEHICLE SAFETY CERTIFICATION LABEL The label is located on the driver-side door shut-
A vehicle safety certification label (Fig. 1) is face.
attached to every DaimlerChrysler Corporation vehi-
cle. The label certifies that the vehicle conforms to all
applicable Federal Motor Vehicle Safety Standards.
The label also lists:
• Month and year of vehicle manufacture.
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR’s) are
based on a minimum rim size and maximum cold tire
inflation pressure.
• Vehicle Identification Number (VIN).
• Type of vehicle.
• Type of rear wheels.
• Bar code.
• Month, Day and Hour (MDH) of final assembly.
• Paint and Trim codes. Fig. 1 Vehicle Safety Certification Label—Typical
• Country of origin. INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.

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 XJ INTRODUCTION 3
DESCRIPTION AND OPERATION (Continued)

1 High Beam 13 Rear Window Washer

2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter

FASTENER IDENTIFICATION FASTENER USAGE

DESCRIPTION WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
GRADE/CLASS IDENTIFICATION SONAL INJURY.
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater Figure art, specifications and torque references in
the bolt strength. Identification is determined by the this Service Manual are identified in metric and SAE
line marks on the top of each bolt head. The actual format.
bolt strength grade corresponds to the number of line During any maintenance or repair procedures, it is
marks plus 2. The most commonly used metric bolt important to salvage all fasteners (nuts, bolts, etc.)
strength classes are 9.8 and 10.9. The metric for reassembly. If the fastener is not salvageable, a
strength class identification number is imprinted on fastener of equivalent specification must be used.
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are THREADED HOLE REPAIR
imprinted with a single-digit strength class on the Most stripped threaded holes can be repaired using
nut face. Refer to the Fastener Identification and a Helicoilt. Follow the manufactures recommenda-
Fastener Strength Charts. tions for application and repair procedures.

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 4 INTRODUCTION XJ
DESCRIPTION AND OPERATION (Continued)
FASTENER IDENTIFICATION

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 XJ INTRODUCTION 5
DESCRIPTION AND OPERATION (Continued)
FASTENER STRENGTH

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 6 INTRODUCTION XJ
DESCRIPTION AND OPERATION (Continued)

METRIC SYSTEM The following chart will assist in converting metric

units to equivalent English and SAE units, or vise
DESCRIPTION versa.
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs
Inches Hg x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
(60° F)
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches
Feet x 0.3048 = Meters (M) M x 3.281 = Feet
Yards x 0.9144 = Meters M x 1.0936 = Yards
mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph
Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph
Kilometers/ x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
Hr. (Km/h) (Km/h)

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert cations Chart for torque references not listed in the
torque values listed in metric Newton- meters (N·m). individual torque charts.
Also, use the chart to convert between millimeters
(mm) and inches (in.)

TORQUE REFERENCES
DESCRIPTION
Individual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Specifi-

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 XJ INTRODUCTION 7
DESCRIPTION AND OPERATION (Continued)
METRIC CONVERSION CHART

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 8 INTRODUCTION XJ
DESCRIPTION AND OPERATION (Continued)
TORQUE SPECIFICATIONS

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 XJ INTRODUCTION 1

INTRODUCTION
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION E-MARK LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . 2

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . 1 MANUFACTURER PLATE . . . . . . . . . . . . . . . . . . . 2

DESCRIPTION AND OPERATION • Body Code Plate.

• Vehicle Safety Certification Label.
VEHICLE IDENTIFICATION NUMBER • Frame rail.
To protect the consumer from theft and possible
DESCRIPTION fraud the manufacturer is required to include a
The Vehicle Identification Number (VIN) plate is Check Digit at the ninth position of the Vehicle Iden-
located on the lower windshield fence near the left tification Number. The check digit is used by the
A-pillar. The VIN contains 17 characters that provide manufacturer and government agencies to verify the
data concerning the vehicle. Refer to the VIN decod- authenticity of the vehicle and official documenta-
ing chart to determine the identification of a vehicle. tion. The formula to use the check digit is not
The Vehicle Identification Number is also released to the general public.
imprinted on the:

VEHICLE IDENTIFICATION NUMBER DECODING CHART

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating F = 4001-5000 lbs.
5 Vehicle Line F = Cherokee 4X4 (LHD)
J = Cherokee 4X4 (RHD) EXPORT
N = Cherokee 4X4 (RHD)
B = Cherokee 4X2 (RHD)
T = Cherokee 4X2 (LHD)
6 Series/Transmission N = 5 Speed Manual
A = 3 Speed Auto
B = 4 Speed Auto
4 = Sport
6 = Cherokee Country/Limited
5 = Classic
7 Body Style 7 = 2dr Sport Utility
8 = 4dr Sport Utility
8 Engine M = 2.5L Diesel
P = 2.5L Gasoline
S = 4.0L Gasoline
9 Check Digit
10 Model Year Y = 2000
11 Assembly Plant L = Toledo Assembly#1
12 thru 17 Vehicle Build Sequence

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 2 INTRODUCTION XJ
DESCRIPTION AND OPERATION (Continued)

E-MARK LABEL MANUFACTURER PLATE

DESCRIPTION DESCRIPTION
An E-mark Label (Fig. 1) is located on the rear The Manufacturer Plate (Fig. 2) is located in the
shut face of the driver’s door. The label contains the engine compartment on the radiator closure panel
following information: crossmember adjacent to the Body Code Plate. The
• Date of Manufacture plate contains five lines of information:
• Month-Day-Hour (MDH) 1. Vehicle Identification Number (VIN)
• Vehicle Identification Number (VIN) 2. Gross Vehicle Mass (GVM)
• Country Codes 3. Gross Train Mass (GTM)
• Regulation Number 4. Gross Front Axle Rating (GFAR)
• Regulation Amendment Number 5. Gross Rear Axle Rating (GRAR)
• Approval Number

Fig. 2 Manufacturer Plate

Fig. 1 E-Mark Label

1 – Country Code
2 – Regulation Number
3 – Approval Number
4 – Amendment Number

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 XJ LUBRICATION AND MAINTENANCE 0-1

LUBRICATION AND MAINTENANCE

TABLE OF CONTENTS

page page

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 JUMP STARTING, TOWING AND HOISTING . . . . . 9

MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . 4

LUBRICANTS

TABLE OF CONTENTS
page page

SERVICE PROCEDURES CLASSIFICATION OF LUBRICANTS. . . . . . . . . . . . 1

PARTS AND LUBRICANT SPECIFICATIONS
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1 FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 3
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . . 1

SERVICE PROCEDURES
PARTS AND LUBRICANT RECOMMENDATIONS
RECOMMENDATIONS
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing Daimler-
Chrysler Corporation vehicles.

INTERNATIONAL SYMBOLS
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
Fig. 1 International Symbols
CLASSIFICATION OF LUBRICANTS
Only lubricants bearing designations defined by ENGINE OIL
the following organization should be used to service a
DaimlerChrysler Corporation vehicle. SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
• Society of Automotive Engineers (SAE) An SAE viscosity grade is used to specify the vis-
• American Petroleum Institute (API) (Fig. 2) cosity of engine oil. SAE 30 specifies a single viscos-
• National Lubricating Grease Institute (NLGI) ity engine oil. Engine oils also have multiple
(Fig. 3) viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
• SAE 30 = single grade engine oil.
• SAE 10W-30 = multiple grade engine oil.
DaimlerChrysler Corporation only recommends
multiple grade engine oils.

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 0-2 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
API QUALITY CLASSIFICATION LUBRICANTS AND GREASES
This symbol (Fig. 2) on the front of an oil container Lubricating grease is rated for quality and usage
means that the oil has been certified by the Ameri- by the NLGI. All approved products have the NLGI
can Petroleum Institute (API) to meet all the lubri- symbol (Fig. 3) on the label. At the bottom NLGI
cation requirements specified by DailmlerChrysler symbol is the usage and quality identification letters.
Corporation. Wheel bearing lubricant is identified by the letter
Refer to Group 9, Engine for gasoline engine oil “G”. Chassis lubricant is identified by the latter “L”.
specification. The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.

Fig. 2 API Symbol

GEAR LUBRICANTS
Fig. 3 NLGI Symbol
SAE ratings also apply to multiple grade gear
1 – WHEEL BEARINGS
lubricants. In addition, API classification defines the 2 – CHASSIS LUBRICATION
lubricants usage. 3 – CHASSIS AND WHEEL BEARINGS

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 XJ LUBRICATION AND MAINTENANCE 0-3

SPECIFICATIONS MANUAL TRANSMISSION

FLUID CAPACITIES AX5 (4X2) . . . . . . . . . . . . . . . . . . . . 3.5 L (3.7 qts.)

AX5 (4X4) . . . . . . . . . . . . . . . . . . . . 3.3 L (3.5 qts.)
FUEL TANK AX15 (4X2) . . . . . . . . . . . . . . . . . . . 3.15 L (3.3 qts.)
AX15 (4X4) . . . . . . . . . . . . . . . . . . . 3.15 L (3.3 qts.)
All . . . . . . . . . . . . . . . . . . . . . . . . 76.4 L (20.2 gal.)
TRANSFER CASE
ENGINE OIL W/FILTER CHANGE
SELEC-TRAC 242 . . . . . . . . . . . . . 1.3 L (2.85 pts.)
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 L (4.0 qts.) COMMAND-TRAC 231 . . . . . . . . . . 1.0 L (2.2 pts.)
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L (6.0 qts.)
FRONT AXLE
COOLING SYSTEM
181–FBI . . . . . . . . . . . . . . . . . . . . 1.48 L (3.13 pts.)
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (10 qts.)* 186–FBI . . . . . . . . . . . . . . . . . . . . . . 1.18L (2.5pts.)
4.0L . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (12 qts.)**
REAR AXLE
*Includes 2.2 L (2.3 qts) for coolant recovery reser-
voir.
194–RBI . . . . . . . . . . . . . . . . . . . . 1.66 L (3.5 pts.*)
**Includes 0.9 L (1.0 qt) for coolant recovery reser-
8-1/4 . . . . . . . . . . . . . . . . . . . . . . 2.08 L (4.4 pts.**)
voir.
* When equipped with TRAC-LOK, include 3.5
AUTOMATIC TRANSMISSION ounces of Friction Modifier Additive.
Dry fill capacity* ** When equipped with TRAC-LOK, include 4
ounces of Friction Modifier Additive.
AW4 . . . . . . . . . . . . . . . . . . . . . . . . 7.8 L (16.5 pts.)
30RH . . . . . . . . . . . . . . . . . . . . . . . 4.67 L (9.86pts.)
POWER STEERING
Power steering fluid capacities are dependent on
*Depending on type and size of internal cooler,
engine/chassis options as well as steering gear/cooler
length and inside diameter of cooler lines, or use of an
options. Depending on type and size of internal
auxiliary cooler, these figures may vary. Refer to
cooler, length and inside diameter of cooler lines, or
Group 21, Transmission for proper fluid fill procedure.
use of an auxiliary cooler, these capacities may vary.
Refer to Section 19 of the service manual for proper
fill and bleed procedures.

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 0-4 LUBRICATION AND MAINTENANCE XJ

MAINTENANCE SCHEDULES

TABLE OF CONTENTS
page page

SERVICE PROCEDURES UNSCHEDULED INSPECTION . . . . . . . . . . . . . . . . 4

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE PROCEDURES • Rotate the tires at each oil change interval

shown on Schedule “A” (7,500 miles) or every other
DESCRIPTION interval shown on Schedule “B” (6,000 miles).
Service and maintenance procedures for compo- • Check coolant level, hoses, and clamps.
nents and systems listed in Schedule “A” or “B” can • After completion of off-road operation, the
be found by using the Group Tab Locator index at underside of the vehicle should be thoroughly
the front of this manual. If it is not clear which inspected. Examine threaded fasteners for looseness.
group contains the information needed, refer to the
index at the back of this manual. EMISSION CONTROL SYSTEM MAINTENANCE
There are two maintenance schedules that show The scheduled emission maintenance listed in bold
proper service based on the conditions that the vehi- type on the Maintenance Schedules, must be done at
cle is subjected to. the mileage specified to assure the continued proper
Schedule “A”, lists scheduled maintenance to be functioning of the emission control system. These,
performed when the vehicle is used for general trans- and all other maintenance services included in this
portation. manual, should be done to provide the best vehicle
Schedule “B”, lists maintenance intervals for vehi- performance and reliability. More frequent mainte-
cles that are operated under the conditions listed at nance may be needed for vehicles in severe operating
the beginning of that schedule section. conditions such as dusty areas and very short trip
Use the schedule that best describes the driving driving.
conditions.
Where time and mileage are listed, follow the FLUID FILL LOCATIONS AND LUBRICATION
interval that occurs first. POINTS
The fluid fill/check locations and lubrication points
UNSCHEDULED INSPECTION are located in each applicable group.

At Each Stop For Fuel SCHEDULE “A”

• Check engine oil level, add as required.
• Check windshield washer solvent and add if 7,500 Miles (12 000 km) or at 6 months
required. • Change engine oil.
• Replace engine oil filter.
Once A Month • Lubricate steering linkage (4x4 only).
• Check tire pressure and look for unusual wear
or damage. 15,000 Miles (24 000 km) or at 12 months
• Inspect battery and clean and tighten terminals • Change engine oil.
as required. Check electrolyte level and add water as • Replace engine oil filter.
needed. • Lubricate steering linkage.
• Check fluid levels of coolant reservoir, power • Lubricate steering and suspension ball joints.
steering, brake master cylinder, and transmission
and add as needed.
22,500 Miles (36 000 km) or at 18 months
• Check all lights and all other electrical items for • Change engine oil.
correct operation. • Replace engine oil filter.
• Inspect brake linings.
At Each Oil Change • Lubricate steering linkage (4x4 only).
• Inspect exhaust system.
• Inspect brake hoses.

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 XJ LUBRICATION AND MAINTENANCE 0-5
SERVICE PROCEDURES (Continued)
30,000 Miles (48 000 km) or at 24 months • Flush and replace engine coolant if it has been
• Change engine oil. 30,000 miles (48 000 km) or 24 months since last
• Replace engine oil filter. change.
• Replace air cleaner element. • Lubricate steering and suspension ball joints.
• Replace spark plugs. • Drain and refill manual transmission fluid.
• Inspect drive belt, adjust tension as necessary.
• Lubricate steering linkage. 82,500 Miles (133 000 km) or at 66 months
• Drain and refill automatic transmission fluid. • Change engine oil.
• Drain and refill transfer case fluid. • Replace engine oil filter.
• Lubricate steering and suspension ball joints. • Flush and replace engine coolant if it has been
30,000 miles (48 000 km) or 24 months since last
37,500 Miles (60 000 km) or at 30 months change.
• Change engine oil. • Lubricate steering linkage (4x4 only).
• Replace engine oil filter.
• Lubricate steering linkage (4x4 only). 90,000 Miles (144 000 km) or at 72 months
• Drain and refill manual transmission fluid. • Change engine oil.
• Replace engine oil filter.
45,000 Miles (72 000 km) or at 36 months • Replace engine air cleaner element.
• Change engine oil. • Replace spark plugs.
• Replace engine oil filter. • Inspect drive belt, adjust tension as necessary.
• Lubricate steering linkage. • Lubricate steering linkage.
• Inspect brake linings. • Drain and refill automatic transmission fluid.
• Flush and replace engine coolant at 36 months, • Drain and refill transfer case fluid.
regardless of mileage. • Inspect brake linings.
• Lubricate steering and suspension ball joints. • Lubricate steering and suspension ball joints.

52,500 Miles (84 000 km) or at 42 months 97,500 Miles (156 000 km) or at 78 months
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Flush and replace engine coolant if not done at • Lubricate steering linkage (4x4 only).
36 months.
• Lubricate steering linkage (4x4 only). 105,000 Miles (168 000 km) or at 84 months
• Change engine oil.
60,000 Miles (96 000 km) or at 48 months • Replace engine oil filter.
• Change engine oil. • Lubricate steering linkage.
• Replace engine oil filter. • Flush and replace engine coolant if it has been
• Replace engine air cleaner element. 30,000 miles (48 000 km) or 24 months since last
• Replace ignition cables. change.
• Replace spark plugs. • Lubricate steering and suspension ball joints.
• Inspect drive belt, adjust tension as necessary.
• Lubricate steering linkage. 112,500 Miles (180 000 km) or at 90 months
• Drain and refill automatic transmission fluid. • Change engine oil.
• Drain and refill transfer case fluid. • Replace engine oil filter.
• Lubricate steering and suspension ball joints. • Inspect brake linings.
• Flush and replace engine coolant if it has been
67,500 Miles (108 000 km) or at 54 months 30,000 miles (48 000 km) or 24 months since last
• Change engine oil. change.
• Replace engine oil filter. • Lubricate steering linkage (4x4 only).
• Inspect brake linings. • Drain and refill manual transmission fluid.
• Lubricate steering linkage (4x4 only).
120,000 Miles (192 000 km) or at 96 months
75,000 Miles (120 000 km) or at 60 months • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Replace engine air cleaner element.
• Lubricate steering linkage. • Replace ignition cables.
• Replace spark plugs.
• Inspect drive belt, adjust tension as necessary.

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 0-6 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
• Lubricate steering linkage. • Lubricate steering and suspension ball joints.
• Drain and refill automatic transmission fluid. • Drain and refill manual transmission fluid.
• Drain and refill transfer case fluid.
• Lubricate steering and suspension ball joints. 21,000 Miles (34 000 km)
Important: Inspection and service should also be • Change engine oil.
performed any time a malfunction is observed or sus- • Replace engine oil filter.
pected. • Lubricate steering linkage.

SCHEDULE “B” 24,000 Miles (38 000 km)

Follow Schedule “B” if the vehicle is usually oper- • Change engine oil.
ated under one or more of the following conditions. • Replace engine oil filter.
• Frequent short trips driving less than 5 miles (8 • Lubricate steering linkage.
km). • Drain and refill automatic transmission fluid.
• Frequent driving in dusty conditions. • Drain and refill front and rear axles.‡
• Frequent trailer towing. • Inspect brake linings.
• Extensive idling. • Lubricate steering and suspension ball joints.
• More than 50% of driving is at sustained high
speeds during hot weather, above 90°F (32°C). 27,000 Miles (43 000 km)
• Off-road driving. • Change engine oil.
• Desert operation. • Replace engine oil filter.
• Lubricate steering linkage.
3,000 Miles (5 000 km)
• Change engine oil. 30,000 Miles (48 000 km)
• Replace engine oil filter. • Change engine oil.
• Lubricate steering linkage. • Replace engine oil filter.
• Replace engine air cleaner element.
6,000 Miles (10 000 km) • Replace spark plugs.
• Change engine oil. • Inspect drive belt, adjust tension as necessary.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage. • Drain and refill transfer case fluid.
• Lubricate steering and suspension ball joints. • Lubricate steering and suspension ball joints.

9,000 Miles (14 000 km) 33,000 Miles (53 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Lubricate steering linkage. • Lubricate steering linkage.

12,000 Miles (19 000 km) 36,000 Miles (58 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Lubricate steering linkage. • Lubricate steering linkage.
• Drain and refill automatic transmission fluid. • Drain and refill automatic transmission fluid.
• Drain and refill front and rear axles.‡ • Drain and refill front and rear axles.‡
• Inspect brake linings. • Inspect brake linings.
• Lubricate steering and suspension ball joints. • Lubricate steering and suspension ball joints.
• Drain and refill manual transmission fluid.
15,000 Miles (24 000 km)
• Change engine oil. 39,000 Miles (62 000 km)
• Replace engine oil filter. • Change engine oil.
• Inspect engine air cleaner element, replace • Replace engine oil filter.
as necessary. • Lubricate steering linkage.
• Lubricate steering linkage.
42,000 Miles (67 000 km)
18,000 Miles (29 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage. • Lubricate steering and suspension ball joints.

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 XJ LUBRICATION AND MAINTENANCE 0-7
SERVICE PROCEDURES (Continued)
45,000 Miles (72 000 km) 66,000 Miles (106 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Inspect engine air cleaner element, replace • Lubricate steering linkage.
as necessary. • Lubricate steering and suspension ball joints.
• Lubricate steering linkage.
69,000 Miles (110 000 km)
48,000 Miles (77 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage.
• Drain and refill automatic transmission fluid. 72,000 Miles (115 000 km)
• Drain and refill front and rear axles.‡ • Change engine oil.
• Inspect brake linings. • Replace engine oil filter.
• Lubricate steering and suspension ball joints. • Lubricate steering linkage.
• Drain and refill automatic transmission fluid.
51,000 Miles (82 000 km) • Drain and refill front and rear axles.‡
• Change engine oil. • Inspect brake linings.
• Replace engine oil filter. • Lubricate steering and suspension ball joints.
• Flush and replace engine coolant. • Drain and refill manual transmission fluid.
• Lubricate steering linkage.
75,000 Miles (120 000 km)
54,000 Miles (86 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Inspect engine air cleaner element, replace
• Lubricate steering linkage. as necessary.
• Lubricate steering and suspension ball joints. • Lubricate steering linkage.
• Drain and refill manual transmission fluid.
78,000 Miles (125 000 km)
57,000 Miles (91 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage. • Lubricate steering and suspension ball joints.

60,000 Miles (96 000 km) 81,000 Miles (130 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Replace engine air cleaner element. • Flush and replace engine coolant if it has been
• Replace ignition cables. 30,000 miles (48 000 km) since last change.
• Replace spark plugs. • Lubricate steering linkage.
• Inspect drive belt, adjust tension as necessary.
• Lubricate steering linkage. 84,000 Miles (134 000 km)
• Drain and refill automatic transmission fluid. • Change engine oil.
• Drain and refill transfer case fluid. • Replace engine oil filter.
• Drain and refill front and rear axles.‡ • Lubricate steering linkage.
• Inspect brake linings. • Drain and refill automatic transmission fluid.
• Lubricate steering and suspension ball joints. • Drain and refill front and rear axles.‡
• Inspect brake linings.
63,000 Miles (101 000 km) • Lubricate steering and suspension ball joints.
• Change engine oil.
• Replace engine oil filter.
• Lubricate steering linkage.

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 0-8 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
87,000 Miles (139 000 km) • Lubricate steering linkage.
• Change engine oil. • Drain and refill automatic transmission fluid.
• Replace engine oil filter. • Drain and refill front and rear axles.‡
• Lubricate steering linkage. • Inspect brake linings.
• Lubricate steering and suspension ball joints.
90,000 Miles (144 000 km) • Drain and refill manual transmission fluid.
• Change engine oil.
• Replace engine oil filter. 111,000 Miles (178 000 km)
• Replace engine air cleaner element. • Change engine oil.
• Replace spark plugs. • Replace engine oil filter.
• Inspect drive belt, adjust tension as necessary. • Flush and replace engine coolant if it has been
• Lubricate steering linkage. 30,000 miles (48 000 km) since last change.
• Drain and refill transfer case fluid. • Lubricate steering linkage.
• Lubricate steering and suspension ball joints.
• Drain and refill manual transmission fluid. 114,000 Miles (182 000 km)
• Change engine oil.
93,000 Miles (149 000 km) • Replace engine oil filter.
• Change engine oil. • Lubricate steering linkage.
• Replace engine oil filter. • Lubricate steering and suspension ball joints.
• Lubricate steering linkage.
117,000 Miles (187 000 km)
96,000 Miles (154 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage.
• Drain and refill automatic transmission fluid. 120,000 Miles (192 000 km)
• Drain and refill front and rear axles.‡ • Change engine oil.
• Inspect brake linings. • Replace engine oil filter.
• Lubricate steering and suspension ball joints. • Replace engine air cleaner element.
• Replace ignition cables.
99,000 Miles (158 000 km) • Replace spark plugs.
• Change engine oil. • Inspect drive belt, adjust tension as necessary.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage. • Drain and refill automatic transmission fluid.
• Drain and refill transfer case fluid.
102,000 Miles (163 000 km) • Drain and refill front and rear axles.‡
• Change engine oil. • Inspect brake linings.
• Replace engine oil filter. • Lubricate steering and suspension ball joints.
• Lubricate steering linkage. ‡Off-highway operation, trailer towing, taxi, limou-
• Lubricate steering and suspension ball joints. sine, bus, snow plowing, or other types of commercial
service or prolonged operation with heavy loading,
105,000 Miles (168 000 km) especially in hot weather, require front and rear axle
• Change engine oil. service indicated with a ‡ in Schedule “B”. Perform
• Replace engine oil filter. these services if the vehicle is usually operated under
• Inspect engine air cleaner element, replace these conditions.
as necessary. Important: Inspection and service should also be
• Lubricate steering linkage. performed any time a malfunction is observed or sus-
pected.
108,000 Miles (173 000 km)
• Change engine oil.
• Replace engine oil filter.

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 XJ LUBRICATION AND MAINTENANCE 0-9

JUMP STARTING, TOWING AND HOISTING

TABLE OF CONTENTS
page page

SERVICE PROCEDURES FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . . . 10

JUMP STARTING PROCEDURE. . . . . . . . . . . . . . . 9 EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . . . 11
TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . . . 10 HOISTING RECOMMENDATIONS. . . . . . . . . . . . . 11

SERVICE PROCEDURES (2) When using another vehicle as a booster

source, turn off all accessories, place gear selector in
JUMP STARTING PROCEDURE park or neutral, set park brake and operate engine at
1200 rpm.
WARNING: REVIEW ALL SAFETY PRECAUTIONS (3) On disabled vehicle, place gear selector in park
AND WARNINGS IN GROUP 8A, BATTERY/START- or neutral and set park brake. Turn off all accesso-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT ries.
JUMP START A FROZEN BATTERY, PERSONAL (4) Connect jumper cables to booster battery. RED
INJURY CAN RESULT. DO NOT JUMP START WHEN clamp to positive terminal (+). BLACK clamp to neg-
MAINTENANCE FREE BATTERY INDICATOR DOT IS ative terminal (-). DO NOT allow clamps at opposite
YELLOW OR BRIGHT COLOR. DO NOT JUMP end of cables to touch, electrical arc will result.
START A VEHICLE WHEN THE BATTERY FLUID IS Review all warnings in this procedure.
BELOW THE TOP OF LEAD PLATES. DO NOT (5) On disabled vehicle, connect RED jumper cable
ALLOW JUMPER CABLE CLAMPS TO TOUCH clamp to positive (+) terminal. Connect BLACK
EACH OTHER WHEN CONNECTED TO A BOOSTER jumper cable clamp to engine ground as close to the
SOURCE. DO NOT USE OPEN FLAME NEAR BAT- ground cable attaching point as possible (Fig. 1).
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.

CAUTION: When using another vehicle as a

booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE:

(1) Raise hood on disabled vehicle and visually
inspect engine compartment for:
• Battery cable clamp condition, clean if necessary.
• Frozen battery.
• Yellow or bright color test indicator, if equipped.
• Low battery fluid level.
• Generator drive belt condition and tension.
• Fuel fumes or leakage, correct if necessary. Fig. 1 Jumper Cable Connections—Typical
1 – POSITIVE CABLE CONNECTION
CAUTION: If the cause of starting problem on dis- 2 – BOOSTER BATTERY
abled vehicle is severe, damage to booster vehicle 3 – NEGATIVE OR GROUND CABLE CONNECTION
charging system can result.

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 0 - 10 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
CAUTION: Do not crank starter motor on disabled TOWING-REAR END LIFTED (WHEEL LIFT)
vehicle for more than 15 seconds, starter will over- (1) Raise front of vehicle off ground and install tow
heat and could fail. dollies under front wheels.
(2) Attach wheel lift to rear wheels.
(6) Allow battery in disabled vehicle to charge to (3) Place transmission in neutral.
at least 12.4 volts (75% charge) before attempting to (4) Raise vehicle to towing height.
start engine. If engine does not start within 15 sec- (5) Place transmission in park (automatic trans-
onds, stop cranking engine and allow starter to cool mission) or fist gear (manual transmission).
(15 min.), before cranking again.
TOWING-FRONT END LIFTED
DISCONNECT CABLE CLAMPS AS FOLLOWS:
To prevent damage to front fascia components, use
• Disconnect BLACK cable clamp from engine only a Wheel-Lift type towing device or Flat-Bed
ground on disabled vehicle. hauling equipment.
• When using a Booster vehicle, disconnect If using the wheel-lift towing method:
BLACK cable clamp from battery negative terminal. (1) Raise rear of vehicle off ground and install tow
Disconnect RED cable clamp from battery positive dollies under rear wheels.
terminal. (2) Attach wheel lift to front wheels.
• Disconnect RED cable clamp from battery posi- (3) Place transmission in neutral.
tive terminal on disabled vehicle. (4) Raise vehicle to towing height.
(5) Place transmission in park (automatic trans-
TWO-WHEEL-DRIVE VEHICLE TOWING mission) or fist gear (manual transmission).
TOWING-REAR END LIFTED (SLING-TYPE) FOUR-WHEEL-DRIVE VEHICLE TOWING
DaimlerChrysler Corporation recommends that a
WARNING: WHEN TOWING A DISABLED VEHICLE
4WD vehicle be transported on a flat bed device. A
AND THE DRIVE WHEELS ARE SECURED IN A
wheel lift or sling type device can be used provided
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
all wheels are lifted off the ground using tow dollies.
TRANSMISSION IS IN THE PARK POSITION (AUTO-
If the vehicle is equipped with a factory installed
MATIC TRANSMISSION) OR A FORWARD DRIVE
trailer tow package, use a SAE approved wheel lift
GEAR (MANUAL TRANSMISSION).
device.

CAUTION: Do not use steering column lock to WARNING: WHEN TOWING A DISABLED VEHICLE
secure steering wheel during towing operation. AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
2WD XJ vehicles can be towed with the front TRANSMISSION IS IN THE PARK POSITION (AUTO-
wheels on the surface for extended distances at MATIC TRANSMISSION) OR A FORWARD DRIVE
speeds not exceeding 48 km/h (30 mph). If the vehicle GEAR (MANUAL TRANSMISSION).
is equipped with a factory installed trailer tow pack-
age, use a SAE approved wheel lift device.
(1) Attach J-hooks around the axle shaft tube out- TOWING-REAR END LIFTED (SLING TYPE)
board of the shock absorber. (1) Raise front of vehicle off ground and install tow
(2) Place the sling crossbar under and forward of dollies under front wheels.
the bumper. (2) Attach J-hooks around rear axle shaft tube out-
(3) Attach safety chains around the frame rails. board of shock absorber.
(4) Turn the ignition switch to the OFF position to (3) Place sling crossbar under and forward of
unlock the steering wheel. bumper.
(5) Secure steering wheel in the straight ahead (4) Attach safety chains around frame rails.
position with a clamp device designed for towing. (5) Turn ignition switch to OFF position to unlock
(6) Verify that steering components are in good steering wheel.
condition. (6) Secure steering wheel in the straight ahead
(7) Shift the transmission to NEUTRAL. position with a clamp device designed for towing.
(7) Shift transfer case to neutral.

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 XJ LUBRICATION AND MAINTENANCE 0 - 11
SERVICE PROCEDURES (Continued)
TOWING-REAR END LIFTED (WHEEL LIFT) FLOOR JACK
(1) Raise front of vehicle off ground and install tow When properly positioned, a floor jack can be used
dollies under front wheels. to lift a Jeep vehicle (Fig. 2) and (Fig. 3). Support the
(2) Attach wheel lift to rear wheels. vehicle in the raised position with jack stands at the
(3) Place transmission in neutral. front and rear ends of the frame rails.
(4) Raise vehicle to towing height.
(5) Place transmission in park (automatic trans-
mission) or first gear (manual transmission).

TOWING-FRONT END LIFTED

To prevent damage to front fascia components, use
only a Wheel-Lift type towing device or Flat-Bed
hauling equipment.
(1) Raise the rear of the vehicle off the ground and
install tow dollies under rear wheels.
(2) Attach wheel lift to front wheels.
(3) Place transmission in neutral.
(4) Raise vehicle to towing height.
(5) Place transmission in park (automatic trans-
mission) or first gear (manual transmission).

EMERGENCY TOW HOOKS

WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.

Some Jeep vehicles are equipped with front and

rear emergency tow hooks. The tow hooks should be
used for EMERGENCY purposes only.

CAUTION: DO NOT use emergency tow hooks for

tow truck hook-up or highway towing.
Fig. 2 Vehicle Lifting Locations

HOISTING RECOMMENDATIONS
Refer to the Owner’s Manual for emergency vehicle
lifting procedures.

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 0 - 12 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:

• An axle tube.
• A body side sill.
• A steering linkage component.
• A drive shaft.
• The engine or transmission oil pan.
• The fuel tank.
• A front suspension arm.

NOTE: Use the correct sub-frame rail or frame rail

lifting locations only.

HOIST
A vehicle can be lifted with:
• A single-post, frame-contact hoist.
• A twin-post, chassis hoist.
• A ramp-type, drive-on hoist.

NOTE: When a frame-contact type hoist is used,

verify that the lifting pads are positioned properly.

WARNING: THE HOISTING AND JACK LIFTING

POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
Fig. 3 Correct Vehicle Lifting Locations CENTER OF GRAVITY IS ALTERED MAKING SOME
1 – SUB-FRAME RAIL LOCATION HOISTING CONDITIONS UNSTABLE. PROPERLY
2 – SUB-FRAME RAIL LOCATION SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.

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 XJ LUBRICATION AND MAINTENANCE 0-1

LUBRICATION AND MAINTENANCE

TABLE OF CONTENTS

page page

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . 2

LUBRICANTS

TABLE OF CONTENTS
page page

SPECIFICATIONS FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 1

ENGINE OIL—DIESEL ENGINES . . . . . . . . . . . . . . 1

SPECIFICATIONS COOLING SYSTEM

ENGINE OIL—DIESEL ENGINES 2.5L Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 L

Use only Diesel Engine Oil meeting standard MIL- MANUAL TRANSMISSION
2104C or API Classification CD or higher or CCML
Recommended lubricant for AX15 transmissions is
D4, D5.
Mopart 75W–90, API Grade GL–3 gear lubricant, or
equivalent.
SAE VISCOSITY GRADE Correct lubricant level is from the bottom edge, to
CAUTION: Low viscosity oils must have the proper no more than 6 mm (1/4 in.) below the bottom edge of
API quality or the CCMC G5 designation. the fill plug hole.
Approximate dry fill lubricant capacity is:
To assure of properly formulated engine oils, it is • 3.10 liters (3.27 qts.) for 4–wheel drive applica-
recommended that SAE Grade 15W-40 engine oils tions.
that meet Chrysler material standard MS-6395, be • 3.15 liters (3.32 qts.) for 2–wheel drive applica-
used. European Grade 10W-40 oils are also accept- tions.
able.
Oils of the SAE 5W-40 or 8W-80 grade number are TRANSFER CASE
preferred when minimum temperatures consistently
fall below -12°C. COMMAND-TRAC 231 . . . . . . . . . . . . . . . . . . 1.3 L
FRONT AXLE
FLUID CAPACITIES
Model 181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 L
FUEL TANK
REAR AXLE
Diesel Engine Equipped Vehicles . . . . . . . . . 76.4 L
Model 194 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L*
ENGINE OIL 8-1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 L**
* When equipped with TRAC-LOK, include 4
2.5L Diesel Engine (includes filter) . . . . . . . . . 6.8 L
ounces of Friction Modifier Additive.
Oil Filter Replacement Only . . . . . . . . . . . . . . 0.4 L
** When equipped with TRAC-LOK, include 5
ounces of Friction Modifier Additive.

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 0-2 LUBRICATION AND MAINTENANCE XJ

MAINTENANCE SCHEDULE

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION SCHEDULE—B . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MAINTENANCE SCHEDULE—DIESEL ENGINE . . . 2
SERVICE PROCEDURES
SCHEDULE—A . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DESCRIPTION AND OPERATION SERVICE PROCEDURES

MAINTENANCE SCHEDULE—DIESEL ENGINE SCHEDULE—A
DESCRIPTION 1 000 KM
The following are engine related Maintenance • Change engine oil.
items which are unique to Diesel engine-equipped • Change engine oil filter.
vehicles. Refer to the 2000 XJ Service Manual for • Check all fluid levels.
gasoline engine and non-engine related Maintenance • Check correct torque, intake manifold mounting
Schedules nuts.
The service intervals are based on odometer read- • Check correct torque, exhaust manifold mount-
ings in kilometers. There are two maintenance sched- ing nuts.
ules that show proper service intervals. Use the • Check correct torque, turbocharger mounting
schedule that best describes the conditions the vehi- nuts.
cle is operated under. Schedule-A lists all the sched- • Check correct torque, water manifold bolts.
uled maintenance to be performed under normal
operating conditions. Schedule-B is the schedule for 10 000 KM
vehicles that are operated under one or more of the • Change engine oil.
following conditions: • Change engine oil filter.
• Day and night temperatures are below freezing.
• Stop and go driving. 20 000 KM
• Long periods of engine idling. • Change engine oil.
• Driving in dusty conditions. • Change engine oil filter.
• Short trips of less than 8 kilometers (5 miles). • Replace air filter element.
• Operation at sustained high speeds during hot • Drive belt visual inspection.
weather above 32°C (90°F).
• Taxi, police or delivery service. 30 000 KM
• Trailer towing. • Change engine oil.
• Change engine oil filter.
AT EACH STOP FOR FUEL OR SCHEDULED
40 000 KM
SERVICE STOP
• Check engine oil level. • Change engine oil.
• Check engine coolant level. • Change engine oil filter.
• Inspect drive belt. • Replace air filter element.
• Visually inspect intercooler for obstruction. • Drive belt visual inspection.
Clean as necessary. • Replace fuel filter/water separator element.**
• Visually inspect radiator for obstruction. Clean
50 000 KM
as necessary.
• Change engine oil.
• Inspect for fuel, oil or coolant leaks.
• Change engine oil filter.
• Inspect battery cable connection and excessive
corrosion. 60 000 KM
• Inspect for presence of water in fuel filter/water
• Change engine oil.
separator, drain if necessary.
• Change engine oil filter.

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 XJ LUBRICATION AND MAINTENANCE 0-3
SERVICE PROCEDURES (Continued)
• Replace air filter element. 1 000 KM
• Replace drive belt. • Change engine oil.
• Check engine smoke. • Change engine oil filter.
• Replace engine coolant. • Check all fluid levels.

70 000 KM 5 000 KM
• Change engine oil. • Change engine oil.
• Change engine oil filter. • Change engine oil filter.

80 000 KM 10 000 KM
• Change engine oil. • Change engine oil.
• Change engine oil filter. • Change engine oil filter.
• Replace air filter element. • Replace air filter element.
• Drive belt visual inspection. • Drive belt visual inspection.
• Replace fuel filter/water separator element.**
15 000 KM
90 000 KM • Change engine oil.
• Change engine oil. • Change engine oil filter.
• Change engine oil filter.
20 000 KM
100 000 KM • Change engine oil.
• Change engine oil. • Change engine oil filter.
• Change engine oil filter. • Replace air filter element.
• Replace air filter element. • Drive belt visual inspection.
• Drive belt visual inspection.
• Check glow plug operation. 25 000 KM
• Change engine oil.
EVERY 40 000 KM AFTER 80 000 KM • Change engine oil filter.
• Replace fuel filter/water separator element.**
**The fuel filter/water separator element should be 30 000 KM
replaced once a year if the vehicle is driven less than • Change engine oil.
40 000 km annually or if power loss from fuel star- • Change engine oil filter.
vation is detected. • Replace air filter element.
• Replace drive belt.
EVERY 10 000 KM AFTER 100 000 KM • Check engine smoke.
• Change engine oil. • Replace engine coolant.
• Change engine oil filter.
35 000 KM
EVERY 20 000 KM AFTER 100 000 KM • Change engine oil.
• Change engine oil. • Change engine oil filter.
• Change engine oil filter.
• Replace air filter element. 40 000 KM
• Drive belt visual inspection. • Change engine oil.
• Check glow plug operation. • Change engine oil filter.
• Replace air filter element.
SCHEDULE—B • Drive belt visual inspection.
• Replace fuel filter/water separator element.
500 KM
• Check correct torque, intake manifold mounting 45 000 KM
nuts. • Change engine oil.
• Check correct torque, exhaust manifold mount- • Change engine oil filter.
ing nuts.
• Check correct torque, turbocharger mounting 50 000 KM
nuts. • Change engine oil.
• Check correct torque, water manifold bolts. • Change engine oil filter.
• Replace air filter element.
• Drive belt visual inspection.

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 0-4 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
55 000 KM 90 000 KM
• Change engine oil. • Change engine oil.
• Change engine oil filter. • Change engine oil filter.
• Replace air filter element.
60 000 KM • Drive belt visual inspection.
• Change engine oil.
• Change engine oil filter. 95 000 KM
• Replace air filter element. • Change engine oil.
• Drive belt visual inspection. • Change engine oil filter.
• Replace fuel filter/water separator element.
100 000 KM
65 000 KM • Change engine oil.
• Change engine oil. • Change engine oil filter.
• Change engine oil filter. • Replace air filter element.
• Drive belt visual inspection.
70 000 KM • Check glow plug operation.
• Change engine oil. • Replace fuel filter/water separator element.
• Change engine oil filter.
• Replace air filter element. EVERY 5 000 KM AFTER 100 000 KM
• Drive belt visual inspection. • Change engine oil.
• Change engine oil filter.
75 000 KM
• Change engine oil. EVERY 10 000 KM AFTER 100 000 KM
• Change engine oil filter. • Change engine oil.
• Change engine oil filter.
80 000 KM • Replace air filter element.
• Change engine oil. • Drive belt visual inspection.
• Change engine oil filter. • Check glow plug operation.
• Replace air filter element.
• Replace drive belt. EVERY 20 000 KM AFTER 100 000 KM
• Check engine smoke. • Replace fuel filter/water separator element.
• Replace engine coolant.

85 000 KM
• Change engine oil.
• Change engine oil filter.

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 XJ SUSPENSION 2-1

SUSPENSION
TABLE OF CONTENTS

page page

ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 16

FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 7

ALIGNMENT

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION SERVICE PROCEDURES

WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1 PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 4
SUSPENSION AND STEERING SYSTEM . . . . . . . . 3 SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

DESCRIPTION AND OPERATION OPERATION

• CASTER is the forward or rearward tilt of the
WHEEL ALIGNMENT steering knuckle from vertical. Tilting the top of the
knuckle rearward provides positive caster. Tilting the
DESCRIPTION top of the knuckle forward provides negative caster.
Wheel alignment involves the correct positioning of Caster is a directional stability angle. This angle
the wheels in relation to the vehicle. The positioning enables the front wheels to return to a straight
is accomplished through suspension and steering ahead position after turns.
linkage adjustments. An alignment is considered • CAMBER is the inward or outward tilt of the
essential for efficient steering, good directional stabil- wheel relative to the center of the vehicle. Tilting the
ity and to minimize tire wear. The most important top of the wheel inward provides negative camber.
measurements of an alignment are caster, camber Tilting the top of the wheel outward provides positive
and toe position (Fig. 1). camber. Incorrect camber will cause wear on the
inside or outside edge of the tire. The angle is not
CAUTION: Never attempt to modify suspension or adjustable, damaged component(s) must be replaced
steering components by heating or bending. to correct the camber angle.
• WHEEL TOE POSITION is the difference
between the leading inside edges and trailing inside
CAUTION: Components attached with a nut and edges of the front tires. Incorrect wheel toe position
cotter pin must be torqued to specification. Then if is the most common cause of unstable steering and
the slot in the nut does not line up with the cotter uneven tire wear. The wheel toe position is the final
pin hole, tighten nut until it is aligned. Never loosen front wheel alignment adjustment.
the nut to align the cotter pin hole. • STEERING AXIS INCLINATION ANGLE is
measured in degrees and is the angle that the steer-
NOTE: Periodic lubrication of the front suspension/ ing knuckles are tilted. The inclination angle has a
steering system components may be required. Rub- fixed relationship with the camber angle. It will not
ber bushings must never be lubricated. Refer to change except when a spindle or ball stud is dam-
Group 0, Lubrication And Maintenance for the rec- aged or bent. The angle is not adjustable, damaged
ommended maintenance schedule. component(s) must be replaced to correct the steering
axis inclination angle.

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 2-2 SUSPENSION XJ
DESCRIPTION AND OPERATION (Continued)
• THRUST ANGLE is the angle of the rear axle
relative to the centerline of the vehicle. Incorrect
thrust angle can cause off-center steering and exces-
sive tire wear. This angle is not adjustable, damaged
component(s) must be replaced to correct the thrust
angle.

Fig. 1 Wheel Alignment Measurements

1 – WHEEL CENTERLINE 5 – TRUE VERTICAL
2 – NEGATIVE CAMBER ANGLE 6 – KING PIN
3 – PIVOT CENTERLINE 7 – VERTICAL
4 – SCRUB RADIUS 8 – POSITIVE CASTER

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 XJ SUSPENSION 2-3

DIAGNOSIS AND TESTING

SUSPENSION AND STEERING SYSTEM

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.

EXCESSIVE PLAY IN 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
STEERING
2. Loose or worn steering or 2. Tighten or replace components as
suspension components. necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.

VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.

2. Loose or worn steering or 2. Tighten or replace components as

suspension components. necessary.
3. Tire pressure. 3. Adjust tire pressure.
4. Alignment. 4. Align vehicle to specifications.

EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.

VEHICLE PULLS TO ONE 1. Uneven tire pressure. 1. Adjust tire pressure.

SIDE DURING BRAKING
2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.

VEHICLE LEADS OR 1. Radial tire lead. 1. Cross front tires.

DRIFTS FROM STRAIGHT 2. Brakes dragging. 2. Repair brake as necessary.
AHEAD DIRECTION ON
3. Weak or broken spring. 3. Replace spring.
UNCROWNED ROAD
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Loose or worn steering or 6. Repair as necessary.
suspension components.
7. Cross caster out of spec. 7. Align vehicle.

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 2-4 SUSPENSION XJ
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

KNOCKING, RATTLING 1. Worn shock bushings. 1. Replace shock.

OR SQUEAKING
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.
3. Shock valve. 3. Replace shock.

IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.

SERVICE PROCEDURES NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
PRE-ALIGNMENT angle has priority over caster. Refer to Group 3 Dif-
Before starting wheel alignment, the following ferential & Driveline for additional information.
inspection and necessary corrections must be com-
pleted. Refer to Suspension and Steering System
Diagnosis Chart for additional information.
(1) Inspect tires for size and tread wear.
(2) Set tire air pressure.
(3) Inspect front wheel bearings for wear.
(4) Inspect front wheels for excessive radial or lat-
eral runout and balance.
(5) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
(6) Inspect suspension components for wear and
noise.

WHEEL ALIGNMENT
Before each alignment reading, the vehicle should
be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and
down several times. Always release the bumper in
the down position. Set the front end alignment to
specifications with the vehicle at its NORMAL RIDE Fig. 2 Caster Adjustment
HEIGHT. 1 – SHIM
2 – SUSPENSION ARM
CAMBER
The wheel camber angle is preset. This angle is not
adjustable and cannot be altered. TOE POSITION (LHD)
NOTE: The wheel toe position adjustment is the
CASTER
final adjustment. The engine must remain running
Before checking the caster of the front axle for cor-
during the entire toe position adjustment.
rect angle, be sure the axle is not bent or twisted.
Road test the vehicle, make left and right turns. If (1) Start the engine and turn wheels both ways
the steering wheel returns to the center position before straightening the wheels. Secure the steering
unassisted, the caster angle is correct. If steering wheel with the front wheels in the straight-ahead
wheel does not return toward the center position position.
unassisted, an incorrect caster angle is probable. (2) Loosen the adjustment sleeve clamp bolts (Fig.
Caster can be adjusted by installing the appropri- 3).
ate size shims (Fig. 2). (3) Adjust the right wheel toe position with the
drag link. Turn the sleeve until the right wheel is at
correct TOE-IN specifications. Position the clamp

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 XJ SUSPENSION 2-5
SERVICE PROCEDURES (Continued)
bolts as shown (Fig. 4) and tighten to 49 N·m (36 ft.
lbs.).

NOTE: Make sure the toe setting does not change

during clamp tightening.

(4) Adjust the left wheel toe position with the tie
rod. Turn the sleeve until the left wheel is at specifi-
cations. Position the clamp bolts as shown (Fig. 4)
and tighten to 27 N·m (20 ft. lbs.).

NOTE: Make sure the toe setting does not change

during clamp tightening.

(5) Verify the right toe setting and turn off engine.
(6) Road test the vehicle on a flat level road to ver-
ify the steering wheel is centered. Fig. 4 Drag Link and Tie Rod Clamp (LHD)
1 – TIE ROD CLAMP
NOTE: Once the toe setting is correct, the steering 2 – DRAG LINK CLAMPS
wheel can be re-centered by adjusting only the drag
link. wheel with the front wheels in the straight-ahead
position.
(2) Loosen the adjustment sleeve clamp bolts (Fig.
TOE POSITION (RHD)
5).
NOTE: The wheel toe position adjustment is the (3) Adjust the left wheel toe position with the drag
final adjustment. The engine must remain running link. Turn the sleeve until the left wheel is at the
during the entire toe position adjustment. correct TOE-IN specifications. Position the clamp
bolts to their original position and tighten to 49 N·m
(1) Start the engine and turn wheels both ways (36 ft. lbs.).
before straightening the wheels. Secure the steering

Fig. 3 Steering Linkage (LHD)

1 – PITMAN ARM 4 – TIE ROD
2 – ADJUSTMENT SLEEVE 5 – STEERING DAMPENER
3 – DRAG LINK

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 2-6 SUSPENSION XJ
SERVICE PROCEDURES (Continued)

Fig. 5 Steering Linkage (RHD)

1 – PITMAN ARM 4 – TIE ROD
2 – DRAG LINK 5 – ADJUSTMENT SLEEVE
3 – STEERING DAMPNER

NOTE: Make sure the toe setting does not change (5) Verify the right toe setting and turn off engine.
during clamp tightening. (6) Road test the vehicle on a flat level road to ver-
ify the steering wheel is centered.
(4) Adjust the right wheel toe position with the tie
rod. Turn the sleeve until the right wheel is at cor- NOTE: Once the toe setting is correct, the steering
rect TOE-IN specifications. Position the clamp bolts wheel can be re-centered by adjusting only the drag
to their original position and tighten to 27 N·m (20 link.
ft. lbs.).

NOTE: Make sure the toe setting does not change

during clamp tightening.

SPECIFICATIONS

ALIGNMENT
NOTE: All alignment specifications are in degrees.

ANGLE PREFERRED RANGE MAX RT/LT DIFFERENCE

CASTER + 7.0° + 5.25° to + 8.5° 1.25°
CAMBER
− 0.25° − 0.75° to + 0.5° 1.0°
(fixed angle)
TOTAL TOE-IN + 0.25° 0° to + 0.45° .05°
THRUST ANGLE 0° 6 0.15°

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 XJ SUSPENSION 2-7

FRONT SUSPENSION

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION COIL SPRING/JOUNCE BUMPER . . . . . . . . . . . . . 9

SUSPENSION COMPONENTS . . . . . . . . . . . . . . . .7 STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 10
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . .7 LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 10
JOUNCE BUMPER. . . . . . . . . . . . . . . . . . . . . . . . .7 UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 11
COIL SPRINGS AND ISOLATORS . . . . . . . . . . . . .8 FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . . . . 11
LOWER SUSPENSION ARMS AND BUSHINGS . . .8 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 12
UPPER SUSPENSION ARMS AND BUSHINGS . . .8 TRACK BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . .9 HUB BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TRACK BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 WHEEL MOUNTING STUDS. . . . . . . . . . . . . . . . . 13
HUB/BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . .9 SPECIFICATIONS
DIAGNOSIS AND TESTING TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 14
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . ...9 SPECIAL TOOLS
REMOVAL AND INSTALLATION FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 15
SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . ...9

DESCRIPTION AND OPERATION NOTE: Periodic lubrication of the front suspension/

steering system components may be required. Rub-
SUSPENSION COMPONENTS ber bushings must never be lubricated. Refer to
The front suspension is a link/coil design (Fig. 1). Group 0, Lubrication And Maintenance for the rec-
This suspension is use on Left Hand Drive (LHD) ommended maintenance schedule.
and Right Hand Drive (RHD) vehicles. The suspen-
sion is comprised of:
• Drive axle (4WD), tube axle (2WD)
SHOCK ABSORBERS
• Dual-action shock absorbers
• Coil springs
DESCRIPTION
The top of the shock absorbers are bolted to a
• Upper and lower suspension arms
frame bracket. The bottom of the shocks are bolted to
• Stabilizer bar
the axle brackets.
• Track bar
• Jounce bumpers
OPERATION
CAUTION: Components attached with a nut and The shock absorbers dampen jounce and rebound
cotter pin must be torqued to specification. Then if motion of the vehicle over various road conditions
the slot in the nut does not line up with the cotter and limit suspension rebound travel.
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole. JOUNCE BUMPER
DESCRIPTION
CAUTION: Suspension components with rubber/ The jounce bumpers are mounted under the frame
urethane bushings (except stabilizer bar) should be rail inside of the coil spring.
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight OPERATION
of the vehicle when the fasteners are torqued. If The jounce bumpers are used to limit suspension
springs are not at their normal ride position, vehicle travel in compression.
ride comfort could be affected and premature bush-
ing wear may occur.

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 2-8 SUSPENSION XJ
DESCRIPTION AND OPERATION (Continued)

Fig. 1 Suspension Components (LHD)

1 – LINKS 6 – JOUNCE BUMPER
2 – SHOCK ABSORBER 7 – LOWER SUSPENSION ARM
3 – UPPER SUSPENSION ARM 8 – TRACK BAR
4 – STABILIZER BAR 9 – AXLE
5 – COIL SPRING

COIL SPRINGS AND ISOLATORS OPERATION

The arm and bushings provide location and react
DESCRIPTION to loads from the axle. The bushings provide isolation
The coil springs mount up in the wheelhouse which from the axle. The lower suspension arms can be
is part of the unitized body bracket. A rubber dough- used to adjust caster and pinion angle, through the
nut isolator is located between the top of the spring use of shims at the frame rail bracket.
and the bracket. The bottom of the spring seats on a
axle pad and retained with a clip. UPPER SUSPENSION ARMS AND BUSHINGS
OPERATION DESCRIPTION
The coil springs control ride quality and maintain The upper suspension arms are steel and use rub-
proper ride height. The isolators provide road noise ber bushings at each end of the arm. The arms
isolation. mount to the frame rail bracket and the axle brack-
ets.
LOWER SUSPENSION ARMS AND BUSHINGS
OPERATION
DESCRIPTION The arm and bushings provide location and react
The lower suspension arms are steel and use bush- to loads from the axle. The bushings provide isolation
ings at one end of the arm. The arms mount to the from the axle.
frame rail bracket and the axle brackets.

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 XJ SUSPENSION 2-9
DESCRIPTION AND OPERATION (Continued)

STABILIZER BAR ing components. Repair as necessary if any of these

conditions exist.
DESCRIPTION A squeaking noise from the shock absorber may be
The spring steel bar extends across the underside caused by the hydraulic valving and may be intermit-
of the chassis frame rails. Links are connected from tent. This condition is not repairable and the shock
the bar to the axle brackets. The stabilizer bar and absorber must be replaced.
links are isolated by rubber bushings. The shock absorbers are not refillable or adjust-
able. If a malfunction occurs, the shock absorber
OPERATION must be replaced. To test a shock absorber, hold it in
The stabilizer bar is used to control vehicle body an upright position and force the piston in and out of
roll during turns. The bar helps to control the vehicle the cylinder four or five times. The action throughout
body in relationship to the suspension. each stroke should be smooth and even.
The shock absorber bushings do not require any
TRACK BAR type of lubrication. Do not attempt to stop bushing
noise by lubricating them. Grease and mineral oil-
DESCRIPTION base lubricants will deteriorate the bushing.
The bar is attached to a frame rail bracket with a
ball stud and an axle bracket with a bushing. The REMOVAL AND INSTALLATION
bar is forged and has non replaceable isolator bush-
ing and ball stud.
SHOCK ABSORBER
OPERATION
REMOVAL
The track bar is used to control front axle lateral
(1) Remove the nut, retainer and grommet from
movement and provides cross car location of the axle
the upper stud in the engine compartment (Fig. 2).
assembly.
(2) Remove the lower nuts and bolts from the axle
bracket.
HUB/BEARING (3) Remove the shock absorber.
DESCRIPTION INSTALLATION
The bearing used on the front hub of this vehicle is (1) Position the lower retainer and grommet on the
the combined hub and bearing unit type assembly. shock stud. Insert the shock absorber through the
This unit assembly combines the front wheel mount- shock tower hole.
ing hub (flange) and the front wheel bearing into a (2) Install the lower bolts and nuts. Tighten nuts
one piece unit. The wheel mounting studs are the to 23 N·m (17 ft. lbs.).
only replaceable component of the hub/bearing (3) Install the upper grommet and retainer on the
assembly. stud. Install the nut and tighten to 22 N·m (16 ft.
lbs.).
OPERATION
The hub/bearing assembly is mounted to the steer-
COIL SPRING/JOUNCE BUMPER
ing knuckle and is retained by three mounting bolts
accessible from the back of the steering knuckle. The
REMOVAL
hub/bearing unit is not serviceable and must be
(1) Raise and support the vehicle. Position a
replaced as an assembly if the bearing or the hub is
hydraulic jack under the axle to support it.
determined to be defective.
(2) Remove the wheel and tire assemblies.
(3) Mark and disconnect the front propeller shaft
DIAGNOSIS AND TESTING from the axle.
(4) Remove lower suspension arms mounting nuts
SHOCK DIAGNOSIS and bolts from the axle (Fig. 2).
A knocking or rattling noise from a shock absorber (5) Remove the stabilizer bar link and shock
may be caused by movement between mounting absorber from the axle.
bushings and metal brackets or attaching compo- (6) Remove the track bar from the body rail
nents. These noises can usually be stopped by tight- bracket.
ening the attaching nuts. If the noise persists, (7) Remove the drag link from the pitman arm.
inspect for damaged and worn bushings, and attach-

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 2 - 10 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 2 Coil Spring & Shock Absorber

1 – SPRING 9 – SPRING
2 – SCREW 10 – NUT
3 – SPRING RETAINER 11 – SCREW
4 – NUT 12 – SHOCK ABSORBER
5 – RETAINER 13 – RETAINER
6 – GROMMET 14 – GROMMET
7 – ISOLATOR 15 – FRAME
8 – BUMPER 16 – CONTROL ARM

(8) Lower the axle until the spring is free from the STEERING KNUCKLE
upper mount. Remove the coil spring clip and remove For service procedures on the steering knuckle and
the spring. ball joints refer to Group 3 Differentials And Driv-
(9) Pull jounce bumper out of mount. eline.

INSTALLATION LOWER SUSPENSION ARM

(1) Install jounce bumper into mount.
(2) Position the coil spring on the axle pad. Install REMOVAL
the spring clip and bolt. Tighten bolt to 21 N·m (16 (1) Raise and support the vehicle.
ft. lbs.). (2) Remove the lower suspension arm nut and bolt
(3) Raise the axle into position until the spring from the axle bracket.
seats in the upper mount. (3) Remove the nut and bolt from the rear bracket
(4) Install the stabilizer bar links and shock and remove the lower suspension arm (Fig. 3).
absorbers to the axle bracket.
(5) Install the track bar to the body rail bracket. INSTALLATION
(6) Install the lower suspension arms to the axle. (1) Position the lower suspension arm at the axle
Install mounting bolts and nuts finger tight. bracket and rear bracket.
(7) Install the front propeller shaft to the axle. (2) Install the bolts and finger tighten the nuts.
(8) Install the wheel and tire assemblies. (3) Remove support and lower the vehicle.
(9) Remove the supports and lower the vehicle. (4) Tighten the front and rear nuts to 115 N·m (85
(10) Tighten lower suspension arms nuts to 115 ft. lbs.).
N·m (85 ft. lbs.).

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 XJ SUSPENSION 2 - 11
REMOVAL AND INSTALLATION (Continued)
(2) Position Spacer 7932-3 over the axle bushing
on a 4x2 vehicle and right side on a 4x4 vehicle.
(3) Place Receiver 7932-1 over flanged end of the
bushing. (Fig. 4).
(4) Place small end of Remover/Install 7932-2
against other side of the bushing.
(5) Install bolt 7604 through remover, bushing and
receiver.
(6) Install Long Nut 7603 and tighten nut too pull
bushing out of the axle bracket.

Fig. 3 Upper and Lower Suspension Arms

1 – BOLT
2 – UPPER ARM
3 – NUT
4 – BOLT Fig. 4 Bushing Removal
5 – NUT 1 – RECEIVER
6 – FRAME RAIL 2 – AXLE BRACKET
7 – LOWER ARM 3 – BOLT
8 – NUT 4 – REMOVER/INSTALLER
9 – BOLT 5 – LONG NUT
10 – NUT

(7) Remove nut, bolt, receiver, remover and bush-

UPPER SUSPENSION ARM ing.

REMOVAL NOTE: On 4x2 vehicle and right side of 4x4 vehicle,

(1) Raise and support the vehicle. leave Spacer 7932-3 in position for bushing instal-
(2) Remove the upper suspension arm nut and bolt lation.
at the axle bracket.
(3) Remove the nut and bolt at the frame rail and
remove the upper suspension arm (Fig. 3). INSTALLATION
(1) Place Receiver 7932-1 on the other side of the
INSTALLATION axle bracket.
(1) Position the upper suspension arm at the axle (2) Position new bushing up to the axle bracket.,
and frame rail. and large end of Remover/Install 7932-2 against the
(2) Install the bolts and finger tighten the nuts. bushing (Fig. 5).
(3) Remove the supports and lower the vehicle. (3) Install bolt 7604 through receiver, bushing and
(4) Tighten the nut at the axle to 75 N·m (55 ft. installer.
lbs.). Tighten the nut at the frame bracket to 90 N·m (4) Install Long Nut 7603 and tighten nut to draw
(66 ft. lbs.). the bushing into the axle bracket.
(5) Remove tools and install the upper suspension
FRONT AXLE BUSHING arm.

REMOVAL
(1) Remove the upper suspension arm from axle.

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 2 - 12 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 5 Bushing Installation

1 – REMOVER/INSTALLER
2 – AXLE BRACKET
3 – BOLT
4 – RECEIVER
5 – LONG NUT

STABILIZER BAR Fig. 6 Stabilizer Bar (LHD)

1 – RETAINER
REMOVAL 2 – GROMMET
3 – BUSHING
(1) Raise and support the vehicle.
4 – CLAMP
(2) Remove nuts, retainers and grommets from the 5 – STABILIZER BAR
links at the stabilizer bar (Fig. 6). 6 – LINK
(3) Remove the links mounting nuts and bolts
from the axle brackets.
(4) Remove the stabilizer bar clamps from the (4) Remove the bolt and flag nut from the axle
body rails. Remove the stabilizer bar. shaft tube bracket (Fig. 7).
(5) Remove the track bar.
INSTALLATION
(1) Inspect stabilizer bar bushings. Replace bush- INSTALLATION
ings if cracked, cut, distorted, or worn. (1) Install the track bar at axle tube bracket.
(2) Position the stabilizer bar on the body rail and Loosely install the retaining bolt and flag nut.
install the bushings and clamps. Ensure the bar is (2) It may be necessary to pry the axle assembly
centered with equal spacing on both sides. Tighten over to install the track bar at the body rail. Install
the bolts to 75 N·m (40 ft. lbs.). track bar at the body rail bracket. Install the retain-
(3) Install the links and grommets onto the stabi- ing nut on the stud.
lizer bar and axle brackets. (3) Remove the supports and lower the vehicle.
(4) Tighten the link nuts at the axle bracket to 95 (4) Tighten the retaining bolt at the axle shaft
N·m (70 ft. lbs.). tube bracket to 54 N·m (40 ft. lbs.).
(5) Tighten the link nuts at the stabilizer bar to 36 (5) Tighten the ball stud nut to 81 N·m (60 ft.
N·m (27 ft. lbs.). lbs.). Install a new cotter pin.
(6) Remove the supports and lower the vehicle.
HUB BEARING
TRACK BAR
REMOVAL
REMOVAL (1) Raise and support the vehicle.
(1) Raise and support the vehicle. (2) Remove the wheel and tire assembly.
(2) Remove the cotter pin and nut from the ball (3) Remove the brake caliper, rotor and ABS wheel
stud end at the body rail bracket. speed sensor, refer to Group 5 Brakes.
(3) Use a universal puller tool to separate the ball (4) Remove the cotter pin, nut retainer and axle
stud from the frame rail bracket. hub nut (Fig. 8).

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 XJ SUSPENSION 2 - 13
REMOVAL AND INSTALLATION (Continued)
(2) Install the hub bearing to knuckle bolts and
tighten to 102 N·m (75 ft. lbs.).
(3) Install the hub washer and nut. Tighten the
hub nut to 237 N·m (175 ft. lbs.). Install the nut
retainer and a new cotter pin.
(4) Install the brake rotor, caliper and ABS wheel
speed sensor, refer to Group 5 Brakes.
(5) Install the wheel and tire assembly.
(6) Remove support and lower the vehicle.

WHEEL MOUNTING STUDS

CAUTION: Do not use a hammer to remove wheel
studs.

REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper, caliper adapter and
rotor, refer to Group 5 Brakes for procedure.
(4) Remove stud from hub with Remover C-4150A
Fig. 7 Track Bar (LHD) (Fig. 9).
1 – NUT
2 – SUPPORT BRACKET INSTALLATION
3 – LEFT FRAME RAIL (1) Install new stud into hub flange.
4 – STUD (2) Install three washers onto stud, then install
5 – SCREW lug nut with the flat side of the nut against the
6 – COTTER PIN washers.
7 – NUT (3) Tighten lug nut until the stud is pulled into
8 – FRAME BRACKET
the hub flange. Verify that the stud is properly
9 – NUT PLATE
seated into the flange.
10 – TRACK BAR
11 – BALL STUD END
(4) Remove lug nut and washers.
12 – NUT (5) Install the brake rotor, caliper adapter, and cal-
iper, refer to Group 5 Brakes for procedure.
(6) Install wheel and tire assembly, use new lug
(5) Remove the hub bearing mounting bolts from nut on stud or studs that were replaced.
the back of the steering knuckle. Remove hub bear- (7) Remove support and lower vehicle.
ing from the steering knuckle and off the axle shaft.

INSTALLATION
(1) Install the hub bearing and brake dust shield
to the knuckle.

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 2 - 14 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 8 Hub Bearing & Knuckle

1 – BRAKE SHIELD 6 – HUB AND BEARING ASSEMBLY
2 – WASHER 7 – STEERING KNUCKLE
3 – RETAINER 8 – BOLT
4 – COTTER PIN 9 – TONE WHEEL (ABS)
5 – NUT

SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut . . . . . . . . . . . . . . . 22 N·m (16 ft. lbs.)
Lower Nut . . . . . . . . . . . . . . . 23 N·m (17 ft. lbs.)
Suspension Arm Upper
Front Nut . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.)
Rear Nut . . . . . . . . . . . . . . . . 89 N·m (66 ft. lbs.)
Suspension Arm Lower
Front Nut . . . . . . . . . . . . . . . 115 N·m (85 ft. lbs.)
Rear Nut . . . . . . . . . . . . . . . 115 N·m (85 ft. lbs.)
Stabilizer Bar
Clamp Bolt . . . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
Fig. 9 Wheel Stud Removal Link Upper Nut . . . . . . . . . . . 36 N·m (27 ft. lbs.)
1 – REMOVER Link Lower Nut . . . . . . . . . . . 95 N·m (70 ft. lbs.)
2 – WHEEL STUD Track Bar
Ball Stud Nut . . . . . . . . . . . . 81 N·m (60 ft. lbs.)
Axle Bracket Bolt . . . . . . . . . . 54 N·m (40 ft. lbs.)

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 XJ SUSPENSION 2 - 15
SPECIFICATIONS (Continued)

DESCRIPTION TORQUE
Track Bar Bracket
Bolts . . . . . . . . . . . . . . . . . . 125 N·m (92 ft. lbs.)
Nut . . . . . . . . . . . . . . . . . . . 100 N·m (74 ft. lbs.)
Support Bolts . . . . . . . . . . . . . 42 N·m (31 ft. lbs.)
Hub/Bearing
Bolts . . . . . . . . . . . . . . . . . . 102 N·m (75 ft. lbs.)
Axle Nut . . . . . . . . . . . . . . 237 N·m (175 ft. lbs.)
Nut, Long 7603
SPECIAL TOOLS
FRONT SUSPENSION

Bolt, Special 7604

Remover/Installer Suspension Bushing 7932

Remover C-4150A

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 2 - 16 SUSPENSION XJ

REAR SUSPENSION

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION

SUSPENSION COMPONENT . . . . . . . . . . . . . . . . 16 SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . 17
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 16 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 17
JOUNCE BUMPERS. . . . . . . . . . . . . . . . . . . . . . . 16 LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 16 LEAF SPRING AND SHACKLE BUSHING. . . . . . . 18
COIL SPRINGS AND ISOLATORS . . . . . . . . . . . . 16 SPECIFICATIONS
DIAGNOSIS AND TESTING TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 19
SPRING AND SHOCK . . . . . . . . . . . . . . . . . . . . . 17

DESCRIPTION AND OPERATION OPERATION

The shock absorbers dampen jounce and rebound
SUSPENSION COMPONENT motion of the vehicle over various road conditions
The rear suspension is comprised of: and limit suspension rebound travel.
• Shock Absorbers
• Jounce Bumpers JOUNCE BUMPERS
• Stabilizer Bar (optional)
• Leaf Springs DESCRIPTION
• Drive Axle The jounce bumpers are bolted to the bottom of the
frame rail.
CAUTION: A vehicle should always be loaded so
the vehicle weight center-line is located immedi- OPERATION
ately forward of the rear axle. Correct vehicle load- The jounce bumpers are used to limit suspension
ing provides proper front tire-to-road contact. This travel in compression.
results in maximum vehicle handling stability and
safety. Incorrect vehicle weight distribution can STABILIZER BAR
cause excessive tire tread wear, spring fatigue or
failure, and erratic steering. DESCRIPTION
The spring steel bar extends across the axle and
mounts to leaf spring brackets. Links are connected
CAUTION: Suspension components with rubber/
from the bar to the underside of the frame rail. The
urethane bushings (except stabilizer bar) should be
stabilizer bar and links are isolated by rubber bush-
tightened with the vehicle at normal ride height. It is
ings.
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
OPERATION
springs are not at their normal ride position, vehicle
The stabilizer bar is used to control vehicle body
ride comfort could be affected and premature bush-
roll during turns. The bar helps to control the vehicle
ing wear may occur.
body in relationship to the suspension.

SHOCK ABSORBERS COIL SPRINGS AND ISOLATORS

DESCRIPTION DESCRIPTION
The top of the shock absorbers are bolted to the The front of the multi-leaf springs mount to frame
body crossmember. The bottom of the shocks are rail brackets. The rear of the spring mounts to shack-
bolted to the axle brackets. les which mount the frame. The springs and shackles
have bushing at the mounting points.

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 XJ SUSPENSION 2 - 17
DESCRIPTION AND OPERATION (Continued)
OPERATION tent. This condition is not repairable and the shock
The leaf springs control ride quality and maintain absorber must be replaced.
proper ride height. The shackles allow the springs to The shock absorbers are not refillable or adjust-
change their length as the vehicle moves over various able. If a malfunction occurs, the shock absorber
road conditions. The bushings are used to isolate must be replaced. To test a shock absorber, hold it in
axle/road noise. an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
DIAGNOSIS AND TESTING The spring eye and shock absorber bushings do not
require any type of lubrication. Do not attempt to
SPRING AND SHOCK stop spring bushing noise by lubricating them.
A knocking or rattling noise from a shock absorber Grease and mineral oil-base lubricants will deterio-
may be caused by movement between mounting rate the bushing rubber.
bushings and metal brackets or attaching compo- If the vehicle is used for severe, off-road operation,
nents. These noises can usually be stopped by tight- the springs should be examined periodically. Check
ening the attaching nuts. If the noise persists, for broken and shifted leafs, loose and missing clips,
inspect for damaged and worn bushings, and attach- and broken center bolts. Refer to Spring and Shock
ing components. Repair as necessary if any of these Absorber Diagnosis chart for additional information.
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-

SPRING AND SHOCK ABSORBER

CONDITION POSSIBLE CAUSES CORRECTION

SPRING SAGS 1. Broken leaf. 1. Replace spring.

2. Spring fatigue. 2. Replace spring.

SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.

2. Worn bushings. 2. Replace bushings.

3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.

SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.

2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.

REMOVAL AND INSTALLATION STABILIZER BAR

SHOCK ABSORBER REMOVAL
(1) Raise and support the vehicle.
REMOVAL (2) Disconnect stabilizer bar links from spring
(1) Remove the shock absorber upper bolts from brackets (Fig. 2).
the body bracket (Fig. 1). (3) Disconnect the stabilizer bar brackets from the
(2) Remove lower attaching nut and washer from body rails. Remove the stabilizer bar and links.
the bracket stud. Remove the shock absorber.
INSTALLATION
INSTALLATION (1) Position the stabilizer bar links at the spring
(1) Install the shock absorber lower eye on the brackets. Install the attaching bolts and nuts and
spring bracket stud. Install the shock absorber and tighten to 74 N·m (55 ft. lbs.).
upper bolts on the body bracket. (2) Attach the stabilizer bar to the body rail brack-
(2) Tighten the lower nut to 62 N·m (46 ft. lbs.). ets with the bolts. Tighten to 54 N·m (40 ft. lbs.).
(3) Tighten the upper bolts to 23 N·m (17 ft. lbs.). (3) Remove the supports and lower the vehicle.

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 2 - 18 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 1 Rear Suspension Components

1 – SHOCK ABSORBER 8 – RETAINER
2 – SPRING BRACKET 9 – SHOCK ABSORBER
3 – NUT 10 – SPRING
4 – BUSHING 11 – U-BOLTS
5 – BUMPER 12 – BUSHING
6 – BRACKET 13 – SHACKLE
7 – NUT

LEAF SPRING (2) Position the rear eye in the shackle bracket.
Loosely install the attaching bolt and nut. Do not
REMOVAL tighten at this time.
(1) Raise vehicle at body rails. (3) Position the axle. Install the spring bracket,
(2) Remove the wheel and tire assemblies. U-bolts and nuts. Tighten the nuts to 70 N·m (52 ft.
(3) Support axle with hydraulic jack to relieve axle lbs.).
weight. (4) Connect the stabilizer bar link to the spring
(4) Disconnect the stabilizer bar link from the bracket.
spring bracket stud. (5) Remove the hydraulic jack.
(5) Remove nuts, U-bolts and spring bracket from (6) Lower the vehicle.
axle. (7) Tighten the spring front eye attaching bolts to
(6) Remove nut and bolt attaching spring front eye 156 N·m (115 ft. lbs.).
to shackle. (8) Tighten the spring rear eye attaching bolts to
(7) Remove nut and bolt from spring rear eye. 108 N·m (80 ft. lbs.).
(8) Remove spring from vehicle. (9) Tighten the stabilizer bar link to 74 N·m (55 ft.
lbs.).
INSTALLATION
(1) Position the spring front eye in the bracket. LEAF SPRING AND SHACKLE BUSHING
Loosely install the attaching bolt and nut. Do not For front bushings bend tabs DOWN before
tighten at this time. removal. Use an appropriate driver tool and force the
original bushing out of the spring eye.

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 XJ SUSPENSION 2 - 19
REMOVAL AND INSTALLATION (Continued)

Fig. 2 Stabilizer Bar Fig. 3 Spring Eye Bushing Removal

1 – LINK 1 – NUT
2 – BUSHING 2 – PIPE
3 – GROMMET (RECEIVER)
4 – FRAME RAIL 3 – SPRING EYE
5 – CLAMP 4 – NUT
6 – SCREW 5 – THREADED ROD
7 – NUT 6 – FLAT WASHER
8 – SPRING BRACKET 7 – SOCKET WRENCH
(DRIVER)
9 – BOLT
10 – SWAY BAR
11 – SCREW
SPECIFICATIONS
(1) Assemble tools shown (Fig. 3). Tighten nut at TORQUE CHART
the socket wrench end of the threaded rod until the
bushing is forced out. DESCRIPTION TORQUE
(2) Assemble and align the bushing installation Shock Absorber
tools.
Upper Bolt . . . . . . . . . . . . . . . 23 N·m (17 ft. lbs.)
(3) Align the bushing with the spring eye or
Lower Nut . . . . . . . . . . . . . . . 62 N·m (46 ft. lbs.)
shackle eye and tighten the nut at the socket wrench
Stabilizer Bar
end of the threaded rod. Tighten until the bushing is
Clamp Bolt . . . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
forced into the spring eye.
Link Upper Bolt . . . . . . . . . . . 12 N·m (9 ft. lbs.)
NOTE: The bushing must be centered in the spring Link Lower Nut . . . . . . . . . . . 74 N·m (55 ft. lbs.)
eye. The ends of the bushing must be flush or Spring
slightly recessed within the end surfaces of the U-Bolt Nut . . . . . . . . . . . . . . . 70 N·m (52 ft. lbs.)
spring eye. Front Pivot Bolt . . . . . . . . . 156 N·m (115 ft. lbs.)
Upper Shackle Bolt . . . . . . 156 N·m (115 ft. lbs.)
(4) For front bushings bend tabs up after installa- Lower Shackle Bolt . . . . . . . 108 N·m (80 ft. lbs.)
tion.

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 XJ DIFFERENTIAL AND DRIVELINE 3-1

DIFFERENTIAL AND DRIVELINE

TABLE OF CONTENTS

page page

PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . 1 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

TUBE, 181, AND 186 FBI AXLE . . . . . . . . . . . . . . 16 8 1/4 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . 103

PROPELLER SHAFTS

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . . 8

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . ...1 DISASSEMBLY AND ASSEMBLY
PROPELLER SHAFT JOINTS . . . . . . . . . . . . . . ...2 SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . . . 9
PROPELLER SHAFT JOINT ANGLE . . . . . . . . . ...3 DOUBLE CARDAN JOINT. . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 14
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . ...5 ADJUSTMENTS
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5 REAR AXLE PINION INPUT ANGLE . . . . . . . . . . . 15
SERVICE PROCEDURES FRONT AXLE PINION INPUT ANGLE . . . . . . . . . . 15
DRIVELINE ANGLE MEASUREMENT SPECIFICATIONS
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . ...6 PROPELLER SHAFTS AND U–JOINTS. . . . . . . . . 15
PROPELLER SHAFT ANGLE MEASUREMENT. ...6 SPECIAL TOOLS
REMOVAL AND INSTALLATION PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 15
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . ...8

DESCRIPTION AND OPERATION ment parts helps to ensure safe operation. All fasten-
ers must be torqued to the specified values for safe
PROPELLER SHAFT operation.
Also make alignment reference marks (Fig. 1) on
DESCRIPTION the propeller shaft yoke and axle, or transmission,
A propeller shaft (Fig. 2) is the shaft which con- yoke prior to servicing. This helps to eliminate possi-
nects the transmission/transfer case to the axle dif- ble vibration.
ferential. This is the link through which the engine
CAUTION: Do not allow the propeller shaft to drop
power is transmitted to the axle.
or hang from any propeller shaft joint during
The propeller shaft is designed and built with the
removal. Attach the propeller shaft to the vehicle
yoke lugs in line with each other which is called zero
underside with wire to prevent damage to the joints.
phasing. This design produces the smoothest running
condition, an out-of-phase shaft can cause a vibra-
OPERATION
tion.
The propeller shaft must operate through con-
Tubular propeller shafts are balanced by the man-
stantly changing relative angles between the trans-
ufacturer with weights spot welded to the tube.
mission and axle when going over various road
PRECAUTIONS surfaces. It must also be capable of changing length
while transmitting torque. The axle rides suspended
Use the exact replacement parts when installing
by springs in a floating motion.This is accomplished
the propeller shafts. The use of the correct replace-
through universal joints, which permit the propeller

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 3-2 PROPELLER SHAFTS XJ
DESCRIPTION AND OPERATION (Continued)
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered to pre-
vent an out-of-balance condition and driveline
vibration.

CAUTION: Use original equipment replacement

parts for attaching the propeller shafts. The speci-
fied torque must always be applied when tightening
the fasteners.

PROPELLER SHAFT JOINTS

DESCRIPTION
Two different types of propeller shaft joints are
used:
Fig. 1 Reference Marks on Yokes • Single cardan universal joint (Fig. 3)
1 – REFERENCE MARKS
• Double cardan (CV) universal joint (Fig. 4)
None of the universal joints are serviceable. If one
becomes worn or damaged, the complete universal
shaft to operate at different angles. The slip joints (or joint assembly must be replaced.
yokes) permit contraction or expansion (Fig. 2).

Fig. 2 Propeller Shafts

1 – FRONT AXLE 5 – REAR AXLE
2 – FRONT PROPELLER SHAFT 6 – STRAP
3 – TRANSFER CASE 7 – REAR PROPELLER SHAFT
4 – BOOT 8 – STRAP

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 XJ PROPELLER SHAFTS 3-3
DESCRIPTION AND OPERATION (Continued)

PROPELLER SHAFT JOINT ANGLE

DESCRIPTION
When two shafts come together at a common joint,
the bend that is formed is called the operating angle.
The larger the angle, the larger the amount of angu-
lar acceleration and deceleration of the joint. This
speeding up and slowing down of the joint must be
cancelled to produce a smooth power flow.

OPERATION
This cancellation is done through the phasing of a
propeller shaft and ensuring that the proper propel-
ler shaft joint working angles are maintained.
A propeller shaft is properly phased when the yoke
ends are in the same plane, or in line. A twisted
shaft will make the yokes out of phase and cause a
noticeable vibration.
When taking propeller shaft joint angle measure-
ments, or checking the phasing, of two piece shafts,
consider each shaft separately.
Fig. 3 Single Cardan Universal Joint Ideally the driveline system should have;
1 – NEEDLE BEARING 6 – BEARING CAP
• Angles that are equal or opposite within 1
2 – BEARING CAP 7 – RETAINING CLIP
degree of each other.
3 – SEAL 8 – YOKE
4 – SPIDER 9 – SEAL
• Have a 3 degree maximum operating angle.
5 – NEEDLE BEARING • Have at least a 1/2 degree continuous operating
(propeller shaft) angle.

Fig. 4 Double Cardan (CV) Universal Joint

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 3-4 PROPELLER SHAFTS XJ
DESCRIPTION AND OPERATION (Continued)
Propeller shaft speed (rpm) is the main factor in DIAGNOSIS AND TESTING
determining the maximum allowable operating angle.
As a guide to the maximum normal operating angles VIBRATION
refer to (Fig. 5). Tires that are out-of-round, or wheels that are
PROPELLER SHAFT MAX. NORMAL unbalanced, will cause a low frequency vibration.
Refer to Group 22, Tires and Wheels, for additional
R.P.M. OPERATING ANGLES information.
5000 3° Brake drums that are unbalanced will cause a
4500 3° harsh, low frequency vibration. Refer to Group 5,
Brakes, for additional information.
4000 4°
Driveline vibration can also result from loose or
3500 5° damaged engine mounts. Refer to Group 9, Engines,
3000 5° for additional information.
2500 7° Propeller shaft vibration increases as the vehicle
speed is increased. A vibration that occurs within a
2000 8° specific speed range is not usually caused by a pro-
1500 11° peller shaft being unbalanced. Defective universal
joints, or an incorrect propeller shaft angle, are usu-
Fig. 5 Maximum Angles And Propeller Shaft Speed ally the cause of such a vibration.

DRIVELINE VIBRATION

Drive Condition Possible Cause Correction

Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash
material on shaft. with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or 3) Install new yoke.
excessive runout.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in 5) Loosen spring u-bolts and seat
seat. center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out 7) Installl new propeller shaft.
of balance.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced 9) Re-index propeller shaft, test,
condition. and evaluate.
10) Excessive drive pinion gear 10) Re-index propeller shaft and
shaft runout. evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.

Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as
necessary.

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 XJ PROPELLER SHAFTS 3-5
DIAGNOSIS AND TESTING (Continued)

UNBALANCE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
vibrations.

If propeller shaft is suspected of being unbalanced,

it can be verified with the following procedure:
(1) Raise the vehicle.
(2) Clean all the foreign material from the propel-
ler shaft and the universal joints.
(3) Inspect the propeller shaft for missing balance
weights, broken welds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) Inspect the universal joints to ensure that they
are not worn, are properly installed, and are cor- Fig. 7 Two Clamp Screws At The Same Position
rectly aligned with the shaft. (13) If the additional clamp causes an additional
(5) Check the universal joint clamp screws torque. vibration, separate the clamps (1/4 inch above and
(6) Remove the wheels and tires. Install the wheel below the mark). Repeat the vibration test (Fig. 8).
lug nuts to retain the brake drums or rotors.
(7) Mark and number the shaft six inches from the
yoke end at four positions 90° apart.
(8) Run and accelerate the vehicle until vibration
occurs. Note the intensity and speed the vibration
occurred. Stop the engine.
(9) Install a screw clamp at position 1 (Fig. 6).

Fig. 8 Clamp Screws Separated

1 – 1⁄2 INCH

(14) Increase distance between the clamp screws

and repeat the test until the amount of vibration is
at the lowest level. Bend the slack end of the clamps
so the screws will not loosen.
(15) If the vibration remains unacceptable, apply
Fig. 6 Clamp Screw At Position 1
the same steps to the front end of the propeller shaft.
1 – CLAMP
(16) Install the wheel and tires. Lower the vehicle.
2 – SCREWDRIVER

RUNOUT
(10) Start the engine and re-check for vibration. If (1) Remove dirt, rust, paint, and undercoating
there is little or no change in vibration, move the from the propeller shaft surface where the dial indi-
clamp to one of the other three positions. Repeat the cator will contact the shaft.
vibration test. (2) The dial indicator must be installed perpendic-
(11) If there is no difference in vibration at the ular to the shaft surface.
other positions, the source of the vibration may not (3) Measure runout at the center and ends of the
be propeller shaft. shaft sufficiently far away from weld areas to ensure
(12) If the vibration decreased, install a second that the effects of the weld process will not enter into
clamp (Fig. 7) and repeat the test. the measurements.

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 3-6 PROPELLER SHAFTS XJ
DIAGNOSIS AND TESTING (Continued)
(4) Refer to Runout Specifications chart. (2) Rotate the shaft until transmission/transfer
(5) If the propeller shaft runout is out of specifica- case output yoke bearing is facing downward.
tion, remove the propeller shaft, index the shaft 180°, Always make measurements from front to
and re-install the propeller shaft. Measure shaft rear. Also, be sure to take all measurements
runout again. while working from the same side of the vehi-
(6) If the propeller shaft runout is now within cle.
specifications, mark the shaft and yokes for proper (3) Place Inclinometer on yoke bearing (A) parallel
orientation. to the shaft (Fig. 9). Center bubble in sight glass and
(7) If the propeller shaft runout is not within spec- record measurement.
ifications, verify that the runout of the transmission/ This measurement will give you the transmis-
transfer case and axle are within specifications. sion or Output Yoke Angle (A).
Correct as necessary and re-measure propeller shaft
runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS

Front of Shaft 0.020 in. (0.50 mm)

Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
Measure front/rear runout approximately 3 inches
(76 mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.

SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION Fig. 9 Front (Output) Angle Measurement (A)
Before measuring universal joint angles, the fol- 1 – SLIP YOKE BEARING CAP
lowing must be done; 2 – SPECIAL TOOL 7663 (J-23498A)
• Inflate all tires to correct pressure.
• Check the angles in the same loaded or
(4) Rotate propeller shaft 90 degrees and place
unloaded condition as when the vibration occurred.
Inclinometer on yoke bearing parallel to the shaft
Propeller shaft angles change according to the
(Fig. 10). Center bubble in sight glass and record
amount of load in the vehicle.
measurement. This measurement can also be taken
• Check the condition of all suspension compo-
at the rear end of the shaft.
nents and verify all fasteners are torqued to specifi-
This measurement will give you the Propeller
cations.
Shaft Angle (C).
• Check the condition of the engine and transmis-
(5) Subtract smaller figure from larger (C minus
sion mounts and verify all fasteners are torqued to
A) to obtain Transmission Output Operating Angle.
specifications.
(6) Rotate propeller shaft 90 degrees and place
Inclinometer on pinion yoke bearing parallel to the
PROPELLER SHAFT ANGLE MEASUREMENT shaft (Fig. 11). Center bubble in sight glass and
To accurately check driveline alignment, raise and record measurement.
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn.
(1) Remove any external bearing snap rings, if
equipped, from universal joint so protractor base sits
flat.

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 XJ PROPELLER SHAFTS 3-7
SERVICE PROCEDURES (Continued)

Fig. 10 Propeller Shaft Angle Measurement (C)

1 – SHAFT YOKE BEARING CAP
Fig. 11 Rear (Input) Angle Measurement (B)
2 – SPECIAL TOOL 7663 (J23498–A)
1 – PINION YOKE BEARING CAP
2 – SPECIAL TOOL 7663 (J-23498A)
This measurement will give you the pinion
shaft or Input Yoke Angle (B).
Refer to rules given below and the example in
(7) Subtract smaller figure from larger (C minus
(Fig. 12) for additional information.
B) to obtain axle Input Operating Angle.

Fig. 12 Universal Joint Angle Example

1 – 4.9° Angle (C) 4 – 3.0° Angle (A)
2 – 3.2° Angle (B) 5 – Output Yoke
3 – Input Yoke

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 3-8 PROPELLER SHAFTS XJ
SERVICE PROCEDURES (Continued)
• Good cancellation of U–joint operating angles
(within 1°).
• Operating angles less than 3°.
• At least 1/2 of one degree continuous operating
(propeller shaft) angle.

REMOVAL AND INSTALLATION

FRONT PROPELLER SHAFT
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Remove the crossmember/skid plate as neces-
sary to gain access to the propeller shaft.
(3) Shift the transmission and transfer case, if nec-
essary, into the Neutral position. Fig. 14 Front Propeller Shaft
1 – FRONT AXLE
(4) Using a suitable marker, mark a line across
2 – BOOT
the yoke at the transfer case, the link yoke, and pro- 3 – PROPELLER SHAFT
peller shaft yoke at the rear of the front propeller 4 – CV-JOINT
shaft for installation reference (Fig. 13). 5 – TRANSFER CASE
(5) Mark a line across the propeller shaft yoke and 6 – BOOT
the pinion shaft yoke for installation reference. 7 – SLINGER
8 – CLAMP
9 – YOKE

(2) Place front universal joint into the axle pinion

yoke.
(3) Align mark on the rear link yoke and universal
joint to the mark on the transfer case yoke (Fig. 13).
(4) Loosely install bolts to hold universal joint to
transfer case yoke.
(5) Align mark on front universal joint to the mark
on the axle pinion yoke.
(6) Tighten the U-joint strap/clamp bolts at the
axle yoke to 19 N·m (14 ft. lbs.) torque.
(7) Tighten the universal joint to transfer case
bolts to 27 N·m (20 ft. lbs.) torque.
(8) Lower the vehicle.
Fig. 13 Reference Marks on Yokes
1 – REFERENCE MARKS REAR PROPELLER SHAFT
REMOVAL
(6) Remove the U-joint strap bolts at the pinion
(1) Shift the transmission and transfer case into
shaft yoke (Fig. 14).
Neutral.
(7) Remove bolts holding rear universal joint to
(2) Hoist and support vehicle on safety stands.
the transfer case yoke.
(3) Scribe alignment marks at the pinion shaft and
(8) Separate the rear universal joint from the
at each end of the propeller shaft. These marks will
transfer case yoke.
be used for installation reference.
(9) Push rear of propeller shaft upward to clear
(4) Remove the U-joint strap bolts at the pinion
transfer case yoke.
shaft yoke.
(10) Separate front universal joint from front axle.
(5) Pry open clamp holding the dust boot to propel-
(11) Separate propeller shaft from vehicle.
ler shaft yoke (Fig. 15).
(6) Slide the slip yoke off of the transmission/
INSTALLATION
transfer case output shaft and remove the propeller
(1) Position front propeller shaft under vehicle
shaft (Fig. 16).
with rear universal joint over the transfer case yoke.

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 XJ PROPELLER SHAFTS 3-9
REMOVAL AND INSTALLATION (Continued)
(4) Lower the vehicle.

Fig. 15 Dust Boot Clamp

Fig. 17 Crimping Dust Boot Clamp
1 – SLINGER
1 – SPECIAL TOOL C-4975–A
2 – BOOT
2 – SLINGER
3 – AWL
3 – BOOT
4 – TRANSFER CASE
4 – CLAMP

DISASSEMBLY AND ASSEMBLY

SINGLE CARDAN UNIVERSAL JOINT
DISASSEMBLY
Individual components of cardan universal joints
are not serviceable. If worn or leaking, they must be
replaced as an assembly.
(1) Remove the propeller shaft.
(2) Using a soft drift, tap the outside of the bear-
ing cap assembly to loosen snap ring.
(3) Remove snap rings from both sides of yoke
(Fig. 18).

Fig. 16 Rear Propeller Shaft

1 – CLAMP
2 – YOKE
3 – PROPELLER SHAFT
4 – AXLE YOKE
5 – CLAMP
6 – OUTPUT SHAFT
7 – BOOT

INSTALLATION
(1) Slide the slip yoke on the transmission/transfer
case output shaft. Align the installation reference
marks at the axle yoke and install the propeller shaft
(Fig. 16).
(2) Tighten the U-joint strap/clamp bolts at the
axle yoke to 19 N·m (14 ft. lbs.) torque. Fig. 18 Remove Snap Ring
(3) Crimp clamp to hold dust boot to propeller 1 – SNAP RING
shaft yoke (Fig. 17).

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 3 - 10 PROPELLER SHAFTS XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Set the yoke in an arbor press or vise with a
socket whose inside diameter is large enough to
receive the bearing cap positioned beneath the yoke.
(5) Position the yoke with the grease fitting, if
equipped, pointing up.
(6) Place a socket with an outside diameter
smaller than the upper bearing cap on the upper
bearing cap and press the cap through the yoke to
release the lower bearing cap (Fig. 19).

Fig. 20 Press Out Remaining Bearing

1 – CROSS
2 – BEARING CAP

Fig. 19 Press Out Bearing

1 – PRESS
2 – SOCKET

(7) If the bearing cap will not pull out of the yoke
by hand after pressing, tap the yoke ear near the
bearing cap to dislodge the cap.
(8) To remove the opposite bearing cap, turn the
yoke over and straighten the cross in the open hole.
Then, carefully press the end of the cross until the
remaining bearing cap can be removed (Fig. 20).

CAUTION: If the cross or bearing cap are not

straight during installation, the bearing cap will
score the walls of the yoke bore and damage can Fig. 21 Install Cross In Yoke
occur. 1 – CROSS
2 – YOKE

ASSEMBLY
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1 (3) Place a bearing cap over the trunnion and
or 2 grease to inside of yoke bores to aid in installa- align the cap with the yoke bore (Fig. 22). Keep the
tion. needle bearings upright in the bearing assembly. A
(2) Position the cross in the yoke with its lube fit- needle bearing lying at the bottom of the cap will
ting, if equipped, pointing up (Fig. 21). prevent proper assembly.

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 XJ PROPELLER SHAFTS 3 - 11
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 22 Install Bearing On Trunnion Fig. 23 Remove Snap Rings

1 – BEARING CAP
2 – TRUNNION

(4) Press the bearing cap into the yoke bore

enough to install a snap ring.
(5) Install a snap ring.
(6) Repeat Step 3 and Step 4to install the opposite
bearing cap. If the joint is stiff or binding, strike the
yoke with a soft hammer to seat the needle bearings.
(7) Add grease to lube fitting, if equipped.
(8) Install the propeller shaft.

DOUBLE CARDAN JOINT

DISASSEMBLY
Individual components of cardan universal joints
are not serviceable. If worn or leaking, they must be
replaced as an assembly.
(1) Remove the propeller shaft.
(2) Using a soft drift, tap the outside of the bear-
ing cap assembly to loosen snap ring. Fig. 24 Press Out Bearing
(3) Remove all the bearing cap snap rings (Fig. 23). (6) Grasp the protruding bearing by vise jaws. Tap
(4) Set the joint in an arbor press or vise with a the link yoke with a mallet and drift to dislodge the
socket whose inside diameter is large enough to bearing cap from the yoke (Fig. 25).
receive the bearing cap positioned beneath the link (7) Flip assembly and repeat Step 4, Step 5, and
yoke. Step 6 to remove the opposite bearing cap. This will
(5) Place a socket with an outside diameter then allow removal of the cross centering kit assem-
smaller than the upper bearing cap on the upper bly and spring (Fig. 26).
bearing cap and partially press one bearing cap from (8) Press the remaining bearing caps out the other
the outboard side of the link yoke enough to grasp end of the link yoke as described above to complete
the bearing cap with vise jaws (Fig. 24). Be sure to the disassembly.
remove grease fittings that interfere with removal.

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 3 - 12 PROPELLER SHAFTS XJ
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 27 Install Cross In Yoke

(3) Place a bearing cap over the trunnion and
align the cap with the yoke bore (Fig. 28). Keep the
Fig. 25 Remove Bearing From Yoke needle bearings upright in the bearing assembly. A
needle bearing lying at the bottom of the cap will
prevent proper assembly.

Fig. 26 Remove Centering Kit

ASSEMBLY
During assembly, ensure that the alignment Fig. 28 Install Bearing Cap
marks on the link yoke and propeller shaft
yoke are aligned. (4) Press the bearing cap into the yoke bore
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1 enough to install a snap ring (Fig. 29).
or 2 grease to inside of yoke bores to aid in installa- (5) Install a snap ring.
tion.
(2) Fit a cross into the propeller shaft yoke (Fig. 27).

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 XJ PROPELLER SHAFTS 3 - 13
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Fit the link yoke on the remaining two trun-
nions and press both bearing caps into place (Fig.
31).
(8) Install snap rings.

Fig. 29 Press In Bearing Cap

(6) Flip the propeller shaft yoke and install the
bearing cap onto the opposite trunnion. Install a Fig. 31 Install Link Yoke
snap ring (Fig. 30).
(9) Install the centering kit assembly inside the
link yoke making sure the spring is properly posi-
tioned (Fig. 32).

Fig. 30 Press In Bearing Cap

Fig. 32 Install Centering Kit

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 3 - 14 PROPELLER SHAFTS XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(10) Place two bearing caps on opposite trunnions
of the remaining cross. Fit the open trunnions into
the link yoke bores and the bearing caps into the
centering kit (Fig. 33).

Fig. 35 Seat Snap Rings In Groove

Fig. 33 Install Remaining Cross
(11) Press the remaining two bearing caps into
place and install snap rings (Fig. 34).

Fig. 36 Check Assembly

CLEANING AND INSPECTION
Fig. 34 Press In Bearing Cap PROPELLER SHAFT
(12) Tap the snap rings to allow them to seat into (1) Clean all universal joint bores with cleaning
the grooves (Fig. 35). solvent and a wire brush.
(13) Check for proper assembly. Flex the joint (2) Inspect the yokes for distortion, cracks, and
beyond center, it should snap over-center in both worn bearing cap bores.
directions when correctly assembled (Fig. 36).
(14) Install the propeller shaft.

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 XJ PROPELLER SHAFTS 3 - 15

ADJUSTMENTS
REAR AXLE PINION INPUT ANGLE
Adjust the rear axle pinion input angle on vehicles
equipped with leaf springs with tapered shims (Fig.
37). Install tapered shims between the springs and
axle pad to correct the angle. Refer to Group 2, Sus-
pension, for additional information.

Fig. 38 Front Axle Angle Adjustment

1 – SHIM
2 – SUSPENSION ARM

SPECIAL TOOLS
Fig. 37 Pinion Angle Adjustment at Leaf Springs
1 – WEDGE PROPELLER SHAFT

FRONT AXLE PINION INPUT ANGLE

Adjust the front axle pinion input angle at the
lower suspension arms with shims (Fig. 38). Adding
shims will decrease the pinion shaft angle but will
also increase the caster angle. The pinion shaft angle
has priority over the caster angle. Refer to Group 2,
Suspension, for additional information.

Inclinometer—7663
SPECIFICATIONS
PROPELLER SHAFTS AND U–JOINTS
DESCRIPTION TORQUE
Bolts, Transfer Case Yoke . . . . . 27 N·m (20 ft. lbs.)
Bolts, Axle Yoke . . . . . . . . . . . . . 19 N·m (14 ft. lbs.)
Bolts, Axle Yoke . . . . . . . . . . . . . 19 N·m (14 ft. lbs.)

Boot Clamp Installer—C-4975-A

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 3 - 16 TUBE, 181, AND 186 FBI AXLE XJ

TUBE, 181, AND 186 FBI AXLE

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . . 36

181 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 AXLE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . . 36
186 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 181 FBI PINION . . . . . . . . . . . . . . . . . . . . . . . . . . 36
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 186 FBI PINION . . . . . . . . . . . . . . . . . . . . . . . . . . 41
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . . 18 RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 19 STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . . 46
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 47
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 21 CLEANING AND INSPECTION
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . . . 21 CARDAN U-JOINT . . . . . . . . . . . . . . . . . . . . . . . . 47
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . 47
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . . 21 ADJUSTMENTS
SERVICE PROCEDURES 181 FBI PINION GEAR DEPTH. . . . . . . . . . . . . . . 48
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . 21 186 FBI PINION GEAR DEPTH. . . . . . . . . . . . . . . 50
REMOVAL AND INSTALLATION 181 FBI DIFFERENTIAL BEARING PRELOAD
DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . 22 AND GEAR BACKLASH . . . . . . . . . . . . . . . . . . 52
TUBE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 23 186 FBI DIFFERENTIAL BEARING PRELOAD
AXLE SHAFT—CARDAN U-JOINT . . . . . . . . . . . . 23 AND GEAR BACKLASH . . . . . . . . . . . . . . . . . . 56
181 FBI PINION SHAFT SEAL . . . . . . . . . . . . . . . 24 GEAR CONTACT PATTERN ANALYSIS . . . . . . . . 59
186 FBI PINION SHAFT SEAL . . . . . . . . . . . . . . . 26 SPECIFICATIONS
COLLAPSIBLE SPACER. . . . . . . . . . . . . . . . . . . . 27 181 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
HUB BEARING AND AXLE SHAFT . . . . . . . . . . . . 30 186 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
STEERING KNUCKLE AND BALL STUDS. . . . . . . 31 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AXLE BUSHING REPLACEMENT . . . . . . . . . . . . . 33 SPECIAL TOOLS
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 33 181 and 186 FBI AXLE . . . . . . . . . . . . . . . . . . . . . 61

DESCRIPTION AND OPERATION For vehicles with ABS brakes, the ABS wheel
speed sensors are attached to the knuckle assem-
181 FBI AXLE blies. The tone rings for the ABS system are pressed
onto the axle shaft. Do not damage ABS tone
DESCRIPTION wheel or the sensor when removing axle shafts.
The 181 Front Beam-design Iron (FBI) axle con- The stamped steel cover provides a means for
sists of a cast iron differential housing with axle inspection and servicing the differential.
shaft tubes extending from either side. The tubes are The 181 FBI axle has the assembly part number
pressed into the differential housing and welded. and gear ratio listed on a tag. The tag is attached to
The integral type housing, hypoid gear design has the housing cover by a cover bolt. Build date identi-
the centerline of the pinion set above the centerline fication codes are stamped on the cover side of the
of the ring gear. axle shaft tube.
The axle has a fitting for a vent hose used to The differential case is a one–piece design. The dif-
relieve internal pressure caused by lubricant vapor- ferential pinion mate shaft is retained with a roll
ization and internal expansion. pin. Differential bearing preload and ring gear back-
The axles are equipped with semi–floating axle lash is adjusted by the use of shims (select thick-
shafts, meaning that loads are supported by the hub ness). The shims are located between the differential
bearings. The axle shafts are retained by nuts at the bearing cones and case. Pinion bearing preload is set
hub bearings. The hub bearings are bolted to the and maintained by the use of shims (select thick-
steering knuckle at the outboard end of the axle tube ness).
yoke. The hub bearings are serviced as an assembly.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 17
DESCRIPTION AND OPERATION (Continued)
OPERATION The differential case is a one–piece design. The dif-
The axle receives power from the transfer case ferential pinion mate shaft is retained with a roll
through the front propeller shaft. The front propeller pin. Differential bearing preload and ring gear back-
shaft is connected to the pinion gear which rotates lash is adjusted by the use of shims (select thick-
the differential through the gear mesh with the ring ness). The shims are located between the differential
gear bolted to the differential case. The engine power bearing cones and case. Pinion bearing preload is set
is transmitted to the axle shafts through the pinion and maintained by the use of a collapsible spacer.
mate and side gears. The side gears are splined to
the axle shafts. OPERATION
The axle receives power from the transfer case
186 FBI AXLE through the front propeller shaft. The front propeller
shaft is connected to the pinion gear which rotates
DESCRIPTION the differential through the gear mesh with the ring
The 186 Front Beam-design Iron (FBI) axle con- gear bolted to the differential case. The engine power
sists of a cast iron differential housing with axle is transmitted to the axle shafts through the pinion
shaft tubes extending from either side. The tubes are mate and side gears. The side gears are splined to
pressed into the differential housing and welded. the axle shafts.
The integral type housing, hypoid gear design has
the centerline of the pinion set below the centerline LUBRICANT
of the ring gear.
The axle has a fitting for a vent hose used to DESCRIPTION
relieve internal pressure caused by lubricant vapor- A multi–purpose, hypoid gear lubricant which con-
ization and internal expansion. forms to the following specifications should be used.
The axles are equipped with semi–floating axle Mopart Hypoid Gear Lubricant conforms to all of
shafts, meaning that loads are supported by the hub these specifications.
bearings. The axle shafts are retained by nuts at the • The lubricant should have MIL–L–2105C and
hub bearings. The hub bearings are bolted to the API GL 5 quality specifications.
steering knuckle at the outboard end of the axle tube • Lubricant is a thermally stable SAE 80W–90
yoke. The hub bearings are serviced as an assembly. gear lubricant.
For vehicles with ABS brakes, the ABS wheel • Lubricant for axles intended for heavy-duty or
speed sensors are attached to the knuckle assem- trailer tow use is SAE 75W–140 SYNTHETIC gear
blies. The tone rings for the ABS system are pressed lubricant.
onto the axle shaft. Do not damage ABS tone The 181 FBI axle lubricant capacity is 1.2 L (2.5
wheel or the sensor when removing axle shafts. pts.). The 186 FBI axle lubricant capacity is 1.18 L
The stamped steel cover provides a means for (2.5 pts.).
inspection and servicing the differential.
The 186 FBI axle has the assembly part number CAUTION: If axle is submerged in water, lubricant
and gear ratio listed on a tag. The tag is attached to must be replaced immediately to avoid possible
the housing cover by a cover bolt. Build date identi- premature axle failure.
fication codes are stamped on the cover side of the
axle shaft tube.

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 3 - 18 TUBE, 181, AND 186 FBI AXLE XJ
DESCRIPTION AND OPERATION (Continued)

STANDARD DIFFERENTIAL
DESCRIPTION
The differential gear system divides the torque
between the axle shafts. It allows the axle shafts to
rotate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
and is positioned at a right angle to the axle shafts.

OPERATION
In operation, power flow occurs as follows:
• The pinion gear rotates the ring gear Fig. 1 Differential Operation—Straight Ahead Driving
• The ring gear (bolted to the differential case) 1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
rotates the case 100% OF CASE SPEED
2 – PINION GEAR
• The differential pinion gears (mounted on the
3 – SIDE GEAR
pinion mate shaft in the case) rotate the side gears
4 – PINION GEARS ROTATE WITH CASE
• The side gears (splined to the axle shafts) rotate
the shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
2). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster Fig. 2 Differential Operation—On Turns
speed. 1 – PINION GEARS ROTATE ON PINION SHAFT

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 19

DIAGNOSIS AND TESTING • Incorrect or contaminated lubricant.

• Overloading (excessive engine torque) or exceed-
GENERAL INFORMATION ing vehicle weight capacity.
Axle bearing problem conditions are usually caused • Incorrect clearance or backlash adjustment.
by: Axle component breakage is most often the result
• Insufficient or incorrect lubricant. of:
• Foreign matter/water contamination. • Severe overloading.
• Incorrect bearing preload torque adjustment. • Insufficient lubricant.
• Incorrect backlash. • Incorrect lubricant.
Axle gear problem conditions are usually the result • Improperly tightened components.
of: • Differential housing bores not square to each
• Insufficient lubrication. other.

DIAGNOSTIC CHART

Condition Possible Causes Correction

Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing. 2. Replace bearing.

Axle Shaft 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
Noise necessary.

2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.

3. End-play in pinion bearings. 3. Refer to pinion pre-load information and correct
as necessary.
4. Excessive gear backlash between 4. Check adjustment of the ring gear and pinion
the ring gear and pinion. backlash. Correct as necessary.
5. Improper adjustment of pinion gear 5. Adjust the pinion bearings pre-load.
bearings.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact surfaces. 7. Inspect and replace as necessary.

Axle Shaft 1. Misaligned axle tube. 1. Replace the broken shaft after correcting tube
Broke mis-alignment.

2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight

on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct erratic
clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect and repair
clutch as necessary.

Differential 1. Improper adjustment of the 1. Replace case and inspect gears and bearings for
Cracked differential bearings. further damage. Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and bearings for
further damage. Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and bearings for
further damage. Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and bearings for
further damage. Avoid erratic use of clutch.

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 3 - 20 TUBE, 181, AND 186 FBI AXLE XJ
DIAGNOSIS AND TESTING (Continued)

Condition Possible Causes Correction

Differential 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the
Gears Scored correct fluid type and quantity.

2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with the
correct fluid type and quantity.
3. Excessive spinning of one wheel/tire. 3. Replace scored gears. Inspect all gears, pinion
bores, and shaft for damage. Service as necessary.

Loss Of 1. Lubricant level too high. 1. Drain lubricant to the correct level.
Lubricant
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.

Axle 1. Lubricant level low. 1. Fill differential to correct level.

Overheating
2. Improper grade of lubricant. 2. Fill differential with the correct fluid type and
quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.

Gear Teeth 1. Overloading. 1. Replace gears. Examine other gears and bearings
Broke for possible damage.

2. Erratic clutch operation. 2. Replace gears and examine the remaining parts
for damage. Avoid erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine remaining parts for
damage.
4. Improper adjustments. 4. Replace gears and examine remaining parts for
damage. Ensure ring gear backlash is correct.

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and
quantity.
2. Improper ring gear and pinion 2. Check ring gear and pinion contact pattern.
adjustment.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring gear and
pinion.
4. Worn teeth on ring gear and/or 4. Replace ring gear and pinion.
pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace components
as necessary.
8. Loose differential bearing cap bolts. 8. Inspect differential components and replace as
necessary. Ensure that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 21
DIAGNOSIS AND TESTING (Continued)

GEAR NOISE VIBRATION

Axle gear noise can be caused by insufficient lubri- Vibration at the rear of the vehicle is usually
cant, incorrect backlash, tooth contact, worn/damaged caused by a:
gears, or the carrier housing not having the proper • Damaged drive shaft.
offset and squareness. • Missing drive shaft balance weight(s).
Gear noise usually happens at a specific speed • Worn or out–of–balance wheels.
range. The noise can also occur during a specific type • Loose wheel lug nuts.
of driving condition. These conditions are accelera- • Worn U–joint(s).
tion, deceleration, coast, or constant load. • Loose/broken springs.
When road testing, first warm-up the axle fluid by • Damaged axle shaft bearing(s).
driving the vehicle at least 5 miles and then acceler- • Loose pinion gear nut.
ate the vehicle to the speed range where the noise is • Excessive pinion yoke run out.
the greatest. Shift out-of-gear and coast through the • Bent axle shaft(s).
peak–noise range. If the noise stops or changes Check for loose or damaged front–end components
greatly: or engine/transmission mounts. These components
• Check for insufficient lubricant. can contribute to what appears to be a rear–end
• Incorrect ring gear backlash. vibration. Do not overlook engine accessories, brack-
• Gear damage. ets and drive belts.
Differential side gears and pinions can be checked All driveline components should be examined
by turning the vehicle. They usually do not cause before starting any repair.
noise during straight–ahead driving when the gears Refer to Group 22, Wheels and Tires, for additional
are unloaded. The side gears are loaded during vehi- vibration information.
cle turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise. DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
BEARING NOISE into gear (or the clutch engaged), can be caused by:
The axle shaft, differential and pinion bearings can • High engine idle speed.
all produce noise when worn or damaged. Bearing • Transmission shift operation.
noise can be either a whining, or a growling sound. • Loose engine/transmission/transfer case mounts.
Pinion bearings have a constant–pitch noise. This • Worn U–joints.
noise changes only with vehicle speed. Pinion bearing • Loose spring mounts.
noise will be higher pitched because it rotates at a • Loose pinion gear nut and yoke.
faster rate. Drive the vehicle and load the differen- • Excessive ring gear backlash.
tial. If bearing noise occurs, the rear pinion bearing • Excessive side gear to case clearance.
is the source of the noise. If the bearing noise is The source of a snap or a clunk noise can be deter-
heard during a coast, the front pinion bearing is the mined with the assistance of a helper. Raise the vehi-
source. cle on a hoist with the wheels free to rotate. Instruct
Worn or damaged differential bearings usually pro- the helper to shift the transmission into gear. Listen
duce a low pitch noise. Differential bearing noise is for the noise, a mechanics stethoscope is helpful in
similar to pinion bearing noise. The pitch of differen- isolating the source of a noise.
tial bearing noise is also constant and varies only
with vehicle speed.
Axle shaft bearings produce noise and vibration SERVICE PROCEDURES
when worn or damaged. The noise generally changes
when the bearings are loaded. Road test the vehicle. LUBRICANT CHANGE
Turn the vehicle sharply to the left and to the right. (1) Raise and support the vehicle.
This will load the bearings and change the noise (2) Remove the lubricant fill hole plug from the
level. Where axle bearing damage is slight, the noise differential housing cover.
is usually not noticeable at speeds above 30 mph. (3) Remove the differential housing cover and
drain the lubricant from the housing.
LOW SPEED KNOCK (4) Clean the housing cavity with a flushing oil,
Low speed knock is generally caused by a worn light engine oil or lint free cloth. Do not use water,
U–joint or by worn side–gear thrust washers. A worn steam, kerosene or gasoline for cleaning.
pinion shaft bore will also cause low speed knock. (5) Remove the sealant from the housing and cover
surfaces. Use solvent to clean the mating surfaces.

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 3 - 22 TUBE, 181, AND 186 FBI AXLE XJ
SERVICE PROCEDURES (Continued)
(6) Apply a bead of Mopart Silicone Rubber Seal- (7) Disconnect the vent hose from the axle shaft
ant, or equivalent, to the housing cover (Fig. 3). tube.
(8) Mark the propeller shaft and yoke for installa-
tion alignment reference.
(9) Remove propeller shaft.
(10) Disconnect stabilizer bar links at the axle.
(11) Disconnect shock absorbers from axle brack-
ets.
(12) Disconnect track bar.
(13) Disconnect the tie rod and drag link from the
steering knuckle. Refer to Group 2, Suspension, for
proper procedures.
(14) Disconnect the steering damper from the axle
bracket.
(15) Disconnect the upper and lower suspension
arms from the axle brackets.
(16) Lower the lifting device enough to remove the
axle. The coil springs will drop with the axle.
(17) Remove the coil springs from the axle.

INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
Fig. 3 Typical Housing Cover With Sealant
are not at their normal ride position, ride height and
1 – SEALING SURFACE
handling could be affected.
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35mm (1/4”)
(1) Install the springs and retainer clips. Tighten
the retainer bolts to 21 N·m (16 ft. lbs.) torque.
Install the housing cover within 5 minutes (2) Support the axle on a suitable lifting device
after applying the sealant. and position axle under the vehicle.
(7) Install the cover and any identification tag. (3) Raise the axle and align it with the spring
Tighten the cover bolts in a criss–cross pattern to 41 pads.
N·m (30 ft. lbs.) torque. (4) Position the upper and lower suspension arms
(8) Refill the differential with Mopart Hypoid in the axle brackets. Loosely install bolts and nuts to
Gear Lubricant, or equivalent, to bottom of the fill hold suspension arms to the axle brackets.
plug hole. Refer to the Lubricant Specifications in (5) Connect the vent hose to the axle shaft tube.
this group for the quantity necessary. (6) Connect the track bar to the axle bracket.
(9) Install the fill hole plug and lower the vehicle. Loosely install the bolt to hold the track bar to the
Tighten fill plug to 34 N·m (25 ft. lbs.). axle bracket.
(7) Install the shock absorbers and tighten the
bolts to 23 N·m (17 ft. lbs.) torque.
REMOVAL AND INSTALLATION (8) Install the stabilizer bar links to the axle
brackets. Tighten the nut to 95 N·m (70 ft. lbs.)
DRIVE AXLE ASSEMBLY torque.
(9) Install the drag link and tie rod to the steering
REMOVAL knuckles. Refer to Group 2, Suspension, for proper
(1) Raise and support the vehicle. procedures.
(2) Position a suitable lifting device under the (10) Install the steering damper to the axle
axle. bracket and tighten the nut to 75 N·m (55 ft. lbs.)
(3) Secure axle to device. torque.
(4) Remove the wheels and tires. (11) Install the brake rotors and calipers. Refer to
(5) Remove the brake rotors and calipers from the Group 5, Brakes, for the proper procedures.
axle. Refer to Group 5, Brakes, for proper procedures. (12) Connect the wheel speed sensor wiring har-
(6) Disconnect the wheel sensor wiring harness ness to the vehicle wiring harness, if necessary.
from the vehicle wiring harness, if necessary.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 23
REMOVAL AND INSTALLATION (Continued)
(13) Align the previously made marks on the pro- (4) Position the upper and lower suspension arms
peller shaft and the yoke. in the axle brackets. Loosely install bolts and nuts to
(14) Install the straps and bolts to hold the propel- hold suspension arms to the axle brackets.
ler shaft to the yoke. (5) Connect the track bar to the axle bracket.
(15) Check and fill axle lubricant. Refer to the Loosely install the bolt to hold the track bar to the
Lubricant Specifications in this group for the quan- axle bracket.
tity necessary. (6) Install the shock absorbers and tighten the
(16) Install the wheel and tire assemblies. bolts to 23 N·m (17 ft. lbs.) torque.
(17) Remove the lifting device from the axle and (7) Install the stabilizer bar links to the axle
lower the vehicle. brackets. Tighten the nut to 95 N·m (70 ft. lbs.)
(18) Tighten the upper suspension arm nuts to 75 torque.
N·m (55 ft. lbs.) torque. Tighten the lower suspension (8) Install the drag link and tie rod to the steering
arm nuts to 115 N·m (85 ft. lbs.) torque. knuckles. Refer to Group 2, Suspension, for proper
(19) Tighten the track bar bolt at the axle bracket procedures.
to 100 N·m (74 ft. lbs.) torque. (9) Install the steering damper to the axle bracket
(20) Check the front wheel alignment. and tighten the nut to 75 N·m (55 ft. lbs.) torque.
(10) Install the brake rotors and calipers. Refer to
TUBE AXLE ASSEMBLY Group 5, Brakes, for the proper procedures.
(11) Connect the wheel speed sensor wiring har-
REMOVAL ness to the vehicle wiring harness, if necessary.
(1) Raise and support the vehicle. (12) Install the wheel and tire assemblies.
(2) Position a suitable lifting device under the (13) Remove the lifting device from the axle and
axle. lower the vehicle.
(3) Secure axle to device. (14) Tighten the upper suspension arm nuts to 75
(4) Remove the wheels and tires. N·m (55 ft. lbs.) torque. Tighten the lower suspension
(5) Remove the brake rotors and calipers from the arm nuts to 115 N·m (85 ft. lbs.) torque.
axle. Refer to Group 5, Brakes, for proper procedures. (15) Tighten the track bar bolt at the axle bracket
(6) Disconnect the wheel sensor wiring harness to 100 N·m (74 ft. lbs.) torque.
from the vehicle wiring harness, if necessary. (16) Check the front wheel alignment.
(7) Disconnect stabilizer bar links at the axle.
(8) Disconnect shock absorbers from axle brackets. AXLE SHAFT—CARDAN U-JOINT
(9) Disconnect track bar. Single cardan U–joint components are not service-
(10) Disconnect the tie rod and drag link from the able. If defective, they must be replaced as a unit. If
steering knuckle. Refer to Group 2, Suspension, for the bearings, seals, spider, or bearing caps are dam-
proper procedures. aged or worn, replace the complete U–joint.
(11) Disconnect the steering damper from the axle
bracket. REMOVAL
(12) Disconnect the upper and lower suspension
arms from the axle brackets. CAUTION: Clamp only the narrow forged portion of
(13) Lower the lifting device enough to remove the the yoke in the vise. Also, to avoid distorting the
axle. The coil springs will drop with the axle. yoke, do not over tighten the vise jaws.
(14) Remove the coil springs from the axle.
(1) Remove axle shaft.
INSTALLATION (2) Remove the bearing cap retaining snap rings
(Fig. 4).
CAUTION: The weight of the vehicle must be sup- It can be helpful to saturate the bearing caps
ported by the springs before suspension arms and with penetrating oil prior to removal.
track bar fasteners can be tightened. If the springs (3) Locate a socket where the inside diameter is
are not at their normal ride position, ride height and larger in diameter than the bearing cap. Place the
handling could be affected. socket (receiver) against the yoke and around the
perimeter of the bearing cap to be removed.
(1) Install the springs and retainer clips. Tighten (4) Locate a socket where the outside diameter is
the retainer bolts to 21 N·m (16 ft. lbs.) torque. smaller in diameter than the bearing cap. Place the
(2) Support the axle on a suitable lifting device socket (driver) against the opposite bearing cap.
and position axle under the vehicle. (5) Position the yoke with the sockets in a vise
(3) Raise the axle and align it with the spring (Fig. 5).
pads.

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 3 - 24 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(6) Compress the vise jaws to force the bearing cap
into the larger socket (receiver).
(7) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(8) Repeat the above procedure for the remaining
bearing cap.
(9) Remove the remaining bearing cap, bearings,
seals and spider from the propeller shaft yoke.

INSTALLATION
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium–base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket wrench in a
vise.
(4) Compress the vise to force the bearing caps
Fig. 4 Axle Shaft Outer U–Joint into the yoke. Force the caps enough to install the
1 – SHAFT YOKE retaining clips.
2 – BEARING CAP (5) Install the bearing cap retaining clips.
3 – SNAP RINGS
(6) Install axle shaft.
4 – BEARING CAP
5 – SPINDLE YOKE
6 – BEARING
181 FBI PINION SHAFT SEAL
7 – BEARING CAP
8 – SNAP RINGS REMOVAL
9 – BEARING CAP (1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Using Holder 6958 to hold the pinion yoke,
remove the pinion nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pinion yoke (Fig. 6).
(10) Use a suitable pry tool or a slide hammer
mounted screw to remove the pinion shaft seal.

INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer C-3972-A
Fig. 5 Yoke Bearing Cap Removal and Handle C-4171 (Fig. 7).
1 – LARGE-DIAMETER SOCKET WRENCH (2) Install yoke on the pinion gear with Installer
2 – VISE
W-162–D, Cup 8109, and Holder 6958 (Fig. 8).
3 – SMALL-DIAMETER SOCKET WRENCH

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 25
REMOVAL AND INSTALLATION (Continued)

Fig. 6 Pinion Yoke Removal Fig. 8 Pinion Yoke Installation

1 – PINION YOKE
1 – SPECIAL TOOL C-3281
2 – AXLE HOUSING
2 – YOKE
3 – SPECIAL TOOL C-452

Fig. 7 Pinion Seal Installation

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A

CAUTION: Do not exceed the minimum tightening

torque when installing the pinion yoke retaining nut
at this point. Damage to the pinion bearings may
result.
Fig. 9 Check Pinion Rotation Torque
(3) Install the pinion washer and a new nut on the 1 – PINION YOKE
pinion gear. Tighten the nut only enough to 2 – INCH POUND TORQUE WRENCH
remove the shaft end play.
(4) Tighten pinion nut to 217 N·m (160 ft. lbs.). (7) Align the installation reference marks on the
(5) Rotate the pinion shaft using a (in. lbs.) torque propeller shaft and yoke, and install the propeller
wrench. Rotating torque should be equal to the read- shaft.
ing recorded during removal, plus an additional 0.56 (8) Check and fill the gear lubricant. Refer to the
N·m (5 in. lbs.) (Fig. 9). Lubricant Specifications for gear lubricant require-
(6) If the rotating torque is low, use Holder 6958 to ments.
hold the pinion yoke, and tighten the pinion shaft (9) Install the brake rotors and calipers. Refer to
nut in 6.8 N·m (5 ft. lbs.) increments until proper Group 5, Brakes, for proper procedures.
rotating torque is achieved. (10) Install wheel and tire assemblies.
(11) Lower the vehicle.

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 3 - 26 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

186 FBI PINION SHAFT SEAL

REMOVAL
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
Fig. 11 Pinion Seal Installation
torque wrench. Record the torque reading for instal-
1 – SPECIAL TOOL C-4171
lation reference. 2 – SPECIAL TOOL C-3972–A
(8) Using Holder 6958 to hold the pinion yoke,
remove the pinion nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pinion yoke (Fig. 10).

Fig. 12 Pinion Yoke Installation

1 – PINION YOKE
2 – AXLE HOUSING
Fig. 10 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281 (3) Install the pinion washer and a new nut on the
2 – YOKE
pinion gear. Tighten the nut only enough to
3 – SPECIAL TOOL C-452
remove the shaft end play.
(4) Rotate the pinion shaft using a (in. lbs.) torque
(10) Use a suitable pry tool or a slide hammer wrench. Rotating torque should be equal to the read-
mounted screw to remove the pinion seal. ing recorded during removal, plus an additional 0.56
N·m (5 in. lbs.) (Fig. 13).
INSTALLATION (5) If the rotating torque is low, use Holder 6958 to
(1) Apply a light coating of gear lubricant on the hold the pinion yoke (Fig. 14), and tighten the pinion
lip of pinion seal. Install seal with Installer C-3972-A shaft nut in 6.8 N·m (5 ft. lbs.) increments until
and Handle C-4171 (Fig. 11). proper rotating torque is achieved.
(2) Install yoke on the pinion gear with Installer
W-162–D, Cup 8109, and Holder 6958 (Fig. 12). CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
CAUTION: Do not exceed the minimum tightening torque, the collapsible spacer may have been dam-
torque when installing the pinion yoke retaining nut aged. Replace the collapsible spacer.
at this point. Damage to collapsible spacer or bear-
ings may result. (6) Align the installation reference marks on the
propeller shaft and yoke and install the propeller
shaft.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 27
REMOVAL AND INSTALLATION (Continued)
(8) Install the brake rotors and calipers. Refer to
Group 5, Brakes, for proper procedures.
(9) Install wheel and tire assemblies.
(10) Lower the vehicle.

COLLAPSIBLE SPACER
REMOVAL W/PINION INSTALLED
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Using Holder 6958 to hold the pinion yoke,
remove the pinion nut and washer.
Fig. 13 Check Pinion Rotation Torque (9) Use Remover C-452 and Wrench C-3281 to
1 – PINION YOKE remove the pinion yoke (Fig. 15).
2 – INCH POUND TORQUE WRENCH (10) Use a suitable pry tool or a slide hammer
mounted screw, remove the pinion seal.
(11) Remove the front pinion bearing using a pair
of suitable pick tools to pull the bearing straight off
the pinion gear shaft. It may be necessary to lightly
tap the end of the pinion gear with a rawhide or rub-
ber mallet if the bearing becomes bound on the pin-
ion shaft.
(12) Remove the collapsible spacer.

Fig. 14 Tightening Pinion Shaft Nut—Typical

1 – PINION FLANGE Fig. 15 Pinion Yoke Removal
2 – FRONT AXLE
1 – SPECIAL TOOL C-3281
3 – TOOL 6958
2 – YOKE
3 – SPECIAL TOOL C-452
(7) Check and fill the gear lubricant. Refer to the
Lubricant Specifications for gear lubricant require-
ments.

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 3 - 28 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL W/PINION REMOVED
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Remove differential assembly from axle hous-
ing.
(9) Using Holder 6958 to hold yoke, remove the
pinion nut and washer.
(10) Using Remover C-452 and Wrench C-3281,
remove the pinion yoke from pinion shaft (Fig. 15).
(11) Remove the pinion gear from housing (Fig.
16). Catch the pinion with your hand to prevent it
from falling and being damaged.
(12) Remove collapsible spacer from pinion shaft. Fig. 17 Collapsible Preload Spacer
1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING

(4) Apply a light coating of gear lubricant on the

lip of pinion seal. Install seal with Installer C-3972-A
and Handle C-4171 (Fig. 18), if necessary.

Fig. 16 Remove Pinion Gear

Fig. 18 Pinion Seal Installation
1 – RAWHIDE HAMMER
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A
INSTALLATION
(1) Install a new collapsible preload spacer on pin- (5) Install yoke with Installer W-162-D, Cup 8109,
ion shaft (Fig. 17). and holder 6958 (Fig. 19).
(2) If pinion gear was removed, install pinion gear (6) If the original pinion bearings are being used,
in housing. install differential assembly and axle shafts, if neces-
(3) Install pinion front bearing, if necessary. sary.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 29
REMOVAL AND INSTALLATION (Continued)

Fig. 19 Pinion Yoke Installation

1 – PINION YOKE
2 – AXLE HOUSING

NOTE: If new pinion bearings were installed, do not

install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque Fig. 20 Tightening Pinion Nut
are set. 1 – PINION FLANGE
2 – FRONT AXLE
(7) Install the pinion washer and a new nut on the 3 – TOOL 6958
pinion gear. Tighten the nut to 217 N·m (160 ft. lbs.)
minimum. Do not over-tighten. Maximum torque is
353 N·m (260 ft. lbs.).

CAUTION: Never loosen pinion gear nut to

decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded, a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.

(8) Using yoke holder 6958 and a torque wrench

set at 353 N·m (260 ft. lbs.), crush collapsible spacer
until bearing end play is taken up (Fig. 20). If more
than 353 N·m (260 ft. lbs.) is needed to begin to col-
lapse the spacer, the spacer is defective and must be
replaced.
(9) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.)
increments until the rotating torque is achieved.
Measure the rotating torque frequently to avoid over
crushing the collapsible spacer (Fig. 21).
(10) Check rotating torque with an inch pound
torque wrench (Fig. 21). The torque necessary to
rotate the pinion gear should be:
• Original Bearings — The reading recorded dur- Fig. 21 Check Pinion Gear Rotation Torque—Typical
ing removal, plus an additional 0.56 N·m (5 in. lbs.). 1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
• New Bearings — 1.5 to 4 N·m (15 to 35 in. lbs.).
(11) Install differential assembly and axle shafts, if
necessary. (13) Install brake rotors and calipers. Refer to
(12) Align marks made previously on yoke and Group 5, Brakes, for proper procedures.
propeller shaft and install propeller shaft.

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 3 - 30 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 22 Hub, Knuckle and Axle Shaft

1 – BRAKE SHIELD 6 – HUB AND BEARING ASSEMBLY
2 – WASHER 7 – STEERING KNUCKLE
3 – RETAINER 8 – BOLT
4 – COTTER PIN 9 – TONE WHEEL (ABS)
5 – NUT

(14) Add gear lubricant, if necessary. Refer to

Lubricant Specifications of this section for lubricant
requirements.
(15) Install wheel and tire assemblies.
(16) Lower vehicle.

HUB BEARING AND AXLE SHAFT

If the axle shaft and hub bearing are being
removed in order to service another component, the
axle shaft and hub bearing can be removed as an
assembly.

REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper and rotor. Refer to
Group 5, Brakes, for proper procedures. Fig. 23 Hub Bearing Bolts
(4) Remove ABS wheel speed sensor, if necessary. 1 – AXLE SHAFT
Refer to Group 5, Brakes, for proper procedures. 2 – AXLE
(5) Remove the cotter pin, nut retainer, and axle 3 – KNUCKLE
hub nut (Fig. 22), if necessary. 4 – HUB BEARING
(6) Remove the hub to knuckle bolts (Fig. 23).
(7) Remove the hub from the steering knuckle and (9) Remove the brake rotor shield from the hub
axle shaft, if necessary. bearing or knuckle (Fig. 22).
(8) Remove hub bearing and axle shaft assembly
(Fig. 24), or axle shaft from axle. Avoid damaging
the axle shaft oil seals in the axle housing.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 31
REMOVAL AND INSTALLATION (Continued)

STEERING KNUCKLE AND BALL STUDS

Ball stud service procedures below require removal
of the hub bearing and axle shaft. Removal and
installation of upper and lower ball studs require the
use of Tool Kit 6289.

KNUCKLE REMOVAL
(1) Remove hub bearing and axle shaft.
(2) Disconnect the tie-rod or drag link from the
steering knuckle arm. Refer to Group 2, Suspension,
for proper procedures.
(3) Remove the cotter pins from the upper and
lower ball studs.
(4) Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
mer to loosen knuckle from the ball studs. Remove
Fig. 24 Hub Bearing and Axle Assembly knuckle from ball studs (Fig. 25).
1 – AXLE
2 – KNUCKLE
3 – HUB BEARING
4 – AXLE SHAFT

INSTALLATION
(1) Thoroughly clean the axle shaft (Fig. 22) and
apply a thin film of Mopart Wheel Bearing Grease,
or equivalent, to the shaft splines, seal contact sur-
face, and hub bore.
(2) Install the brake rotor shield to the knuckle.
(3) Install the hub bearing and axle shaft assem-
bly, or axle shaft, into the housing and differential
side gears. Avoid damaging the axle shaft oil seals in
the axle housing.
(4) Install the hub bearing, if necessary.
(5) Install the hub to knuckle bolts and tighten to
102 N·m (75 ft. lbs.) torque.
(6) Install the hub washer and nut, if necessary.
Tighten the hub nut to 237 N·m (175 ft. lbs.) torque.
Install the nut retainer and a new cotter pin (Fig.
22).
(7) Install ABS wheel speed sensor, if necessary. Fig. 25 Steering Knuckle Removal/Installation
1 – AXLE YOKE
Refer to Group 5, Brakes, for proper procedures.
2 – UPPER BALL STUD
(8) Install the brake rotor and caliper. Refer to
3 – LOWER BALL STUD
Group 5, Brakes, for proper procedures. 4 – STEERING KNUCKLE
(9) Install the wheel and tire assembly.
(10) Remove support and lower the vehicle.

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 3 - 32 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 26 Upper Ball Stud Remove/Install

UPPER BALL STUD REPLACEMENT (2) Install and tighten the bottom retaining nut to
(1) Position tools as shown to remove and install 109 N·m (80 ft. lbs.) torque. Install new cotter pin.
ball stud (Fig. 26). (3) Install and tighten the top retaining nut to 101
N·m (75 ft. lbs.) torque. Install new cotter pin.
LOWER BALL STUD REPLACEMENT (4) Install the hub bearing and axle shaft.
(1) Position tools as shown to remove and install (5) Connect the tie-rod or drag link end to the
ball stud (Fig. 27). steering knuckle arm. Refer to Group 2, Suspension,
for proper procedures.
KNUCKLE INSTALLATION
(1) Position the steering knuckle on the ball studs.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 33
REMOVAL AND INSTALLATION (Continued)

Fig. 27 Lower Ball Stud Remove/Install

1 – SPECIAL TOOL 6289–12 4 – SPECIAL TOOL 4212F
2 – SPECIAL TOOL 6289–4 5 – SPECIAL TOOL 6289–1
3 – SPECIAL TOOL 4212F 6 – SPECIAL TOOL 6289–3

AXLE BUSHING REPLACEMENT

Refer to Group 2, Suspension, for the proper axle
bushing procedures.

DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove the lubricant fill hole plug from the
differential housing cover.
(3) Remove the differential housing cover and
allow fluid to drain.
(4) Remove hub bearings and axle shafts.
(5) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 28).
(6) Loosen the differential bearing cap bolts. Fig. 28 Bearing Cap Identification
(7) Position Spreader W–129–B, utilizing some 1 – INSTALLATION REFERENCE LETTERS
2 – INSTALLATION REFERENCE LETTERS
items from Adapter Kit 6987, with the tool dowel
pins seated in the locating holes (Fig. 29). Install the
holddown clamps and tighten the tool turnbuckle fin-
ger–tight.

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 3 - 34 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 30 Install Dial Indicator

1 – SPECIAL TOOL
C-3339
2 – DIAL INDICATOR
3 – LEVER ADAPTER
Fig. 29 Install Axle Housing Spreader 4 – SPECIAL TOOL
W-129–B
1 –
AXLE HOUSING
5 – SPECIAL TOOL
2 –
DOWEL C-3288–B
3 –
SAFETY HOLD DOWN
4 –
SPECIAL TOOL
W-129–B
5 – TURNBUCKLE

(8) Install a Guide Pin C-3288-B at the left side of

the differential housing. Attach Dial Indicator C-3339
to guide pin. Load the lever adapter against the
opposite side of the housing (Fig. 30) and zero the
indicator.

CAUTION: Do not spread over 0.50 mm (0.020 in). If

the housing is over-spread, it could be distorted or
damaged.

(9) Spread the housing enough to remove the dif-

ferential case from the housing. Measure the dis-
tance with the dial indicator (Fig. 31).
(10) Remove the dial indicator.
(11) While holding the differential case in position,
remove the differential bearing cap bolts and caps.
(12) Remove the differential, and the differential
preload shims for the 181FBI axles, from the hous-
ing. Ensure that the differential bearing cups remain
in position on the differential bearings (Fig. 32). Fig. 31 Spread Axle Housing
(13) Mark or tag the differential bearing cups, and 1 – SPECIAL TOOL
the differential preload shims for the 181FBI axles, C-3339
2 – SPECIAL TOOL
to indicate which side of the differential they were W-129–B
removed from.
(14) Remove spreader from housing.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 35
REMOVAL AND INSTALLATION (Continued)

Fig. 32 Differential Case Removal

1 – AXLE HOUSING
2 – DIFFERENTIAL CASE
3 – BEARING CUPS

INSTALLATION Fig. 33 Install Axle Housing Spreader

If replacement differential bearings or differential 1 –
AXLE HOUSING
case are being installed, differential side bearing 2 –
DOWEL
shim requirements may change. Refer to the Differ- 3 –
SAFETY HOLD DOWN
4 –
SPECIAL TOOL
ential Bearing Preload and Gear Backlash proce- W-129–B
dures in this section to determine the proper shim 5 – TURNBUCKLE
selection.
(1) Position Spreader W-129-B, utilizing some
items from Adapter Kit 6987, with the tool dowel
pins seated in the locating holes (Fig. 33). Install the
holddown clamps and tighten the tool turnbuckle fin-
ger–tight.
(2) Install a Guide Pin C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to guide pin. Load the lever adapter against the
opposite side of the housing (Fig. 30) and zero the
indicator.

CAUTION: Do not spread over 0.50 mm (0.020 in). If

the housing is over-spread, it could be distorted or
damaged.

(3) Spread the housing enough to install the case

in the housing. Measure the distance with the dial
indicator (Fig. 31). Fig. 34 Differential Bearing Cap Reference Letters
(4) Remove the dial indicator. 1 – INSTALLATION REFERENCE LETTERS
(5) Install differential case, and the differential 2 – INSTALLATION REFERENCE LETTERS
preload shims for the 181FBI axles, in the housing.
Ensure that the differential bearing cups remain in (8) Remove axle housing spreader.
position on the differential bearings. Tap the differ- (9) Tighten the bearing cap bolts to 61 N·m (45 ft.
ential case to ensure the bearings cups are fully lbs.) torque.
seated in the housing. (10) Install the hub bearings and axle shafts.
(6) Install the bearing caps at their original loca-
tions (Fig. 34).
(7) Loosely install differential bearing cap bolts.

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 3 - 36 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

DIFFERENTIAL SIDE BEARINGS

REMOVAL
(1) Remove differential case from axle housing.
(2) Remove the bearings from the differential case
with Puller/Press C-293-PA, C-293-39 Adapter
Blocks, and Plug SP-3289 (Fig. 35).

Fig. 36 Differential Side Bearing Installation

1 – SPECIAL TOOL C-3716–A
2 – SPECIAL TOOL C-4171

AXLE SHAFT OIL SEAL

REMOVAL
(1) Raise and support vehicle.
(2) Remove differential assembly.
(3) Remove the inner axle shaft seals with a pry
bay.

Fig. 35 Differential Bearing Removal INSTALLATION

1 – SPECIAL TOOL C–293–39 (1) Remove any sealer remaining from original
2 – BEARING seals.
3 – DIFFERENTIAL (2) Remove sealer from axle tube to housing junc-
4 – SPECIAL TOOL SP–3289 tion, if necessary.
5 – SPECIAL TOOL C–293–PA
(3) Install oil seals with Discs 8110 and Turn-
buckle 6797 (Fig. 37). Tighten tool until disc bottoms
INSTALLATION in housing.
If replacement differential side bearings or differ- (4) Install differential assembly.
ential case are being installed, differential side bear-
ing shim requirements may change. Refer to the 181 FBI PINION
Differential Bearing Preload and Gear Backlash pro- The ring gear and pinion are serviced as a matched
cedures in this section to determine the proper shim set. Do not replace the pinion without replacing the
selection. ring gear.
(1) Install differential side bearing shims onto dif-
ferential case hubs, for 186FBI axles. REMOVAL
(2) Using Installer C-3716-A and Handle C-4171, (1) Remove differential assembly from axle hous-
install differential side bearings (Fig. 36). ing.
(3) Install differential in axle housing. (2) Mark pinion yoke and propeller shaft for
installation alignment.
(3) Disconnect propeller shaft from pinion yoke.
Using suitable wire, tie propeller shaft to underbody.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 37
REMOVAL AND INSTALLATION (Continued)

Fig. 37 Axle Seal Installation Fig. 39 Remove Pinion Gear

1 – TURNBUCKLE 6797 1 – RAWHIDE HAMMER
2 – DISCS 8110

(7) Remove the front pinion bearing cup, bearing,

(4) Using Holder 6958 to hold yoke, remove the oil slinger, if equipped, and pinion seal with Remover
pinion nut and washer. D-147 and Handle C–4171 (Fig. 40).
(5) Using Remover C-452 and Holder C-3281,
remove the pinion yoke from pinion shaft (Fig. 38).

Fig. 38 Pinion Yoke Removal

1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452
Fig. 40 Front Bearing Cup Removal
1 – REMOVER
(6) Remove the pinion gear and preload shims
2 – HANDLE
from housing (Fig. 39). Catch the pinion with your
hand to prevent it from falling and being damaged.

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 3 - 38 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(8) Remove the rear pinion bearing cup and oil
slinger from the axle housing (Fig. 41). Use Remover
D-149 and Handle C–4171. Record the thickness of
the oil slinger for future reference.

Fig. 42 Rear Bearing Removal

1 – SPECIAL TOOL C-293–PA
2 – VISE
3 – ADAPTERS
Fig. 41 Rear Bearing Cup Removal 4 – DRIVE PINION GEAR SHAFT
1 – DRIVER
2 – HANDLE

(9) Remove the rear pinion bearing from the pin-

ion with Puller/Press C–293-PA and Adapters
C-293-39 (Fig. 42).
Place 4 adapter blocks so they do not damage
the bearing cage.
(10) Remove the pinion depth shim/oil baffle from
the pinion shaft. Record the thickness of the depth
shim/oil baffle.

INSTALLATION
NOTE: A pinion depth shim/oil baffle is placed
between the rear pinion bearing cone and pinion
gear. If the factory installed ring and pinion gears
are reused, the pinion depth shim/oil baffle should
not require replacement. Refer to Pinion Gear Depth
to select the proper thickness shim before installing
pinion gear.

(1) Install a new oil slinger of the same thickness

as the original into the rear pinion bearing bore of
the axle housing. Fig. 43 Rear Pinion Bearing Cup Installation
(2) Apply Mopart Door Ease, or equivalent, stick 1 – INSTALLER
2 – HANDLE
lubricant to outside surface of rear pinion bearing
cup. Install the bearing cup with Installer D-146 and
Handle C–4171 (Fig. 43). Verify cup is correctly
seated.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 39
REMOVAL AND INSTALLATION (Continued)
(3) Apply Mopart Door Ease, or equivalent, stick (6) Install the rear pinion bearing and pinion
lubricant to outside surface of front pinion bearing depth shim/oil baffle onto the pinion gear with
cup. Install the bearing cup with Installer D-144 and Installer W-262 and a shop press (Fig. 46).
Handle C–4171 (Fig. 44).

Fig. 44 Pinion Outer Bearing Cup Installation

1 – INSTALLER
2 – HANDLE

(4) Install front pinion bearing, and oil slinger, if Fig. 46 Rear Pinion Bearing Installation
equipped. 1 – PRESS
(5) Apply a light coating of gear lubricant on the 2 – INSTALLATION TOOL
lip of pinion seal. Install seal with Installer C-3972-A 3 – PINION DEPTH SHIM/OIL BAFFLE
and Handle C–4171 (Fig. 45). 4 – DRIVE PINION
5 – DRIVE PINION SHAFT REAR BEARING

(7) Install pinion bearing preload shims onto the

pinion gear (Fig. 47).
(8) Install pinion gear in housing.
(9) Install yoke with Installer W-162-B, Cup 8109,
and Holder 6958 (Fig. 48).

Fig. 45 Pinion Seal Installation

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A

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 3 - 40 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 47 Pinion Preload Shims–Typical

1 – PINION PRELOAD SHIMS 5 – WASHER
2 – FRONT BEARING CUP 6 – PINION NUT
3 – SLINGER 7 – PINION OIL SEAL
4 – PINION YOKE 8 – FRONT BEARING CONE

(10) Install the pinion washer and a new nut on

the pinion gear. Tighten the nut to 217 N·m (160 ft.
lbs.).

CAUTION: Never loosen pinion gear nut to

decrease pinion gear bearing rotating torque and
never exceed specified preload rotating torque.

(11) Check bearing preload torque with an inch

pound torque wrench (Fig. 49). The torque necessary
to rotate the pinion gear should be:
• Original Bearings—1 to 2 N·m (10 to 20 in. lbs.).
• New Bearings—1.5 to 4 N·m (15 to 35 in. lbs.).
(12) If rotating torque is above the desired
amount, remove the pinion yoke and increase the
preload shim pack thickness. Increasing the shim
Fig. 48 Pinion Yoke Installation pack thickness 0.025 mm (0.001 in.) will decrease the
1 – PINION YOKE rotating torque approximately 0.9 N·m (8 in. lbs.).
2 – AXLE HOUSING (13) Tighten pinion shaft nut in 6.8 N·m (5 ft. lbs.)
increments until the maximum tightening or desired
rotating torque is reached. Maximum tightening
torque is 271 N·m (200 ft.lbs.).

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 41
REMOVAL AND INSTALLATION (Continued)
(14) If the maximum tightening torque is reached (4) Using Holder 6958 to the hold yoke, remove
prior to achieving the desired rotating torque, remove the pinion nut and washer (Fig. 50).
the pinion yoke and decrease the thickness of the (5) Using Remover C–452 and Holder C-3281,
preload shim pack. Decreasing the shim pack thick- remove the pinion yoke from pinion shaft (Fig. 51).
ness 0.025 mm (0.001 in.) will increase the rotating
torque approximately 0.9 N·m (8 in. lbs.).

Fig. 50 Pinion Yoke Holder—Typical

1 – 1 in. PIPE
2 – PINION YOKE
3 – SPECIAL TOOL
6958
4 – LOWER CONTROL ARM

Fig. 49 Check Pinion Gear Rotating Torque

1 – in. lbs. TORQUE WRENCH
2 – PINION YOKE

(15) Install differential assembly.

186 FBI PINION

The ring gear and pinion are serviced as a matched
set. Do not replace the pinion without replacing the
ring gear.

REMOVAL
(1) Remove differential assembly from axle hous- Fig. 51 Pinion Yoke Removal
ing. 1 – SPECIAL TOOL C-3281
(2) Mark pinion yoke and propeller shaft for 2 – YOKE
3 – SPECIAL TOOL C-452
installation alignment.
(3) Disconnect propeller shaft from pinion yoke.
Using suitable wire, tie propeller shaft to underbody.

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 3 - 42 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(6) Remove the pinion and collapsible spacer from (8) Remove the rear pinion bearing cup from axle
housing (Fig. 52). Catch the pinion with your hand to housing (Fig. 54). Use Remover D-149 and Handle
prevent it from falling and being damaged. C–4171.

Fig. 54 Rear Bearing Cup Removal

1 – DRIVER
Fig. 52 Remove Pinion 2 – HANDLE
1 – RAWHIDE HAMMER
(9) Remove the collapsible preload spacer from
(7) Remove the front pinion bearing cup, bearing, pinion gear (Fig. 55).
oil slinger, if equipped, and pinion seal with Remover
C-4345 and Handle C–4171 (Fig. 53).

Fig. 55 Collapsible Spacer

1 – COLLAPSIBLE SPACER
2 – SHOULDER
Fig. 53 Front Bearing Cup Removal 3 – PINION
1 – REMOVER 4 – PINION DEPTH SHIM
2 – HANDLE 5 – REAR BEARING

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 43
REMOVAL AND INSTALLATION (Continued)
(10) Remove the rear pinion bearing from the pin-
ion with Puller/Press C–293-PA and Adapters
C–293–39 (Fig. 56).
Place 4 adapter blocks so they do not damage
the bearing cage.

Fig. 57 Rear Pinion Bearing Cup Installation

1 – INSTALLER
2 – HANDLE

Fig. 56 Inner Bearing Removal

1 – SPECIAL TOOL C-293–PA
2 – VISE
3 – ADAPTERS
4 – DRIVE PINION GEAR SHAFT

(11) Remove the depth shim/oil slinger from the

pinion shaft. Record the thickness of the depth shim/
oil slinger.

INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If the factory installed ring gear and pinion
are reused, the pinion depth shim/oil slinger should Fig. 58 Pinion Outer Bearing Cup Installation
not require replacement. Refer to Pinion Gear Depth 1 – INSTALLER
to select the proper thickness shim/oil slinger 2 – HANDLE
before installing pinion.

(1) Apply Mopart Door Ease, or equivalent, stick (3) Install front pinion bearing, and oil slinger, if
lubricant to outside surface of rear pinion bearing equipped.
cup. Install the bearing cup with Installer D-146 and (4) Apply a light coating of gear lubricant on the
Driver Handle C–4171 (Fig. 57). Verify cup is cor- lip of pinion seal. Install seal with Installer C-3972-A
rectly seated. and Handle C–4171 (Fig. 59).
(2) Apply Mopart Door Ease, or equivalent, stick (5) Install the rear pinion bearing and the pinion
lubricant to outside surface of front pinion bearing depth shim/oil slinger onto the pinion with Installer
cup. Install the bearing cup with Installer D-130 and W-262 and a shop press (Fig. 60).
Handle C–4171 (Fig. 58).

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 3 - 44 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 59 Pinion Seal Installation

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A

Fig. 61 Collapsible Preload Spacer

1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING

Fig. 60 Rear Pinion Bearing Installation

1 – PRESS
2 – INSTALLATION TOOL
3 – PINION DEPTH SHIM/OIL BAFFLE
4 – DRIVE PINION
5 – DRIVE PINION SHAFT REAR BEARING

Fig. 62 Pinion Yoke Installation

(6) Install a new collapsible preload spacer on pin-
1 – PINION YOKE
ion shaft and install pinion in housing (Fig. 61). 2 – AXLE HOUSING
(7) Install yoke with Installer W-162-B, Cup 8109,
and Holder 6958 (Fig. 62).
(8) Install the pinion washer and a new nut onto specified preload torque. If preload torque is
the pinion. Tighten the nut to 216 N·m (160 ft. lbs.) exceeded a new collapsible spacer must be
minimum. Do not over–tighten. Maximum torque installed. The torque sequence will then have to be
is 352 N·m (260 ft. lbs.). repeated.

CAUTION: Never loosen the pinion nut to decrease (9) Using Holder 6958 and torque wrench (set at
pinion bearing rotating torque and never exceed 352 N·m (260 ft. lbs.)), crush collapsible spacer until

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 45
REMOVAL AND INSTALLATION (Continued)
bearing end play is taken up (Fig. 63). If more than
353 N·m (260 ft. lbs.) is needed to begin to collapse
the spacer, the spacer is defective and must be
replaced.
(10) Slowly tighten the nut in 6.8 N·m (5 ft. lb.)
increments until the rotating torque is achieved.
Measure the rotating torque frequently to avoid over
crushing the collapsible spacer (Fig. 64).

Fig. 64 Check Pinion Rotation Torque

1 – in. lbs. TORQUE WRENCH
2 – PINION YOKE

(4) Using a soft hammer, drive ring gear from dif-

ferential case (Fig. 65).

Fig. 63 Tightening Pinion Nut—Typical

1 – PINION FLANGE
2 – FRONT AXLE
3 – TOOL 6958

(11) Check bearing rotating torque with an inch

pound torque wrench (Fig. 64). The torque necessary
to rotate the pinion should be:
• Original Bearings — 1 to 2 N·m (10 to 20 in.
lbs.).
• New Bearings — 1.5 to 4 N·m (15 to 35 in. lbs.).
(12) Install differential assembly.

RING GEAR
NOTE: The ring gear and pinion are serviced as a Fig. 65 Ring Gear Removal
1 – CASE
matched set. Do not replace the ring gear without
2 – RING GEAR
replacing the pinion.
3 – RAWHIDE HAMMER

REMOVAL INSTALLATION
(1) Remove differential from axle housing.
(2) Place differential case in a suitable vise with CAUTION: Do not reuse the bolts that held the ring
soft metal jaw protectors. (Fig. 65) gear to the differential case. The bolts can fracture
(3) Remove bolts holding ring gear to differential causing extensive damage.
case.

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 3 - 46 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(1) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(2) Invert the differential case in the vise.
(3) Install new ring gear bolts and alternately
tighten to 95–122 N·m (70–90 ft. lbs.) torque (Fig.
66).
(4) Install differential in axle housing and verify
gear mesh and contact pattern.

Fig. 67 Mate Shaft Roll Pin Removal

1 – DRIFT
2 – LOCKPIN
3 – MATE SHAFT

Fig. 66 Ring Gear Bolt Installation

1 – TORQUE WRENCH
2 – RING GEAR BOLT
3 – RING GEAR
4 – CASE

DISASSEMBLY AND ASSEMBLY

STANDARD DIFFERENTIAL
DISASSEMBLY
(1) Remove the ring gear.
(2) Using a suitable roll pin punch, drive out the
roll pin holding pinion gear mate shaft in the differ-
ential case (Fig. 67).
(3) Remove the pinion gear mate shaft from the
differential case and the pinion mate gears.
(4) Rotate differential side gears and remove the Fig. 68 Pinion Mate Gear Removal
pinion mate gears and thrust washers (Fig. 68). 1 – THRUST WASHER
(5) Remove the differential side gears and thrust 2 – SIDE GEAR
washers. 3 – PINION MATE GEAR

ASSEMBLY (2) Install the pinion mate gears and thrust wash-
(1) Install the differential side gears and thrust ers.
washers.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 47
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Install the pinion gear mate shaft. Align the
roll pin holes in shaft and the differential case.
(4) Install the roll pin to hold the pinion mate
shaft in the differential case (Fig. 69).

Fig. 70 Typical Housing Cover With Sealant

1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35mm (1/4”)

Fig. 69 Mate Shaft Roll Pin Installation

1 – PUNCH CLEANING AND INSPECTION
2 – PINION MATE SHAFT
3 – MATE SHAFT LOCKPIN CARDAN U-JOINT
Clean all the U–joint yoke bores with cleaning sol-
(5) Install the ring gear. vent and a wire brush. Ensure that all the rust and
(6) Lubricate all differential components with foreign matter are removed from the bores.
hypoid gear lubricant. Inspect the yokes for distortion, cracks and worn
bearing cap bores.
FINAL ASSEMBLY Replace the complete U–joint if any of the compo-
(1) Scrape the residual sealant from the housing nents are defective.
and cover mating surfaces. Clean the mating surfaces
with mineral spirits. Apply a bead of Mopart Silicone AXLE COMPONENTS
Rubber Sealant, or equivalent, on the housing cover Wash differential components with cleaning solvent
(Fig. 70). and dry with compressed air. Do not steam clean
Install the housing cover within 5 minutes the differential components.
after applying the sealant. Wash bearings with solvent and towel dry, or dry
(2) Install the cover on the differential with the with compressed air. DO NOT spin bearings with
attaching bolts. Install the identification tag. Tighten compressed air. Cup and bearing must be
the cover bolts to 41 N·m (30 ft. lbs.) torque. replaced as matched sets only.
Clean axle shaft tubes and oil channels in housing.
CAUTION: Overfilling the differential can result in Inspect for;
lubricant foaming and overheating. • Smooth appearance with no broken/dented sur-
faces on the bearing rollers or the roller contact sur-
(3) Refill the differential housing with gear lubri- faces.
cant. Refer to the Lubricant Specifications section of • Bearing cups must not be distorted or cracked.
this group for the gear lubricant requirements. • Machined surfaces should be smooth and with-
(4) Install the fill hole plug. out any raised edges.
• Raised metal on shoulders of cup bores should
be removed with a hand stone.

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 3 - 48 TUBE, 181, AND 186 FBI AXLE XJ
CLEANING AND INSPECTION (Continued)
• Wear and damage to pinion gear mate shaft, Compensation for pinion depth variance is
pinion gears, side gears and thrust washers. Replace achieved with a select shim/oil baffle. The shims are
as a matched set only. placed between the rear pinion bearing and the pin-
• Ring and pinion gear for worn and chipped ion gear head (Fig. 72).
teeth.
• Ring gear for damaged bolt threads. Replaced as
a matched set only.
• Pinion yoke for cracks, worn splines, pitted
areas, and a rough/corroded seal contact surface.
Repair or replace as necessary.
• Preload shims for damage and distortion. Install
new shims, if necessary.

ADJUSTMENTS
181 FBI PINION GEAR DEPTH
GENERAL INFORMATION
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
71). A plus (+) number, minus (–) number or zero (0)
is etched into the face of the pinion gear. This num-
ber is the amount (in thousandths of an inch) the
depth varies from the standard depth setting of a
pinion etched with a (0). The standard setting from
the center line of the ring gear to the back face of the Fig. 72 Shim Locations
1 – PINION GEAR DEPTH SHIM/OIL BAFFLE
pinion is 92.08 mm (3.625 in.). The standard depth
2 – DIFFERENTIAL BEARING SHIM
provides the best gear tooth contact pattern. Refer to
Backlash and Contact Pattern Analysis paragraph in
this section for additional information. If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract this number from the
thickness of the original depth shim/oil slinger to
compensate for the difference in the depth variances.
Refer to the Depth Variance chart.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus the amount needed.
Note the etched number on the face of the pinion
gear head (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
Fig. 71 Pinion Gear ID Numbers
1 – PRODUCTION NUMBERS
2 – DRIVE PINION GEAR DEPTH VARIANCE
3 – GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 49
ADJUSTMENTS (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion Replacement Pinion Gear Depth Variance
Gear Depth
Variance −4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008

PINION DEPTH MEASUREMENT AND ADJUSTMENT (2) Insert assembled height gauge components,
Measurements are taken with pinion bearing cups rear bearing and screw into axle housing through
and pinion bearings installed in the axle housing. pinion bearing cups (Fig. 74).
Take measurements with Pinion Gauge Set and Dial (3) Install front pinion bearing and Cone-nut 6740
Indicator C-3339 (Fig. 73). hand tight (Fig. 73).

Fig. 74 Pinion Height Block—Typical

1 – PINION BLOCK
2 – PINION HEIGHT BLOCK

(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-

Fig. 73 Pinion Gear Depth Gauge Tools—Typical tion in axle housing side bearing cradles (Fig. 75).
1 – DIAL INDICATOR Install differential bearing caps on Arbor Discs and
2 – ARBOR tighten cap bolts to 41 N·m (30 ft. lbs.).
3 – PINION HEIGHT BLOCK
4 – CONE NOTE: Arbor Discs 6732 has different step diame-
5 – SCREW ters to fit other axles. Choose proper step for axle
6 – PINION BLOCK being serviced.
7 – SCOOTER BLOCK
8 – ARBOR DISC (5) Assemble Dial Indicator C-3339 into Scooter
Block D-115-2 and secure set screw.
(1) Assemble Pinion Height Block 6739, Pinion (6) Place Scooter Block/Dial Indicator in position
Block 6733, and rear pinion bearing onto Screw 6741 in axle housing so dial probe and scooter block are
(Fig. 73). flush against the rearward surface of the pinion

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 3 - 50 TUBE, 181, AND 186 FBI AXLE XJ
ADJUSTMENTS (Continued)

Fig. 75 Gauge Tools In Housing—Typical

Fig. 76 Pinion Gear Depth Measurement—Typical
1 – ARBOR DISC
1 – ARBOR
2 – PINION BLOCK
2 – SCOOTER BLOCK
3 – ARBOR
3 – DIAL INDICATOR
4 – PINION HEIGHT BLOCK

pinion is 92.08 mm (3.625 in.). The standard depth

height block (Fig. 73). Hold scooter block in place and
provides the best gear tooth contact pattern. Refer to
zero the dial indicator face to the pointer. Tighten
Backlash and Contact Pattern Analysis paragraph in
dial indicator face lock screw.
this section for additional information.
(7) With scooter block still in position against the
pinion height block, slowly slide the dial indicator
probe over the edge of the pinion height block.
(8) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 76). When the dial probe contacts the arbor bar,
the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not
turn dial face. Continue moving the dial probe to the
crest of the arbor bar and record the highest reading.
If the dial indicator can not achieve the zero reading,
the rear bearing cup or the pinion depth gauge set is
not installed correctly.
(9) Select a shim/oil baffle equal to the dial indica-
tor reading plus the pinion depth variance number
etched in the face of the pinion (Fig. 71). For exam- Fig. 77 Pinion Gear ID Numbers
ple, if the depth variance is –2, add +0.002 in. to the 1 – PRODUCTION NUMBERS
dial indicator reading. 2 – DRIVE PINION GEAR DEPTH VARIANCE
3 – GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
186 FBI PINION GEAR DEPTH
GENERAL INFORMATION Compensation for pinion depth variance is
Ring gear and pinion are supplied as matched sets achieved with a select shim/oil slinger. The shim/oil
only. The identifying numbers for the ring gear and slinger is placed between the rear pinion bearing and
pinion are etched into the face of each gear (Fig. 77). the pinion gear head (Fig. 78).
A plus (+) number, minus (–) number or zero (0) is If a new gear set is being installed, note the depth
etched into the face of the pinion gear head. This variance etched into both the original and replace-
number is the amount (in thousandths of an inch) ment pinion. Add or subtract the thickness of the
the depth varies from the standard depth setting of a original depth shims to compensate for the difference
pinion etched with a (0). The standard setting from in the depth variances. Refer to the Depth Variance
the center line of the ring gear to the back face of the chart.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 51
ADJUSTMENTS (Continued)
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken with pinion bearing cups
and pinion bearings installed in the axle housing.
Take measurements with Pinion Gauge Set 6774 and
Dial Indicator C-3339 (Fig. 79).

Fig. 78 Shim Locations

1 – PINION GEAR DEPTH SHIM/OIL BAFFLE
2 – DIFFERENTIAL BEARING SHIM

Note where Old and New Pinion Marking columns

intersect. Intersecting figure represents plus or Fig. 79 Pinion Gear Depth Gauge Tools—Typical
minus the amount needed. 1 – DIAL INDICATOR
Note the etched number on the face of the drive 2 – ARBOR
pinion (–1, –2, 0, +1, +2, etc.). The numbers repre- 3 – PINION HEIGHT BLOCK
sent thousands of an inch deviation from the stan- 4 – CONE
5 – SCREW
dard. If the number is negative, add that value to the
6 – PINION BLOCK
required thickness of the depth shim/oil slinger. If 7 – SCOOTER BLOCK
the number is positive, subtract that value from the 8 – ARBOR DISC
thickness of the depth shim/oil slinger. If the number
is 0 no change is necessary.

PINION GEAR DEPTH VARIANCE

Original Pinion Replacement Pinion Gear Depth Variance
Gear Depth
Variance −4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008

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 3 - 52 TUBE, 181, AND 186 FBI AXLE XJ
ADJUSTMENTS (Continued)
(1) Assemble Pinion Height Block 6739, Pinion
Block 6733, and rear pinion bearing onto Screw 6741
(Fig. 79).
(2) Insert assembled height gauge components,
rear bearing and screw into axle housing through
pinion bearing cups (Fig. 80).
(3) Install front pinion bearing and Cone-nut 6740
hand tight (Fig. 79).

Fig. 81 Gauge Tools In Housing—Typical

1 – ARBOR DISC
2 – PINION BLOCK
3 – ARBOR
4 – PINION HEIGHT BLOCK

If the dial indicator can not achieve the zero reading,

the rear bearing cup or the pinion depth gauge set is
not installed correctly.
Fig. 80 Pinion Height Block—Typical (9) Select a shim/oil slinger equal to the dial indi-
1 – PINION BLOCK cator reading plus the drive pinion depth variance
2 – PINION HEIGHT BLOCK number etched in the face of the pinion (Fig. 77). For
example, if the depth variance is –2, add +0.002 in.
(4) Place Arbor Disc 6732 on Arbor D-115-3 in posi- to the dial indicator reading.
tion in axle housing side bearing cradles (Fig. 81).
Install differential bearing caps on Arbor Discs and
tighten cap bolts to 41 N·m (30 ft. lbs.).

NOTE: Arbor Discs 6732 has different step diame-

ters to fit other axles. Choose proper step for axle
being serviced.

(5) Assemble Dial Indicator C-3339 into Scooter

Block D-115-2 and secure set screw.
(6) Place Scooter Block/Dial Indicator in position
in axle housing so dial probe and scooter block are
flush against the rearward surface of the pinion
height block (Fig. 79). Hold scooter block in place and
zero the dial indicator face to the pointer. Tighten
dial indicator face lock screw.
(7) With scooter block still in position against the Fig. 82 Pinion Gear Depth Measurement—Typical
pinion height block, slowly slide the dial indicator 1 – ARBOR
2 – SCOOTER BLOCK
probe over the edge of the pinion height block.
3 – DIAL INDICATOR
(8) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block 181 FBI DIFFERENTIAL BEARING PRELOAD
(Fig. 82). When the dial probe contacts the arbor bar, AND GEAR BACKLASH
the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not
INTRODUCTION
turn dial face. Continue moving the dial probe to the
Differential side bearing preload and gear backlash
crest of the arbor bar and record the highest reading.
is achieved by selective shims positioned behind the

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 53
ADJUSTMENTS (Continued)
differential side bearing cones. The proper shim (2) Remove factory installed shims from differen-
thickness can be determined using slip-fit dummy tial case.
bearings D-348 in place of the differential side bear- (3) Install ring gear on differential case and
ings and a dial indicator C-3339. Before proceeding tighten bolts to specification.
with the differential bearing preload and gear back- (4) Install dummy side bearings D-348 on differen-
lash measurements, measure the pinion gear depth tial case.
and prepare the pinion for installation. Establishing (5) Install differential case in axle housing.
proper pinion gear depth is essential to establishing (6) Install the marked bearing caps in their correct
gear backlash and tooth contact patterns. After the positions. Install and snug the bolts (Fig. 84).
overall shim thickness to take up differential side
play is measured, the pinion is installed, and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading and the preload specification added together.
The gear backlash measurement determines the
thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the dif-
ferential (Fig. 83). Differential shim measurements
are performed with axle spreader W-129-B removed.

Fig. 84 Tighten Bolts Holding Bearing Caps

1 – BEARING CAP
2 – AXLE HOUSING
3 – DIFFERENTIAL CASE

(7) Using a dead-blow type mallet, seat the differ-

ential dummy bearings to each side of the axle hous-
ing (Fig. 85) and (Fig. 86).

Fig. 83 Axle Adjustment Shim Locations

1 – PINION GEAR DEPTH SHIM/OIL BAFFLE
2 – DIFFERENTIAL BEARING SHIM

SHIM SELECTION
Fig. 85 Seat Pinion Gear Side Differential Dummy
NOTE: It is difficult to salvage the differential side Side Bearing
bearings during the removal procedure. Install 1 – MALLET
replacement bearings if necessary. 2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
(1) Remove differential side bearings from differ-
ential case. (8) Thread guide stud C-3288-B into rear cover
bolt hole below ring gear (Fig. 87).

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 3 - 54 TUBE, 181, AND 186 FBI AXLE XJ
ADJUSTMENTS (Continued)

Fig. 86 Seat Ring Gear Side Differential Dummy Fig. 88 Hold Differential Case and Zero Dial
Side Bearing Indicator
1 – AXLE HOUSING 1 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 – MALLET 2 – SPECIAL TOOL C-3288–B
3 – DIFFERENTIAL CASE 3 – SPECIAL TOOL C-3339
4 – ZERO DIAL INDICATOR FACE

(9) Attach a dial indicator C-3339 to guide stud.

Position the dial indicator plunger on a flat surface (12) Push and hold differential case to ring gear
between the ring gear bolt heads (Fig. 87). side of the axle housing (Fig. 89).
(13) Record dial indicator reading (Fig. 89).

Fig. 89 Hold Differential Case and Read Dial

Indicator
1 – READ DIAL INDICATOR
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 – AXLE HOUSING
Fig. 87 Differential Side play Measurement
1 – DIFFERENTIAL CASE (14) Add 0.008 in. (0.2 mm) to the zero end play
2 – AXLE HOUSING total. This new total represents the thickness of
3 – SPECIAL TOOL C-3288–B shims to compress, or preload the new bearings when
4 – SPECIAL TOOL C-3339
the differential is installed.
(15) Rotate dial indicator out of the way on the
(10) Push and hold differential case to pinion gear guide stud.
side of axle housing (Fig. 88). (16) Remove differential case and dummy bearings
(11) Zero dial indicator face to pointer (Fig. 88). from axle housing.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 55
ADJUSTMENTS (Continued)
(17) Install the pinion gear in axle housing. Install
the pinion yoke and establish the correct pinion
rotating torque.
(18) Install differential case and dummy bearings
D-348 in axle housing (without shims), install bear-
ing caps and tighten bolts snug.
(19) Seat ring gear side dummy bearing (Fig. 86).
(20) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads. (Fig. 87).
(21) Push and hold differential case toward pinion
gear (Fig. 90).
(22) Zero dial indicator face to pointer (Fig. 90).

Fig. 91 Hold Differential Case and Read Dial

Indicator
1 – READ DIAL INDICATOR
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 – PINION GEAR
4 – AXLE HOUSING
5 – DIFFERENTIAL CASE

(31) Install spreader W-129-B, utilizing some items

from Adapter Set 6987, on axle housing and spread
axle opening enough to receive differential case.
(32) Install differential case into the axle housing.
Fig. 90 Hold Differential Case and Zero Dial (33) Remove spreader from axle housing.
Indicator (34) Rotate the differential case several times to
1 – ZERO DIAL INDICATOR FACE seat the side bearings.
2 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE (35) Position the indicator plunger against a ring
3 – PINION GEAR gear tooth (Fig. 92).
4 – AXLE HOUSING (36) Push and hold ring gear upward while not
5 – DIFFERENTIAL CASE allowing the pinion gear to rotate.
(37) Zero dial indicator face to pointer.
(23) Push and hold differential case to ring gear (38) Push and hold ring gear downward while not
side of the axle housing (Fig. 91). allowing the pinion gear to rotate. Dial indicator
(24) Record dial indicator reading (Fig. 91). reading should be between 0.12 mm (0.005 in.) and
(25) Subtract 0.002 in. (0.05 mm) from the dial 0.20 mm (0.008 in.). If backlash is not within specifi-
indicator reading to compensate for backlash between cations transfer the necessary amount of shim thick-
ring and pinion gears. This total is the thickness ness from one side of the axle housing to the other
shim required to achieve proper backlash. (Fig. 93).
(26) Subtract the backlash shim thickness from (39) Verify differential case and ring gear runout
the total preload shim thickness. The remainder is by measuring ring to pinion gear backlash at eight
the shim thickness required on the pinion side of the locations around the ring gear. Readings should not
axle housing. vary more than 0.05 mm (0.002 in.). If readings vary
(27) Rotate dial indicator out of the way on guide more than specified, the ring gear or the differential
stud. case is defective.
(28) Remove differential case and dummy bearings After the proper backlash is achieved, perform
from axle housing. Gear Contact Pattern Analysis procedure.
(29) Install the selected side bearing shims onto
the differential case hubs.
(30) Install side bearings and cups on differential
case.

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 3 - 56 TUBE, 181, AND 186 FBI AXLE XJ
ADJUSTMENTS (Continued)
proper pinion gear depth is essential to establishing
gear backlash and tooth contact patterns. After the
overall shim thickness to take up differential side
play is measured, the pinion is installed, and the
gear backlash shim thickness is measured. The over-
all shim thickness is the total of the dial indicator
reading and the preload specification added together.
The gear backlash measurement determines the
thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the dif-
ferential (Fig. 94). Differential shim measurements
are performed with axle spreader W-129-B removed.

Fig. 92 Ring Gear Backlash Measurement

1 – DIAL INDICATOR

Fig. 94 Axle Adjustment Shim Locations

1 – PINION GEAR DEPTH SHIM/OIL BAFFLE
2 – DIFFERENTIAL BEARING SHIM

SHIM SELECTION
Fig. 93 Backlash Shim Adjustment
NOTE: It is difficult to salvage the differential side
186 FBI DIFFERENTIAL BEARING PRELOAD
bearings during the removal procedure. Install
AND GEAR BACKLASH replacement bearings if necessary.

INTRODUCTION (1) Remove differential side bearings from differ-

Differential side bearing preload and gear backlash ential case.
is achieved by selective shims positioned behind the (2) Remove factory installed shims from differen-
differential side bearing cones. The proper shim tial case.
thickness can be determined using slip-fit dummy (3) Install ring gear on differential case and
bearings D-348 in place of the differential side bear- tighten bolts to specification.
ings and a dial indicator C-3339. Before proceeding (4) Install dummy side bearings D-348 on differen-
with the differential bearing preload and gear back- tial case.
lash measurements, measure the pinion gear depth (5) Install differential case in axle housing.
and prepare the pinion for installation. Establishing

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 57
ADJUSTMENTS (Continued)
(6) Install the marked bearing caps in their correct
positions. Install and snug the bolts (Fig. 95).

Fig. 97 Seat Ring Gear Side Differential Dummy

Side Bearing
Fig. 95 Tighten Bolts Holding Bearing Caps 1 – AXLE HOUSING
1 – BEARING CAP 2 – MALLET
2 – AXLE HOUSING 3 – DIFFERENTIAL CASE
3 – DIFFERENTIAL CASE

(7) Using a dead-blow type mallet, seat the differ-

ential dummy bearings to each side of the axle hous-
ing (Fig. 96) and (Fig. 97).

Fig. 96 Seat Pinion Gear Side Differential Dummy

Side Bearing
1 – MALLET
Fig. 98 Differential Side play Measurement
2 – AXLE HOUSING 1 – DIFFERENTIAL CASE
3 – DIFFERENTIAL CASE 2 – AXLE HOUSING
3 – SPECIAL TOOL C-3288–B
4 – SPECIAL TOOL C-3339
(8) Thread guide stud C-3288-B into rear cover
bolt hole below ring gear (Fig. 98).
(12) Push and hold differential case to ring gear
(9) Attach a dial indicator C-3339 to guide stud.
side of the axle housing (Fig. 100).
Position the dial indicator plunger on a flat surface
(13) Record dial indicator reading (Fig. 100).
between the ring gear bolt heads (Fig. 98).
(14) Add 0.008 in. (0.2 mm) to the zero end play
(10) Push and hold differential case to pinion gear
total. This new total represents the thickness of
side of axle housing (Fig. 99).
(11) Zero dial indicator face to pointer (Fig. 99).

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 3 - 58 TUBE, 181, AND 186 FBI AXLE XJ
ADJUSTMENTS (Continued)
(19) Seat ring gear side dummy bearing (Fig. 97).
(20) Position the dial indicator plunger on a flat
surface between the ring gear bolt heads. (Fig. 98).
(21) Push and hold differential case toward pinion
gear (Fig. 101).
(22) Zero dial indicator face to pointer (Fig. 101).

Fig. 99 Hold Differential Case and Zero Dial

Indicator
1 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 – SPECIAL TOOL C-3288–B
3 – SPECIAL TOOL C-3339
4 – ZERO DIAL INDICATOR FACE

Fig. 101 Hold Differential Case and Zero Dial

Indicator
1 – ZERO DIAL INDICATOR FACE
2 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
3 – PINION GEAR
4 – AXLE HOUSING
5 – DIFFERENTIAL CASE

(23) Push and hold differential case to ring gear

side of the axle housing (Fig. 102).
(24) Record dial indicator reading (Fig. 102).

Fig. 100 Hold Differential Case and Read Dial

Indicator
1 – READ DIAL INDICATOR
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 – AXLE HOUSING

shims to compress, or preload the new bearings when

the differential is installed.
(15) Rotate dial indicator out of the way on the
guide stud.
(16) Remove differential case and dummy bearings
from axle housing. Fig. 102 Hold Differential Case and Read Dial
(17) Install the pinion in the axle housing. Install Indicator
1 – READ DIAL INDICATOR
the pinion yoke and establish the correct pinion
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
rotating torque.
3 – PINION GEAR
(18) Install differential case and dummy bearings 4 – AXLE HOUSING
D-348 in axle housing (without shims), install bear- 5 – DIFFERENTIAL CASE
ing caps and tighten bolts snug.

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 59
ADJUSTMENTS (Continued)
(25) Subtract 0.002 in. (0.05 mm) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. This total is the thickness
shim required to achieve proper backlash.
(26) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
axle housing.
(27) Rotate dial indicator out of the way on guide
stud.
(28) Remove differential case and dummy bearings
from axle housing.
(29) Install side bearing shims on differential case
hubs.
(30) Install side bearings and cups on differential
case.
(31) Install spreader W-129-B, utilizing some items Fig. 103 Ring Gear Backlash Measurement
from Adapter Set 6987, on axle housing and spread 1 – DIAL INDICATOR
axle opening enough to receive differential case.
(32) Install differential case in axle housing.
(33) Remove spreader from axle housing.
(34) Rotate the differential case several times to
seat the side bearings.
(35) Position the indicator plunger against a ring
gear tooth (Fig. 103).
(36) Push and hold ring gear upward while not
allowing the pinion gear to rotate.
(37) Zero dial indicator face to pointer.
(38) Push and hold ring gear downward while not
allowing the pinion gear to rotate. Dial indicator
reading should be between 0.12 mm (0.005 in.) and
0.20 mm (0.008 in.). If backlash is not within specifi-
cations transfer the necessary amount of shim thick-
ness from one side of the axle housing to the other
(Fig. 104).
(39) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform Fig. 104 Backlash Shim Adjustment
Gear Contact Pattern Analysis procedure. pinion. This will provide a more distinct contact pat-
tern.
GEAR CONTACT PATTERN ANALYSIS (3) Using a boxed end wrench on a ring gear bolt,
The ring gear and pinion teeth contact patterns Rotate the differential case one complete revolution
will show if the pinion depth is correct in the axle in both directions while a load is being applied from
housing. It will also show if the ring gear backlash shop towel.
has been adjusted correctly. The backlash can be The areas on the ring gear teeth with the greatest
adjusted within specifications to achieve desired degree of contact against the pinion teeth will squee-
tooth contact patterns. gee the compound to the areas with the least amount
(1) Apply a thin coat of hydrated ferric oxide, or of contact. Note and compare patterns on the ring
equivalent, to the drive and coast side of the ring gear teeth to Gear Tooth Contact Patterns chart (Fig.
gear teeth. 105) and adjust pinion depth and gear backlash as
(2) Wrap, twist, and hold a shop towel around the necessary.
pinion yoke to increase the turning resistance of the

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 3 - 60 TUBE, 181, AND 186 FBI AXLE XJ
ADJUSTMENTS (Continued)

Fig. 105 Gear Tooth Contact Patterns

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 61

SPECIFICATIONS SPECIAL TOOLS

181 FBI AXLE 181 and 186 FBI AXLE
Axle Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hypoid
Lubricant–Std. . . . . SAE Thermally Stable 80W–90
Lubricant–Heavy Duty . . . SAE 75W–140 Synthetic
Lube Capacity . . . . . . . . . . . . . . . 1.48 L (3.13 pts.)
Axle Ratio . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.10
Differential Side Gear Clearance . . . 0.12–0.20 mm
(0.005–0.008 in.)
Ring Gear Diameter . . . . . . . . . 18.09 cm (7.125 in.) Puller—C-293-PA
Backlash . . . . . . . . . . . 0–0.15 mm (0.005–0.008 in.)
Pinion Std. Depth . . . . . . . . . . . 92.1 mm (3.625 in.)
Pinion Bearing Rotating Torque . . . . . . . . . . . . . . .
Original Bearings . . . . . . . 1–2 N·m (10–20 in. lbs.)
New Bearings . . . . . . . . . 1.5–4 N·m (15–35 in. lbs.)
186 FBI AXLE
Axle Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hypoid
Lubricant–Std. . . . . SAE Thermally Stable 80W–90
Lubricant–Heavy Duty . . . SAE 75W–140 Synthetic Plug—SP-3289
Lube Capacity . . . . . . . . . . . . . . . . 1.18 L (2.5 pts.)
Axle Ratio . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.10
Differential Side Gear Clearance . . . 0.12–0.20 mm
(0.005–0.008 in.)
Ring Gear Diameter . . . . . . . . . 18.59 cm (7.33 in.)
Backlash . . . . . . . . . . . 0–0.15 mm (0.005–0.008 in.)
Pinion Std. Depth . . . . . . . . . . . 92.1 mm (3.625 in.)
Pinion Bearing Rotating Torque . . . . . . . . . . . . . . .
Original Bearings . . . . . . . 1–2 N·m (10–20 in. lbs.)
New Bearings . . . . . . . . . 1.5–4 N·m (15–35 in. lbs.) Adapter—C-293-39

TORQUE
DESCRIPTION TORQUE
Fill Hole Plug . . . . . . . . . . . . . . 34 N·m (25 ft. lbs.)
Diff. Cover Bolt . . . . . . . . . . . . . 41 N·m (30 ft. lbs.)
Bearing Cap Bolt . . . . . . . . . . . . 61 N·m (45 ft. lbs.)
Ring Gear Bolt . . . . . . . 95–122 N·m (70–90 ft. lbs.)
Axle Nut . . . . . . . . . . . . . . . . 237 N·m (175 ft. lbs.)
Hub Brg. Bolt . . . . . . . . . . . . . 102 N·m (75 ft. lbs.) Puller—C-452
Lower Ball Stud . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Upper Ball Stud . . . . . . . . . . . 101 N·m (75 ft. lbs.)

Wrench—C-3281

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 3 - 62 TUBE, 181, AND 186 FBI AXLE XJ
SPECIAL TOOLS (Continued)

Dial Indicator—C-3339
Installer—W-162-D

Driver—C-3716-A

Cup—8109

Remover/Installer—6289

Handle—C-4171

Installer—6761
Installer—D-146

Remover—D-149 Installer—6752

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 XJ TUBE, 181, AND 186 FBI AXLE 3 - 63
SPECIAL TOOLS (Continued)

Installer Discs—8110 Installer—C-3972-A

Turnbuckle—6797
Spreader—W-129-B

Tool Set, Pinion Depth—6774

Adapter Kit—6987

Gauge Block—6733
Pilot Stud—C-3288-B

Spanner—6958

Remover—D-147

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 3 - 64 TUBE, 181, AND 186 FBI AXLE XJ
SPECIAL TOOLS (Continued)

Installer—D-144

Installer—W-262

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 XJ 194 RBI AXLE 3 - 65

194 RBI AXLE

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 78

194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . . 80
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . . 66 PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
TRAC-LOKY DIFFERENTIAL . . . . . . . . . . . . . . . . 66 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 85
DIAGNOSIS AND TESTING DISASSEMBLY AND ASSEMBLY
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 67 STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . . 86
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 TRAC-LOKY DIFFERENTIAL . . . . . . . . . . . . . . . . 87
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 70 CLEANING AND INSPECTION
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . . . 70 AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . 91
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 TRAC-LOKY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . . 70 ADJUSTMENTS
TRAC–LOKY DIFFERENTIAL NOISE . . . . . . . . . . 70 PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . . . 91
TRAC–LOKY TEST . . . . . . . . . . . . . . . . . . . . . . . 71 DIFFERENTIAL BEARING PRELOAD AND
SERVICE PROCEDURES GEAR BACKLASH. . . . . . . . . . . . . . . . . . . . . . . 94
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . 71 GEAR CONTACT PATTERN ANALYSIS . . . . . . . . 97
REMOVAL AND INSTALLATION SPECIFICATIONS
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . . . 72 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
COLLAPSIBLE SPACER. . . . . . . . . . . . . . . . . . . . 74 SPECIAL TOOLS
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
AXLE SHAFT SEAL AND BEARING . . . . . . . . . . . 77

DESCRIPTION AND OPERATION The 194 RBI axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
194 RBI AXLE the differential housing by a cover bolt. Build date
identification codes are stamped on the cover side of
DESCRIPTION an axle shaft tube.
The 194 Rear Beam-design Iron (RBI) axle housing The differential case is a one-piece design. The dif-
has an iron center casting (differential housing) with ferential pinion mate shaft is retained with a
axle shaft tubes extending from either side. The threaded pin. Differential bearing preload and ring
tubes are pressed into and welded to the differential gear backlash is adjusted by the use of selective
housing to form a one-piece axle housing. spacer shims. Pinion bearing preload is set and
The integral type, hypoid gear design, housing has maintained by the use of a collapsible spacer (Fig. 1).
the centerline of the pinion set below the centerline Axles equipped with a Trac-Loky differential are
of the ring gear. optional. A Trac-Lok differential has a one-piece dif-
The axle has a vent hose to relieve internal pres- ferential case, and the same internal components as
sure caused by lubricant vaporization and internal a standard differential, plus two clutch disc packs.
expansion.
The axles are equipped with semi–floating axle OPERATION
shafts, meaning that loads are supported by the axle The axle receives power from the transmission/
shaft and bearings. The axle shafts are retained by transfer case through the rear propeller shaft. The
C–clips in the differential side gears. rear propeller shaft is connected to the pinion gear
The cover provides a means for servicing the differ- which rotates the differential through the gear mesh
ential without removing the axle. with the ring gear bolted to the differential case. The
For vehicles equipped with ABS brakes, the axles engine power is transmitted to the axle shafts
have a tone ring pressed onto the axle shaft. Use care through the pinion mate and side gears. The side
when removing axle shafts to ensure that the tone gears are splined to the axle shafts.
wheel or the wheel speed sensor are not damaged.

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 3 - 66 194 RBI AXLE XJ
DESCRIPTION AND OPERATION (Continued)
OPERATION
In operation, power flow occurs as follows:
• The pinion gear rotates the ring gear
• The ring gear (bolted to the differential case)
rotates the case
• The differential pinion gears (mounted on the
pinion mate shaft in the case) rotate the side gears
• The side gears (splined to the axle shafts) rotate
the shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
Fig. 1 Shim Locations pinion mate shaft but do not rotate around it (Fig. 2).
1 – PINION GEAR DEPTH SHIM
2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 – RING GEAR
4 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 – COLLAPSIBLE SPACER

LUBRICANT
DESCRIPTION
A multi-purpose, hypoid gear lubricant which con-
forms to the following specifications should be used.
Mopart Hypoid Gear Lubricant conforms to all of
these specifications.
• The lubricant should have MIL–L–2105C and
API GL 5 quality specifications. Fig. 2 Differential Operation—Straight Ahead Driving
• Lubricant is a thermally stable SAE 80W–90 1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
gear lubricant. 2 – PINION GEAR
• Lubricant for axles intended for heavy-duty or 3 – SIDE GEAR
trailer tow use is SAE 75W–140 SYNTHETIC gear 4 – PINION GEARS ROTATE WITH CASE
lubricant.
Trac-lok differentials require the addition of 3.5 oz.
When turning corners, the outside wheel must
of friction modifier to the axle lubricant. The 194 RBI
travel a greater distance than the inside wheel to
axle lubricant capacity is 1.66L (3.50 pts.) total,
complete a turn. The difference must be compensated
including the friction modifier if necessary.
for to prevent the tires from scuffing and skidding
CAUTION: If axle is submerged in water, lubricant through turns. To accomplish this, the differential
must be replaced immediately to avoid possible allows the axle shafts to turn at unequal speeds (Fig.
premature axle failure. 3). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
STANDARD DIFFERENTIAL directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
DESCRIPTION speed.
The differential gear system divides the torque
between the axle shafts. It allows the axle shafts to TRAC-LOKY DIFFERENTIAL
rotate at different speeds when turning corners.
Each differential side gear is splined to an axle DESCRIPTION
shaft. The pinion gears are mounted on a pinion In a standard differential, if one wheel spins, the
mate shaft and are free to rotate on the shaft. The opposite wheel will generate only as much torque as
pinion gear is fitted in a bore in the differential case the spinning wheel.
and is positioned at a right angle to the axle shafts.

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 XJ 194 RBI AXLE 3 - 67
DESCRIPTION AND OPERATION (Continued)

Fig. 3 Differential Operation—On Turns

1 – PINION GEARS ROTATE ON PINION SHAFT

In the Trac-loky differential, part of the ring gear

torque is transmitted through clutch packs which
contain multiple discs. The clutches will have radial
grooves on the plates, and concentric grooves on the
discs or bonded fiber material that is smooth in
appearance.

OPERATION
In operation, the Trac-loky clutches are engaged
by two concurrent forces. The first being the preload Fig. 4 Trac-lokY Limited Slip Differential Operation
force exerted through Belleville spring washers 1 – CASE
within the clutch packs. The second is the separating 2 – RING GEAR
forces generated by the side gears as torque is 3 – DRIVE PINION
applied through the ring gear (Fig. 4). 4 – PINION GEAR
The Trac-loky design provides the differential 5 – MATE SHAFT
action needed for turning corners and for driving 6 – CLUTCH PACK
straight ahead during periods of unequal traction. 7 – SIDE GEAR
When one wheel looses traction, the clutch packs 8 – CLUTCH PACK
transfer additional torque to the wheel having the
most traction. Trac-loky differentials resist wheel • Incorrect backlash.
spin on bumpy roads and provide more pulling power Axle gear problem conditions are usually the result
when one wheel looses traction. Pulling power is pro- of:
vided continuously until both wheels loose traction. If • Insufficient lubrication.
both wheels slip due to unequal traction, Trac-loky • Incorrect or contaminated lubricant.
operation is normal. In extreme cases of differences • Overloading (excessive engine torque) or exceed-
of traction, the wheel with the least traction may ing vehicle weight capacity.
spin. • Incorrect clearance or backlash adjustment.
Axle component breakage is most often the result
of:
DIAGNOSIS AND TESTING • Severe overloading.
• Insufficient lubricant.
GENERAL INFORMATION • Incorrect lubricant.
Axle bearing problem conditions are usually caused • Improperly tightened components.
by: • Differential housing bores not square to each
• Insufficient or incorrect lubricant. other.
• Foreign matter/water contamination.
• Incorrect bearing preload torque adjustment.

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 3 - 68 194 RBI AXLE XJ
DIAGNOSIS AND TESTING (Continued)
DIAGNOSTIC CHART

Condition Possible Causes Correction

Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing. 2. Replace bearing.

Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
necessary.

2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.

3. End-play in pinion bearings. 3. Refer to pinion pre-load information and
correct as necessary.
4. Excessive gear backlash 4. Check adjustment of the ring gear and
between the ring gear and pinion. pinion backlash. Correct as necessary.
5. Improper adjustment of pinion 5. Adjust the pinion bearings pre-load.
gear bearings.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact 7. Inspect and replace as necessary.
surfaces.

Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting
tube mis-alignment.

2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive

weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct
erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect and
repair clutch as necessary.

Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears and
differential bearings. bearings for further damage. Set differential
bearing pre-load properly.

2. Excessive ring gear backlash. 2. Replace case and inspect gears and
bearings for further damage. Set ring gear
backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and
bearings for further damage. Avoid excessive
vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and
bearings for further damage. Avoid erratic use
of clutch.

Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with
the correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with
the correct fluid type and quantity.
3. Excessive spinning of one 3. Replace scored gears. Inspect all gears,
wheel/tire. pinion bores, and shaft for damage. Service
as necessary.

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 XJ 194 RBI AXLE 3 - 69
DIAGNOSIS AND TESTING (Continued)

Condition Possible Causes Correction

Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.

2. Worn axle shaft seals. 2. Replace seals.

3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.

Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.

2. Improper grade of lubricant. 2. Fill differential with the correct fluid type
and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.

Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and
bearings for possible damage.

2. Erratic clutch operation. 2. Replace gears and examine the remaining

parts for damage. Avoid erratic clutch
operation.
3. Ice-spotted pavement. 3. Replace gears and examine remaining
parts for damage.
4. Improper adjustments. 4. Replace gears and examine remaining
parts for damage. Ensure ring gear backlash
is correct.

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type
and quantity.
2. Improper ring gear and pinion 2. Check ring gear and pinion contact pattern.
adjustment.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring gear
and pinion.
4. Worn teeth on ring gear and/or 4. Replace ring gear and pinion.
pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap 8. Inspect differential components and replace
bolts. as necessary. Ensure that the bearing caps
are torqued tot he proper specification.
9. Housing not machined properly. 9. Replace housing.

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 3 - 70 194 RBI AXLE XJ
DIAGNOSIS AND TESTING (Continued)

GEAR NOISE VIBRATION

Axle gear noise can be caused by insufficient lubri- Vibration at the rear of the vehicle is usually
cant, incorrect backlash, tooth contact, worn/damaged caused by a:
gears, or the carrier housing not having the proper • Damaged drive shaft.
offset and squareness. • Missing drive shaft balance weight(s).
Gear noise usually happens at a specific speed • Worn or out–of–balance wheels.
range. The noise can also occur during a specific type • Loose wheel lug nuts.
of driving condition. These conditions are accelera- • Worn U–joint(s).
tion, deceleration, coast, or constant load. • Loose/broken springs.
When road testing, first warm-up the axle fluid by • Damaged axle shaft bearing(s).
driving the vehicle at least 5 miles and then acceler- • Loose pinion gear nut.
ate the vehicle to the speed range where the noise is • Excessive pinion yoke run out.
the greatest. Shift out-of-gear and coast through the • Bent axle shaft(s).
peak–noise range. If the noise stops or changes Check for loose or damaged front–end components
greatly: or engine/transmission mounts. These components
• Check for insufficient lubricant. can contribute to what appears to be a rear–end
• Incorrect ring gear backlash. vibration. Do not overlook engine accessories, brack-
• Gear damage. ets and drive belts.
Differential side gears and pinions can be checked All driveline components should be examined
by turning the vehicle. They usually do not cause before starting any repair.
noise during straight–ahead driving when the gears Refer to Group 22, Wheels and Tires, for additional
are unloaded. The side gears are loaded during vehi- vibration information.
cle turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise. DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
BEARING NOISE into gear (or the clutch engaged), can be caused by:
The axle shaft, differential and pinion bearings can • High engine idle speed.
all produce noise when worn or damaged. Bearing • Transmission shift operation.
noise can be either a whining, or a growling sound. • Loose engine/transmission/transfer case mounts.
Pinion bearings have a constant–pitch noise. This • Worn U–joints.
noise changes only with vehicle speed. Pinion bearing • Loose spring mounts.
noise will be higher pitched because it rotates at a • Loose pinion gear nut and yoke.
faster rate. Drive the vehicle and load the differen- • Excessive ring gear backlash.
tial. If bearing noise occurs, the rear pinion bearing • Excessive side gear to case clearance.
is the source of the noise. If the bearing noise is The source of a snap or a clunk noise can be deter-
heard during a coast, the front pinion bearing is the mined with the assistance of a helper. Raise the vehi-
source. cle on a hoist with the wheels free to rotate. Instruct
Worn or damaged differential bearings usually pro- the helper to shift the transmission into gear. Listen
duce a low pitch noise. Differential bearing noise is for the noise, a mechanics stethoscope is helpful in
similar to pinion bearing noise. The pitch of differen- isolating the source of a noise.
tial bearing noise is also constant and varies only
with vehicle speed. TRAC–LOKY DIFFERENTIAL NOISE
Axle shaft bearings produce noise and vibration The most common problem is a chatter noise when
when worn or damaged. The noise generally changes turning corners. Before removing a Trac-loky unit
when the bearings are loaded. Road test the vehicle. for repair, drain, flush and refill the axle with the
Turn the vehicle sharply to the left and to the right. specified lubricant. Refer to Lubricant change in this
This will load the bearings and change the noise Group.
level. Where axle bearing damage is slight, the noise A container of Mopart Trac-loky Lubricant (fric-
is usually not noticeable at speeds above 30 mph. tion modifier) should be added after repair service or
during a lubricant change.
LOW SPEED KNOCK After changing the lubricant, drive the vehicle and
Low speed knock is generally caused by a worn make 10 to 12 slow, figure-eight turns. This maneu-
U–joint or by worn side–gear thrust washers. A worn ver will pump lubricant through the clutches. This
pinion shaft bore will also cause low speed knock. will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.

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 XJ 194 RBI AXLE 3 - 71
DIAGNOSIS AND TESTING (Continued)

TRAC–LOKY TEST (3) Remove the differential housing cover and

drain the lubricant from the housing.
WARNING: WHEN SERVICING VEHICLES WITH A (4) Clean the housing cavity with a flushing oil,
TRAC–LOKY DIFFERENTIAL DO NOT USE THE light engine oil, or lint free cloth. Do not use water,
ENGINE TO TURN THE AXLE AND WHEELS. BOTH steam, kerosene, or gasoline for cleaning.
REAR WHEELS MUST BE RAISED AND THE VEHI- (5) Remove the original sealant from the housing
CLE SUPPORTED. A TRAC–LOKY AXLE CAN and cover surfaces.
EXERT ENOUGH FORCE IF ONE WHEEL IS IN CON- (6) Apply a bead of Mopart Silicone Rubber Seal-
TACT WITH A SURFACE TO CAUSE THE VEHICLE ant, or equivalent, to the housing cover (Fig. 6).
TO MOVE.

The differential can be tested without removing the

differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 to
studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 5).
Fig. 6 Apply Sealant
1 – SEALANT
2 – AXLE HOUSING COVER

Install the housing cover within 5 minutes

after applying the sealant.
(7) Install the cover and any identification tag.
Tighten the cover bolts to 41 N·m (30 ft. lbs.) torque.
(8) For Trac–loky differentials, a quantity of
Mopart Trac–loky lubricant (friction modifier), or
equivalent, must be added after repair service or a
lubricant change. Refer to the Lubricant Specifica-
tions section of this group for the quantity necessary.
(9) Fill differential with Mopart Hypoid Gear
Lubricant, or equivalent, to bottom of the fill plug
hole. Refer to the Lubricant Specifications section of
Fig. 5 Trac-lokY Test —Typical this group for the quantity necessary.
1 – SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 – TORQUE WRENCH CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

(6) If rotating torque is less than 22 N·m (30 ft. (10) Install the fill hole plug and lower the vehicle.
lbs.) or more than 271 N·m (200 ft. lbs.) on either (11) Trac–loky differential equipped vehicles
wheel the unit should be serviced. should be road tested by making 10 to 12 slow figure-
eight turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
SERVICE PROCEDURES ter noise complaint.
LUBRICANT CHANGE
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
differential housing cover.

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 3 - 72 194 RBI AXLE XJ

REMOVAL AND INSTALLATION (8) Connect the brake hose to the axle junction
block. Refer to Group 5, Brakes, for proper proce-
REAR AXLE dures.
(9) Install axle vent hose.
REMOVAL (10) Align propeller shaft and pinion yoke refer-
(1) Raise and support the vehicle. ence marks. Install U-joint straps and bolts. Tighten
(2) Position a suitable lifting device under the to 19 N·m (14 ft. lbs.) torque.
axle. (11) Install the wheels and tires.
(3) Secure axle to device. (12) Add gear lubricant, if necessary. Refer to
(4) Remove the wheels and tires. Lubricant Specifications in this section for lubricant
(5) Remove the brake drums from the axle. Refer requirements.
to Group 5, Brakes, for proper procedures. (13) Remove lifting device from axle and lower the
(6) Disconnect parking brake cables from brackets vehicle.
and lever.
(7) Remove wheel speed sensors, if necessary. PINION SHAFT SEAL
Refer to Group 5, Brakes, for proper procedures.
(8) Disconnect the brake hose at the axle junction REMOVAL
block. Do not disconnect the brake hydraulic lines at (1) Raise and support the vehicle.
the wheel cylinders. Refer to Group 5, Brakes, for (2) Remove wheel and tire assemblies.
proper procedures. (3) Remove the brake drums. Refer to Group 5,
(9) Disconnect the vent hose from the axle shaft Brakes, for proper procedures.
tube. (4) Mark the propeller shaft and pinion yoke for
(10) Mark the propeller shaft and yokes for instal- installation alignment reference.
lation alignment reference. (5) Remove the propeller shaft from the yoke.
(11) Remove propeller shaft. (6) Rotate the pinion gear three or four times.
(12) Disconnect stabilizer bar links. (7) Measure the amount of torque necessary to
(13) Disconnect shock absorbers from axle. rotate the pinion gear with a (in. lbs.) dial-type
(14) Remove the U-bolts which hold the axle to the torque wrench. Record the torque reading for instal-
spring brackets. lation reference.
(15) Separate the axle from the vehicle. (8) Using Holder 6958 to hold the pinion yoke,
remove the pinion nut and washer.
INSTALLATION (9) Use Remover C-452 and Wrench C-3281 to
remove the pinion yoke (Fig. 7).
NOTE: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, vehicle ride
height and handling could be affected.

(1) Raise the axle with lifting device and align the
spring centering bolts with the mating holes in the
axle spring perch.
(2) Install the U-bolts which hold the axle to the
spring brackets. Tighten nuts to 70 N·m (52 ft. lbs.).
(3) Install shock absorbers and tighten nuts to 60
N·m (44 ft. lbs.) torque.
(4) Install stabilizer bar links and tighten nuts to
74 N·m (55 ft. lbs.) torque.
(5) Install the wheel speed sensors, if necessary.
Refer to Group 5, Brakes, for proper procedures.
(6) Connect parking brake cable to brackets and Fig. 7 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
lever.
2 – YOKE
(7) Install the brake drums. Refer to Group 5,
3 – SPECIAL TOOL C-452
Brakes, for proper procedures.

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 XJ 194 RBI AXLE 3 - 73
REMOVAL AND INSTALLATION (Continued)
(10) Use a suitable pry tool or slide hammer CAUTION: Never loosen pinion gear nut to
mounted screw to remove the pinion gear seal. decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
INSTALLATION torque or rotating torque is exceeded a new col-
(1) Apply a light coating of gear lubricant on the lapsible spacer must be installed. The torque
lip of pinion seal. Install seal with Installer C-3972-A sequence will then have to be repeated.
and Handle C-4171 (Fig. 8).
(5) Rotate the pinion shaft using a (in. lbs.) torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal plus an additional 0.56
N·m (5 in. lbs.) (Fig. 10).

Fig. 8 Pinion Seal Installation

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A

(2) Install yoke on the pinion gear with Screw

8112, Cup 8109, and Holder 6958 (Fig. 9).

CAUTION: Do not exceed the minimum tightening

torque when installing the pinion yoke at this point.
Damage to the collapsible spacer or bearings may
result.

(3) Install the yoke washer and a new nut on the

pinion gear and tighten the pinion nut until there is
zero bearing end-play. Fig. 10 Check Pinion Rotation Torque
1 – PINION YOKE
(4) Tighten the nut to 271 N·m (200 ft. lbs.).
2 – INCH POUND TORQUE WRENCH

(6) If the rotating torque is low, use Holder 6958 to

hold the pinion yoke (Fig. 11), and tighten the pinion
shaft nut in 6.8 N·m (5 ft. lbs.) increments until the
proper rotating torque is achieved.

CAUTION: If the maximum tightening torque is

reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.

(7) Align the installation reference marks on the

propeller shaft and yoke and install the propeller
shaft.
(8) Add gear lubricant to the differential housing,
Fig. 9 Pinion Yoke Installation if necessary. Refer to the Lubricant Specifications for
1 – PINION YOKE gear lubricant requirements.
2 – AXLE HOUSING (9) Install the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(10) Install wheel and tire assemblies.

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 3 - 74 194 RBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 11 Tightening Pinion Shaft Nut–Typical Fig. 12 Pinion Yoke Removal

1 – SPECIAL TOOL 6958 1 – SPECIAL TOOL C-3281
2 – 1 in. PIPE 2 – YOKE
3 – 3/4 DRIVE TORQUE WRENCH 3 – SPECIAL TOOL C-452

(11) Lower the vehicle. (4) Mark the propeller shaft and pinion yoke for
installation reference.
COLLAPSIBLE SPACER (5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
REMOVAL W/PINION INSTALLED (7) Measure the amount of torque necessary to
(1) Raise and support the vehicle. rotate the pinion gear with a (in. lbs.) dial-type
(2) Remove wheel and tire assemblies. torque wrench. Record the torque reading for instal-
(3) Remove rear brake drums. Refer to Group 5, lation reference.
Brakes, for proper procedures. (8) Remove differential assembly from axle hous-
(4) Mark the propeller shaft and pinion yoke for ing.
installation reference. (9) Using Holder 6958 to hold yoke, remove the
(5) Remove the propeller shaft from the yoke. pinion yoke nut and washer.
(6) Rotate the pinion gear three or four times. (10) Using Remover C–452 and Wrench C–3281,
(7) Measure the amount of torque necessary to remove the pinion yoke from pinion shaft (Fig. 12).
rotate the pinion gear with a (in. lbs.) dial-type (11) Remove the pinion gear from housing (Fig.
torque wrench. Record the torque reading for instal- 13). Catch the pinion with your hand to prevent it
lation reference. from falling and being damaged.
(8) Using Holder 6958 to hold the pinion yoke, (12) Remove collapsible spacer from pinion shaft.
remove the pinion nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to INSTALLATION
remove the pinion yoke (Fig. 12). (1) Install a new collapsible preload spacer on pin-
(10) Use a suitable pry tool or a slide hammer ion shaft (Fig. 14).
mounted screw to remove the pinion shaft seal. (2) If pinion gear was removed, install pinion gear
(11) Remove the front pinion bearing using a pair of in housing.
suitable pick tools to pull the bearing straight off the (3) Install pinion front bearing, if necessary.
pinion gear shaft. It may be necessary to lightly tap the (4) Apply a light coating of gear lubricant on the
end of the pinion gear with a rawhide or rubber mallet lip of pinion seal. Install seal with Installer C-3972-A
if the bearing becomes bound on the pinion shaft. and Handle C–4171 (Fig. 15).
(12) Remove the collapsible spacer. (5) Install yoke with Screw 8112, Cup 8109, and
Holder 6958 (Fig. 16).
REMOVAL W/PINION REMOVED (6) If the original pinion bearings are being used,
(1) Raise and support the vehicle. install differential assembly and axle shafts, if neces-
(2) Remove wheel and tire assemblies. sary.
(3) Remove rear brake drums. Refer to Group 5,
Brakes, for proper procedures.

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 XJ 194 RBI AXLE 3 - 75
REMOVAL AND INSTALLATION (Continued)

Fig. 15 Pinion Seal Installation

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A

Fig. 13 Remove Pinion Gear

1 – RAWHIDE HAMMER

Fig. 16 Pinion Yoke Installation

1 – PINION YOKE
2 – AXLE HOUSING

(7) Install the yoke washer and a new nut on the

pinion gear. Tighten the pinion nut until there is zero
bearing end-play.
(8) Tighten the nut to 271 N·m (200 ft. lbs.).

CAUTION: Never loosen pinion gear nut to

decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new col-
Fig. 14 Collapsible Preload Spacer
lapsible spacer must be installed. The torque
1 – COLLAPSIBLE SPACER
2 – SHOULDER sequence will then have to be repeated.
3 – PINION GEAR
4 – OIL SLINGER (9) Using yoke holder 6958 and a torque wrench
5 – REAR BEARING set at 474 N·m (350 ft. lbs.), crush collapsible spacer
until bearing end play is taken up (Fig. 17).
NOTE: If new pinion bearings were installed, do not NOTE: If more than 474 N·m (350 ft. lbs.) of torque
install the differential assembly and axle shafts until is necessary to remove the bearing end play, the
after the pinion bearing preload and rotating torque collapsible spacer is defective and must be
are set. replaced.

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 3 - 76 194 RBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(10) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.)
increments until the rotating torque is achieved.
Measure the rotating torque frequently to avoid over
crushing the collapsible spacer (Fig. 18).

Fig. 17 Tightening Pinion Nut–Typical

1 – SPECIAL TOOL 6958
2 – 1 in. PIPE Fig. 18 Check Pinion Gear Rotation Torque
3 – 3/4 DRIVE TORQUE WRENCH 1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH

(11) Check rotating torque with a (in. lbs.) torque

wrench (Fig. 18). The torque necessary to rotate the (6) Rotate differential case so that pinion mate
pinion gear should be: gear shaft lock screw is accessible. Remove lock
• Original Bearings — The reading recorded dur- screw and pinion mate gear shaft from differential
ing removal, plus an additional 0.56 N·m (5 in. lbs.). case (Fig. 19).
• New Bearings — 1.5 to 4 N·m (15 to 35 in. lbs.).
(12) Install differential assembly and axle shafts,
if necessary.
(13) Align marks made previously on yoke and
propeller shaft and install propeller shaft.
(14) Install rear brake drums. Refer to Group 5,
Brakes, for proper procedures.
(15) Add gear lubricant, if necessary. Refer to
Lubricant Specifications of this section for lubricant
requirements.
(16) Install wheel and tire assemblies.
(17) Lower vehicle.

AXLE SHAFT
REMOVAL
(1) Raise and support vehicle. Ensure that the Fig. 19 Mate Shaft Lock Screw
transmission is in neutral. 1 – LOCK SCREW
(2) Remove wheel and tire assembly. 2 – PINION GEAR MATE SHAFT
(3) Remove brake drum. Refer to Group 5, Brakes,
for proper procedure. (7) Push axle shaft inward and remove axle shaft
(4) Clean all foreign material from housing cover C–clip lock from the axle shaft (Fig. 20).
area. (8) Remove axle shaft. Use care to prevent damage
(5) Loosen housing cover bolts. Drain lubricant to axle shaft bearing and seal, which will remain in
from the housing and axle shaft tubes. Remove hous- axle shaft tube. Also, exercise care not to damage the
ing cover.

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 XJ 194 RBI AXLE 3 - 77
REMOVAL AND INSTALLATION (Continued)

AXLE SHAFT SEAL AND BEARING

REMOVAL
(1) Remove the axle shaft.
(2) Remove the axle shaft seal from the end of the
axle shaft tube with a small pry bar.

NOTE: The seal and bearing can be removed at the

same time with the bearing removal tool.

(3) Remove the axle shaft bearing from the axle

tube with Bearing Removal Tool Set 6310 using
Adapter Foot 6310-5 (Fig. 21).

Fig. 20 Axle Shaft C–Clip Lock

1 – C-CLIP LOCK
2 – AXLE SHAFT
3 – SIDE GEAR

wheel speed sensor on vehicles equipped with ABS

brakes.
(9) Inspect axle shaft seal for leakage or damage.
(10) Inspect roller bearing contact surface on axle
shaft for signs of brinelling, galling and pitting. If
any of these conditions exist, the axle shaft and/or
bearing and seal must be replaced.

INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant. Insert axle shaft through seal, bearing,
and engage it into side gear splines.

NOTE: Use care to prevent shaft splines from dam-

aging axle shaft seal lip. Also, exercise care not to
damage the wheel speed sensor on vehicles Fig. 21 Axle Shaft Bearing Removal
equipped with ABS brakes 1 – AXLE SHAFT TUBE
2 – NUT
(2) Insert C–clip lock in end of axle shaft. Push 3 – GUIDE PLATE
axle shaft outward to seat C–clip lock in side gear. 4 – GUIDE
(3) Insert pinion mate shaft into differential case 5 – THREADED ROD
and through thrust washers and pinion gears. 6 – ADAPTER
7 – FOOT
(4) Align hole in shaft with hole in the differential
case and install lock screw with Loctitet on the
threads. Tighten lock screw to 19 N·m (14 ft. lbs.) (4) Inspect the axle shaft tube bore for roughness
torque. and burrs. Remove as necessary.
(5) Install cover and add fluid. Refer to Lubricant
Change procedure in this section for procedure and INSTALLATION
lubricant requirements. Do not install the original axle shaft seal.
(6) Install brake drum. Refer to Group 5, Brakes, Always install a new seal.
for proper procedures. (1) Wipe the axle shaft tube bore clean.
(7) Install wheel and tire. (2) Install axle shaft bearing with Installer 6436
(8) Lower vehicle. and Handle C–4171. Ensure that the part number on
the bearing is against the installer.
(3) Install the new axle shaft seal with Installer
6437 and Handle C–4171 (Fig. 22).

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 3 - 78 194 RBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(6) Loosen the differential bearing cap bolts.
(7) Position Spreader W–129–B, utilizing some
items from Adapter set 6987, with the tool dowel pins
seated in the locating holes (Fig. 24). Install the hold-
down clamps and tighten the tool turnbuckle finger–
tight.

Fig. 22 Axle Shaft Seal Installation

1 – SPECIAL TOOL 6437
2 – SEAL
3 – AXLE SHAFT TUBE
4 – SPECIAL TOOL C-4171

(4) Install the axle shaft.

DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove the lubricant fill hole plug from the Fig. 24 Install Axle Housing Spreader
1 – AXLE HOUSING
differential housing cover.
2 – DOWEL
(3) Remove the differential housing cover and
3 – SAFETY HOLD DOWN
allow fluid to drain. 4 – SPECIAL TOOL W-129–B
(4) Remove axle shafts. 5 – TURNBUCKLE
(5) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 23). (8) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing (Fig. 25) and zero the
indicator.

CAUTION: Do not spread over 0.38 mm (0.015 in). If

the housing is over–spread, it could be distorted or
damaged.

(9) Spread the housing enough to remove the dif-

ferential case from the housing. Measure the dis-
tance with the dial indicator (Fig. 26).
(10) Remove the dial indicator.
(11) While holding the differential case in position,
remove the differential bearing cap bolts and caps.
(12) Remove the differential from the housing.
Ensure that the differential bearing cups remain in
Fig. 23 Bearing Cap Identification position on the differential bearings (Fig. 27).
1 – INSTALLATION REFERENCE LETTERS (13) Mark or tag the differential bearing cups to
2 – INSTALLATION REFERENCE LETTERS indicate which side of the differential they were
removed from.

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 XJ 194 RBI AXLE 3 - 79
REMOVAL AND INSTALLATION (Continued)

Fig. 25 Install Dial Indicator Fig. 27 Differential Case Removal

1 – SPECIAL TOOLC-3339 1 – AXLE HOUSING
2 – DIAL INDICATOR 2 – DIFFERENTIAL CASE
3 – LEVER ADAPTER 3 – BEARING CUPS
4 – SPECIAL TOOL W-129–B
5 – SPECIAL TOOL C-3288–B
INSTALLATION
If replacement differential bearings or differential
case are being installed, differential side bearing
shim requirements may change. Refer to the Differ-
ential Bearing Preload and Gear Backlash proce-
dures in this section to determine the proper shim
selection.
(1) Position Spreader W–129–B, utilizing some items
from Adapter set 6987, with the tool dowel pins seated
in the locating holes (Fig. 28). Install the holddown
clamps and tighten the tool turnbuckle finger–tight.
(2) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing (Fig. 25) and zero the
indicator.

CAUTION: Do not spread over 0.38 mm (0.015 in). If

the housing is over–spread, it could be distorted or
damaged.

(3) Spread the housing enough to install the case

in the housing. Measure the distance with the dial
indicator (Fig. 26).
Fig. 26 Spread Axle Housing
(4) Remove the dial indicator.
1 – SPECIAL TOOL C-3339
2 – SPECIAL TOOL W-129–B
(5) Install differential case in the housing. Ensure
that the differential bearing cups remain in position
on the differential bearings and that the preload
(14) Retrieve differential case preload shims from shims remain between the face of the bearing cup
axle housing. Mark or tag the differential case pre- and the housing. Tap the differential case to ensure
load shims to indicate which side of the differential the bearings cups and shims are fully seated in the
they were removed from. housing.
(15) Remove spreader from housing. (6) Install the bearing caps at their original loca-
tions (Fig. 29).
(7) Loosely install differential bearing cap bolts.
(8) Remove axle housing spreader.

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 3 - 80 194 RBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(2) Remove the bearings from the differential case
with Puller/Press C-293-PA, C-293-39 Blocks, and
Plug SP-3289 (Fig. 30).

Fig. 28 Install Axle Housing Spreader

1 – AXLE HOUSING
2 – DOWEL
3 – SAFETY HOLD DOWN
4 – SPECIAL TOOL W-129–B
5 – TURNBUCKLE

Fig. 30 Differential Bearing Removal

1 – SPECIAL TOOL C-293–39
2 – BEARING
3 – DIFFERENTIAL
4 – SPECIAL TOOL SP-3289
5 – SPECIAL TOOL C-293–PA

INSTALLATION
(1) Using tool C-3716-A with handle C-4171,
install differential side bearings (Fig. 31).
(2) Install differential in axle housing.

RING GEAR
Fig. 29 Differential Bearing Cap Reference Letters NOTE: The ring gear and pinion are serviced as a
1 – INSTALLATION REFERENCE LETTERS
matched set. Do not replace the ring gear without
2 – INSTALLATION REFERENCE LETTERS
replacing the pinion.

(9) Tighten the bearing cap bolts to 77 N·m (57 ft.

lbs.) torque. REMOVAL
(10) Install the axle shafts. (1) Remove differential from axle housing.
(2) Place differential case in a suitable vise with
DIFFERENTIAL SIDE BEARINGS soft metal jaw protectors. (Fig. 32)
(3) Remove bolts holding ring gear to differential
REMOVAL case.
(1) Remove differential from axle housing. (4) Using a soft hammer, drive ring gear from dif-
ferential case (Fig. 32).

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 XJ 194 RBI AXLE 3 - 81
REMOVAL AND INSTALLATION (Continued)
(1) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(2) Invert the differential case in the vise.
(3) Install new ring gear bolts and alternately
tighten to 95–122 N·m (70–90 ft. lbs.) torque (Fig.
33).
(4) Install differential in axle housing and verify
gear mesh and contact pattern.

Fig. 31 Install Differential Side Bearings

1 – HANDLE C-4171
2 – DIFFERENTIAL
3 – BEARING
4 – TOOL C-3716–A

Fig. 33 Ring Gear Bolt Installation

1 – TORQUE WRENCH
2 – RING GEAR BOLT
3 – RING GEAR
4 – CASE

PINION GEAR
The ring and pinion gears are serviced in a
matched set. Do not replace the pinion gear without
replacing the ring gear.

REMOVAL
(1) Remove differential from the axle housing.
Fig. 32 Ring Gear Removal (2) Mark pinion yoke and propeller shaft for
1 – CASE installation alignment.
2 – RING GEAR
(3) Disconnect propeller shaft from pinion yoke.
3 – RAWHIDE HAMMER
Using suitable wire, tie propeller shaft to underbody.
(4) Using Holder 6958 to hold yoke, remove the
INSTALLATION pinion yoke nut and washer.
(5) Using Remover C–452 and Wrench C–3281,
CAUTION: Do not reuse the bolts that held the ring remove the pinion yoke from pinion shaft (Fig. 34).
gear to the differential case. The bolts can fracture (6) Remove the pinion gear from housing (Fig. 35).
causing extensive damage. Catch the pinion with your hand to prevent it from
falling and being damaged.

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 3 - 82 194 RBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 34 Pinion Yoke Removal

1 – SPECIAL TOOL C-3281
2 – YOKE
3 – SPECIAL TOOL C-452

Fig. 36 Front Bearing Cup Removal

1 – REMOVER
2 – HANDLE

Fig. 35 Remove Pinion Gear

1 – RAWHIDE HAMMER

(7) Use a suitable pry tool or a slide hammer Fig. 37 Rear Bearing Cup Removal
mounted screw to remove the pinion shaft seal. 1 – DRIVER
(8) Remove oil slinger, if equipped, and front pin- 2 – HANDLE
ion bearing.
(9) Remove the front pinion bearing cup with
(12) Remove the rear bearing from the pinion with
Remover C-4345 and Handle C–4171 (Fig. 36).
Puller/Press C-293-PA and Adapters C-293-40 (Fig.
(10) Remove the rear bearing cup from housing
39).
(Fig. 37). Use Remover D-149 and Handle C–4171.
Place 4 adapter blocks so they do not damage
(11) Remove the collapsible preload spacer (Fig.
the bearing cage.
38).

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 XJ 194 RBI AXLE 3 - 83
REMOVAL AND INSTALLATION (Continued)
(13) Remove the depth shims from the pinion gear
shaft. Record the thickness of the depth shims.

INSTALLATION
(1) Apply Mopart Door Ease, or equivalent, stick
lubricant to outside surface of bearing cup.
(2) Install the pinion rear bearing cup with
Installer D-146 and Driver Handle C–4171 (Fig. 40).
Ensure cup is correctly seated.

Fig. 38 Collapsible Spacer

1 – COLLAPSIBLE SPACER
2 – SHOULDER
3 – PINION GEAR
4 – OIL SLINGER
5 – REAR BEARING

Fig. 40 Pinion Rear Bearing Cup Installation

1 – INSTALLER
2 – HANDLE

(3) Apply Mopart Door Ease, or equivalent, stick

lubricant to outside surface of bearing cup.
(4) Install the pinion front bearing cup with
Installer D–130 and Handle C–4171 (Fig. 41).
(5) Install pinion front bearing, and oil slinger, if
equipped.
(6) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer C-3972-A
and Handle C–4171 (Fig. 42).

NOTE: Pinion depth shims are placed between the

rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pin-
ion depth shim should not require replacement. If
Fig. 39 Rear Bearing Removal required, refer to Pinion Gear Depth to select the
1 – SPECIAL TOOL C-293–PA
proper thickness shim before installing rear pinion
2 – VISE
bearing.
3 – ADAPTERS
4 – DRIVE PINION GEAR SHAFT
(7) Place the proper thickness depth shim on the
pinion gear.

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REMOVAL AND INSTALLATION (Continued)

Fig. 41 Pinion Front Bearing Cup Installation

1 – INSTALLER
2 – HANDLE

Fig. 43 Shaft Rear Bearing Installation

1 – PRESS
2 – INSTALLATION TOOL
3 – DRIVE PINION GEAR
4 – DRIVE PINION GEAR SHAFT REAR BEARING

Fig. 42 Pinion Seal Installation

1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL C-3972–A

(8) Install the rear bearing and slinger, if

equipped, on the pinion gear with Installer W-262
(Fig. 43).
(9) Install a new collapsible preload spacer on pin-
ion shaft and install pinion gear in housing (Fig. 44).
(10) Install pinion gear in housing.
(11) Install yoke with Installer Screw 8112, Cup
8109, and holder 6958 (Fig. 45).
(12) Install the yoke washer and a new nut on the
pinion gear and tighten the pinion nut until there is
zero bearing end-play.
(13) Tighten the nut to 271 N·m (200 ft. lbs.).
Fig. 44 Collapsible Preload Spacer
CAUTION: Never loosen pinion gear nut to 1 – COLLAPSIBLE SPACER
decrease pinion gear bearing rotating torque and 2 – SHOULDER
never exceed specified preload torque. If preload 3 – PINION GEAR
torque or rotating torque is exceeded a new col- 4 – OIL SLINGER
lapsible spacer must be installed. The torque 5 – REAR BEARING
sequence will then have to be repeated.

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 XJ 194 RBI AXLE 3 - 85
REMOVAL AND INSTALLATION (Continued)
• Original Bearings — 1 to 2 N·m (10 to 20 in.
lbs.).
• New Bearings — 1.5 to 4 N·m (15 to 35 in. lbs.).

Fig. 45 Pinion Yoke Installation

1 – PINION YOKE
2 – AXLE HOUSING

(14) Using yoke holder 6958 and a torque wrench

set at 474 N·m (350 ft. lbs.), crush collapsible spacer
until bearing end play is taken up (Fig. 46).

NOTE: If the spacer requires more than 474 N·m

(350 ft. lbs.) torque to crush, the collapsible spacer
Fig. 47 Check Pinion Gear Rotating Torque
is defective and must be replaced.
1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH
(15) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.)
increments until the rotating torque is achieved.
Measure the rotating torque frequently to avoid over (17) Install differential in housing.
crushing the collapsible spacer (Fig. 47).
FINAL ASSEMBLY
(1) Scrape the residual sealant from the housing
and cover mating surfaces. Clean the mating surfaces
with mineral spirits. Apply a bead of Mopart Silicone
Rubber Sealant, or equivalent, on the housing cover
(Fig. 48).
Install the housing cover within 5 minutes
after applying the sealant.
(2) Install the cover on the differential with the
attaching bolts. Install the identification tag. Tighten
the cover bolts to 41 N·m (30 ft. lbs.) torque.

CAUTION: Overfilling the differential can result in

lubricant foaming and overheating.

(3) Refill the differential housing with gear lubri-

cant. Refer to the Lubricant Specifications section of
Fig. 46 Tightening Pinion Nut–Typical this group for the gear lubricant requirements.
1 – SPECIAL TOOL 6958 (4) Install the fill hole plug.
2 – 1 in. PIPE
3 – 3/4 DRIVE TORQUE WRENCH

(16) Check bearing rotating torque with a (in. lbs.)

torque wrench (Fig. 47). The torque necessary to
rotate the pinion gear should be:

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 3 - 86 194 RBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 49 Pinion Mate Shaft Lock Screw

1 – LOCK SCREW
2 – PINION MATE SHAFT

Fig. 48 Typical Housing Cover With Sealant

1 – SEALING SURFACE
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35mm (1/4”)

DISASSEMBLY AND ASSEMBLY

STANDARD DIFFERENTIAL
DISASSEMBLY
(1) Remove pinion mate shaft lock screw (Fig. 49).
(2) Remove pinion mate shaft.
(3) Rotate the differential side gears and remove
the differential pinion gears and thrust washers (Fig.
50).
(4) Remove the differential side gears and thrust
washers.

ASSEMBLY
(1) Install the differential side gears and thrust Fig. 50 Pinion Mate Gear Removal
washers. 1 – THRUST WASHER
(2) Install the differential pinion gears and thrust 2 – SIDE GEAR
washers. 3 – PINION MATE GEAR
(3) Install the pinion mate shaft.
(4) Align the hole in the pinion mate shaft with
the hole in the differential case and install the pinion
mate shaft lock screw.
(5) Lubricate all differential components with
hypoid gear lubricant.

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 XJ 194 RBI AXLE 3 - 87
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 51 Trac–lokY Differential Components

1 – THRUST WASHER 6 – RETAINER
2 – PINION 7 – DISC
3 – SHAFT LOCK SCREW 8 – CLUTCH PACK
4 – PINION MATE SHAFT 9 – DIFFERENTIAL CASE
5 – SIDE GEAR 10 – RETAINER

TRAC-LOKY DIFFERENTIAL
The Trac–loky differential components are illus-
trated in (Fig. 51). Refer to this illustration during
repair service.

DISASSEMBLY
(1) Clamp Side Gear Holding Tool 6965 in a vise.
(2) Position the differential case on Side Gear
Holding Tool 6965 (Fig. 52).
(3) Remove ring gear, if necessary. Ring gear
removal is necessary only if the ring gear is to be
replaced. The Trac-loky differential can be serviced
with the ring gear installed.
(4) Remove the pinion gear mate shaft lock screw
(Fig. 53).
(5) Remove the pinion gear mate shaft. If neces-
sary, use a drift and hammer (Fig. 54).
(6) Install and lubricate Step Plate C-6960-3 (Fig.
55).

Fig. 52 Differential Case Holding Tool

1 – SPECIAL TOOL 6965
2 – VISE
3 – DIFFERENTIAL

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 3 - 88 194 RBI AXLE XJ
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 53 Mate Shaft Lock Screw

1 – LOCK SCREW
2 – PINION GEAR MATE SHAFT
Fig. 55 Step Plate Tool Installation
1 – LOWER SIDE GEAR
2 – DIFFERENTIAL CASE
3 – SPECIAL TOOL C-6960–3

Fig. 54 Mate Shaft Removal

1 – PINION MATE SHAFT
2 – SIDE GEAR
3 – DRIFT
4 – PINION MATE GEAR

(7) Assemble Threaded Adapter C-6960-1 into top

side gear. Thread Forcing Screw C-6960-4 into
adapter until it becomes centered in adapter plate.
(8) Position a small screw driver in slot of
Threaded Adapter C-6960-1 (Fig. 56) to prevent Fig. 56 Threaded Adapter Installation
adapter from turning. 1 – SOCKET
(9) Tighten forcing screw tool 122 N·m (90 ft. lbs.) 2 – SLOT IN ADAPTER
maximum to compress Belleville springs in clutch 3 – SCREWDRIVER
packs (Fig. 57). 4 – DISC C-6960–3
5 – THREADED ROD C-6960–4
6 – THREADED ADAPTER DISC C–6960–1

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 XJ 194 RBI AXLE 3 - 89
DISASSEMBLY AND ASSEMBLY (Continued)
(13) Rotate differential case until the pinion gears
can be removed.
(14) Remove pinion gears from differential case.

Fig. 57 Tighten Belleville Spring Compressor Tool

1 – TORQUE WRENCH
2 – TOOL ASSEMBLED
3 – DIFFERENTIAL CASE
Fig. 59 Pinion Gear Removal
1 – PINION GEARS
(10) Using an appropriate size feeler gauge, 2 – TOOL
remove thrust washers from behind the pinion gears
(Fig. 58). (15) Remove Forcing Screw C-6960-4, Step Plate
C-6960-3, and Threaded Adapter C-6960-1.
(16) Remove top side gear, clutch pack retainer,
and clutch pack. Keep plates in correct order during
removal (Fig. 60).

Fig. 58 Remove Pinion Gear Thrust Washer

1 – THRUST WASHER
2 – FEELER GAUGE

Fig. 60 Side Gear & Clutch Disc Removal

(11) Insert Turning Bar C-6960-2 in case (Fig. 59). 1 – DIFFERENTIAL CASE
(12) Loosen the Forcing Screw C-6960-4 in small 2 – RETAINER
increments until the clutch pack tension is relieved 3 – SIDE GEAR AND CLUTCH DISC PACK
and the differential case can be turned using Turning
Bar C-6960-2.

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 3 - 90 194 RBI AXLE XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(17) Remove differential case from Side Gear Hold-
ing Tool 6965. Remove side gear, clutch pack retainer,
and clutch pack. Keep plates in correct order during
removal.

ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.

Lubricate each component with gear lubricant

before assembly.
(1) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 61).

Fig. 62 Clutch Discs & Lower Side Gear Installation

1 – DIFFERENTIAL CASE
2 – LOWER SIDE GEAR AND CLUTCH DISC PACK

Fig. 61 Clutch Disc Pack

1 – CLUTCH PACK
2 – RETAINER
3 – SIDE GEAR
4 – RETAINER

(2) Position assembled clutch disc packs on the

side gear hubs.
Fig. 63 Upper Side Gear & Clutch Disc Pack
(3) Install clutch pack and side gear in the ring
Installation
gear side of the differential case (Fig. 62). Be sure
1 – UPPER SIDE GEAR AND CLUTCH DISC PACK
clutch pack retaining clips remain in position 2 – DIFFERENTIAL CASE
and are seated in the case pockets. 3 – SPECIAL TOOL C-6960–3
(4) Position the differential case on Side Gear
Holding Tool 6965.
(5) Install lubricated Step Plate C-6960-3 in lower (8) Insert Forcing Screw C-6960-4.
side gear (Fig. 63). (9) Tighten forcing screw tool to slightly compress
(6) Install the upper side gear and clutch disc pack clutch discs.
(Fig. 63). (10) Place pinion gears in position in side gears
(7) Hold assembly in position. Insert Threaded and verify that the pinion mate shaft hole is aligned.
Adapter C-6960-1 into top side gear.

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 XJ 194 RBI AXLE 3 - 91
DISASSEMBLY AND ASSEMBLY (Continued)
(11) Rotate case with Turning Bar C-6960-2 until TRAC-LOKY
the pinion mate shaft holes in pinion gears align Clean all components in cleaning solvent. Dry com-
with holes in case. It may be necessary to slightly ponents with compressed air. Inspect clutch pack
tighten the forcing screw in order to install the pin- plates for wear, scoring or damage. Replace both
ion gears. clutch packs if any one component in either pack is
(12) Tighten forcing screw to 122 N·m (90 ft. lbs.) damaged. Inspect side gears and pinions. Replace
maximum to compress the Belleville springs. any gear that is worn, cracked, chipped or damaged.
(13) Lubricate and install thrust washers behind Inspect differential case and pinion shaft. Replace if
pinion gears and align washers with a small screw worn or damaged.
driver. Insert mate shaft into each pinion gear to ver-
ify alignment. PRESOAK PLATES AND DISC
(14) Remove Forcing Screw C-6960-4, Step Plate Plates and discs with fiber coating (no grooves or
C-6960-3, and Threaded Adapter C-6960-1. lines) must be presoaked in Friction Modifier before
(15) Install pinion gear mate shaft and align holes assembly. Soak plates and discs for a minimum of 20
in shaft and case. minutes.
(16) Install the pinion mate shaft lock screw finger
tight to hold shaft during differential installation.
If replacement gears and thrust washers were ADJUSTMENTS
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close PINION GEAR DEPTH
machining tolerances during manufacture.
(17) Lubricate all differential components with GENERAL INFORMATION
hypoid gear lubricant. Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
CLEANING AND INSPECTION 64). A plus (+) number, minus (–) number or zero (0)
is etched into the face of the pinion gear. This num-
AXLE COMPONENTS ber is the amount (in thousandths of an inch) the
Wash differential components with cleaning solvent depth varies from the standard depth setting of a
and dry with compressed air. Do not steam clean pinion etched with a (0). The standard setting from
the differential components. the center line of the ring gear to the back face of the
Wash bearings with solvent and towel dry, or dry pinion is 96.850 mm (3.813 in.). The standard depth
with compressed air. DO NOT spin bearings with provides the best teeth contact pattern. Refer to
compressed air. Cup and bearing must be Backlash and Contact Pattern Analysis Paragraph in
replaced as matched sets only. this section for additional information.
Clean axle shaft tubes and oil channels in housing.
Inspect for;
• Smooth appearance with no broken/dented sur-
faces on the bearing rollers or the roller contact sur-
faces.
• Bearing cups must not be distorted or cracked.
• Machined surfaces should be smooth and with-
out any raised edges.
• Raised metal on shoulders of cup bores should
be removed with a hand stone.
• Wear and damage to pinion gear mate shaft,
pinion gears, side gears and thrust washers. Replace
as a matched set only.
• Ring and pinion gear for worn and chipped
teeth.
• Ring gear for damaged bolt threads. Replaced as
a matched set only. Fig. 64 Pinion Gear ID Numbers
• Pinion yoke for cracks, worn splines, pitted 1 – PRODUCTION NUMBERS
areas, and a rough/corroded seal contact surface. 2 – DRIVE PINION GEAR DEPTH VARIANCE
Repair or replace as necessary. 3 – GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
• Preload shims for damage and distortion. Install
new shims, if necessary.

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 3 - 92 194 RBI AXLE XJ
ADJUSTMENTS (Continued)
Compensation for pinion depth variance is
achieved with select shims. The shims are placed
under the inner pinion bearing cone (Fig. 65).
If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion gear. Add or subtract the thickness of
the original depth shims to compensate for the differ-
ence in the depth variances. Refer to the Depth Vari-
ance charts.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus amount needed.
Note the etched number on the face of the drive
pinion gear (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
Fig. 65 Shim Locations
dard. If the number is negative, add that value to the
1 – PINION GEAR DEPTH SHIM
required thickness of the depth shim(s). If the num-
2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
ber is positive, subtract that value from the thickness 3 – RING GEAR
of the depth shim(s). If the number is 0 no change is 4 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
necessary. Refer to the Pinion Gear Depth Variance 5 – COLLAPSIBLE SPACER
Chart.
PINION GEAR DEPTH VARIANCE
Original Pinion Replacement Pinion Gear Depth Variance
Gear Depth
Variance −4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008

PINION DEPTH MEASUREMENT AND ADJUSTMENT (4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
Measurements are taken with pinion cups and pin- tion in axle housing side bearing cradles (Fig. 68).
ion bearings installed in housing. Take measure- Install differential bearing caps on Arbor Discs and
ments with a Pinion Gauge Set, Pinion Block 6735, tighten cap bolts. Refer to the Torque Specifications
Arbor Discs 6732, and Dial Indicator C-3339 (Fig. in this section.
66).
(1) Assemble Pinion Height Block 6739, Pinion NOTE: Arbor Discs 6732 have different step diame-
Block 6735, and rear pinion bearing onto Screw 6741 ters to fit other axle sizes. Pick correct size step for
(Fig. 66). axle being serviced.
(2) Insert assembled height gauge components,
(5) Assemble Dial Indicator C-3339 into Scooter
rear bearing and screw into axle housing through
Block D-115-2 and secure set screw.
pinion bearing cups (Fig. 67).
(3) Install front pinion bearing and Cone 6740
hand tight (Fig. 66).

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 XJ 194 RBI AXLE 3 - 93
ADJUSTMENTS (Continued)

Fig. 68 Gauge Tools In Housing—Typical

1 – ARBOR DISC
2 – PINION BLOCK
3 – ARBOR
4 – PINION HEIGHT BLOCK

Fig. 66 Pinion Gear Depth Gauge Tools—Typical (6) Place Scooter Block/Dial Indicator in position
1 – DIAL INDICATOR in axle housing so dial probe and scooter block are
2 – ARBOR flush against the surface of the pinion height block.
3 – PINION HEIGHT BLOCK Hold scooter block in place and zero the dial indica-
4 – CONE tor face to the pointer. Tighten dial indicator face
5 – SCREW lock screw.
6 – PINION BLOCK
(7) With scooter block still in position against the
7 – SCOOTER BLOCK
pinion height block, slowly slide the dial indicator
8 – ARBOR DISC
probe over the edge of the pinion height block.
Observe how many revolutions counterclockwise the
dial pointer travels (approximately 0.125 in.) to the
out-stop of the dial indicator.
(8) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 69). When the dial probe contacts the arbor bar,
the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not
turn dial face. Continue moving the dial probe to the
crest of the arbor bar and record the highest reading.
If the dial indicator can not achieve the zero reading,
the rear bearing cup or the pinion depth gauge set is
not installed correctly.
(9) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
etched in the face of the pinion gear (Fig. 64) using
Fig. 67 Pinion Height Block—Typical the opposite sign on the variance number. For exam-
1 – PINION BLOCK ple, if the depth variance is –2, add +0.002 in. to the
2 – PINION HEIGHT BLOCK dial indicator reading.
(10) Remove the pinion depth gauge components
from the axle housing

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 3 - 94 194 RBI AXLE XJ
ADJUSTMENTS (Continued)

Fig. 70 Axle Adjustment Shim Locations

Fig. 69 Pinion Gear Depth Measurement—Typical 1 – PINION GEAR DEPTH SHIM
1 – ARBOR 2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
2 – SCOOTER BLOCK 3 – RING GEAR
3 – DIAL INDICATOR 4 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 – COLLAPSIBLE SPACER

DIFFERENTIAL BEARING PRELOAD AND GEAR (3) Install dummy side bearings D-348 on differen-
BACKLASH tial case.
Differential side bearing preload and gear backlash (4) Install differential case in axle housing.
is achieved by selective shims inserted between the (5) Insert Dummy Shims 8107 (0.118 in. (3.0 mm))
bearing cup and the axle housing. The proper shim starting point shims between the dummy bearing
thickness can be determined using slip-fit dummy and the axle housing (Fig. 71).
bearings D-348 in place of the differential side bear-
ings and a dial indicator C-3339. Before proceeding
with the differential bearing preload and gear back-
lash measurements, measure the pinion gear depth
and prepare the pinion gear for installation. Estab-
lishing proper pinion gear depth is essential to estab-
lishing gear backlash and tooth contact patterns.
After the overall shim thickness to take up differen-
tial side play is measured, the pinion gear is
installed, and the gear backlash shim thickness is
measured. The overall shim thickness is the total of
the dial indicator reading, starting point shim thick-
ness, and the preload specification added together.
The gear backlash measurement determines the
thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the dif-
ferential (Fig. 70).

SHIM SELECTION
NOTE: It is difficult to salvage the differential side Fig. 71 Insert Starting Point Shims
bearings during the removal procedure. Install 1 – SPECIAL TOOL 8107
replacement bearings if necessary. 2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
(1) Remove side bearings from differential case. 4 – SPECIAL TOOL D-348
(2) Install ring gear, if necessary, on differential
case and tighten bolts to specification.

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 XJ 194 RBI AXLE 3 - 95
ADJUSTMENTS (Continued)
(6) Install the marked bearing caps in their correct
positions. Install and snug the bolts.
(7) Using a dead-blow type mallet, seat the differ-
ential dummy bearings to each side of the axle hous-
ing (Fig. 72) and (Fig. 73).

Fig. 72 Seat Pinion Gear Dummy Side Bearing

1 – MALLET Fig. 74 Differential Side play Measurement
2 – AXLE HOUSING 1 – DIFFERENTIAL CASE
3 – DIFFERENTIAL CASE 2 – AXLE HOUSING
3 – SPECIAL TOOL C-3288–B
4 – SPECIAL TOOL C-3339

(12) Push firmly and hold differential case to ring

gear side of the axle housing (Fig. 76).
(13) Record dial indicator reading.

Fig. 73 Seat Ring Gear Side Dummy Bearing

1 – AXLE HOUSING
2 – MALLET
3 – DIFFERENTIAL CASE

Fig. 75 Hold Differential Case and Zero Dial

(8) Thread guide stud C-3288-B into rear cover
Indicator
bolt hole below ring gear (Fig. 74).
1 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
(9) Attach dial indicator C-3339 to guide stud. 2 – SPECIAL TOOL C-3288–B
Position the dial indicator plunger on a flat surface 3 – SPECIAL TOOL C-3339
on a ring gear bolt head (Fig. 74). 4 – ZERO DIAL INDICATOR FACE
(10) Push firmly and hold differential case to pin-
ion gear side of axle housing (Fig. 75).
(11) Zero dial indicator face to pointer.

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 3 - 96 194 RBI AXLE XJ
ADJUSTMENTS (Continued)
(22) Zero dial indicator face to pointer.
(23) Push and hold differential case to ring gear
side of the axle housing.
(24) Record dial indicator reading.
(25) Subtract 0.002 in. (0.05 mm) from the dial
indicator reading to compensate for backlash between
ring and pinion gears. This total is the thickness of
shim required to achieve proper backlash.
(26) Subtract the backlash shim thickness from
the total preload shim thickness. The remainder is
the shim thickness required on the pinion side of the
axle housing.
(27) Rotate dial indicator out of the way on guide
stud.
(28) Remove differential case and dummy bearings
from axle housing.
Fig. 76 Hold Differential Case and Read Dial (29) Install new side bearing cones and cups on
Indicator differential case.
1 – READ DIAL INDICATOR (30) Install spreader W-129-B, utilizing some com-
2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE ponents of Adapter Set 6987, on axle housing and
3 – AXLE HOUSING spread axle opening enough to receive differential
case.
(14) Add the dial indicator reading to the starting (31) Place side bearing shims in axle housing
point shim thickness to determine total shim thick- against axle tubes.
ness to achieve zero differential end play. (32) Install differential case in axle housing.
(15) Add 0.008 in. (0.2 mm) to the zero end play (33) Rotate the differential case several times to
total. This new total represents the thickness of seat the side bearings.
shims to compress, or preload the new bearings when (34) Position the indicator plunger against a ring
the differential is installed. gear tooth (Fig. 77).
(16) Rotate dial indicator out of the way on guide (35) Push and hold ring gear upward while not
stud. allowing the pinion gear to rotate.
(17) Remove differential case, dummy bearings, (36) Zero dial indicator face to pointer.
and starting point shims from axle housing. (37) Push and hold ring gear downward while not
(18) Install pinion gear in axle housing. Install the allowing the pinion gear to rotate. Dial indicator
yoke and establish the correct pinion rotating torque. reading should be between 0.12 mm (0.005 in.) and
(19) Install differential case and dummy bearings 0.20 mm (0.008 in.). If backlash is not within specifi-
in axle housing (without shims) and tighten retaining cations transfer the necessary amount of shim thick-
cap bolts. ness from one side of the differential housing to the
(20) Position the dial indicator plunger on a flat other (Fig. 78).
surface between the ring gear bolt heads (Fig. 74).
(21) Push and hold differential case toward pinion
gear.

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 XJ 194 RBI AXLE 3 - 97
ADJUSTMENTS (Continued)
(38) Verify differential case and ring gear runout
by measuring ring to pinion gear backlash at eight
locations around the ring gear. Readings should not
vary more than 0.05 mm (0.002 in.). If readings vary
more than specified, the ring gear or the differential
case is defective.
After the proper backlash is achieved, perform the
Gear Contact Pattern Analysis procedure.

Fig. 78 Backlash Shim Adjustment

(2) Wrap, twist, and hold a shop towel around the
Fig. 77 Ring Gear Backlash Measurement pinion yoke to increase the turning resistance of the
1 – DIAL INDICATOR pinion. This will provide a more distinct contact pat-
tern.
(3) Using a boxed end wrench on a ring gear bolt,
GEAR CONTACT PATTERN ANALYSIS Rotate the differential case one complete revolution
The ring gear and pinion teeth contact patterns in both directions while a load is being applied from
will show if the pinion depth is correct in the axle shop towel.
housing. It will also show if the ring gear backlash The areas on the ring gear teeth with the greatest
has been adjusted correctly. The backlash can be degree of contact against the pinion teeth will squee-
adjusted within specifications to achieve desired gee the compound to the areas with the least amount
tooth contact patterns. of contact. Note and compare patterns on the ring
(1) Apply a thin coat of hydrated ferric oxide, or gear teeth to Gear Tooth Contact Patterns chart (Fig.
equivalent, to the drive and coast side of the ring 79) and adjust pinion depth and gear backlash as
gear teeth. necessary.

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 3 - 98 194 RBI AXLE XJ
ADJUSTMENTS (Continued)

Fig. 79 Gear Tooth Contact Patterns

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 XJ 194 RBI AXLE 3 - 99

SPECIFICATIONS
194 RBI AXLE
DESCRIPTION SPECIFICATION
Axle Type . . . . . . . . . . . . . . . Semi–Floating Hypoid
Lubricant . . . . . . . . SAE Thermally Stable 80W–90
Lubricant Trailer Tow . . . . . . . Synthetic 75W–140
Lube Capacity . . . . . . . . . . . . . . . 1.66 L (3.50 pts.) Adapter—C-293-40
Friction Modifier . . . . . . . . . . . . . 0.12 L (3.50 ozs.)
Axle Ratios . . . . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73
Differential Bearing Preload . . . 0.1 mm (0.008 in.)
Differential Side Gear Clearance . . . . . . 0–0.15 mm
(0–0.006 in.)
Ring Gear Diameter . . . . . . . . . 19.2 cm (7.562 in.)
Ring Gear Backlash . . 0–0.15 mm (0.005–0.008 in.)
Pinion Std. Depth . . . . . . . . . . 96.85 mm (3.813 in.)
Pinion Bearing Preload-Original
Bearings . . . . . . . . . . . . 1–2 N·m (10–20 in. lbs.)
Pinion Bearing Preload-New Bearings . . 1.5–4 N·m
(15–35 in. lbs.) Plug—SP-3289
194 RBI AXLE
DESCRIPTION TORQUE
Bolt, Diff. Cover . . . . . . . . . . . . 41 N·m (30 ft. lbs.)
Bolt, Bearing Cap . . . . . . . . . . . 77 N·m (57 ft. lbs.)
Nut, Pinion . . . . . . . 271–474 N·m (200–350 ft. lbs.)
Screw, Pinion Mate Shaft Lock . . . . . . . . 16.25 N·m
(12 ft. lbs.)
Bolt, Ring Gear . . . . . . 95–122 N·m (70–90 ft. lbs.) Puller—C-452
Bolt, RWAL/ABS Sensor . . . . . . . 8 N·m (70 in. lbs.)

SPECIAL TOOLS
194 RBI AXLE

Wrench—C-3281

Puller—C-293-PA

Installer—C-3972-A

Adapter—C-293-39

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 3 - 100 194 RBI AXLE XJ
SPECIAL TOOLS (Continued)

Installer—D-130
Spanner—6958

Installer—D-146

Installer Screw—8112

Cup—8109 Remover—C-4345

Remover—D-149

Handle—C-4171

Installer—W-262

Driver—C-3716-A

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 XJ 194 RBI AXLE 3 - 101
SPECIAL TOOLS (Continued)

Installer—6436
Trac-lok Tool Set—6960

Holder—6965

Installer—6437

Puller—7794-A

Disc, Axle Arbor—6732

Starting Point Shim—8107

Gauge Block—6735

Spreader—W-129-B

Tool Set, Pinion Depth—6774

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 3 - 102 194 RBI AXLE XJ
SPECIAL TOOLS (Continued)

Bearing Remover Tool Set—6310

Adapter Kit—6987

Guide Pin—C-3288-B
Hub Puller—6790

Dial Indicator—C-3339

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 XJ 8 1/4 REAR AXLE 3 - 103

8 1/4 REAR AXLE

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . 114

8 1/4 AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . 115
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 105 PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 117
TRAC-LOKY DIFFERENTIAL . . . . . . . . . . . . . . . 105 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 120
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 106 TRAC-LOKY DIFFERENTIAL . . . . . . . . . . . . . . . 121
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 CLEANING AND INSPECTION
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . 109 8 1/4 AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . . 109 TRAC-LOKY . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 ADJUSTMENTS
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . 109 8 1/4 AXLE PINION GEAR DEPTH . . . . . . . . . . . 126
TRAC–LOKY DIFFERENTIAL NOISE . . . . . . . . . 109 DIFFERENTIAL BEARING PRELOAD AND
TRAC–LOKY TEST . . . . . . . . . . . . . . . . . . . . . . 110 GEAR BACKLASH. . . . . . . . . . . . . . . . . . . . . . 127
SERVICE PROCEDURES GEAR CONTACT PATTERN ANALYSIS. . . . . . . . 129
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . 110 SIDE GEAR CLEARANCE . . . . . . . . . . . . . . . . . 129
REMOVAL AND INSTALLATION SPECIFICATIONS
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 8 1/4 INCH AXLE . . . . . . . . . . . . . . . . . . . . . . . . 131
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 8 1/4 INCH AXLE . . . . . . . . . . . . . . . . . . . . . . . . 131
AXLE SEAL AND BEARING . . . . . . . . . . . . . . . . 112 SPECIAL TOOLS
PINION SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 8 1/4 AXLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

DESCRIPTION AND OPERATION threaded pin. Differential bearing preload and ring
gear backlash are set and maintained by threaded
8 1/4 AXLE adjusters at the outside of the differential housing.
Pinion bearing preload is set and maintained by the
DESCRIPTION use of a collapsible spacer.
The 8 1/4 inch axle housings consist of a cast iron Axles equipped with a Trac-Loky differential are
center section with axle tubes extending from either optional. A Trac-Lok differential has a one-piece dif-
side. The tubes are pressed into and welded to the ferential case, and the same internal components as
differential housing to form a one-piece axle housing a standard differential, plus two clutch disc packs.
(Fig. 1).
AXLE IDENTIFICATION
The axles have a vent hose to relieve internal pres-
sure caused by lubricant vaporization and internal The axle differential cover can be used for identifi-
expansion. cation of the axle (Fig. 2). A tag is also attached to
The axles are equipped with semi-floating axle the cover.
shafts, meaning vehicle loads are supported by the
axle shaft and bearings. The axle shafts are retained
OPERATION
by C-locks in the differential side gears. The axle receives power from the transmission/
The removable, stamped steel cover provides a transfer case through the rear propeller shaft. The
means for inspection and service without removing rear propeller shaft is connected to the pinion gear
the complete axle from the vehicle. which rotates the differential through the gear mesh
The 8 1/4 axle have a date tag and a gear ratio tag. with the ring gear bolted to the differential case. The
The tags are attached to the differential housing by a engine power is transmitted to the axle shafts
cover bolt. through the pinion mate and side gears. The side
The differential case is a one-piece design. The dif- gears are splined to the axle shafts.
ferential pinion mate shaft is retained with a

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 3 - 104 8 1/4 REAR AXLE XJ
DESCRIPTION AND OPERATION (Continued)

Fig. 1 8 1/4 Axle

LUBRICANT
DESCRIPTION
Multi-purpose, hypoid gear lubricant should be
used for rear axles with a standard differential. The
lubricant should have a MIL-L-2105C and API GL 5
quality specifications.
Trac-Lok differentials require the addition of 4 oz.
of friction modifier to the axle lubricant after service.
The 8 1/4 axle lubricant capacity is 2.08 L (4.4 pts.)
total, including the friction modifier, if necessary.

CAUTION: If the rear axle is submerged in water,

the lubricant must be replaced immediately. Avoid
the possibility of premature axle failure resulting
from water contamination of the lubricant.

Fig. 2 Differential Cover 8 1/4 Inch Axle

1 – DIFFERENTIAL COVER
2 – IDENTIFICATION TAG
3 – PUSH-IN FILL PLUG
4 – DATE TAG

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 XJ 8 1/4 REAR AXLE 3 - 105
DESCRIPTION AND OPERATION (Continued)

STANDARD DIFFERENTIAL When turning corners, the outside wheel must

travel a greater distance than the inside wheel to
DESCRIPTION complete a turn. The difference must be compensated
The differential gear system divides the torque for to prevent the tires from scuffing and skidding
between the axle shafts. It allows the axle shafts to through turns. To accomplish this, the differential
rotate at different speeds when turning corners. allows the axle shafts to turn at unequal speeds (Fig.
Each differential side gear is splined to an axle 4). In this instance, the input torque applied to the
shaft. The pinion gears are mounted on a pinion pinion gears is not divided equally. The pinion gears
mate shaft and are free to rotate on the shaft. The now rotate around the pinion mate shaft in opposite
pinion gear is fitted in a bore in the differential case directions. This allows the side gear and axle shaft
and is positioned at a right angle to the axle shafts. attached to the outside wheel to rotate at a faster
speed.
OPERATION
In operation, power flow occurs as follows:
• The pinion gear rotates the ring gear
• The ring gear (bolted to the differential case)
rotates the case
• The differential pinion gears (mounted on the
pinion mate shaft in the case) rotate the side gears
• The side gears (splined to the axle shafts) rotate
the shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 3).
Fig. 4 Differential Operation—On Turns
1 – PINION GEARS ROTATE ON PINION SHAFT

TRAC-LOKY DIFFERENTIAL
DESCRIPTION
In a standard differential, if one wheel spins, the
opposite wheel will generate only as much torque as
the spinning wheel.
In the Trac-loky differential, part of the ring gear
torque is transmitted through clutch packs which
contain multiple discs. The clutches will have radial
grooves on the plates, and concentric grooves on the
discs or bonded fiber material that is smooth in
Fig. 3 Differential Operation—Straight Ahead Driving appearance.
1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED OPERATION
2 – PINION GEAR In operation, the Trac-loky clutches are engaged
3 – SIDE GEAR by two concurrent forces. The first being the preload
4 – PINION GEARS ROTATE WITH CASE
force exerted through Belleville spring washers
within the clutch packs. The second is the separating
forces generated by the side gears as torque is
applied through the ring gear (Fig. 5).

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 3 - 106 8 1/4 REAR AXLE XJ
DESCRIPTION AND OPERATION (Continued)
straight ahead during periods of unequal traction.
When one wheel looses traction, the clutch packs
transfer additional torque to the wheel having the
most traction. Trac-loky differentials resist wheel
spin on bumpy roads and provide more pulling power
when one wheel looses traction. Pulling power is pro-
vided continuously until both wheels loose traction. If
both wheels slip due to unequal traction, Trac-loky
operation is normal. In extreme cases of differences
of traction, the wheel with the least traction may
spin.

DIAGNOSIS AND TESTING

GENERAL INFORMATION
Axle bearing problem conditions are usually caused
by:
• Insufficient or incorrect lubricant.
• Foreign matter/water contamination.
• Incorrect bearing preload torque adjustment.
• Incorrect backlash.
Axle gear problem conditions are usually the result
of:
• Insufficient lubrication.
• Incorrect or contaminated lubricant.
• Overloading (excessive engine torque) or exceed-
Fig. 5 Trac-lokY Limited Slip Differential Operation ing vehicle weight capacity.
1 – CASE
• Incorrect clearance or backlash adjustment.
2 – RING GEAR Axle component breakage is most often the result
3 – DRIVE PINION of:
4 – PINION GEAR • Severe overloading.
5 – MATE SHAFT • Insufficient lubricant.
6 – CLUTCH PACK • Incorrect lubricant.
7 – SIDE GEAR • Improperly tightened components.
8 – CLUTCH PACK • Differential housing bores not square to each
other.
The Trac-loky design provides the differential
action needed for turning corners and for driving

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 XJ 8 1/4 REAR AXLE 3 - 107
DIAGNOSIS AND TESTING (Continued)
DIAGNOSTIC CHART

Condition Possible Causes Correction

Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.

2. Faulty, brinelled wheel bearing. 2. Replace bearing.

Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
necessary.

2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.

3. End-play in pinion bearings. 3. Refer to pinion pre-load information and
correct as necessary.
4. Excessive gear backlash 4. Check adjustment of the ring gear and
between the ring gear and pinion. pinion backlash. Correct as necessary.
5. Improper adjustment of pinion 5. Adjust the pinion bearings pre-load.
gear bearings.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact 7. Inspect and replace as necessary.
surfaces.

Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting
tube mis-alignment.

2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive

weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct
erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect and
repair clutch as necessary.

Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears and
differential bearings. bearings for further damage. Set differential
bearing pre-load properly.

2. Excessive ring gear backlash. 2. Replace case and inspect gears and
bearings for further damage. Set ring gear
backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and
bearings for further damage. Avoid excessive
vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and
bearings for further damage. Avoid erratic use
of clutch.

Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with
the correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with
the correct fluid type and quantity.
3. Excessive spinning of one 3. Replace scored gears. Inspect all gears,
wheel/tire. pinion bores, and shaft for damage. Service
as necessary.

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 3 - 108 8 1/4 REAR AXLE XJ
DIAGNOSIS AND TESTING (Continued)

Condition Possible Causes Correction

Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.

2. Worn axle shaft seals. 2. Replace seals.

3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.

Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.

2. Improper grade of lubricant. 2. Fill differential with the correct fluid type
and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.

Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and
bearings for possible damage.

2. Erratic clutch operation. 2. Replace gears and examine the remaining

parts for damage. Avoid erratic clutch
operation.
3. Ice-spotted pavement. 3. Replace gears and examine remaining
parts for damage.
4. Improper adjustments. 4. Replace gears and examine remaining
parts for damage. Ensure ring gear backlash
is correct.

Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type
and quantity.
2. Improper ring gear and pinion 2. Check ring gear and pinion contact pattern.
adjustment.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring gear
and pinion.
4. Worn teeth on ring gear and/or 4. Replace ring gear and pinion.
pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap 8. Inspect differential components and replace
bolts. as necessary. Ensure that the bearing caps
are torqued tot he proper specification.
9. Housing not machined properly. 9. Replace housing.

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 XJ 8 1/4 REAR AXLE 3 - 109
DIAGNOSIS AND TESTING (Continued)

GEAR NOISE VIBRATION

Axle gear noise can be caused by insufficient lubri- Vibration at the rear of the vehicle is usually
cant, incorrect backlash, tooth contact, worn/damaged caused by a:
gears, or the carrier housing not having the proper • Damaged drive shaft.
offset and squareness. • Missing drive shaft balance weight(s).
Gear noise usually happens at a specific speed • Worn or out–of–balance wheels.
range. The noise can also occur during a specific type • Loose wheel lug nuts.
of driving condition. These conditions are accelera- • Worn U–joint(s).
tion, deceleration, coast, or constant load. • Loose/broken springs.
When road testing, first warm-up the axle fluid by • Damaged axle shaft bearing(s).
driving the vehicle at least 5 miles and then acceler- • Loose pinion gear nut.
ate the vehicle to the speed range where the noise is • Excessive pinion yoke run out.
the greatest. Shift out-of-gear and coast through the • Bent axle shaft(s).
peak–noise range. If the noise stops or changes Check for loose or damaged front–end components
greatly: or engine/transmission mounts. These components
• Check for insufficient lubricant. can contribute to what appears to be a rear–end
• Incorrect ring gear backlash. vibration. Do not overlook engine accessories, brack-
• Gear damage. ets and drive belts.
Differential side gears and pinions can be checked All driveline components should be examined
by turning the vehicle. They usually do not cause before starting any repair.
noise during straight–ahead driving when the gears Refer to Group 22, Wheels and Tires, for additional
are unloaded. The side gears are loaded during vehi- vibration information.
cle turns. A worn pinion mate shaft can also cause a
snapping or a knocking noise. DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted
BEARING NOISE into gear (or the clutch engaged), can be caused by:
The axle shaft, differential and pinion bearings can • High engine idle speed.
all produce noise when worn or damaged. Bearing • Transmission shift operation.
noise can be either a whining, or a growling sound. • Loose engine/transmission/transfer case mounts.
Pinion bearings have a constant–pitch noise. This • Worn U–joints.
noise changes only with vehicle speed. Pinion bearing • Loose spring mounts.
noise will be higher pitched because it rotates at a • Loose pinion gear nut and yoke.
faster rate. Drive the vehicle and load the differen- • Excessive ring gear backlash.
tial. If bearing noise occurs, the rear pinion bearing • Excessive side gear to case clearance.
is the source of the noise. If the bearing noise is The source of a snap or a clunk noise can be deter-
heard during a coast, the front pinion bearing is the mined with the assistance of a helper. Raise the vehi-
source. cle on a hoist with the wheels free to rotate. Instruct
Worn or damaged differential bearings usually pro- the helper to shift the transmission into gear. Listen
duce a low pitch noise. Differential bearing noise is for the noise, a mechanics stethoscope is helpful in
similar to pinion bearing noise. The pitch of differen- isolating the source of a noise.
tial bearing noise is also constant and varies only
with vehicle speed. TRAC–LOKY DIFFERENTIAL NOISE
Axle shaft bearings produce noise and vibration The most common problem is a chatter noise when
when worn or damaged. The noise generally changes turning corners. Before removing a Trac-loky unit
when the bearings are loaded. Road test the vehicle. for repair, drain, flush and refill the axle with the
Turn the vehicle sharply to the left and to the right. specified lubricant. Refer to Lubricant change in this
This will load the bearings and change the noise Group.
level. Where axle bearing damage is slight, the noise A container of Mopart Trac-loky Lubricant (fric-
is usually not noticeable at speeds above 30 mph. tion modifier) should be added after repair service or
during a lubricant change.
LOW SPEED KNOCK After changing the lubricant, drive the vehicle and
Low speed knock is generally caused by a worn make 10 to 12 slow, figure-eight turns. This maneu-
U–joint or by worn side–gear thrust washers. A worn ver will pump lubricant through the clutches. This
pinion shaft bore will also cause low speed knock. will correct the condition in most instances. If the
chatter persists, clutch damage could have occurred.

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 3 - 110 8 1/4 REAR AXLE XJ
DIAGNOSIS AND TESTING (Continued)

TRAC–LOKY TEST (3) Remove the differential housing cover and

drain the lubricant from the housing.
WARNING: WHEN SERVICING VEHICLES WITH A (4) Clean the housing cavity with a flushing oil,
TRAC–LOKY DIFFERENTIAL DO NOT USE THE light engine oil, or lint free cloth. Do not use water,
ENGINE TO TURN THE AXLE AND WHEELS. BOTH steam, kerosene, or gasoline for cleaning.
REAR WHEELS MUST BE RAISED AND THE VEHI- (5) Remove the original sealant from the housing
CLE SUPPORTED. A TRAC–LOKY AXLE CAN and cover surfaces.
EXERT ENOUGH FORCE IF ONE WHEEL IS IN CON- (6) Apply a bead of Mopart Silicone Rubber Seal-
TACT WITH A SURFACE TO CAUSE THE VEHICLE ant, or equivalent, to the housing cover (Fig. 7).
TO MOVE.

The differential can be tested without removing the

differential case by measuring rotating torque. Make
sure brakes are not dragging during this measure-
ment.
(1) Place blocks in front and rear of both front
wheels.
(2) Raise one rear wheel until it is completely off
the ground.
(3) Engine off, transmission in neutral, and park-
ing brake off.
(4) Remove wheel and bolt Special Tool 6790 to
studs.
(5) Use torque wrench on special tool to rotate
wheel and read rotating torque (Fig. 6).
Fig. 7 Apply Sealant
1 – SEALANT
2 – AXLE HOUSING COVER

Install the housing cover within 5 minutes

after applying the sealant.
(7) Install the cover and any identification tag.
Tighten the cover bolts to 41 N·m (30 ft. lbs.) torque.
(8) For Trac–loky differentials, a quantity of
Mopart Trac–loky lubricant (friction modifier), or
equivalent, must be added after repair service or a
lubricant change. Refer to the Lubricant Specifica-
tions section of this group for the quantity necessary.
(9) Fill differential with Mopart Hypoid Gear
Lubricant, or equivalent, to bottom of the fill plug
hole. Refer to the Lubricant Specifications section of
Fig. 6 Trac-lokY Test —Typical this group for the quantity necessary.
1 – SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 – TORQUE WRENCH CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.

(6) If rotating torque is less than 22 N·m (30 ft. (10) Install the fill hole plug and lower the vehicle.
lbs.) or more than 271 N·m (200 ft. lbs.) on either (11) Trac–loky differential equipped vehicles
wheel the unit should be serviced. should be road tested by making 10 to 12 slow figure-
eight turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
SERVICE PROCEDURES ter noise complaint.
LUBRICANT CHANGE
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
differential housing cover.

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 XJ 8 1/4 REAR AXLE 3 - 111

REMOVAL AND INSTALLATION AXLE SHAFT

REAR AXLE REMOVAL
(1) Raise and support vehicle. Ensure that the
REMOVAL transmission is in neutral.
(1) Raise and support the vehicle. (2) Remove wheel and tire assembly.
(2) Position a suitable lifting device under the (3) Remove brake drum. Refer to Group 5, Brakes,
axle. for proper procedure.
(3) Secure axle to device. (4) Clean all foreign material from housing cover
(4) Remove the wheels and tires. area.
(5) Secure brake drums to the axle shaft. (5) Loosen housing cover bolts. Drain lubricant
(6) Disconnect the brake hose at the axle junction from the housing and axle tubes. Remove housing
block. Do not disconnect the brake hydraulic lines at cover.
the wheel cylinders. Refer to Group 5, Brakes, for (6) Rotate differential case so that pinion mate
proper procedures. shaft lock screw is accessible. Remove lock screw and
(7) Disconnect the parking brake cables and cable pinion mate shaft from differential case (Fig. 8).
brackets.
(8) Disconnect the vent hose from the axle tube.
(9) Mark the propeller shaft and yoke for installa-
tion alignment reference.
(10) Remove propeller shaft.
(11) Disconnect shock absorbers from axle.
(12) Remove the stabilizer links.
(13) Remove the spring clamps and spring brack-
ets. Refer to Group 2, Suspension, for proper proce-
dures.
(14) Separate the axle from the vehicle.

INSTALLATION
(1) Raise the axle with lifting device and align to
the leaf spring centering bolts.
(2) Install the spring clamps and spring brackets.
Refer to Group 2, Suspension, for proper procedures. Fig. 8 Pinion Mate Shaft Lock Screw
(3) Install shock absorbers and tighten nuts to 60 1 – LOCK SCREW
N·m (44 ft. lbs.) torque. 2 – PINION MATE SHAFT
(4) Install the stabilizer links. Tighten sway bar
links to 74 N·m (55 ft. lbs.). (7) Push axle shaft inward and remove axle shaft
(5) Connect the parking brake cables and cable C–lock from the axle shaft (Fig. 9).
brackets. (8) Remove axle shaft. Use care to prevent damage
(6) Install the brake drums. Refer to Group 5, to axle shaft bearing and seal, which will remain in
Brakes, for proper procedures. axle tube.
(7) Connect the brake hose to the axle junction (9) Inspect axle shaft seal for leakage or damage.
block. Refer to Group 5, Brakes, for proper proce- (10) Inspect roller bearing contact surface on axle
dures. shaft for signs of brinelling, galling and pitting. If
(8) Install axle vent hose. any of these conditions exist, the axle shaft and/or
(9) Align propeller shaft and pinion yoke reference bearing and seal must be replaced.
marks. Install universal joint straps and bolts.
Tighten to 19 N·m (14 ft. lbs.) torque. INSTALLATION
(10) Install the wheels and tires. (1) Lubricate bearing bore and seal lip with gear
(11) Add gear lubricant, if necessary. Refer to lubricant. Insert axle shaft through seal, bearing,
Lubricant Specifications in this section for lubricant and engage it into side gear splines.
requirements.
(12) Remove lifting device from axle and lower the NOTE: Use care to prevent shaft splines from dam-
vehicle. aging axle shaft seal lip.

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 3 - 112 8 1/4 REAR AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 9 Axle Shaft C–Lock Fig. 10 Axle Seal Removal

1 – C—LOCK 1 – AXLE TUBE
2 – AXLE SHAFT 2 – AXLE SEAL
3 – SIDE GEAR 3 – PRY BAR

(2) Insert C–lock in end of axle shaft. Push axle

shaft outward to seat C–lock in side gear.
(3) Insert pinion shaft into differential case and
through thrust washers and differential pinions.
(4) Align hole in shaft with hole in the differential
case and install lock screw with Loctitet on the
threads. Tighten lock screw to 11 N·m (8 ft. lbs.)
torque.
(5) Install cover and add fluid. Refer to Lubricant
Change procedure in this section for procedure and
lubricant requirements.
(6) Install brake drum. Refer to Group 5, Brakes,
for proper procedures.
(7) Install wheel and tire.
(8) Lower vehicle.

AXLE SEAL AND BEARING

REMOVAL
(1) Remove axle shaft.
(2) Remove axle shaft seal from the end of the axle
tube with a small pry bar (Fig. 10). Fig. 11 Axle Shaft Bearing Removal Tool
1 – NUT
NOTE: The seal and bearing can be removed at the
2 – GUIDE PLATE
same time with the bearing removal tool. 3 – GUIDE
4 – THREADED ROD
(3) Remove the axle shaft bearing from the axle 5 – ADAPTER
tube with Bearing Removal Tool Set 6310, using 6 – FOOT
Adapter Foot 6310-9 (Fig. 11). 7 – AXLE TUBE

INSTALLATION
(2) Install the axle shaft bearing with Installer
NOTE: Do not install the original axle shaft seal. C-4198 and Handle C-4171 (Fig. 12). Ensure that the
Always install a new seal. bearing part number is against the installer. Verify
that the bearing in installed straight and the tool
(1) Wipe the axle tube bore clean. Remove any old fully contacts the axle tube when seating the bearing.
sealer or burrs from the tube.

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 XJ 8 1/4 REAR AXLE 3 - 113
REMOVAL AND INSTALLATION (Continued)
(3) Install a new axle seal with Installer C-4076-B
and Handle C-4735-1. When the tool contacts the
axle tube, the seal is installed to the correct depth.
(4) Coat the lip of the seal with axle lubricant for
protection prior to installing the axle shaft.
(5) Install the axle shaft.

Fig. 13 Yoke Removal

1 – PINION YOKE
2 – TOOL C452

(3) Inspect pinion yoke for cracks, worn splines

and worn seal contact surface. Replace yoke if neces-
Fig. 12 Axle Shaft Seal and Bearing Installation sary.
1 – HANDLE
2 – INSTALLER NOTE: The outer perimeter of the seal is pre-coated
3 – AXLE TUBE with a special sealant. An additional application of
sealant is not required.
PINION SEAL (4) Apply a light coating of gear lubricant on the
lip of pinion seal.
REMOVAL (5) Install the new pinion seal with Installer
(1) Raise and support the vehicle. C-4076-B and Handle C-4735-1 (Fig. 14).
(2) Scribe a mark on the universal joint, pinion
yoke, and pinion shaft for reference.
(3) Disconnect the propeller shaft from the pinion
yoke. Secure the propeller shaft in an upright posi-
tion to prevent damage to the rear universal joint.
(4) Remove the wheel and tire assemblies.
(5) Remove the brake drums to prevent any drag.
The drag may cause a false bearing preload torque
measurement.
(6) Rotate the pinion yoke three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Hold the yoke with Wrench 6719. Remove the
pinion nut and washer.
(9) Remove the yoke with Remover C-452 (Fig. 13).
Fig. 14 8 1/4 Axle Pinion Seal Installation
(10) Remove the pinion seal with suitable pry tool
1 – SPECIAL TOOL C-4735
or slide-hammer mounted screw.
2 – DIFFERENTIAL HOUSING
3 – SPECIAL TOOL C-4076-A
INSTALLATION
(1) Clean the seal contact surface in the housing
bore. NOTE: The seal is correctly installed when the seal
(2) Examine the splines on the pinion shaft for flange contacts the face of the differential housing
burrs or wear. Remove any burrs and clean the shaft. flange.

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 3 - 114 8 1/4 REAR AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(6) Position the pinion yoke on the end of the shaft
with the reference marks aligned.
(7) Seat yoke on pinion shaft with Installer C-3718
and Wrench 6719.
(8) Remove the tools and install the pinion yoke
washer. The convex side of the washer must face out-
ward.

CAUTION: Do not exceed the minimum tightening

torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer or bear-
ings may result.

(9) Hold pinion yoke with Yoke Holder 6719 and

tighten shaft nut to 285 N·m (210 ft. lbs.) (Fig. 15).
Rotate the pinion several revolutions to ensure the
bearing rollers are seated.

Fig. 16 Check Pinion Rotation Torque

1 – PINION YOKE
2 – INCH POUND TORQUE WRENCH

(11) If the rotating torque is low, use Yoke Holder

6719 to hold the pinion yoke (Fig. 15) and tighten the
pinion nut in 6.8 N·m (5 ft. lbs.) increments until
proper rotating torque is achieved.

NOTE: The bearing rotating torque should be con-

stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.

(12) The seal replacement is unacceptable if the

final pinion nut torque is less than 285 N·m (210 ft.
lbs.).
Fig. 15 Tightening Pinion Nut (13) Install the propeller shaft with the installa-
1 – DIFFERENTIAL HOUSING tion reference marks aligned.
2 – YOKE HOLDER (14) Tighten the universal joint yoke clamp screws
3 – TORQUE WRENCH to 19 N·m (14 ft. lbs.).
(15) Install the brake drums.
(10) Rotate the pinion using an (in. lbs.) torque (16) Install wheel and tire assemblies and lower
wrench. Rotating torque should be equal to the read- the vehicle.
ing recorded during removal, plus an additional 0.56 (17) Check the differential housing lubricant level.
N·m (5 in. lbs.) (Fig. 16).
DIFFERENTIAL
CAUTION: Never loosen pinion nut to decrease pin-
ion gear bearing rotating torque and never exceed REMOVAL
specified preload torque. If preload torque is (1) Remove the axle shafts.
exceeded a new collapsible spacer must be
installed. The torque sequence will then have to be NOTE: Side play resulting from bearing races being
repeated. loose on case hubs requires replacement of the dif-
ferential case.

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 XJ 8 1/4 REAR AXLE 3 - 115
REMOVAL AND INSTALLATION (Continued)
(2) Mark the differential housing and the differen- INSTALLATION
tial bearing caps for installation reference (Fig. 17). (1) Apply a coating of hypoid gear lubricant to the
differential bearings, bearing cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters in position. Carefully position the assem-
bled differential case in the housing.
(2) Observe the reference marks and install the
differential bearing caps at their original locations
(Fig. 19).

Fig. 17 Mark For Installation Reference

1 – INSTALLATION REFERENCE MARKS
2 – INSTALLATION REFERENCE MARKS
3 – DIFFERENTIAL HOUSING
4 – BEARING CAP

(3) Remove bearing threaded adjuster lock from

each bearing cap. Loosen the bolts, but do not Fig. 19 Bearing Caps & Bolts
remove the bearing caps. 1 – INSTALLATION REFERENCE MARKS
(4) Loosen the threaded adjusters with Wrench 2 – INSTALLATION REFERENCE MARKS
C-4164 (Fig. 18). 3 – DIFFERENTIAL HOUSING
4 – BEARING CAP

(3) Install bearing cap bolts and tighten the upper

bolts to 14 N·m (10 ft. lbs.). Tighten the lower bolts
finger-tight until the bolt head is seated.
(4) Perform the differential bearing preload and
adjustment procedure.

NOTE: Be sure that all bearing cap bolts are tight-

ened to the final torque of 95 N·m (70 ft.lbs) before
proceeding.

(5) Install axle shafts and differential housing

cover.

DIFFERENTIAL SIDE BEARINGS

Fig. 18 Threaded Adjuster Tool
1 – AXLE TUBE REMOVAL
2 – BACKING PLATE (1) Remove differential case from axle housing.
3 – TOOL C-4164 (2) Remove the bearings from the differential case
with Puller/Press C-293-PA and Adapters C-293-48
(5) Hold the differential case while removing bear- and Plug SP-3289 (Fig. 20).
ing caps and adjusters.
(6) Remove the differential case. INSTALLATION
(1) Install differential side bearings. Use Installer
NOTE: Each differential bearing cup and threaded C-4340 with handle C-4171 (Fig. 21).
adjuster must be kept with their respective bearing. (2) Install differential case in axle housing.

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 3 - 116 8 1/4 REAR AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 21 Install Differential Side Bearings

1 – HANDLE C-4171
2 – DIFFERENTIAL
3 – BEARING
4 – TOOL C-4340

Fig. 20 Differential Bearing Removal

1 – SPECIAL TOOL C-293–PA
2 – SPECIAL TOOL C-293–48
3 – BEARING
4 – DIFFERENTIAL
5 – SPECIAL TOOL SP-3289

RING GEAR
The ring gear and pinion are serviced in a matched
set. Do not replace the ring gear without replacing
the pinion.

REMOVAL
(1) Remove differential from axle housing.
(2) Place differential case in a suitable vise with
soft metal jaw protectors. (Fig. 22).
(3) Remove bolts holding ring gear to differential Fig. 22 Ring Gear Removal
case. 1 – CASE
(4) Using a soft hammer, drive ring gear from dif- 2 – RING GEAR
ferential case (Fig. 22). 3 – RAWHIDE HAMMER

INSTALLATION
(2) Position ring gear on the differential case and
CAUTION: Do not reuse the bolts that held the ring start two ring gear bolts. This will provide case-to-
gear to the differential case. The bolts can fracture ring gear bolt hole alignment.
causing extensive damage. (3) Invert the differential case in the vise.
(4) Install new ring gear bolts and alternately
(1) Invert the differential case. tighten to 102 N·m (75 ft. lbs.) torque (Fig. 23).
(5) Install differential in axle housing and verify
gear mesh and contact pattern.

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 XJ 8 1/4 REAR AXLE 3 - 117
REMOVAL AND INSTALLATION (Continued)

Fig. 24 Pinion Yoke Removal

1 – PINION YOKE
2 – TOOL C452

Fig. 23 Ring Gear Bolt Installation

1 – TORQUE WRENCH
2 – RING GEAR BOLT
3 – RING GEAR
4 – CASE

PINION GEAR
The ring gear and pinion are serviced in a matched
set. Do not replace the pinion without replacing the
ring gear.

REMOVAL
(1) Remove differential from the axle housing.
(2) Mark pinion yoke and propeller shaft for
installation alignment.
(3) Disconnect propeller shaft from pinion yoke.
Using suitable wire, tie propeller shaft to underbody.
(4) Using Yoke Holder 6719 to hold yoke and
Fig. 25 Remove Pinion Gear
remove the pinion yoke nut and washer.
1 – RAWHIDE HAMMER
(5) Using Remover C–452, remove the pinion yoke
from pinion shaft (Fig. 24).
(6) Partially install pinion nut onto pinion to pro- (12) Remove the collapsible preload spacer (Fig. 28).
tect the threads. (13) Remove the rear bearing from the pinion (Fig.
(7) Remove the pinion from housing (Fig. 25). 29) with Puller/Press C-293-PA and Adapters C-293-47.
Catch the pinion with your hand to prevent it from Place 4 adapter blocks so they do not damage
falling and being damaged. the bearing cage.
(8) Remove the pinion shaft seal with suitable pry (14) Remove the depth shims from the pinion
tool or slide-hammer mounted screw. shaft. Record the thickness of the depth shims.
(9) Remove oil slinger, if equipped, and front pin-
ion bearing. INSTALLATION
(10) Remove the front pinion bearing cup with (1) Apply Mopart Door Ease, or equivalent, stick
Remover C-4345 and Handle C–4171 (Fig. 26). lubricant to outside surface of bearing cup.
(11) Remove the rear bearing cup from housing (2) Install the pinion rear bearing cup (Fig. 30)
(Fig. 27). Use Remover C-4307 and Handle C–4171. with Installer C-4308 and Driver Handle C–4171.

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 3 - 118 8 1/4 REAR AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 28 Collapsible Spacer

Fig. 26 Front Bearing Cup Removal
1 – COLLAPSIBLE SPACER
1 – REMOVER
2 – SHOULDER
2 – HANDLE
3 – PINION
4 – PINION DEPTH SHIM
5 – REAR BEARING

Fig. 27 Rear Bearing Cup Removal

1 – DRIVER
2 – HANDLE
Fig. 29 Rear Bearing Removal
(2) Ensure cup is correctly seated. 1 – SPECIAL TOOL C-293–PA
(3) Apply Mopart Door Ease, or equivalent, stick 2 – VISE
3 – ADAPTERS
lubricant to outside surface of bearing cup.
4 – DRIVE PINION GEAR SHAFT
(4) Install the pinion front bearing cup (Fig. 31)
with Installer D–130 and Handle C–4171.
(5) Install pinion front bearing, and oil slinger, if (6) Apply a light coating of gear lubricant on the
equipped. lip of pinion seal. Install seal with Installer
C-4076–B and Handle C-4735-1 (Fig. 32).

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 XJ 8 1/4 REAR AXLE 3 - 119
REMOVAL AND INSTALLATION (Continued)

Fig. 32 Pinion Seal Installation

1 – SPECIAL TOOL C-4735
2 – DIFFERENTIAL HOUSING
3 – SPECIAL TOOL C-4076-A

(8) Install the rear bearing and slinger, if

Fig. 30 Pinion Rear Bearing Cup Installation equipped, on the pinion (Fig. 33) with Installer 6448.
1 – INSTALLER
2 – HANDLE

Fig. 31 Pinion Front Bearing Cup Installation

1 – INSTALLER
2 – HANDLE Fig. 33 Shaft Rear Bearing Installation
1 – PRESS
NOTE: Pinion depth shims are placed between the 2 – INSTALLATION TOOL
3 – DRIVE PINION
rear pinion bearing cone and pinion head to
4 – DRIVE PINION SHAFT REAR BEARING
achieve proper ring and pinion gear mesh. If the
factory installed ring gear and pinion are reused,
the pinion depth shim should not require replace- (9) Install a new collapsible preload spacer on pin-
ment. If required, refer to Pinion Gear Depth to ion shaft and install pinion in housing (Fig. 34).
select the proper thickness shim before installing (10) Install pinion in housing.
rear pinion bearing. (11) Install yoke with Installer C-3718 and Yoke
Holder 6719.
(7) Place the proper thickness depth shim on the (12) Install the yoke washer and a new nut on the
pinion. pinion and tighten the pinion nut until there is zero

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 3 - 120 8 1/4 REAR AXLE XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 34 Collapsible Preload Spacer

Fig. 35 Check Pinion Rotating Torque
1 – COLLAPSIBLE SPACER
1 – PINION YOKE
2 – SHOULDER
2 – INCH POUND TORQUE WRENCH
3 – PINION
4 – PINION DEPTH SHIM
5 – REAR BEARING
DISASSEMBLY AND ASSEMBLY
bearing end-play. It will not be possible at this point STANDARD DIFFERENTIAL
to achieve zero bearing end-play if a new collapsible
spacer was installed. DISASSEMBLY
(13) Tighten the nut to 285 N·m (210 ft. lbs.). (1) Remove pinion mate shaft lock screw (Fig. 36).
(2) Remove pinion mate shaft.
CAUTION: Never loosen pinion nut to decrease pin- (3) Rotate the differential side gears and remove the
ion bearing rotating torque and never exceed spec- differential pinion gears and thrust washers (Fig. 37).
ified preload torque. If preload torque or rotating
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.

(14) Using Yoke Holder 6719, crush collapsible

spacer until bearing end play is taken up.
(15) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.)
increments until the desired rotating torque is
achieved. Measure the rotating torque frequently to
avoid over crushing the collapsible spacer (Fig. 35).
(16) Check bearing rotating torque with an inch
pound torque wrench (Fig. 35). The torque necessary
to rotate the pinion gear should be:
• Original Bearings — 1 to 2 N·m (10 to 20 in. lbs.).
• New Bearings — 1 to 5 N·m (10 to 30 in. lbs.). Fig. 36 Pinion Mate Shaft Lock Screw
(17) Install propeller shaft. 1 – LOCK SCREW
(18) Install differential in housing. 2 – PINION MATE SHAFT

(4) Remove the differential side gears and thrust

washers.

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 XJ 8 1/4 REAR AXLE 3 - 121
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Install the differential side gears and thrust
washers.
(2) Install the differential pinion gears and thrust
washers.
(3) Install the pinion mate shaft.
(4) Align the hole in the pinion mate shaft with
the hole in the differential case and install the pinion
mate shaft lock screw.
(5) Lubricate all differential components with
hypoid gear lubricant.

TRAC-LOKY DIFFERENTIAL
The Trac–loky differential components are illus-
trated in (Fig. 38). Refer to this illustration during
repair service.

DISASSEMBLY
(1) Clamp Side Gear Holding Tool 8138 in a vise.
(2) Position the differential case on Side Gear
Holding Tool 8138 (Fig. 39).
Fig. 37 Pinion Mate Gear Removal (3) Remove ring gear, if necessary. Ring gear
1 – THRUST WASHER removal is necessary only if the ring gear is to be
2 – SIDE GEAR replaced. The Trac-loky differential can be serviced
3 – PINION MATE GEAR with the ring gear installed.

Fig. 38 Trac–lokY Differential Components

1 – THRUST WASHER 6 – RETAINER
2 – PINION 7 – DISC
3 – SHAFT LOCK SCREW 8 – CLUTCH PACK
4 – PINION MATE SHAFT 9 – DIFFERENTIAL CASE
5 – SIDE GEAR 10 – RETAINER

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 3 - 122 8 1/4 REAR AXLE XJ
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 41 Mate Shaft Removal

1 – PINION MATE SHAFT
2 – SIDE GEAR
3 – DRIFT
4 – PINION MATE GEAR

Fig. 39 Differential Case Holding Tool

1 – SIDE GEAR HOLDING TOOL
2 – VISE
3 – DIFFERENTIAL

(4) Remove the pinion mate shaft lock screw (Fig.

40).

Fig. 42 Step Plate Tool Installation

1 – SPECIAL TOOL 8140–2
2 – LOWER SIDE GEAR
3 – DIFFERENTIAL CASE

Fig. 40 Mate Shaft Lock Screw (8) Position a small screw driver in slot of
1 – LOCK SCREW
Threaded Adapter 8140-1 (Fig. 43) to prevent adapter
2 – PINION MATE SHAFT
from turning.
(9) Tighten forcing screw tool 122 N·m (90 ft. lbs.)
(5) Remove the pinion mate shaft. If necessary, use maximum to compress Belleville springs in clutch
a drift and hammer (Fig. 41). packs (Fig. 44).
(6) Install and lubricate Step Plate 8140–2 (Fig. (10) Using an appropriate size feeler gauge,
42). remove thrust washers from behind the differential
(7) Assemble Threaded Adapter 8140-1 into top pinions (Fig. 45).
side gear. Thread Forcing Screw 6960-4 into adapter (11) Insert Turning Bar 6960-2 in case (Fig. 46).
until it becomes centered in adapter plate.

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 XJ 8 1/4 REAR AXLE 3 - 123
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 43 Threaded Adapter Installation

1 – SOCKET Fig. 45 Remove Pinion Thrust Washer
2 – SLOT IN ADAPTER 1 – THRUST WASHER
3 – SCREWDRIVER 2 – FEELER GAUGE
4 – DISC 8140–2
5 – THREADED ROD C-6960–4
6 – THREADED ADAPTER DISC 8140–1 (14) Remove pinions from differential case.

Fig. 46 Pinion Gear Removal

1 – PINION GEARS
Fig. 44 Tighten Belleville Spring Compressor Tool
2 – TOOL
1 – TORQUE WRENCH
2 – TOOL ASSEMBLED
3 – DIFFERENTIAL CASE (15) Remove Forcing Screw 6960-4, Step Plate
8140–2, and Threaded Adapter 8140–1.
(12) Loosen the Forcing Screw 6960-4 in small (16) Remove top side gear, clutch pack retainer,
increments until the clutch pack tension is relieved and clutch pack. Keep plates in correct order during
and the differential case can be turned using Turning removal (Fig. 47).
Bar 6960-2. (17) Remove differential case from Side Gear Hold-
(13) Rotate differential case until the differential ing Tool 8138. Remove side gear, clutch pack retainer,
pinions can be removed.

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 3 - 124 8 1/4 REAR AXLE XJ
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 47 Side Gear & Clutch Disc Removal Fig. 48 Clutch Disc Pack
1 – DIFFERENTIAL CASE 1 – CLUTCH PACK
2 – RETAINER 2 – RETAINER
3 – SIDE GEAR AND CLUTCH DISC PACK 3 – SIDE GEAR
4 – RETAINER

and clutch pack. Keep plates in correct order during

removal.

ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.

Lubricate each component with gear lubricant

before assembly.
(1) Assemble the clutch discs into packs and
secure disc packs with retaining clips (Fig. 48).
(2) Position assembled clutch disc packs on the
side gear hubs.
(3) Install clutch pack and side gear in the ring
gear side of the differential case (Fig. 49). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
(4) Position the differential case on Side Gear
Holding Tool 8138. Fig. 49 Clutch Discs & Lower Side Gear Installation
(5) Install lubricated Step Plate 8140–2 in lower 1 – DIFFERENTIAL CASE
side gear (Fig. 50). 2 – LOWER SIDE GEAR AND CLUTCH DISC PACK
(6) Install the upper side gear and clutch disc pack
(Fig. 50). (10) Place differential pinions in position in side
(7) Hold assembly in position. Insert Threaded gears and verify that the pinion mate shaft holes are
Adapter 8140-1 into top side gear. aligned.
(8) Insert Forcing Screw 6960-4. (11) Rotate case with Turning Bar 6960-2 until the
(9) Tighten forcing screw tool to slightly compress pinion mate shaft holes in the differential pinions
clutch discs. align with holes in case. It may be necessary to

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 XJ 8 1/4 REAR AXLE 3 - 125
DISASSEMBLY AND ASSEMBLY (Continued)
Be sure that the axle tubes and oil channels are
thoroughly cleaned in the housing.
Inspect for:
• Smooth appearance with no broken/dented sur-
faces on the bearing rollers or the roller contact sur-
faces.
• Bearing cups must not be distorted or cracked.
• Machined surfaces should be smooth and with-
out any raised edges.
• Raised metal on shoulders of cup bores should
be removed with a hand stone.
• Wear and damage to pinion mate shaft, pinions,
side gears and thrust washers. Replace as a matched
set only.
• Ring gear and pinion for worn and chipped
teeth.
• Ring gear for damaged bolt threads. Replaced as
a matched set only.
• Pinion yoke for cracks, worn splines, pitted
areas, and a rough/corroded seal contact surface.
Fig. 50 Upper Side Gear & Clutch Disc Pack Repair or replace as necessary.
Installation • Pinion depth shims for damage and distortion.
1 – UPPER SIDE GEAR AND CLUTCH DISC PACK Install new shims if necessary.
2 – DIFFERENTIAL CASE • The differential case. Replace the case if cracked
3 – SPECIAL TOOL 8140–2 or damaged.
• The axle shaft C-locks for cracks and excessive
wear. Replace them if necessary.
slightly tighten the forcing screw in order to install
• Each threaded adjuster to determine if it rotates
the pinions.
freely. If an adjuster binds, repair the damaged
(12) Tighten forcing screw to 122 N·m (90 ft. lbs.)
threads or replace the adjuster.
maximum to compress the Belleville springs.
Polish each axle shaft sealing surface with No. 600
(13) Lubricate and install thrust washers behind
crocus cloth. This can remove slight surface damage.
pinions and align washers with a small screw driver.
Do not reduce the diameter of the axle shaft seal con-
Insert mate shaft into each pinion to verify align-
tact surface. When polishing, the crocus cloth should
ment.
be moved around the circumference of the shaft (not
(14) Remove Forcing Screw 6960-4, Step Plate
in-line with the shaft).
8140–2, and Threaded Adapter 8140-1.
(15) Install pinion mate shaft and align holes in
shaft and case.
TRAC-LOKY
(16) Install the pinion mate shaft lock screw finger Clean all components in cleaning solvent. Dry com-
tight to hold shaft during differential installation. ponents with compressed air. Inspect clutch pack
(17) Lubricate all differential components with plates for wear, scoring or damage. Replace both
hypoid gear lubricant. clutch packs if any one component in either pack is
damaged. Inspect side gears and pinions. Replace
any gear that is worn, cracked, chipped or damaged.
CLEANING AND INSPECTION Inspect differential case and pinion shaft. Replace if
worn or damaged.
8 1/4 AXLE
Wash differential components with cleaning solvent PRESOAK PLATES AND DISC
and dry with dry compressed air. Do not steam Plates and discs with fiber coating (no grooves or
clean the differential components. lines) must be presoaked in Friction Modifier before
Wash bearings with solvent and towel dry, or dry assembly. Soak plates and discs for a minimum of 20
with compressed air. DO NOT spin bearings with minutes.
compressed air. Cup and bearing must be
replaced as matched sets only.

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 3 - 126 8 1/4 REAR AXLE XJ

ADJUSTMENTS
8 1/4 AXLE PINION GEAR DEPTH
GENERAL INFORMATION
Ring gears and pinions are supplied as matched
sets only. The identifying numbers for the ring gear
and pinion are etched into the face of each gear (Fig.
51). A plus (+) number, minus (–) number or zero (0)
is etched into the face of the pinion. This number is
the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
etched with a (0). The standard depth provides the
best gear tooth contact pattern. Refer to Backlash
and Contact Pattern Analysis paragraph in this sec-
tion for additional information. Fig. 52 Shim Locations
1 – AXLE HOUSING
2 – COLLAPSIBLE SPACER
3 – PINION BEARING
4 – PINION DEPTH SHIM
5 – PINION GEAR
6 – BEARING CUP

the depth shim. If the number is 0 no change is nec-

essary.

PINION DEPTH MEASUREMENT AND ADJUSTMENT

Measurements are taken with pinion bearing cups
and pinion bearings installed in the axle housing.
Take measurements with Pinion Gauge Set and Dial
Indicator C-3339 (Fig. 53).
(1) Assemble Pinion Height Block 6739, Pinion
Fig. 51 Pinion Gear ID Numbers
Block 8540, and rear pinion bearing onto Screw 6741
1 – PRODUCTION NUMBERS
2 – DRIVE PINION GEAR DEPTH VARIANCE
(Fig. 53).
3 – GEAR MATCHING NUMBER (SAME AS RING GEAR (2) Insert assembled height gauge components,
NUMBER) rear bearing, and screw into axle housing through
pinion bearing cups (Fig. 54).
Compensation for pinion depth variance is (3) Install front pinion bearing and Cone-Nut 6740
achieved with select shims. The shims are placed hand tight (Fig. 53).
behind the rear pinion bearing (Fig. 52). (4) Place Arbor Disc 8541 on Arbor D-115-3 in posi-
If a new gear set is being installed, note the depth tion in axle housing side bearing cradles (Fig. 55).
variance etched into both the original and replace- Install differential bearing caps on Arbor Discs and
ment pinion. Add or subtract the thickness of the tighten cap bolts to 41 N·m (30 ft. lbs.).
original depth shims to compensate for the difference
NOTE: Arbor Discs 8541 has different step diame-
in the depth variances. Refer to the Depth Variance
ters to fit other axles. Choose proper step for axle
chart.
being serviced.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or (5) Assemble Dial Indicator C-3339 into Scooter
minus the amount needed. Block D-115-2 and secure set screw.
Note the etched number on the face of the pinion (6) Place Scooter Block/Dial Indicator in position
gear head (–1, –2, 0, +1, +2, etc.). The numbers rep- in axle housing so dial probe and scooter block are
resent thousands of an inch deviation from the stan- flush against the rearward surface of the pinion
dard. If the number is negative, add that value to the height block (Fig. 53). Hold scooter block in place and
required thickness of the depth shims. If the number zero the dial indicator face to the pointer. Tighten
is positive, subtract that value from the thickness of dial indicator face lock screw.

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 XJ 8 1/4 REAR AXLE 3 - 127
ADJUSTMENTS (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion Replacement Pinion Gear Depth Variance
Gear Depth
Variance −4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003
0 +0.004 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004
−1 +0.003 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005
−2 +0.002 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006
−3 +0.001 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007
−4 0 −0.001 −0.002 −0.003 −0.004 −0.005 −0.006 −0.007 −0.008

Fig. 54 Pinion Height Block—Typical

1 – PINION BLOCK
2 – PINION HEIGHT BLOCK

pointer back to zero against the arbor bar, do not

Fig. 53 Pinion Gear Depth Gauge Tools—Typical turn dial face. Continue moving the dial probe to the
1 – DIAL INDICATOR crest of the arbor bar and record the highest reading.
2 – ARBOR If the dial indicator can not achieve the zero reading,
3 – PINION HEIGHT BLOCK
the rear bearing cup or the pinion depth gauge set is
4 – CONE
not installed correctly.
5 – SCREW
6 – PINION BLOCK
(9) Select a shim equal to the dial indicator read-
7 – SCOOTER BLOCK ing plus the drive pinion gear depth variance number
8 – ARBOR DISC etched in the face of the pinion (Fig. 51). For exam-
ple, if the depth variance is –2, add +0.002 in. to the
dial indicator reading.
(7) With scooter block still in position against the
pinion height block, slowly slide the dial indicator DIFFERENTIAL BEARING PRELOAD AND GEAR
probe over the edge of the pinion height block.
(8) Slide the dial indicator probe across the gap BACKLASH
between the pinion height block and the arbor bar The following must be considered when adjusting
with the scooter block against the pinion height block bearing preload and gear backlash:
(Fig. 56). When the dial probe contacts the arbor bar, • The maximum ring gear backlash variation is
the dial pointer will turn clockwise. Bring dial 0.003 inch (0.076 mm).

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 3 - 128 8 1/4 REAR AXLE XJ
ADJUSTMENTS (Continued)
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
• Maintain the gear teeth engaged (meshed) as
marked.
• The bearings must be seated by rapidly rotat-
ing the pinion gear a half turn back and forth.
• Do this five to ten times each time the threaded
adjusters are adjusted.

(1) Use Wrench C-4164 to adjust each threaded

adjuster inward until the differential bearing free-
play is eliminated (Fig. 57). Allow some ring gear
backlash (approximately 0.01 inch/0.25 mm) between
the ring and pinion gear. Seat the bearing cups with
Fig. 55 Gauge Tools In Housing—Typical the procedure described above.
1 – ARBOR DISC
2 – PINION BLOCK
3 – ARBOR
4 – PINION HEIGHT BLOCK

Fig. 57 Threaded Adjuster Tool

1 – AXLE TUBE
2 – BACKING PLATE
3 – TOOL C-4164

Fig. 56 Pinion Gear Depth Measurement—Typical

(2) Install dial indicator and position the plunger
1 – ARBOR
against the drive side of a ring gear tooth (Fig. 58).
2 – SCOOTER BLOCK
3 – DIAL INDICATOR
Measure the backlash at 4 positions (90 degrees
apart) around the ring gear. Locate and mark the
area of minimum backlash.
• Mark the gears so the same teeth are meshed (3) Rotate the ring gear to the position of the least
during all backlash measurements. backlash. Mark the gear so that all future backlash
• Maintain the torque while adjusting the bearing measurements will be taken with the same gear
preload and ring gear backlash. teeth meshed.
• Excessive adjuster torque will introduce a high (4) Loosen the right-side, tighten the left-side
bearing load and cause premature bearing failure. threaded adjuster. Obtain backlash of 0.003 to 0.004
Insufficient adjuster torque can result in excessive inch (0.076 to 0.102 mm) with each adjuster tight-
differential case free-play and ring gear noise. ened to 14 N·m (10 ft. lbs.). Seat the bearing cups
• Insufficient adjuster torque will not support the with the procedure described above.
ring gear correctly and can cause excessive differen- (5) Tighten the differential bearing cap bolts 95
tial case free-play and ring gear noise. N·m (70 ft. lbs.).
(6) Tighten the right-side threaded adjuster to 102
N·m (75 ft. lbs.). Seat the bearing cups with the pro-

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 XJ 8 1/4 REAR AXLE 3 - 129
ADJUSTMENTS (Continued)
pinion. This will provide a more distinct contact pat-
tern.
(3) Using a boxed end wrench on a ring gear bolt,
Rotate the differential case one complete revolution
in both directions while a load is being applied from
shop towel.
The areas on the ring gear teeth with the greatest
degree of contact against the pinion teeth will squee-
gee the compound to the areas with the least amount
of contact. Note and compare patterns on the ring
gear teeth to Gear Tooth Contact Patterns chart (Fig.
59) and adjust pinion depth and gear backlash as
necessary.

SIDE GEAR CLEARANCE

When measuring side gear clearance, check each
Fig. 58 Ring Gear Backlash Measurement gear independently. If it necessary to replace a side
1 – DIAL INDICATOR gear, replace both gears as a matched set.
2 – RING GEAR (1) Install the axle shafts and C-locks and pinion
3 – EXCITER RING mate shaft.
(2) Measure each side gear clearance. Insert a
cedure described above. Continue to tighten the matched pair of feeler gauge blades between the gear
right-side adjuster and seat bearing cups until the and differential housing on opposite sides of the hub
torque remains constant at 102 N·m (75 ft. lbs.) (Fig. 60).
(7) Measure the ring gear backlash. The range of (3) If side gear clearances is no more than 0.005
backlash is 0.006 to 0.008 inch (0.15 to 0.203 mm). inch. Determine if the axle shaft is contacting the
(8) Continue increasing the torque at the right- pinion mate shaft. Do not remove the feeler
side threaded adjuster until the specified backlash is gauges, inspect the axle shaft with the feeler
obtained. gauge inserted behind the side gear. If the end of
the axle shaft is not contacting the pinion mate
NOTE: The left-side threaded adjuster torque shaft, the side gear clearance is acceptable.
should have approximately 102 N·m (75 ft. lbs.). If (4) If clearance is more than 0.005 inch (axle shaft
the torque is considerably less, the complete not contacting mate shaft), record the side gear clear-
adjustment procedure must be repeated. ance. Remove the thrust washer and measure its
thickness with a micrometer. Add the washer thick-
(9) Tighten the left-side threaded adjuster until ness to the recorded side gear clearance. The sum of
102 N·m (75 ft. lbs.) torque is indicated. Seat the gear clearance and washer thickness will determine
bearing rollers with the procedure described above. required thickness of replacement thrust washer
Do this until the torque remains constant. (Fig. 61).
(10) Install the threaded adjuster locks and In some cases, the end of the axle shaft will move
tighten the lock screws to 10 N·m (90 in. lbs.). and contact the mate shaft when the feeler gauge is
After the proper backlash is achieved, perform the inserted. The C-lock is preventing the side gear from
Gear Contact Analysis procedure. sliding on the axle shaft.
(5) If there is no side gear clearance, remove the
GEAR CONTACT PATTERN ANALYSIS C-lock from the axle shaft. Use a micrometer to mea-
The ring gear and pinion teeth contact patterns sure the thrust washer thickness. Record the thick-
will show if the pinion depth is correct in the axle ness and re-install the thrust washer. Assemble the
housing. It will also show if the ring gear backlash differential case without the C-lock installed and re-
has been adjusted correctly. The backlash can be measure the side gear clearance.
adjusted within specifications to achieve desired (6) Compare both clearance measurements. If the
tooth contact patterns. difference is less than 0.012 inch (0.305 mm), add
(1) Apply a thin coat of hydrated ferric oxide, or clearance recorded when the C-lock was installed to
equivalent, to the drive and coast side of the ring thrust washer thickness measured. The sum will
gear teeth. determine the required thickness of the replacement
(2) Wrap, twist, and hold a shop towel around the thrust washer.
pinion yoke to increase the turning resistance of the

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 3 - 130 8 1/4 REAR AXLE XJ
ADJUSTMENTS (Continued)

Fig. 59 Gear Tooth Contact Patterns

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 XJ 8 1/4 REAR AXLE 3 - 131
ADJUSTMENTS (Continued)

8 1/4 INCH AXLE

DESCRIPTION TORQUE
Diff. Cover Bolt . . . . . . . . . . . . . 41 N·m (30 ft. lbs.)
Bearing Cap Bolt . . . . . . . . . . 136 N·m (100 ft. lbs.)
Pinion Nut–Minimum . . . . . . 285 N·m (210 ft. lbs.)
Ring Gear Bolt . . . . . . . . . . . . . 95 N·m (70 ft. lbs.)
Backing Plate Bolt . . . . . . . . . 614 N·m (45 ft. lbs.)
RWAL/ABS Sensor Bolt . . . . . . 24 N·m (18. ft. lbs.)

SPECIAL TOOLS
8 1/4 AXLES

Fig. 60 Side Gear Clearance Measurement

1 – FEELER GAUGE BLADES
2 – SIDE GEAR

Puller, Hub—6790

Fig. 61 Side Gear Calculations

(7) If clearance is 0.012 inch (0.305 mm) or
greater, both side gears must be replaced (matched
set) and the clearance measurements repeated.
(8) If clearance (above) continues to be 0.012 inch
(0.305 mm) or greater, the case must be replaced.
Remover, Bearing—6310

SPECIFICATIONS
8 1/4 INCH AXLE
Axle Type . . . . . . . . . . . . . . . Semi-floating, hypoid
Lubricant . . . . . . . . . . . . . . . . . . . . . . SAE 80W-90
Lube Capacity . . . . . . . . . . . . . . . . 2.08 L (4.4 pts.)
Trac-Lok Additive . . . . . . . . . . . . . . . 118 ml (4 oz.)
Axle Ratio . . . . . . . . . . . . . . . . . . . . 3.07, 3.55,.4.10
Differential
Case Clearance . . . . . . . . . . . . . 0.12 mm (0.005 in.) Installer—C-4198
Case Flange Runout . . . . . . . . 0.076 mm (0.003 in.)
Ring Gear
Diameter . . . . . . . . . . . . . . . . . . 20.95 cm (8.25 in.)
Backlash . . . . . . . . . 0.12-0.20 mm (0.005-0.008 in.)
Runout . . . . . . . . . . . . . . . . . . 0.127 mm (0.005 in.)
Pinion Bearing
Preload-Used Bearings . . . . 1-2 N·m (10-20 in.lbs.)
Preload-New Bearings . . . . . 1-5 N·m (10-30 in.lbs.)

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 3 - 132 8 1/4 REAR AXLE XJ
SPECIAL TOOLS (Continued)

Puller—C-452

Handle—C-4171

Installer—C-3718

Installer—C-4076-B

Adjustment Rod—C-4164

Handle—C-4735-1

Puller/Press—C-293–PA

Holder—6719

Adapters—C-293-48

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 XJ 8 1/4 REAR AXLE 3 - 133
SPECIAL TOOLS (Continued)

Plug—SP-3289 Installer—C-4345

Adapters—C-293-47
Remover—C-4307

Installer—C-4308
Installer—C-4340

Installer—D-130

Holder—8138

Installer—6448

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 3 - 134 8 1/4 REAR AXLE XJ
SPECIAL TOOLS (Continued)

Trac-lokY Tools—8140
Pinion Gauge Block—8540

Trac-lokY Tools—6960
Arbor Discs—8541

Pinion Gauge Set

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 XJ BRAKES 5-1

BRAKES
TABLE OF CONTENTS

page page

BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . . 33

BASE BRAKE SYSTEM

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2 COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 16
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . . 2 MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 16
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 17
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2 FRONT DISC BRAKE CALIPER . . . . . . . . . . . . . . 18
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 3 FRONT DISC BRAKE SHOES . . . . . . . . . . . . . . . 20
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . 3 DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 21
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 3 DRUM BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . 21
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . . 3 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT DISC BRAKES. . . . . . . . . . . . . . . . . . . . . . 4 BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . . . 22
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . . 5 REAR PARKING BRAKE CABLES . . . . . . . . . . . . 23
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . 5 PARKING BRAKE LEVER. . . . . . . . . . . . . . . . . . . 23
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . . . 7 DISASSEMBLY AND ASSEMBLY
DIAGNOSIS AND TESTING MASTER CYLINDER RESERVOIR . . . . . . . . . . . . 24
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 7 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 25
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 9 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 28
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . . . 9 CLEANING AND INSPECTION
MASTER CYLINDER/POWER BOOSTER . . . . . . . 10 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 11 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 29
DISC BRAKE ROTOR. . . . . . . . . . . . . . . . . . . . . . 11 WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ADJUSTMENTS
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . . 12 BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 30
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 12 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . 30
SERVICE PROCEDURES PARKING BRAKE CABLE TENSIONER . . . . . . . . 31
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 12 SPECIFICATIONS
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 12 BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BASE BRAKE BLEEDING. . . . . . . . . . . . . . . . . . . 13 BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . . . 32
DISC ROTOR MACHINING. . . . . . . . . . . . . . . . . . 13 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 32
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . 14 SPECIAL TOOLS
BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . . . . 14 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL AND INSTALLATION
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 15

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 5-2 BRAKES XJ

DESCRIPTION AND OPERATION CAUTION: Never use gasoline, kerosene, alcohol,

motor oil, transmission fluid, or any fluid containing
BRAKE SYSTEM mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
DESCRIPTION fresh brake fluid or Mopar brake cleaner to clean or
Power assist front disc and rear drum brakes are flush brake system components. These are the only
standard equipment. Disc brake components consist cleaning materials recommended. If system contam-
of single piston calipers and ventilated rotors. Rear ination is suspected, check the fluid for dirt, discol-
drum brakes are dual shoe units with cast brake oration, or separation into distinct layers. Also
drums. check the reservoir cap seal for distortion. Drain
The parking brake mechanism is lever and cable and flush the system with new brake fluid if con-
operated. The cables are attached to levers on the tamination is suspected.
rear drum brake secondary shoes. The parking
brakes are operated by a hand lever. CAUTION: Use Mopar brake fluid, or an equivalent
A dual diaphragm vacuum power brake booster is quality fluid meeting SAE/DOT standards J1703 and
used for all applications. All models have an alumi- DOT 3. Brake fluid must be clean and free of con-
num master cylinder with plastic reservoir. taminants. Use fresh fluid from sealed containers
All models are equipped with a combination valve. only to ensure proper antilock component opera-
The valve contains a pressure differential valve and tion.
switch and a fixed rate rear proportioning valve.
Factory brake lining on all models consists of an
organic base material combined with metallic parti- CAUTION: Use Mopar multi-mileage or high temper-
cles. The original equipment linings do not contain ature grease to lubricate caliper slide surfaces,
asbestos. drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
SERVICE WARNINGS & CAUTIONS 661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
DESCRIPTION
WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PEDAL
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM AFTERMARKET DESCRIPTION
LININGS. BREATHING EXCESSIVE CONCENTRA- A suspended-type brake pedal is used, the pedal
TIONS OF ASBESTOS FIBERS CAN CAUSE SERI- pivots on a shaft mounted in the pedal support
OUS BODILY HARM. EXERCISE CARE WHEN bracket. The bracket is attached to the dash panel
SERVICING BRAKE PARTS. DO NOT CLEAN and steering support bracket. The unit is serviced as
BRAKE PARTS WITH COMPRESSED AIR OR BY an assembly, except for the pedal pad.
DRY BRUSHING. USE A VACUUM CLEANER SPE-
CIFICALLY DESIGNED FOR THE REMOVAL OF OPERATION
ASBESTOS FIBERS FROM BRAKE COMPONENTS. The brake pedal is attached to the booster push
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL- rod. When the pedal is depressed, the primary
ABLE, CLEANING SHOULD BE DONE WITH A booster push rod is depressed which move the booster
WATER DAMPENED CLOTH. DO NOT SAND, OR secondary rod. The booster secondary rod depress the
GRIND BRAKE LINING UNLESS EQUIPMENT USED master cylinder piston.
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF ALL RESIDUE CONTAINING ASBES- BRAKE LAMP SWITCH
TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH- DESCRIPTION
ERS. FOLLOW PRACTICES PRESCRIBED BY THE The plunger type brake lamp switch is mounted on
OCCUPATIONAL SAFETY AND HEALTH ADMINIS- a bracket attached to the brake pedal support. The
TRATION AND THE ENVIRONMENTAL PROTECTION switch can be adjusted when necessary.
AGENCY FOR THE HANDLING, PROCESSING, AND
DISPOSITION OF DUST OR DEBRIS THAT MAY OPERATION
CONTAIN ASBESTOS FIBERS. The brake lamp switch is used to for the brake
lamp, speed control and brake sensor circuits.

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 XJ BRAKES 5-3
DESCRIPTION AND OPERATION (Continued)

RED BRAKE WARNING LAMP MASTER CYLINDER

DESCRIPTION DESCRIPTION
A red warning lamp is used for the service brake The master cylinder has a removable nylon reser-
portion of the hydraulic system. The lamp is located voir. The cylinder body is made of aluminum and
in the instrument cluster. contains a primary and secondary piston assembly.
The cylinder body including the piston assemblies
OPERATION are not serviceable. If diagnosis indicates an internal
The red warning light alerts the driver if a pres- problem with the cylinder body, it must be replaced
sure differential exists between the front and rear as an assembly. The reservoir and grommets are the
hydraulic systems or the parking brakes are applied. only replaceable parts on the master cylinder.
The lamp is turned on momentarily when the igni-
tion switch is turn to the on position. This is a self OPERATION
test to verify the lamp is operational. The master cylinder bore contains a primary and
secondary piston. The primary piston supplies
POWER BRAKE BOOSTER hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
DESCRIPTION The master cylinder reservoir stores reserve brake
The booster assembly consists of a housing divided fluid for the hydraulic brake circuits.
into separate chambers by two internal diaphragms.
The outer edge of each diaphragm is attached to the COMBINATION VALVE
booster housing. The diaphragms are connected to
the booster primary push rod. DESCRIPTION
Two push rods are used in the booster. The pri- The combination valve contains a pressure differ-
mary push rod connects the booster to the brake ential valve and switch and a rear brake proportion-
pedal. The secondary push rod connects the booster ing valve. The valve is not repairable and must be
to the master cylinder to stroke the cylinder pistons. replaced as an assembly if diagnosis indicates this is
necessary.
OPERATION
The atmospheric inlet valve is opened and closed OPERATION
by the primary push rod. Booster vacuum supply is
through a hose attached to an intake manifold fitting PRESSURE DIFFERENTIAL VALVE
at one end and to the booster check valve at the The pressure differential switch is connected to the
other. The vacuum check valve in the booster housing brake warning light. The switch is actuated by move-
is a one-way device that prevents vacuum leak back. ment of the switch valve. The switch monitors fluid
Power assist is generated by utilizing the pressure pressure in the separate front/rear brake hydraulic
differential between normal atmospheric pressure circuits.
and a vacuum. The vacuum needed for booster oper- A decrease or loss of fluid pressure in either
ation is taken directly from the engine intake mani- hydraulic circuit will cause the switch valve to shut-
fold. The entry point for atmospheric pressure is tle to the low pressure side. Movement of the valve
through a filter and inlet valve at the rear of the pushes the switch plunger upward. This action closes
housing (Fig. 1). the switch internal contacts completing the electrical
The chamber areas forward of the booster dia- circuit to the red warning light. The switch valve will
phragms are exposed to vacuum from the intake remain in an actuated position until repairs to the
manifold. The chamber areas to the rear of the dia- brake system are made.
phragms, are exposed to normal atmospheric pres-
sure of 101.3 kilopascals (14.7 pounds/square in.). PROPORTIONING VALVE
Brake pedal application causes the primary push The proportioning valve is used to balance front-
rod to open the atmospheric inlet valve. This exposes rear brake action at high decelerations. The valve
the area behind the diaphragms to atmospheric pres- allows normal fluid flow during moderate braking.
sure. The resulting pressure differential provides the The valve only controls fluid flow during high decel-
extra apply force for power assist. erations brake stops.
The booster check valve, check valve grommet and
booster seals are serviceable.

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 5-4 BRAKES XJ
DESCRIPTION AND OPERATION (Continued)

Fig. 1 Power Brake Booster–Typical

1 – VACUUM CHECK VALVE 7 – PRIMARY PUSH ROD (TO BRAKE PEDAL)
2 – FRONT DIAPHRAGM 8 – ATMOSPHERIC INLET VALVE ASSEMBLY
3 – REAR DIAPHRAGM 9 – BOOSTER MOUNTING STUDS (4)
4 – HOUSING 10 – SECONDARY PUSH ROD (TO MASTER CYLINDER)
5 – SEAL 11 – MASTER CYLINDER MOUNTING STUD (2)
6 – AIR FILTER 12 – SPRING

FRONT DISC BRAKES pressure exerted against the caliper piston and
within the caliper bore will be equal (Fig. 2).
DESCRIPTION Fluid pressure applied to the piston is transmitted
The calipers are a single piston type. The calipers directly to the inboard brake shoe. This forces the
are free to slide laterally, this allows continuous com- shoe lining against the inner surface of the disc
pensation for lining wear. brake rotor. At the same time, fluid pressure within
the piston bore forces the caliper to slide inward on
OPERATION the mounting bolts. This action brings the outboard
When the brakes are applied fluid pressure is brake shoe lining into contact with the outer surface
exerted against the caliper piston. The fluid pressure of the disc brake rotor.
is exerted equally and in all directions. This means

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 XJ BRAKES 5-5
DESCRIPTION AND OPERATION (Continued)

Fig. 3 Lining Wear Compensation By Piston Seal

1 – PISTON
2 – CYLINDER BORE
3 – PISTON SEAL BRAKE PRESSURE OFF
4 – CALIPER HOUSING
5 – DUST BOOT
6 – PISTON SEAL BRAKE PRESSURE ON

REAR DRUM BRAKE

Fig. 2 Brake Caliper Operation
1 – CALIPER DESCRIPTION
2 – PISTON The rear brakes use a leading shoe (primary) and
3 – PISTON BORE trailing shoe (secondary) design (Fig. 4).
4 – SEAL
5 – INBOARD SHOE OPERATION
6 – OUTBOARD SHOE When the brake pedal is depressed hydraulic pres-
sure pushes the rear brake wheel cylinder pistons
In summary, fluid pressure acting simultaneously outward. The wheel cylinder push rods then push the
on both piston and caliper, produces a strong clamp- brake shoes outward against the brake drum. When
ing action. When sufficient force is applied, friction the brake pedal is released return springs attached
will attempt to stop the rotors from turning and to the brake shoes pull the shoes back to there orig-
bring the vehicle to a stop. inal position.
Application and release of the brake pedal gener-
ates only a very slight movement of the caliper and PARKING BRAKE
piston. Upon release of the pedal, the caliper and pis-
ton return to a rest position. The brake shoes do not DESCRIPTION
retract an appreciable distance from the rotor. In The parking bake is a hand lever and cable oper-
fact, clearance is usually at, or close to zero. The rea- ated system used to apply the rear brakes.
sons for this are to keep road debris from getting
between the rotor and lining and in wiping the rotor OPERATION
surface clear each revolution. A hand operated lever in the passenger compart-
The caliper piston seal controls the amount of pis- ment is the main application device. The front cable
ton extension needed to compensate for normal lining is connected between the hand lever and the ten-
wear. sioner. The tensioner rod is attached to the equalizer
During brake application, the seal is deflected out- which is the connecting point for the rear cables (Fig.
ward by fluid pressure and piston movement (Fig. 3). 5).
When the brakes (and fluid pressure) are released, The rear cables are connected to the actuating
the seal relaxes and retracts the piston. lever on each secondary brake shoe. The levers are
The amount of piston retraction is determined by attached to the brake shoes by a pin either pressed
the amount of seal deflection. Generally the amount into, or welded to the lever. A clip is used to secure
is just enough to maintain contact between the pis- the pin in the brake shoe. The pin allows each lever
ton and inboard brake shoe. to pivot independently of the brake shoe.
To apply the parking brakes, the hand lever is
pulled upward. This pulls the rear brake shoe actu-

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 5-6 BRAKES XJ
DESCRIPTION AND OPERATION (Continued)

Fig. 4 Brake Components

1 – ADJUSTER LEVER 11 – PARK BRAKE STRUT AND SPRING
2 – ADJUSTER CABLE 12 – ADJUSTER SCREW ASSEMBLY
3 – HOLDDOWN SPRING AND RETAINERS 13 – HOLDDOWN SPRING AND RETAINERS
4 – ADJUSTER LEVER SPRING 14 – LEADING SHOE
5 – TRAILING SHOE 15 – CABLE GUIDE
6 – CYLINDER-TO-SUPPORT SEAL 16 – SHOE RETURN SPRINGS
7 – HOLDDOWN PINS 17 – SHOE GUIDE PLATE
8 – ACCESS PLUGS 18 – PIN
9 – SUPPORT PLATE 19 – SHOE SPRING
10 – CABLE HOLE PLUG 20 – PARK BRAKE LEVER

ating levers forward, by means tensioner and cables.

As the actuating lever is pulled forward, the parking
brake strut (which is connected to both shoes), exerts
a linear force against the primary brake shoe. This
action presses the primary shoe into contact with the
drum. Once the primary shoe contacts the drum,
force is exerted through the strut. This force is trans-
ferred through the strut to the secondary brake shoe
causing it to pivot into the drum as well.
A gear type ratcheting mechanism is used to hold
the lever in an applied position. Parking brake
release is accomplished by the hand lever release
button.
A parking brake switch is mounted on the parking
brake lever and is actuated by movement of the
lever. The switch, which is in circuit with the red
warning light in the dash, will illuminate the warn-
Fig. 5 Parking Brake Components
ing light whenever the parking brakes are applied.
1 – REAR CABLES
2 – EQUALIZER
Parking brake adjustment is controlled by a cable
3 – FRONT CABLE tensioner mechanism. The cable tensioner, once
4 – TENSIONER ROD adjusted at the factory, should not need further
adjustment under normal circumstances. Adjustment

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 XJ BRAKES 5-7
DESCRIPTION AND OPERATION (Continued)
may be required if a new tensioner, or cables are (5) Check brake pedal operation. Verify that pedal
installed, or disconnected. does not bind and has adequate free play. If pedal
lacks free play, check pedal and power booster for
BRAKE HOSES AND LINES being loose or for bind condition. Do not road test
until condition is corrected.
DESCRIPTION (6) Check booster vacuum check valve and hose.
Flexible rubber hose is used at both front brakes (7) If components checked appear OK, road test
and at the rear axle junction block. Double walled the vehicle.
steel tubing is used to connect the master cylinder to
the major hydraulic braking components and then to ROAD TESTING
the flexible rubber hoses. Double inverted style and (1) If complaint involved low brake pedal, pump
ISO style flares are used on the brake lines. pedal and note if it comes back up to normal height.
(2) Check brake pedal response with transmission
in Neutral and engine running. Pedal should remain
DIAGNOSIS AND TESTING firm under constant foot pressure.
(3) During road test, make normal and firm brake
BASE BRAKE SYSTEM stops in 25-40 mph range. Note faulty brake opera-
Base brake components consist of the brake shoes, tion such as low pedal, hard pedal, fade, pedal pulsa-
calipers, wheel cylinders, brake drums, rotors, brake tion, pull, grab, drag, noise, etc.
lines, master cylinder, booster, and parking brake (4) Attempt to stop the vehicle with the parking
components. brake only and note grab, drag, noise, etc.
Brake diagnosis involves determining if the prob-
lem is related to a mechanical, hydraulic, or vacuum PEDAL FALLS AWAY
operated component. A brake pedal that falls away under steady foot
The first diagnosis step is the preliminary check. pressure is generally the result of a system leak. The
leak point could be at a brake line, fitting, hose, or
PRELIMINARY BRAKE CHECK caliper/wheel cylinder. If leakage is severe, fluid will
(1) Check condition of tires and wheels. Damaged be evident at or around the leaking component.
wheels and worn, damaged, or underinflated tires Internal leakage (seal by-pass) in the master cylin-
can cause pull, shudder, vibration, and a condition der caused by worn or damaged piston cups, may
similar to grab. also be the problem cause.
(2) If complaint was based on noise when braking, An internal leak in the ABS or RWAL system may
check suspension components. Jounce front and rear also be the problem with no physical evidence.
of vehicle and listen for noise that might be caused
by loose, worn or damaged suspension or steering LOW PEDAL
components. If a low pedal is experienced, pump the pedal sev-
(3) Inspect brake fluid level and condition. Note eral times. If the pedal comes back up worn linings,
that the brake reservoir fluid level will decrease in rotors, drums, or rear brakes out of adjustment are
proportion to normal lining wear. Also note that the most likely causes. The proper course of action is
brake fluid tends to darken over time. This is to inspect and replace all worn component and make
normal and should not be mistaken for contam- the proper adjustments.
ination.
(a) If fluid level is abnormally low, look for evi- SPONGY PEDAL
dence of leaks at calipers, wheel cylinders, brake A spongy pedal is most often caused by air in the
lines, and master cylinder. system. However, thin brake drums or substandard
(b) If fluid appears contaminated, drain out a brake lines and hoses can also cause a spongy pedal.
sample to examine. System will have to be flushed The proper course of action is to bleed the system,
if fluid is separated into layers, or contains a sub- and replace thin drums and substandard quality
stance other than brake fluid. The system seals brake hoses if suspected.
and cups will also have to be replaced after flush-
ing. Use clean brake fluid to flush the system. HARD PEDAL OR HIGH PEDAL EFFORT
(4) Check parking brake operation. Verify free A hard pedal or high pedal effort may be due to
movement and full release of cables and pedal. Also lining that is water soaked, contaminated, glazed, or
note if vehicle was being operated with parking badly worn. The power booster or check valve could
brake partially applied. also be faulty.

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 5-8 BRAKES XJ
DIAGNOSIS AND TESTING (Continued)
PEDAL PULSATION BRAKE PULL
Pedal pulsation is caused by components that are Front brake pull condition could result from:
loose, or beyond tolerance limits. • Contaminated lining in one caliper
The primary cause of pulsation are disc brake • Seized caliper piston
rotors with excessive lateral runout or thickness vari- • Binding caliper
ation, or out of round brake drums. Other causes are • Loose caliper
loose wheel bearings or calipers and worn, damaged • Rusty caliper slide surfaces
tires. • Improper brake shoes
• Damaged rotor
NOTE: Some pedal pulsation may be felt during A worn, damaged wheel bearing or suspension
ABS activation. component are further causes of pull. A damaged
front tire (bruised, ply separation) can also cause
pull.
BRAKE DRAG
A common and frequently misdiagnosed pull condi-
Brake drag occurs when the lining is in constant tion is where direction of pull changes after a few
contact with the rotor or drum. Drag can occur at one stops. The cause is a combination of brake drag fol-
wheel, all wheels, fronts only, or rears only. lowed by fade at one of the brake units.
Drag is a product of incomplete brake shoe release. As the dragging brake overheats, efficiency is so
Drag can be minor or severe enough to overheat the reduced that fade occurs. Since the opposite brake
linings, rotors and drums. unit is still functioning normally, its braking effect is
Minor drag will usually cause slight surface char- magnified. This causes pull to switch direction in
ring of the lining. It can also generate hard spots in favor of the normally functioning brake unit.
rotors and drums from the overheat-cool down pro- An additional point when diagnosing a change in
cess. In most cases, the rotors, drums, wheels and pull condition concerns brake cool down. Remember
tires are quite warm to the touch after the vehicle is that pull will return to the original direction, if the
stopped. dragging brake unit is allowed to cool down (and is
Severe drag can char the brake lining all the way not seriously damaged).
through. It can also distort and score rotors and
drums to the point of replacement. The wheels, tires REAR BRAKE GRAB OR PULL
and brake components will be extremely hot. In Rear grab or pull is usually caused by improperly
severe cases, the lining may generate smoke as it adjusted or seized parking brake cables, contami-
chars from overheating. nated lining, bent or binding shoes and support
Common causes of brake drag are: plates, or improperly assembled components. This is
• Seized or improperly adjusted parking brake particularly true when only one rear wheel is
cables. involved. However, when both rear wheels are
• Loose/worn wheel bearing. affected, the master cylinder or proportioning valve
• Seized caliper or wheel cylinder piston. could be at fault.
• Caliper binding on corroded bushings or rusted
slide surfaces. BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
• Loose caliper mounting. WATER PUDDLES
• Drum brake shoes binding on worn/damaged This condition is generally caused by water soaked
support plates. lining. If the lining is only wet, it can be dried by
• Mis-assembled components. driving with the brakes very lightly applied for a
• Long booster output rod. mile or two. However, if the lining is both soaked and
If brake drag occurs at all wheels, the problem dirt contaminated, cleaning and/or replacement will
may be related to a blocked master cylinder return be necessary.
port, or faulty power booster (binds-does not release).
BRAKE LINING CONTAMINATION
BRAKE FADE Brake lining contamination is mostly a product of
Brake fade is usually a product of overheating leaking calipers or wheel cylinders, worn seals, driv-
caused by brake drag. However, brake overheating ing through deep water puddles, or lining that has
and resulting fade can also be caused by riding the become covered with grease and grit during repair.
brake pedal, making repeated high deceleration stops Contaminated lining should be replaced to avoid fur-
in a short time span, or constant braking on steep ther brake problems.
mountain roads. Refer to the Brake Drag information
in this section for causes.

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 XJ BRAKES 5-9
DIAGNOSIS AND TESTING (Continued)
WHEEL AND TIRE PROBLEMS BRAKE LAMP SWITCH
Some conditions attributed to brake components The brake lamp switch operation can be tested
may actually be caused by a wheel or tire problem. with an ohmmeter. The ohmmeter is used to check
A damaged wheel can cause shudder, vibration and continuity between the pin terminals (Fig. 6).
pull. A worn or damaged tire can also cause pull.
Severely worn tires with very little tread left can SWITCH CIRCUIT IDENTIFICATION
produce a grab-like condition as the tire loses and • Terminals 1 and 2: brake sensor circuit
recovers traction. Flat-spotted tires can cause vibra- • Terminals 3 and 4: speed control circuit if
tion and generate shudder during brake operation. A equipped
tire with internal damage such as a severe bruise, • Terminals 5 and 6: brake lamp circuit
cut, or ply separation can cause pull and vibration.

BRAKE NOISES
Some brake noise is common with rear drum
brakes and on some disc brakes during the first few
stops after a vehicle has been parked overnight or
stored. This is primarily due to the formation of trace
corrosion (light rust) on metal surfaces. This light
corrosion is typically cleared from the metal surfaces
after a few brake applications causing the noise to
subside.

BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to linings that
are wet or contaminated with brake fluid, grease, or
oil. Glazed linings and rotors with hard spots can
also contribute to squeak. Dirt and foreign material Fig. 6 Brake Lamp Switch Terminal Identification
embedded in the brake lining will also cause squeak/ 1 – TERMINAL PINS
squeal. 2 – PLUNGER TEST POSITIONS
A very loud squeak or squeal is frequently a sign of
severely worn brake lining. If the lining has worn SWITCH CONTINUITY TEST
through to the brake shoes in spots, metal-to-metal
contact occurs. If the condition is allowed to continue, NOTE: Disconnect switch harness before testing
rotors and drums can become so scored that replace- switch continuity.
ment is necessary.
With the switch plunger retracted, attach test
BRAKE CHATTER leads to terminal pins 1 and 2. Replace switch if
Brake chatter is usually caused by loose or worn meter indicates no continuity.
components, or glazed/burnt lining. Rotors with hard With the switch plunger retracted, attach test
spots can also contribute to chatter. Additional causes leads to terminal pins 3 and 4. Replace switch if
of chatter are out-of-tolerance rotors, brake lining not meter indicates no continuity.
securely attached to the shoes, loose wheel bearings With the switch plunger extended, attach test
and contaminated brake lining. leads to terminal pins 5 and 6. Replace switch if
meter indicates no continuity.
THUMP/CLUNK NOISE
Thumping or clunk noises during braking are fre- RED BRAKE WARNING LAMP
quently not caused by brake components. In many The red brake warning lamp will illuminate under
cases, such noises are caused by loose or damaged the following conditions:
steering, suspension, or engine components. However, • Self test at start-up.
calipers that bind on the slide surfaces can generate • Parking brakes are applied.
a thump or clunk noise. In addition, worn out, • Leak in front/rear brake hydraulic circuit.
improperly adjusted, or improperly assembled rear If the red light remains on after start-up, first ver-
brake shoes can also produce a thump noise. ify that the parking brakes are fully released. Then
check pedal action and fluid level. If the lamp on and
the brake pedal is low this indicates the pressure dif-

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 5 - 10 BRAKES XJ
DIAGNOSIS AND TESTING (Continued)
ferential switch and valve have been actuated due to
a leak in the hydraulic system.
On models with ABS brakes, the amber warning
lamp only illuminates during the self test and when
an ABS malfunction has occurred. The ABS lamp
operates independently of the red warning lamp.
For additional information refer to Group 8W.

MASTER CYLINDER/POWER BOOSTER

(1) Start engine and check booster vacuum hose
connections. A hissing noise indicates vacuum leak.
Correct any vacuum leak before proceeding.
(2) Stop engine and shift transmission into Neu-
tral.
(3) Pump brake pedal until all vacuum reserve in
booster is depleted.
(4) Press and hold brake pedal under light foot
pressure. The pedal should hold firm, if the pedal
falls away master cylinder is faulty (internal leak-
age).
(5) Start engine and note pedal action. It should
Fig. 7 Typical Booster Vacuum Test Connections
fall away slightly under light foot pressure then hold
1 – TEE FITTING
firm. If no pedal action is discernible, power booster,
2 – SHORT CONNECTING HOSE
vacuum supply, or vacuum check valve is faulty. Pro- 3 – CHECK VALVE
ceed to the POWER BOOSTER VACUUM TEST. 4 – CHECK VALVE HOSE
(6) If the POWER BOOSTER VACUUM TEST 5 – CLAMP TOOL
passes, rebuild booster vacuum reserve as follows: 6 – INTAKE MANIFOLD
Release brake pedal. Increase engine speed to 1500 7 – VACUUM GAUGE
rpm, close the throttle and immediately turn off igni-
tion to stop engine.
(5) Vacuum should hold steady. If gauge on pump
(7) Wait a minimum of 90 seconds and try brake
indicates vacuum loss, check valve is faulty and
action again. Booster should provide two or more vac-
should be replaced.
uum assisted pedal applications. If vacuum assist is
not provided, booster is faulty.

POWER BOOSTER VACUUM TEST

(1) Connect vacuum gauge to booster check valve
with short length of hose and T-fitting (Fig. 7).
(2) Start and run engine at curb idle speed for one
minute.
(3) Observe the vacuum supply. If vacuum supply
is not adequate, repair vacuum supply.
(4) Clamp hose shut between vacuum source and
check valve.
(5) Stop engine and observe vacuum gauge.
(6) If vacuum drops more than one inch HG (33
millibars) within 15 seconds, booster diaphragm or
check valve is faulty. Fig. 8 Vacuum Check Valve And Seal
1 – BOOSTER CHECK VALVE
POWER BOOSTER CHECK VALVE TEST 2 – APPLY TEST VACUUM HERE
3 – VALVE SEAL
(1) Disconnect vacuum hose from check valve.
(2) Remove check valve and valve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Apply 15-20 inches vacuum at large end of
check valve (Fig. 8).

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 XJ BRAKES 5 - 11
DIAGNOSIS AND TESTING (Continued)

COMBINATION VALVE brake shoes. Position the dial indicator plunger

approximately 25.4 mm (1 in.) inward from the rotor
PRESSURE DIFFERENTIAL SWITCH edge. Maximum allowable rotor runout is 0.102 mm
(1) Have helper sit in drivers seat to apply brake (0.004 in.).
pedal and observe red brake warning light.
(2) Raise vehicle on hoist.
(3) Connect bleed hose to a rear wheel cylinder
and immerse hose end in container partially filled
with brake fluid.
(4) Have helper press and hold brake pedal to floor
and observe warning light.
(a) If warning light illuminates, switch is operat-
ing correctly.
(b) If light fails to illuminate, check circuit fuse,
bulb, and wiring. The parking brake switch can be
used to aid in identifying whether or not the brake
light bulb and fuse is functional. Repair or replace
parts as necessary and test differential pressure
switch operation again.
(5) If warning light still does not illuminate,
switch is faulty. Replace combination valve assembly,
bleed brake system and verify proper switch and
valve operation. Fig. 9 Checking Rotor Runout And Thickness
Variation
REAR PROPORTIONING VALVE 1 – DIAL INDICATOR
The valve controls fluid flow. If fluid enters the
valve and does not exit the valve the combination ROTOR THICKNESS VARIATION
valve must be replaced. Variations in rotor thickness will cause pedal pul-
sation, noise and shudder.
DISC BRAKE ROTOR Measure rotor thickness at 6 to 12 points around
The rotor braking surfaces should not be refinished the rotor face (Fig. 10).
unless necessary. Position the micrometer approximately 25.4 mm (1
Light surface rust and scale can be removed with a in.) from the rotor outer circumference for each mea-
lathe equipped with dual sanding discs. The rotor surement.
surfaces can be restored by machining in a disc brake Thickness should not vary by more than 0.013 mm
lathe if surface scoring and wear are light. (0.0005 in.) from point-to-point on the rotor. Machine
Replace the rotor under the following conditions: or replace the rotor if necessary.
• severely scored
• tapered BRAKE DRUM
• hard spots The maximum allowable diameter of the drum
• cracked braking surface is indicated on the drum outer edge.
• below minimum thickness Generally, a drum can be machined to a maximum of
1.52 mm (0.060 in.) oversize. Always replace the
ROTOR MINIMUM THICKNESS drum if machining would cause drum diameter to
Measure rotor thickness at the center of the brake exceed the size limit indicated on the drum.
shoe contact surface. Replace the rotor if worn below
minimum thickness, or if machining would reduce BRAKE DRUM RUNOUT
thickness below the allowable minimum. Measure drum diameter and runout with an accu-
Rotor minimum thickness is usually specified on rate gauge. The most accurate method of measure-
the rotor hub. The specification is either stamped or ment involves mounting the drum in a brake lathe
cast into the hub surface. and checking variation and runout with a dial indi-
cator.
ROTOR RUNOUT Variations in drum diameter should not exceed
Check rotor lateral runout with dial indicator 0.076 mm (0.003 in.). Drum runout should not exceed
C-3339 (Fig. 9). Excessive lateral runout will cause 0.20 mm (0.008 in.) out of round. Machine the drum
brake pedal pulsation and rapid, uneven wear of the if runout or variation exceed these values. Replace

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 5 - 12 BRAKES XJ
DIAGNOSIS AND TESTING (Continued)

BRAKE FLUID CONTAMINATION

Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of
petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses.

SERVICE PROCEDURES
Fig. 10 Measuring Rotor Thickness BRAKE FLUID LEVEL
1 – MICROMETER
Always clean the master cylinder reservoir and cap
2 – ROTOR
before adding fluid. This will prevent dirt from fall-
ing in the reservoir and contaminating the brake
the drum if machining causes the drum to exceed the fluid.
maximum allowable diameter. The reservoir has a ADD and a FULL mark on the
side (Fig. 11) fill to the FULL mark.
BRAKE LINE AND HOSES
Flexible rubber hose is used at both front brakes
and at the rear axle junction block. Inspect the hoses
whenever the brake system is serviced, at every
engine oil change, or whenever the vehicle is in for
service.
Inspect the hoses for surface cracking, scuffing, or
worn spots. Replace any brake hose immediately if
the fabric casing of the hose is exposed due to cracks
or abrasions.
Also check brake hose installation. Faulty installa-
tion can result in kinked, twisted hoses, or contact
with the wheels and tires or other chassis compo-
nents. All of these conditions can lead to scuffing,
cracking and eventual failure.
The steel brake lines should be inspected periodi-
cally for evidence of corrosion, twists, kinks, leaks, or Fig. 11 Master Cylinder Fluid Level
other damage. Heavily corroded lines will eventually 1 – FLUID LEVEL MARKS
rust through causing leaks. In any case, corroded or 2 – RESERVOIR
damaged brake lines should be replaced.
Factory replacement brake lines and hoses are rec-
ommended to ensure quality, correct length and supe- MASTER CYLINDER BLEEDING
rior fatigue life. Care should be taken to make sure A new master cylinder should be bled before instal-
that brake line and hose mating surfaces are clean lation on the vehicle. Required bleeding tools include
and free from nicks and burrs. Also remember that bleed tubes and a wood dowel to stroke the pistons.
right and left brake hoses are not interchangeable. Bleed tubes can be fabricated from brake line.
Use new copper seal washers at all caliper connec-
tions. Be sure brake line connections are properly BLEEDING PROCEDURE
made (not cross threaded) and tightened to recom- (1) Mount master cylinder in vise.
mended torque. (2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into reservoir (Fig. 12).

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 XJ BRAKES 5 - 13
SERVICE PROCEDURES (Continued)
(3) Fill reservoir with fresh brake fluid. (3) Attach one end of bleed hose to bleed screw
(4) Press cylinder pistons inward with wood dowel. and insert opposite end in glass container partially
Then release pistons and allow them to return under filled with brake fluid (Fig. 13). Be sure end of bleed
spring pressure. Continue bleeding operations until hose is immersed in fluid.
air bubbles are no longer visible in fluid.

Fig. 12 Master Cylinder Bleeding–Typical

1 – BLEEDING TUBES
2 – RESERVOIR

Fig. 13 Bleed Hose Setup

BASE BRAKE BLEEDING 1 – BLEED HOSE
Use Mopar brake fluid, or an equivalent quality 2 – FLUID CONTAINER PARTIALLY FILLED WITH FLUID
fluid meeting SAE J1703-F and DOT 3 standards
only. Use fresh, clean fluid from a sealed container at (4) Open up bleeder, then have a helper press
all times. down the brake pedal. Once the pedal is down close
Do not pump the brake pedal at any time while the bleeder. Repeat bleeding until fluid stream is
bleeding. Air in the system will be compressed into clear and free of bubbles. Then move to the next
small bubbles that are distributed throughout the wheel.
hydraulic system. This will make additional bleeding
operations necessary. PRESSURE BLEEDING
Do not allow the master cylinder to run out of fluid Follow the manufacturers instructions carefully
during bleed operations. An empty cylinder will allow when using pressure equipment. Do not exceed the
additional air to be drawn into the system. Check the tank manufacturers pressure recommendations. Gen-
cylinder fluid level frequently and add fluid as erally, a tank pressure of 15-20 psi is sufficient for
needed. bleeding.
Bleed only one brake component at a time in the Fill the bleeder tank with recommended fluid and
following sequence: purge air from the tank lines before bleeding.
• Master Cylinder Do not pressure bleed without a proper master cyl-
• Combination Valve inder adapter. The wrong adapter can lead to leak-
• Right Rear Wheel age, or drawing air back into the system. Use
• Left Rear Wheel adapter provided with the equipment or Adapter
• Right Front Wheel 6921.
• Left Front Wheel
DISC ROTOR MACHINING
MANUAL BLEEDING The disc brake rotor can be machined if scored or
(1) Remove reservoir filler caps and fill reservoir. worn. The lathe must machine both sides of the rotor
(2) If calipers, or wheel cylinders were overhauled, simultaneously with dual cutter heads. The rotor
open all caliper and wheel cylinder bleed screws. mounting surface must be clean before placing on the
Then close each bleed screw as fluid starts to drip lathe. Equipment capable of machining only one side
from it. Top off master cylinder reservoir once more at a time may produce a tapered rotor. A hub
before proceeding.

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 5 - 14 BRAKES XJ
SERVICE PROCEDURES (Continued)
mounted on-vehicle lathe is recommended. This type
of lathe trues the rotor to the vehicles hub/bearing.

CAUTION: Brake rotors that do not meet minimum

thickness specifications before or after machining
must be replaced.

BRAKE DRUM MACHINING

The brake drums can be machined on a drum lathe
when necessary. Initial machining cuts should be lim-
ited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as
heavier feed rates can produce taper and surface
variation. Final finish cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 in.) are recommended and will gen-
erally provide the best surface finish.
Be sure the drum is securely mounted in the lathe
before machining operations. A damper strap should
always be used around the drum to reduce vibration
and avoid chatter marks.
The maximum allowable diameter of the drum Fig. 14 Inverted Flare And ISO Flare
braking surface is stamped or cast into the drum 1 – ISO-STYLE FLARE
outer edge. 2 – DOUBLE INVERTED-STYLE FLARE

CAUTION: Replace the drum if machining will

cause the drum to exceed the maximum allowable (10) Remove the plug gauge and complete the
diameter. inverted flare.

BRAKE TUBE FLARING

A preformed metal brake tube is recommended and
preferred for all repairs. However, double-wall steel
tube can be used for emergency repair when factory
replacement parts are not readily available.
Special bending tools are needed to avoid kinking
or twisting of metal brake tubes. Special flaring tools
are needed to make a double inverted flare or ISO
flare (Fig. 14).

DOUBLE INVERTED FLARING

(1) Cut off damaged tube with Tubing Cutter.
(2) Ream cut edges of tubing to ensure proper
flare.
(3) Install replacement tube nut on the tube.
(4) Insert tube in flaring tool.
(5) Place gauge form over the end of the tube.
(6) Push tubing through flaring tool jaws until
tube contacts recessed notch in gauge that matches
tube diameter. Fig. 15 Inverted Flare Tools
(7) Tighten the tool bar on the tube
(8) Insert plug on gauge in the tube. Then swing ISO FLARING
compression disc over gauge and center tapered flar- To make a ISO flare use Snap-Ont Flaring Tool
ing screw in recess of compression disc (Fig. 15). TFM-428 or equivalent.
(9) Tighten tool handle until plug gauge is (1) Cut off damaged tube with Tubing Cutter.
squarely seated on jaws of flaring tool. This will start (2) Remove any burrs from the inside of the tube.
the inverted flare. (3) Install tube nut on the tube.

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 XJ BRAKES 5 - 15
SERVICE PROCEDURES (Continued)
(4) Position the tube in the flaring tool flush with
the top of the tool bar (Fig. 16). Then tighten the tool
bar on the tube.
(5) Install the correct size adaptor on the flaring
tool yoke screw.
(6) Lubricate the adaptor.
(7) Align the adaptor and yoke screw over the tube
(Fig. 16).
(8) Turn the yoke screw in until the adaptor is
squarely seated on the tool bar.

Fig. 17 Brake Lamp Switch

1 – SWITCH
2 – HARNESS CONNECTOR

INSTALLATION
(1) Pull switch plunger all the way out to fully
extended position.
(2) Connect harness wires to switch.
(3) Press and hold brake pedal in applied position.
(4) Install switch as follows: Align tab on switch
with notch in switch bracket. Then insert switch in
Fig. 16 ISO Flaring
bracket and turn it clockwise about 30° to lock it in
1 – ADAPTER
place.
2 – LUBRICATE HERE
3 – PILOT
(5) Release brake pedal. Then pull pedal lightly
4 – FLUSH WITH BAR rearward. Pedal will set plunger to correct position
5 – TUBING as pedal pushes plunger into switch body. Switch will
6 – BAR ASSEMBLY make ratcheting sound as it self adjusts.

CAUTION: Booster damage may occur if the pedal

REMOVAL AND INSTALLATION pull exceeds 20 lbs..

BRAKE LAMP SWITCH

BRAKE PEDAL
REMOVAL
(1) Remove steering column cover and lower trim REMOVAL
panel for switch access (if necessary). (1) Remove knee blocker under the steering col-
(2) Press brake pedal downward to fully applied umn.
position. (2) Remove retainer clip securing booster push rod
(3) Rotate switch approximately 30° in counter- to pedal (Fig. 18).
clockwise direction to unlock switch retainer. Then (3) Remove brake lamp switch.
pull switch rearward and out of bracket. (4) Remove nuts securing the booster to the pedal
(4) Disconnect switch harness and remove switch support bracket and nuts to the column bracket.
from vehicle (Fig. 17). (5) Remove pedal and support bracket as an
assembly from the vehicle.

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 5 - 16 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 18 Booster Push Rod

1 – BRAKE PEDAL
2 – BOOSTER ROD
3 – BUSHING

INSTALLATION Fig. 19 Differential Pressure Switch

(1) Install pedal and support bracket as an assem- 1 – SWITCH TERMINAL
bly into the vehicle. 2 – COMBINATION VALVE
3 – WIRE HARNESS CONNECTOR
(2) Install nuts securing the booster to the pedal
support bracket and nuts to the column bracket.
(3) Tighten nuts to 39 N·m (29 ft. lbs.).
(4) Lubricate the brake pedal pin and bushings
with Mopar multi-mileage grease.
(5) Install booster push rod on pedal pin and
install new retainer clip.
(6) Install knee blocker.

COMBINATION VALVE
NOTE: The combination valve is not repairable. The
valve is serviced as an assembly only.

REMOVAL
(1) Remove air cleaner cover and hose for access to
valve.
Fig. 20 Combination Valve
(2) Unsnap connector lock tabs and disconnect dif-
1 – COMBINATION VALVE
ferential pressure switch wire at combination valve
2 – MASTER CYLINDER
(Fig. 19). Do not pull switch wire to disconnect.
(3) Disconnect brake lines at combination valve
(Fig. 20). (4) Connect wire to pressure differential switch.
(4) Remove mounting nut and remove valve. (5) Bleed base brakes.

INSTALLATION MASTER CYLINDER

(1) Install valve and tighten mounting nut to 17
N·m (155 in. lbs.). REMOVAL
(2) Connect brake lines to replacement valve. Start (1) Remove brake lines at master cylinder and
line fittings by hand to avoid cross threading. combination valve (Fig. 20).
(3) Tighten brake line fittings to 14 N·m (124 in. (2) Disconnect differential pressure switch wire
lbs.). from the combination valve.

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 XJ BRAKES 5 - 17
REMOVAL AND INSTALLATION (Continued)
(3) Remove mounting nuts from the combination POWER BRAKE BOOSTER
valve bracket and remove the valve (Fig. 20).
(4) Remove mounting nuts from the master cylin- REMOVAL
der (Fig. 21). (1) On RHD vehicles remove the coolant reserve/
(5) Remove master cylinder. overflow tank. Refer to Group 7 Cooling System.
(6) Remove cylinder cover and drain fluid. (2) Disconnect brake lines at master cylinder.
(7) If master cylinder reservoir requires service, (3) Disconnect wire at combination valve differen-
refer to reservoir replacement procedure in this sec- tial pressure switch.
tion. (4) Remove nut mounting combination valve
bracket to booster studs and remove valve.
(5) Remove nuts mounting master cylinder to
booster studs and remove cylinder.
(6) Disconnect vacuum hose from booster check
valve.
(7) Remove knee blocker under the steering col-
umn.
(8) Remove retaining clip that secures booster
push rod to brake pedal (Fig. 22).
(9) Remove nuts attaching booster to passenger
compartment side of dash panel (Fig. 23).

Fig. 21 Master Cylinder

1 – BOOSTER
2 – MASTER CYLINDER

INSTALLATION
NOTE: If master cylinder is replaced, bleed cylinder
before installation.

(1) Remove protective sleeve from primary piston

shank on new master cylinder.
(2) Clean cylinder mounting surface of brake Fig. 22 Booster Push Rod
booster. 1 – BRAKE PEDAL
(3) Install master cylinder onto brake booster 2 – BOOSTER ROD
studs. 3 – BUSHING
(4) Install mounting nuts and tighten to 17 N·m
(155 in. lbs.). (10) In engine compartment, slide booster studs
(5) Install combination valve and install mounting out of dash panel, tilt booster upward, and remove
nuts. booster from engine compartment.
(6) Connect brake lines to master cylinder and (11) Remove dash seal from booster.
combination valve and tighten to 14 N·m (124 in.
lbs.). INSTALLATION
(7) Connect differential pressure switch wire to the (1) Install dash seal on booster.
combination valve. (2) Align and position booster on dash panel.
(8) On RHD vehicles install the coolant reserve/ (3) In passenger compartment, install booster
overflow tank. Refer to Group 7 Cooling System. mounting nuts. Tighten nuts just enough to hold
(9) Fill and bleed base brake system. booster in place.
(4) Slide booster push rod onto the brake pedal.
Then secure push rod to pedal pin with retaining
clip.

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 5 - 18 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)
(3) Drain small amount of fluid from master cylin-
der brake reservoir with suction gun.
(4) Bottom caliper piston in bore with C-clamp.
Position clamp screw on outboard brake shoe and
clamp frame on rear of caliper (Fig. 24). Do not
allow clamp screw to bear directly on outboard
shoe retainer spring. Use wood or metal spacer
between shoe and clamp screw.

Fig. 23 Booster Mounting

1 – BOOSTER

NOTE: Lubricate the pedal pin and bushing with

Mopar multi-mileage grease before installation.

(5) Tighten booster mounting nuts to 39 N·m (29

ft. lbs.).
(6) Install the knee blocker. Fig. 24 Bottoming Caliper Piston With C-Clamp
(7) If original master cylinder is being installed, 1 – CALIPER BOSS
check condition of seal at rear of master cylinder. 2 – OUTBOARD BRAKESHOE
Replace seal if cut, or torn. 3 – C-CLAMP
(8) Clean cylinder mounting surface of brake
booster. Use shop towel wetted with brake cleaner for
(5) Remove brake hose mounting bolt and discard
this purpose. Dirt, grease, or similar materials will
washers (Fig. 25).
prevent proper cylinder seating and could result in
vacuum leak.
(9) Align and install master cylinder on booster
studs. Install mounting nuts and tighten to 17.5 N·m
(155 in. lbs.).
(10) Connect vacuum hose to booster check valve.
(11) Connect and secure brake lines to combination
valve and master cylinder. Start all brake line fit-
tings by hand to avoid cross threading.
(12) Install combination valve on booster studs.
Tighten bracket mounting nuts to 17.5 N·m (155 in.
lbs.).
(13) Connect wire to combination valve switch.
(14) On RHD vehicles install the coolant reserve/
overflow tank. Refer to Group 7 Cooling System.
(15) Fill and bleed base brake system.
(16) Verify proper brake operation before moving
vehicle.

FRONT DISC BRAKE CALIPER Fig. 25 Brake Hose And Bolt

1 – FITTING WASHERS
REMOVAL 2 – CALIPERS
(1) Raise and support vehicle.
(2) Remove front wheel and tire assembly.
(6) Remove caliper mounting bolts (Fig. 26).

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 XJ BRAKES 5 - 19
REMOVAL AND INSTALLATION (Continued)

Fig. 26 Caliper Mounting Bolts

1 – CALIPER MOUNTING BOLT (2)
Fig. 28 Caliper Lubrication Points
2 – CALIPER
1 – BUSHINGS
2 – CALIPER MOUNTING BOLTS
(7) Tilt top of caliper outward with pry tool if nec- 3 – MOUNTING LEDGES
essary (Fig. 27) and remove caliper.

Fig. 27 Caliper Removal

1 – TILT CALIPER OUTBOARD TO REMOVE

(8) Remove caliper from vehicle.

INSTALLATION Fig. 29 Caliper Installation

(1) Clean brake shoe mounting ledges with wire 1 – TOP LEDGE
brush and apply light coat of Mopar multi-mileage 2 – BRAKESHOE TAB ON LEDGE OUTER SURFACE
grease to surfaces (Fig. 28). 3 – LEDGE SEATED IN BRAKESHOE NOTCH
(2) Install caliper by position notches at lower end 4 – BOTTOM LEDGE
of brake shoes on bottom mounting ledge. Then
rotate caliper over rotor and seat notches at upper condition, check caliper bolt length before proceed-
end of shoes on top mounting ledge (Fig. 29). ing. Bolts must not have a shank length greater
(3) Coat caliper mounting bolts with silicone than 67.6 mm (2.66 in.) (Fig. 30).
grease. Then install and tighten bolts to 15 N·m (11
ft. lbs.). (4) Install brake hose to caliper with new seal
washers and tighten fitting bolt to 31 N·m (23 ft.
CAUTION: If new caliper bolts are being installed, lbs.).
or if the original reason for repair was a drag/pull

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 5 - 20 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 30 Mounting Bolt Dimensions

1 – 67 mm (6 0.6 mm) 2.637 in. (6 0.0236 in.) Fig. 31 Outboard Brake Shoe Removal
2 – 22 mm (0.866 in.) THREAD LENGTH 1 – OUTBOARD BRAKESHOE
3 – CALIPER BOLT 2 – SHOE SPRING
3 – LOCATING LUG
4 – CALIPER
CAUTION: Verify brake hose is not twisted or 5 – LOCATING LUG
kinked before tightening fitting bolt.

(5) Bleed base brake system.

(6) Install wheel and tire assemblies.
(7) Remove supports and lower vehicle.
(8) Verify firm pedal before moving vehicle.

FRONT DISC BRAKE SHOES

REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove caliper.
(4) Pressing one end of outboard shoe inward to
disengage shoe lug. Then rotate shoe upward until
retainer spring clears caliper. Press opposite end of
shoe inward to disengage shoe lug and rotate shoe up
and out of caliper (Fig. 31).
(5) Grasp ends of inboard shoe and tilt shoe out- Fig. 32 Inboard Brake Shoe Removal
ward to release springs from caliper piston (Fig. 32) 1 – CALIPER PISTON
2 – SHOE SPRINGS
and remove shoe from caliper.
3 – INBOARD BRAKESHOE
NOTE: If original brake shoes will be used, keep
them in sets left and right. They are not inter- INSTALLATION
changeable. (1) Install inboard shoe in caliper and verify shoe
retaining is fully seated into the piston.
(6) Secure caliper to nearby suspension part with (2) Starting one end of outboard shoe in caliper
wire. Do not allow brake hose to support caliper and rotating shoe downward into place. Verify shoe
weight. locating lugs and shoe spring are seated.
(7) Wipe caliper off with shop rags or towels. (3) Install caliper.
(4) Install wheel and tire assembly.
CAUTION: Do not use compressed air, this can
(5) Remove support and lower vehicle.
unseat dust boot and force dirt into piston bore.
(6) Pump brake pedal until caliper pistons and
brake shoes are seated.
(7) Top off brake fluid level if necessary.

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 XJ BRAKES 5 - 21
REMOVAL AND INSTALLATION (Continued)

DISC BRAKE ROTOR (6) Remove hold-down springs, retainers and pins
with standard retaining spring tool.
REMOVAL (7) Install spring clamps on wheel cylinders to
(1) Remove wheel and tire assemble. hold pistons in place.
(2) Remove caliper. (8) Remove adjuster lever, adjuster screw and
(3) Remove retainers securing rotor to hub studs spring.
(Fig. 33). (9) Remove adjuster cable and cable guide.
(4) Remove rotor from hub. (10) Remove brake shoes and parking brake strut.
(5) If rotor shield requires service, remove front (11) Disconnect cable from parking brake lever and
hub and bearing assembly. remove lever.

INSTALLATION
(1) Clean support plate with brake cleaner.
(2) If new drums are being installed, remove pro-
tective coating with carburetor cleaner followed by
final rinse with brake cleaner.
(3) Clean and lubricate anchor pin with light coat
of Mopar multi-mileage grease.
(4) Apply Mopar multi-mileage grease to brake
shoe contact surfaces of support plate (Fig. 35).
(5) Lubricate adjuster screw threads and pivot
with spray lube.
(6) Attach parking brake lever to secondary brake
shoe. Use new washer and U-clip to secure lever.
(7) Remove wheel cylinder clamps.
(8) Attach parking brake cable to lever.
Fig. 33 Rotor & Hub (9) Install brake shoes on support plate. Secure
1 – ROTOR shoes with new hold-down springs, pins and retain-
2 – RETAINER ers.
3 – BEARING NUT
(10) Install parking brake strut and spring.
4 – NUT LOCK
(11) Install guide plate and adjuster cable on
5 – COTTER PIN
6 – WASHER
anchor pin.
(12) Install primary and secondary return springs.
(13) Install adjuster cable guide on secondary
INSTALLATION shoe.
(1) If new rotor is being installed, remove protec- (14) Lubricate and assemble adjuster screw.
tive coating from rotor surfaces with carburetor (15) Install adjuster screw, spring and lever and
cleaner. connect to adjuster cable.
(2) Install rotor on hub. (16) Adjust shoes to drum.
(3) Install caliper. (17) Install wheel/tire assemblies and lower vehi-
(4) Install wheel and tire assembly. cle.
(18) Verify firm brake pedal before moving vehicle.
DRUM BRAKE SHOES
WHEEL CYLINDER
REMOVAL
(1) Raise vehicle and remove rear wheels. REMOVAL
(2) Remove and discard spring nuts securing (1) Remove wheel and tire assembly.
drums to wheel studs. (2) Remove brake drum.
(3) Remove brake drums. If drums prove difficult (3) Disconnect wheel cylinder brake line.
to remove, retract brake shoes. Remove access plug (4) Remove brake shoe return springs and move
at the rear of backing plate and back off adjuster shoes out of engagement with cylinder push rods.
screw with brake tool and screwdriver. (5) Remove cylinder attaching bolts and remove
(4) Remove U-clip and washer securing adjuster cylinder from support plate.
cable to parking brake lever (Fig. 34).
(5) Remove primary and secondary return springs
from anchor pin with brake spring pliers.

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 5 - 22 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 34 Drum Brake Components—Typical

1 – ADJUSTER LEVER 11 – PARK BRAKE STRUT AND SPRING
2 – ADJUSTER CABLE 12 – ADJUSTER SCREW ASSEMBLY
3 – HOLDDOWN SPRING AND RETAINERS 13 – HOLDDOWN SPRING AND RETAINERS
4 – ADJUSTER LEVER SPRING 14 – LEADING SHOE
5 – TRAILING SHOE 15 – CABLE GUIDE
6 – CYLINDER-TO-SUPPORT SEAL 16 – SHOE RETURN SPRINGS
7 – HOLDDOWN PINS 17 – SHOE GUIDE PLATE
8 – ACCESS PLUGS 18 – PIN
9 – SUPPORT PLATE 19 – SHOE SPRING
10 – CABLE HOLE PLUG 20 – PARK BRAKE LEVER

INSTALLATION
(1) Apply bead of silicone sealer around cylinder
mounting surface of support plate.
(2) Install cylinder mounting bolts and tighten to
20 N·m (15 ft. lbs.).
(3) Connect brake line to cylinder.
(4) Install brake shoe return spring.
(5) Install brake drum.
(6) Install wheel and tire assembly.
(7) Bleed base brake system.

BRAKE SUPPORT PLATE

REMOVAL
(1) Remove wheel and tire assembly and brake
Fig. 35 Shoe Contact Surfaces drum.
1 – ANCHOR PIN (2) Remove brake shoe assembly.
2 – SUPPORT PLATE (3) Remove parking brake cable from parking
3 – SHOE CONTACT SURFACES brake lever.
(4) Compress parking brake cable retainer tabs.
Then push retainer and cable through and out of
support plate.

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 XJ BRAKES 5 - 23
REMOVAL AND INSTALLATION (Continued)
(5) Disconnect brake line at wheel cylinder.
(6) Remove wheel cylinder from support plate.
(7) Remove axle shaft, refer to Group 3 for proce-
dures.
(8) Remove bolts attaching support plate to axle
and remove support plate.

INSTALLATION
(1) Apply bead of silicone sealer around axle
mounting surface of support plate.
(2) Install support plate on axle flange. Tighten
attaching bolts to 115 N·m (85 ft. lbs.).
(3) Apply bead of silicone sealer around wheel cyl-
inder mounting surface and install wheel cylinder.
(4) Install brake line in wheel cylinder.
(5) Install parking brake cable in support plate.
(6) Install axle shaft, refer to Group 3 for proce-
Fig. 36 Parking Brake Cables
dure.
1 – REAR CABLES
(7) Connect parking brake cable to lever on sec- 2 – EQUALIZER
ondary shoe and install brake shoes on support plate. 3 – FRONT CABLE
(8) Adjust brake shoes to drum with brake gauge. 4 – TENSIONER ROD
(9) Install brake drum and wheel and tire assem-
bly.
(10) Bleed brake system.

REAR PARKING BRAKE CABLES

REMOVAL
(1) Raise vehicle and loosen equalizer nuts until
rear cables are slack.
(2) Disengage cables from equalizer and compress
cable retainers with a worm drive hose clamp.
(3) Remove cables from the cable bracket (Fig. 36).
(4) Remove rear wheel and brake drums.
(5) Remove secondary brake shoe and disconnect
cable from lever on brake shoe.
(6) Compress cables retainer with worm drive hose
clamp (Fig. 37) and remove cables from backing
plates.

INSTALLATION
(1) Install new cables in backing plates. Be sure
cable retainer is seated.
(2) Attach cable to lever on brake shoe and install
brake shoe on backing plate.
(3) Adjust brake shoes to drum with brake gauge.
Fig. 37 Cable Retainer
(4) Install brake drums and wheels.
1 – CABLE RETAINER
(5) Install cables into the cable bracket and insure
2 – REAR CABLE
retainers are seated in the bracket. 3 – WORM DRIVE HOSE CLAMP
(6) Engage the cable ends into the equalizer and
install equalizer nut.
(7) Adjust parking brakes. PARKING BRAKE LEVER
The center console must be removed to service the
parking brake lever. Refer to Group 23 Interior Com-
ponents for service procedures.

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 5 - 24 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Release parking brakes.
(2) Raise vehicle.
(3) Remove adjusting nut from tensioner rod at the
equalizer (Fig. 38).

Fig. 39 Parking Brake Lever Assembly

1 – MOUNTING BOLTS
2 – FRONT CABLE LEVER
3 – PARKING BRAKE SWITCH
4 – PARKING BRAKE LEVER

Fig. 38 Parking Brake Equalizer (10) Verify correct parking brake operation.
1 – REAR CABLES
2 – EQUALIZER
3 – FRONT CABLE DISASSEMBLY AND ASSEMBLY
4 – TENSIONER ROD
MASTER CYLINDER RESERVOIR
(4) Lower vehicle.
REMOVAL
(5) Disengage front cable from the cable lever.
(1) Remove reservoir cap and empty fluid into
(6) Compress cable retainer with worm drive hose
drain container.
clamp and remove the cable from the parking brake
(2) Remove pins that retain reservoir to master
lever base.
cylinder. Use hammer and pin punch to remove pins
(7) Disconnect parking brake lamp switch wire
(Fig. 40).
(Fig. 39).
(8) Remove parking brake lever assembly mount-
ing bolts (Fig. 39).
(9) Remove lever assembly.
(10) Remove parking brake lamp switch.

INSTALLATION
(1) Install parking brake lamp switch.
(2) Position lever assembly on floorpan and install
lever mounting bolts.
(3) Tighten lever mounting bolts to 10 to 14 N·m
(7 to 10 ft. lbs.).
(4) Insert front cable through the parking brake
lever base. Insure the cable retainer is seated into
the base.
(5) Attach the front cable to the cable lever (Fig.
39).
(6) Connect parking brake lamp switch wire. Fig. 40 Reservoir Retaining Pins
(7) Raise vehicle. 1 – PIN PUNCH
(8) Install adjusting nut to the tensioner rod and 2 – RESERVOIR
adjust parking brakes. 3 – BODY
4 – ROLL PINS
(9) Lower vehicle.

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 XJ BRAKES 5 - 25
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Clamp cylinder body in vise with brass protec-
tive jaws.
(4) Loosen reservoir from grommets with pry tool
(Fig. 41).

Fig. 43 Grommet Removal

1 – MASTER CYLINDER BODY
2 – GROMMETS

(1) Lubricate new grommets with clean brake fluid

and Install new grommets in cylinder body (Fig. 44).
Use finger pressure to install and seat grommets.

Fig. 41 Loosening Reservoir

1 – PRY TOOL
2 – RESERVOIR
3 – GROMMET
4 – MASTER CYLINDER BODY

(5) Remove reservoir by rocking it to one side and

pulling free of grommets (Fig. 42).

Fig. 44 Grommet Installation

1 – WORK NEW GROMMETS INTO PLACE USING FINGER
PRESSURE ONLY

(2) Start reservoir in grommets. Then rock reser-

Fig. 42 Reservoir Removal voir back and forth while pressing downward to seat
1 – RESERVOIR it in grommets.
2 – GROMMETS (3) Install pins that retain reservoir to cylinder
body.
(6) Remove old grommets from cylinder body (Fig. (4) Fill and bleed master cylinder on bench before
43). installation in vehicle.

INSTALLATION DISC BRAKE CALIPER

CAUTION: Do not use any type of tool to install the DISASSEMBLY
grommets. Tools may cut, or tear the grommets cre- (1) Remove brake shoes from caliper.
ating a leak problem after installation. Install the (2) Drain brake fluid out of caliper.
grommets using finger pressure only. (3) Take a piece of wood and pad it with one-inch
thickness of shop towels. Place this piece in the out-
board shoe side of the caliper in front of the piston.

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 5 - 26 BRAKES XJ
DISASSEMBLY AND ASSEMBLY (Continued)
This will cushion and protect caliper piston during
removal (Fig. 45).

Fig. 45 Padding Caliper Interior

1 – SHOP TOWELS OR CLOTHS
2 – CALIPER

(4) Remove caliper piston with short bursts of Fig. 46 Caliper Piston Removal
low pressure compressed air. Direct air through fluid 1 – AIR GUN
inlet port and ease piston out of bore (Fig. 46). 2 – CALIPER PISTON
3 – PADDING MATERIAL
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out.

WARNING: NEVER ATTEMPT TO CATCH THE PIS-

TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.

(5) Remove caliper piston dust boot with suitable

pry tool (Fig. 47).
(6) Remove caliper piston seal with wood or plastic
tool (Fig. 48). Do not use metal tools as they will
scratch piston bore.
(7) Remove caliper mounting bolt bushings and
boots (Fig. 49).

ASSEMBLY Fig. 47 Caliper Piston Dust Boot Removal

1 – COLLAPSE BOOT WITH PUNCH OR SCREWDRIVER
CAUTION: Dirt, oil, and solvents can damage cali-
2 – PISTON DUST BOOT
per seals. Insure assembly area is clean and dry.

(1) Lubricate caliper piston bore, new piston seal (4) Install new piston seal into seal groove with
and piston with clean brake fluid. finger (Fig. 51).
(2) Lubricate caliper bushings and interior of (5) Install new dust boot on caliper piston and seat
bushing boots with silicone grease. boot in piston groove (Fig. 52).
(3) Install bushing boots in caliper, then insert (6) Press piston into caliper bore by hand, use a
bushing into boot and push bushing into place (Fig. turn and push motion to work piston into seal (Fig.
50). 53).
(7) Press caliper piston to bottom of bore.

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 XJ BRAKES 5 - 27
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 48 Piston Seal Removal Fig. 51 Piston Seal Installation

1 – REMOVE SEAL WITH WOOD PENCIL OR SIMILAR TOOL 1 – SEAL GROOVE
2 – PISTON SEAL 2 – PISTON SEAL

Fig. 49 Mounting Bolt Bushing And Boot

1 – CALIPER SLIDE BUSHING Fig. 52 Dust Boot On Piston
2 – BOOT 1 – PISTON
2 – DUST BOOT

Fig. 50 Bushings And Boots Installation

1 – BUSHING
2 – BOOT Fig. 53 Caliper Piston Installation
1 – PISTON
2 – BOOT

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 5 - 28 BRAKES XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(8) Seat dust boot in caliper with Installer Tool
C-4842 and Tool Handle C-4171 (Fig. 54).

Fig. 55 Wheel Cylinder Components–Typical

1 – SPRING
2 – CYLINDER
3 – PISTON CLIP
4 – BOOT
5 – PUSH ROD
6 – PISTON
7 – BLEED SCREW
8 – CUP EXPANDERS

CLEANING AND INSPECTION

Fig. 54 Piston Dust Boot Installation CALIPER

1 – HANDLE C-4171
2 – INSTALLER C-4842 CLEANING
3 – DUST BOOT Clean the caliper components with clean brake
fluid or brake clean only. Wipe the caliper and piston
dry with lint free towels or use low pressure com-
(9) Replace caliper bleed screw if removed.
pressed air.
WHEEL CYLINDER CAUTION: Do not use gasoline, kerosene, thinner,
or similar solvents. These products may leave a
DISASSEMBLY residue that could damage the piston and seal.
(1) Remove push rods and boots (Fig. 55).
(2) Press pistons, cups and spring and expander
out of cylinder bore. INSPECTION
(3) Remove bleed screw. The piston is made from a phenolic resin (plastic
material) and should be smooth and clean.
ASSEMBLY The piston must be replaced if cracked or scored.
(1) Lubricate wheel cylinder bore, pistons, piston Do not attempt to restore a scored piston surface by
cups and spring and expander with clean brake fluid. sanding or polishing.
(2) Install first piston in cylinder bore. Then
install first cup in bore and against piston. Be sure CAUTION: If the caliper piston is replaced, install
lip of piston cup is facing inward (toward the same type of piston in the caliper. Never inter-
spring and expander) and flat side is against change phenolic resin and steel caliper pistons.
piston. The pistons, seals, seal grooves, caliper bore and
(3) Install spring and expander followed by piston tolerances are different.
remaining piston cup and piston.
(4) Install boots on each end of cylinder and insert The bore can be lightly polished with a brake
push rods in boots. hone to remove very minor surface imperfections
(5) Install cylinder bleed screw. (Fig. 56). The caliper should be replaced if the bore is
severely corroded, rusted, scored, or if polishing
would increase bore diameter more than 0.025 mm
(0.001 inch).

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 XJ BRAKES 5 - 29
CLEANING AND INSPECTION (Continued)

Fig. 56 Polishing Piston Bore

1 – SPECIAL HONE
Fig. 57 Shoe Contact Surfaces
2 – CALIPER 1 – ANCHOR PIN
3 – PISTON BORE 2 – SUPPORT PLATE
3 – SHOE CONTACT SURFACES

REAR DRUM BRAKE

WHEEL CYLINDER
CLEANING
Clean the individual brake components, including
CLEANING
the support plate and wheel cylinder exterior, with a Clean the cylinder and pistons with clean brake
water dampened cloth or with brake cleaner. Do not fluid or brake cleaner only. Do not use any other
use any other cleaning agents. Remove light rust and cleaning agents.
scale from the brake shoe contact pads on the sup- Dry the cylinder and pistons with compressed air.
port plate with fine sandpaper. Do not use rags or shop towels to dry the cylinder
components. Lint from cloth material will adhere to
INSPECTION the cylinder bores and pistons.
As a general rule, riveted brake shoes should be
replaced when worn to within 0.78 mm (1/32 in.) of
INSPECTION
the rivet heads. Bonded lining should be replaced Inspect the cylinder bore. Light discoloration and
when worn to a thickness of 1.6 mm (1/16 in.). dark stains in the bore are normal and will not
Examine the lining contact pattern to determine if impair cylinder operation.
the shoes are bent or the drum is tapered. The lining The cylinder bore can be lightly polished but only
should exhibit contact across its entire width. Shoes with crocus cloth. Replace the cylinder if the bore is
exhibiting contact only on one side should be scored, pitted or heavily corroded. Honing the bore to
replaced and the drum checked for runout or taper. restore the surface is not recommended.
Inspect the adjuster screw assembly. Replace the Inspect the cylinder pistons. The piston surfaces
assembly if the star wheel or threads are damaged, should be smooth and free of scratches, scoring and
or the components are severely rusted or corroded. corrosion. Replace the pistons if worn, scored, or cor-
Discard the brake springs and retainer components roded. Do attempt to restore the surface by sanding
if worn, distorted or collapsed. Also replace the or polishing.
springs if a brake drag condition had occurred. Over- Discard the old piston cups and the spring and
heating will distort and weaken the springs. expander. These parts are not reusable. The original
Inspect the brake shoe contact pads on the support dust boots may be reused but only if they are in good
plate, replace the support plate if any of the pads are condition.
worn or rusted through. Also replace the plate if it is
bent or distorted (Fig. 57).

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 5 - 30 BRAKES XJ

ADJUSTMENTS (5) Reverse gauge and install it on brake shoes.

Position gauge legs at shoe centers as shown (Fig.
BRAKE LAMP SWITCH 59). If gauge does not fit (too loose/too tight), adjust
(1) Press and hold brake pedal in applied position. shoes.
(2) Pull switch plunger all the way out to fully
extended position.
(3) Release brake pedal. Then pull pedal lightly
rearward. Pedal will set plunger to correct position
as pedal pushes plunger into switch body. Switch will
make ratcheting sound as it self adjusts.

CAUTION: Booster damage may occur if the pedal

pull exceeds 20 lbs..

REAR DRUM BRAKE

The rear drum brakes are equipped with a self-ad-
justing mechanism. Under normal circumstances, the
only time adjustment is required is when the shoes
are replaced, removed for access to other parts, or
when one or both drums are replaced. Fig. 59 Adjusting Gauge On Brake Shoes
Adjustment can be made with a standard brake 1 – BRAKE GAUGE
gauge or with adjusting tool. Adjustment is per- 2 – BRAKE SHOES
formed with the complete brake assembly installed
on the backing plate.
(6) Pull shoe adjuster lever away from adjuster
screw star wheel.
ADJUSTMENT WITH BRAKE GAUGE (7) Turn adjuster screw star wheel (by hand) to
(1) Be sure parking brakes are fully released.
expand or retract brake shoes. Continue adjustment
(2) Raise rear of vehicle and remove wheels and
until gauge outside legs are light drag-fit on shoes.
brake drums.
(8) Install brake drums and wheels and lower
(3) Verify that left and right automatic adjuster
vehicle.
levers and cables are properly connected.
(9) Drive vehicle and make one forward stop fol-
(4) Insert brake gauge in drum. Expand gauge
lowed by one reverse stop. Repeat procedure 8-10
until gauge inner legs contact drum braking surface.
times to operate automatic adjusters and equalize
Then lock gauge in position (Fig. 58).
adjustment.

NOTE: Bring vehicle to complete standstill at each

stop. Incomplete, rolling stops will not activate
automatic adjusters.

ADJUSTMENT WITH ADJUSTING TOOL

(1) Be sure parking brake lever is fully released.
(2) Raise vehicle so rear wheels can be rotated
freely.
(3) Remove plug from each access hole in brake
support plates.
(4) Loosen parking brake cable adjustment nut
until there is slack in front cable.
(5) Insert adjusting tool through support plate
access hole and engage tool in teeth of adjusting
screw star wheel (Fig. 60).
Fig. 58 Adjusting Gauge On Drum
(6) Rotate adjuster screw star wheel (move tool
1 – BRAKE GAUGE
2 – BRAKE DRUM
handle upward) until slight drag can be felt when
wheel is rotated.

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 XJ BRAKES 5 - 31
ADJUSTMENTS (Continued)
(4) Check rear brake shoe adjustment with stan-
dard brake gauge.

CAUTION: Excessive shoe-to-drum clearance, or

worn brake components will result in faulty parking
brake adjustment and operation.

(5) Verify that parking brake cables operate freely

and are not binding, or seized. Replace faulty cables,
before proceeding.
(6) Reinstall brake drums and wheel/tire assem-
blies after brake shoe adjustment is complete.
(7) Lower vehicle enough for access to parking
brake lever. Then fully apply parking brakes. Leave
brakes applied until adjustment is complete.
(8) Raise vehicle and mark tensioner rod 6.5 mm
(1/4 in.) from tensioner bracket (Fig. 61).
(9) Tighten adjusting nut at equalizer until mark
Fig. 60 Brake Adjustment
on tensioner rod moves into alignment with tensioner
1 – STAR WHEEL
bracket.
2 – LEVER
3 – BRAKE SHOE WEB
(10) Lower vehicle until rear wheels are 15-20 cm
4 – SCREWDRIVER (6-8 in.) off shop floor.
5 – ADJUSTING TOOL (11) Release parking brake lever and verify that
6 – ADJUSTER SPRING rear wheels rotate freely without drag.
(12) Lower vehicle.
(7) Push and hold adjuster lever away from star NOTE: Do not loosen/tighten equalizer adjusting
wheel with thin screwdriver. nut for any reason after completing adjustment.
(8) Back off adjuster screw star wheel until brake
drag is eliminated.
(9) Repeat adjustment at opposite wheel. Be sure
adjustment is equal at both wheels.
(10) Install support plate access hole plugs.
(11) Adjust parking brake cable and lower vehicle.
(12) Drive vehicle and make one forward stop fol-
lowed by one reverse stop. Repeat procedure 8-10
times to operate automatic adjusters and equalize
adjustment.

NOTE: Bring vehicle to complete standstill at each

stop. Incomplete, rolling stops will not activate
automatic adjusters.

PARKING BRAKE CABLE TENSIONER Fig. 61 Tensioner Rod Measurement

1 – TENSIONER BRACKET
NOTE: Parking brake adjustment is only necessary 2 – 6.5 mm (1/4 in.)
when the tensioner, or a cable has been replaced or 3 – TENSIONER ROD
disconnected. 4 – ROD TO EQUALIZER

ADJUSTMENT SPECIFICATIONS
(1) Raise vehicle.
(2) Back off tensioner adjusting nut to create slack BRAKE FLUID
in cables. The brake fluid used in this vehicle must conform
(3) Remove rear wheel/tire assemblies and remove to DOT 3 specifications and SAE J1703 standards.
brake drums. No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use

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 5 - 32 BRAKES XJ
SPECIFICATIONS (Continued)
only Mopar brake fluid or an equivalent from a SPECIAL TOOLS
tightly sealed container.
BASE BRAKES
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.

CAUTION: Never use any type of a petroleum-

based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid, etc.
Installer Caliper Dust Boot 8280
BRAKE COMPONENTS
Disc Brake Caliper
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sliding
Disc Brake Rotor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilated
Max. Runout . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Max. Thickness Variation . . 0.013 mm (0.0005 in.)
Min. Thickness . . . . . . . . . . 22.7 mm (0.8937 in.)
Brake Drum
Size . . . . . . . . . . . . . . . . . . . . . . . . 9 in. or 10 in.
Brake Booster
Type . . . . . . . . . . . . . . . . . . . . . Dual Diaphragm
TORQUE CHART
Handle C-4171
DESCRIPTION TORQUE
Brake Pedal
Pivot Bolt/Nut . . . . . . . . . . . . 35 N·m (26 ft. lbs.)
Brake Booster
Mounting Nuts . . . . . . . . . . . 39 N·m (29 ft. lbs.)
Master Cylinder
Mounting Nuts . . . . . . . . . 17.5 N·m (155 in. lbs.)
Brake Lines . . . . . . . . . . . . . 14 N·m (124 in. lbs.)
Combination Valve
Mounting Nuts . . . . . . . . . 17.5 N·m (155 in. lbs.)
Brake Lines . . . . . . . . . . . . . 14 N·m (124 in. lbs.)
Adapter Pressure Bleeder 6921
Caliper
Mounting Bolts . . . . . . . . . . . 15 N·m (11 ft. lbs.)
Brake Hose Bolt . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Wheel Cylinder
Mounting Bolts . . . . . . . . . . . . 10 N·m (7 ft. lbs.)
Brake Line . . . . . . . . . . . . . 14 N·m (124 in. lbs.)
Parking Brake
Lever Screws . . . . . . . . . 10-14 N·m (7-10 ft. lbs.)
Lever Bracket Screws . . 10-14 N·m (7-10 ft. lbs.)
Cable Retainer Nut . . . . . . . 1.5 N·m (14 in. lbs.)

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 XJ BRAKES 5 - 33

ANTILOCK BRAKES

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION

ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . 33 HYDRAULIC CONTROL UNIT/CONTROLLER
CONTROLLER ANTILOCK BRAKES . . . . . . . . . . . 33 ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . 36
HYDRAULIC CONTROL UNIT. . . . . . . . . . . . . . . . 34 FRONT WHEEL SPEED SENSOR . . . . . . . . . . . . 37
WHEEL SPEED SENSORS AND TONE WHEEL . . 34 REAR WHEEL SPEED SENSOR . . . . . . . . . . . . . 37
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 35 G-SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
G-SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 DISASSEMBLY AND ASSEMBLY
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . 35 HYDRAULIC CONTROL UNIT/CONTROLLER
DIAGNOSIS AND TESTING ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . . . . 39
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . . . . . 36 SPECIFICATIONS
SERVICE PROCEDURES T0RQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 40
BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . . . 36

DESCRIPTION AND OPERATION would in a vehicle without ABS. The HCU compo-
nents are not activated.
ANTILOCK BRAKE SYSTEM During antilock braking fluid pressure is modu-
lated according to wheel speed, degree of slip and
DESCRIPTION rate of deceleration. A sensor at each wheel converts
The purpose of the antilock system is to prevent wheel speed into electrical signals. These signals are
wheel lockup during periods of high wheel slip. Pre- transmitted to the CAB for processing and determi-
venting lockup helps maintain vehicle braking action nation of wheel slip and deceleration rate.
and steering control. The ABS system has three fluid pressure control
The antilock CAB activates the system whenever channels. The front brakes are controlled separately
sensor signals indicate periods of high wheel slip. and the rear brakes in tandem. A speed sensor input
High wheel slip can be described as the point where signal indicating a high slip condition activates the
wheel rotation begins approaching 20 to 30 percent of CAB antilock program. Two solenoid valves are used
actual vehicle speed during braking. Periods of high in each antilock control channel. The valves are all
wheel slip occur when brake stops involve high pedal located within the HCU valve body and work in pairs
pressure and rate of vehicle deceleration. to either increase, hold, or decrease apply pressure as
Battery voltage is supplied to the CAB ignition ter- needed in the individual control channels. The sole-
minal when the ignition switch is turned to Run posi- noid valves are not static during antilock braking.
tion. The CAB performs a system initialization They are cycled continuously to modulate pressure.
procedure at this point. Initialization consists of a Solenoid cycle time in antilock mode can be mea-
static and dynamic self check of system electrical sured in milliseconds.
components.
The static check occurs after the ignition switch is CONTROLLER ANTILOCK BRAKES
turned to Run position. The dynamic check occurs
when vehicle road speed reaches approximately 30 DESCRIPTION
kph (18 mph). During the dynamic check, the CAB The CAB is mounted to the HCU and operates the
briefly cycles the pump and solenoids to verify oper- ABS system (Fig. 1) separate from other vehicle elec-
ation. trical circuits.
If an ABS component exhibits a fault during ini-
tialization, the CAB illuminates the amber warning OPERATION
light and registers a fault code in the microprocessor The CAB voltage source is through the ignition
memory. switch in the RUN position. The CAB contains dual

OPERATION
During normal braking, the master cylinder, power
booster and wheel brake units all function as they

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 5 - 34 BRAKES XJ
DESCRIPTION AND OPERATION (Continued)
microprocessors. A logic block in each microprocessor power booster operate the same as a vehicle without
receives identical sensor signals. These signals are an ABS brake system.
processed and compared simultaneously. The CAB During antilock braking, solenoid valve pressure
contains a self check program that illuminates the modulation occurs in three stages, pressure increase,
ABS warning light when a system fault is detected. pressure hold, and pressure decrease. The valves are
Faults are stored in a diagnostic program memory all contained in the valve body portion of the HCU.
and are accessible with the DRB scan tool. ABS
faults remain in memory until cleared, or until after PRESSURE DECREASE
the vehicle is started approximately 50 times. Stored The outlet valve is opened and the inlet valve is
faults are not erased if the battery is disconnected. closed during the pressure decrease cycle.
A pressure decrease cycle is initiated when speed
sensor signals indicate high wheel slip at one or
more wheels. At this point, the CAB closes the inlet
then opens the outlet valve, which also opens the
return circuit to the accumulators. Fluid pressure is
allowed to bleed off (decrease) as needed to prevent
wheel lock.
Once the period of high wheel slip has ended, the
CAB closes the outlet valve and begins a pressure
increase or hold cycle as needed.

PRESSURE HOLD
Both solenoid valves are closed in the pressure
hold cycle. Fluid apply pressure in the control chan-
nel is maintained at a constant rate. The CAB main-
tains the hold cycle until sensor inputs indicate a
Fig. 1 Controller Antilock Brakes pressure change is necessary.
1 – HCU
2 – MOTOR PRESSURE INCREASE
3 – CAB The inlet valve is open and the outlet valve is
closed during the pressure increase cycle. The pres-
sure increase cycle is used to counteract unequal
HYDRAULIC CONTROL UNIT wheel speeds. This cycle controls re-application of
fluid apply pressure due to changing road surfaces or
DESCRIPTION wheel speed.
The HCU consists of a valve body, pump motor,
and wire harness (Fig. 1). WHEEL SPEED SENSORS AND TONE WHEEL
OPERATION DESCRIPTION
Accumulators in the valve body store extra fluid A speed sensor is used at each wheel. The front
released to the system for ABS mode operation. The sensors are mounted to the steering knuckles. The
pump provides the fluid volume needed and is oper- rear sensors at the outboard end of the axle.
ated by a DC type motor. The motor is controlled by
the CAB. OPERATION
The valves modulate brake pressure during The sensors convert wheel speed into a small AC
antilock braking and are controlled by the CAB. electrical signal. This signal is transmitted to the
The HCU provides three channel pressure control CAB. The CAB converts the AC signal into a digital
to the front and rear brakes. One channel controls signal for each wheel. This voltage is generated by
the rear wheel brakes in tandem. The two remaining magnetic induction when a tone wheel passes by the
channels control the front wheel brakes individually. stationary magnet of the wheel speed sensor.
During antilock braking, the solenoid valves are A gear type tone ring serves as the trigger mecha-
opened and closed as needed. The valves are not nism for each sensor. The tone rings are mounted at
static. They are cycled rapidly and continuously to the outboard ends of the front and rear axle shafts.
modulate pressure and control wheel slip and decel- Different sensors are used at the front and rear
eration. wheels (Fig. 2). The front/rear sensors have the same
During normal braking, the HCU solenoid valves electrical values but are not interchangeable. The
and pump are not activated. The master cylinder and

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 XJ BRAKES 5 - 35
DESCRIPTION AND OPERATION (Continued)
sensors have a resistance between 900 and 1300 OPERATION
ohms.
PRESSURE DIFFERENTIAL VALVE
The pressure differential switch is connected to the
brake warning light. The switch is actuated by move-
ment of the switch valve. The switch monitors fluid
pressure in the separate front/rear brake hydraulic
circuits.
A decrease or loss of fluid pressure in either
hydraulic circuit will cause the switch valve to shut-
tle to the low pressure side. Movement of the valve
pushes the switch plunger upward. This action closes
the switch internal contacts completing the electrical
circuit to the red warning light. The switch valve will
remain in an actuated position until repairs to the
brake system are made.

Fig. 2 Wheel Speed Sensors PROPORTIONING VALVE

1 – FRONT SENSOR The proportioning valve is used to balance front-
2 – REAR SENSOR rear brake action at high decelerations. The valve
3 – PICKUP FACE allows normal fluid flow during moderate braking.
The valve only controls fluid flow during high decel-
FRONT SENSOR AIR GAP erations brake stops.
Front sensor air gap is fixed and not adjustable.
Only rear sensor air gap is adjustable. G-SWITCH
Although front air gap is not adjustable, it can be
checked if diagnosis indicates this is necessary. Front DESCRIPTION
air gap should be 0.36 to 1.5 mm (0.014 to 0.059 in.). If The G-switch is located under the rear seat. The
gap is incorrect, the sensor is either loose, or damaged. switch has directional arrow and must be mounted
with the arrow pointing towards the front of the
REAR SENSOR AIR GAP vehicle.
A rear sensor air gap adjustment is only needed
when reinstalling an original sensor. Replacement OPERATION
sensors have an air gap spacer attached to the sensor The switch (Fig. 3), provides an additional vehicle
pickup face. The spacer establishes correct air gap deceleration reference during 4x4 operation. The
when pressed against the tone ring during installa- switch is monitored by the CAB at all times. The
tion. As the tone ring rotates, it peels the spacer off switch reference signal is utilized by the CAB when
the sensor to create the required air gap. Rear sensor all wheels are decelerating at the same speed.
air gap is 0.92-1.275 mm (0.036-0.05 in.).
Sensor air gap measurement, or adjustment proce- ABS WARNING LAMP
dures are provided in this section. Refer to the front,
or rear sensor removal and installation procedures as DESCRIPTION
required. The amber ABS warning lamp is located in the
instrument cluster. The lamp illuminates at start-up
COMBINATION VALVE to perform a self check. The lamp goes out when the
self check program determines the system is operat-
DESCRIPTION ing normal.
The combination valve contains a pressure differ-
ential valve and switch and a rear brake proportion- OPERATION
ing valve. The valve is not repairable and must be If an ABS component exhibits a fault the CAB will
replaced as an assembly if diagnosis indicates this is illuminate the lamp and register a trouble code in
necessary. the microprocessor. The lamp is controlled by the
CAB. The lamp is illuminated when the CAB sends a
ground signal to the ABS relay. The ABS relay then
grounds the lamp circuit and illuminates the lamp.

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 5 - 36 BRAKES XJ
DESCRIPTION AND OPERATION (Continued)
(3) Select ANTILOCK BRAKES, followed by MIS-
CELLANEOUS, then ABS BRAKES. Follow the
instructions displayed. When scan tool displays TEST
COMPLETE, disconnect scan tool and proceed.
(4) Perform base brake bleeding a second time.
Refer to base brake section for procedure.
(5) Top off master cylinder fluid level and verify
proper brake operation before moving vehicle.

REMOVAL AND INSTALLATION

HYDRAULIC CONTROL UNIT/CONTROLLER
ANTILOCK BRAKES
REMOVAL
Fig. 3 G-Switch (1) Remove negative battery cable from the bat-
1 – SWITCH PART NUMBER tery.
2 – ARROW INDICATES FRONT OF SWITCH FOR PROPER (2) Pull up on the CAB harness connector release
MOUNTING
(Fig. 4) and remove connector.
(3) Remove brake lines from the HCU.
DIAGNOSIS AND TESTING (4) Remove HCU/CAB mounting nuts and bolt
(Fig. 5) and remove HCU/CAB.
ANTILOCK BRAKES
The ABS brake system performs several self-tests
every time the ignition switch is turned on and the
vehicle is driven. The CAB monitors the systems
input and output circuits to verify the system is oper-
ating correctly. If the on board diagnostic system
senses that a circuit is malfunctioning the system
will set a trouble code in its memory.

NOTE: An audible noise may be heard during the

self-test. This noise should be considered normal.

NOTE: The MDS or DRB III scan tool is used to

diagnose the ABS system. For additional informa-
tion refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diag- Fig. 4 CAB Harness Connector Release
nostic Manual. 1 – CAB
2 – CAB HARNESS RELEASE

SERVICE PROCEDURES INSTALLATION

(1) Install HCU/CAB on the mounting studs.
BLEEDING ABS BRAKE SYSTEM (2) Install mounting nuts and bolt. Tighten to 11.5
ABS system bleeding requires conventional bleed- N·m (102 in. lbs.).
ing methods plus use of the DRB scan tool. The pro- (3) Install brake lines to the HCU and tighten to
cedure involves performing a base brake bleeding, 19 N·m (170 in. lbs.).
followed by use of the scan tool to cycle and bleed the (4) Install wiring harness connector to the CAB
HCU pump and solenoids. A second base brake bleed- and push down on the release to secure the connec-
ing procedure is then required to remove any air tor.
remaining in the system. (5) Install negative battery cable to the battery.
(1) Perform base brake bleeding. Refer to base (6) Bleed ABS brake system.
brake section for procedure.
(2) Connect scan tool to the Data Link Connector.

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 XJ BRAKES 5 - 37
REMOVAL AND INSTALLATION (Continued)

Fig. 5 HCU/CAB Mounting

1 – HCU
2 – CAB
3 – HCU/CAB BRACKET
4 – MOTOR

Fig. 6 Front Wheel Speed Sensor

FRONT WHEEL SPEED SENSOR 1 – WHEEL SPEED SENSOR PIGTAIL
2 – STEERING KNUCKLE
REMOVAL 3 – TONE WHEEL
(1) Raise vehicle and turn wheel outward for eas- 4 – FRONT WHEEL SPEED SENSOR
ier access to sensor.
(2) Remove sensor wire from mounting brackets. (6) Secure sensor wire to steering knuckle and
(3) Clean sensor and surrounding area with shop body brackets.
towel before removal. (7) Route sensor wire forward and behind shock
(4) Remove bolt attaching sensor to steering absorber. Then attach sensor wire to spring seat
knuckle and remove sensor (Fig. 6). bracket with grommets on sensor wire.
(5) Remove sensor wire from brackets on body and (8) Route sensor wire to outer sill bracket. Remove
steering knuckle. all twists or kinks from wire.
(6) Unseat sensor wire grommet in wheel house (9) Attach sensor wire to sill bracket with grom-
panel. met. Be sure wire is free of twists and kinks.
(7) In engine compartment, disconnect sensor wire (10) Verify sensor wire routing. Wire should loop
connector at harness plug. Then remove sensor and forward and above sill bracket. Loose end of wire
wire. should be below sill bracket and towards brake hose.
(11) Seat sensor wire grommet in body panel and
INSTALLATION clip wire to brake line at grommet location.
(1) If original sensor will be installed, wipe all (12) Connect sensor wire to harness in engine com-
traces of old spacer material off sensor pickup face. partment.
Use a dry shop towel for this purpose.
(2) Apply Mopar Lock N’ Seal or Loctite t 242 to REAR WHEEL SPEED SENSOR
bolt that secures sensor in steering knuckle. Use new
sensor bolt if original bolt is worn or damaged. REMOVAL
(3) Position sensor on steering knuckle. Seat sen- (1) Raise and fold rear seat forward for access to
sor locating tab in hole in knuckle and install sensor rear sensor connectors (Fig. 7).
attaching bolt finger tight. (2) Disconnect sensors at rear harness connectors.
(4) Tighten sensor attaching bolt to 4.7 N·m (42 in. (3) Push sensor grommets and sensor wires
lbs.). through floorpan.
(5) If original sensor has been installed, check sen- (4) Raise vehicle.
sor air gap. Air gap should be 0.36 to 1.5 mm (0.014 (5) Disconnect sensor wires at rear axle connec-
to 0.059 in.). If gap is incorrect, sensor is either loose, tors.
or damaged. (6) Remove wheel and tire assembly.

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 5 - 38 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 8 Rear Wheel Speed Sensor

1 – TONE WHEEL
2 – WHEEL SPEED SENSOR

Fig. 7 Acceleration Switch And Rear Sensor

Connections
1 – REAR SEAT CROSSMEMBER
2 – ACCELERATION SENSOR
3 – SENSOR MOUNTING BRACKET
4 – TO R. R. WHEEL SENSOR
5 – TO L. R. WHEEL SENSOR
6 – FLOORPAN
7 – SENSOR HARNESS

(7) Remove brake drum. Fig. 9 Setting Air Gap On Original Rear Sensor
(8) Remove clips securing sensor wires to brake 1 – WHEEL SPEED SENSOR
lines, rear axle and, brake hose. 2 – BRASS FEELER GAUGE
(9) Unseat sensor wire support plate grommet. 3 – TONE RING
(10) Remove bolt attaching sensor to bracket and
remove sensor (Fig. 8). Then tighten sensor bolt to 13 N·m (115 in. lbs.). Cor-
rect air gap will be established as tone ring rotates
INSTALLATION and peels spacer off sensor face.
(1) If original sensor is being installed, remove (7) Route sensor wires to rear seat area.
any remaining pieces of cardboard spacer from sen- (8) Feed sensor wires through floorpan access hole
sor pickup face. Use dry shop towel only to remove and seat sensor grommets in floorpan.
old spacer material. (9) Verify that rear sensor wires are secured to
(2) Insert sensor wire through support plate hole. rear brake hose and axle with clips. Verify that wire
Then seat sensor grommet in support plate. is clear of rotating components.
(3) Apply Mopar Lock N’ Seal or Loctite t 242 to (10) Install brake drum and wheel and tire assem-
original sensor bolt. Use new bolt if original is worn bly.
or damaged. (11) Lower vehicle.
(4) Install sensor bolt finger tight only at this (12) Connect sensor wire to harness connector.
time. Then reposition carpet and fold rear seat down.
(5) If original rear sensor was installed, adjust
sensor air gap to 0.92-1.275 mm (0.036-0.05 in.). Use G-SWITCH
feeler gauge to measure air gap (Fig. 9). Tighten sen-
sor bolt to 13 N·m (115 in. lbs.). REMOVAL
(6) If new sensor was installed, push cardboard (1) Raise and fold rear seat assembly forward for
spacer on sensor face against tone ring (Fig. 10). access to sensor.

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 XJ BRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)

Fig. 10 New Rear Sensor Fig. 12 G-Switch

1 – REAR SENSOR 1 – SWITCH PART NUMBER
2 – AIR GAP SPACER ATTACHED TO SENSOR FACE 2 – ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING

(2) Disconnect switch harness.

(3) Remove switch mounting screws (Fig. 11) (3) Connect harness to switch. Be sure harness
(4) Remove the acceleration switch. connector is firmly seated.
(4) Move seat back to normal position.

DISASSEMBLY AND ASSEMBLY

HYDRAULIC CONTROL UNIT/CONTROLLER
ANTILOCK BRAKE
DISASSEMBLY
(1) Remove pump motor connector from the CAB.
(2) Remove CAB mounting screws from the HCU
(Fig. 13).
(3) Remove CAB from the HCU.

Fig. 11 G-Switch Mounting

1 – ACCELERATION SWITCH
2 – SWITCH BRACKET
3 – REAR SEAT CROSSMEMBER

INSTALLATION
CAUTION: The mercury switch (inside the
G-switch), will not function properly if the switch is
installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig.
12).

(1) Position switch in mounting bracket. Fig. 13 CAB Mounting Screws

(2) Install switch mounting bolts and tighten to 3 1 – MOUNTING SCREWS
N·m (27.5 in. lbs.). 2 – CAB

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 5 - 40 BRAKES XJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY SPECIFICATIONS
(1) Install the CAB onto the HCU.
(2) Install the CAB mounting screws and tighten T0RQUE CHART
to 1.8 N·m (16 in. lbs.).
(3) Install pump motor connector to the CAB. DESCRIPTION TORQUE
G-Sensor
Sensor Bolt . . . . . . . . . . . . . . 3 N·m (27.5 in. lbs.)
Bracket Bolt . . . . . . . . . . . . . 2.7 N·m (24 in. lbs.)
Hydraulic Control Unit/Controller Antilock
Brakes
Mounting Nuts . . . . . . . . . 11.5 N·m (102 in. lbs.)
Brake Lines . . . . . . . . . . . . . 19 N·m (170 in. lbs.)
Controller Antilock Brakes
Mounting Screws . . . . . . . . . 1.8 N·m (16 in. lbs.)
Wheel Speed Sensors
Front Mounting Bolt . . . . . . 4.7 N·m (42 in. lbs.)
Rear Mounting Bolt . . . . . . . 13 N·m (115 in. lbs.)

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 XJ BRAKES 5-1

BRAKES
TABLE OF CONTENTS

page page

REMOVAL AND INSTALLATION SPECIFICATIONS

BRAKE BOOSTER – RHD DIESEL . . . . . . . . . . . . 1 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 4
MASTER CYLINDER – RHD DIESEL . . . . . . . . . . 3

REMOVAL AND INSTALLATION

BRAKE BOOSTER – RHD DIESEL
REMOVAL
(1) Open hood and disconnect the negative battery
cable

NOTE: Pump the brake pedal several times to

relieve vacuum in the brake booster. This will pre-
vent booster from sucking any contaminants when
master cylinder is removed.

(2) Remove the short brake lines leading from the

master cylinder to the combination valve (Fig. 1).

Fig. 2 Differential Pressure Switch Electrical

1 – SWITCH TERMINAL
2 – COMBINATION VALVE
3 – WIRE HARNESS CONNECTOR

(6) Disconnect the vacuum supply hose from the

brake booster.
(7) Disconnect the coolant level switch electrical
connector. Located on the side of the coolant reser-
Fig. 1 Brake Line Orientation voir.
1 – COMBINATION VALVE
2 – MASTER CYLINDER NOTE: It is not necessary to drain the cooling sys-
tem to perform this procedure.
(3) Disconnect differential pressure switch wire
(8) Remove the coolant reservoir retaining screws
from the combination valve. Lift the release tab on
so reservoir can be positioned out of the way.
the underside of the electrical connector and pull
(9) Working inside the vehicle, remove the hood
straight off (Fig. 2).
release cable handle retaining screws from the
(4) Remove the combination valve support bracket
underside of the instrument panel.
retaining nuts and remove the valve and bracket
(10) Remove the plastic and steel knee blockers
assembly from the vehicle.
from the vehicle. Refer to Group 23, Body for the pro-
(5) Remove the master cylinder retaining nuts
cedure.
(Fig. 8) and remove the master cylinder from the
brake booster by sliding straight off mounting studs.

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 5-2 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 3 Master Cylinder Fig. 5 Booster Mounting

1 – BOOSTER 1 – BOOSTER
2 – MASTER CYLINDER

NOTE: If a new master cylinder is being installed,

(11) Remove the retaining clip that secures the cylinder must be bench bleed prior to installation.
booster push rod to the brake pedal (Fig. 4).
(1) Install the brake booster on the bulkhead, be
certain dash seal is installed on booster studs prior
to installation.
(2) From under the instrument panel, install
booster mounting nuts. Tighten nuts just enough to
hold booster in place.

NOTE: Lubricate the pedal pin and bushing with

Mopar multi-mileage grease before installation.

(3) Slide booster push rod onto the brake pedal

pin. Then secure push rod to pedal pin with retaining
clip.
(4) Torque booster mounting nuts to 39 N·m (29 ft.
lbs.).
(5) Install the steel and plastic knee blocker in the
vehicle. Refer to Group 23, Body for the procedure.
Fig. 4 Booster Push Rod
(6) Install the hood release cable handle.
1 – BRAKE PEDAL
(7) Install the coolant reservoir bottle retaining
2 – BOOSTER ROD
3 – BUSHING
screws and connect the coolant level switch.
(8) Connect the vacuum supply hose on the brake
booster.
(12) Remove nuts attaching booster to passenger (9) Install master cylinder on brake booster and
compartment side of dash panel (Fig. 5). install retaining nuts. Torque the nuts to 17.5 N·m
(13) Working inside the engine compartment, posi- (155 in. lbs.).
tion the coolant reservoir out of the way and remove (10) Install combination valve/bracket and retain-
the brake booster by pulling straight out. ing nuts.
(11) Install brake lines on cylinder and valve.
INSTALLATION Torque brake lines to 19 N·m (170 in. lbs.).
(12) Connect differential pressure switch wire on
NOTE: Be certain rubber o-ring vacuum seal is the combination valve.
installed in the master cylinder mounting flange (13) Fill and bleed the brake system. Refer to the
prior to installation. procedure in this group.
(14) Connect the negative battery cable.

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 XJ BRAKES 5-3
REMOVAL AND INSTALLATION (Continued)
(15) Adjust the brake lamp switch. Refer to the
procedure in this group.

WARNING: Be certain a firm brake pedal is

achieved prior to attempting to operate the vehicle.

MASTER CYLINDER – RHD DIESEL

REMOVAL
(1) Open hood and disconnect the negative battery
cable

NOTE: Pump the brake pedal several times to

relieve vacuum in the brake booster. This will pre-
vent booster from sucking any contaminants when
master cylinder is removed.

(2) Remove the short brake lines leading from the

master cylinder to the combination valve (Fig. 6).

Fig. 7 Differential Pressure Switch Electrical

1 – SWITCH TERMINAL
2 – COMBINATION VALVE
3 – WIRE HARNESS CONNECTOR

Fig. 6 Brake Line Orientation

1 – COMBINATION VALVE
2 – MASTER CYLINDER

(3) Disconnect differential pressure switch wire

from the combination valve. Lift the release tab on
the underside of the electrical connector and pull
straight off (Fig. 7).
Fig. 8 Master Cylinder
(4) Remove the combination valve support bracket
1 – BOOSTER
retaining nuts and remove the valve and bracket 2 – MASTER CYLINDER
assembly from the vehicle.
(5) Remove the master cylinder retaining nuts
(Fig. 8) and remove the master cylinder from the NOTE: If a new master cylinder is being installed,
brake booster by sliding straight off mounting studs. cylinder must be bench bleed prior to installation.

INSTALLATION (1) If equipped, remove protective sleeve from pri-

mary piston shank on new master cylinder.
NOTE: Be certain rubber o-ring vacuum seal is (2) Clean cylinder mounting surface of brake
installed in the master cylinder mounting flange booster.
prior to installation. (3) Install master cylinder on brake booster and
install retaining nuts. Torque the nuts to 17.5 N·m
(155 in. lbs.).

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 5-4 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)
(4) Install combination valve/bracket and retaining SPECIFICATIONS
nuts.
(5) Install brake lines on cylinder and valve. TORQUE SPECIFICATIONS
Torque brake lines to 19 N·m (170 in. lbs.).
(6) Connect differential pressure switch wire on DESCRIPTION TORQUE
the combination valve. Brake Booster to Cowl Panel
(7) Fill and bleed the brake system. Refer to the Nuts . . . . . . . . . . . . . . . . . . . . . 39 N·m (29 ft. lbs.)
procedure in this group.
Brake Lines at Master Cylinder and
(8) Connect the negative battery cable.
Combination Valve
(9) Adjust the brake lamp switch. Refer to the pro-
Tube Nuts . . . . . . . . . . . . . . . . 19 N·m (170 in. lbs.)
cedure in this group.
Master Cylinder to Vacuum Booster
WARNING: Be certain a firm brake pedal is Nuts . . . . . . . . . . . . . . . . . . . 17.5 N·m (155 in. lbs.)
achieved prior to attempting to operate the vehicle.

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 XJ CLUTCH 6-1

CLUTCH
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION CLUTCH FLYWHEEL RUNOUT . . . . . . . . . . . . . . . 6

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CLUTCH COVER AND DISC RUNOUT . . . . . . . . . 7
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CLUTCH DIAGNOSIS CHARTS . . . . . . . . . . . . . . . 7
CLUTCH DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SERVICE PROCEDURES
CLUTCH PRESSURE PLATE . . . . . . . . . . . . . . . . . 2 CLUTCH COMPONENT LUBRICATION . . . . . . . . . 9
CLUTCH RELEASE BEARING . . . . . . . . . . . . . . . . 3 CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . . . 9
HYDRAULIC CLUTCH LINKAGE . . . . . . . . . . . . . . 4 CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 10
DIAGNOSIS AND TESTING FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 4 REMOVAL AND INSTALLATION
INSTALLATION METHODS AND PARTS CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . 11
USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RELEASE BEARING . . . . . . . . . . . . . . . . . . . . . . 12
CLUTCH DIAGNOSTIC INFORMATION . . . . . . . . . 4 PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . 12
CLUTCH CONTAMINATION . . . . . . . . . . . . . . . . . . 6 CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . 13
IMPROPER CLUTCH RELEASE OR CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . . . 13
ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIFICATIONS
CLUTCH MISALIGNMENT. . . . . . . . . . . . . . . . . . . 6 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CLUTCH HOUSING MISALIGNMENT . . . . . . . . . . 6

DESCRIPTION AND OPERATION

CLUTCH
DESCRIPTION
The clutch mechanism consists of a flywheel, a sin-
gle, dry-type disc, and a diaphragm style clutch cover
(Fig. 1). A hydraulic linkage is used to operate the
clutch release bearing and fork. The flywheel is
bolted to the rear flange of the crankshaft. The
clutch pressure plate is bolted to the flywheel with
the clutch disc located between these two compo-
nents. The clutch system provides the mechanical,
but still easily detachable, link between the engine
and the transmission. The system is designed to
ensure that the full torque output of the engine is
transfered to the transmission while isolating the
transmission from the engine firing pulses to mini-
mize concerns such as gear rattle.

OPERATION
Leverage, clamping force, and friction are what
make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate Fig. 1 Engine Powerflow
provide the clamping force. The clutch pedal, hydrau-
lic linkage, release lever and bearing provide the
leverage.

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 6-2 CLUTCH XJ
DESCRIPTION AND OPERATION (Continued)
The clutch master cylinder push rod is connected
to the clutch pedal. When the clutch pedal is
depressed, the slave cylinder is operated by the
clutch master cylinder mounted on the dash panel.
The release fork is actuated by the hydraulic slave
cylinder mounted on the transmission housing. The
release bearing is operated by a release fork pivoting
on a ball stud mounted in the transmission housing.
The release bearing then depresses the pressure
plate spring fingers, thereby releasing pressure on
the clutch disc and allowing the engine crankshaft to
spin independently of the transmission input shaft
(Fig. 2).

Fig. 3 Flywheel
1 – CRANKSHAFT
2 – RING GEAR
3 – FLYWHEEL

OPERATION
The flywheel serves to dampen the engine firing
pulses. The heavy weight of the flywheel relative to
the rotating mass of the engine components serves to
stabilize the flow of power to the remainder of the
drivetrain. The crankshaft has the tendency to
attempt to speed up and slow down in response to
the cylinder firing pulses. The flywheel dampens
these impulses by absorbing energy when the crank-
shaft speeds and releasing the energy back into the
system when the crankshaft slows down.

CLUTCH DISC
DESCRIPTION
Fig. 2 Clutch Operation The clutch disc friction material is riveted to the
1 – FLYWHEEL disc hub (Fig. 4). The hub bore is splined for installa-
2 – PRESSURE PLATE FINGERS tion on the transmission input shaft. The clutch disc
3 – PIVOT POINT has cushion springs in the disc hub to dampen disc
4 – RELEASE BEARING PUSHED IN vibrations during application and release of the clutch.
5 – CLUTCH DISC ENGAGED
6 – CLUTCH DISC ENGAGED
7 – RELEASE BEARING
OPERATION
The clutch disc is held onto the surface of the fly-
wheel by the force exerted by the pressure plate’s dia-
FLYWHEEL phragm spring. The friction material of the clutch disc
then transfers the engine torque from the flywheel and
DESCRIPTION pressure plate to the input shaft of the transmission.
The flywheel (Fig. 3) is a heavy plate bolted to the
rear of the crankshaft. The flywheel incorporates the CLUTCH PRESSURE PLATE
ring gear around the outer circumference to mesh
with the starter to permit engine cranking. The rear DESCRIPTION
face of the flywheel serves as the driving member to The clutch pressure plate assembly is a diaphragm
the clutch disc. type with a one-piece spring and multiple release fin-
gers (Fig. 5). The pressure plate release fingers are
preset during manufacture and are not adjustable.
The assembly also contains the cover, pressure plate,
and fulcrum components.

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 XJ CLUTCH 6-3
DESCRIPTION AND OPERATION (Continued)
OPERATION
The clutch pressure plate assembly clamps the
clutch disc against the flywheel. When the release
bearing is depressed by the shift fork, the pressure
exerted on the clutch disc by the pressure plate
spring is decreased. As additional force is applied,
the bearing presses the diaphragm spring fingers
inward on the fulcrums. This action moves the pres-
sure plate rearward relieving clamp force on the disc.
The clutch disc is disengaged and freewheeling at
this point.

CLUTCH RELEASE BEARING

DESCRIPTION
A conventional release bearing (Fig. 6) is used to
engage and disengage the clutch pressure plate
assembly. The clutch release bearing is mounted on
the transmission front bearing retainer. The bearing
is attached to the release fork, which moves the bear-
ing into contact with the clutch cover diaphragm
Fig. 4 Clutch Disc-Typical spring.
1 – FACING MATERIAL
2 – DAMPER SPRINGS
3 – HUB

Fig. 6 Clutch Release Bearing

1 – RELEASE BEARING
2 – RELEASE FORK

OPERATION
The release bearing is operated by a release fork in
the clutch housing. Slave cylinder force causes the
release lever to move the release bearing into contact
with the diaphragm spring. As additional force is
applied, the bearing presses the diaphragm spring
Fig. 5 Clutch Pressure Plate-Typical fingers inward on the fulcrums. This action moves
1 – COVER the pressure plate rearward relieving clamp force on
2 – RELEASE FINGERS the disc. Releasing pedal pressure removes clutch
3 – PRESSURE PLATE hydraulic pressure. The release bearing then moves
away from the diaphragm spring which allows the
pressure plate to exert clamping force on the clutch
disc.

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 6-4 CLUTCH XJ
DESCRIPTION AND OPERATION (Continued)

HYDRAULIC CLUTCH LINKAGE COMPONENTS. BREATHING EXCESSIVE CONCEN-

TRATIONS OF THESE FIBERS CAN CAUSE SERIOUS
DESCRIPTION BODILY HARM. WEAR A RESPIRATOR DURING SER-
The hydraulic linkage consists of a clutch master VICE AND NEVER CLEAN CLUTCH COMPONENTS
cylinder with integral reservoir, a clutch slave cylin- WITH COMPRESSED AIR OR WITH A DRY BRUSH.
der and an interconnecting fluid line (Fig. 7). EITHER CLEAN THE COMPONENTS WITH A WATER
The clutch master cylinder push rod is connected to DAMPENED RAGS OR USE A VACUUM CLEANER
the clutch pedal. The slave cylinder push rod is con- SPECIFICALLY DESIGNED FOR REMOVING ASBES-
nected to the clutch release fork. The master cylinder is TOS FIBERS AND DUST. DO NOT CREATE DUST BY
mounted on the driver side of the dash panel adjacent SANDING A CLUTCH DISC. REPLACE THE DISC IF
to the brake master cylinder and booster assembly. THE FRICTION MATERIAL IS DAMAGED OR CON-
TAMINATED. DISPOSE OF ALL DUST AND DIRT CON-
TAINING ASBESTOS FIBERS IN SEALED BAGS OR
CONTAINERS. THIS WILL HELP MINIMIZE EXPOSURE
TO YOURSELF AND TO OTHERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
SAFETY AGENCY (EPA), FOR THE HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBESTOS.

INSTALLATION METHODS AND PARTS USAGE

Distortion of clutch components during installation
and the use of non-standard components are common
causes of clutch malfunction.
Improper clutch cover bolt tightening can distort
the cover. The usual result is clutch grab, chatter
Fig. 7 Clutch Master Cylinder and rapid wear. Tighten the cover bolts as described
1 – CAP
in Removal and Installation section.
2 – FILL LINE
3 – CLUTCH MASTER CYLINDER
An improperly seated flywheel and/or clutch hous-
4 – RESERVOIR ing are additional causes of clutch failure. Improper
seating will produce misalignment and additional
OPERATION clutch problems.
The clutch linkage uses hydraulic pressure to oper- The use of non-standard or low quality parts will
ate the clutch. Depressing the clutch pedal develops also lead to problems and wear. Use recommended
fluid pressure in the clutch master cylinder. This factory quality parts to avoid comebacks.
pressure is transmitted to the slave cylinder through A cocked pilot bearing is another cause of clutch
a connecting line. In turn, the slave cylinder operates noise, drag, hard shifting, and rapid bearing wear.
the clutch release lever. Always use an alignment tool to install a new bear-
Slave cylinder force causes the release lever to ing. This practice helps avoid cocking the bearing
move the release bearing into contact with the dia- during installation.
phragm spring. As additional force is applied, the
bearing presses the diaphragm spring fingers inward CLUTCH DIAGNOSTIC INFORMATION
on the fulcrums. This action moves the pressure Unless the cause of a clutch problem is obvious, accu-
plate rearward relieving clamp force on the disc. rate problem diagnosis will usually require a road test to
confirm a problem. Component inspection (Fig. 8) will
then be required to determine the actual problem cause.
DIAGNOSIS AND TESTING During a road test, drive the vehicle at normal
speeds. Shift the transmission through all gear
SAFETY PRECAUTIONS ranges and observe clutch action. If chatter, grab,
slip, or improper release is experienced, remove and
WARNING: EXERCISE CARE WHEN SERVICING inspect the clutch components. However, if the prob-
CLUTCH COMPONENTS. FACTORY INSTALLED lem is noise or hard shifting, further diagnosis may
CLUTCH DISCS DO NOT CONTAIN ASBESTOS be needed as the transmission or another driveline
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY component may be at fault. Careful observation dur-
CONTAIN ASBESTOS FIBERS FROM AFTERMARKET ing the test will help narrow the problem area.

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 XJ CLUTCH 6-5
DIAGNOSIS AND TESTING (Continued)

Fig. 8 Clutch Components And Inspection

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 6-6 CLUTCH XJ
DIAGNOSIS AND TESTING (Continued)

CLUTCH CONTAMINATION of any clutch component will cause grab, chatter and
Fluid contamination is a frequent cause of clutch improper clutch release.
malfunctions. Oil, water, or clutch fluid on the clutch
disc and pressure plate surfaces will cause chatter, CLUTCH HOUSING MISALIGNMENT
slip and grab. Clutch housing alignment is important to proper
During inspection, note if any components are con- clutch operation. The housing maintains alignment
taminated with oil, hydraulic fluid, or water/road between the crankshaft and transmission input
splash. shaft. Misalignment can cause clutch noise, hard
Oil contamination indicates a leak at either the shifting, incomplete release and chatter. It can also
rear main seal or transmission input shaft. Oil leak- result in premature wear of the pilot bearing, cover
age produces a residue of oil on the housing interior release fingers and clutch disc. In severe cases, mis-
and on the clutch cover and flywheel. Heat buildup alignment can also cause premature wear of the
caused by slippage between the cover, disc and fly- transmission input shaft and front bearing.
wheel, can sometimes bake the oil residue onto the Housing misalignment is generally caused by
components. The glaze-like residue ranges in color incorrect seating on the engine or transmission, loose
from amber to black. housing bolts, missing alignment dowels, or housing
Road splash contamination means dirt/water is damage. Infrequently, misalignment may also be
entering the clutch housing due to loose bolts, hous- caused by housing mounting surfaces that are not
ing cracks, or through hydraulic line openings. Driv- completely parallel. Misalignment can be corrected
ing through deep water puddles can force water/road with shims.
splash into the housing through such openings.
Clutch fluid leaks are usually from damaged slave CLUTCH FLYWHEEL RUNOUT
cylinder push rod seals. This type of leak can only be Check flywheel runout whenever misalignment is
confirmed by visual inspection. suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
IMPROPER CLUTCH RELEASE OR the flywheel face with a dial indicator. Mount the
ENGAGEMENT indicator on a stud installed in place of one of the fly-
Clutch release or engagement problems are caused wheel bolts.
by wear, or damage to one or more clutch compo- Common causes of runout are:
nents. A visual inspection of the release components • heat warpage
will usually reveal the problem part. • improper machining
Release problems can result in hard shifting and • incorrect bolt tightening
noise. Items to look for are: leaks at the clutch cylin- • improper seating on crankshaft flange shoulder
• foreign material on crankshaft flange
ders and interconnecting line; loose slave cylinder
Flywheel machining is not recommended. The fly-
bolts; worn/loose release fork and pivot stud; dam-
aged release bearing; and a worn clutch disc, or pres- wheel clutch surface is machined to a unique contour
sure plate. and machining will negate this feature. However,
Normal condensation in vehicles that are stored or minor flywheel scoring can be cleaned up by hand
out of service for long periods of time can generate with 180 grit emery, or with surface grinding equip-
enough corrosion to make the disc stick to the fly- ment. Remove only enough material to reduce scor-
wheel, or pressure plate. If this condition is experi- ing (approximately 0.001 - 0.003 in.). Heavy stock
removal is not recommended. Replace the flywheel
enced, correction only requires that the disc be
loosened manually through the inspection plate open- if scoring is severe and deeper than 0.076 mm (0.003
ing. in.). Excessive stock removal can result in flywheel
Engagement problems usually result in slip, chat- cracking or warpage after installation; it can also
ter/shudder, and noisy operation. The primary causes weaken the flywheel and interfere with proper clutch
are clutch disc contamination; clutch disc wear; mis- release.
alignment, or distortion; flywheel damage; or a com- Clean the crankshaft flange before mounting the
bination of the foregoing. A visual inspection is flywheel. Dirt and grease on the flange surface may
required to determine the part actually causing the cock the flywheel causing excessive runout. Use new
problem. bolts when remounting a flywheel and secure the
bolts with Mopart Lock And Seal. Tighten flywheel
bolts to specified torque only. Overtightening can dis-
CLUTCH MISALIGNMENT
tort the flywheel hub causing runout.
Clutch components must be in proper alignment
with the crankshaft and transmission input shaft.
Misalignment caused by excessive runout or warpage

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 XJ CLUTCH 6-7
DIAGNOSIS AND TESTING (Continued)

CLUTCH COVER AND DISC RUNOUT CLUTCH DIAGNOSIS CHARTS

Check the clutch disc before installation. Axial The clutch inspection chart (Fig. 8) outlines items
(face) runout of a new disc should not exceed 0.50 to be checked before and during clutch installation.
mm (0.020 in.). Measure runout about 6 mm (1/4 in.) Use the chart as a check list to help avoid overlook-
from the outer edge of the disc facing. Obtain ing potential problem sources during service opera-
another disc if runout is excessive. tions.
Check condition of the clutch before installation. A The diagnosis charts describe common clutch prob-
warped cover or diaphragm spring will cause grab lems, causes and correction. Fault conditions are
and incomplete release or engagement. Be careful listed at the top of each chart. Conditions, causes and
when handling the cover and disc. Impact can distort corrective action are outlined in the indicated col-
the cover, diaphragm spring, release fingers and the umns.
hub of the clutch disc. The charts are provided as a convenient reference
Use an alignment tool when positioning the disc on when diagnosing faulty clutch operation.
the flywheel. The tool prevents accidental misalign-
ment which could result in cover distortion and disc
damage.
A frequent cause of clutch cover distortion (and
consequent misalignment) is improper bolt tighten-
ing.

DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION

Disc facing worn out 1. Normal wear. 1. Replace cover and disc.

2. Driver frequently rides (slips) the 2. Replace cover and disc.

clutch. Results in rapid overheating
and wear.
3. Insufficient clutch cover 3. Replace cover and disc.
diaphragm spring tension.

Clutch disc facing contaminated with 1. Leak at rear main engine seal or 1. Replace appropriate seal.
oil, grease, or clutch fluid. transmission input shaft seal.

2. Excessive amount of grease 2. Remove grease and apply the

applied to the input shaft splines. correct amount of grease.
3. Road splash, water entering 3. Replace clutch disc. Clean clutch
housing. cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.

Clutch is running partially 1. Release bearing sticking or 1. Verify failure. Replace the release
disengaged. binding and does not return to the bearing and transmission front
normal running position. bearing retainer as necessary.

Flywheel below minimum thickness 1. Improper flywheel machining. 1. Replace flywheel.

specification. Flywheel has excessive taper or
excessive material removal.

Clutch disc, cover and/or diaphragm 1. Rough handling. Impact bent 1. Replace disc or cover as
spring warped or distorted. cover, spring, or disc. necessary.

2. Improper bolt tightening 2. Tighten clutch cover using proper

procedure. procedure.

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 6-8 CLUTCH XJ
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

Facing on flywheel side of disc torn, 1. Flywheel surface scored or 2. Correct surface condition if
gouged, or worn. nicked. possible. Replace flywheel and disc
as necessary.

2. Clutch disc sticking or binding on 2. Inspect components and

transmission input shaft. correct/replace as necessary.

Clutch disc facing burnt. Flywheel 1. Frequent operation under high 1. Correct condition of flywheel and
and cover pressure plate surfaces loads or hard acceleration pressure plate surface. Replace
heavily glazed. conditions. clutch cover and disc. Alert driver to
problem cause.

2. Driver frequently rides (slips) 2. Correct condition of flywheel and

clutch. Results in rapid wear and pressure plate surface. Replace
overheating of disc and cover. clutch cover and disc. Alert driver to
problem cause.

Clutch disc binds on input shaft 1. Clutch disc hub splines damaged 1. Clean, smooth, and lubricate hub
splines. during installation. splines if possible. Replace disc if
necessary.

2. Input shaft splines rough, 2. Clean, smooth, and lubricate

damaged, or corroded. shaft splines if possible. Replace
input shaft if necessary.

Clutch disc rusted to flywheel and/or 1. Clutch not used for and extended 1. Sand rusted surfaces with 180
pressure plate. period of time (e.g. long term grit sanding paper. Replace clutch
vehicle storage). cover and flywheel if necessary.

Pilot bearing seized, loose, or rollers 1. Bearing cocked during 1. Install and lubricate a new
are worn. installation. bearing.

2. Bearing defective. 2. Install and lubricate a new

bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.

Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.

2. Clutch cover loose. 2. Follow proper bolt tightening

procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring 4. Replace clutch cover.
bent or warped.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot 6. Replace fork or pivot as
loose or damaged. necessary.
7. Clutch master or slave cylinder 7. Replace hydraulic linkage
failure. assembly.

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 XJ CLUTCH 6-9
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.

2. Master cylinder bushing not 2. Lubricate master cylinder

lubricated. bushing.
3. Pedal bushings worn out or 3. Replace and lubricate bushings.
cracked.

Clutch master or slave cylinder 1. Master or slave cylinder 1. Replace clutch hydraulic linkage
plunger dragging andør binding components worn or corroded. assembly.

Release bearing is noisy. 1. Release bearing defective or 1. Replace release bearing.

damaged.

Contact surface of release bearing 1. Clutch cover incorrect or release 1. Replace clutch cover and release
damaged. fingers bent or distorted. bearing.

2. Release bearing defective or 2. Replace the release bearing.

damaged.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.

Partial engagement of clutch disc. 1. Clutch pressure plate position 1. Replace clutch disc and cover.
One side of disc is worn and the incorrect.
other side is glazed and lightly 2. Clutch cover, spring, or release 2. Replace clutch disc and cover.
worn. fingers bent or distorted.
3. Clutch disc damaged or 2. Replace clutch disc.
distorted.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andør
clutch housing. Correct as
necessary.

SERVICE PROCEDURES • Input shaft pilot hub.

• Transmission front bearing retainer slide sur-
CLUTCH COMPONENT LUBRICATION face.
Proper clutch component lubrication is important
NOTE: Never apply grease to any part of the clutch
to satisfactory operation. Using the correct lubricant
cover, or disc.
and not over lubricating are equally important. Apply
recommended lubricant sparingly to avoid disc and
pressure plate contamination. RECOMMENDED LUBRICANTS
Clutch and transmission components requiring Use Mopart multi-purpose grease for the clutch
lubrication are: pedal bushings and pivot shaft. Use Mopart high
• Pilot bearing. temperature grease (or equivalent) for all other lubri-
• Release lever pivot ball stud. cation requirements. Apply recommended amounts
• Release lever contact surfaces. and do not over lubricate.
• Release bearing bore.
• Clutch disc hub splines. CLUTCH LINKAGE FLUID
• Clutch pedal pivot shaft bore. If inspection or diagnosis indicates additional fluid
• Clutch pedal bushings. may be needed, use Mopart brake fluid, or an equiv-
• Input shaft splines.

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 6 - 10 CLUTCH XJ
SERVICE PROCEDURES (Continued)
alent meeting standards SAE J1703 and DOT 3. Do cleanup of minor flywheel scoring can be performed
not use any other type of fluid. by hand with 180 grit emery, or with surface grind-
ing equipment. Replace the flywheel if scoring is
CLUTCH FLUID LEVEL deeper than 0.0762 mm (0.003 in.).
The clutch fluid reservoir, master cylinder, slave Heavy stock removal by grinding is not recom-
cylinder and fluid lines are pre-filled with fluid at mended. Excessive stock removal can result in fly-
the factory during assembly operations. wheel cracking or warpage after installation. It can
The hydraulic system should not require additional also weaken the flywheel and interfere with proper
fluid under normal circumstances. In fact, the reser- clutch release.
voir fluid level will actually increase as normal Check flywheel runout if misalignment is sus-
clutch wear occurs. For this reason, it is impor- pected. Runout should not exceed 0.08 mm (0.003
tant to avoid overfilling, or removing fluid from in.). Measure runout at the outer edge of the fly-
the reservoir. wheel face with a dial indicator. Mount the dial indi-
Clutch fluid level is checked at the master cylinder cator on a stud installed in place of one of the clutch
reservoir (Fig. 9). An indicator ring is provided on the housing attaching bolts.
outside rim of the reservoir. Clean the crankshaft flange before mounting the
Be sure to wipe the reservoir and cover clean flywheel. Dirt and grease on the flange surface may
before removing the cover. This will avoid having dirt cock the flywheel causing excessive runout.
or foreign material fall into the reservoir during a Check condition of the flywheel hub and attaching
fluid level check. bolts. Replace the flywheel if the hub exhibits cracks
in the area of the attaching bolt holes.
Install new attaching bolts whenever the flywheel
is replaced and use Mopart Lock N’ Seal, or Loctite
242 on the replacement bolt threads.
Recommended flywheel bolt torques are:
• 142 N·m (105 ft. lbs.) for 6-cylinder flywheels
• 95 N·m (70 ft. lbs.) for 4-cylinder flywheels
Inspect the teeth on the starter ring gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom-
mended and preferred method of repair.
In cases where a new flywheel is not readily avail-
able, a replacement ring gear can be installed. How-
ever, the following precautions must be observed to
avoid damaging the flywheel and replacement gear.
(1) Mark position of the old gear for alignment ref-
erence on the flywheel. Use a scriber for this pur-
Fig. 9 Clutch Master Cylinder Reservoir And Cap pose.
1 – CAP (2) Wear protective goggles or approved safety
2 – FILL LINE glasses. Also wear heat resistent gloves when han-
3 – CLUTCH MASTER CYLINDER
dling a heated ring gear.
4 – RESERVOIR
(3) Remove the old gear by cutting most of the way
through it (at one point) with an abrasive cut-off
FLYWHEEL wheel. Then complete removal with a cold chisel or
Inspect the flywheel whenever the clutch disc, punch.
cover and housing are removed for service. Check (4) The ring gear is a shrink fit on the flywheel.
condition of the flywheel face, hub, ring gear teeth, This means the gear must be expanded by heating in
and flywheel bolts. order to install it. The method of heating and
Minor scratches, burrs, or glazing on the flywheel expanding the gear is extremely important.
face can be reduced with 180 grit emery cloth. How- Every surface of the gear must be heated at the same
ever, the flywheel should be replaced if the disc con- time to produce uniform expansion. An oven or simi-
tact surface is severely scored, heat checked, cracked, lar enclosed heating device must be used. Tempera-
or obviously worn. ture required for uniform expansion is approximately
Flywheel machining is not recommended. The fly- 375° F.
wheel surface is manufactured with a unique contour
that would be negated by machining. However,

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 XJ CLUTCH 6 - 11
SERVICE PROCEDURES (Continued)
CAUTION: Do not use an oxy/acetylene torch to (a) Slide disc onto transmission input shaft
remove the old gear, or to heat and expand a new splines. Disc should slide freely on splines.
gear. The high temperature of the torch flame can (b) Leave disc on shaft and check face runout
cause localized heating that will damage the fly- with dial indicator. Check runout at disc hub and
wheel. In addition, using the torch to heat a replace- about 6 mm (1/4 in.) from outer edge of facing.
ment gear will cause uneven heating and (c) Face runout should not exceed 0.5 mm (0.020
expansion. The torch flame can also anneal the in.). Obtain another clutch disc if runout exceeds
gear teeth resulting in rapid wear and damage after this limit.
installation. (4) Position clutch disc on flywheel. Be sure side of
disc marked flywheel side is positioned against fly-
(5) The heated gear must be installed evenly to wheel (Fig. 10). If disc is not marked, be sure flat
avoid misalignment or distortion. A shop press and side of disc hub is toward flywheel.
suitable press plates should be used to install the (5) Inspect condition of pressure plate surface of
gear if at all possible. clutch cover (Fig. 10). Replace cover if this surface is
(6) Be sure to wear eye and hand protection. Heat worn, heat checked, cracked, or scored.
resistent gloves and safety goggles are needed for (6) Insert clutch alignment tool in clutch disc (Fig.
personal safety. Also use metal tongs, vise grips, or 11).
similar tools to position the gear as necessary for (7) Insert alignment tool in pilot bearing and posi-
installation. tion disc on flywheel. Be sure disc hub is positioned
(7) Allow the flywheel and ring gear to cool down correctly. Side of hub marked Flywheel Side should
before installation. Set the assembly on a workbench face flywheel (Fig. 10). If disc is not marked, place
and let it cool in normal shop air. flat side of disc against flywheel.

CAUTION: Do not use water, or compressed air to

cool the flywheel. The rapid cooling produced by
water or compressed air can distort, or crack the
gear and flywheel.

REMOVAL AND INSTALLATION

CLUTCH COVER AND DISC
REMOVAL
(1) Remove transmission. Refer to procedures in
Group 21.
(2) If original clutch cover will be reinstalled, mark
position of cover on flywheel for assembly reference. Fig. 10 Clutch Disc And Pressure Plate Inspection
Use paint or a scriber for this purpose. 1 – DISC
(3) If clutch cover is to be replaced, cover bolts can 2 – INSPECT THIS SURFACE
be removed in any sequence. However, if original 3 – CLUTCH COVER
cover will be reinstalled, loosen cover bolts evenly 4 – “FLYWHEEL SIDE” STAMPED ON THIS SURFACE
and in rotation to relieve spring tension equally. This
is necessary to avoid warping cover. (8) Position clutch cover over disc and on flywheel
(4) Remove cover bolts and remove cover and disc (Fig. 11).
(Fig. 10). (9) Install clutch cover bolts finger tight.
(10) Tighten cover bolts evenly and in rotation a
INSTALLATION few threads at a time. Cover bolts must be tight-
(1) Lightly scuff sand flywheel face with 180 grit ened evenly and to specified torque to avoid
emery cloth. Then clean surface with a wax and distorting cover. Tightening torques are 31 N·m
grease remover. (23 ft. lbs.) on 2.5L engines and 50N·m (37ft. lbs.)
(2) Lubricate pilot bearing with Mopar high tem- on 4.0 L engines.
perature bearing grease. (a) Start all 6 bolts by hand.
(3) Check runout and free operation of new clutch (b) Tighten 3 pilot hole bolts 3/4s of the way
disc as follows: (any sequence).

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 6 - 12 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)
(2) Lubricate input shaft splines, bearing retainer
slide surface, fork pivot and release fork pivot surface
with Mopart high temperature grease.
(3) Install new release bearing. Be sure bearing is
properly secured to release fork.
(4) Install transmission.

Fig. 11 Typical Method Of Aligning Clutch Disc

1 – FLYWHEEL
2 – CLUTCH COVER AND DISC
3 – CLUTCH DISC ALIGNMENT TOOL

(c) Starting 180 degrees from the last pilot bolt, Fig. 12 Release Bearing Attachment
tighten 3 large hole bolts 3/4s of the way (any 1 – RETURN SPRING
sequence). 2 – PIVOT BALL STUD
(d) Tighten 3 pilot hole bolts all the way (any 3 – CLUTCH HOUSING
4 – RELEASE FORK
sequence).
5 – RELEASE BEARING
(e) Starting 180 degrees from last pilot bolt,
tighten 3 large bolts all the way (any sequence).
(11) Apply light coat of Mopart high temperature PILOT BEARING
bearing grease to clutch disc hub and splines of
transmission input shaft. Do not over lubricate REMOVAL
shaft splines. This will result in grease contam- (1) Remove transmission. Refer to Group 21,
ination of disc. Transmission and Transfer Case, for proper proce-
(12) Install transmission. dures.
(2) Remove clutch cover and disc.
RELEASE BEARING (3) Use a suitable blind hole puller to remove pilot
bearing.
REMOVAL
(1) Remove transmission. INSTALLATION
(2) Disconnect release bearing from release lever (1) Clean bearing bore with solvent and wipe dry
and remove bearing (Fig. 12). with shop towel.
(3) Inspect bearing slide surface of transmission (2) Lubricate new pilot bearing with Mopart high
front bearing retainer. Replace retainer if slide sur- temperature grease.
face is scored, worn, or cracked. (3) Position and start new bearing in bearing bore
(4) Inspect release fork and fork pivot. Be sure by hand. Note that pilot bearing has seal at one end.
pivot is secure and in good condition. Be sure fork is Install bearing so seal is facing outward toward
not distorted or worn. Replace release fork retainer transmission.
spring if bent or damaged. (4) Seat pilot bearing with clutch alignment tool
(Fig. 13). Keep bearing straight during installation.
INSTALLATION Do not allow bearing to become cocked. Tap bearing
(1) Lubricate crankshaft pilot bearing with Mopart into place until flush with edge of bearing bore. Do
high temperature bearing grease. Apply grease to not recess bearing.
end of long shank, small diameter flat blade screw- (5) Install transmission. Refer to Group 21, Trans-
driver. Then insert tool through clutch disc hub to mission and Transfer Case, for proper procedures.
reach bearing.

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 XJ CLUTCH 6 - 13
REMOVAL AND INSTALLATION (Continued)

Fig. 13 Typical Method Of Installing Pilot Bearing

1 – PILOT BEARING
2 – ALIGNMENT TOOL
3 – BEARING SEAL MUST FACE TRANSMISSION
Fig. 14 Clutch Housing Attachment
1 – HOUSING-TO-TRANSMISSION BOLTS (46 N·m/34 ft. lbs.)
CLUTCH HOUSING 2 – CLUTCH HOUSING
The clutch housing is removable and can be 3 – TRANSMISSION
replaced when the transmission is out of the vehicle.
The bolts attaching the housing to the transmis-
REMOVAL
sion case are located inside the housing (Fig. 14).
(1) Raise vehicle.
Recommended tightening torque for the clutch hous-
(2) Remove fasteners attaching slave cylinder to
ing-to-transmission bolts is 46 N·m (34 ft. lbs.).
clutch housing.
NOTE: Be sure the transmission and housing mat- (3) Remove slave cylinder from clutch housing
ing surfaces are clean before installing an original, (Fig. 15).
or replacement clutch housing. Dirt/foreign material (4) Disengage clutch fluid line from body clips, if
trapped between the housing and transmission will applicable.
cause misalignment. If misalignment is severe (5) Lower vehicle.
enough, the result will be clutch drag, incomplete (6) Verify that cap on clutch master cylinder reser-
release and hard shifting. voir is tight. This is necessary to avoid spilling fluid
during removal.
(7) Remove clutch master cylinder attaching nuts
CLUTCH HYDRAULIC LINKAGE (Fig. 16) or (Fig. 17).
The clutch master cylinder, slave cylinder and con- (8) Disengage captured bushing on clutch master
necting line are serviced as an assembly only. The cylinder actuator from pivot pin on pedal arm (Fig.
linkage components cannot be overhauled or serviced 18).
separately. The cylinders and connecting line are (9) Slide actuator off pivot pin.
sealed units. Also note that removal/installation pro- (10) Disconnect clutch interlock safety switch
cedures for right and left hand drive models are basi- wires.
cally the same. Only master cylinder location is (11) Remove clutch hydraulic linkage through
different. engine compartment.

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 6 - 14 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 17 Right Hand Drive Clutch Master Cylinder

1 – CLUTCH MASTER CYLINDER

Fig. 15 Slave Cylinder

1 – CLUTCH SLAVE CYLINDER

Fig. 18 Clutch Pedal Attachment

1 – CLUTCH MASTER CYLINDER

(3) Position clutch master cylinder on dash panel

(Fig. 16) or (Fig. 17).
Fig. 16 Left Hand Drive Clutch Master Cylinder (4) Attach clutch master cylinder actuator to pivot
1 – CLUTCH MASTER CYLINDER pin on clutch pedal (Fig. 18).
(5) Install and tighten clutch master cylinder
attaching nuts to 38 N·m (28 ft. lbs.) torque.
INSTALLATION
(6) Raise vehicle.
(1) Be sure reservoir cover on clutch master cylin-
(7) Insert slave cylinder push rod through clutch
der is tight to avoid spills.
housing opening and into release lever. Be sure cap
(2) Position clutch linkage components in vehicle.
on end of rod is securely engaged in lever. Check this
Work connecting line and slave cylinder downward
before installing cylinder attaching nuts.
past engine and adjacent to clutch housing (Fig. 16)
(8) Install and tighten slave cylinder attaching
or (Fig. 17).
nuts to 23 N·m (17 ft. lbs.) torque.

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 XJ CLUTCH 6 - 15
REMOVAL AND INSTALLATION (Continued)
(9) Secure clutch fluid line in body and transmis- SPECIFICATIONS
sion clips.
(10) Lower vehicle. TORQUE
(11) Connect clutch interlock safety switch wires.
DESCRIPTION TORQUE
Bolts, clutch cover 2.5 L . . . . . . . 31 N·m (23 ft. lbs)
Bolts, clutch cover 4.0 L . . . . . . . 50 N·m (37 ft. lbs)
Bolt/Nut, clutch cyl. mount . . . 23 N·m (200 in. lbs)
Bolt, clutch housing M12 . . . . . . 75 N·m (55 ft. lbs)
Bolt, clutch housing 3/8 . . . . . . . 37 N·m (27 ft. lbs)
Bolt, clutch housing 7/16 . . . . . . 58 N·m (43 ft. lbs)
Bolt, clutch housing/trans. . . . . . 46 N·m (34 ft. lbs)
Bolt, dust shield M8 . . . . . . . . . . 8 N·m (72 in. lbs)
Bolt, dust shield lower . . . . . . . . 50 N·m (37 ft. lbs)
Bolt, X-member/frame . . . . . . . . 41 N·m (30 ft. lbs)
Bolt, X-member/rear support . . . 45 N·m (33 ft. lbs.)
Bolts, flywheel 4.0 L . . . . . . . . 142 N·m (105 ft. lbs)
Bolts, flywheel 2.5 L . . . . . . . . . 95 N·m (70 ft. lbs)
Bolt, starter motor . . . . . . . . . . . 45 N·m (33 ft. lbs)
Bolts, U-joints . . . . . . . . . . . . . 19 N·m (170 in. lbs.)

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 XJ CLUTCH 6-1

CLUTCH
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . . . 1 FLYWHEEL RING GEAR . . . . . . . . . . . . . . . . . . . . 7
CLUTCH HYDRAULIC SYSTEM . . . . . . . . . . . . . . 1 SPECIFICATIONS
REMOVAL AND INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8
CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . . 1 SPECIAL TOOLS
PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DESCRIPTION AND OPERATION

CLUTCH COMPONENTS
The clutch mechanism consists of a single, dry-type
clutch disc and a diaphragm style clutch cover. A
hydraulic linkage is used to operate the clutch disc
and cover. The clutch components are very similar to
those used in gas engine models.
A pilot bearing is used to support the transmission
input shaft. The bearing is seated in a separate,
removable housing bolted to the flywheel hub.

CLUTCH HYDRAULIC SYSTEM

The clutch hydraulic system should not require
additional fluid under normal circumstances.

NOTE: The reservoir fluid level will actually

increase as normal clutch wear occurs. For this rea-
son, it is important to avoid over filling, or remov-
ing fluid from the reservoir.

If inspection indicates additional fluid is needed,

add fluid from a sealed container only. Use Mopart Fig. 1 Clutch Cover (Pressure Plate) View
brake fluid, or an equivalent meeting standards SAE 1 – VEHICLE UNDERBODY
J1703 and DOT 3. Do not use any other type of fluid. 2 – ENGINE SPEED SENSOR
3 – PRESSURE PLATE RETAINING BOLTS
4 – CLUTCH COVER (PRESSURE PLATE)
REMOVAL AND INSTALLATION 5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS

CLUTCH COVER AND DISC

a star pattern to relieve spring tension equally. This
REMOVAL is necessary to avoid warping the cover.
(1) Remove the transmission. Refer to Group 21, (4) Remove the clutch cover bolts and remove
Transmission and Transfer Case for procedure. cover and disc (Fig. 1).
(2) If the original clutch cover will be reinstalled,
mark position of cover on flywheel for assembly ref- INSTALLATION
erence. Use paint or scribe for this purpose. (1) Lightly scuff sand flywheel face with 180 grit
(3) If the clutch cover is to be replaced, cover bolts emery cloth. Then clean surface with brake cleaner.
can be removed in any sequence. However, if original (2) Lightly lubricate the pilot bearing with Mopart
cover will be reinstalled, loosen cover bolts evenly in high temperature bearing grease.

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 6-2 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 2 Clutch Components (VM Diesel)

1 – ENGINE BLOCK 4 – CLUTCH COVER
2 – FLYWHEEL 5 – CLUTCH DISC
3 – CLUTCH HOUSING AND TRANSMISSION

(3) Check free operation of clutch disc by sliding

disc onto transmission output shaft splines. Disc
should slide onto splines freely without binding.
(4) Position the clutch disc on flywheel. Be sure
side of disc marked “flywheel side” is positioned
against flywheel (Fig. 3). If disc is not marked, be
sure flat side of disc hub is placed toward the fly-
wheel.
(5) Insert the clutch alignment tool (Fig. 4) in
clutch disc and pilot bearing.
(6) Position the clutch cover over the disc and on
the flywheel (Fig. 5).
(7) Install the clutch cover bolts finger tight (Fig.
5).
(8) Starting with the bolts marked “P” on the cover
first, tighten clutch cover bolts in a star pattern to 50
N·m torque (37 ft. lbs.).
(9) Apply light coat of Mopart high temperature
bearing grease to pilot bearing and splines of trans-
mission input shaft.
Fig. 3 Clutch Disc Position
CAUTION: Do not over-lubricate as this will result 1 – INSPECT THIS SURFACE
in grease contamination of the disc. 2 – “FLYWHEEL SIDE” STAMPED ON THIS SURFACE

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 XJ CLUTCH 6-3
REMOVAL AND INSTALLATION (Continued)

PILOT BEARING
REMOVAL
(1) Remove the transmission and transfer case.
Refer to Group 21, Transmission and Transfer Case
for procedures.

Fig. 4 Clutch Disc Alignment – Typical

1 – FLYWHEEL
2 – CLUTCH COVER AND DISC
3 – CLUTCH DISC ALIGNMENT TOOL

Fig. 6 Clutch Cover (Pressure Plate) View

1 – VEHICLE UNDERBODY
2 – ENGINE SPEED SENSOR
3 – PRESSURE PLATE RETAINING BOLTS
4 – CLUTCH COVER (PRESSURE PLATE)
5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS

(2) Remove the clutch cover and disc (Fig. 6). Refer
to clutch cover and disc removal and installation in
this group.
(3) Remove the four bolts that attach the pilot
bearing retainer to the flywheel (Fig. 7).
(4) Remove the pilot bearing retainer.
(5) Support the bearing retainer on two wood
Fig. 5 Clutch Cover (Pressure Plate) View blocks.
1 – VEHICLE UNDERBODY (6) Remove the pilot bearing with a suitable sized
2 – ENGINE SPEED SENSOR socket and extension (Fig. 8). Use mallet to tap bear-
3 – PRESSURE PLATE RETAINING BOLTS ing out of retainer.
4 – CLUTCH COVER (PRESSURE PLATE)
5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS

(10) Install the transmission and transfer case.

Refer to Group 21, Transmission and Transfer Case
for procedure.

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 6-4 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 9 Pilot Bearing Installation

Fig. 7 Pilot Bearing Retainer Bolt Removal/ 1 – HOUSING
Installation 2 – SPECIAL TOOL C-4171
1 – RETAINER 3 – BEARING
2 – PILOT BEARING
3 – FLYWHEEL

Fig. 10 Pilot Bearing Seated In Retainer

1 – SEAT PILOT BEARING FLUSH WITH LOWER EDGE OF
Fig. 8 Pilot Bearing Removal CHAMFER (IN BORE)
1 – HOUSING
2 – SUITABLE SIZE SOCKET
(1) Lightly scuff sand the flywheel surface with
3 – EXTENSION
180 grit emery cloth. Clean the surface with Mopart
brake or carburetor cleaner.
INSTALLATION (2) Install the new pilot bearing with hammer and
tool handle C-4171. (Fig. 9). Seat the bearing flush
CAUTION: The bearing can be installed incorrectly with lower edge of chamfer in retainer bore (Fig. 10).
if care is not exercised. Make sure the stamped let- Reposition the bearing if necessary.
ters on the bearing will be facing out (toward rear (3) Install the bearing retainer. Torque bolts to 28
of vehicle) after installation. N·m (20 ft. lbs.)
(4) Lubricate the pilot bearing with Mopart high
temperature wheel bearing grease.

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 XJ CLUTCH 6-5
REMOVAL AND INSTALLATION (Continued)

Fig. 11 Clutch Cover (Pressure Plate) View Fig. 12 Clutch Cover (Pressure Plate) View
1 – VEHICLE UNDERBODY 1 – VEHICLE UNDERBODY
2 – ENGINE SPEED SENSOR 2 – ENGINE SPEED SENSOR
3 – PRESSURE PLATE RETAINING BOLTS 3 – PRESSURE PLATE RETAINING BOLTS
4 – CLUTCH COVER (PRESSURE PLATE) 4 – CLUTCH COVER (PRESSURE PLATE)
5 – ENGINE OIL PAN 5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS 6 – PRESSURE PLATE RETAINING BOLTS

(5) Install the clutch disc and cover (Fig. 11). Refer INSPECTION
to clutch cover and disc removal and installation in Examine the flywheel mounting surfaces, clutch
this group. contact surface, and ring gear. Check condition of fly-
(6) Install the transmission and transfer case. wheel hub and attaching bolts. Replace flywheel if
Refer to Group 21, Transmission and Transfer Case hub exhibits cracks in the area of attaching bolt
for procedures. holes. Replace ring gear if the teeth are damaged.
Resurface the flywheel if the clutch contact surface is
FLYWHEEL scored or rough (refer to flywheel finishing and ring
gear replacement information in this section.
REMOVAL Check flywheel runout if misalignment is sus-
(1) Remove the transmission and clutch housing. pected. Runout should not exceed 0.08 mm. Measure
Refer to Group 21, Transmission and Transfer Case flywheel face runout with a dial indicator (Fig. 13).
for procedure. Mount the indicator on a stud installed in the engine
(2) Remove the clutch cover and disc (Fig. 12) as block or in one of the flywheel attaching bolt holes.
described in this section. Face runout can be corrected by resurfacing if neces-
(3) Remove the bolts that attach pilot bearing sary. Surface grinding equipment is recommended for
retainer to flywheel. this purpose. Stock removal should not exceed 0.25
(4) Remove the pilot bearing and retainer. mm.
(5) Remove the flywheel bolts.
(6) Grasp the flywheel firmly and work it off the INSTALLATION
crankshaft flange.
(7) Remove the o-ring from the crankshaft flange, CAUTION: Use NEW flywheel bolts for the following
or the mounting shoulder of the flywheel (Fig. 14). procedure.
(8) Clean the flywheel in solvent.
(1) Clean the crankshaft flange before mounting
the flywheel. Dirt or grease on flange surface may
cock flywheel causing run-out.

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 6-6 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 13 Checking Flywheel Runout

1 – DIAL INDICATOR
2 – FLYWHEEL FACE
Fig. 15 Cross Tightening Method
(c) Loosen one bolt at a time and tighten to 19.6
N•m (14 ft. lbs.) plus 75° using the cross tighten-
ing method until completion.

Fig. 14 Flywheel Mounting (VM Diesel)

1 – O-RING
2 – PILOT BEARING HOUSING
3 – FLYWHEEL
4 – STARTER RING GEAR
Fig. 16 Clutch Cover (Pressure Plate) View
1 – VEHICLE UNDERBODY
(2) Install new o-ring in the flywheel mounting 2 – ENGINE SPEED SENSOR
flange (Fig. 14). Use grease to hold the ring in place. 3 – PRESSURE PLATE RETAINING BOLTS
(3) Install the flywheel on the crankshaft and 4 – CLUTCH COVER (PRESSURE PLATE)
align the bolt holes. 5 – ENGINE OIL PAN
(4) Install and tighten the new flywheel bolts as 6 – PRESSURE PLATE RETAINING BOLTS
follows:
(a) Lubricate and install the 6 new flywheel (5) Install the clutch cover and disc (Fig. 16). Refer
bolts. to clutch cover and disc removal and installation pro-
(b) Torque the 6 flywheel bolts to 49 N•m (36 ft. cedure in this section.
lbs.) starting with one bolt and following with the (6) Install the transmission and transfer case.
opposite one (cross tightening) until completion, in Refer to Group 21, Transmission and Transfer Case
a clockwise direction (Fig. 15). for removal and installation procedure.

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 XJ CLUTCH 6-7
REMOVAL AND INSTALLATION (Continued)

FLYWHEEL RING GEAR NOTE: The method of heating and expanding the
new ring gear is extremely important. Every surface
REMOVAL of the gear must be heated at the same time to pro-
(1) Remove the transmission and transfer case. duce uniform expansion. An oven or similar
Refer to Group 21, Transmission and Transfer Case enclosed heating device must be used. Temperature
for removal and installation procedures. required for uniform expansion is approximately
350°-375°.

CAUTION: Do not use an oxy/acetylene torch to

remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.

INSTALLATION
(1) Position and install the heated ring gear on the
flywheel:
(a) Wear heat resistant gloves to handle the hot
ring gear.
(b) Align the ring gear on the flywheel evenly.
(c) Use hammer and brass drift to tap ring gear
onto the flywheel.
(d) Seat the ring gear on flywheel
Fig. 17 Clutch Cover (Pressure Plate) View (2) Allow the ring gear to cool down before instal-
1 – VEHICLE UNDERBODY lation on the engine. Place flywheel on work bench
2 – ENGINE SPEED SENSOR and let it cool in normal shop air.
3 – PRESSURE PLATE RETAINING BOLTS (3) Install the flywheel and torque bolts. Refer to
4 – CLUTCH COVER (PRESSURE PLATE) flywheel removal and installation in this group.
5 – ENGINE OIL PAN
(4) Install the clutch cover and disc (Fig. 18). Refer
6 – PRESSURE PLATE RETAINING BOLTS
to clutch cover and disc removal and installation in
this group.
(2) Remove the clutch cover and disc (Fig. 17). (5) Install the transmission and transfer case.
Refer to clutch cover and disc removal and installa- Refer to Group 21, Transmission and Transfer Case
tion in this group. for removal and installation procedures.
(3) Remove the flywheel. Refer to flywheel removal
and installation in this group. CAUTION: Do not use water or compressed air to
(4) Mark position of the old gear for alignment ref- cool the flywheel. The rapid cooling produced by
erence. Use a carbide tipped scribe to mark gear loca- water or compressed air will distort or crack the
tion on flywheel. new gear.
(5) Wear protective goggles or approved safety
glasses.
(6) Remove the old gear by cutting most of the way
through it at one point. Use an abrasive cut off wheel
for this purpose. Break the ring gear at cut with a
hammer and a cold chisel or punch
(7) Ring gear is shrink fit on flywheel. This means
the gear must be expanded by heating in order to
install it.

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 6-8 CLUTCH XJ
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
SPECIFICATIONS
DESCRIPTION TORQUE
Clutch Cover to Flywheel
Bolts . . . . . . . . . . . . . . . . . . . 50 N·m (37 ft. lbs.)
Clutch Housing to Transmission
Bolts . . . . . . . . . . . . . . . . . . . 46 N·m (34 ft. lbs.)
Flywheel to Crankshaft
Bolts . . . . . See removal and installation procedure.
Pilot Bearing Retainer to Flywheel/Crankshaft
Bolts . . . . . . . . . . . . . . . . . . . 28 N·m (20 ft. lbs.)
Clutch Housing to Engine
Top (2) Bolts . . . . . . . . . . . . . . 37 N·m (27 ft. lbs.)
Middle (2) Bolts . . . . . . . . . . . 58 N·m (43 ft. lbs.)
Bottom (2) Bolts . . . . . . . . . . . 75 N·m (55 ft. lbs.)

SPECIAL TOOLS
SPECIAL TOOLS
Fig. 18 Clutch Cover (Pressure Plate) View
1 – VEHICLE UNDERBODY
2 – ENGINE SPEED SENSOR
3 – PRESSURE PLATE RETAINING BOLTS
4 – CLUTCH COVER (PRESSURE PLATE)
5 – ENGINE OIL PAN
6 – PRESSURE PLATE RETAINING BOLTS

Universal Handle—C-4171

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 XJ COOLING SYSTEM 7-1

COOLING SYSTEM
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION COOLANT—LEVEL CHECK . . . . . . . . . . . . . . . . . 21

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 1 COOLING SYSTEM—DRAINING AND
AUTOMATIC TRANSMISSION OIL COOLER. . . . . 2 FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COOLANT RESERVE/OVERFLOW SYSTEM . . . . . 2 COOLING SYSTEM—REVERSE FLUSHING . . . . 22
COOLING SYSTEM FANS . . . . . . . . . . . . . . . . . . . 3 REMOVAL AND INSTALLATION
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TRANSMISSION OIL COOLERS . . . . . . . . . . . . . 23
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 COOLANT RESERVE TANK . . . . . . . . . . . . . . . . . 23
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 24
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . . . 5 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 RADIATOR—2.5L . . . . . . . . . . . . . . . . . . . . . . . . 29
HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 RADIATOR—4.0L . . . . . . . . . . . . . . . . . . . . . . . . 31
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . 7 ELECTRIC COOLING FAN—2.5L . . . . . . . . . . . . 33
ELECTRIC COOLING FAN . . . . . . . . . . . . . . . . . . . 8 ELECTRIC COOLING FAN—4.0L . . . . . . . . . . . . 34
DIAGNOSIS AND TESTING BLOCK HEATER . . . . . . . . . . . . . . . . . . . . . . . . . 35
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . . 9 ENGINE ACCESSORY DRIVE BELTS. . . . . . . . . . 35
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 9 COOLING SYSTEM FANS . . . . . . . . . . . . . . . . . . 38
ACCESSORY DRIVE BELT DIAGNOSIS. . . . . . . . . 9 VISCOUS FAN DRIVE REMOVAL/
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . . 11 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 39
RADIATOR COOLANT FLOW CHECK . . . . . . . . . 17 CLEANING AND INSPECTION
COOLING SYSTEM—TESTING FOR LEAKS . . . . 17 RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . . 39
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . 19 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ELECTRIC COOLING FAN . . . . . . . . . . . . . . . . . . 19 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 39
RADIATOR CAP-TO-FILLER NECK FAN BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SEAL—PRESSURE RELIEF CHECK . . . . . . . . . 20 COOLING SYSTEM HOSES. . . . . . . . . . . . . . . . . 40
RADIATOR CAP—PRESSURE TESTING. . . . . . . 20 SPECIFICATIONS
COOLANT—LOW LEVEL AERATION . . . . . . . . . 21 BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 40
SERVICE PROCEDURES SPECIAL TOOLS
COOLANT—ROUTINE LEVEL CHECK. . . . . . . . . 21 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
COOLANT—ADDING ADDITIONAL. . . . . . . . . . . 21

DESCRIPTION AND OPERATION matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
COOLING SYSTEM pump to circulate coolant throughout the system.
An optional factory installed heavy duty cooling
DESCRIPTION package is available on most models. The package
The cooling system regulates engine operating tem- consists of a radiator that has an increased number
perature. It allows the engine to reach normal oper- of cooling fins. Vehicles equipped with a 2.5L/4.0L
ating temperature as quickly as possible, maintains engine and heavy duty cooling and/or air condition-
normal operating temperature and prevents over- ing also have an auxiliary electric cooling fan.
heating. The cooling system consists of:
The cooling system also provides a means of heat- • A radiator
ing the passenger compartment and cooling the auto- • Cooling fan (mechanical and/or electrical)
• Thermal viscous fan drive

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 7-2 COOLING SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
• Fan shroud Transmission oil is cooled when it passes through
• Radiator pressure cap this separate cooler. In case of a leak in the internal
• Thermostat radiator mounted transmission oil cooler, engine cool-
• Coolant reserve/overflow system ant may become mixed with transmission fluid or
• Transmission oil cooler (if equipped with an transmission fluid may enter engine cooling system.
automatic transmission) Both cooling system and transmission should be
• Coolant drained and inspected if the internal radiator
• Water pump mounted transmission cooler is leaking.
• Hoses and hose clamps An auxiliary air-to-oil transmission oil cooler is
Cooling system circulation for 2.5L/4.0L models is available with most engine packages.
shown in (Fig. 1). The auxiliary air-to-oil transmission oil cooler is
located in front of the radiator or A/C condenser (if
equipped) and behind the grill. It is mounted to the
front frame crossmember.
The auxiliary oil coolers on all models operate in
conjunction with the internal radiator mounted main
oil cooler. The transmission oil is routed through the
main cooler first, then the auxiliary cooler, before
returning to the transmission.

Fig. 2 Auxiliary Transmission Oil Cooler

Fig. 1 Coolant Circulation—2.5L/4.0L Engines 1 – AUXILIARY TRANSMISSION OIL COOLER
1 – HEATER CORE
2 – TO COOLANT RESERVE/OVERFLOW TANK
3 – THERMOSTAT HOUSING
COOLANT RESERVE/OVERFLOW SYSTEM
4 – RADIATOR
5 – WATER PUMP DESCRIPTION
The system works along with the radiator pressure
cap. This is done by using thermal expansion and
AUTOMATIC TRANSMISSION OIL COOLER contraction of the coolant to keep the coolant free of
trapped air. It provides:
DESCRIPTION • A volume for coolant expansion and contraction.
All models equipped with an automatic transmis- • A convenient and safe method for checking/ad-
sion are equipped with a transmission oil cooler justing coolant level at atmospheric pressure. This is
mounted internally within the radiator tank. This done without removing the radiator pressure cap.
internal cooler is supplied as standard equipment on • Some reserve coolant to the radiator to cover
all models equipped with an automatic transmission. minor leaks and evaporation or boiling losses.

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 XJ COOLING SYSTEM 7-3
DESCRIPTION AND OPERATION (Continued)
The coolant reserve/overflow system consists of a
radiator mounted pressurized cap, a plastic reserve/
overflow tank (Fig. 3) (Fig. 4), a tube (hose) connect-
ing the radiator and tank, and an overflow tube on
the side of the tank.

Fig. 4 Reserve/Overflow Tank—With Right Hand

Drive
1 – CLAMP
2 – COOLANT RESERVE/OVERFLOW TANK
3 – MOUNTING BOLTS
Fig. 3 Reserve/Overflow Tank—Except Right Hand 4 – LOWER BRACKET
Drive 5 – TUBE TO RADIATOR
1 – COOLANT RESERVE/OVERFLOW TANK
2 – CLAMP
3 – MOUNTING BOLTS
4 – TUBE TO RADIATOR

OPERATION
As the engine cools, a vacuum is formed in the
cooling system of both the radiator and engine. Cool-
ant will then be drawn from the coolant tank and
returned to a proper level in the radiator.

COOLING SYSTEM FANS

DESCRIPTION
All models are equipped with a viscous fan. This
thermal viscous fan drive is a torque-and-tempera-
ture-sensitive clutch unit. It automatically increases
or decreases fan speed to provide proper engine cool-
ing. Vehicles with a 2.5L/4.0L engine with air condi-
tioning, or 4.0L with “max” cooling also have an
auxiliary electrical cooling fan.
Fig. 5 Viscous Fan Drive and Fan Blade Assembly
1 – VISCOUS FAN DRIVE
2 – FAN BLADE ASSEMBLY

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 7-4 COOLING SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)

BLOCK HEATER THERMOSTAT

DESCRIPTION DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS CAUTION: Do not operate an engine without a ther-
BLOCK HEATER CORD HAS BEEN DISCONNECTED mostat, except for servicing or testing.
FROM POWER SOURCE AND SECURED IN PLACE.
A pellet-type thermostat controls the operating
An optional engine block heater is available for all temperature of the engine by controlling the amount
models. The heater is equipped with a power cord. of coolant flow to the radiator. On all engines the
The cord is attached to an engine compartment com- thermostat is closed below 195°F (90°C). Above this
ponent with tie-straps. The heater warms the engine temperature, coolant is allowed to flow to the radia-
providing easier engine starting and faster warm-up tor. This provides quick engine warm-up and overall
in low temperatures. The heater is mounted in a core temperature control.
hole of the engine cylinder block (in place of a freeze An arrow plus the word UP is stamped on the
plug) with the heating element immersed in engine front flange next to the air bleed. The words TO
coolant. RAD are stamped on one arm of the thermostat.
BLOCK HEATER SPECIFICATIONS They indicate the proper installed position.
• 2.5L 4-Cylinder Engine: 115 Volts 400 Watts The same thermostat is used for winter and sum-
• 4.0L 6-Cylinder Engine: 120 Volts 600 Watts mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes other prob-
lems. These are: A ’check engine’ light and a DTC
will eventually be set, longer engine warm-up time,
unreliable warm-up performance, increased exhaust
emissions and crankcase condensation. This conden-
sation can result in sludge formation.

Fig. 6 Engine Block Heater

1 – BLOCK HEATER
2 – CYLINDER BLOCK
3 – BLOCK HEATER POWER CORD

OPERATION
Connecting the power cord to a grounded 110-120
volt AC electrical outlet with a grounded, three-wire Fig. 7 Thermostat and Housing
extension cord activates the block heater. 1 – LONG BOLT
2 – GASKET
3 – THERMOSTAT
4 – THERMOSTAT HOUSING
5 – SHORT BOLT

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 XJ COOLING SYSTEM 7-5
DESCRIPTION AND OPERATION (Continued)

RADIATOR A rubber gasket seals radiator filler neck. This is

done to maintain vacuum during coolant cool-down
DESCRIPTION and to prevent leakage when system is under pres-
sure.
CAUTION: Plastic tanks, while stronger than brass,
are subject to damage by impact, such as
wrenches.

Radiators for both engines are the cross flow type.

Plastic tanks are used on all radiators.

Fig. 8 Cross Flow Radiator

1 – RADIATOR

Fig. 9 Radiator Pressure Cap and Filler Neck—

RADIATOR PRESSURE CAP Typical
1 – FILLER NECK SEAL
DESCRIPTION 2 – VACUUM VENT VALVE
All radiators are equipped with a pressure cap. 3 – PRESSURE RATING
This cap releases pressure at some point within a 4 – PRESSURE VALVE
range of 83-110 kPa (12-16 psi). The pressure relief
point (in pounds) is engraved on top of the cap (Fig. OPERATION
9). A vent valve in the center of cap allows a small
The cooling system will operate at pressures coolant flow through cap when coolant is below boil-
slightly above atmospheric pressure. This results in a ing temperature. The valve is completely closed when
higher coolant boiling point allowing increased radi- boiling point is reached. As the coolant cools, it con-
ator cooling capacity. The cap contains a spring- tracts and creates a vacuum in the cooling system.
loaded pressure relief valve that opens when system This causes the vacuum valve to open and coolant in
pressure reaches release range of 83-110 kPa (12-16 the reserve/overflow tank to be drawn through its
psi). connecting hose into radiator. If the vacuum valve is
stuck shut, the radiator hoses will collapse on cool-
down.

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 7-6 COOLING SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)

WATER PUMP HOSE CLAMPS

DESCRIPTION DESCRIPTION
The cooling system utilizes both worm drive and
CAUTION: All engines are equipped with a reverse spring type hose clamps. If a spring type clamp
(counter-clockwise) rotating water pump and vis- replacement is necessary, replace with the original
cous fan drive assembly. REVERSE is stamped or Mopart equipment spring type clamp.
imprinted on the cover of the viscous fan drive and
inner side of the fan. The letter R is stamped into CAUTION: A number or letter is stamped into the
the back of the water pump impeller (Fig. 10). tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
A centrifugal water pump circulates coolant with matching number or letter (Fig. 11).
through the water jackets, passages, intake manifold,
radiator core, cooling system hoses and heater core.
The pump is driven from the engine crankshaft by a
drive belt on all engines.
The water pump impeller is pressed onto the rear
of a shaft that rotates in bearings pressed into the
housing. The housing has a small hole to allow seep-
age to escape. The water pump seals are lubricated
by the antifreeze in the coolant mixture. No addi-
tional lubrication is necessary.

Fig. 11 Spring Clamp Size Location

1 – SPRING CLAMP SIZE LOCATION

OPERATION
The worm type hose clamp uses a specified torque
value to maintain proper tension on a hose connec-
tion.
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, use Special Tool 6094 or equivalent, con-
stant tension clamp pliers (Fig. 12) to compress the
Fig. 10 Reverse Rotating Water Pump—Typical hose clamp.
1 – R STAMPED INTO IMPELLER

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 XJ COOLING SYSTEM 7-7
DESCRIPTION AND OPERATION (Continued)
A thermostatic bimetallic spring coil is located on
the front face of the viscous fan drive unit. A typical
viscous unit is shown in (Fig. 13). This spring coil
reacts to the temperature of the radiator discharge
air. It engages the viscous fan drive for higher fan
speed if the air temperature from the radiator rises
above a certain point. Until additional engine cooling
is necessary, the fan will remain at a reduced rpm
regardless of engine speed.
Vehicles equipped with 2.5L engines have what is
know as an hybrid cooling fan system. This means
that not only do they have a viscous fan but they also
have an electric fan as well. The hybrid viscous fan
drive has a low speed characteristic. This causes the
mechanical fan speeds to be very low 200–400 rpm
range when not engaged allowing the engine to have
Fig. 12 Hose Clamp Tool
additional performance and horsepower gaines.
1 – HOSE CLAMP TOOL 6094
2 – HOSE CLAMP

VISCOUS FAN DRIVE

DESCRIPTION
CAUTION: Engines equipped with poly–V drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.

The thermal viscous fan drive is a silicone-fluid-

filled coupling used to connect the fan blades to Fig. 13 Typical Viscous Fan Drive
either the engine or the water pump shaft. The cou- 1 – VISCOUS FAN DRIVE
pling allows the fan to be driven in a normal manner. 2 – MOUNTING HUB
3 – THERMOSTATIC SPRING
This is done at low engine speeds while limiting the
top speed of the fan to a predetermined maximum
level at higher engine speeds. OPERATION
2.5L vehicles with A/C are equipped with a viscous Only when sufficient heat is present, will the vis-
fan drive which is designed to “free wheel” during cous fan drive engage. This is when the air flowing
most of the ambient conditions encountered by the through the radiator core causes a reaction to the
vehicle and will only engage during high heat loads bimetallic coil. It then increases fan speed to provide
as seen in trailer towing or high ambient tempera- the necessary additional engine cooling.
tures. Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again
reacts and the fan speed is reduced to the previous
disengaged speed.

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 7-8 COOLING SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)

ELECTRIC COOLING FAN OPERATION

Electric cooling fan 2.5L: When air conditioning
DESCRIPTION is not requested, the electric fan will not come on
Vehicles equipped with a 2.5L/4.0L engine and air unless the coolant temperature is at least 103° C
conditioning and 4.0L vehicles equipped with the (218° F), at which time the fan will come on and
“max” cooling package also have an electrical cooling remain on until the coolant temperature drops to 99°
fan. The fan is controlled by the cooling fan relay, C (210° F) or below. When air conditioning is
which is located in the power distribution center requested (including defroster operation), the fan will
(PDC) (Fig. 15). For the location of relay within the cycle on and off in conjunction with the A/C compres-
PDC, refer to the label on PDC cover. sor unless the coolant temperature is at least 97° C
The electric fan on the 2.5L engine equipped vehi- (207° F), at which time the fan will come on and
cles is considered the primary fan (low to moderate remain on until the coolant temperature drops to 93°
ambient conditions) and is energized when the JTEC C (199° F) or below. Then, the cycle fan operation
receives input from the coolant temperature sensor will resume. When the fan is scheduled to be on, the
or the a/c system and supplies ground to the cooling powertrain control module (PCM) provides a ground
fan relay. path for the fan relay. This ground is provided to the
The cooling fan motor is protected by a 40 amp cooling fan relay through pin C2 of PCM connector
maxi-fuse located in the PDC. The fan relay is pro- C3. Battery voltage is then applied to the fan
tected by a 15 amp fuse located in the junction block. through the relay. When the fan is scheduled to be
off, the PCM opens the ground path to the relay. This
will prevent the cooling fan from being energized.

Fig. 14 Electric Cooling Fan

1 – (LHD) 6 – RADIATOR
2 – (RHD) 7 – LOWER CROSSMEMBER
3 – VISCOUS FAN SHROUD 8 – U-NUT
4 – ELECTRIC FAN MODULE 9 – UPPER CROSSMEMBER
5 – ISOLATOR

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 XJ COOLING SYSTEM 7-9
DESCRIPTION AND OPERATION (Continued)
to Group 25, Emission Control Systems for proper
procedures)

ACCESSING DIAGNOSTIC TROUBLE CODES

To read DTC’s and to obtain cooling system data,
refer to Group 25, Emission Control Systems for
proper procedures.

DRB SCAN TOOL

For operation of the DRB scan tool, refer to the
appropriate Powertrain Diagnostic Procedures ser-
vice manual.

ACCESSORY DRIVE BELT DIAGNOSIS

VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 16), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) are not nor-
Fig. 15 Power Distribution Center (PDC) mal. Any belt with cracks running along a rib must
1 – RIGHT FENDER
be replaced (Fig. 16). Also replace the belt if it has
2 – BATTERY excessive wear, frayed cords or severe glazing.
3 – POWER DISTRIBUTION CENTER Refer to the Accessory Drive Belt Diagnosis charts
for further belt diagnosis.
Electric cooling fan 4.0L: With or without A/C
request the electric fan will come on only when the
coolant temperature is at least 106° C (223° F), and
will remain on until the coolant temperature drops to
103° C (217° F) or below. Regardless of coolant tem-
perature, When air conditioning system pressures
reach 2068.5 6 138 kPa (300 6 20 psi) the electric
fan will engage and continue to run until the A/C
system pressure drops to 1620.3 kPa (235 psi) mini-
mum, then the electric fan will shut off.

DIAGNOSIS AND TESTING

ON-BOARD DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The Powertrain Control Module (PCM) has been
programmed to monitor the certain following cooling
system components:
• If the engine has remained cool for too long a Fig. 16 Belt Wear Patterns
period, such as with a stuck open thermostat, a Diag- 1 – NORMAL CRACKS BELT OK
nostic Trouble Code (DTC) can be set. 2 – NOT NORMAL CRACKS REPLACE BELT
• If an open or shorted condition has developed in
the relay circuit controlling the electric radiator fan,
a Diagnostic Trouble Code (DTC) can be set.
NOISE DIAGNOSIS
If the problem is sensed in a monitored circuit Noises generated by the accessory drive belt are
often enough to indicate an actual problem, a DTC is most noticeable at idle. Before replacing a belt to
stored. The DTC will be stored in the PCM memory resolve a noise condition, inspect all of the accessory
for eventual display to the service technician. (Refer drive pulleys for alignment, glazing, or excessive end
play.

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 7 - 10 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)
ACCESSORY DRIVE BELT DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION

RIB CHUNKING (One or more ribs 1. Foreign objects imbedded in 1. Remove foreign objects from
has separated from belt body) pulley grooves. pulley grooves. Replace belt.

2. Installation damage 2. Replace belt

RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)

2. Abrasive environment 2. Clean pulley(s). Replace belt if

necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove 4. Replace pulley. Inspect belt.
tips
5. Belt rubber deteriorated 5. Replace belt

BELT SLIPS 1. Belt slipping because of 1. Adjust tension (2.5L)

insufficient tension

2. Belt or pulley exposed to 2. Replace belt and clean pulleys

substance that has reduced friction
(belt dressing, oil, ethylene glycol)
3. Driven component bearing failure 3. Replace faulty component or
(seizure) bearing
4. Belt glazed or hardened from 4. Replace belt.
heat and excessive slippage

LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt
groove

2. Pulley groove tip has worn away 2. Replace belt

rubber to tensile member

9GROOVE JUMPING” 1. Belt tension either too low or too 1. Adjust belt tension (2.5L)
(Belt does not maintain correct high
position on pulley)
2. Pulley(s) not within design 2. Replace pulley(s)
tolerance
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt

BELT BROKEN 1. Excessive tension 1. Replace belt and adjust tension

(Note: Identify and correct problem to specification
before new belt is installed)
2. Tensile member damaged during 2. Replace belt
belt installation
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt

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 XJ COOLING SYSTEM 7 - 11
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

NOISE (Objectionable squeal, 1. Belt slippage 1. Adjust belt tension (2.5L)

squeak, or rumble is heard or felt
while drive belt is in operation) 2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced 5. Locate defective driven
vibration component and repair
6. System resonant frequency 6. Vary belt tension within
induced vibration specifications.

TENSION SHEETING FABRIC 1. Tension sheeting contacting 1. Correct rubbing condition

FAILURE stationary object
(Woven fabric on outside,
circumference of belt has cracked or 2. Excessive heat causing woven 2. Replace belt
separated from body of belt) fabric to age
3. Tension sheeting splice has 3. Replace belt
fractured

CORD EDGE FAILURE 1. Excessive tension 1. Adjust belt tension (2.5L)

(Tensile member exposed at edges 2. Belt contacting stationary object 2. Replace belt
of belt or separated from belt body)
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between 4. Replace belt and adjust tension
tensile member and rubber matrix to specifications

PRELIMINARY CHECKS RECENT SERVICE OR ACCIDENT REPAIR:

Determine if any recent service has been per-
ENGINE COOLING SYSTEM OVERHEATING formed on vehicle that may effect cooling system.
Establish what driving conditions caused the com- This may be:
plaint. Abnormal loads on the cooling system such as • Engine adjustments (incorrect timing)
the following may be the cause: • Slipping engine accessory drive belt(s)
• Brakes (possibly dragging)
PROLONGED IDLE, VERY HIGH AMBIENT TEMPERATURE, • Changed parts. Incorrect water pump or pump
SLIGHT TAIL WIND AT IDLE, SLOW TRAFFIC, TRAFFIC rotating in wrong direction due to belt not correctly
JAMS, HIGH SPEED OR STEEP GRADES. routed
Driving techniques that avoid overheating are: • Reconditioned radiator or cooling system refill-
• Idle with A/C off when temperature gauge is at ing (possibly under filled or air trapped in system).
end of normal range.
• Increasing engine speed for more air flow is rec- NOTE: If investigation reveals none of the previous
ommended. items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
TRAILER TOWING: charts.
Consult Trailer Towing section of owners manual.
Do not exceed limits. These charts are to be used as a quick-reference
only. Refer to the group text for information.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maximum cooling package should have been
ordered with vehicle if add-on or after market A/C is
installed. If not, maximum cooling system compo-
nents should be installed for model involved per
manufacturer’s specifications.

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 7 - 12 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)
COOLING SYSTEM DIAGNOSIS CHART

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to Group 25, Emission
LOW (DTC) been set indicating a stuck Systems for On-Board Diagnostics
open thermostat? and DTC information. Replace
thermostat if necessary.

2. Is the temperature sending unit 2. Check the temperature sensor

connected? connector. Refer to Group 8E.
Repair connector if necessary.
3. Is the temperature gauge 3. Check gauge operation. Refer to
operating OK? Group 8E. Repair as necessary.
4. Coolant level low in cold ambient 4. Check coolant level in the coolant
temperatures accompanied with reserve/overflow tank and the
poor heater performance. radiator. Inspect system for leaks.
Repair leaks as necessary. Refer to
the Coolant section of the manual
text for WARNINGS and
CAUTIONS associated with
removing the radiator cap.
5. Improper operation of internal 5. Inspect heater and repair as
heater doors or heater controls. necessary. Refer to Group 24,
Heating and Air Conditioning for
procedures.

TEMPERATURE GAUGE READS 1. Trailer is being towed, a steep 1. This may be a temporary
HIGH OR THE COOLANT hill is being climbed, vehicle is condition and repair is not
WARNING LAMP ILLUMINATES. operated in slow moving traffic, or necessary. Turn off the air
COOLANT MAY OR MAY NOT BE engine is being idled with very high conditioning and attempt to drive the
LOST OR LEAKING FROM THE ambient (outside) temperatures and vehicle without any of the previous
COOLING SYSTEM the air conditioning is on. Higher conditions. Observe the temperature
altitudes could aggravate these gauge. The gauge should return to
conditions. the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair. Refer to Possible
Causes (2-20).

2. Is the temperature gauge reading 2. Check gauge. Refer to Group 8E.

correctly? Repair as necessary.
3. Is the temperature warning 3. Check warning lamp operation.
illuminating unnecessarily? Refer to Group 8E. Repair as
necessary.
4. Coolant low in coolant reserve/ 4. Check for coolant leaks and
overflow tank and radiator? repair as necessary. Refer to
Testing Cooling System for Leaks in
this Group.
5. Pressure cap not installed tightly. 5. Tighten cap
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following Step 6.

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 XJ COOLING SYSTEM 7 - 13
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE READS 6. Poor seals at the radiator cap. 6. (a) Check condition of cap and
HIGH OR THE COOLANT cap seals. Refer to Radiator Cap.
WARNING LAMP ILLUMINATES. Replace cap if necessary.
COOLANT MAY OR MAY NOT BE (b) Check condition of radiator filler
LOST OR LEAKING FROM THE neck. If neck is bent or damaged,
COOLING SYSTEM (CONTINUED) replace radiator.
7. Coolant level low in radiator but 7. (a) Check condition of radiator
not in coolant reserve/overflow cap and cap seals. Refer to
tank. This means the radiator is not Radiator Cap in this Group. Replace
drawing coolant from the coolant cap if necessary.
reserve/overflow tank as the engine (b) Check condition of radiator filler
cools neck. If neck is bent or damaged,
replace radiator.
(c) Check condition of the hose from
the radiator to the coolant tank. It
should fit tight at both ends without
any kinks or tears. Replace hose if
necessary.
(d) Check coolant reserve/overflow
tank and tanks hoses for blockage.
Repair as necessary.
8. Incorrect coolant concentration 8. Check coolant. Refer to Coolant
section in this Group for correct
coolant/water mixture ratio.
9. Coolant not flowing through 9. Check for coolant flow at radiator
system filler neck with some coolant
removed, engine warm and
thermostat open. Coolant should be
observed flowing through radiator. If
flow is not observed, determine area
of obstruction and repair as
necessary.
10. Radiator or A/C condenser fins 10. Remove insects and debris.
are dirty or clogged. Refer to Radiator Cleaning in this
Group.
11. Radiator core is corroded or 11. Have radiator re-cored or
plugged. replaced.
12. Aftermarket A/C installed 12. Install proper radiator.
without proper radiator.
13. Fuel or ignition system 13. Refer to Fuel and Ignition
problems. System Groups for diagnosis.
14. Dragging brakes. 14. Check and correct as
necessary. Refer to Group 5,
Brakes for correct procedures.
15. Bug screen or cardboard is 15. Remove bug screen or
being used, reducing airflow. cardboard.
16. Thermostat partially or 16. Check thermostat operation and
completely shut. replace as necessary. Refer to
Thermostats in this Group.

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 7 - 14 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE READS 17. Viscous fan drive not operating 17. Check fan drive operation and
HIGH OR THE COOLANT properly. replace as necessary. Refer to
WARNING LAMP ILLUMINATES. Viscous Fan Drive in this Group.
COOLANT MAY OR MAY NOT BE
LOST OR LEAKING FROM THE 18. Electric cooling fan not 18. Check electric fan operation and
COOLING SYSTEM (CONTINUED) operating properly (vehicles repair as necessary. Refer to
equipped with 2.5L/4.0L and air Electric Cooling Fan in this Group.
conditioning
19. Cylinder head gasket leaking. 19. Check for cylinder head gasket
leaks. Refer to Cooling System-
Testing For Leaks in this Group. For
repair, refer to Group 9, Engines.
20. Heater core leaking. 20. Check heater core for leaks.
Refer to Group 24, Heating and Air
Conditioning. Repair as necessary.

TEMPERATURE GAUGE READING 1. On vehicles equipped with an 1. This is a normal condition. No

IS INCONSISTENT (FLUCTUATES, electric fan, the gauge may cycle correction is necessary unless the
CYCLES OR IS ERRATIC) up and down. This is due to the gauge cycles into the red (overheat)
cycling of the electric radiator fan. zone. Refer to Electric Cooling Fan
Diagnosis and Testing in this group.

2. During cold weather operation, 2. A normal condition. No correction

with the heater blower in the high is necessary.
position, the gauge reading may
drop slightly.
3. Temperature gauge or engine 3. Check operation of gauge and
mounted gauge sensor defective or repair if necessary. Refer to Group
shorted. Also, corroded or loose 8E, Instrument Panel and Gauges.
wiring in this circuit.
4. Gauge reading rises when 4. A normal condition. No correction
vehicle is brought to a stop after is necessary. Gauge should return
heavy use (engine still running) to normal range after vehicle is
driven.
5. Gauge reading high after 5. A normal condition. No correction
re-starting a warmed up (hot) is necessary. The gauge should
engine. return to normal range after a few
minutes of engine operation.
6. Coolant level low in radiator (air 6. Check and correct coolant leaks.
will build up in the cooling system Refer to Cooling System-Testing for
causing the thermostat to open leaks in this group.
late).
7. Cylinder head gasket leaking 7. (a) Check for cylinder head
allowing exhaust gas to enter gasket leaks. Refer to Cooling
cooling system causing a System-Testing for Leaks in this
thermostat to open late. group.
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.

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 XJ COOLING SYSTEM 7 - 15
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE READING 8. Water pump impeller loose on 8. Check water pump and replace
IS INCONSISTENT (FLUCTUATES, shaft. as necessary. Refer to water Pumps
CYCLES OR IS ERRATIC) in this group.
(CONTINUED)
9. Loose accessory drive belt. 9. Refer to Accessory Drive Belts in
(water pump slipping) this group. Check and correct as
necessary.
10. Air leak on the suction side of 10. Locate leak and repair as
the water pump allows air to build necessary.
up in cooling system causing
thermostat to open late.

PRESSURE CAP IS BLOWING 1. Pressure relief valve in radiator 1. Check condition of radiator cap
OFF STEAM AND/OR COOLANT cap is defective. and cap seals. Refer to Radiator
TO COOLANT TANK. Caps in this group. Replace cap as
TEMPERATURE GAUGE READING necessary.
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK

COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
GROUND WITHOUT PRESSURE system hoses, water pump or necessary. Refer to Cooling
CAP BLOWOFF. GAUGE READING engine. System-Testing For Leaks in this
HIGH OR HOT group.

DETONATION OR PRE-IGNITION 1. engine overheating. 1. Check reason for overheating

(NOT CAUSED BY IGNITION and repair as necessary.
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH 2. Freeze point of coolant not 2. Check coolant concentration.
correct. Mixture is too rich or too Refer to the Coolant section of this
lean. group and adjust ratio as required.

HOSE OR HOSES COLLAPSE 1. Vacuum created in cooling 1. (a) Radiator cap relief valve
WHILE ENGINE IS RUNNING system on engine cool-down is not stuck. Refer to Radiator Cap in this
being relieved through coolant group. Replace if necessary
reserve/overflow system.

(b) Hose between coolant

reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and
repair as necessary.
(d) Reserve/overflow tank is
internally blocked or plugged. Check
for blockage and repair as
necessary.

ELECTRIC RADIATOR FAN RUNS 1. Fan relay, powertrain control 1. Refer to Electric Cooling Fan
ALL OF THE TIME (2.5L/4.0L module (PCM) or coolant Diagnosis and Testing. Also refer to
MODELS EQUIPPED WITH A/C temperature sensor defective. Group 8W, Wiring Diagrams. Repair
AND 4.0L MODELS EQUIPPED as necessary.
WITH MAX COOLING)

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 7 - 16 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

ELECTRIC RADIATOR FAN WILL 1. Blown Fuse in Power Distribution 1. Determine reason for blown fuse
NOT RUN AT ALL. GAUGE Center (PDC) and repair as necessary.
READING HIGH OR HOT
(2.5L/4.0L MODELS EQUIPPED 2. Fan relay, powertrain control 2. Refer to Electric Cooling Fan
WITH A/C AND 4.0L MODELS module (PCM) or coolant Diagnosis and Testing. Also refer to
EQUIPPED WITH MAX COOLING) temperature sensor defective. Group 8W, Wiring Diagrams. Repair
as necessary.
3. Fan Motor Defective 3. Refer to Electric Cooling Fan
Diagnosis and Testing. Also refer to
Group 8W, Wiring Diagrams. Repair
as necessary.

NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly.
Refer to Cooling System Fans in
this Group

2. Fan blades striking a surrounding 2. Locate point of fan blade contact

object. and repair as necessary.
3. Air obstructions at radiator or air 3. Remove obstructions and/or
conditioning condenser. clean debris or insects from radiator
or A/C condenser.
4. Thermal viscous fan drive has 4. Replace fan drive. Bearing is not
defective bearing. serviceable. Refer to Viscous Fan
Drive in this group.
5. A certain amount of fan noise 5. Refer to Viscous Fan Drive in this
may be evident on models group for an explanation of normal
equipped with a thermal viscous fan fan noise.
drive. Some of this noise is normal.

INADEQUATE HEATER 1. Has a Diagnostic trouble Code 1. Refer to Group 25, Emissions for
PERFORMANCE. THERMOSTAT (DTC) been set? correct procedures and replace
FAILED IN OPEN POSITION thermostat if necessary
2. Coolant level low 2. Refer to Cooling System-Testing
For Leaks in this group.
3. Obstructions in heater hose/ 3. Remove heater hoses at both
fittings ends and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping 5. Refer to Water Pump in this
water to/through the heater core. group. If a slipping belt is detected,
When the engine is fully warmed refer to Accessory Drive Belts in this
up, both heater hoses should be group. If heater core obstruction is
hot to the touch. If only one of the detected, refer to Group 24, Heating
hoses is hot, the water pump may and Air Conditioning.
not be operating correctly or the
heater core may be plugged.
Accessory drive belt may be
slipping causing poor water pump
operation.

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 XJ COOLING SYSTEM 7 - 17
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

STEAM IS COMING FROM THE 1. During wet weather, moisture 1. Occasional steam emitting from
FRONT OF VEHICLE NEAR THE (snow, ice or rain condensation) on this area is normal. No repair is
GRILL AREA WHEN WEATHER IS the radiator will evaporate when the necessary.
WET, ENGINE IS WARMED UP thermostat opens. This opening
AND RUNNING, AND VEHICLE IS allows heated water into the
STATIONARY. TEMPERATURE radiator. When the moisture
GAUGE IS IN NORMAL RANGE contacts the hot radiator, steam
may be emitted. This usually occurs
in cold weather with no fan or
airflow to blow it away.

COOLANT COLOR 1. Coolant color is not necessarily 1. Refer to Coolant in this group for
an indication of adequate corrosion coolant concentration information.
or temperature protection. Do not Adjust coolant mixture as
rely on coolant color for determining necessary.
condition of coolant.

COOLANT LEVEL CHANGES IN 1. Level changes are to be 1. A normal condition. No repair is

COOLANT RESERVE/OVERFLOW expected as coolant volume necessary.
TANK. TEMPERATURE GAUGE IS fluctuates with engine temperature.
IN NORMAL RANGE If the level in the tank was between
the FULL and ADD marks at normal
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.

RADIATOR COOLANT FLOW CHECK

The following procedure will determine if coolant is
flowing through the cooling system.
If engine is cold, idle engine until normal operating
temperature is reached. Then feel the upper radiator
hose. If hose is hot, the thermostat is open and water
is circulating through cooling system.

COOLING SYSTEM—TESTING FOR LEAKS

ULTRAVIOLET LIGHT METHOD
All Jeep models have a leak detection additive
added to the cooling system before they leave the fac-
tory. The additive is highly visible under ultraviolet
light (black light). If the factory original coolant has
been drained, pour one ounce of additive into the
cooling system. The additive is available through the
part’s department. Place the heater control unit in
HEAT position. Start and operate the engine until
the radiator upper hose is warm to the touch. Aim
the commercially available black light tool at the
components to be checked. If leaks are present, the
black light will cause the additive to glow a bright Fig. 17 Leak Detection Using Black Light—Typical
green color. 1 – TYPICAL BLACK LIGHT TOOL
The black light can be used along with a pressure
tester to determine if any external leaks exist (Fig.
17).

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 7 - 18 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)
PRESSURE TESTER METHOD • Drops Slowly: Shows a small leak or seepage is
The engine should be at the normal operating tem- occurring. Examine all connections for seepage or
perature. Recheck the system cold if the cause of slight leakage with a flashlight. Inspect the radiator,
coolant loss is not located during warm engine exam- hoses, gasket edges and heater. Seal any small leak
ination. holes with a Sealer Lubricant or equivalent. Repair
leak holes and reinspect the system with pressure
WARNING: HOT, PRESSURIZED COOLANT CAN applied.
CAUSE INJURY BY SCALDING. • Drops Quickly: Shows that a serious leakage is
occurring. Examine the system for serious external
Carefully remove the radiator pressure cap from leakage. If no leaks are visible, inspect for internal
the filler neck and check the coolant level. Push leakage. Large radiator leak holes should be repaired
down on the cap to disengage it from the stop tabs. by a reputable radiator repair shop.
Wipe the inner part of the filler neck and examine
the lower inside sealing seat for nicks, cracks, paint, INTERNAL LEAKAGE INSPECTION
dirt and solder residue. Inspect the reserve/overflow Remove the engine oil pan drain plug and drain a
tank tube for internal obstructions. Insert a wire small amount of engine oil. Coolant, being heavier
through the tube to be sure it is not obstructed. than engine oil, will drain first. Another way of test-
Inspect the cams on the outside part of the filler ing is to operate the engine and check for water glob-
neck. If the cams are bent, seating of pressure cap ules on the engine oil dipstick. Also inspect the
valve and tester seal will be affected. Replace cap if automatic transmission oil dipstick for water glob-
cams are bent. ules. Inspect the automatic transmission fluid cooler
Attach pressure tester 7700 (or an equivalent) to for leakage. Operate the engine without the pressure
the radiator filler neck (Fig. 18). cap on the radiator until thermostat opens.
Attach a pressure tester to the filler neck. If pres-
sure builds up quickly, a leak exists as a result of a
faulty cylinder head gasket or crack in the engine.
Repair as necessary.

WARNING: DO NOT ALLOW PRESSURE TO

EXCEED 124 KPA (18 PSI). TURN THE ENGINE OFF.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.

If there is no immediate pressure increase, pump

the pressure tester until the indicated pressure is
within the system range. Vibration of the gauge
pointer indicates compression or combustion leakage
Fig. 18 Pressurizing System—Typical into the cooling system.
1 – TYPICAL COOLING SYSTEM PRESSURE TESTER
WARNING: DO NOT DISCONNECT THE SPARK
PLUG WIRES WHILE THE ENGINE IS OPERATING.
Operate the tester pump to apply 124 kPa (18 psi)
pressure to the system. If the hoses enlarge exces-
sively or bulge while testing, replace as necessary. CAUTION: Do not operate the engine with a spark
Observe the gauge pointer and determine the condi- plug shorted for more than a minute. The catalytic
tion of the cooling system according to the following converter may be damaged.
criteria:
• Holds Steady: If the pointer remains steady for Isolate the compression leak by shorting each
two minutes, there are no serious coolant leaks in spark plug to the cylinder block. The gauge pointer
the system. However, there could be an internal leak should stop or decrease vibration when spark plug
that does not appear with normal system test pres- for leaking cylinder is shorted. This happens because
sure. Inspect for interior leakage or do the Internal of the absence of combustion pressure.
Leakage Test. Do this if it is certain that coolant is
being lost and no leaks can be detected.

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 XJ COOLING SYSTEM 7 - 19
DIAGNOSIS AND TESTING (Continued)
COMBUSTION LEAKAGE TEST (WITHOUT 105°C (0°-to-220° F). Insert thermometer through the
PRESSURE TESTER) hole in the shroud. Be sure that there is adequate
DO NOT WASTE reusable coolant. If the solution clearance from the fan blades.
is clean, drain the coolant into a clean container for (3) Connect a tachometer and an engine ignition
reuse. timing light (timing light is to be used as a strobe
light).
WARNING: DO NOT REMOVE THE CYLINDER (4) Block the air flow through the radiator. Secure
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR a sheet of plastic in front of the radiator (or air con-
DRAINCOCK WITH THE SYSTEM HOT AND UNDER ditioner condenser). Use tape at the top to secure the
PRESSURE. SERIOUS BURNS FROM COOLANT plastic and be sure that the air flow is blocked.
CAN OCCUR. (5) Be sure that the air conditioner (if equipped) is
turned off.
Drain sufficient coolant to allow for thermostat
removal. Refer to Thermostat Replacement. Discon- WARNING: USE EXTREME CAUTION WHEN THE
nect the water pump drive belt. ENGINE IS OPERATING. DO NOT STAND IN A
Disconnect the upper radiator hose from the ther- DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
mostat housing. Remove the housing and thermostat. HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
Install the thermostat housing. NOT WEAR LOOSE CLOTHING.
Add coolant to the radiator to bring the level to
within 6.3 mm (1/4 in) of the top of the thermostat (6) Start the engine and operate at 2400 rpm.
housing. Within ten minutes the air temperature (indicated on
the dial thermometer) should be up to 88° C (190° F).
CAUTION: Avoid overheating. Do not operate the Fan drive engagement should have started to occur
engine for an excessive period of time. Open the at between 74° to 82° C (165° to 180° F). Engage-
draincock immediately after the test to eliminate ment is distinguishable by a definite increase in fan
boil over of coolant. flow noise (roaring). The timing light also will indi-
cate an increase in the speed of the fan.
Start the engine and accelerate rapidly three times (7) When the air temperature reaches 88° C (190°
(to approximately 3000 rpm) while observing the F), remove the plastic sheet. Fan drive disengage-
coolant. If internal engine combustion gases are leak- ment should have started to occur at between 57° to
ing into the cooling system, bubbles will appear in 79° C (135° to 175° F). A definite decrease of fan
the coolant. If bubbles do not appear, there is no flow noise (roaring) should be noticed. If not, replace
internal combustion gas leakage. the defective viscous fan drive unit.

VISCOUS FAN DRIVE ELECTRIC COOLING FAN

LEAKS ELECTRIC COOLING FAN AND RELAY DIAGNOSIS
Viscous fan drive operation is not affected by small
oil stains near the drive bearing. If leakage appears NOTE: Refer to Electrical Group 8W for electric
excessive, replace the fan drive unit. cooling fan and relay circuit schematic.

TESTING The powertrain control module (PCM) will enter a

If the fan assembly free-wheels without drag (the diagnostic trouble code (DTC) in memory if it detects
fan blades will revolve more than five turns when a problem in the auxiliary cooling fan relay or circuit.
spun by hand), replace the fan drive. This spin test Refer to Group 25, Emission Control Systems for cor-
must be performed when the engine is cool. rect DTC retrieval procedures.
For the following test, the cooling system must be If the electric cooling fan is inoperative, check the
in good condition. It also will ensure against exces- 15A fuse in the junction block and the 40A fuse in
sively high coolant temperature. the Power Distribution Center (PDC) with a 12 volt
test lamp or DVOM. Refer to the inside of the PDC
WARNING: BE SURE THAT THERE IS ADEQUATE cover for the exact location of the fuse. If fuses are
FAN BLADE CLEARANCE BEFORE DRILLING. o.k., refer to Group 8W for electric cooling fan and
relay circuit schematic.
(1) Drill a 3.18-mm (1/8-in) diameter hole in the
top center of the fan shroud.
(2) Obtain a dial thermometer with an 8 inch stem
(or equivalent). It should have a range of -18°-to-

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 7 - 20 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)

RADIATOR CAP-TO-FILLER NECK SEAL— There is no need to remove the radiator cap
except for the following purposes:
PRESSURE RELIEF CHECK
(1) To check and adjust antifreeze freeze point.
With radiator cap installed on filler neck, remove
(2) To refill system with new antifreeze.
coolant reserve/ overflow tank hose from nipple on
(3) For conducting service procedures.
filler neck. Connect a hand operated vacuum pump
(4) When checking for vacuum leaks.
to nipple. Operate pump until a reading of 47-to-61
kPa (14- to-18 in. Hg) appears on gauge. If the read- WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
ing stays steady, or drops slightly and then remains WAIT AT LEAST 15 MINUTES BEFORE REMOVING
steady, the pressure valve seal is good. Replace radi- RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR
ator cap if reading does not hold. UPPER HOSE TO CHECK IF SYSTEM IS UNDER
PRESSURE. PLACE A RAG OVER THE CAP AND
WARNING: THE WARNING WORDS -DO NOT OPEN
WITHOUT PUSHING DOWN, ROTATE CAP
HOT- ON THE RADIATOR PRESSURE CAP (Fig. 19)
COUNTER-CLOCKWISE TO THE FIRST STOP.
ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
ALLOW FLUID TO ESCAPE THROUGH OVERFLOW
SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
HOSE INTO COOLANT RESERVE/OVERFLOW
VENT SCALDING OR INJURY, THE RADIATOR CAP
TANK. SQUEEZE RADIATOR UPPER HOSE TO
SHOULD NOT BE REMOVED WHILE THE SYSTEM
DETERMINE WHEN PRESSURE HAS BEEN
IS HOT AND/OR UNDER PRESSURE.
RELEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY.

RADIATOR CAP—PRESSURE TESTING

Remove cap from radiator. Be sure that sealing
surfaces are clean. Moisten rubber gasket with water
and install the cap on pressure tester (tool 7700 or
an equivalent) (Fig. 20).

Fig. 19 Radiator Pressure Cap

1 – FILLER NECK SEAL
2 – VACUUM VENT VALVE
3 – PRESSURE RATING
4 – PRESSURE VALVE
Fig. 20 Pressure Testing Radiator Pressure
Cap—Typical
1 – PRESSURE CAP
2 – TYPICAL COOLING SYSTEM PRESSURE TESTER

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 XJ COOLING SYSTEM 7 - 21
DIAGNOSIS AND TESTING (Continued)
Operate the tester pump and observe the gauge The coolant reserve/overflow system provides a
pointer at its highest point. The cap release pressure quick visual method for determining coolant level
should be 83-to-110 kPa (12-to-16 psi). The cap is sat- without removing radiator pressure cap. With engine
isfactory when the pressure holds steady. It is also cold and not running, observe coolant level in
good if it holds pressure within the 83-to-110 kPa reserve/overflow tank. The coolant level should be
(12-to-16 psi) range for 30 seconds or more. If the between ADD and FULL marks.
pointer drops quickly, replace the cap.
COOLANT—ADDING ADDITIONAL
CAUTION: Radiator pressure testing tools are very Do not remove radiator cap to add coolant to
sensitive to small air leaks, which will not cause system. When adding coolant to maintain correct
cooling system problems. A pressure cap that does level, do so at coolant reserve/overflow tank. Use a
not have a history of coolant loss should not be 50/50 mixture of ethylene-glycol antifreeze containing
replaced just because it leaks slowly when tested Alugard 340-2 y and low mineral content water.
with this tool. Add water to tool. Turn tool upside Remove radiator cap only for testing or when refill-
down and recheck pressure cap to confirm that cap ing system after service. Removing cap unnecessarily
needs replacement. can cause loss of coolant and allow air to enter sys-
tem, which produces corrosion.
CAP INSPECTION
Visually inspect the pressure valve gasket on the
COOLANT—LEVEL CHECK
cap. Replace cap if the gasket is swollen, torn or
The cooling system is closed and designed to main-
worn. Inspect the area around radiator filler neck for
tain coolant level to top of radiator.
white deposits that indicate a leaking cap.
WARNING: DO NOT OPEN RADIATOR DRAINCOCK
COOLANT—LOW LEVEL AERATION WITH ENGINE RUNNING OR WHILE ENGINE IS HOT
If the coolant level in radiator drops below top of AND COOLING SYSTEM IS UNDER PRESSURE.
radiator core tubes, air will enter cooling system.
Low coolant level can cause thermostat pellet to be When vehicle servicing requires a coolant level
suspended in air instead of coolant. This will cause check in radiator, drain several ounces of coolant
thermostat to open later, which in turn causes higher from radiator drain cock. Do this while observing
coolant temperature. Air trapped in cooling system coolant reserve/overflow system tank. The coolant
also reduces amount of coolant circulating in heater level in reserve/overflow tank should drop slightly. If
core resulting in low heat output. not, inspect for a leak between radiator and coolant
reserve/overflow system connection. Remove radiator
DEAERATION cap. The coolant level should be to top of radiator. If
As the engine operates, any air trapped in cooling not and if coolant level in reserve/overflow tank is at
system gathers under the radiator cap. The next time ADD mark, check for:
the engine is operated, thermal expansion of coolant • An air leak in coolant reserve/overflow tank or
will push any trapped air past radiator cap into the its hose
coolant reserve/overflow tank. Here it escapes to the • An air leak in radiator filler neck
atmosphere into the tank. When the engine cools • Leak in pressure cap seal to radiator filler neck
down the coolant, it will be drawn from the reserve/
overflow tank into the radiator to replace any COOLING SYSTEM—DRAINING AND FILLING
removed air.
DRAINING
SERVICE PROCEDURES WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
COOLANT—ROUTINE LEVEL CHECK DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
NOTE: Do not remove radiator cap for routine CAN OCCUR.
coolant level inspections. The coolant level can be
checked at coolant reserve/overflow tank. DO NOT WASTE reusable coolant. If the solution
is clean, drain the coolant into a clean container for
reuse.
(1) Remove radiator pressure cap.

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 7 - 22 COOLING SYSTEM XJ
SERVICE PROCEDURES (Continued)
(2) For access to radiator draincock (Fig. 21), Reverse flushing of the cooling system is the forc-
remove radiator grille mounting screws and remove ing of water through the cooling system. This is done
grill. Refer to Group 23, Body for correct procedure. using air pressure in the opposite direction of normal
coolant flow. It is usually only necessary with very
dirty systems with evidence of partial plugging.

CHEMICAL CLEANING
If visual inspection indicates the formation of
sludge or scaly deposits, use a radiator cleaner
(Mopar Radiator Kleen or equivalent) before flushing.
This will soften scale and other deposits and aid the
flushing operation.

CAUTION: Be sure instructions on the container

are followed.

REVERSE FLUSHING RADIATOR

Disconnect the radiator hoses from the radiator fit-
tings. Attach a section of radiator hose to the radia-
tor bottom outlet fitting and insert the flushing gun.
Connect a water supply hose and air supply hose to
the flushing gun.
Fig. 21 Radiator Petcock—2.5L/4.0L (LHD/RHD)
1 – RADIATOR PETCOCK
CAUTION: The cooling system normally operates at
97-to-124 kPa (14- to-18 psi) pressure. Exceeding
(3) Attach one end of a 24 inch long X 1/4 inch ID this pressure may damage the radiator or hoses.
hose to the radiator draincock. Put the other end into
a clean container. Open draincock and drain coolant Allow the radiator to fill with water. When radiator
from radiator. is filled, apply air in short blasts allowing radiator to
(4) Drain coolant from engine by removing the refill between blasts. Continue this reverse flushing
drain plug and coolant temperature sensor on left until clean water flows out through rear of radiator
side of block. cooling tube passages. For more information, refer to
operating instructions supplied with flushing equip-
REFILLING ment. Have radiator cleaned more extensively by a
(1) Tighten the radiator petcock and the cylinder radiator repair shop.
block drain plug(s).
(2) Install grille. REVERSE FLUSHING ENGINE
(3) Fill system using a 50/50 mixture of water and Drain the cooling system. Remove the thermostat
antifreeze as described in the Coolant section of this housing and thermostat. Install the thermostat hous-
group. Fill radiator to top and install radiator cap. ing. Disconnect the radiator upper hose from the
Add sufficient coolant to reserve/overflow tank to radiator and attach the flushing gun to the hose. Dis-
raise level to FULL mark. connect the radiator lower hose from the water
(4) With heater control unit in the HEAT position, pump. Attach a lead away hose to the water pump
operate engine with radiator cap in place. inlet fitting.
(5) After engine has reached normal operating
temperature, shut engine off and allow it to cool. CAUTION: Be sure that the heater control valve is
(6) Add coolant to reserve/overflow tank as neces- closed (heat off). This is done to prevent coolant
sary. Only add coolant when the engine is cold. flow with scale and other deposits from entering
Coolant level in a warm engine will be higher the heater core.
due to thermal expansion.
Connect the water supply hose and air supply hose
to the flushing gun. Allow the engine to fill with
COOLING SYSTEM—REVERSE FLUSHING water. When the engine is filled, apply air in short
CAUTION: The cooling system normally operates at blasts, allowing the system to fill between air blasts.
97-to-124 kPa (14- to-18 psi) pressure. Exceeding Continue until clean water flows through the lead
this pressure may damage the radiator or hoses. away hose. For more information, refer to operating
instructions supplied with flushing equipment.

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 XJ COOLING SYSTEM 7 - 23
SERVICE PROCEDURES (Continued)
Remove the lead away hose, flushing gun, water
supply hose and air supply hose. Remove the thermo-
stat housing and install thermostat. Install the ther-
mostat housing with a replacement gasket. Refer to
Thermostat Replacement. Connect the radiator
hoses. Refill the cooling system with the correct anti-
freeze/water mixture.

REMOVAL AND INSTALLATION

TRANSMISSION OIL COOLERS
WATER-TO-OIL COOLER
The internal transmission oil cooler located within
the radiator is not serviceable. If it requires service,
the radiator must be replaced.
Once the repaired or replacement radiator has been
installed, fill the cooling system and inspect for leaks.
Refer to the Refilling Cooling System and Testing Fig. 22 Auxiliary Air-To-Oil Cooler
Cooling System For Leaks sections in this group. If 1 – AIR CONDITIONING CONDENSER
the transmission operates properly after repairing the 2 – HOSE CLAMPS (2)
3 – AUXILIARY AUTOMATIC TRANSMISSION OIL COOLER
leak, drain the transmission and remove the transmis-
4 – MOUNTING BOLT
sion oil pan. Inspect for sludge and/or rust. Inspect for
5 – MOUNTING BOLT
a dirty or plugged inlet filter. If none of these condi-
tions are found, the transmission and torque convertor
may not require reconditioning. Refer to Group 21 for (2) Remove the tank mounting bolts and remove
automatic transmission servicing. tank (Fig. 23) (Fig. 24).

AIR-TO-OIL COOLER
REMOVAL
(1) Remove the grill mounting screws and remove
the grill. Refer to Group 23, Body for procedures.
(2) Place a drain pan below the transmission oil
cooler.
(3) Remove the two constant tension clamps at oil
cooler inlet and outlet tubes.
(4) Remove the two oil cooler mounting bolts (Fig.
22).
(5) Remove the oil cooler from vehicle.

INSTALLATION
(1) Position and secure oil cooler to vehicle.
Tighten mounting bolts to 8 N·m (72 in. lbs.) torque.
(2) Secure inlet and outlet tubes with constant
tension clamps.
Install the grill.
(3) Start engine and check transmission fluid level. Fig. 23 Reserve/Overflow Tank—Except Right Hand
Add fluid if necessary. Drive
1 – COOLANT RESERVE/OVERFLOW TANK
COOLANT RESERVE TANK 2 – CLAMP
3 – MOUNTING BOLTS
REMOVAL 4 – TUBE TO RADIATOR
(1) Remove the tube clamp at the tank and remove
tube.

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 7 - 24 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 25 Reverse Rotating Water Pump—Typical

1 – R STAMPED INTO IMPELLER
Fig. 24 Reserve/Overflow Tank—With Right Hand
Drive
1 – CLAMP The water pump impeller is pressed on the rear of
2 – COOLANT RESERVE/OVERFLOW TANK the pump shaft and bearing assembly. The water
3 – MOUNTING BOLTS pump is serviced only as a complete assembly.
4 – LOWER BRACKET
5 – TUBE TO RADIATOR WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
INSTALLATION WITH THE SYSTEM HOT AND UNDER PRESSURE.
(1) Position tank and tighten to 2 N·m (17 in. lbs.) SERIOUS BURNS FROM COOLANT CAN OCCUR.
torque.
DO NOT WASTE reusable coolant. If the solution
(2) Position tube and secure clamp.
is clean, drain coolant into a clean container for
reuse.
WATER PUMP
CAUTION: If the water pump is replaced because of
REMOVAL-2.5L ENGINE (LHD/RHD)
(1) Disconnect battery negative cable.
mechanical damage, the fan blades and viscous fan
(2) Drain cooling system. Refer to Cooling System-
drive should also be inspected. These components
Draining and Filling in this group.
could have been damaged due to excessive vibra-
(3) Remove upper radiator hose.
tion.
(4) Loosen (but do not remove at this time) the
The water pump can be removed without discharg- four fan hub-to-water pump pulley mounting nuts
ing the air conditioning system (if equipped). (Fig. 26).
(5) Remove accessory drive belt. (Refer to Acces-
CAUTION: All engines have a reverse (counter- sory Drive Belt, Removal and Installation in this
clockwise) rotating water pump. The letter R is group)
stamped into the back of the water pump impeller (6) Disconnect electric cooling fan connector (if
(Fig. 25) to identify. Engines from previous model equipped).
years, depending upon application, may be (7) Unbolt fan shroud.
equipped with a forward (clockwise) rotating water (8) Remove the four fan hub-to-water pump pulley
pump. Installation of the wrong water pump will nuts and remove fan and shroud together.
cause engine over heating.

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 XJ COOLING SYSTEM 7 - 25
REMOVAL AND INSTALLATION (Continued)
CAUTION: After removing fan blade/viscous fan
drive assembly, do not place thermal viscous fan
drive in horizontal position. If stored horizontally,
silicone fluid in viscous fan drive could drain into
its bearing assembly and contaminate lubricant.

(9) Remove power steering pump and bracket (Fig.

27), refer to Group 19 Steering for correct procedure.
(10) Remove lower radiator hose from water pump.
Remove heater hose from water pump pipe.
(11) Remove the four pump mounting bolts (Fig.
28) and remove pump from vehicle. Discard old gas-
ket. Note that one of the four bolts is longer than the
other bolts.
(12) If pump is to be replaced, the heater hose fit-
ting must be removed. Note position of fitting before Fig. 27 Power Steering Pump Attachment-2.5L
removal. 1 – INTAKE MANIFOLD
2 – PUMP ASSEMBLY 2.5L
3 – PUMP BRACKET

Fig. 26 Fan Mounting Nuts

1 – THERMAL VISCOUS FAN DRIVE
2 – (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
3 – (4) FAN HUB-TO-PUMP PULLEY STUDS
4 – WATER PUMP
5 – WATER PUMP PULLEY
6 – FAN BLADE
7 – (4) FAN HUB-TO-PUMP PULLEY NUTS

Fig. 28 Water Pump Remove/Install—Typical

INSTALLATION-2.5L ENGINE (LHD/RHD) 1 – HEATER HOSE FITTING
(1) If pump is being replaced, install the heater 2 – UPPER VENT HOLE
hose pipe to the pump. Use a sealant on the fitting 3 – PUMP GASKET
such as Mopart Thread Sealant With Teflon. Refer to 4 – WATER PUMP
the directions on the package. 5 – LOWER VENT HOLE
6 – LONG BOLT
(2) Clean the gasket mating surfaces. If the origi-
7 – BOLTS (3) SHORT
nal pump is used, remove any deposits or other for-
eign material. Inspect the cylinder block and water

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 7 - 26 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
pump mating surfaces for erosion or damage from
cavitation.
(3) Install the gasket and water pump. The sili-
cone bead on the gasket should be facing the water
pump. Also, the gasket is installed dry. Tighten
mounting bolts to 23 N·m (17 ft. lbs.) torque. Rotate
the shaft by hand to be sure it turns freely.
(4) Connect the radiator and heater hoses to the
water pump.
(5) Install power steering pump and bracket. Refer
to Group 19, Steering.
(6) Position water pump pulley to water pump
hub.
(7) Install shroud and fan together and install four
nuts to water pump hub studs. Tighten nuts to 27
N·m (20 ft. lbs.) torque.
(8) Install and tighten upper fan shroud nuts to 4
Fig. 29 Water Pump Pulley Bolts
N·m (31 in. lbs.).
1 – WATER PUMP HUB
(9) Connect electric fan connector (if equipped).
2 – BOLTS (4)
3 – PUMP PULLEY
CAUTION: When installing the accessory drive belt,
the belt MUST be routed correctly. If not, the engine
may overheat due to the water pump rotating in the (8) Remove the four viscous fan to idler pulley
wrong direction. Refer to the Belt Removal and nuts and remove the fan and shroud together.
Installation in this group for appropriate belt rout-
ing. You may also refer to the Belt Routing Label in CAUTION: After removing fan blade/viscous fan
the vehicle engine compartment. drive assembly, do not place thermal viscous fan
drive in horizontal position. If stored horizontally,
(10) Install and tension accessory drive belt, refer silicone fluid in viscous fan drive could drain into
to Accessory Drive Belt removal and installation in its bearing assembly and contaminate lubricant.
this group.
(11) Install upper radiator hose. (9) Remove the four water pump pulley bolts and
(12) Fill cooling system with coolant and check for remove the pulley.
leaks. Refer to Refilling Cooling System in this (10) Remove power steering pump and bracket
group. (Fig. 30), refer to Group 19 Steering.
(13) Connect battery negative cable. (11) Remove lower radiator hose from water pump.
(14) Start and warm the engine. Check for leaks. Remove heater hose from water pump fitting.
(12) Remove the four pump mounting bolts (Fig.
REMOVAL-4.0L ENGINE (LHD/RHD) 31) and remove pump from vehicle. Discard old gas-
(1) Disconnect battery negative cable. ket. Note that one of the four bolts is longer than the
(2) Drain the cooling system. (Refer to Cooling other bolts.
System-Draining and Filling in this group.) (13) If pump is to be replaced, the heater hose fit-
(3) Disconnect electric cooling fan connector. ting must be removed. Note position of fitting before
(4) Remove electric cooling fan/shroud assembly (if removal.
equipped).
(5) Remove viscous fan shroud bolts (2). INSTALLATION-4.0L ENGINE (LHD/RHD)
(6) Loosen (but do not remove at this time) the (1) If pump is being replaced, install the heater
four water pump pulley-to-water pump hub mounting hose fitting to the pump. Use a sealant on the fitting
bolts (Fig. 29) and the four viscous fan to idler pulley such as Mopart Thread Sealant With Teflon. Refer to
nuts. the directions on the package.
(2) Clean the gasket mating surfaces. If the origi-
NOTE: The accessory drive belt must be removed nal pump is used, remove any deposits or other for-
prior to removing the fan (if installed at pump) or eign material. Inspect the cylinder block and water
fan pulley. pump mating surfaces for erosion or damage from
cavitation.
(7) Remove accessory drive belt (refer to Accessory (3) Install the gasket and water pump. The sili-
Drive Belt, Removal and Installation in this group) cone bead on the gasket should be facing the water

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 XJ COOLING SYSTEM 7 - 27
REMOVAL AND INSTALLATION (Continued)

Fig. 30 Power Steering Pump Attachment-4.0L

1 – PUMP ASSEMBLY
2 – PUMP BRACKET

pump. Also, the gasket is installed dry. Tighten

mounting bolts to 23 N·m (17 ft. lbs.) torque. Rotate
the shaft by hand to be sure it turns freely.
(4) Connect the radiator and heater hoses to the
water pump.
(5) Position water pump pulley to water pump
hub.
(6) Install four pump pulley bolts. Tighten bolts (or
nuts) to 27 N·m (20 ft. lbs.) torque.
(7) Install power steering pump. Refer to Group
19, Steering for proper procedure and torque values.
(8) Install the viscous fan and shroud together.
Install the four fan to idler pulley nuts and tighten
to 27 N·m (20 ft. lbs.).

CAUTION: When installing the accessory drive belt,

the belt MUST be routed correctly. If not, the engine
may overheat due to the water pump rotating in the
wrong direction. Refer to the Belt Removal and
Installation in this group for appropriate belt rout-
ing. You may also refer to the Belt Routing Label in
the vehicle engine compartment.

(9) Install and tighten viscous fan shroud bolts to

4 N·m (31 in. lbs.).
(10) Install and tension the accessory drive belt,
refer to Accessory Drive Belt removal and installa- Fig. 31 Water Pump Remove/Install—Typical
tion in this group. 1 – HEATER HOSE FITTING
2 – UPPER VENT HOLE
(11) Install the electric cooling fan/shroud assy.
3 – PUMP GASKET
(12) Install and tighten electric fan shroud bolts to
4 – WATER PUMP
4 N·m (31 in. lbs.). Connect fan connector. 5 – LOWER VENT HOLE
6 – LONG BOLT
7 – BOLTS (3) SHORT

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 7 - 28 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
(13) Fill cooling system with coolant and check for
leaks. Refer to Refilling Cooling System in this
group.
(14) Connect battery negative cable.
(15) Start and warm the engine. Check for leaks.

THERMOSTAT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.

DO NOT WASTE reusable coolant. If the solution

is clean, drain the coolant into a clean container for
reuse.
(1) Drain the coolant from the radiator until the
level is below the thermostat housing.

WARNING: CONSTANT TENSION HOSE CLAMPS

ARE USED ON MOST COOLING SYSTEM HOSES.
Fig. 32 Thermostat Removal/Installation
WHEN REMOVING OR INSTALLING, USE ONLY
1 – LONG BOLT
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
2 – GASKET
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 3 – THERMOSTAT
6094) (Fig. 12). SNAP-ON CLAMP TOOL (NUMBER 4 – THERMOSTAT HOUSING
HPC-20) MAY BE USED FOR LARGER CLAMPS. 5 – SHORT BOLT
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.

CAUTION: A number or letter is stamped into the

tongue of constant tension clamps (Fig. 11). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.

(2) Remove radiator upper hose and heater hose at

thermostat housing.
(3) Disconnect wiring connector at engine coolant
temperature sensor.
(4) Remove thermostat housing mounting bolts,
thermostat housing, gasket and thermostat (Fig. 32).
Discard old gasket.
(5) Clean the gasket mating surfaces.

INSTALLATION
(1) Install the replacement thermostat so that the
pellet, which is encircled by a coil spring, faces the
engine. All thermostats are marked on the outer
flange to indicate the proper installed position.
(a) Observe the recess groove in the engine cyl-
inder head (Fig. 33). Fig. 33 Thermostat Recess
(b) Position thermostat into this groove with 1 – GROOVE
arrow and air bleed hole on outer flange pointing
up.
(2) Install replacement gasket and thermostat
housing.

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 XJ COOLING SYSTEM 7 - 29
REMOVAL AND INSTALLATION (Continued)
CAUTION: Tightening the thermostat housing (7) Disconnect electric cooling fan electrical con-
unevenly or with the thermostat out of its recess nector, if equipped.
may result in a cracked housing.

(3) Tighten the housing bolts to 20 N·m (15 ft. lbs.)

torque.
(4) Install hoses to thermostat housing.
(5) Install electrical connector to coolant tempera-
ture sensor.
(6) Be sure that the radiator draincock is tightly
closed. Fill the cooling system to the correct level
with the required coolant mixture. Refer to Refilling
Cooling System in this group.
(7) Start and warm the engine. Check for leaks.

RADIATOR—2.5L
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR. Fig. 34 Radiator Petcock—Typical
1 – RADIATOR PETCOCK
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
(8) Disconnect CRS hose from radiator filler neck
WARNING: CONSTANT TENSION HOSE CLAMPS and remove from shroud retaining loops.
ARE USED ON MOST COOLING SYSTEM HOSES. (9) Remove the four (4) viscous fan/drive assembly
WHEN REMOVING OR INSTALLING, USE ONLY nuts from the water pump pulley and remove fan/
TOOLS DESIGNED FOR SERVICING THIS TYPE OF drive assy.
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER (10) Remove the four (4) fan shroud to core sup-
6094) (Fig. 12). SNAP-ON CLAMP TOOL (NUMBER port mounting screws.
HPC-20) MAY BE USED FOR LARGER CLAMPS. (11) Remove the electric fan (if equipped) and
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- shroud assembly from the vehicle (Fig. 36).
ING CONSTANT TENSION CLAMPS. (12) Remove radiator upper crossmember (Fig. 36).
(13) If equipped with air conditioning, separate
radiator from condenser by removing condenser-to-ra-
CAUTION: A number or letter is stamped into the diator mounting brackets (Fig. 35).
tongue of constant tension clamps (Fig. 11). If (14) Disconnect upper and lower radiator hoses.
replacement is necessary, use only an original (15) If equipped, disconnect and plug automatic
equipment clamp with matching number or letter. transmission fluid cooler lines. Quick Connect Fitting
Release Tool 6935 may be needed. If equipped with
remote transmission cooler, remove line to cooler
REMOVAL from bracket at bottom of radiator.
(1) Disconnect battery negative cable. (16) Lift radiator straight up and out of engine
(2) Observe the previous WARNINGS. compartment taking care not to damage fins.
(3) Remove radiator pressure cap. (17) If radiator is to be replaced, be sure to remove
(4) For access to radiator draincock, remove radia- and transfer any components not included with
tor grill mounting screws and remove grill. Refer to replacement radiator.
Group 23, Body for procedures.
(5) Attach one end of a 24 inch long X 1/4 inch ID INSTALLATION
hose to the radiator petcock (Fig. 34). Put the other The radiator is supplied with two alignment dowels
end into a clean container. Open petcock and drain (Fig. 41). They are located on the bottom tank and fit
radiator. into rubber grommets in the radiator lower cross-
(6) Detach power steering fluid reservoir from fan member.
shroud and lay aside.

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 7 - 30 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
(1) Lower radiator into engine compartment. Posi-
tion alignment dowels into rubber grommets in radi-
ator lower crossmember (Fig. 41).
(2) If equipped with air conditioning, attach con-
denser to radiator with mounting brackets (Fig. 35).
(3) Install radiator upper crossmember and four
mounting bolts.
(4) Install radiator upper crossmember-to-isolator
nuts. Tighten nuts to 10 N·m (86 in. lbs.) torque. If
isolator-to-radiator nuts had been removed, tighten
them to 5 N·m (47 in. lbs.) torque.
(5) Connect radiator upper and lower hoses.
(6) If equipped, connect automatic transmission
fluid cooler lines. If equipped with remote cooler,
attach cooler line to bracket at bottom of radiator.
(7) Install electric fan (if equipped) and shroud
assembly.. Insert alignment tabs at bottom of fan
shroud into slots in bracket at bottom of radiator.
Tighten mounting bolts to 3 N·m (31 in. lbs.) torque.
(8) Connect electric cooling fan electrical connector.
(9) Install power steering reservoir to fan shroud.
Fig. 35 Condenser-to-Radiator Mounting Brackets (10) Install grill.
1 – CONDENSER TO RADIATOR MOUNTING BRACKETS
(11) Connect battery negative cable.

Fig. 36 Radiator Removal/Installation—2.5L Engines

1 – ELECTRIC FAN/SHROUD ASSEMBLY 4 – RADIATOR
2 – UPPER CROSSMEMBER 5 – LOWER CROSSMEMBER
3 – ISOLATOR 6 – U-NUT

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 XJ COOLING SYSTEM 7 - 31
REMOVAL AND INSTALLATION (Continued)
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 11). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.

REMOVAL
(1) Disconnect battery negative cable.
(2) Observe the previous WARNINGS.
(3) Remove radiator pressure cap.
(4) For access to radiator draincock, remove radia-
tor grill mounting screws and remove grill. Refer to
Group 23, Body for procedures.
(5) Attach one end of a 24 inch long X 1/4 inch ID
hose to the radiator petcock (Fig. 38). Put the other
end into a clean container. Open petcock and drain
radiator.
(6) Disconnect electric cooling fan electrical con-
nector, if equipped.

Fig. 37 Radiator Alignment Dowels—Typical

1 – ALIGNMENT DOWEL
2 – RADIATOR
3 – AIR CONDITIONING CONDENSER
4 – GROMMET

(12) Fill cooling system with correct coolant. Refer

to the Coolant section of this group.
(13) Install pressure cap.
(14) Check and adjust automatic transmission
fluid level (if equipped).
(15) Start engine and visually check for leaks.

RADIATOR—4.0L
WARNING: DO NOT REMOVE THE CYLINDER Fig. 38 Radiator Petcock—Typical
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR 1 – RADIATOR PETCOCK
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
(7) If equipped, remove two electric cooling fan
CAN OCCUR.
mounting bolts. Lift cooling fan straight up until
DO NOT WASTE reusable coolant. If solution is alignment tabs at the bottom are clear of slots in
clean, drain coolant into a clean container for reuse. bracket at bottom of radiator (Fig. 39).
(8) Remove the two mechanical (non-electrical) fan
WARNING: CONSTANT TENSION HOSE CLAMPS shroud mounting bolts. Lift shroud straight up until
ARE USED ON MOST COOLING SYSTEM HOSES. alignment tabs at the bottom are clear of slots in
WHEN REMOVING OR INSTALLING, USE ONLY bracket at bottom of radiator (Fig. 39). Place shroud
TOOLS DESIGNED FOR SERVICING THIS TYPE OF over mechanical fan.
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER (9) If equipped, disconnect and plug automatic
6094) (Fig. 12). SNAP-ON CLAMP TOOL (NUMBER transmission fluid cooler lines. Quick Connect Fitting
HPC-20) MAY BE USED FOR LARGER CLAMPS. Release Tool 6935 may be needed. If equipped with
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- remote transmission cooler, remove line to cooler
ING CONSTANT TENSION CLAMPS. from bracket at bottom of radiator.

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 7 - 32 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 39 Radiator Removal/Installation—4.0L Engines

1 – (LHD) 6 – RADIATOR
2 – (RHD) 7 – LOWER CROSSMEMBER
3 – VISCOUS FAN SHROUD 8 – U-NUT
4 – ELECTRIC FAN MODULE 9 – UPPER CROSSMEMBER
5 – ISOLATOR

(10) Disconnect radiator upper and lower hoses (1) Lower radiator into engine compartment. Posi-
clamps. Disconnect radiator upper and lower hoses. tion alignment dowels into rubber grommets in radi-
(11) Mark the position of the hood latch striker on ator lower crossmember (Fig. 41)
the radiator crossmember and remove hood latch (2) If equipped with air conditioning, attach con-
striker. denser to radiator with mounting brackets (Fig. 40).
(12) Remove two radiator upper crossmember to (3) Install radiator upper crossmember and four
isolator nuts (Fig. 39). mounting bolts.
(13) Remove four radiator upper crossmember (4) Install radiator upper crossmember-to-isolator
bolts and remove upper crossmember. nuts. Tighten nuts to 10 N·m (86 in. lbs.) torque. If
(14) If equipped with air conditioning, separate isolator-to-radiator nuts had been removed, tighten
radiator from condenser by removing condenser-to-ra- them to 5 N·m (47 in. lbs.) torque.
diator mounting brackets (Fig. 40). (5) Install hood latch striker. Note previously
(15) Lift radiator straight up and out of engine marked position.
compartment taking care not to damage fins. (6) Connect radiator upper and lower hoses.
(7) If equipped, connect automatic transmission
INSTALLATION fluid cooler lines. Refer to Group 21, Transmissions
The radiator is supplied with two alignment dowels for procedures. If equipped with remote cooler, attach
(Fig. 41). They are located on the bottom tank and fit cooler line to bracket at bottom of radiator.
into rubber grommets in the radiator lower cross-
member.

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 XJ COOLING SYSTEM 7 - 33
REMOVAL AND INSTALLATION (Continued)
(8) Install electric cooling fan (if equipped). Insert
alignment tabs at bottom of fan shroud into slots in
bracket at bottom of radiator. Tighten mounting bolts
to 3 N·m (31 in. lbs.) torque.
(9) Connect electric cooling fan electrical connector.
(10) Install mechanical cooling fan shroud. Insert
alignment tabs at bottom of shroud into slots in
bracket at bottom of radiator. Tighten mounting bolts
to 3 N·m (31 in. lbs.) torque.
(11) Close radiator draincock.
(12) Install grill.
(13) Connect negative battery cable.
(14) Fill cooling system with correct coolant. Refer
to the Coolant section of this group.
(15) Install pressure cap.
(16) Check and adjust automatic transmission
fluid level (if equipped).

ELECTRIC COOLING FAN—2.5L

The electric fan module is only to be serviced as an
assembly.
Fig. 40 Condenser to Radiator Mounting Brackets—
4.0L Engine REMOVAL
1 – CONDENSER TO RADIATOR MOUNTING BRACKETS (1) Disconnect battery negative cable.
(2) Disconnect CRS hose from radiator filler neck
and pull through (remove) the shroud retaining
loops.
(3) Detach power steering reservoir from fan
shroud and lay aside.
(4) Remove the four viscous fan/drive assembly
mounting nuts from the water pump studs and
remove viscous fan assembly.
(5) Disconnect cooling fan electrical connector.
(6) Remove the four upper fan shroud to radiator
crossmember mounting screws (Fig. 42).
(7) Lift fan and shroud assy. from vehicle
(8) Detach fan harness from shroud.
(9) Remove four fan module to shroud phillips
head screws (Fig. 43) and remove module from
shroud.

INSTALLATION
(1) Position fan module in shroud so that the har-
ness exits the motor at the 12 o’clock postion (Fig.
43).
(2) Install and tighten fan module to shroud
screws to 3 N·m (31 in. lbs.).
(3) Route fan harness through the shroud and
Fig. 41 Radiator Alignment Dowels—Typical attach to shroud at correct position.
1 – ALIGNMENT DOWEL (4) Lower fan and shroud assembly into place,
2 – RADIATOR making sure the shroud alignment tabs rest in their
3 – AIR CONDITIONING CONDENSER corresponding lower radiator slots.
4 – GROMMET (5) Install upper fan shroud screws and tighten to
3 N·m (31 in. lbs.).

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 7 - 34 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 42 Fan Shroud Removal/Installation

1 – ELECTRIC FAN/SHROUD ASSEMBLY 4 – RADIATOR
2 – UPPER CROSSMEMBER 5 – LOWER CROSSMEMBER
3 – ISOLATOR 6 – U-NUT

(6) Connect fan electrical connector.

(7) Install power steering reservoir to shoud.
(8) Install viscous fan drive assy. to water pump
hub and tighten nuts to 27 N·m (20 ft. lbs.)
(9) Connect battery negative cable.

ELECTRIC COOLING FAN—4.0L

REMOVAL
The auxiliary cooling fan is attached to the radia-
tor upper crossmember behind the radiator.
(1) Remove the two fan mounting bolts from radi-
ator upper crossmember (Fig. 44).
(2) Disconnect the electric fan connector.
(3) Lift fan straight up and out of vehicle.

INSTALLATION
(1) Align lower retaining tabs of fan shroud with
Fig. 43 Fan Module Orientation and Mounting slots in bracket at bottom of radiator. Push fan down
1 – FAN MOTOR HARNESS AT 12 O’CLOCK POSITION into position.
2 – MOUNTING SCREWS (4) (2) Tighten the mounting bolts to 4 N·m (31 in.
3 – FAN CONNECTOR
lbs.) torque.

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 XJ COOLING SYSTEM 7 - 35
REMOVAL AND INSTALLATION (Continued)
(2) Insert block heater assembly into core hole
with element loop pointing Up.
(3) Seat block heater flush against block face.
Tighten mounting screw to 3.6 N·m (32 in. lbs.)
torque.
(4) Fill cooling system with coolant. Pressurize
system and inspect for leaks.
(5) Plug power cord into block heater. Route cord
away from moving parts, linkages and exhaust sys-
tem components. Secure cord in place with tie-straps.

Fig. 44 Auxiliary Cooling Fan—Remove/Install—

Typical
1 – ELECTRIC COOLING FAN
2 – MOUNTING BOLT
3 – ELECTRIC COOLING FAN CONNECTOR Fig. 45 Heater and Cord— 2.5L 4-Cylinder Engine
4 – MOUNTING BOLT 1 – POWER CORD LOCATION
2 – BLOCK HEATER

(3) Connect auxiliary cooling fan electrical connec-

tor. ENGINE ACCESSORY DRIVE BELTS
BLOCK HEATER
REMOVAL
Refer to correct illustration (Fig. 45) (Fig. 46) when
servicing block heater.

WARNING: DO NOT REMOVE THE CYLINDER

BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.

DO NOT WASTE reusable coolant. If solution is

clean, drain coolant into a clean container for reuse.
(1) Drain coolant from radiator and engine cylin-
der block.
Fig. 46 Heater and Cord—4.0L 6-Cylinder Engine
(2) Unplug power cord from block heater.
1 – POWER CORD LOCATION
(3) Loosen screw in center of block heater (Fig. 45)
2 – BLOCK HEATER
(Fig. 46).
(4) Remove block heater from cylinder block.
Correct drive belt tension is required to ensure
INSTALLATION optimum performance of the belt driven engine acces-
(1) Thoroughly clean the engine core hole and the sories. There are different types of adjustment
block heater seat. gauges for checking either a serpentine or a V-type
belt. Refer to the instructions supplied with the

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 7 - 36 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
gauge. Use the correct gauge when checking belt ten-
sion. Place gauge in the middle of the section of belt
being tested (between two pulleys) to check tension.
Do not allow the gauge (or gauge adapter) to contact
anything but the belt.

BELT SCHEMATICS
The belt routing schematics are published from the
latest information available at the time of publica-
tion. If anything differs between these schemat-
ics and the Belt Routing Label, use the
schematics on Belt Routing Label. This label is
located in the engine compartment.
Refer to (Fig. 47) (Fig. 48) (Fig. 49) (Fig. 50) for
proper belt routing on vehicles with conventional left
hand drive. Refer to (Fig. 51) (Fig. 52) for proper belt
routing on vehicles with right hand drive (RHD). Or,
refer to the Belt Routing Label located in the vehicle
engine compartment.
Fig. 48 Models with 2.5L Engine—Without A/C

Fig. 47 Models with 2.5L Engine—With A/C

Fig. 49 Models with 4.0L Engine—Without A/C—
BELT REPLACEMENT OR ADJUSTMENT—LEFT Except RHD
HAND DRIVE
Belt tension is adjusted at the power steering INSTALLATION
pump bracket and idler pulley assembly. (1) Check condition of all pulleys.
(1) Disconnect negative battery cable from battery.
(2) Loosen idler pulley bolt at the power steering CAUTION: When installing the serpentine acces-
bracket (Fig. 53). sory drive belt, the belt MUST be routed correctly. If
(3) Loosen adjusting bolt until belt can be removed not, the engine may overheat due to the water
from pulleys. pump rotating in the wrong direction. Refer to (Fig.
(4) Remove belt. 47) (Fig. 48) (Fig. 49) (Fig. 50) for correct belt rout-
ing.

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 XJ COOLING SYSTEM 7 - 37
REMOVAL AND INSTALLATION (Continued)

Fig. 52 Models With 4.0L Engine—Without A/C—

Fig. 50 Models With 4.0L Engine—With A/C—Except With RHD
RHD

Fig. 51 Models With 4.0L Engine—With A/C—With Fig. 53 Power Steering Pump Bracket and Idler
RHD Pulley
(2) Install new belt. 1 – ADJUSTING BOLT
(3) Using serpentine belt tension gauge, tighten 2 – IDLER PULLEY BOLT
adjusting bolt until belt reaches proper tension. Refer
to Belt Tension at the rear of this section for proper (3) Loosen upper alternator mounting nut.
belt tension. (4) Loosen adjusting bolt at upper alternator bracket
(4) After belt is tensioned correctly, tighten idler (Fig. 54) until belt can be removed from pulleys.
pulley bolt to 47 N·m (35 ft. lbs.) (5) Remove belt.
(5) After idler pulley has been tightened into posi-
tion, recheck belt tension. Adjust if necessary. INSTALLATION
(1) Check condition of all pulleys.
BELT REPLACEMENT OR ADJUSTMENT—RIGHT
HAND DRIVE (4.0L)
(1) Disconnect negative battery cable from battery.
(2) Loosen lower alternator mounting bolt and nut.

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 7 - 38 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 54 Generator Belt Tension Adjust Bracket

1 – TENSION ADJUSTMENT BOLT
2 – UPPER ALTERNATOR NUT Fig. 55 Water Pump Mounted Cooling Fan
1 – THERMAL VISCOUS FAN DRIVE
2 – (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
CAUTION: When installing the serpentine acces- 3 – (4) FAN HUB-TO-PUMP PULLEY STUDS
sory drive belt, the belt MUST be routed correctly. If 4 – WATER PUMP
not, the engine may overheat due to the water 5 – WATER PUMP PULLEY
pump rotating in the wrong direction. Refer to (Fig. 6 – FAN BLADE
51) (Fig. 52) for correct belt routing. 7 – (4) FAN HUB-TO-PUMP PULLEY NUTS

(2) Install new belt. drive should be removed from the vehicle as one
(3) Using serpentine belt tension gauge, tighten assembly.
adjusting bolt until belt reaches proper tension. Refer (4) Remove four fan hub mounting nuts (Fig. 55)
to Belt Tension at the rear of this section for proper (Fig. 56) and remove fan/viscous fan drive assembly
belt tension. from vehicle.
(4) Tighten alternator upper and lower mounting (5) After removing fan blade/viscous fan drive
bolts. assembly, do not place thermal viscous fan drive in
(5) After generator and adjust bracket have been horizontal position. If stored horizontally, silicone
tightened into position, recheck belt tension. Adjust if fluid in viscous fan drive could drain into its bearing
necessary. assembly and contaminate lubricant.

COOLING SYSTEM FANS INSTALLATION

(1) Assemble fan blade to viscous fan drive.
REMOVAL Tighten mounting bolts to 27 N·m (20 ft. lbs.) torque.
Some engines have the mechanical fan/viscous fan (2) Position mounting flange of fan blade/viscous
drive assembly mounted directly to the water pump fan drive assembly onto hub. Install four nuts and
hub (Fig. 55). It may also be mounted to a hub/bear- tighten to 24 N·m (18 ft. lbs.) torque. Tighten the
ing attached to an aluminum bracket on the right first two nuts 180 degrees apart. Then tighten last
front side of engine (Fig. 56). two nuts.
(1) Loosen but do not remove at this time, the four
fan hub mounting nuts (Fig. 55) (Fig. 56). CAUTION: When installing a serpentine accessory
(2) Remove accessory serpentine drive belt. Refer drive belt, the belt MUST be routed correctly. If not,
to Belt Service in the Engine Accessory Drive Belt the engine may overheat due to the water pump
section of this group. rotating in the wrong direction. Refer to appropriate
(3) Some models with certain engines may require Engine Accessory Drive Belt Schematic in this
the removal of the fan shroud to remove the viscous group for correct belt routing.
fan drive. The fan shroud and fan blade/viscous fan

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 XJ COOLING SYSTEM 7 - 39
REMOVAL AND INSTALLATION (Continued)

RADIATOR
CLEANING
Clean radiator fins With the engine cold, apply cold
water and compressed air to the back (engine side) of
the radiator to flush the radiator and/or A/C con-
denser of debris.

INSPECTION
The radiator cooling fins should be checked for
damage or deterioration. Inspect cooling fins to make
sure they are not bent or crushed, these areas result
in reduced heat exchange causing the cooling system
to operate at higher temperatures. Inspect the plastic
end tanks for cracks, damage or leaks.
Inspect the radiator neck for damage or distortion.

WATER PUMP
CLEANING
Clean the gasket mating surface. Use caution not
Fig. 56 Bracket Mounted Cooling Fan to damage the gasket sealing surface.
1 – WATER PUMP (2.5L ENGINE)
2 – HUB/BEARING (4.0L ENGINE) INSPECTION
3 – PULLEY NUTS
Inspect the water pump assembly for cracks in the
4 – PULLEY
housing, Water leaks from shaft seal, Loose or rough
5 – BRACKET
turning bearing or Impeller rubbing either the pump
body or timing chain case/cover.
(3) Install accessory drive belts. Tension belts to
specifications. Refer to the Specifications section at FAN BLADE
the end of this group.
CLEANING
VISCOUS FAN DRIVE REMOVAL/INSTALLATION Clean the fan blades using a mild soap and water.
Refer to Cooling System Fan for removal and Do not use an abrasive to clean the blades.
installation procedures of the viscous drive unit.
INSPECTION
Viscous Fan Drive Fluid Pump Out Requirement:
After installing a new viscous fan drive, bring the WARNING: DO NOT ATTEMPT TO BEND OR
engine speed up to approximately 2000 rpm and hold STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
for approximately two minutes. This will ensure SPECIFICATIONS.
proper fluid distribution within the drive.
CAUTION: If fan blade assembly is replaced
CLEANING AND INSPECTION because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
RADIATOR PRESSURE CAP components could have been damaged due to
excessive vibration.
CLEANING
Clean the radiator pressure cap using a mild soap (1) Remove fan blade assembly from viscous fan
and water only. drive unit (four bolts).
(2) Lay fan on a flat surface with leading edge fac-
INSPECTION ing down. With tip of blade touching flat surface,
Visually inspect the pressure valve gasket on the replace fan if clearance between opposite blade and
cap. Replace cap if the gasket is swollen, torn or surface is greater than 2.0 mm (.090 inch). Rocking
worn. Inspect the area around radiator filler neck for motion of opposite blades should not exceed 2.0 mm
white deposits that indicate a leaking cap. (.090 inch). Test all blades in this manner.

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 7 - 40 COOLING SYSTEM XJ
CLEANING AND INSPECTION (Continued)
(3) Inspect fan assembly for cracks, bends, loose
DESCRIPTION N·m Ft. In.
rivets or broken welds. Replace fan if any damage is
found. Lbs. Lbs.
Water Pump or Hub 27 20 —
COOLING SYSTEM HOSES Bearing—Nuts

INSPECTION Water Pump—Bolts 23 17 —

Inspect the hoses at regular intervals. Replace
hoses that are cracked, feel brittle when squeezed or SPECIAL TOOLS
swell excessively when the system is pressurized.
The use of molded replacement hoses is recom-
mended. When performing a hose inspection, inspect
COOLING
the radiator lower hose for proper position and con-
dition of the spring.

SPECIFICATIONS
BELT TENSION
Belt tension must be adjusted. Refer to the follow-
ing Belt Tension chart for specifications.

DESCRIPTION N·f Lbs. ft.

New Serpentine Belt* 800-900 180-200 Hose Clamp Tool—6094
Used Serpentine Belt 623-712 140-160
* Belt is considered new if it has been used 15
minetes or less.

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. In.

Lbs. Lbs.
Trans. Auxiliary Oil 2 — 18 Cooling System Pressure Tester—7700A
Cooler—Screws
Block Heater—Screw 4 — 20
Condenser-to-Radiator— 6 — 55
Bolts
Electric Cooling Fan—Bolts 3 — 31
Fan Blade Assy to Viscous
Fan Drive—Bolts 24 18 —
Fan Shroud—Bolts 3 — 31
3/8” Quick Connect Release Tool—6935
Isolator-to-Crossmember— 10 — 86
Nuts
Isolator-to-Radiator—Nuts 5 — 47
Radiator—Bolts
4.0L Engine 8 — 70
2.5L Engine 6 — 55
Thermostat Housing—Bolts 20 15 —
Viscous Fan Drive Assy. to

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 XJ COOLING SYSTEM 7-1

COOLING SYSTEM
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION SERVICE PROCEDURES

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 1 COOLANT LEVEL CHECK . . . . . . . . . . . . . . . . . . 18
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DRAINING COOLING SYSTEM . . . . . . . . . . . . . . 19
ENGINE ACCESSORY DRIVE BELT. . . . . . . . . . . . 3 REFILLING COOLING SYSTEM. . . . . . . . . . . . . . 19
COOLANT TANK . . . . . . . . . . . . . . . . . . . . . . . . . . 3 COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . 20
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOVAL AND INSTALLATION
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LOW COOLANT LEVEL SENSOR . . . . . . . . . . . . . 3 FAN BLADE REMOVAL . . . . . . . . . . . . . . . . . . . . 21
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . 22
PRESSURE/VENT CAP . . . . . . . . . . . . . . . . . . . . . 4 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
COOLANT PERFORMANCE . . . . . . . . . . . . . . . . . . 5 DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COOLING SYSTEM HOSES. . . . . . . . . . . . . . . . . . 5 AUTOMATIC BELT TENSIONER . . . . . . . . . . . . . 23
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . 6 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CLEANING AND INSPECTION
AUTOMATIC BELT TENSIONER . . . . . . . . . . . . . . 7 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING RADIATOR CLEANING . . . . . . . . . . . . . . . . . . . . 26
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . . . 8 FAN BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PRESSURE/VENT CAP . . . . . . . . . . . . . . . . . . . . 27
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . . 14 COOLING SYSTEM CLEANING/REVERSE
RADIATOR COOLANT FLOW CHECK . . . . . . . . . 15 FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TESTING COOLING SYSTEM FOR LEAKS . . . . . 15 SPECIFICATIONS
PRESSURE/VENT CAP . . . . . . . . . . . . . . . . . . . . 16 COOLING SYSTEM CAPACITY . . . . . . . . . . . . . . 28
LOW COOLANT LEVEL- AERATION . . . . . . . . . . 16 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BELT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 17 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 28

DESCRIPTION AND OPERATION COOLING SYSTEM COMPONENTS

The cooling system consists of:
COOLING SYSTEM • Charge Air Cooler
• Electric Cooling Fan
DESCRIPTION • An aluminum radiator with plastic side tanks
The cooling system regulates engine operating tem- • A radiator mounted fill vent valve
perature. It allows the engine to reach normal oper- • A separate pressurized coolant tank
ating temperature as quickly as possible, maintains • A threaded-on, pressure/vent cap mounted to the
normal operating temperature and prevents over- coolant tank
heating. • Cooling fan (mechanical)
The cooling system also provides a means of heat- • Thermal viscous fan drive
ing the passenger compartment. The cooling system • Fan shroud
is pressurized and uses a centrifugal water pump to • Thermostat
circulate coolant throughout the system. A water • Coolant
manifold collects coolant from the cylinder heads. A • Low coolant level sensor
separate and remotely mounted, pressurized coolant • Low coolant warning lamp
tank using a pressure/vent cap is used. • Coolant temperature gauge
• Water pump
• Hoses and hose clamps

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 7-2 COOLING SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
COOLANT ROUTING
For cooling system flow routing, refer to (Fig. 1)

Fig. 1 Coolant Flow—2.5L Diesel Engine—Typical

1 – PRESSURIZED COOLANT TANK 11 – THERMOSTAT
2 – PRESSURE/VENT CAP 12 – FILL VENT CAP
3 – HOSE 13 – WATER PUMP
4 – HEATER HOSES 14 – LOWER RADIATOR HOSE
5 – HEATER CORE 15 – VENT HOSE
6 – WATER MANIFOLD FITTING 16 – LARGER FITTING TO COOLANT TANK
7 – WATER MANIFOLD (TOP OF CYLINDER HEAD) 17 – HOSES
8 – ENGINE (TOP VIEW) 18 – HOSE
9 – UPPER RADIATOR HOSE 19 – ENGINE OIL COOLER
10 – RADIATOR 20 – LOW COOLANT LEVEL SENSOR

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 XJ COOLING SYSTEM 7-3
DESCRIPTION AND OPERATION (Continued)

RADIATOR
DESCRIPTION
The radiator used with the 2.5L diesel is con-
structed of a horizontal flow aluminum core with
plastic side tanks.

CAUTION: Plastic tanks, while stronger than brass,

are subject to damage by impact, such as
wrenches.

ENGINE ACCESSORY DRIVE BELT

DESCRIPTION
The accessory drive components are operated by a
single, crankshaft driven, serpentine drive belt. An
automatic belt tensioner is used to maintain correct
belt tension at all times. Fig. 2 Pressurized Coolant Tank
1 – LOW COOLANT LEVEL SWITCH
CAUTION: When installing a serpentine accessory 2 – COOLANT RESERVOIR
drive belt, the belt MUST be routed correctly. If not, 3 – LOW COOLANT LEVEL SWITCH HARNESS CONNECTOR
the engine may overheat due to water pump rotat-
ing in wrong direction.
A drain hose is attached to this tube. The water
pump seals is lubricated by the antifreeze in the cool-
COOLANT TANK ant mixture. No additional lubrication is necessary.
A rubber o-ring (instead of a gasket) is used as a
DESCRIPTION seal between the water pump and the water pump
A pressurized, plastic coolant tank is used with adapter (Fig. 3).
this cooling system (Fig. 2). The tank is located at A quick test to determine if the pump is working is
the right-rear side of the engine compartment and is to check if the heater warms properly. A defective
mounted as the highest point of the cooling system. water pump will not be able to circulate heated cool-
This allows any air or vapor exceeding the pressure/ ant through the heater hoses and the heater core.
vent cap rating to escape through the cap. Coolant
flows through the tank at all times during engine COOLANT
operation whether the engine is cold or at normal
operating temperature. The coolant tank is equipped DESCRIPTION
with a threaded pressure/vent cap. Refer to Pressure/ Coolant flows through the engine water jackets
Vent Cap for additional information. and cylinder heads absorbing heat produced by the
The low coolant level sensor is located near the engine during operation. The coolant carries heat to
bottom of the tank (Fig. 2). the radiator and heater core. Here it is transferred to
the ambient air passing through the radiator and
WATER PUMP heater core fins.

DESCRIPTION LOW COOLANT LEVEL SENSOR

A centrifugal water pump circulates coolant
through the water jackets, passages, water manifold, DESCRIPTION
radiator core, pressurized coolant tank, cooling sys- The low coolant level sensor checks for low coolant
tem hoses and heater core. The pump is driven from level in the coolant tank (Fig. 4).
the engine crankshaft by a drive belt. The water
pump is bolted to the water pump adapter (Fig. 3). OPERATION
The water pump adapter is bolted to the engine. When the coolant level gets low a signal will be
The water pump impeller is pressed onto the rear sent from this sensor to the powertrain control mod-
of a shaft that rotates in bearings pressed into the ule (PCM). When the PCM determines low coolant
housing. The bottom of the housing is equipped with level, the instrument panel mounted low coolant level
a small vent tube (Fig. 3) to allow seepage to escape. warning lamp is illuminated. The sensor is located

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 7-4 COOLING SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)

Fig. 4 Low Coolant Level Sensor

1 – PRESSURE/VENT CAP
2 – PRESSURIZED COOLANT TANK
3 – LOW COOLANT LEVEL SENSOR

the radiator. This provides quicker engine warmup

and overall temperature control.
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes other prob-
lems. These are: longer engine warmup time, unreli-
Fig. 3 Water Pump— Typical able warmup performance, increased exhaust
1 – O-RING SEAL emissions and crankcase condensation. This conden-
2 – WATER PUMP ADAPTER
sation can result in sludge formation.
3 – DRAIN HOSE
4 – WASHER
CAUTION: Do not operate an engine without a ther-
5 – PUMP MOUNTING BOLTS (4)
mostat, except for servicing or testing.
6 – WASHER
7 – WATER PUMP PULLEY BOLTS (3)
8 – WATER PUMP PULLEY
9 – VENT TUBE
PRESSURE/VENT CAP
10 – PUMP HUB
11 – WATER PUMP DESCRIPTION
The pressure/vent cap is threaded-on to the coolant
tank. This cap releases excess pressure at some point
on the front of the coolant tank (Fig. 4). For informa-
within a range of 90-117 kPa (13- 17 psi). The actual
tion, refer to Group 8E, Instrument Panel and
pressure relief point (in pounds) is labeled on top of
Gauges.
the cap (Fig. 5).
If this lamp is illuminated, it indicates the need for
service. OPERATION
The cooling system will operate at pressures up to
THERMOSTAT 103 kPa (15 psi). This results in a higher coolant
boiling point allowing increased radiator cooling
DESCRIPTION capacity. The cap (Fig. 5) contains a spring-loaded
A pellet-type thermostat controls the operating pressure relief valve. This valve opens when system
temperature of the engine by controlling the amount pressure reaches approximately 103 kPa (15 psi).
of coolant flow to the radiator. When the engine is cooling down, vacuum is
formed within the cooling system. To prevent collapse
OPERATION of the radiator and coolant hoses from this vacuum, a
The thermostat starts to open at 80°C (176°F). vacuum valve is used within the cap. This valve pre-
Above this temperature, coolant is allowed to flow to vents excessive pressure differences from occurring

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 XJ COOLING SYSTEM 7-5
DESCRIPTION AND OPERATION (Continued)
ponents may be severely damaged by corrosion.
Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7 deg. C (-90 deg. F). A
higher percentage will freeze at a warmer tempera-
ture. Also, a higher percentage of antifreeze can
cause the engine to overheat because the specific
heat of antifreeze is lower than that of water.

100 Percent Ethylene-Glycol—Should Not Be Used in

DaimlerChrysler Corporation Vehicles
Use of 100 percent ethylene-glycol will cause for-
mation of additive deposits in the system, as the cor-
rosion inhibitive additives in ethylene-glycol require
the presence of water to dissolve. The deposits act as
insulation, causing temperatures to rise to as high as
149 deg. C (300) deg. F). This temperature is hot
enough to melt plastic and soften solder. The
increased temperature can result in engine detona-
tion. In addition, 100 percent ethylene-glycol freezes
at 22 deg. C (-8 deg. F ).

Propylene-glycol Formulations—Should Not Be Used in

DaimlerChrysler Corporation Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications. It’s overall effec-
tive temperature range is smaller than that of ethyl-
ene-glycol. The freeze point of 50/50 propylene-glycol
Fig. 5 Coolant Tank Pressure/Vent Cap and water is -32 deg. C (-26 deg. F). 5 deg. C higher
1 – RELEASE PRESSURE than ethylene-glycol’s freeze point. The boiling point
2 – CAP COVER (protection against summer boil-over) of propylene-
3 – SPRING glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi),
4 – GASKET compared to 128 deg. C (263 deg. F) for ethylene-gly-
5 – RUBBER VACUUM VALVE col. Use of propylene-glycol can result in boil-over or
6 – PRESSURE VALVE freeze-up in Chrysler vehicles, which are designed for
ethylene-glycol. Propylene glycol also has poorer heat
between the closed cooling system and the atmo- transfer characteristics than ethylene glycol. This
sphere. If the vacuum valve is stuck shut, the radia- can increase cylinder head temperatures under cer-
tor and/or cooling system hoses will collapse on cool- tain conditions.
down.
Propylene-glycol/Ethylene-glycol Mixtures—Should Not Be
NOTE: Do not use any type of tool when tightening Used in DaimlerChrysler Corporation Vehicles
the cap. Hand tighten only. Propylene-glycol/ethylene-glycol Mixtures can
cause the destabilization of various corrosion inhibi-
tors, causing damage to the various cooling system
COOLANT PERFORMANCE components. Also, once ethylene-glycol and propy-
lene-glycol based coolants are mixed in the vehicle,
DESCRIPTION conventional methods of determining freeze point will
The required ethylene-glycol (antifreeze) and water not be accurate. Both the refractive index and spe-
mixture depends upon the climate and vehicle oper- cific gravity differ between ethylene glycol and propy-
ating conditions. The recommended mixture of 50/50 lene glycol.
ethylene-glycol and water will provide protection
against freezing to -37 deg. C (-35 deg. F). The anti- COOLING SYSTEM HOSES
freeze concentration must always be a minimum of
44 percent, year-round in all climates. If percentage DESCRIPTION
is lower than 44 percent, engine parts may be Rubber hoses route coolant to and from the radia-
eroded by cavitation, and cooling system com- tor, and heater core.

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 7-6 COOLING SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
The radiator lower hose is spring-reinforced to pre-
vent collapse from water pump suction at high
engine speeds.

WARNING: CONSTANT TENSION HOSE CLAMPS

ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP (Fig. 6). ALWAYS WEAR SAFETY GLASSES
WHEN SERVICING CONSTANT TENSION CLAMPS.

Fig. 7 Clamp Number/Letter Location

1 – TYPICAL CONSTANT TENSION HOSE CLAMP
2 – CLAMP NUMBER/LETTER LOCATION
3 – TYPICAL HOSE
Fig. 6 Hose Clamp Tool
1 – HOSE CLAMP TOOL 6094
VISCOUS FAN DRIVE
2 – HOSE CLAMP

DESCRIPTION
CAUTION: A number or letter is stamped into the The thermal viscous fan drive (Fig. 8) is a silicone-
tongue of constant tension clamps (Fig. 7). If fluid-filled coupling. It connects the fan blade assem-
replacement is necessary, use only an original bly to the fan pulley.
equipment clamp with matching number or letter.

Inspect the hoses at regular intervals. Replace

hoses that are cracked, feel brittle when squeezed, or
swell excessively when the system is pressurized.
For all vehicles: Be sure that hoses are positioned
with sufficient clearance. Check clearance from
exhaust manifolds and pipe, fan blades, drive belts
and sway bars. Improperly positioned hoses can be
damaged, resulting in coolant loss and engine over-
heating.
Ordinary worm gear type hose clamps (when
equipped) can be removed with a straight screw-
driver or a hex socket. To prevent damage to Fig. 8 Viscous Fan Drive
hoses or clamps, the hose clamps should be 1 – MOUNTING NUT TO FAN PULLEY SHAFT
tightened to 4 N·m (34 in. lbs.) torque. Do not 2 – THERMOSTATIC SPRING
over tighten hose clamps. 3 – VISCOUS FAN DRIVE
When performing a hose inspection, inspect the
radiator lower hose for proper position and condition
OPERATION
of the internal spring.
The coupling allows the fan to be driven in a nor-
mal manner. This is done at low engine speeds while
limiting the top speed of the fan to a predetermined
maximum level at higher engine speeds. A bimetallic

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 XJ COOLING SYSTEM 7-7
DESCRIPTION AND OPERATION (Continued)
coil spring is located on the front face. This spring An automatic belt tensioner is used to maintain
coil reacts to the temperature of the radiator dis- correct belt tension at all times. Do not attempt to
charge air. It engages the viscous fan drive for higher check belt tension with a belt tension gauge on vehi-
fan speed if the air temperature from the radiator cles equipped with an automatic belt tensioner.
rises above a certain point. Until additional engine
cooling is necessary, the fan will remain at a reduced AUTOMATIC BELT TENSIONER
rpm regardless of engine speed.
The viscous fan drive will only engage when suffi- DESCRIPTION
cient heat is present. This is when the air flowing Drive belt tension is controlled by a spring loaded
through the radiator core causes a reaction from the automatic belt tensioner located below and to the
bimetallic coil. It then increases fan speed to provide front of the engine oil filter (Fig. 9).
the necessary additional engine cooling.
Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again
reacts and the fan speed is reduced to the previous
disengaged speed.

CAUTION: Some engines equipped with serpentine

drive belts have reverse rotating fans and viscous
fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
engine overheating.

NOISE

NOTE: It is normal for fan noise to be louder (roar-

ing) when:

• The underhood temperature is above the engage-

ment point for the viscous drive coupling. This may
occur when ambient (outside air temperature) is very
high.
• Engine loads and temperatures are high such as Fig. 9 Automatic Belt Tensioner Assembly
when towing a trailer. 1 – FAN PULLEY
• Cool silicone fluid within the fan drive unit is 2 – IDLER PULLEY
being redistributed back to its normal disengaged 3 – IDLER PULLEY
(warm) position. This can occur during the first 15 4 – GENERATOR
seconds to one minute after engine start-up on a cold 5 – POWER STEERING PUMP
engine. 6 – DRIVE BELT
7 – CRANKSHAFT PULLEY
LEAKS 8 – AUTOMATIC BELT TENSIONER

Viscous fan drive operation is not affected by small

oil stains near the drive bearing. If leakage appears WARNING: BECAUSE OF HIGH SPRING PRES-
excessive, replace the fan drive unit. SURE, DO NOT ATTEMPT TO DISASSEMBLE THE
AUTOMATIC BELT TENSIONER. UNIT IS SERVICED
BELT TENSION AS AN ASSEMBLY.

DESCRIPTION
Correct accessory drive belt tension is required to
be sure of optimum performance of belt driven engine
accessories. If specified tension is not maintained,
belt slippage may cause; engine overheating, lack of
power steering assist, loss of air conditioning capac-
ity, reduced generator output rate and greatly
reduced belt life.

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 7-8 COOLING SYSTEM XJ

DIAGNOSIS AND TESTING (3) RECENT SERVICE OR ACCIDENT REPAIR:

Determine if any recent service has been per-
PRELIMINARY CHECKS formed on vehicle that may effect cooling system.
This may be:
ENGINE COOLING SYSTEM OVERHEATING • Engine adjustments (incorrect timing)
Establish what driving conditions caused the com- • Slipping engine accessory drive belt
plaint. Abnormal loads on the cooling system such as • Brakes (possibly dragging)
the following may be the cause: • Changed parts (incorrect water pump)
(1) PROLONGED IDLE, VERY HIGH AMBIENT • Reconditioned radiator or cooling system refill-
TEMPERATURE, SLIGHT TAIL WIND AT IDLE, ing (possibly under filled or air trapped in system).
SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED
NOTE: If investigation reveals none of the previous
OR STEEP GRADES.
items as a cause for an engine overheating com-
Driving techniques that avoid overheating are:
plaint, refer to following Cooling System Diagnosis
• Idle with A/C off when temperature gauge is at
charts.
end of normal range.
• Increasing engine speed for more air flow is rec- These charts are to be used as a quick-reference
ommended. only. Refer to the group text for information.
(2) TRAILER TOWING:
Consult Trailer Towing section of owners manual.
Do not exceed limits.

COOLING SYSTEM DIAGNOSIS–DIESEL ENGINE

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE 1. Diesel engines, due to their inherent 1. The low gauge reading may be
READS LOW efficiency are slower to warm up than normal. Refer to thermostats in the
gasoline powered engines, and will manual text for information. See
operate at lower temperatures when the Thermostat Diagnosis - Diesel
vehicle is unloaded. Engine.
2. Is the temperature gauge connected to 2. Check, the engine temperature
the temperature gauge coolant sensor on sensor connector in the engine
the engine? compartment. Refer to Group 8E.
Repair as necessary.
3. Is the temperature gauge operating 3. Check gauge operation. Refer to
OK? Group 8E. Repair as necessary.
4. Coolant level low in cold ambient 4. Check coolant level in the
temperatures accompanied with poor coolant tank. Inspect system for
heater performance. leaks. Repair leaks as necessary.
Refer to the Coolant section of the
manual text for WARNINGS and
precautions before removing the
pressure cap.
5. Improper operation of internal heater 5. Inspect heater and repair as
doors or heater controls. necessary. Refer to Group 24,
Heating and Air Conditioning for
procedures.

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 XJ COOLING SYSTEM 7-9
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE 1. Trailer is being towed, a steep hill is 1. This may be a temporary
READS HIGH. COOLANT MAY being climbed, vehicle is operated in condition and repair is not
OR MAY NOT BE LOST OR slow moving traffic, or engine is being necessary. Turn off the air
LEAKING FROM COOLING idled with very high ambient (outside) conditioning and attempt to drive
SYSTEM temperatures and the air conditioning is the vehicle without any of the
on. Higher altitudes could aggravate previous conditions. Observe the
these conditions. temperature gauge. The gauge
should return to the normal range. If
the gauge does not return to normal
range, determine the cause for
overheating and repair. Refer to
POSSIBLE CAUSES (numbers 2
through 16).
2. Is temperature gauge reading 2. Check gauge. Refer to Group
correctly? 8E. Repair as necessary.
3. Coolant low in coolant tank and 3. Check for coolant leaks and
radiator? repair as necessary. Refer to
Testing Cooling System For Leaks
in this group.
4. Pressure cap not installed tightly. If 4. Tighten cap.
cap is loose, boiling point of coolant will
be lowered. Also refer to the following
step 5.
5. Poor seals at pressure/vent cap. 5. (a) Check condition of cap and
cap seals. Refer to Pressure/Vent
Cap.
(b) Check condition of coolant tank
filler neck. Make sure it does not
leak pressure.
6. Freeze point of antifreeze not correct. 6. Check antifreeze. Refer to
Mixture may be too rich. Coolant section of this group. Adjust
antifreeze -to-water ratio as
required.

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 7 - 10 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE 7. Coolant not flowing through system. 7. Check for coolant flow in coolant
READS HIGH. COOLANT MAY tank with engine warm and
OR MAY NOT BE LOST OR thermostat open. Coolant should be
LEAKING FROM COOLING observed flowing through tank. If
SYSTEM - CONT. flow is not observed, determine
reason for lack of flow and repair as
necessary.
8. Radiator or A/C condenser fins are 8. Clean insects or debris. Refer to
dirty or clogged. Radiator Cleaning in this group.
9. Radiator core is corroded or plugged. 9. Have radiator re-cored or
replaced.
10. Aftermarket A/C installed without 10. Install proper A/C condenser.
proper A/C condenser.
11. Dragging brakes. 11. Check and correct as
necessary. Refer to Group 5,
Brakes in the manual text.
12. Non-factory bug screen is being used 12. Only a factory approved screen
reducing airflow. may be used.
13. Thermostat partially or completely 13. Check thermostat operation and
shut. This is more prevalent on high replace as necessary. Refer to
mileage vehicles. Thermostats in this group.
14. Thermal viscous fan drive not 14. Check fan drive operation and
operating properly. replace if necessary. Refer to
Viscous Fan Drive in this group.
15. Cylinder head gasket leaking. 15. Check for cylinder head gasket
leaks. Refer to Testing Cooling
System For Leaks in this group. For
repair, refer to Group 9, Engines.
16. Heater core leaking. 16. Check heater core for leaks.
Refer to Group 24, Heating and Air
Conditioning. Repair as necessary.

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 XJ COOLING SYSTEM 7 - 11
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

TEMPERATURE GAUGE 1. During cold weather operation, with 1. A normal condition. No correction
READING IS INCONSISTENT the heater blower in the high position, is necessary.
(FLUCTUATES, CYCLES OR the gauge reading may drop slightly.
IS ERRATIC) Fluctuation is also influenced by loads,
outside temperature and extended idle
time with diesel engines.
2. Temperature gauge or engine 2. Check operation of gauge and
mounted gauge sensor defective or repair if necessry. Refer to Group
shorted. Also, corroded or loose wiring in 8E, Instrument Panel And Gauges.
this circuit.
3. Gauge reading rises when vehicle is 3. A normal condition. No correction
brought to a stop after heavy use (engine is necessary. Gauge reading should
still running). return to normal range after vehicle
is driven.
4. Gauge reading high after restarting a 4. A normal condition. No correction
warmed-up (hot) engine. is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
5. Coolant level low in coolant tank (air 5. Check and correct coolant leaks.
will build up in the cooling system Refer to Testing Cooling System
causing the thermostat to open late). For Leaks in this group.
6. Cylinder head gasket leaking allowing 6. (a) Check for cylinder head
exhaust gas to enter cooling system gasket leaks with a commercially
causing thermostat to open late. available Block Leak Tester. Repair
as necessary.

(b) Check for coolant in the engine

oil. Inspect for white steam emitting
from exhaust system. Repair as
necessary.
7. Water pump impeller loose on shaft. 7. Check water pump and replace
as necessary. Refer to Water
Pumps in this group.
8. Loose accessory drive belt (water 8. Refer to Engine Accessory Drive
pump slipping). Belts in this group. Check and
correct as necessary.
9. Air leak on the suction side of water Locate leak and repair as
pump allows air to build up in cooling necessary.
system causing thermostat to open late.

PRESSURE CAP IS 1. Pressure relief valve in pressure/vent 1. Check condition of pressure/vent

BLOWING OFF STEAM cap is defective. cap and cap seals. Refer to
AND/OR COOLANT. Pressure/Vent Caps in this group.
TEMPERATURE GAUGE Replace cap as necessary.
READING MAY BE ABOVE
NORMAL BUT NOT HIGH. 2. Major head gasket leak or cracked 2. Refer to Engine group and repair
COOLANT LEVEL MAY BE cylinder head. as necessary.
HIGH IN COOLANT TANK.

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 7 - 12 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
GROUND WITHOUT system hoses, water pump or engine. necessary. Refer to Testing Cooling
PRESSURE CAP BLOWOFF. System For Leaks in this group.
GAUGE IS READING HIGH
OR HOT

HOSE OR HOSES COLLAPSE 1. Vacuum created in cooling system on 1. Cap relief valve stuck. Refer to
WHEN ENGINE IS COOLING engine cool-down is not being relieved Pressure/Vent Cap in this group.
through pressure/vent cap. Replace if necessary.

NOISY FAN 1. Fan blades loose. 1. Replace fan blade assembly.

Refer to Cooling Sytem Fans in this
group.

2. Fan blades striking a surrounding 2. Locate point of fan blade contact

object. and repair as necessary.
3. Air obstructions at radiator or air 3. Remove obstructions and/or
conditioning condenser. clean debris or insects from radiator
or A/C condenser.
4. Thermal viscous fan drive has 4. Replace fan drive. Bearing is not
defective bearing. serviceable. Refer to Viscous Fan
Drive in this group.
5. A certain amount of fan noise (roaring) 5. Refer to Viscous Fan Drive in
may be evident on models equipped with this group for an explanation of
a thermal viscous fan drive. Some of this normal fan noise.
noise is normal.

INADEQUATE AIR 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean
CONDITIONER restricted, obstructed or dirty (insects, as necessary. Refer to Radiator
PERFORMANCE (COOLING leaves etc.). Cleaning in this group.
SYSTEM SUSPECTED) 2. Thermal viscous fan drive is 2. Refer to Viscous Fan Drive for
freewheeling. diagnosis. Repair as necessary.
3. Engine is overheating (heat may be 3. Correct overheating condition.
transferred from radiator to A/C Refer to text in Group 7, Cooling.
condenser. High underhood temperatures
due to engine overheating may also
transfer heat to A/C components).
4. The cooling system is equipped with 4. Check for missing or damaged
air seals at the radiator and/or A/C air seals and repair as necessary.
condenser. If these seals are missing or
damaged, not enough air flow will be
pulled through the radiator and A/C
condenser.

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 XJ COOLING SYSTEM 7 - 13
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

INADEQUATE HEATER 1. Diesel engines, due to their inherent 1. The low gauge reading may be
PERFORMANCE. MAY BE efficiency are slower to warm up than normal. Refer to Thermostats in the
ACCOMPANIED BY LOW gasoline powered engines, and will manual text for information. See
GAUGE READING operate at lower temperatures when the Thermostat Diagnosis - Diesel
vehicle is unloaded. Engine.

2. Coolant level low. 2. Refer to Testing Cooling System

For Leaks in the manual text.
Repair as necessary.
3. Obstructions in heater hose fittings at 3. Remove heater hoses at both
engine. ends and check for obstructions.
Repair as neccessary.
4. Heater hose kinked. 4. Located kinked area and repair
as necessary.
5. Water pump is not pumping water to 5. Refer to Water Pumps in this
heater core. When the engine is fully group. Repair as necessary. If a
warmed up, both heater hoses should be slipping belt is detected, refer to
hot to the touch. If only one of the hoses Engine Accessory Drive Belts in this
is hotk the water pump may not be group. Repair as necessary.
operating correctly. The accessory drive
belt may also be slipping causing poor
water pump operation.

HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and
certain drive line components. One or replace or repair as necessary.
more of these shields may be missing.

2. Is temperature gauge reading above 2. Refer to the previous

the normal range? Temperature Gauge Reads High in
these Diagnosis Charts. Repair as
necessary.
3. Is cooling fan operating correctly? 3. Refer to Cooling System Fan in
this group for diagnosis. Repair as
necessary.
4. Has undercoating been applied to any 4. Clean undercoating as
unnecessary component? necessary.

STEAM IS COMING FROM 1. During wet weather, moisture (snow, 1. Occasional steam emitting from
FRONT OF VEHICLE NEAR ice or rain condensation) on the radiator this area is normal. No repair is
GRILL AREA WHEN will evaporate when the thermostat necessary.
WEATHER IS WET, ENGINE opens. This opening allows heated water
IS WARMED UP AND into the radiator. When the moisture
RUNNING, AND VEHICLE IS contacts the hot radiator, steam may be
STATIONARY. emitted. This usually occurs in cold
TEMPERATURE GAUGE IS IN weather with no fan or airflow to blow it
NORMAL RANGE away.

COOLANT COLOR 1. Coolant color is not necessarily an 1. Refer to Coolant in this group for
indication of adequate corrosion or antifreeze tests. Adjust antifreeze-
temperatue protection. Do not rely on to-water ratio as necessary.
coolant color for determining condition of
coolant.

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 7 - 14 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

COOLANT LEVEL CHANGES 1. Level changes are to be expected as 1. A normal condition. No repair is
IN COOLANT TANK. coolant volume fluctuates with engine necessary.
TEMPERATURE GAUGE IS IN temperature. If the level in the tank was
NORMAL RANGE between the HOT and COLD marks at
normal engine operating temperature, the
level should return to within that range
after operation at elevated temperatures.

THERMOSTAT VISCOUS FAN DRIVE

DIAGNOSIS TESTING
Diesel engines, due to their inherent efficiency are If the fan assembly free-wheels without drag (the
slower to warm up than gasoline powered engines, fan blades will revolve more than five turns when
and will operate at lower temperatures when the spun by hand), replace the fan drive. This spin test
vehicle is unloaded. Because of this, lower tempera- must be performed when the engine is cool.
ture gauge readings for diesel versus gasoline The cooling system must be in good condition. This
engines may, at times be normal. is checked prior to performing the following test. It
also will ensure against excessively high coolant tem-
TESTING perature.

NOTE: The DRB scan tool cannot be used to mon- WARNING: BE SURE OF ADEQUATE FAN BLADE
itor engine coolant temperature on the diesel CLEARANCE BEFORE DRILLING.
engine.
(1) Drill a 3.12-mm (1/8-in) diameter hole in the
(1) To determine if the thermostat is defective, it top center of the fan shroud.
must be removed from the vehicle. Refer to Thermo- (2) Obtain a dial thermometer with an 8 inch stem
stats for removal and installation procedures. (or equivalent). It should have a range of -18°-to-
(2) After the thermostat has been removed, exam- 105°C (0°-to-220° F). Insert thermometer through the
ine the thermostat and inside of thermostat housing hole in the shroud. Be sure that there is adequate
for contaminants. If contaminants are found, the clearance from the fan blades.
thermostat may already be in a “stuck open” position. (3) Block the air flow through the radiator. Secure
Flush the cooling system before replacing thermostat. a sheet of plastic in front of the radiator (or air con-
Refer to Cooling System Cleaning/Reverse Flushing ditioner condenser). Use tape at the top to secure the
in this group for additional information. plastic and be sure that the air flow is blocked.
(3) Place the thermostat into a container filled (4) Be sure that the air conditioner (if equipped) is
with water. turned off.
(4) Place the container on a hot plate or other suit-
able heating device. WARNING: USE EXTREME CAUTION WHEN THE
(5) Place a commercially available radiator ther- ENGINE IS OPERATING. DO NOT STAND IN A
mometer into the water. DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
(6) Apply heat to the water while observing the HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
thermostat and thermometer. NOT WEAR LOOSE CLOTHING.
(7) When the water temperature reaches 80°C
(176°F) the thermostat should start to open (valve (5) Start the engine and operate at 2400 rpm.
will start to move). If the valve starts to move before Within ten minutes the air temperature (indicated on
this temperature is reached, it is opening too early. the dial thermometer) should be up to 93° C (200° F).
Replace thermostat. The thermostat should be fully Fan drive engagement should have started to occur
open (valve will stop moving) at approximately 89°C at between 82° to 91° C (180° to 195° F). Engage-
(192°F). If the valve is still moving after the water ment is distinguishable by a definite increase in fan
temperature reaches this temperature, it is opening flow noise (roaring).
too late. Replace thermostat. (6) When the air temperature reaches 93° C (200°
(8) If the valve refuses to move at any time, F), remove the plastic sheet. Fan drive disengage-
replace thermostat. ment should have started to occur at between 57° to
79° C (135° to 175° F). A definite decrease of fan

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 XJ COOLING SYSTEM 7 - 15
DIAGNOSIS AND TESTING (Continued)
flow noise (roaring) should be noticed. If not, replace
the defective viscous fan drive unit.

RADIATOR COOLANT FLOW CHECK

There is coolant flow through the coolant tank (bot-
tle) before and after the thermostat opens.

CAUTION: Do not remove the vent valve to insert a

temperature gauge thought the opening, coolant
will spill out of the system and the engine will not
be filled with coolant up to the heads. Major dam-
age could happen if you run the engine in this con-
dition.

TESTING COOLING SYSTEM FOR LEAKS

ULTRAVIOLET LIGHT METHOD
All Jeepy models have a leak detection additive
added to the cooling system before they leave the fac-
tory. The additive is highly visible under ultraviolet
light (black light). If the factory original coolant has
been drained, pour one ounce of additive into the Fig. 10 Leak Detection Using Black Light—Typical
cooling system. The additive is available through the 1 – TYPICAL BLACK LIGHT TOOL
parts department. Place the heater control unit in
HEAT position. Start and operate the engine until
the radiator upper hose is warm to the touch. Aim Attach one of the adapters to the coolant pressure
the commercially available black light tool at the tank neck. Adapter must first be threaded to tank.
components to be checked. If leaks are present, the Attach pressure tester to adapter.
black light will cause the additive to glow a bright
green color.
The black light can be used along with a radiator
pressure tester to determine if any external leaks
exist (Fig. 10).

PRESSURE TESTER METHOD

WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE SERIOUS INJURY BY SCALDING. NEVER
REMOVE THE PRESSURE/VENT CAP OR PRES-
SURE TESTER WHEN THE COOLING SYSTEM IS
HOT OR UNDER PRESSURE!

Allow the engine to cool sufficiently so that the

system is not under pressure and carefully remove
the pressure/vent cap from the filler neck. Warm the Fig. 11 Typical Pressure Tester Adapters
engine with the pressure/vent cap off to normal oper- 1 – TO PRESSURE TESTER
ating temperature. With the engine turned off attach 2 – TO CAP
the cooling system pressure tester and test the sys- 3 – TO TANK
tem as described below.
Recheck the system cold if the cause of coolant loss Operate the tester pump to apply 103 kPa (15 psi)
is not located during warm engine examination. pressure to the system. If the hoses enlarge exces-
A two-piece, threaded adapter set (Fig. 11) must be sively or bulge while testing, replace as necessary.
used to adapt a standard pressure-type tester (Fig. Observe the gauge pointer and determine the condi-
12) when testing either the coolant tank or pressure tion of the cooling system according to the following
cap. Use Kent-Mooret adapter set number criteria:
J-24460-92 or Snap-Ont numbers TA-32 and TA-33.

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 7 - 16 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)
result of a faulty cylinder head gasket or crack in the
engine. Repair as necessary.

WARNING: DO NOT ALLOW PRESSURE TO

EXCEED 117 KPA (17 PSI). TURN THE ENGINE OFF.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.

If there is no immediate pressure increase, pump

the pressure tester until the indicated pressure is
within the system range. Vibration of the gauge
pointer indicates compression or combustion leakage
into the cooling system.

PRESSURE/VENT CAP
PRESSURE TESTING
Remove the cap from the coolant tank. Be sure
that sealing surfaces are clean. Moisten rubber gas-
ket with water.
Fig. 12 Typical Cooling System Pressure Tester A two-piece, threaded adapter set (Fig. 11) must be
1 – PRESSURE CAP used to adapt a standard pressure-type tester (Fig.
2 – TYPICAL COOLING SYSTEM PRESSURE TESTER 12) when testing either the coolant tank or pressure
cap. Use Kent-Mooret adapter set number
• Holds Steady: If the pointer remains steady for J-24460-92 or Snap-Ont numbers TA-32 and TA-33.
two minutes, there are no serious coolant leaks in Attach the adapter to the cap. Adapter must first be
the system. However, there could be an internal leak threaded to cap. Attach pressure tester to adapter.
that does not appear with normal system test pres- Operate the tester pump and observe the gauge
sure. Inspect for interior leakage or do the Internal pointer at its highest point. The cap release pressure
Leakage Test. Do this if it is certain that coolant is should be 90-to-117 kPa (13-to-17 psi). The cap is sat-
being lost and no leaks can be detected. isfactory when the pressure holds steady. It is also
• Drops Slowly: Shows a small leak or seepage is good if it holds pressure within the 90-to-117 kPa
occurring. Examine all connections for seepage or (13-to-17 psi) range for 30 seconds or more. If the
slight leakage with a flashlight. Inspect the radiator, pointer drops quickly, replace the cap.
hoses, gasket edges and heater. Seal any small leak
holes with a Sealer Lubricant or equivalent. Repair CAUTION: Radiator pressure testing tools are very
leak holes and reinspect the system with pressure sensitive to small air leaks, which will not cause
applied. cooling system problems. A pressure cap that does
• Drops Quickly: Shows that a serious leakage is not have a history of coolant loss should not be
occurring. Examine the system for serious external replaced just because it leaks slowly when tested
leakage. If no leaks are visible, inspect for internal with this tool. Add water to tool. Turn tool upside
leakage. Large radiator leak holes should be repaired down and recheck pressure/vent cap to confirm
by a reputable radiator repair shop. that cap needs replacement.

INTERNAL LEAKAGE INSPECTION

Remove the oil pan drain-plug and drain a small
LOW COOLANT LEVEL- AERATION
amount of engine oil. Coolant, being heavier will
CAUTION: Engine damage could occur if the cool-
drain first, or operate engine to churn oil, then exam-
ant level is allowed to get this low. Always ensure
ine dipstick for water globules. Operate the engine
that the coolant level is not below the full mark. For
without the pressure/vent cap on the coolant tank
better visibility of the coolant level use a shop lamp
until thermostat opens.
to light the pressurized coolant tank and look
Attach a radiator pressure tester to the tank filler
through the pressurized coolant tank.
neck. If pressure builds up quickly, a leak exists as

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 XJ COOLING SYSTEM 7 - 17
DIAGNOSIS AND TESTING (Continued)

BELT DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib to rib (Fig. 13), are considered normal.
These are not a reason to replace the belt. However,
cracks running along a rib (not across) are not nor-
mal. Any belt with cracks running along a rib must
be replaced (Fig. 13). Also replace the belt if it has
excessive wear, frayed cords or severe glazing.
Refer to the Serpentine Drive Belt Diagnosis chart
for further belt diagnosis.

Fig. 13 Serpentine Belt Wear Patterns

1 – NORMAL CRACKS BELT OK
2 – NOT NORMAL CRACKS RELACE BELT

CONDITION POSSIBLE CAUSES CORRECTION

RIB CHUNKING (ONE OR MORE 1. Foreign objects imbedded in 1. Remove foreign objects from
RIBS HAS SEPARATED FROM pulley grooves. pulley grooves. Replace belt.
BELT BODY
2. Installation damage. 2. Replace belt.

RIB OR BELT WEAR 1. Pulley(s) misaligned. 1. Align pulley(s).

2. Abrasive environment. 2. Clean pulley(s). Replace belt if

necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove 4. Replace pulley.
tips.
5. Rubber deteriorated. 5. Replace belt.

LONGITUDINAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt.
(CRACKS BETWEEN TWO RIBS) groove.
2. Pulley groove tip has worn away 2. Replace belt.
rubber to tensile member

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 7 - 18 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

BELT SLIPS 1. Belt slipping because of 1. Replace automatic belt tensioner.

insufficient tension.

2. Incorrect belt. 2. Replace belt.

3. Belt or pulley subjected to 3. Replace belt and clean pulleys.
substance (belt dressing, oil,
ethylene glycol) that has reduced
friction.
4. Driven component bearing 4. Replace faulty component
failure. bearing.
5. Belt glazed and hardened from 5. Replace belt.
heat and exessive slippage.

88GROOVE JUMPING” (BELT 1. Belt tension either too high or too 1. Replace automatic belt tensioner.
DOES NOT MAINTAIN CORRECT low.
POSITION ON PULLEY)
2. Incorrect belt. 2. Replace belt.
3. Pulley(s) not within design Replace pulley(s).
tolerance.
4. Foreign object(s) in grooves. 4 Remove foreign objects from
grooves.
4. Pulley misalignment. 4. Check and replace.
5. Belt cordline is broken. 5. Replace belt.

BELT BROKEN (NOTE: IDENTIFY 1. Excessive tension. 1. Replace belt and automatic belt
AND CORRECT PROBLEM tensioner.
BEFORE NEW BELT IS 2. Incorrect belt. 2. Replace belt.
INSTALLED)
3. Tensile member damaged during 3. Replace belt.
belt installation.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing 5. Replace defective component
failure. and belt.
NOISE (OBJECTIONAL SQUEAL, 1. Belt slippage. 1. Replace belt or automatic belt
SQUEAK, OR RUMBLE IS HEARD tensioner.
OR FELT WHILE DRIVE BELT IS 2. Bearing noise. 2. Locate and repair.
IN OPERATION)
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
SERPENTINE DRIVE BELT DIAGNOSIS

SERVICE PROCEDURES threaded-on pressure/vent cap. Refer to Pressure/

Vent Cap for additional information.
COOLANT LEVEL CHECK A coolant reserve/overflow system with a separate
The coolant level is checked and adjusted at the tank is not used with the 2.5L diesel engine.
pressurized coolant tank (Fig. 14). The tank is
NOTE: The coolant level should be checked after
located at the right-rear side of the engine compart-
the engine has been operated at normal operating
ment and is mounted as the highest point of the cool-
temperature for approximately 5–10 minutes.
ing system. This will allow any air or vapor
exceeding the pressure/vent cap rating to escape (1) Add coolant into the coolant tank up to the
through the cap. The coolant tank is equipped with a FULL mark. If possible, only add coolant when
the engine is cold. Coolant level in a warm

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 XJ COOLING SYSTEM 7 - 19
SERVICE PROCEDURES (Continued)
removing the left front headlamp bezel and the radi-
ator grille assembly from the bottom of vehicle.
(a) Attach one end of a 24 inch long X 1/4 inch
ID drain-hose to the nipple below the radiator
draincock.
(b) Put the other end of drain-hose into a clean
container.
(c) Open the draincock (counterclockwise as
viewed from left side of vehicle) and drain coolant
from radiator.
(3) If the complete cooling system must be drained,
raise the vehicle and remove the cylinder block
drain-plug. This hex- headed plug is located on the
right/rear side of the engine above the starter motor.

REFILLING COOLING SYSTEM

Fig. 14 Coolant Tank and Pressure/Vent Cap
The cooling system is equipped with a pressurized
1 – PRESSURE/VENT CAP
coolant tank using a pressure/vent cap. Refilling of
2 – PRESSURIZED COOLANT TANK
3 – LOW COOLANT LEVEL SENSOR
the system is done through this tank.

NOTE: The radiator draincock is equipped with a

engine will be higher in the tank due to ther- rubber o-ring. Do not over tighten draincock.
mal expansion.
(2) After the engine has been operated through a (1) Tighten the radiator draincock and (if
few heat-up and cool-down cycles, recheck the coolant removed), the cylinder block drain-plug.
level in the tank. (2) Open the plastic radiator fill vent valve
(unscrews counter- clockwise) from the radiator. The
DRAINING COOLING SYSTEM fill vent valve is located on the top of the right radi-
The cooling system is equipped with a pressurized ator tank.
coolant tank using a pressure/vent cap. (3) With the fill vent valve open, proceed to fill the
system using a 50/50 mixture of water and antifreeze
WARNING: DO NOT REMOVE THE CYLINDER as described in the Coolant section of this group.
BLOCK DRAIN-PLUG, THE COOLANT TANK CAP, (4) Continue to fill the cooling system until coolant
THE RADIATOR FILL VENT VALVE, OR LOOSEN is observed escaping from the fill vent opening. When
THE RADIATOR DRAINCOCK WITH THE SYSTEM this occurs, close the fill vent valve. The plastic fill
HOT AND PRESSURIZED. SERIOUS BURNS FROM vent valve is equipped with a rubber o- ring. Do
THE COOLANT CAN OCCUR. not over tighten the fill vent valve.
(5) Continue to fill the system until the coolant
tank is full.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, (6) Install and tighten the coolant tank pressure/
WAIT AT LEAST 15 MINUTES BEFORE REMOVING vent cap. Do not use any type of tool when tight-
COOLANT TANK CAP. WITH A RAG, SQUEEZE THE ening the cap. Hand tighten only.
UPPER RADIATOR HOSE TO CHECK IF SYSTEM IS (7) Operate engine with coolant tank cap tight-
UNDER PRESSURE. PLACE A RAG OVER THE CAP. ened.
VERY SLOWLY ROTATE THE CAP COUNTER- (8) After engine has reached normal operating
CLOCKWISE ALLOWING PRESSURE TO SLOWLY temperature, shut engine off and allow it to cool.
RELEASE. AFTER ALL PRESSURE HAS BEEN (9) Remove coolant tank cap.
RELEASED, REMOVE THE COOLANT TANK CAP (10) Add coolant into the coolant tank up to the
COMPLETELY. FULL mark. If possible, only add coolant when
the engine is cold. Coolant level in a warm
DO NOT WASTE reusable coolant. If the solution
engine will be higher in the tank due to ther-
is clean, drain the coolant into a clean container for
mal expansion.
reuse.
(11) After the engine has been operated through a
(1) Observe the previous WARNINGS and remove
few heat-up and cool-down cycles, recheck the coolant
the coolant tank pressure/vent cap.
level in the tank.
(2) The plastic radiator draincock is located on the
bottom of the left radiator tank. It can be accessed by

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 7 - 20 COOLING SYSTEM XJ
SERVICE PROCEDURES (Continued)

COOLANT REPLACEMENT
It is recommended that the cooling system be
drained and flushed at 84,000 kilometers (52,500
miles), or 3 years, whichever occurs first. Then every
two years, or 48,000 kilometers (30,000 miles),
whichever occurs first.

REMOVAL AND INSTALLATION

RADIATOR
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN-PLUG, THE COOLANT TANK CAP,
THE RADIATOR FILL VENT VALVE, OR LOOSEN
THE RADIATOR DRAINCOCK WITH THE SYSTEM
HOT AND PRESSURIZED. SERIOUS BURNS FROM
THE COOLANT CAN OCCUR.

DO NOT WASTE reusable coolant. If solution is

clean, drain coolant into a clean container for reuse.

WARNING: CONSTANT TENSION HOSE CLAMPS Fig. 16 Clamp Number/Letter Location

ARE USED ON MOST COOLING SYSTEM HOSES. 1 – TYPICAL CONSTANT TENSION HOSE CLAMP
WHEN REMOVING OR INSTALLING, USE ONLY 2 – CLAMP NUMBER/LETTER LOCATION
TOOLS DESIGNED FOR SERVICING THIS TYPE OF 3 – TYPICAL HOSE
CLAMP (Fig. 15). ALWAYS WEAR SAFETY
GLASSES WHEN SERVICING CONSTANT TENSION REMOVAL
CLAMPS. (1) Disconnect negative battery cable at battery.
(2) Observe the previous WARNINGS.
CAUTION: A number or letter is stamped into the (3) Drain cooling system. Refer to Draining Cool-
tongue of constant tension clamps (Fig. 16). If ing System in this group.
replacement is necessary, use only an original (4) Remove the upper fan shroud-to-upper cross-
equipment clamp with matching number or letter. member mounting bolts. One of the bolts is mounted
vertically at the bottom of the fan shroud.
(5) Lift the fan shroud up until alignment tabs at
the bottom are clear of slots in bracket at bottom of
radiator. Slip the fan shroud rearward and position it
over the fan blades.
(6) Remove radiator hose clamps and remove radi-
ator hoses.
(7) Mark the position of the hood latch striker on
the radiator crossmember and remove hood latch
striker.
(8) Remove radiator upper crossmember.
(9) If equipped with air conditioning, separate the
radiator from the A/C condenser by removing the
condenser-to-radiator mounting brackets.
(10) Lift radiator straight up and out of engine
compartment taking care not to damage radiator or
Fig. 15 Hose Clamp Tool A/C condenser fins.
1 – HOSE CLAMP TOOL 6094
2 – HOSE CLAMP INSTALLATION
The radiator is equipped with two alignment dow-
els (Fig. 17). They are located on the bottom of the

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 XJ COOLING SYSTEM 7 - 21
REMOVAL AND INSTALLATION (Continued)
plastic side tanks and fit into rubber grommets (2) The thermal viscous fan drive/fan blade assem-
located in the front lower crossmember. bly is attached (threaded) to the fan pulley shaft
(1) Carefully lower the radiator into engine com- (Fig. 18). Remove fan blade/viscous fan drive assem-
partment. Position the alignment dowels on the bot- bly from fan pulley by turning mounting nut counter-
tom of radiator into the rubber grommets in front clockwise as viewed from front. Threads on viscous
lower crossmember (Fig. 17). fan drive are RIGHT HAND. Snap-Ont 36 MM Fan
Wrenches (number SP346) can be used to turn the
mounting nut and to hold the fan pulley from rotat-
ing.
(3) Do not attempt to remove fan/viscous fan drive
assembly from vehicle at this time.
(4) Do not unbolt fan blade assembly from viscous
fan drive at this time.

Fig. 17 Radiator Alignment Dowels—Typical

1 – ALIGNMENT DOWEL
2 – RADIATOR
3 – AIR CONDITIONING CONDENSER
4 – GROMMET

(2) If equipped with air conditioning, attach con-

denser to radiator with mounting brackets.
(3) Install radiator upper crossmember.
(4) Install hood latch striker.
(5) Connect radiator upper and lower hoses. Fig. 18 Thermal Viscous Fan Drive and Blade
(6) Insert alignment tabs at bottom of fan shroud Assembly
into slots in bracket at bottom of radiator. Install and 1 – FAN PULLEY
2 – FAN DRIVE-TO-FAN BLADE BOLTS (4)
tighten fan shroud bolts to 3 N·m (31 in. lbs.) torque.
3 – MOUNTING NUT
(7) Connect negative battery cable.
4 – THERMAL VISCOUS FAN DRIVE
(8) Fill cooling system with correct coolant. Refer 5 – FAN BLADES
to Refilling Cooling System in this group. 6 – FAN PULLEY SHAFT
(9) Start and warm the engine. Check for coolant 7 – WATER PUMP
leaks.
(5) Remove the fan shroud mounting bolts.
FAN BLADE REMOVAL
(6) Remove the fan shroud and fan blade/viscous
fan drive assembly as a complete unit from vehicle.
FAN BLADE REMOVAL
(7) After removing fan blade/viscous fan drive
Accessory drive belt removal is not necessary for
assembly, do not place viscous fan drive in horizon-
fan blade or viscous fan drive removal.
tal position. If stored horizontally, silicone fluid in
(1) Disconnect negative battery cable from battery.
the viscous fan drive could drain into its bearing
assembly and contaminate lubricant.

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 7 - 22 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: Do not attempt to remove the fan pulley bimetallic coil. It then increases fan speed to provide
bolts. The fan pulley is under tension from the drive the necessary additional engine cooling.
belt. Once the engine has cooled, the radiator discharge
temperature will drop. The bimetallic coil again
(7) Remove four bolts securing fan blade assembly reacts and the fan speed is reduced to the previous
to viscous fan drive (Fig. 18). disengaged speed.

FAN BLADE INSTALLATION NOISE

(1) Install fan blade assembly to viscous fan drive.
Tighten bolts (Fig. 18) to 23 N·m (200 in. lbs.) torque. NOTE: It is normal for fan noise to be louder (roar-
(2) Position fan shroud and fan blade/viscous fan ing) when:
drive assembly to vehicle as a complete unit.
(3) Install and tighten fan shroud bolts to 3 N·m • The underhood temperature is above the engage-
(31 in. lbs.) torque. ment point for the viscous drive coupling. This may
(4) Install fan blade/viscous fan drive assembly to occur when ambient (outside air temperature) is very
fan pulley shaft (Fig. 18). high.
(5) Connect the negative battery cable. • Engine loads and temperatures are high such as
when towing a trailer.
VISCOUS FAN DRIVE • Cool silicone fluid within the fan drive unit is
Refer to the FAN BLADE removal and installation being redistributed back to its normal disengaged
procedure for replacement of the viscous fan drive. (warm) position. This can occur during the first 15
The thermal viscous fan drive (Fig. 19) is a sili- seconds to one minute after engine start-up on a cold
cone-fluid-filled coupling. It connects the fan blade engine.
assembly to the fan pulley. The coupling allows the
fan to be driven in a normal manner. This is done at LEAKS
low engine speeds while limiting the top speed of the Viscous fan drive operation is not affected by small
fan to a predetermined maximum level at higher oil stains near the drive bearing. If leakage appears
engine speeds. A bimetallic spring coil is located on excessive, replace the fan drive unit.
the front face. This spring coil reacts to the temper-
ature of the radiator discharge air. It engages the THERMOSTAT
viscous fan drive for higher fan speed if the air tem-
perature from the radiator rises above a certain REMOVAL
point. Until additional engine cooling is necessary,
the fan will remain at a reduced rpm regardless of WARNING: DO NOT REMOVE THE CYLINDER
engine speed. BLOCK DRAIN-PLUG, THE COOLANT TANK CAP,
THE RADIATOR FILL VENT VALVE, OR LOOSEN
THE RADIATOR DRAINCOCK WITH THE SYSTEM
HOT AND PRESSURIZED. SERIOUS BURNS FROM
THE COOLANT CAN OCCUR.

DO NOT WASTE reusable coolant. If the solution

is clean, drain the coolant into a clean container for
reuse.
(1) Drain the coolant from the radiator until the
level is below the thermostat housing. Refer to
Draining Cooling System for procedures.

WARNING: CONSTANT TENSION HOSE CLAMPS

ARE USED ON MOST COOLING SYSTEM HOSES.
Fig. 19 Viscous Fan Drive
WHEN REMOVING OR INSTALLING, USE ONLY
1 – MOUNTING NUT TO FAN PULLEY SHAFT
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
2 – THERMOSTATIC SPRING
3 – VISCOUS FAN DRIVE
CLAMP (Fig. 15). ALWAYS WEAR SAFETY
GLASSES WHEN SERVICING CONSTANT TENSION
CLAMPS.
The viscous fan drive will only engage when suffi-
cient heat is present. This is when the air flowing
through the radiator core causes a reaction from the

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 XJ COOLING SYSTEM 7 - 23
REMOVAL AND INSTALLATION (Continued)
CAUTION: A number or letter is stamped into the the thermostat vent is in the 12 o’clock position (Fig.
tongue of constant tension clamps (Fig. 16). If 20).
replacement is necessary, use only an original (3) Position the thermostat housing and four bolts
equipment clamp with matching number or letter. to the water manifold.

(2) Remove the upper radiator hose at the thermo- CAUTION: Tightening the thermostat housing
stat housing. unevenly or with the thermostat out of its recess
(3) Remove the four thermostat housing bolts (Fig. groove, may result in a cracked housing.
20)
(4) Tighten the four housing bolts to 11 N·m (98
in. lbs.) torque.
(5) Install radiator hose to thermostat housing.
(6) Be sure that the radiator drain is tightly
closed. Fill the cooling system to the correct level
with the required coolant mixture. Refer to Refilling
Cooling System in this group for procedures.
(7) Start and warm the engine. Check thermostat
and hose for leaks.

DRIVE BELT
CAUTION: The drive belt on the 2.5L diesel engine
is equipped with a spring loaded automatic belt ten-
sioner. After belt installation, do not attempt to
check belt tension with a belt tension gauge.

AUTOMATIC BELT TENSIONER

WATER PUMP
Fig. 20 Thermostat Removal/Installation
1 – THERMOSTAT RECESS GROOVE
REMOVAL
2 – WATER MANIFOLD ADAPTER The water pump can be removed without discharg-
3 – THERMOSTAT ing the air conditioning system (if equipped).
4 – THERMOSTAT HOUSING The water pump is serviced by replacing the pump
5 – HOUSING BOLTS (4) and its impeller only. The water pump adapter (Fig.
6 – WASHER 22) does not have to be removed. The pump impeller
7 – RUBBER SEAL is pressed on the rear of the pump shaft and bearing
8 – VENT assembly. The pump is serviced only as a complete
assembly with the impeller, housing, hub and bear-
(4) Remove the thermostat housing from the water ing.
manifold. A rubber o-ring seal (instead of a gasket) is used as
(5) Remove the thermostat and rubber seal from a seal between the water pump and the water pump
the water manifold. adapter.
(6) Thoroughly clean the rubber seal mating sur-
faces. WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN-PLUG, THE COOLANT TANK CAP,
INSTALLATION THE RADIATOR FILL VENT VALVE, OR LOOSEN
(1) Install a new rubber seal around the outer lip THE RADIATOR DRAINCOCK WITH THE SYSTEM
of the thermostat (a notch is provided in the rubber HOT AND PRESSURIZED. SERIOUS BURNS FROM
seal). Do not apply any adhesive to this seal. THE COOLANT CAN OCCUR.
(2) Install the replacement thermostat and rubber
DO NOT WASTE reusable coolant. If the solution
seal as one assembly into the water manifold adapter
is clean, drain coolant into a clean container for
(the pointed end of the thermostat should be facing
reuse.
towards the front of engine (Fig. 20). Observe the
(1) Disconnect the negative battery cable.
recess groove in the water manifold adapter. Be sure

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 7 - 24 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 21 Automatic Belt Tensioner Assembly

1 – FAN PULLEY
2 – IDLER PULLEY
3 – IDLER PULLEY
4 – GENERATOR
5 – POWER STEERING PUMP
6 – DRIVE BELT Fig. 22 WATER PUMP REMOVAL/INSTALL—
7 – CRANKSHAFT PULLEY TYPICAL
8 – AUTOMATIC BELT TENSIONER 1 – O-RING SEAL
2 – WATER PUMP ADAPTER
3 – DRAIN HOSE
(2) Drain the cooling system. Refer to Draining
4 – WASHER
Cooling System in this group.
5 – PUMP MOUNTING BOLTS (4)
(3) The thermal viscous fan drive and the fan 6 – WASHER
blade assembly are attached (threaded) to the fan 7 – WATER PUMP PULLEY BOLTS (3)
pulley shaft (Fig. 23). Remove the fan/fan drive 8 – WATER PUMP PULLEY
assembly from the fan pulley by turning the mount- 9 – VENT TUBE
ing nut counterclockwise (as viewed from front). 10 – PUMP HUB
Threads on the fan drive are RIGHT HAND. Snap- 11 – WATER PUMP
Ont 36 MM Fan Wrenches (number SP346) can be
used to turn the mounting nut and to hold the fan Removal/Installation in the Engine Accessory Drive
pulley from rotating. Belt section of this group.
(4) If the water pump is being replaced, do not
unbolt the fan blade assembly (Fig. 23) from the WARNING: CONSTANT TENSION HOSE CLAMPS
thermal viscous fan drive. ARE USED ON MOST COOLING SYSTEM HOSES.
(5) Remove the upper fan shroud-to-upper cross- WHEN REMOVING OR INSTALLING, USE ONLY
member mounting bolts. One of the bolts is mounted TOOLS DESIGNED FOR SERVICING THIS TYPE OF
vertically at the bottom of the fan shroud. CLAMP (Fig. 24). ALWAYS WEAR SAFETY
(6) Slip the fan shroud rearward. Remove the fan GLASSES WHEN SERVICING CONSTANT TENSION
shroud and viscous drive/fan blade together as one CLAMPS.
assembly from the engine compartment.
(7) Loosen but do not remove the 3 water pump
pulley bolts (Fig. 22). CAUTION: A number or letter is stamped into the
(8) Remove the drive belt by relieving the tension tongue of constant tension clamps (Fig. 25). If
on the belt tensioner. For procedures, refer to Belt replacement is necessary, use only an original
equipment clamp with matching number or letter.

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 XJ COOLING SYSTEM 7 - 25
REMOVAL AND INSTALLATION (Continued)

Fig. 25 Clamp Number/Letter Location

1 – TYPICAL CONSTANT TENSION HOSE CLAMP
2 – CLAMP NUMBER/LETTER LOCATION
3 – TYPICAL HOSE
Fig. 23 Thermal Viscous Fan Drive and Blade
Assembly
(9) A metal coolant tube (used to connect rubber
1 – FAN PULLEY
coolant hoses), and its mounting bracket are attached
2 – FAN DRIVE-TO-FAN BLADE BOLTS (4)
3 – MOUNTING NUT
to the front of the water pump (Fig. 26). A rubber
4 – THERMAL VISCOUS FAN DRIVE hose connects this tube to the engine. Disconnect the
5 – FAN BLADES hose clamp and rubber hose at the back of the ther-
6 – FAN PULLEY SHAFT mostat. Position the hose to the side.
7 – WATER PUMP

Fig. 26 Coolant Tube at Water Pump

1 – COOLANT TUBE
Fig. 24 Hose Clamp Tool 2 – WATER PUMP
1 – HOSE CLAMP TOOL 6094 3 – BRACKET
2 – HOSE CLAMP

(10) Remove the 3 water pump pulley bolts (Fig.

22).

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 7 - 26 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
(11) Remove the water pump pulley from the • Water leaks from the shaft seal. This is evident
water pump. by traces of coolant below the vent tube drain hose
(12) Disconnect the drain hose from the vent tube • Loose or rough turning bearing.
at the bottom of water pump (Fig. 22). • Impeller rubs either the water pump body or
(13) Remove the 4 water pump mounting bolts water pump adapter.
(Fig. 22).
(14) Remove water pump from engine. RADIATOR CLEANING
The radiator and air conditioning fins should be
INSTALLATION cleaned when an accumulation of bugs, leaves etc.
(1) Clean the o-ring mating surfaces. If the origi- has occurred. Clean radiator fins are necessary for
nal pump is to be reinstalled, remove any deposits or good heat transfer. With the engine cold, apply cold
other foreign material. Inspect the water pump, water and compressed air to the back (engine side) of
water pump adapter and water pump mating sur- the radiator to flush the radiator and/or A/C con-
faces for erosion or damage from cavitation. denser of debris.
(2) Position a new rubber o-ring seal (Fig. 22)
between the pump and pump adapter. Hold the seal FAN BLADE
with petroleum jelly.
(3) Position the pump on the engine. INSPECTION
(4) Position the metal coolant tube and its mount- The fan cannot be repaired. If fan is damaged, it
ing bracket on the pump. must be replaced. Inspect fan as follows:
(5) Install the four water pump mounting bolts. (1) Remove fan blade and viscous fan drive as an
Torque bolts to 24 N·m (18 ft. lbs.). assembly from the engine.
(6) Install drain hose to vent tube at bottom of (2) Remove fan blade assembly from viscous fan
pump. drive unit (four bolts) (Fig. 27).
(7) Position the water pump pulley to the water (3) Lay fan on a flat surface with leading edge fac-
pump. ing down. With tip of blade touching flat surface,
(8) Install the water pump pulley bolts finger replace fan if clearance between opposite blade and
tight. surface is greater than 2.0 mm (.090 inch). Rocking
(9) Install the rubber coolant hose near the ther- motion of opposite blades should not exceed 2.0 mm
mostat. (.090 inch). Test all blades in this manner.
(10) Install the accessory drive belt. For proce-
dures, refer to Belt Removal/Installation in the WARNING: DO NOT ATTEMPT TO BEND OR
Engine Accessory Drive Belt section of this group. STRAIGHTEN FAN BLADES IF NOT WITHIN SPECI-
(11) Torque the water pump pulley bolts to 24 N·m FICATIONS.
(18 ft. lbs.).
(12) Position the viscous drive/fan blade and fan (4) Inspect fan assembly for cracks, bends, loose
shroud to the engine compartment as one assembly. rivets or broken welds. Replace fan if any damage is
(13) Install the thermal viscous fan drive and fan found.
blade to fan pulley. Torque to 56 N·m (41 ft. lbs.).
(14) Install the fan shroud mounting bolts. Torque CAUTION: If fan blade assembly is replaced
bolts to 3 N·m (31 in. lbs.). because of mechanical damage, the fan pulley bear-
(15) Fill the cooling system with coolant and check ing and viscous fan drive should also be inspected.
for leaks. Refer to Refilling Cooling System in this These components could have been damaged due
group. to excessive vibration.
(16) Connect the negative battery cable.
(17) Start and warm the engine. Check for leaks. CAUTION: Some engines equipped with serpentine
drive belts have reverse rotating fans and viscous
CLEANING AND INSPECTION fan drives. They are marked with the word
REVERSE to designate their usage. Installation of
the wrong fan or viscous fan drive can result in
WATER PUMP
engine overheating.
INSPECTION
Replace the water pump assembly if it has any of
the following conditions:
• The body is cracked or damaged

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 XJ COOLING SYSTEM 7 - 27
CLEANING AND INSPECTION (Continued)
CLEANING
Drain cooling system and refill with water. Run
engine with coolant tank pressure/vent cap installed
until upper radiator hose is hot. Stop engine and
drain water from system. If water is dirty, fill system
with water, run engine and drain system. Repeat
until water drains clean.

REVERSE FLUSHING
Reverse flushing of the cooling system is the forc-
ing of water through the cooling system. This is done
using air pressure in the opposite direction of normal
coolant flow. It is usually only necessary with very
dirty systems with evidence of partial plugging.

REVERSE FLUSHING RADIATOR

Disconnect the radiator hoses from the radiator fit-
tings. Attach a section of radiator hose to the radia-
tor bottom outlet fitting and insert the flushing gun.
Connect a water supply hose and air supply hose to
the flushing gun.

CAUTION: The cooling system normally operates at

90-to-117 kPa (13- to-17 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Fig. 27 Thermal Viscous Fan Drive and Blade
Allow the coolant tank and radiator to fill with
Assembly
water. When radiator is filled, apply air in short
1 – FAN PULLEY
blasts allowing radiator to refill between blasts. Con-
2 – FAN DRIVE-TO-FAN BLADE BOLTS (4)
3 – MOUNTING NUT
tinue this reverse flushing until clean water flows
4 – THERMAL VISCOUS FAN DRIVE out through rear of radiator cooling tube passages.
5 – FAN BLADES For more information, refer to operating instructions
6 – FAN PULLEY SHAFT supplied with flushing equipment. Have radiator
7 – WATER PUMP cleaned more extensively by a radiator repair shop.

REVERSE FLUSHING ENGINE

PRESSURE/VENT CAP Drain the cooling system. Remove the thermostat
housing and thermostat. Install the thermostat hous-
INSPECTION ing. Disconnect the radiator upper hose from the
Visually inspect the gasket on the cap. Replace cap radiator and attach the flushing gun to the hose. Dis-
if the gasket is swollen, torn or worn. Inspect the connect the radiator lower hose from the water
area around the coolant tank filler neck for white pump. Attach a lead away hose to the water pump
deposits that indicate a leaking cap. inlet fitting.
The cap must be replaced by a similar threaded-on
unit with the correct operating pressures if replace- CAUTION: Be sure that the heater water control
ment is necessary. valve is closed (heat off). This is done to prevent
coolant flow with scale and other deposits from
COOLING SYSTEM CLEANING/REVERSE entering the heater core.
FLUSHING
Connect the water supply hose and air supply hose
CAUTION: The cooling system normally operates at to the flushing gun. Allow the engine to fill with
90-to-117 kPa (13- to-17 psi) pressure. Exceeding water. When the engine is filled, apply air in short
this pressure may damage the radiator or hoses. blasts, allowing the system to fill between air blasts.
Continue until clean water flows through the lead
away hose. For more information, refer to operating
instructions supplied with flushing equipment.

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 7 - 28 COOLING SYSTEM XJ
CLEANING AND INSPECTION (Continued)
Remove the lead away hose, flushing gun, water TORQUE SPECIFICATIONS
supply hose and air supply hose. Remove the thermo-
stat housing and install thermostat. Install the ther- DESCRIPTION TORQUE
mostat housing with a new replacement rubber seal. Automatic Belt Tensioner-to-Mounting Bracket
Refer to Thermostat Installation. Connect the radia- Bolt (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N·m
tor hoses. Refill the cooling system with the correct Automatic Belt Tensioner to Block
antifreeze/water mixture. Bolts (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 N·m
Coolant Tank
CHEMICAL CLEANING
Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N·m
In some instances, use a radiator cleaner (Mopar
Fan Shroud-to-Radiator Mounting
Radiator Kleen or equivalent) before flushing. This
Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 N·m
will soften scale and other deposits and aid the flush-
ing operation. Fan Blade-to-Thermal Viscous Fan Drive
Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N·m
CAUTION: Be sure instructions on the container Hose
are followed. Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 N·m
Radiator-to-A/C Condenser Isolator
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N·m
Thermal Viscous Fan Drive-to-Fan Hub
SPECIFICATIONS Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 N·m
Thermostat Housing
COOLING SYSTEM CAPACITY Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 N·m
2.5L Diesel Engine: 9.8 Liters (10.4 qts.)
Water Pump Mounting
Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m
THERMOSTAT Water Pump Pulley
Starts to open at 80°C (176°F).
Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m

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 XJ BATTERY 8A - 1

BATTERY
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION

BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . 18
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . . 3 BATTERY HOLD DOWNS . . . . . . . . . . . . . . . . . . 20
BATTERY HOLD DOWNS . . . . . . . . . . . . . . . . . . . 4 BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BATTERY THERMOGUARD . . . . . . . . . . . . . . . . . . 5 BATTERY THERMOGUARD. . . . . . . . . . . . . . . . . 22
BATTERY TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BATTERY TRAY. . . . . . . . . . . . . . . . . . . . . . . . . . 22
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BATTERY CABLES . . . . . . . . . . . . . . . . . . . . . . . 14 SPECIFICATIONS
SERVICE PROCEDURES BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . 16

DESCRIPTION AND OPERATION A large capacity, low-maintenance storage battery

(Fig. 1) is standard factory-installed equipment on
BATTERY this model. Male post type terminals made of a soft
lead material protrude from the top of the molded
DESCRIPTION plastic battery case to provide the means for connect-
ing the battery to the vehicle electrical system. The
battery positive terminal post is visibly larger in
diameter than the negative terminal post, for easy
identification. The letters POS and NEG are also
molded into the top of the battery case adjacent to
their respective positive and negative terminal posts
for additional identification confirmation. Refer to
Battery Cables in the index of this service manual
for the location of more information on the battery
cables that connect the battery to the vehicle electri-
cal system.
This battery is designed to provide a safe, efficient
and reliable means of storing electrical energy in a
chemical form. This means of energy storage allows
the battery to produce the electrical energy required
to operate the engine starting system, as well as to
Fig. 1 Low-Maintenance Battery - Typical operate many of the other vehicle accessory systems
1 – POSITIVE POST
for limited durations while the engine and/or the
2 – VENT charging system are not operating. The battery is
3 – CELL CAP made up of six individual cells that are connected in
4 – TEST INDICATOR series. Each cell contains positively charged plate
5 – CELL CAP groups that are connected with lead straps to the
6 – VENT positive terminal post, and negatively charged plate
7 – NEGATIVE POST groups that are connected with lead straps to the
8 – GREEN BALL negative terminal post. Each plate consists of a stiff
9 – ELECTROLYTE LEVEL mesh framework or grid coated with lead dioxide
10 – PLATE GROUPS
(positive plate) or sponge lead (negative plate). Insu-
11 – LOW-MAINTENANCE BATTERY
lators or plate separators made of a non-conductive
material are inserted between the positive and nega-
tive plates to prevent them from contacting or short-

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 8A - 2 BATTERY XJ
DESCRIPTION AND OPERATION (Continued)
ing against one another. These dissimilar metal BATTERY SIZE AND RATINGS
plates are submerged in a sulfuric acid and water The battery Group Size number, the Cold Cranking
solution called an electrolyte. Amperage (CCA) rating, and the Reserve Capacity
The factory-installed battery has a built-in test (RC) rating or Ampere-Hours (AH) rating can be
indicator (hydrometer). The color visible in the sight found on the original equipment battery label. Be
glass of the indicator will reveal the battery condi- certain that a replacement battery has the correct
tion. For more information on the use of the built-in Group Size number, as well as CCA, and RC or AH
test indicator, refer to Battery in the index of this ratings that equal or exceed the original equipment
service manual for the location of the proper battery specification for the vehicle being serviced. Refer to
diagnosis and testing procedures. The factory-in- Battery in the index of this service manual for the
stalled low-maintenance battery has removable location of the proper factory-installed battery speci-
battery cell caps. Water can be added to this bat- fications. Battery sizes and ratings are discussed in
tery. The battery is not sealed and has vent holes in more detail below.
the cell caps. The chemical composition of the metal • Group Size
coated plates within the low-maintenance battery The outside dimensions and terminal placement of
reduces battery gassing and water loss, at normal the battery conform to standards established by the
charge and discharge rates. Therefore, the battery Battery Council International (BCI). Each battery is
should not require additional water in normal ser- assigned a BCI Group Size number to help identify a
vice. If the electrolyte level in this battery does correctly-sized replacement.
become low, water must be added. However, rapid • Cold Cranking Amperage
loss of electrolyte can be caused by an overcharging The Cold Cranking Amperage (CCA) rating specifies
condition. Be certain to diagnose the charging system how much current (in amperes) the battery can
after replenishing the water in the battery for a low deliver for thirty seconds at -18° C (0° F). Terminal
electrolyte condition and before returning the vehicle voltage must not fall below 7.2 volts during or after
to service. Refer to Charging System in the index of the thirty second discharge period. The CCA required
this service manual for the location of the proper is generally higher as engine displacement increases,
charging system diagnosis and testing procedures. depending also upon the starter current draw
For battery maintenance schedules and jump start- requirements.
ing procedures, see the owner’s manual in the vehicle • Reserve Capacity
glove box. Optionally, refer to Maintenance Sched- The Reserve Capacity (RC) rating specifies the time
ules and Jump Starting, Towing and Hoisting in (in minutes) it takes for battery terminal voltage to
the index of this service manual for the location of fall below 10.5 volts, at a discharge rate of 25
the recommended battery maintenance schedules and amperes. RC is determined with the battery fully-
the proper battery jump starting procedures. While charged at 26.7° C (80° F). This rating estimates how
battery charging can be considered a maintenance long the battery might last after a charging system
procedure, the battery charging procedures and infor- failure, under minimum electrical load.
mation are located in the service procedures section • Ampere-Hours
of this service manual. This was done because the The Ampere-Hours (AH) rating specifies the current
battery must be fully-charged before any battery (in amperes) that a battery can deliver steadily for
diagnosis or testing procedures can be performed. twenty hours, with the voltage in the battery not fall-
Refer to Battery Charging in the index of this ser- ing below 10.5 volts. This rating is also sometimes
vice manual for the location of the proper battery identified as the twenty-hour discharge rating.
charging procedures.
OPERATION
NOTE: This group covers both Left-Hand Drive When an electrical load is applied to the terminals
(LHD) and Right-Hand Drive (RHD) versions of this of the battery, an electrochemical reaction occurs.
model. Whenever required and feasible, the RHD This reaction causes the battery to discharge electri-
versions of affected vehicle components have been cal current from its terminals. As the battery dis-
constructed as mirror-image of the LHD versions. charges, a gradual chemical change takes place
While most of the illustrations used in this group within each cell. The sulfuric acid in the electrolyte
represent only the LHD version, the diagnostic and combines with the plate materials, causing both
service procedures outlined can generally be plates to slowly change to lead sulfate. At the same
applied to either version. Exceptions to this rule time, oxygen from the positive plate material com-
have been clearly identified as LHD or RHD, if a bines with hydrogen from the sulfuric acid, causing
special illustration or procedure is required. the electrolyte to become mainly water. The chemical
changes within the battery are caused by the move-

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 XJ BATTERY 8A - 3
DESCRIPTION AND OPERATION (Continued)
ment of excess or free electrons between the positive
and negative plate groups. This movement of elec-
trons produces a flow of electrical current through
the load device attached to the battery terminals.
As the plate materials become more similar chem-
ically, and the electrolyte becomes less acid, the volt-
age potential of each cell is reduced. However, by
charging the battery with a voltage higher than that
of the battery itself, the battery discharging process
is reversed. Charging the battery gradually changes
the sulfated lead plates back into sponge lead and
lead dioxide, and the water back into sulfuric acid.
This action restores the difference in the electron
charges deposited on the plates, and the voltage
potential of the battery cells. For a battery to remain
useful, it must be able to produce high-amperage cur-
rent over an extended period. A battery must also be Fig. 2 Battery Cables
able to accept a charge, so that its voltage potential 1 – BATTERY
may be restored. 2 – RADIATOR CROSSMEMBER
The battery is vented to release excess hydrogen 3 – TERMINAL CLAMPS
gas that is created when the battery is being charged 4 – FENDER INNER SHIELD
or discharged. However, even with these vents, 5 – NEGATIVE CABLE
6 – POSITIVE CABLE
hydrogen gas can collect in or around the battery. If
hydrogen gas is exposed to flame or sparks, it may
ignite. If the electrolyte level is low, the battery may have a red insulating jacket to provide visual identi-
arc internally and explode. If the battery is equipped fication and features a larger female battery terminal
with removable cell caps, add distilled water when- clamp to allow connection to the larger battery posi-
ever the electrolyte level is below the top of the tive terminal post. The battery negative cable wires
plates. If the battery cell caps cannot be removed, the have a black insulating jacket and a smaller female
battery must be replaced if the electrolyte level battery terminal clamp.
becomes low. The battery cables cannot be repaired and, if dam-
In addition to producing and storing electrical aged or faulty they must be replaced. Both the bat-
energy, the battery serves as a capacitor and voltage tery positive and negative cables are available for
stabilizer for the electrical system of the vehicle. It service replacement only as a unit with the battery
absorbs most abnormal or transient voltages caused wire harness, which may include portions of the wir-
by the switching of any of the electrical components ing circuits for the generator and other components
in the vehicle. on some models. Refer to Wiring Diagrams in the
index of this service manual for the location of more
BATTERY CABLES information on the various wiring circuits included in
the battery wire harness for the vehicle being ser-
DESCRIPTION viced.
The battery cables (Fig. 2) are large gauge,
stranded copper wires sheathed within a heavy plas- OPERATION
tic or synthetic rubber insulating jacket. The wire The battery cables connect the battery terminal
used in the battery cables combines excellent flexibil- posts to the vehicle electrical system. These cables
ity and reliability with high electrical current carry- also provide a return path for electrical current gen-
ing capacity. Refer to Wiring Diagrams in the index erated by the charging system for restoring the volt-
of this service manual for the location of the proper age potential of the battery. The female battery
battery cable wire gauge information. terminal clamps on the ends of the battery cable
A clamping type female battery terminal made of wires provide a strong and reliable connection of the
soft lead is die cast onto one end of the battery cable battery cable to the battery terminal posts. The ter-
wire. A square headed pinch-bolt and hex nut are minal pinch bolts allow the female terminal clamps
installed at the open end of the female battery termi- to be tightened around the male terminal posts on
nal clamp. Large eyelet type terminals are crimped the top of the battery. The eyelet terminals secured
onto the opposite end of the battery cable wire and to the ends of the battery cable wires opposite the
then solder-dipped. The battery positive cable wires female battery terminal clamps provide secure and

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 8A - 4 BATTERY XJ
DESCRIPTION AND OPERATION (Continued)
reliable connection of the battery to the vehicle elec- The battery hold down hardware (Fig. 3) includes
trical system. two T-bolts with plastic push-on retainers, a hold
The battery positive cable terminal clamp is die down bracket, a stamped steel battery support strap,
cast onto the ends of two wires. One wire has an eye- two hex nuts with coned washers and a single hex
let terminal that connects the battery positive cable screw with a coned washer. The battery hold down
to the B(+) terminal stud of the Power Distribution bracket consists of a formed steel rod with a stamped
Center (PDC), and the other wire has an eyelet ter- steel angle bracket welded to each end. The hold
minal that connects the battery positive cable to the down bracket assembly is then plastic-coated for cor-
B(+) terminal stud of the engine starter motor sole- rosion protection.
noid. The battery negative cable terminal clamp is When installing a battery into the battery tray, be
also die cast onto the ends of two wires. One wire certain that the hold down hardware is properly
has an eyelet terminal that connects the battery neg- installed and that the fasteners are tightened to the
ative cable to the vehicle powertrain through a stud proper specifications. Improper hold down fastener
on the right side of the engine block. The other wire tightness, whether too loose or too tight, can result in
has an eyelet terminal that connects the battery neg- damage to the battery, the vehicle or both. Refer to
ative cable to the vehicle body through a ground Battery Hold Downs in the index of this service
screw on the right front fender inner shield, near the manual for the location of the proper battery hold
battery. down installation procedures, including the proper
hold down fastener tightness specifications.
BATTERY HOLD DOWNS
OPERATION
DESCRIPTION The battery hold down hardware secures the bat-
tery to the battery tray in the engine compartment.
The hold down support strap provides an additional
anchor point for the upper end of the battery and
hold down hardware at the upper radiator crossmem-
ber. This hardware is designed to prevent battery
movement during vehicle operation. Unrestrained
battery movement during vehicle operation can
result in damage to the vehicle, the battery or both.
The hold down T-bolts are installed onto the bat-
tery tray before the tray is installed in the engine
compartment. The T-bolts are inserted through a hole
in a molded formation integral to each side of the
battery tray from underneath, with the threaded
ends of the bolts extending upward. A plastic push-on
retainer is installed over each T-bolt to secure the
T-bolts to the battery tray for ease of assembly dur-
ing the vehicle manufacturing process. However,
these plastic push-on retainers are not available or
required for service replacement.
The battery hold down bracket is installed across
the top of the battery case and over the two upright
threaded ends of the T-bolts. The round hole in the
support strap is then installed over the threaded end
of the forward T-bolt and the slotted hole of the strap
Fig. 3 Battery Hold Downs is secured by a screw with washer to the upper radi-
1 – SCREW AND WASHER (1) ator cross member. A hex nut with coned washer is
2 – NUT AND WASHER (2) then installed and tightened onto each of the T-bolts
3 – T-BOLT (2) to securely hold down the battery in the battery tray.
4 – RETAINER (2)
5 – BATTERY TRAY
6 – UPPER RADIATOR CROSS MEMBER
7 – BRACKET
8 – STRAP

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 XJ BATTERY 8A - 5
DESCRIPTION AND OPERATION (Continued)

BATTERY THERMOGUARD
DESCRIPTION

Fig. 4 Battery Thermoguard

1 – THERMOGUARD
2 – BATTERY

A flexible plastic bubble-wrap style thermoguard

(Fig. 4) slides over the battery case to enclose the Fig. 5 Battery Tray
sides of the battery. The thermoguard consists of a 1 – TRAY
heavy black plastic outer skin and two lighter plies of 2 – NUT AND WASHER (3)
plastic that have been formed into a sheet with hun- 3 – T-BOLT (2)
dreds of small air pockets entrapped between them. 4 – RETAINER (2)
The resulting material is very similar to the bubble- 5 – WELD STUD (3)
wrap used to protect items in many parcel packaging
and shipping applications. manual for the location of more information on the
battery temperature sensor. Refer to Battery Hold
OPERATION Downs in the index of this service manual for the
The thermoguard protects the battery from engine location of more information on the battery hold
compartment temperature extremes. The air trapped down hardware.
between the plastic plies of the thermoguard create a
dead air space, which helps to insulate the sides of OPERATION
the battery case from the surrounding engine com- The battery tray provides a mounting location and
partment air temperature. support for the vehicle battery. The battery tray also
provides anchor points for the battery hold down
BATTERY TRAY hardware. The battery tray and the battery hold
down hardware combine to secure and stabilize the
DESCRIPTION battery in the engine compartment, which prevents
The battery is mounted in a molded plastic tray battery movement during vehicle operation. Unre-
(Fig. 5) located in the right front corner of the engine strained battery movement during vehicle operation
compartment. Two T-bolts that are part of the bat- can result in damage to the vehicle, the battery or
tery hold down hardware are assembled to the bat- both.
tery tray before the tray is installed in the vehicle.
The battery tray is secured by three hex nuts with
coned washers to three weld studs located on the DIAGNOSIS AND TESTING
front extension of the right front wheelhouse inner
panel, forward of the right front wheel. BATTERY
A hole in the bottom of the battery tray is fitted
with a battery temperature sensor. Refer to Battery DIAGNOSIS
Temperature Sensor in the index of this service The battery, starting system and charging system
in the vehicle operate with one another, and must be

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 8A - 6 BATTERY XJ
DIAGNOSIS AND TESTING (Continued)
tested as a complete system. In order for the engine AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
to start and the battery to charge properly, all of the OF THE REACH OF CHILDREN.
components that are used in these systems must per- • IF THE BATTERY IS EQUIPPED WITH REMOV-
form within specifications. It is important that the ABLE CELL CAPS, BE CERTAIN THAT EACH OF
battery, starting system and charging system be thor- THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
oughly tested and inspected any time a battery needs THE BATTERY IS RETURNED TO SERVICE. PER-
to be charged or replaced. The cause of abnormal dis- SONAL INJURY AND/OR VEHICLE DAMAGE MAY
charge, overcharging or early battery failure must be RESULT FROM LOOSE OR MISSING CELL CAPS.
diagnosed and corrected before a battery is replaced
and before a vehicle is returned to service. The ser- The condition of a battery is determined by two cri-
vice information for these systems has been sepa- teria:
rated within this service manual to make it easier to 1. State-Of-Charge
locate the specific information you are seeking. How- This can be determined by checking the specific grav-
ever, when attempting to diagnose any of these sys- ity of the battery electrolyte (built-in test indicator or
tems, it is important that you keep their hydrometer test), or by checking the battery voltage
interdependency in mind. (open-circuit voltage test).
The diagnostic procedures used for the battery, 2. Cranking Capacity
starting system and charging system include the This can be determined by performing a battery load
most basic conventional diagnostic methods, to the test, which measures the ability of the battery to
more sophisticated On-Board Diagnostics (OBD) built supply high-amperage current.
into the Powertrain Control Module (PCM). Use of an First, determine the battery state-of-charge. This
induction-type milliampere ammeter, a volt/ohmme- can be done in one of three ways. If the battery has a
ter, a battery charger, a carbon pile rheostat (load built-in test indicator, view the test indicator to
tester) and a 12-volt test lamp may be required. All determine the state-of-charge. If the battery has no
OBD-sensed systems are monitored by the PCM. test indicator but does have removable cell caps, per-
Each monitored circuit is assigned a Diagnostic Trou- form the hydrometer test to determine the state-of-
ble Code (DTC). The PCM will store a DTC in elec- charge. If the battery cell caps are not removable, or
tronic memory for any failure it detects. Refer to a hydrometer is not available, perform the open-cir-
Charging System, On-Board Diagnostic Test in cuit voltage test to determine the state-of-charge.
the index of this service manual for the location of The battery must be charged before proceeding
the proper on-board diagnostic test procedures. with a load test if:
The battery must be completely charged and the • The battery built-in test indicator has a black or
top, posts and terminal clamps should be properly dark color visible.
cleaned and inspected before diagnostic procedures • The temperature corrected specific gravity of the
are performed. Refer to Battery in the index of this battery electrolyte is less than 1.235.
service manual for the location of the proper battery • The battery open-circuit voltage is less than 12.4
cleaning and inspection procedures. Refer to Battery volts.
Charging in the index of this service manual for the A battery that will not accept a charge is faulty,
location of the proper battery charging procedures. and must be replaced. Further testing is not
required. A fully-charged battery must be load tested
WARNING: to determine its cranking capacity. A battery that is
• IF THE BATTERY SHOWS SIGNS OF FREEZ- fully-charged, but does not pass the load test, is
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- faulty and must be replaced.
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY NOTE: Completely discharged batteries may take
AND EXPLODE. PERSONAL INJURY AND/OR VEHI- several hours to accept a charge. Refer to Battery
CLE DAMAGE MAY RESULT. Charging in the index of this service manual for the
• EXPLOSIVE HYDROGEN GAS FORMS IN AND location of the proper battery charging procedures.
AROUND THE BATTERY. DO NOT SMOKE, USE A battery is fully-charged when:
FLAME, OR CREATE SPARKS NEAR THE BATTERY. • All battery cells are gassing freely during charging.
PERSONAL INJURY AND/OR VEHICLE DAMAGE • A green color is visible in the sight glass of the
MAY RESULT. battery built-in test indicator.
• THE BATTERY CONTAINS SULFURIC ACID, • Three corrected specific gravity tests, taken at
WHICH IS POISONOUS AND CAUSTIC. AVOID CON- one-hour intervals, indicate no increase in the spe-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN cific gravity of the battery electrolyte.
THE EVENT OF CONTACT, FLUSH WITH WATER • Open-circuit voltage of the battery is 12.4 volts
or greater.

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 XJ BATTERY 8A - 7
DIAGNOSIS AND TESTING (Continued)

Battery Diagnosis
Condition Possible Causes Correction
The battery seems weak or 1. The battery has an 1. Refer to Battery in the index of this service
dead when attempting to start incorrect size or rating for manual for the location of the proper battery
the engine. this vehicle. specifications. Replace an incorrect battery, as
2. The battery is physically required.
damaged. 2. Inspect the battery for loose terminal posts or a
3. The battery terminal cracked and leaking case. Replace the damaged
connections are loose or battery, as required.
corroded. 3. Refer to Battery Cables in the index of this
4. The battery is discharged. service manual for the location of the proper
5. The electrical system battery cable diagnosis and testing procedures.
ignition-off draw is excessive. Clean and tighten the battery terminal
6. The battery is faulty. connections, as required.
7. The starting system is 4. Determine the battery state-of-charge. Refer to
faulty. Built-In Test Indicator, Hydrometer Test, or
8. The charging system is Open-Circuit Voltage Test in this section for the
faulty. proper test procedures. Charge the faulty battery,
as required.
5. Refer to Ignition-Off Draw Test in this section
for the proper test procedures. Repair the faulty
electrical system, as required.
6. Determine the battery cranking capacity. Refer
to Load Test in this section for the proper test
procedures. Replace the faulty battery, as
required.
7. Determine if the starting system is performing
to specifications. Refer to Starting System in the
index of this service manual for the location of the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. Determine if the charging system is performing
to specifications. Refer to Charging System in the
index of this service manual for the location of the
proper charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.

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 8A - 8 BATTERY XJ
DIAGNOSIS AND TESTING (Continued)

Battery Diagnosis
Condition Possible Causes Correction
The battery state-of-charge 1. The battery has an 1. Refer to Battery in the index of this service
cannot be maintained. incorrect size or rating for manual for the location of the proper battery
this vehicle. specifications. Replace an incorrect battery, as
2. The battery terminal required.
connections are loose or 2. Refer to Battery Cables in the index of this
corroded. service manual for the location of the proper
3. The generator drive belt is battery cable diagnosis and testing procedures.
slipping. Clean and tighten the battery terminal
4. The electrical system connections, as required.
ignition-off draw is excessive. 3. Refer to Accessory Drive Belt Diagnosis in the
5. The battery is faulty. index of this service manual for the location of the
6. The starting system is proper accessory drive belt diagnosis and testing
faulty. procedures. Replace or adjust the faulty
7. The charging system is generator drive belt, as required.
faulty. 4. Refer to Ignition-Off Draw Test in this section
8. Electrical loads exceed the for the proper test procedures. Repair the faulty
output of the charging electrical system, as required.
system. 5. Determine the battery cranking capacity. Refer
9. Slow driving or prolonged to Load Test in this section for the proper test
idling with high-amperage procedures. Replace the faulty battery, as
draw systems in use. required.
6. Determine if the starting system is performing
to specifications. Refer to Starting System in the
index of this service manual for the location of the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
7. Determine if the charging system is performing
to specifications. Refer to Charging System in the
index of this service manual for the location of the
proper charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
8. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
9. Advise the vehicle operator, as required.
The battery will not accept a 1. The battery is faulty. 1. Refer to Battery Charging in the index of this
charge. service manual for the location of the proper
battery charging procedures. Charge or replace
the faulty battery, as required.

ABNORMAL BATTERY DISCHARGING 4. Slow driving speeds (heavy traffic conditions) or

Any of the following conditions can result in abnor- prolonged idling, with high-amperage draw systems
mal battery discharging: in use.
1. Corroded or loose battery posts and terminal 5. A faulty circuit or component causing excessive
clamps. ignition-off draw.
2. A loose or worn generator drive belt. 6. A faulty or incorrect charging system compo-
3. Electrical loads that exceed the output of the nent. Refer to Charging System in the index of this
charging system. This can be due to equipment service manual for the location of the proper charg-
installed after manufacture, or repeated short trip ing system diagnosis and testing procedures.
use.

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 XJ BATTERY 8A - 9
DIAGNOSIS AND TESTING (Continued)
7. A faulty or incorrect starting system component. • IF THE BATTERY IS EQUIPPED WITH REMOV-
Refer to Starting System in the index of this ser- ABLE CELL CAPS, BE CERTAIN THAT EACH OF
vice manual for the location of the proper starting THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
system diagnosis and testing procedures. THE BATTERY IS RETURNED TO SERVICE. PER-
8. A faulty or incorrect battery. SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
TESTING
Before testing, visually inspect the battery for any
BUILT-IN TEST INDICATOR damage (a cracked case or cover, loose posts, etc.)
A test indicator (hydrometer) built into the top of that would cause the battery to be faulty. In order to
the battery case provides visual information for bat- obtain correct indications from the built-in test indi-
tery testing (Fig. 6). Like a hydrometer, the built-in cator, it is important that the battery be level and
test indicator measures the specific gravity of the have a clean sight glass. Additional light may be
battery electrolyte. The test indicator reveals the bat- required to view the indicator. Do not use open
tery state-of-charge; however, it will not reveal the flame as a source of additional light.
cranking capacity of the battery. A load test must be To read the built-in test indicator, look into the
performed to determine the battery cranking capac- sight glass and note the color of the indicator (Fig. 7).
ity. Refer to Load Test in this section for the proper The battery condition that each color indicates is
battery load testing procedures. described in the following list:
• Green
Indicates 75% to 100% battery state-of-charge. The
battery is adequately charged for further testing or
return to service. If the starter will not crank for a
minimum of fifteen seconds with a fully-charged bat-
tery, the battery must be load tested. Refer to Load
Test in this section for the proper battery load test-
ing procedures.
• Black or Dark
Indicates 0% to 75% battery state-of-charge. The bat-
tery is inadequately charged and must be charged
until a green indication is visible in the sight glass
Fig. 6 Built-In Test Indicator (12.4 volts or more), before the battery is tested fur-
1 – SIGHT GLASS ther or returned to service. Refer to Battery Charg-
2 – BATTERY TOP ing in the index of this service manual for the
3 – GREEN BALL location of the proper battery charging procedures.
4 – PLASTIC ROD Also refer to Abnormal Battery Discharging in
this section for the possible causes of the discharged
WARNING: battery condition.
• IF THE BATTERY SHOWS SIGNS OF FREEZ- • Clear or Bright
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- Indicates a low battery electrolyte level. The electro-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR lyte level in the battery is below the test indicator. A
CHARGE. THE BATTERY MAY ARC INTERNALLY maintenance-free battery with non-removable cell
AND EXPLODE. PERSONAL INJURY AND/OR VEHI- caps must be replaced if the electrolyte level is low.
CLE DAMAGE MAY RESULT. Water must be added to a low-maintenance battery
• EXPLOSIVE HYDROGEN GAS FORMS IN AND with removable cell caps before it is charged. Refer to
AROUND THE BATTERY. DO NOT SMOKE, USE Battery Charging in the index of this service man-
FLAME, OR CREATE SPARKS NEAR THE BATTERY. ual for the location of the proper battery charging
PERSONAL INJURY AND/OR VEHICLE DAMAGE procedures. A low electrolyte level may be caused by
MAY RESULT. an overcharging condition. Refer to Charging Sys-
• THE BATTERY CONTAINS SULFURIC ACID, tem in the index of this service manual for the loca-
WHICH IS POISONOUS AND CAUSTIC. AVOID CON- tion of the proper charging system diagnosis and
TACT WITH THE SKIN, EYES, OR CLOTHING. IN testing procedures.
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.

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 8A - 10 BATTERY XJ
DIAGNOSIS AND TESTING (Continued)
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.

Before testing, visually inspect the battery for any

damage (a cracked case or cover, loose posts, etc.)
that would cause the battery to be faulty. Then
remove the battery cell caps and check the electrolyte
level. Add distilled water if the electrolyte level is
below the top of the battery plates.
See the instructions provided by the manufacturer
of the hydrometer for recommendations on the cor-
rect use of the hydrometer that you are using.
Fig. 7 Built-In Test Indicator Sight Glass Remove only enough electrolyte from the battery cell
so that the float is off the bottom of the hydrometer
HYDROMETER TEST
barrel with pressure on the bulb released. To read
The hydrometer test reveals the battery state-of- the hydrometer correctly, hold it with the top surface
charge by measuring the specific gravity of the elec- of the electrolyte at eye level (Fig. 8).
trolyte. This test cannot be performed on
maintenance-free batteries with non-removable CAUTION: Exercise care when inserting the tip of
cell caps. If the battery has non-removable cell caps, the hydrometer into a battery cell to avoid damag-
refer to Built-In Test Indicator or Open-Circuit ing the plate separators. Damaged plate separators
Voltage Test in this section for the proper proce- can cause early battery failure.
dures for performing these alternate tests of the bat-
tery state-of-charge.
Specific gravity is a comparison of the density of
the battery electrolyte to the density of pure water.
Pure water has a specific gravity of 1.000, and sulfu-
ric acid has a specific gravity of 1.835. Sulfuric acid
makes up approximately 35% of the battery electro-
lyte by weight, or 24% by volume. In a fully-charged
battery the electrolyte will have a temperature-cor-
rected specific gravity of 1.260 to 1.290. However, a
specific gravity of 1.235 or above is satisfactory for
battery load testing and/or return to service.

WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY. Fig. 8 Hydrometer - Typical
PERSONAL INJURY AND/OR VEHICLE DAMAGE 1 – BULB
MAY RESULT. 2 – SURFACE COHESION
• THE BATTERY CONTAINS SULFURIC ACID, 3 – SPECIFIC GRAVITY READING
WHICH IS POISONOUS AND CAUSTIC. AVOID CON- 4 – TEMPERATURE READING
5 – HYDROMETER BARREL
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
6 – FLOAT
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN. Hydrometer floats are generally calibrated to indi-
• IF THE BATTERY IS EQUIPPED WITH REMOV- cate the specific gravity correctly only at 26.7° C (80°
ABLE CELL CAPS, BE CERTAIN THAT EACH OF F). When testing the specific gravity at any other
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE temperature, a correction factor is required. The cor-

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 XJ BATTERY 8A - 11
DIAGNOSIS AND TESTING (Continued)
rection factor is approximately a specific gravity PERSONAL INJURY AND/OR VEHICLE DAMAGE
value of 0.004, which may also be identified as four MAY RESULT.
points of specific gravity. For each 5.5° C above 26.7° • THE BATTERY CONTAINS SULFURIC ACID,
C (10° F above 80° F), add four points. For each 5.5° WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
C below 26.7° C (10° F below 80° F), subtract four TACT WITH THE SKIN, EYES, OR CLOTHING. IN
points. Always correct the specific gravity for temper- THE EVENT OF CONTACT, FLUSH WITH WATER
ature variation. AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
EXAMPLE: A battery is tested at -12.2° C (10° F) OF THE REACH OF CHILDREN.
and has a specific gravity of 1.240. Determine the • IF THE BATTERY IS EQUIPPED WITH REMOV-
actual specific gravity as follows: ABLE CELL CAPS, BE CERTAIN THAT EACH OF
(1) Determine the number of degrees above or THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
below 26.7° C (80° F): 26.6° C - -12.2° C = 38.8° C THE BATTERY IS RETURNED TO SERVICE. PER-
(80° F - 10° F = 70° F) SONAL INJURY AND/OR VEHICLE DAMAGE MAY
(2) Divide the result from Step 1 by 5.5° C (10° F): RESULT FROM LOOSE OR MISSING CELL CAPS.
38.8° C 4 5.5° C = 7 (70° F 4 10° F = 7)
(3) Multiply the result from Step 2 by the temper- Before proceeding with this test, completely charge
ature correction factor (0.004): 7 X 0.004 = 0.028 the battery. Refer to Battery Charging in the index
(4) The temperature at testing was below 26.7° C of this service manual for the location of the proper
(80° F); therefore, the temperature correction factor battery charging procedures.
is subtracted: 1.240 - 0.028 = 1.212 (1) Before measuring the open-circuit voltage, the
(5) The corrected specific gravity of the battery cell surface charge must be removed from the battery.
in this example is 1.212. Turn on the headlamps for fifteen seconds, then
Test the specific gravity of the electrolyte in each allow up to five minutes for the battery voltage to
battery cell. If the specific gravity of all cells is above stabilize.
1.235, but the variation between cells is more than (2) Disconnect and isolate both battery cables, neg-
fifty points (0.050), the battery should be replaced. If ative cable first.
the specific gravity of one or more cells is less than (3) Using a voltmeter connected to the battery
1.235, charge the battery at a rate of approximately posts (see the instructions provided by the manufac-
five amperes. Continue charging the battery until turer of the voltmeter), measure the open-circuit volt-
three consecutive specific gravity tests, taken at one- age (Fig. 9).
hour intervals, are constant. If the cell specific grav-
ity variation is more than fifty points (0.050) at the
end of the charge period, replace the battery.
When the specific gravity of all cells is above 1.235,
and the cell variation is less than fifty points (0.050),
the battery may be load tested to determine its
cranking capacity. Refer to Load Test in this section
for the proper battery load testing procedures.

OPEN-CIRCUIT VOLTAGE TEST

A battery open-circuit voltage (no load) test will
show the state-of-charge of a battery. This test can be
used in place of the hydrometer test when a hydrom-
eter is not available, or for maintenance-free batter-
ies with non-removable cell caps.
Fig. 9 Testing Open-Circuit Voltage - Typical
WARNING: See the Open-Circuit Voltage chart. This voltage
• IF THE BATTERY SHOWS SIGNS OF FREEZ- reading will indicate the battery state-of-charge, but
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- will not reveal its cranking capacity. If a battery has
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR an open-circuit voltage reading of 12.4 volts or
CHARGE. THE BATTERY MAY ARC INTERNALLY greater, it may be load tested to reveal its cranking
AND EXPLODE. PERSONAL INJURY AND/OR VEHI- capacity. Refer to Load Test in this section for the
CLE DAMAGE MAY RESULT. proper battery load testing procedures.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.

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 8A - 12 BATTERY XJ
DIAGNOSIS AND TESTING (Continued)

Open Circuit Voltage age Test in this section for the proper battery open-
circuit voltage test procedures. The battery open-
Open Circuit Volts Charge Percentage circuit voltage must be 12.4 volts or greater.
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%

LOAD TEST
A battery load test will verify the battery cranking
capacity. The test is based on the Cold Cranking
Amperage (CCA) rating of the battery. See the label
affixed to the battery case, or refer to Battery in the
index of this service manual for the location of the
proper factory-installed battery specifications to
determine the battery CCA rating. Fig. 10 Volt-Ammeter-Load Tester - Typical

WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN Fig. 11 Volt-Ammeter-Load Tester Connections -
THE EVENT OF CONTACT, FLUSH WITH WATER Typical
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT 1 – INDUCTION AMMETER CLAMP
OF THE REACH OF CHILDREN. 2 – NEGATIVE CLAMP
• IF THE BATTERY IS EQUIPPED WITH REMOV- 3 – POSITIVE CLAMP
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE (3) Rotate the load control knob (carbon pile rheo-
THE BATTERY IS RETURNED TO SERVICE. PER- stat) to apply a 300 ampere load to the battery for
SONAL INJURY AND/OR VEHICLE DAMAGE MAY fifteen seconds, then return the control knob to the
RESULT FROM LOOSE OR MISSING CELL CAPS. Off position (Fig. 12). This will remove the surface
charge from the battery.
Before proceeding with this test, completely charge (4) Allow the battery to stabilize to open-circuit
the battery. Refer to Battery Charging in the index voltage. It may take up to five minutes for the bat-
of this service manual for the location of the proper tery voltage to stabilize.
battery charging procedures. (5) Rotate the load control knob to maintain a load
(1) Disconnect and isolate both battery cables, neg- equal to 50% of the CCA rating of the battery (Fig.
ative cable first. The battery top and posts should be 13). After fifteen seconds, record the loaded voltage
clean. reading, then return the load control knob to the Off
(2) Connect a suitable volt-ammeter-load tester position.
(Fig. 10) to the battery posts (Fig. 11). See the (6) The voltage drop will vary with the battery
instructions provided by the manufacturer of the temperature at the time of the load test. The battery
tester you are using. Check the open-circuit voltage temperature can be estimated by using the ambient
(no load) of the battery. Refer to Open-Circuit Volt- temperature during the past several hours. If the

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 XJ BATTERY 8A - 13
DIAGNOSIS AND TESTING (Continued)

Load Test Temperature

Temperature
Minimum Voltage
°F °C
9.6 volts 70° and above 21° and above
9.5 volts 60° 16°
9.4 volts 50° 10°
9.3 volts 40° 4°
9.1 volts 30° -1°
8.9 volts 20° -7°
8.7 volts 10° -12°
8.5 volts 0° -18°
Fig. 12 Remove Surface Charge from Battery -
Typical non-ignition controlled circuits in proper working
order. The twenty-five milliamperes are needed to
enable the memory functions for the Powertrain Con-
trol Module (PCM), digital clock, electronically tuned
radio, and other modules which may vary with the
vehicle equipment.
A vehicle that has not been operated for approxi-
mately twenty days, may discharge the battery to an
inadequate level. When a vehicle will not be used for
twenty days or more (stored), remove the IOD fuse
from the Power Distribution Center (PDC). This will
reduce battery discharging.
Excessive IOD can be caused by:
• Electrical items left on.
• Faulty or improperly adjusted switches.
• Faulty or shorted electronic modules and compo-
Fig. 13 Load 50% CCA Rating - Note Voltage -
nents.
Typical
• An internally shorted generator.
battery has been charged, boosted, or loaded a few • Intermittent shorts in the wiring.
minutes prior to the test, the battery will be some- If the IOD is over twenty-five milliamperes, the
what warmer. See the Load Test Temperature chart problem must be found and corrected before replac-
for the proper loaded voltage reading. ing a battery. In most cases, the battery can be
(7) If the voltmeter reading falls below 9.6 volts, at charged and returned to service after the excessive
a minimum battery temperature of 21° C (70° F), the IOD condition has been corrected.
battery is faulty and must be replaced. (1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
IGNITION-OFF DRAW TEST all doors. If the vehicle is equipped with an illumi-
The term Ignition-Off Draw (IOD) identifies a nor- nated entry system or an electronically tuned radio,
mal condition where power is being drained from the allow the electronic timer function of these systems
battery with the ignition switch in the Off position. A to automatically shut off (time out). This may take
normal vehicle electrical system will draw from five up to three minutes. See the Electronic Module Igni-
to twenty-five milliamperes (0.005 to 0.025 ampere) tion-Off Draw table for more information.
with the ignition switch in the Off position, and all

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 8A - 14 BATTERY XJ
DIAGNOSIS AND TESTING (Continued)

Electronic Module Ignition-Off Draw (IOD)

Time Out? IOD After Time
Module IOD
(If Yes, Interval and Wake-Up Input) Out
1 to 3
Radio No N/A
milliamperes
Audio Power up to 1
No N/A
Amplifier milliampere
Central Timer Module 4.75
No N/A
(CTM) milliamperes
Powertrain Control
No 0.95 milliampere N/A
Module (PCM)
ElectroMechanical
Instrument Cluster No 0.44 milliampere N/A
(EMIC)
Combination Flasher No 0.08 milliampere N/A

(2) Determine that the under-hood lamp is operat- breaker, disconnect the wire harness from the gener-
ing properly, then disconnect the lamp wire harness ator. If the amperage reading now becomes very low
connector or remove the lamp bulb. or nonexistent, refer to Charging System in the
(3) Disconnect the battery negative cable. index of this service manual for the location of the
(4) Set an electronic digital multi-meter to its proper charging system diagnosis and testing proce-
highest amperage scale. Connect the multi-meter dures. After the high-amperage IOD has been cor-
between the disconnected battery negative cable ter- rected, switch the multi-meter to progressively lower
minal clamp and the battery negative terminal post. amperage scales and, if necessary, repeat the fuse
Make sure that the doors remain closed so that the and circuit breaker remove-and-replace process to
illuminated entry system is not activated. The multi- identify and correct all sources of excessive IOD. It is
meter amperage reading may remain high for up to now safe to select the lowest milliampere scale of the
three minutes, or may not give any reading at all multi-meter to check the low-amperage IOD.
while set in the highest amperage scale, depending
upon the electrical equipment in the vehicle. The CAUTION: Do not open any doors, or turn on any
multi-meter leads must be securely clamped to the electrical accessories with the lowest milliampere
battery negative cable terminal clamp and the bat- scale selected, or the multi-meter may be damaged.
tery negative terminal post. If continuity between the (6) Observe the multi-meter reading. The low-am-
battery negative terminal post and the negative cable perage IOD should not exceed twenty-five milliam-
terminal clamp is lost during any part of the IOD peres (0.025 ampere). If the current draw exceeds
test, the electronic timer function will be activated twenty-five milliamperes, isolate each circuit using
and all of the tests will have to be repeated. the fuse and circuit breaker remove-and-replace pro-
(5) After about three minutes, the high-amperage cess in Step 5. The multi-meter reading will drop to
IOD reading on the multi-meter should become very within the acceptable limit when the source of the
low or nonexistent, depending upon the electrical excessive current draw is disconnected. Repair this
equipment in the vehicle. If the amperage reading circuit as required; whether a wiring short, incorrect
remains high, remove and replace each fuse or circuit switch adjustment, or a component failure is at fault.
breaker in the Power Distribution Center (PDC) and
then in the Junction Block (JB) one at a time (refer BATTERY CABLES
to Power Distribution Center and Junction
Block in the index of this service manual for the DIAGNOSIS
location of complete PDC and JB fuse and circuit A voltage drop test will determine if there is exces-
breaker identification contained in the wiring dia- sive resistance in the battery cable terminal connec-
grams) until the amperage reading becomes very low, tions or the battery cables. If excessive resistance is
or nonexistent. This will isolate each circuit and found in the battery cable connections, the connec-
identify the circuit that is the source of the high-am- tion point should be disassembled, cleaned of all cor-
perage IOD. If the amperage reading remains high rosion or foreign material, then reassembled.
after removing and replacing each fuse and circuit Following reassembly, check the voltage drop for the

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 XJ BATTERY 8A - 15
DIAGNOSIS AND TESTING (Continued)
battery cable connection and the battery cable again • Fully engage the parking brake.
to confirm repair. • If the vehicle is equipped with an automatic
When performing the voltage drop test, it is impor- transmission, place the gearshift selector lever in the
tant to remember that the voltage drop is giving an Park position. If the vehicle is equipped with a man-
indication of the resistance between the two points at ual transmission, place the gearshift selector lever in
which the voltmeter probes are attached. EXAM- the Neutral position and block the clutch pedal in the
PLE: When testing the resistance of the battery pos- fully depressed position.
itive cable, touch the voltmeter leads to the battery • Verify that all lamps and accessories are turned
positive cable terminal clamp and to the battery pos- off.
itive cable eyelet terminal at the starter solenoid • To prevent the engine from starting, remove the
B(+) terminal stud. If you probe the battery positive Automatic ShutDown (ASD) relay. The ASD relay is
terminal post and the battery positive cable eyelet located in the Power Distribution Center (PDC), in
terminal at the starter solenoid B(+) terminal stud, the engine compartment. See the fuse and relay lay-
you are reading the combined voltage drop in the out label affixed to the underside of the PDC cover
battery positive cable terminal clamp-to-terminal for ASD relay identification and location.
post connection and the battery positive cable. (1) Connect the positive lead of the voltmeter to
the battery negative terminal post. Connect the neg-
TESTING ative lead of the voltmeter to the battery negative
cable terminal clamp (Fig. 14). Rotate and hold the
VOLTAGE DROP TEST ignition switch in the Start position. Observe the
voltmeter. If voltage is detected, correct the poor con-
WARNING: nection between the battery negative cable terminal
• IF THE BATTERY SHOWS SIGNS OF FREEZ- clamp and the battery negative terminal post.
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV- Fig. 14 Test Battery Negative Connection
ABLE CELL CAPS, BE CERTAIN THAT EACH OF Resistance - Typical
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE 1 – VOLTMETER
THE BATTERY IS RETURNED TO SERVICE. PER- 2 – BATTERY
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS. (2) Connect the positive lead of the voltmeter to
the battery positive terminal post. Connect the nega-
The following operation will require a voltmeter
tive lead of the voltmeter to the battery positive cable
accurate to 1/10 (0.10) volt. Before performing this
terminal clamp (Fig. 15). Rotate and hold the ignition
test, be certain that the following procedures are
switch in the Start position. Observe the voltmeter. If
accomplished:
voltage is detected, correct the poor connection
• The battery is fully-charged and load tested.
between the battery positive cable terminal clamp
Refer to Battery Charging in the index of this ser-
and the battery positive terminal post.
vice manual for the location of the proper battery
(3) Connect the voltmeter to measure between the
charging procedures. Refer to Battery in the index of
battery positive cable terminal clamp and the starter
this service manual for the location of the battery
solenoid B(+) terminal stud (Fig. 16). Rotate and hold
diagnosis and testing procedures, including the
the ignition switch in the Start position. Observe the
proper battery load test procedures.

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 8A - 16 BATTERY XJ
DIAGNOSIS AND TESTING (Continued)
(4) Connect the voltmeter to measure between the
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 17). Rotate
and hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable
eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.

Fig. 15 Test Battery Positive Connection Resistance

- Typical
1 – VOLTMETER
2 – BATTERY

voltmeter. If the reading is above 0.2 volt, clean and

tighten the battery positive cable eyelet terminal con-
nection at the starter solenoid B(+) terminal stud.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable. Fig. 17 Test Ground Circuit Resistance - Typical
1 – VOLTMETER
2 – BATTERY
3 – ENGINE GROUND

SERVICE PROCEDURES
BATTERY CHARGING
Battery charging is the means by which the bat-
tery can be restored to its full voltage potential. A
battery is fully-charged when:
• All of the battery cells are gassing freely during
battery charging.
• A green color is visible in the sight glass of the
battery built-in test indicator.
• Three hydrometer tests, taken at one-hour inter-
Fig. 16 Test Battery Positive Cable Resistance - vals, indicate no increase in the temperature-cor-
Typical rected specific gravity of the battery electrolyte.
1 – BATTERY • Open-circuit voltage of the battery is 12.4 volts
2 – VOLTMETER or above.
3 – STARTER MOTOR

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 XJ BATTERY 8A - 17
SERVICE PROCEDURES (Continued)
WARNING: cranking capacity. Refer to Battery in the index of
• IF THE BATTERY SHOWS SIGNS OF FREEZ- this service manual for the location of the battery
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- diagnosis and testing procedures for more informa-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR tion on the proper battery load testing procedures. If
CHARGE. THE BATTERY MAY ARC INTERNALLY the battery will endure a load test, return the bat-
AND EXPLODE. PERSONAL INJURY AND/OR VEHI- tery to service. If the battery will not endure a load
CLE DAMAGE MAY RESULT. test, it is faulty and must be replaced.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND Clean and inspect the battery hold downs, tray,
AROUND THE BATTERY. DO NOT SMOKE, USE terminals, posts, and top before completing battery
FLAME, OR CREATE SPARKS NEAR THE BATTERY. service. Refer to Battery in the index of this service
PERSONAL INJURY AND/OR VEHICLE DAMAGE manual for the location of the proper battery clean-
MAY RESULT. ing and inspection procedures.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON- CHARGING A COMPLETELY DISCHARGED
TACT WITH THE SKIN, EYES, OR CLOTHING. IN BATTERY
THE EVENT OF CONTACT, FLUSH WITH WATER The following procedure should be used to recharge
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT a completely discharged battery. Unless this proce-
OF THE REACH OF CHILDREN. dure is properly followed, a good battery may be
• IF THE BATTERY IS EQUIPPED WITH REMOV- needlessly replaced.
ABLE CELL CAPS, BE CERTAIN THAT EACH OF (1) Measure the voltage at the battery posts with a
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE voltmeter, accurate to 1/10 (0.10) volt (Fig. 18). If the
THE BATTERY IS RETURNED TO SERVICE. PER- reading is below ten volts, the battery charging cur-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY rent will be low. It could take some time before the
RESULT FROM LOOSE OR MISSING CELL CAPS. battery accepts a current greater than a few milliam-
peres. Such low current may not be detectable on the
ammeters built into many battery chargers.
CAUTION:
• Always disconnect and isolate the battery neg-
ative cable before charging a battery. Do not exceed
sixteen volts while charging a battery. Damage to
the vehicle electrical system components may
result.
• Battery electrolyte will bubble inside the bat-
tery case during normal battery charging. Electro-
lyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
• The battery should not be hot to the touch. If
the battery feels hot to the touch, turn off the
charger and let the battery cool before continuing Fig. 18 Voltmeter Accurate to 1/10 Volt Connected -
the charging operation. Damage to the battery may Typical
result.
(2) Disconnect and isolate the battery negative
Some battery chargers are equipped with polarity- cable. Connect the battery charger leads. Some bat-
sensing circuitry. This circuitry protects the battery tery chargers are equipped with polarity-sensing cir-
charger and the battery from being damaged if they cuitry. This circuitry protects the battery charger and
are improperly connected. If the battery state-of- the battery from being damaged if they are improp-
charge is too low for the polarity-sensing circuitry to erly connected. If the battery state-of-charge is too
detect, the battery charger will not operate. This low for the polarity-sensing circuitry to detect, the
makes it appear that the battery will not accept battery charger will not operate. This makes it
charging current. See the instructions provided by appear that the battery will not accept charging cur-
the manufacturer of the battery charger for details rent. See the instructions provided by the manufac-
on how to bypass the polarity-sensing circuitry. turer of the battery charger for details on how to
After the battery has been charged to 12.4 volts or bypass the polarity-sensing circuitry.
greater, perform a load test to determine the battery

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 8A - 18 BATTERY XJ
SERVICE PROCEDURES (Continued)
(3) Battery chargers vary in the amount of voltage Battery Charging Timetable
and current they provide. The amount of time
required for a battery to accept measurable charging Charging 5 10 20
current at various voltages is shown in the Charge Amperage Amperes Amperes Amperes
Rate chart. If the charging current is still not mea- Open
surable at the end of the charging time, the battery Circuit Hours Charging at 21° C (70° F)
is faulty and must be replaced. If the charging cur- Voltage
rent is measurable during the charging time, the bat- 12.25 to 6 hours 3 hours 1.5 hours
tery may be good and the charging should be 12.49
completed in the normal manner.
12.00 to 10 hours 5 hours 2.5 hours
Charge Rate 12.24
Voltage Hours 10.00 to 14 hours 7 hours 3.5 hours
11.99
16.0 volts maximum up to 4 hours
*Below 18 hours 9 hours 4.5 hours
14.0 to 15.9 volts up to 8 hours
10.00
13.9 volts or less up to 16 hours
*Refer to Charging A Completely Discharged Battery

CHARGING TIME REQUIRED

The time required to charge a battery will vary,
REMOVAL AND INSTALLATION
depending upon the following factors:
• Battery Capacity BATTERY CABLES
A completely discharged heavy-duty battery requires Both the battery negative cable and the battery
twice the charging time of a small capacity battery. positive cable are serviced in the battery wire har-
• Temperature ness. If either battery cable is damaged or faulty, the
A longer time will be needed to charge a battery at battery wire harness unit must be replaced.
-18° C (0° F) than at 27° C (80° F). When a fast bat-
tery charger is connected to a cold battery, the cur- REMOVAL
rent accepted by the battery will be very low at first. (1) Turn the ignition switch to the Off position. Be
As the battery warms, it will accept a higher charg- certain that all electrical accessories are turned off.
ing current rate (amperage). (2) Loosen the battery negative cable terminal
• Charger Capacity clamp pinch-bolt hex nut.
A battery charger that supplies only five amperes (3) Disconnect the battery negative cable terminal
will require a longer charging time. A battery charger clamp from the battery negative terminal post. If
that supplies twenty amperes or more will require a necessary, use a battery terminal puller to remove
shorter charging time. the terminal clamp from the battery post.
• State-Of-Charge (4) Loosen the battery positive cable terminal
A completely discharged battery requires more charg- clamp pinch-bolt hex nut.
ing time than a partially discharged battery. Electro- (5) Disconnect the battery positive cable terminal
lyte is nearly pure water in a completely discharged clamp from the battery positive terminal post. If nec-
battery. At first, the charging current (amperage) will essary, use a battery terminal puller to remove the
be low. As the battery charges, the specific gravity of terminal clamp from the battery post.
the electrolyte will gradually rise. (6) Unlatch and remove the B(+) terminal stud
cover from the front of the Power Distribution Center
WARNING: NEVER EXCEED TWENTY AMPERES (PDC).
WHEN CHARGING A COLD (-1° C or 30° F) BAT- (7) Remove the nut that secures the battery posi-
TERY. THE BATTERY MAY ARC INTERNALLY AND tive cable eyelet terminal and the generator output
EXPLODE. PERSONAL INJURY AND/OR VEHICLE cable eyelet terminal to the B(+) terminal stud on the
DAMAGE MAY RESULT. PDC.
(8) Remove the battery positive cable eyelet termi-
nal and the generator output cable eyelet terminal
from the B(+) terminal stud on the PDC.
(9) Disconnect the battery wire harness connector
from the headlamp and dash wire harness connector
located below the front of the PDC.

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 XJ BATTERY 8A - 19
REMOVAL AND INSTALLATION (Continued)
(10) Remove the screw that secures the battery (5) Install and tighten the nut that secures the
negative cable eyelet terminal to the inner fender battery positive cable eyelet terminal to the B(+) ter-
shield near the battery. minal stud on the starter solenoid. Tighten the nut to
(11) On LHD models with air conditioning, discon- 10 N·m (90 in. lbs.).
nect the compressor clutch wire harness connector (6) On models with a 2.5L engine, install and
from the battery wire harness connector. tighten the nut that secures the battery wire harness
(12) Unlatch and remove the cover from the gener- locator clip to the stud on the right side engine block
ator output terminal stud housing on the back of the oil pan rail below and forward of the engine oil filter
generator. adapter. Tighten the nut to 8.4 N·m (75 in. lbs.).
(13) Remove the nut that secures the generator (7) On models with a 4.0L engine, install and
output cable eyelet terminal to the generator output tighten the screw that secures the battery wire har-
terminal stud. ness locator clip to the right side of the engine block
(14) Remove the generator output cable eyelet ter- between and below the right engine mount and the
minal from the generator output terminal stud. oil filter adapter. Tighten the screw to 8.4 N·m (75 in.
(15) Disconnect the battery wire harness connector lbs.).
from the generator field terminal connector recepta- (8) Install the battery negative cable ground eyelet
cle on the back of the generator. terminal onto the stud on the right side of the engine
(16) Remove the nut that secures the battery neg- block.
ative cable ground eyelet terminal to the stud on the (9) Install and tighten the nut that secures the
right side of the engine block. battery negative cable ground eyelet terminal to the
(17) Remove the battery negative cable ground stud on the right side of the engine block. Tighten
eyelet terminal from the engine block stud. the nut to 15.8 N·m (140 in. lbs.).
(18) On models with a 2.5L engine, remove the nut (10) Reconnect the battery wire harness connector
that secures the battery wire harness locator clip to to the generator field terminal connector receptacle
the stud on the right side engine block oil pan rail on the back of the generator.
below and forward of the engine oil filter adapter. (11) Install the generator output cable eyelet ter-
(19) On models with a 4.0L engine, remove the minal onto the generator output terminal stud.
screw that secures the battery wire harness locator (12) Install and tighten the nut that secures the
clip to the right side of the engine block between and generator output cable eyelet terminal to the genera-
below the right engine mount and the oil filter tor output terminal stud. Tighten the nut to 8.4 N·m
adapter. (75 in. lbs.).
(20) Remove the nut that secures the battery pos- (13) Position the cover for the generator output
itive cable eyelet terminal to the B(+) terminal stud terminal stud housing onto the back of the generator
on the starter solenoid. and snap it into place.
(21) Remove the battery positive cable eyelet ter- (14) On LHD models with air conditioning, recon-
minal from the B(+) terminal stud on the starter nect the compressor clutch wire harness connector to
solenoid. the battery wire harness connector.
(22) Disconnect the battery wire harness connector (15) Install and tighten the screw that secures the
from the connector receptacle on the starter solenoid. battery negative cable eyelet terminal to the inner
(23) Remove the battery wire harness from the fender shield near the battery. Tighten the screw to
engine compartment. 24.8 N·m (220 in. lbs.).
(16) Reconnect the battery wire harness connector
INSTALLATION to the headlamp and dash wire harness connector
(1) Clean and inspect the battery cable terminal located below the front of the PDC.
clamps and the battery terminal posts. Refer to Bat- (17) Install the battery positive cable eyelet termi-
tery in the index of this service manual for the loca- nal and the generator output cable eyelet terminal
tion of the proper battery cable terminal clamp and onto the PDC B(+) terminal stud.
battery terminal post cleaning and inspection proce- (18) Install and tighten the nut that secures the
dures. battery positive cable eyelet terminal and the gener-
(2) Position the battery wire harness into the ator output cable eyelet terminal to the PDC B(+)
engine compartment. terminal stud. Tighten the nut to 10.7 N·m (95 in.
(3) Reconnect the battery wire harness connector lbs.).
to the connector receptacle on the starter solenoid. (19) Engage the tabs on the lower edge of the B(+)
(4) Install the battery positive cable eyelet termi- terminal stud cover in the slots on the front of the
nal onto the B(+) terminal stud on the starter sole- PDC housing, then engage the latch on the top of the
noid. cover with the latch tabs on the PDC housing.

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 8A - 20 BATTERY XJ
REMOVAL AND INSTALLATION (Continued)
(20) Reconnect the battery positive cable terminal
clamp to the battery positive terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
in. lbs.).
(21) Reconnect the battery negative cable terminal
clamp to the battery negative terminal post. Tighten
the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
in. lbs.).
(22) Apply a thin coating of petroleum jelly or
chassis grease to the exposed surfaces of the battery
cable terminal clamps and the battery terminal
posts.

BATTERY HOLD DOWNS

All of the battery hold down hardware except for
the T-bolts can be serviced without removal of the
battery or the battery tray. The battery tray must be
removed from the vehicle to service the T-bolts. If the
T-bolts require service replacement, refer to Battery
Tray in the index of this service manual for the loca-
tion of the proper battery tray removal and installa-
tion procedures.

REMOVAL
Fig. 19 Battery Hold Downs Remove/Install
(1) Turn the ignition switch to the Off position. Be
1 – SCREW AND WASHER (1)
certain that all electrical accessories are turned off. 2 – NUT AND WASHER (2)
(2) Loosen the battery negative cable terminal 3 – T-BOLT (2)
clamp pinch-bolt hex nut. 4 – RETAINER (2)
(3) Disconnect the battery negative cable terminal 5 – BATTERY TRAY
clamp from the battery negative terminal post. If 6 – UPPER RADIATOR CROSS MEMBER
necessary, use a battery terminal puller to remove 7 – BRACKET
the terminal clamp from the battery post. 8 – STRAP
(4) Remove the nut with washer from the threaded
end of each of the two T-bolts (Fig. 19). (3) Position the battery support strap with the
(5) Remove the screw with washer that secures the round hole over the threaded end of the T-bolt near-
end of the battery support strap with a slotted hole est to the front of the vehicle and the slotted hole
to the top of the upper radiator crossmember. over the mounting hole in the top of the upper radi-
(6) Remove the battery support strap from the ator crossmember.
threaded end of the T-bolt nearest to the front of the (4) Install and tighten the screw with washer that
vehicle. secures the end of the battery support strap with a
(7) Remove the battery hold down bracket from slotted hole to the top of the upper radiator cross-
the threaded ends of the two T-bolts and the top of member. Tighten the screw to 8.7 N·m (77 in. lbs.).
the battery case. (5) Install and tighten the nut with washer onto
the threaded end of each of the two T-bolts. Tighten
INSTALLATION the nuts to 2.2 N·m (20 in. lbs.).
(1) Clean and inspect the battery hold down hard- (6) Reconnect the battery negative cable terminal
ware. Refer to Battery in the index of this service clamp to the battery negative terminal post. Tighten
manual for the location of the proper battery hold the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
down hardware cleaning and inspection procedures. in. lbs.).
(2) Position the battery hold down bracket onto the
threaded ends of the two T-bolts and across the top of
the battery case.

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 XJ BATTERY 8A - 21
REMOVAL AND INSTALLATION (Continued)

BATTERY tion of the proper battery cleaning and inspection

procedures.
REMOVAL (2) Reinstall the battery thermoguard onto the
(1) Turn the ignition switch to the Off position. Be battery case. Refer to Battery Thermoguard in the
certain that all electrical accessories are turned off. index of this service manual for the location of the
(2) Loosen the battery negative cable terminal proper battery thermoguard installation procedures.
clamp pinch-bolt hex nut. (3) Position the battery and the battery thermo-
(3) Disconnect the battery negative cable terminal guard onto the battery tray as a unit. Ensure that
clamp from the battery negative terminal post. If the battery positive and negative terminal posts are
necessary, use a battery terminal puller to remove correctly positioned. The battery cable terminal
the terminal clamp from the battery post (Fig. 20). clamps must reach the correct battery terminal post
without stretching the cables (Fig. 21).

Fig. 20 Remove Battery Cable Terminal Clamp -

Typical
1 – BATTERY
2 – BATTERY TERMINAL PULLER
Fig. 21 Battery Cables
(4) Loosen the battery positive cable terminal 1 – RADIATOR CROSSMEMBER
clamp pinch-bolt hex nut. 2 – WHEELHOUSE INNER PANEL
3 – NEGATIVE CABLE
(5) Disconnect the battery positive cable terminal
4 – POSITIVE CABLE
clamp from the battery positive terminal post. If nec-
5 – BATTERY
essary, use a battery terminal puller to remove the
terminal clamp from the battery post.
(6) Remove the battery hold downs from the bat- (4) Reinstall the battery hold downs onto the bat-
tery. Refer to Battery Hold Downs in the index of tery. Refer to Battery Hold Downs in the index of
this service manual for the location of the proper bat- this service manual for the location of the proper bat-
tery hold down removal procedures. tery hold down installation procedures.

WARNING: WEAR A SUITABLE PAIR OF RUBBER CAUTION: Be certain that the battery cable terminal
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN clamps are connected to the correct battery termi-
REMOVING A BATTERY BY HAND. SAFETY nal posts. Reversed battery polarity may damage
GLASSES SHOULD ALSO BE WORN. IF THE BAT- electrical components of the vehicle.
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES. (5) Clean the battery cable terminal clamps and
the battery terminal posts. Refer to Battery in the
(7) Remove the battery and the battery thermo- index of this service manual for the location of the
guard from the battery tray as a unit. proper battery cleaning and inspection procedures.
(8) Remove the battery thermoguard from the bat- (6) Reconnect the battery positive cable terminal
tery case. Refer to Battery Thermoguard in the clamp to the battery positive terminal post. Tighten
index of this service manual for the location of the the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
proper battery thermoguard removal procedures. in. lbs.).
(7) Reconnect the battery negative cable terminal
INSTALLATION clamp to the battery negative terminal post. Tighten
(1) Clean and inspect the battery. Refer to Bat- the terminal clamp pinch-bolt hex nut to 8.4 N·m (75
tery in the index of this service manual for the loca- in. lbs.).

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 8A - 22 BATTERY XJ
REMOVAL AND INSTALLATION (Continued)
(8) Apply a thin coating of petroleum jelly or chas- location of the proper battery temperature sensor
sis grease to the exposed surfaces of the battery cable removal procedures.
terminal clamps and the battery terminal posts. (3) Remove the three nuts with washers that
secure the battery tray to the weld studs on the front
BATTERY THERMOGUARD extension of the right front wheelhouse inner panel
(Fig. 23).
REMOVAL
(1) Remove the battery and the battery thermo-
guard from the battery tray as a unit. Refer to Bat-
tery in the index of this service manual for the
location of the proper battery removal procedures.
(2) Carefully and evenly slide the battery thermo-
guard up off of the battery case (Fig. 22).

Fig. 22 Battery Thermoguard Remove/Install

1 – THERMOGUARD
2 – BATTERY Fig. 23 Battery Tray Remove/Install
1 – TRAY
2 – NUT AND WASHER (3)
INSTALLATION 3 – T-BOLT (2)
(1) Clean and inspect the battery thermoguard. 4 – RETAINER (2)
Refer to Battery in the index of this service manual 5 – WELD STUD (3)
for the location of the proper battery thermoguard
cleaning and inspection procedures. (4) Remove the battery tray from the weld studs
(2) Carefully and evenly slide the battery thermo- on the front extension of the right front wheelhouse
guard down over the battery case. inner panel.
(3) Install the battery and the battery thermo- (5) From the top of the battery tray, remove the
guard into the battery tray as a unit. Refer to Bat- plastic push-on retainers from the T-bolts that secure
tery in the index of this service manual for the them to the tray.
location of the proper battery installation procedures. (6) From the bottom of the battery tray, remove
the two T-bolts from the T-bolt mounts on the tray.
BATTERY TRAY
INSTALLATION
REMOVAL (1) Clean and inspect the battery tray. Refer to
(1) Remove the battery from the battery tray. Battery in the index of this service manual for the
Refer to Battery in the index of this service manual location of the proper battery tray cleaning and
for the location of the proper battery removal proce- inspection procedures.
dures. (2) From the bottom of the battery tray, position
(2) Remove the battery temperature sensor from the two T-bolts into the T-bolt mounts on the tray.
the battery tray. Refer to Battery Temperature (3) From the top of the battery tray, install the
Sensor in the index of this service manual for the plastic push-on retainers onto the T-bolts to secure
them to the tray.

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 XJ BATTERY 8A - 23
REMOVAL AND INSTALLATION (Continued)
(4) Position the battery tray onto the weld studs
on the front extension of the right front wheelhouse
inner panel.
(5) Install and tighten the three nuts with washers
that secure the battery tray to the weld studs on the
front extension of the right front wheelhouse inner
panel. Tighten the nuts to 5 N·m (45 in. lbs.).
(6) Install the battery temperature sensor onto the
battery tray. Refer to Battery Temperature Sensor
in the index of this service manual for the location of
the proper battery temperature sensor installation
procedures.
(7) Install the battery onto the battery tray. Refer
to Battery in the index of this service manual for
the location of the proper battery installation proce-
dures.

CLEANING AND INSPECTION

BATTERY
The following information details the recommended
cleaning and inspection procedures for the battery Fig. 24 Clean Battery Cable Terminal Clamp -
and related components. In addition to the mainte- Typical
nance schedules found in this service manual and the 1 – TERMINAL BRUSH
2 – BATTERY CABLE
owner’s manual, it is recommended that these proce-
dures be performed any time the battery or related
components must be removed for vehicle service.

CLEANING
(1) Clean the battery cable terminal clamps of all
corrosion. Remove any corrosion using a wire brush
or a post and terminal cleaning tool, and a sodium
bicarbonate (baking soda) and warm water cleaning
solution (Fig. 24).
(2) Clean the battery tray and battery hold down
hardware of all corrosion. Remove any corrosion
using a wire brush and a sodium bicarbonate (baking
soda) and warm water cleaning solution. Paint any
exposed bare metal.
(3) If the removed battery is to be reinstalled,
clean the outside of the battery case and the top
cover with a sodium bicarbonate (baking soda) and
warm water cleaning solution using a stiff bristle
parts cleaning brush to remove any acid film (Fig.
25). Rinse the battery with clean water. Ensure that
the cleaning solution does not enter the battery cells
through the vent holes. If the battery is being
replaced, refer to Battery in the index of this service
manual for the location of the factory-installed bat- Fig. 25 Clean Battery - Typical
tery specifications. Confirm that the replacement bat- 1 – CLEANING BRUSH
tery is the correct size and has the correct ratings for 2 – WARM WATER AND BAKING SODA SOLUTION
the vehicle. 3 – BATTERY
(4) Clean the battery thermoguard with a sodium
bicarbonate (baking soda) and warm water cleaning
solution using a stiff bristle parts cleaning brush to
remove any acid film.

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 8A - 24 BATTERY XJ
CLEANING AND INSPECTION (Continued)
(5) Clean any corrosion from the battery terminal damaged cases or loose terminal posts must be
posts with a wire brush or a post and terminal replaced.
cleaner, and a sodium bicarbonate (baking soda) and (4) Inspect the battery thermoguard for tears,
warm water cleaning solution (Fig. 26). cracks, deformation or other damage. Replace any
battery thermoguard that has been damaged.
(5) Inspect the electrolyte level in the battery. Use
a putty knife or another suitable wide flat-bladed tool
to pry the cell caps off (Fig. 27). Do not use a screw-
driver. Add distilled water to each cell until the liq-
uid reaches the bottom of the vent well. DO NOT
OVERFILL.

Fig. 26 Clean Battery Terminal Post - Typical

1 – TERMINAL BRUSH Fig. 27 Removing Battery Cell Caps - Typical
2 – BATTERY CABLE 1 – PUTTY KNIFE
3 – BATTERY

(6) Inspect the battery built-in test indicator sight

INSPECTION glass for an indication of the battery condition. If the
(1) Inspect the battery cable terminal clamps for battery is discharged, charge as required. Refer to
damage. Replace any battery cable that has a dam- Battery in the index of this service manual for the
aged or deformed terminal clamp. location of the proper battery diagnosis and testing
(2) Inspect the battery tray and battery hold down procedures for more information on the use of the
hardware for damage. Replace any damaged parts. battery built-in test indicator. Also refer to Battery
(3) Slide the thermoguard off of the battery case. Charging in the index of this service manual for the
Inspect the battery case for cracks or other damage location of the proper battery charging procedures.
that could result in electrolyte leaks. Also, check the
battery terminal posts for looseness. Batteries with

SPECIFICATIONS
BATTERY

Battery Classifications and Ratings

Cold
BCI Group Size Reserve Load Test
Part Number Cranking Ampere-Hours
Classification Capacity Amperage
Amperage
56041105AB 34 500 110 Minutes 60 250

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 XJ STARTING SYSTEMS 8B - 1

STARTING SYSTEMS
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 10

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . 2 STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . 11
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 3 STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 4 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14
STARTER MOTOR NOISE - 2.5L ENGINE . . . . . . 8 SPECIFICATIONS
STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . 9 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 15

DESCRIPTION AND OPERATION Refer to Battery in the index of this service manual
for the location of more information on the battery.
STARTING SYSTEM • The battery cables connect the battery to the
electrical system of the vehicle and to the starting
DESCRIPTION system. Refer to Battery Cables in the index of this
An electrically operated engine starting system is service manual for the location of more information
standard factory-installed equipment on this model. on the battery cables.
The starting system is designed to provide the vehi- The starting system low-amperage control circuit
cle operator with a convenient, efficient and reliable includes the ignition switch, the clutch pedal position
means of cranking and starting the internal combus- switch (manual transmission), the park/neutral posi-
tion engine used to power the vehicle and all of its tion switch (automatic transmission), the starter
accessory systems. The starting system includes the relay, the electromagnetic windings of the starter
following major components: solenoid, and the wire harnesses that connect these
• Battery components. The following starting system control
• Battery cables circuit components are covered in more detail in
• Clutch pedal position switch (manual transmis- other areas of this service manual:
sion) • The ignition switch is mounted on the bottom of
• Ignition switch the steering column and actuates the starting system
• Park/neutral position switch (automatic trans- when a properly coded ignition key is inserted in the
mission) ignition lock cylinder on the right side of the steering
• Starter motor (including the integral starter column and turned to the spring-loaded momentary
solenoid) Start position. Refer to Ignition Switch and Key
• Starter relay. Lock Cylinder in the index of this service manual
The starting system consists of two separate cir- for the location of more information on the ignition
cuits. A high-amperage feed circuit that feeds the switch.
starter motor between 150 and 350 amperes of bat- • The clutch pedal position switch is integral to
tery current, and a low-amperage control circuit that the master cylinder of the clutch hydraulic linkage
operates on less than 20 amperes of battery current. assembly on models equipped with a manual trans-
The starting system high-amperage feed circuit mission. Refer to Clutch Hydraulic Linkage in the
includes the battery, the battery cables, the contact index of this service manual for the location of more
disc portion of the starter solenoid, and the starter information on the clutch pedal position switch.
motor. The following starting system feed circuit • On models with the 2.5L engine, the park/neu-
components are covered in more detail in other areas tral position switch is threaded into the left side of
of this service manual: the automatic transmission case and has a spring-
• The battery is located in the passenger side loaded plunger that is actuated by a cam integral to
front corner of the engine compartment, near the the gearshift mechanism within the transmission.
upper radiator crossmember and provides the electri- The back up lamp switch is also integral to the park/
cal current needed to operate the starting system. neutral position switch. On models with the 4.0L

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 8B - 2 STARTING SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
engine, the park/neutral position switch is mounted by engaging the starter pinion gear with the starter
on the right side of the automatic transmission case. ring gear. Once the engine starts, the ignition switch
The switch is indexed to and driven by the transmis- key is released by the vehicle operator. When the
sion manual valve shaft. Refer to Park/Neutral ignition switch key is released, the switch automati-
Position Switch in the index of this service manual cally returns to the On position, which de-energizes
for the location of more information on either version the starting system.
of the park/neutral position switch.
Following are general descriptions of the starter STARTER MOTOR
relay and the starter motor. See the owner’s manual
in the vehicle glove box for more information on the DESCRIPTION
features, use and operation of the starting system.
Refer to Starting System in the index of this ser-
vice manual for the location of complete wiring dia-
grams for the starting system.

NOTE: This group covers both Left-Hand Drive

(LHD) and Right-Hand Drive (RHD) versions of this
model. Whenever required and feasible, the RHD
versions of affected vehicle components have been
constructed as mirror-image of the LHD versions.
While most of the illustrations used in this group
represent only the LHD version, the diagnostic and
service procedures outlined can generally be
applied to either version. Exceptions to this rule
have been clearly identified as LHD or RHD, if a
special illustration or procedure is required. Fig. 1 Starter Motors
1 – STARTER SOLENOID

OPERATION
The starter motors used for both the 2.5L and the
If the vehicle is equipped with a manual transmis-
4.0L engines available in this model are not inter-
sion, the clutch pedal position switch is installed in
changeable (Fig. 1). However, each of these starter
series between the ignition switch and the coil bat-
motors incorporates several of the same features to
tery terminal of the starter relay. This normally open
create a reliable, efficient, compact, lightweight and
switch prevents the starter relay from being ener-
powerful unit. Both starters feature high torque
gized when the ignition switch is turned to the
direct current electric motors. Inside both starter
momentary Start position, unless the clutch pedal is
motors the commutator of the rotating motor arma-
fully depressed. This feature prevents starter motor
ture is contacted by four brushes. The starter motor
operation while the clutch disc and the flywheel are
for the 2.5L engine is driven by four permanent mag-
engaged. The starter relay coil ground terminal is
net field poles, while the starter motor for the 4.0L
always grounded on vehicles with a manual trans-
engine is driven by four electromagnetic field coils
mission.
wound around four pole shoes. The 2.5L starter
If the vehicle is equipped with an automatic trans-
motor is rated at 1.2 kilowatts (about 1.6 horse-
mission, battery voltage is supplied through the low-
power) output at 12 volts, while the 4.0L starter
amperage control circuit to the coil battery terminal
motor is rated at 1.4 kilowatts (about 1.9 horse-
of the starter relay when the ignition switch is
power) output at 12 volts.
turned to the momentary Start position. The park/
These starter motors are equipped with a plane-
neutral position switch is installed in series between
tary gear reduction (intermediate transmission) sys-
the starter relay coil ground terminal and ground.
tem. The planetary gear reduction system consists of
This normally open switch prevents the starter relay
a gear that is integral to the output end of the elec-
from being energized and the starter motor from
tric motor armature shaft that is in continual
operating unless the automatic transmission gear
engagement with a larger gear that fits on a spline
selector is in the Neutral or Park positions.
on the input end of the starter pinion gear shaft.
When the starter relay coil windings are energized,
This feature makes it possible to reduce the dimen-
the relay directs battery current to the starter sole-
sions of the starter. At the same time, it allows
noid coil windings. When the starter solenoid coil
higher armature rotational speed and delivers
windings are energized, the solenoid directs battery
increased torque through the starter pinion gear.
current to the starter motor, which cranks the engine

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 XJ STARTING SYSTEMS 8B - 3
DESCRIPTION AND OPERATION (Continued)
Both starter motors use an overrunning clutch and STARTER RELAY
starter pinion gear unit to engage and drive the
starter ring gear, which is integral to the flywheel DESCRIPTION
(manual transmission) or torque converter drive
plate (automatic transmission) mounted on the rear
crankshaft flange. Shims are available and can be
used to adjust the 2.5L starter motor mounting posi-
tion to correct for improper starter pinion gear to
starter ring gear engagement.
The starter motors for both engines are activated
by an integral heavy duty starter solenoid switch
mounted to the overrunning clutch housing. This
electromechanical switch connects and disconnects
the feed of battery current to the starter motor
through a movable contact on one end of the solenoid TERMINAL LEGEND
core or plunger. At the same time, the solenoid
plunger actuates a shift fork that engages and disen- NUMBER IDENTIFICATION
gages the starter pinion gear with a starter ring 30 COMMON FEED
gear. The starter solenoid has two electromagnetic 85 COIL GROUND
windings or coils, a pull-in coil and a hold-in coil. The
86 COIL BATTERY
pull-in coil requires more battery current and pro-
duces a stronger electromagnetic field than the 87 NORMALLY OPEN
hold-in coil. 87A NORMALLY CLOSED
Both starter motors are serviced only as a unit
with their starter solenoids, and cannot be repaired. Fig. 2 Starter Relay
If either component is faulty or damaged, the entire
starter motor and starter solenoid unit must be The starter relay (Fig. 2) is an electromechanical
replaced. device that switches battery current to the pull-in
coil of the starter solenoid when the ignition switch
OPERATION is turned to the Start position. The starter relay is
When the starter solenoid pull-in coil windings are located in the Power Distribution Center (PDC), in
energized the solenoid plunger is drawn into the elec- the engine compartment. See the fuse and relay lay-
tromagnetic coil. The solenoid plunger pulls the shift out label affixed to the inside surface of the PDC
lever in the starter motor. This engages the starter cover for starter relay identification and location.
overrunning clutch and pinion gear with the starter The starter relay is a International Standards
ring gear on the manual transmission flywheel or on Organization (ISO) relay. Relays conforming to the
the automatic transmission torque converter drive ISO specifications have common physical dimensions,
plate. As the solenoid plunger reaches the end of its current capacities, terminal patterns, and terminal
travel, it moves the solenoid contact disc to complete functions.
the high-amperage starter feed circuit and energizes The starter relay cannot be repaired or adjusted
the solenoid hold-in coil windings. Battery current and, if faulty or damaged, it must be replaced.
now flows between the solenoid battery terminal and
the starter field terminal, energizing the starter and OPERATION
cranking the engine. The ISO relay consists of an electromagnetic coil, a
Once the engine starts, the overrunning clutch pro- resistor or diode, and three (two fixed and one movable)
tects the starter motor from damage by allowing the electrical contacts. The movable (common feed) relay
starter pinion gear to spin faster than the pinion contact is held against one of the fixed contacts (nor-
shaft. When the solenoid plunger hold-in coil is de- mally closed) by spring pressure. When the electromag-
energized, the solenoid plunger return spring returns netic coil is energized, it draws the movable contact
the plunger to its relaxed position. This causes the away from the normally closed fixed contact, and holds
solenoid contact disc to open the starter feed circuit, it against the other (normally open) fixed contact.
and the shift lever to disengage the overrunning When the electromagnetic coil is de-energized,
clutch and pinion gear unit from the starter ring spring pressure returns the movable contact to the
gear. normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in the
relay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.

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 8B - 4 STARTING SYSTEMS XJ

DIAGNOSIS AND TESTING The diagnostic procedures used for the battery,
starting system and charging system include the
STARTING SYSTEM most basic conventional diagnostic methods, to the
more sophisticated On-Board Diagnostics (OBD) built
DIAGNOSIS into the Powertrain Control Module (PCM). Use of an
The battery, starting system and charging system induction-type milliampere ammeter, a volt/ohmme-
in the vehicle operate with one another, and must be ter, a battery charger, a carbon pile rheostat (load
tested as a complete system. In order for the engine tester) and a 12-volt test lamp may be required. All
to start and the battery to charge properly, all of the OBD-sensed systems are monitored by the PCM.
components that are used in these systems must per- Each monitored circuit is assigned a Diagnostic Trou-
form within specifications. The service information ble Code (DTC). The PCM will store a DTC in elec-
for these systems has been separated within this ser- tronic memory for any failure it detects. Refer to
vice manual to make it easier to locate the specific Charging System, On-Board Diagnostic Test in
information you are seeking. However, when the index of this service manual for the location of
attempting to diagnose any of these systems, it is the proper on-board diagnostic test procedures.
important that you keep their interdependency in
mind.

Starting System Diagnosis

Condition Possible Cause Correction
Starter fails to operate. 1. Battery discharged or 1. Refer to Battery in the index of this service manual for
faulty. the location of the proper battery diagnosis and testing
2. Starting circuit wiring procedures. Replace the faulty battery, as required.
faulty. 2. Refer to Starting System in the index of this service
3. Starter relay faulty. manual for the location of complete starting system wiring
4. Ignition switch faulty. diagrams. Test and repair the faulty starter feed and/or
5. Clutch pedal position control circuits, as required.
switch faulty. 3. Refer to Starter Relay in the index of this service
6. Park/Neutral position manual for the location ofr the proper starter relay
switch faulty or diagnosis and testing procedures. Replace the faulty
misadjusted. starter relay, as required.
7. Starter solenoid faulty. 4. Refer to Ignition Switch and Key Lock Cylinder in the
8. Starter motor faulty. index of this service manual for the location of the proper
ignition switch diagnosis and testing procedures. Replace
the faulty ignition switch, as required.
5. Refer to Clutch Pedal Position Switch in the index of
this service manual for the location of the proper clutch
pedal position switch diagnosis and testing procedures.
Replace the faulty clutch hydraulic linkage unit, as
required.
6. Refer to Park/Neutral Position Switch in the index of
this service manual for the location of the proper
park/neutral position switch diagnosis and testing
procedures. Replace the faulty park/neutral position
switch, as required.
7. Refer to Starter Motor in the index of this service
manual for the location of the proper starter solenoid
diagnosis and testing procedures. Replace the faulty
starter motor, as required.
8. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
diagnosis and testing procedures. Replace the faulty
starter motor, as required.

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 XJ STARTING SYSTEMS 8B - 5
DIAGNOSIS AND TESTING (Continued)

Starting System Diagnosis

Condition Possible Cause Correction
Starter engages, fails to 1. Battery discharged or 1. Refer to Battery in the index of this service manual for
turn engine. faulty. the location of the proper battery diagnosis and testing
2. Starting circuit wiring procedures. Replace the faulty battery, as required.
faulty. 2. Refer to Starting System in the index of this service
3. Starter motor faulty. manual for the location of complete starting system wiring
4. Engine seized. diagrams. Test and repair the faulty starter feed and/or
control circuits, as required.
3. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
diagnosis and testing procedures. Replace the faulty
starter motor, as required.
4. Refer to Engine Diagnosis in the index of this service
manual for the location of the proper engine diagnosis
and testing procedures. Repair or replace the faulty
engine, as required.
Starter engages, spins 1. Starter ring gear faulty. 1. Refer to Starter Motor in the index of this service
out before engine starts. 2. Starter motor faulty. manual for the location of the proper starter motor
removal and installation procedures. Remove the starter
motor to inspect the starter ring gear. Replace the faulty
starter ring gear, as required.
2. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
diagnosis and testing procedures. Replace the faulty
starter motor, as required.
Starter does not 1. Starter motor 1. Refer to Starter Motor in the index of this service
disengage. improperly installed. manual for the location of the proper starter motor
2. Starter relay faulty. installation procedures. Tighten the starter motor
3. Ignition switch faulty. mounting hardware to the correct tightness specifications,
4. Starter motor faulty. as required.
2. Refer to Starter Relay in the index of this service
manual for the location of the proper starter relay
diagnosis and testing procedures. Replace the faulty
starter relay, as required.
3. Refer to Ignition Switch and Key Lock Cylinder in the
index of this service manual for the location of the proper
ignition switch diagnosis and testing procedures. Replace
the faulty ignition switch, as required.
4. Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
diagnosis and testing procedures. Replace the faulty
starter motor, as required.

TESTING tem wiring diagrams. Before performing this test, be

Before testing the starting system perform a visual certain that the following procedures are accom-
inspection of the starting system components and plished:
connections. Refer to Starting System in the index • The battery is fully-charged and load tested.
of this service manual for the location of the proper Refer to Battery Charging in the index of this ser-
starting system cleaning and inspection procedures. vice manual for the location of the proper battery
charging procedures. Refer to Battery in the index of
COLD CRANKING TEST this service manual for the location of the battery
Refer to Starting System in the index of this ser- diagnosis and testing procedures, including the
vice manual for the location of complete starting sys- proper battery load test procedures.

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 8B - 6 STARTING SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
• Fully engage the parking brake. (b) If the voltage reads above 9.6 volts and the
• If the vehicle is equipped with an automatic current (amperage) draw reads below specifica-
transmission, place the gearshift selector lever in the tions, refer to the Feed Circuit Test in this sec-
Park position. If the vehicle is equipped with a man- tion.
ual transmission, place the gearshift selector lever in (c) If the voltage reads 12.5 volts or greater and
the Neutral position and block the clutch pedal in the the starter motor does not turn, refer to the Con-
fully depressed position. trol Circuit Test in this section.
• Verify that all lamps and accessories are turned (d) If the voltage reads 12.5 volts or greater and
off. the starter motor turns very slowly, refer to the
• To prevent the engine from starting, remove the Feed Circuit Test in this section.
Automatic ShutDown (ASD) relay. The ASD relay is
located in the Power Distribution Center (PDC), in NOTE: A cold engine will increase the starter cur-
the engine compartment. See the fuse and relay lay- rent (amperage) draw reading, and reduce the bat-
out label affixed to the underside of the PDC cover tery voltage reading.
for ASD relay identification and location.
(1) Connect a suitable volt-ampere tester to the
FEED CIRCUIT TEST
battery terminals (Fig. 3). See the instructions pro-
vided by the manufacturer of the volt-ampere tester The starter feed circuit test (voltage drop method)
being used. will determine if there is excessive resistance in the
high-amperage starter feed circuit. Refer to Starting
System in the index of this service manual for the
location of complete starting system wiring diagrams.
When performing the voltage drop test, it is impor-
tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached. EXAM-
PLE: When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive cable eyelet terminal at the starter solenoid
B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet
terminal at the starter solenoid B(+) terminal stud,
you are reading the combined voltage drop in the
battery positive cable terminal clamp-to-terminal
Fig. 3 Volts-Amps Tester Connections - Typical
post connection and the battery positive cable.
1 – POSITIVE CLAMP
2 – NEGATIVE CLAMP
The following operation will require a voltmeter
3 – INDUCTION AMMETER CLAMP accurate to 1/10 (0.10) volt. Before performing this
test, be certain that the following procedures are
accomplished:
(2) Rotate and hold the ignition switch in the Start • The battery is fully-charged and load tested.
position. Note the cranking voltage and current Refer to Battery Charging in the index of this ser-
(amperage) draw readings shown on the volt-ampere vice manual for the location of the proper battery
tester. charging procedures. Refer to Battery in the index of
(a) If the voltage reads below 9.6 volts, refer to this service manual for the location of the battery
Starter Motor in the index of this service manual diagnosis and testing procedures, including the
for the location of the proper starter motor diagno- proper battery load test procedures.
sis and testing procedures. If the starter motor • Fully engage the parking brake.
tests OK, refer to Engine Diagnosis in the index • If the vehicle is equipped with an automatic
of this service manual for the location of the proper transmission, place the gearshift selector lever in the
engine diagnosis and testing procedures. If the Park position. If the vehicle is equipped with a man-
starter motor is not OK, replace the faulty starter ual transmission, place the gearshift selector lever in
motor. the Neutral position and block the clutch pedal in the
fully depressed position.
• Verify that all lamps and accessories are turned
off.

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 XJ STARTING SYSTEMS 8B - 7
DIAGNOSIS AND TESTING (Continued)
• To prevent the engine from starting, remove the
Automatic ShutDown (ASD) relay. The ASD relay is
located in the Power Distribution Center (PDC), in
the engine compartment. See the fuse and relay lay-
out label affixed to the underside of the PDC cover
for ASD relay identification and location.
(1) Connect the positive lead of the voltmeter to
the battery negative terminal post. Connect the neg-
ative lead of the voltmeter to the battery negative
cable terminal clamp (Fig. 4). Rotate and hold the
ignition switch in the Start position. Observe the
voltmeter. If voltage is detected, correct the poor con-
tact between the battery negative cable terminal
clamp and the battery negative terminal post.

Fig. 5 Test Battery Positive Connection Resistance -

Typical
1 – VOLTMETER
2 – BATTERY

Fig. 4 Test Battery Negative Connection Resistance

- Typical
1 – VOLTMETER
2 – BATTERY

(2) Connect the positive lead of the voltmeter to

Fig. 6 Test Battery Positive Cable Resistance -
the battery positive terminal post. Connect the nega-
Typical
tive lead of the voltmeter to the battery positive cable
1 – BATTERY
terminal clamp (Fig. 5). Rotate and hold the ignition
2 – VOLTMETER
switch in the Start position. Observe the voltmeter. If 3 – STARTER MOTOR
voltage is detected, correct the poor connection
between the battery positive cable terminal clamp
and the battery positive terminal post. (4) Connect the voltmeter to measure between the
(3) Connect the voltmeter to measure between the battery negative cable terminal clamp and a good
battery positive cable terminal clamp and the starter clean ground on the engine block (Fig. 7). Rotate and
solenoid B(+) terminal stud (Fig. 6). Rotate and hold hold the ignition switch in the Start position.
the ignition switch in the Start position. Observe the Observe the voltmeter. If the reading is above 0.2
voltmeter. If the reading is above 0.2 volt, clean and volt, clean and tighten the battery negative cable
tighten the battery positive cable eyelet terminal con- eyelet terminal connection to the engine block.
nection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt,
Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable.
replace the faulty battery positive cable.

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 8B - 8 STARTING SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
If the resistance tests detect no feed circuit prob-
lems, refer to Starter Motor in the index of this ser-
vice manual for the location of the proper starter
motor diagnosis and testing procedures.

CONTROL CIRCUIT TEST

The starter control circuit components should be
tested in the order in which they are listed, as fol-
lows:
• Starter Relay Refer to Starter Relay in the
index of this service manual for the location of the
proper starter relay diagnosis and testing procedures.
• Starter Solenoid Refer to Starter Motor in the
index of this service manual for the location of the
proper starter solenoid diagnosis and testing proce-
Fig. 7 Test Ground Circuit Resistance - Typical dures.
1 – VOLTMETER • Ignition Switch Refer to Ignition Switch and
2 – BATTERY Key Lock Cylinder in the index of this service
3 – ENGINE GROUND manual for the location of the proper ignition switch
diagnosis and testing procedures.
(5) Connect the positive lead of the voltmeter to • Clutch Pedal Position Switch If the vehicle is
the starter housing. Connect the negative lead of the equipped with a manual transmission, refer to
voltmeter to the battery negative terminal post (Fig. Clutch Pedal Position Switch in the index of this
8). Rotate and hold the ignition switch in the Start service manual for the location of the proper clutch
position. Observe the voltmeter. If the reading is pedal position switch diagnosis and testing proce-
above 0.2 volt, correct the poor starter to engine dures.
block ground contact. • Park/Neutral Position Switch If the vehicle is
equipped with an automatic transmission, refer to
Park/Neutral Position Switch in the index of this
service manual for the location of the proper park/
neutral position switch diagnosis and testing proce-
dures.

STARTER MOTOR NOISE - 2.5L ENGINE

See the Starter Motor Noise Diagnosis chart (Fig.
9). If the complaint is similar to Conditions 1 and 2
in the chart, correction can be made by placing shims
between the starter motor and the engine block using
the following procedures:

Fig. 8 Test Starter Ground - Typical

1 – STARTER MOTOR
2 – BATTERY
3 – VOLTMETER

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 XJ STARTING SYSTEMS 8B - 9
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSE CORRECTION

1. VERY HIGH FREQUENCY 1. Excessive distance between pinion 1. Move starter motor toward
WHINE BEFORE ENGINE gear and flywheel/drive plate gear. flywheel/drive plate by removing
STARTS; ENGINE STARTS OK. shim(s), if possible.
2. VERY HIGH FREQUENCY 2. Insufficient distance between 2. Shim starter motor away from
WHINE AFTER ENGINE STARTS starter motor pinion gear and flywheel/drive plate. Inspect
WITH IGNITION KEY RELEASED. flywheel/drive plate runout can cause flywheel/drive plate for damage;
ENGINE STARTS OK. noise to be intermittent. bent, unusual wear, and excessive
runout. Replace flywheel/drive
plate as necessary.
3. A LOUD “WHOOP” AFTER 3. Most probably cause is defective 3. Replace starter motor.
ENGINE STARTS WHILE overrunning clutch.
STARTER MOTOR IS ENGAGED.
4. A “RUMBLE,” “GROWL,” OR 4. Most probable cause is bent or 4. Replace starter motor.
“KNOCK” AS STARTER MOTOR unbalanced starter motor armature.
COASTS TO STOP AFTER
ENGINE STARTS.
NOTE: A high frequency whine during cranking is normal for this starter motor.
FIG. 9 STARTER MOTOR NOISE DIAGNOSIS

(1) If the complaint is similar to Condition 1, the (2) If the complaint is similar to Condition 2, the
starter motor must be moved toward the starter ring starter motor must be moved away from the starter
gear by removing shims from both starter mounting ring gear. This is done by installing shim(s) across
pads on the engine block (Fig. 10). Refer to Starter both starter mounting pads on the engine block.
Motor in the index of this service manual for the More than one shim may be required. Refer to
location of the proper starter motor removal and Starter Motor in the index of this service manual
installation procedures. for the location of the proper removal and installa-
tion procedures.
NOTE: The shim thickness is 0.381 mm (0.015 in.).
These shims may be stacked if additional thickness NOTE: This is a condition that will generally cause
is required. broken starter (flywheel/torque converter drive
plate) ring gear teeth or broken starter motor hous-
ings.

STARTER MOTOR
Correct starter motor operation can be confirmed
by performing the following free running bench test.
This test can only be performed with the starter
motor removed from the vehicle. Refer to Starting
System in the index of this service manual for the
location of the proper starter motor specifications.

CAUTION: The 2.5L engine uses a permanent mag-

net starter. Permanent magnet starters are highly
sensitive to hammering, shocks, external pressure
and reverse polarity. This starter motor must never
Fig. 10 Starter Motor Shim be clamped in a vise by the starter field frame. The
1 – STARTER MOTOR SHIM
starter should only be clamped by the mounting
flange. Do not reverse the battery cable connec-
tions to this starter motor when testing. The perma-
nent magnets may be damaged and the starter
rendered unserviceable if it is subjected to any of
these conditions.

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 8B - 10 STARTING SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
STARTER MOTOR
(1) Remove the starter motor from the vehicle.
Refer to Starter Motor in the index of this service
manual for the location of the proper starter motor
removal and installation procedures.
(2) Mount the starter motor securely in a soft-
jawed bench vise. The vise jaws should be clamped
on the mounting flange of the starter motor. Never
clamp on the starter motor by the field frame.
(3) Connect a suitable volt-ampere tester and a Fig. 11 Continuity Test Between Solenoid Terminal
12-volt battery to the starter motor in series, and set and Field Coil Terminal - Typical
1 – SOLENOID
the ammeter to the 100 ampere scale. See the
2 – SOLENOID TERMINAL
instructions provided by the manufacturer of the
3 – OHMMETER
volt-ampere tester being used. 4 – FIELD COIL TERMINAL
(4) Install a jumper wire from the solenoid termi-
nal to the solenoid B(+) terminal stud. The starter
motor should operate. If the starter motor fails to
operate, replace the faulty starter motor.
(5) Adjust the carbon pile load of the tester to
obtain the free running test voltage. Refer to Start-
ing System in the index of this service manual for
the location of the proper starter motor free running
test voltage specifications.
(6) Note the reading on the ammeter and compare
this reading to the free running test maximum
amperage draw. Refer to Starting System in the Fig. 12 Continuity Test Between Solenoid Terminal
index of this service manual for the location of the and Solenoid Case - Typical
proper starter motor free running test maximum 1 – SOLENOID
amperage draw specifications. 2 – SOLENOID TERMINAL
(7) If the ammeter reading exceeds the maximum 3 – OHMMETER
amperage draw specification, replace the faulty
starter motor.
to the underside of the PDC cover for starter relay
identification and location. Refer to Starting Sys-
STARTER SOLENOID tem in the index of this service manual for the loca-
This test can only be performed with the starter
tion of complete starting system wiring diagrams.
motor removed from the vehicle.
(1) Remove the starter motor from the vehicle. RELAY TEST
Refer to Starter Motor in the index of this service
(1) Remove the starter relay from the PDC. Refer
manual for the location of the proper starter motor
to Starter Relay in the index of this service manual
removal and installation procedures.
for the location of the proper starter relay removal
(2) Disconnect the wire from the solenoid field coil
and installation procedures.
terminal.
(2) A relay in the de-energized position should
(3) Check for continuity between the solenoid ter-
have continuity between terminals 87A and 30, and
minal and the solenoid field coil terminal with a con-
no continuity between terminals 87 and 30. If OK, go
tinuity tester (Fig. 11). There should be continuity. If
to Step 3. If not OK, replace the faulty relay.
OK, go to Step 4. If not OK, replace the faulty starter
(3) Resistance between terminals 85 and 86 (elec-
motor.
tromagnet) should be 75 6 5 ohms. If OK, go to Step
(4) Check for continuity between the solenoid ter-
4. If not OK, replace the faulty relay.
minal and the solenoid case (Fig. 12). There should
(4) Connect a battery to terminals 85 and 86.
be continuity. If not OK, replace the faulty starter
There should now be continuity between terminals
motor.
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
STARTER RELAY follows. If not OK, replace the faulty relay.
The starter relay (Fig. 13) is located in the Power
Distribution Center (PDC), in the engine compart-
ment. Refer to the fuse and relay layout label affixed

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 XJ STARTING SYSTEMS 8B - 11
DIAGNOSIS AND TESTING (Continued)
mission or if not OK with an automatic transmission,
check for an open or shorted fused ignition switch
output (start) circuit to the ignition switch and
repair, as required. If the fused ignition switch out-
put (start) circuit is OK, refer to Ignition Switch
and Key Lock Cylinder in the index of this service
manual for the location of the proper ignition switch
diagnosis and testing procedures.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. On vehicles with a
manual transmission, it is grounded at all times. On
TERMINAL LEGEND vehicles with an automatic transmission, it is
NUMBER IDENTIFICATION grounded through the park/neutral position switch
only when the gearshift selector lever is in the Park
30 COMMON FEED or Neutral positions. Check for continuity to ground
85 COIL GROUND at the cavity for relay terminal 85. If not OK with a
86 COIL BATTERY manual transmission, repair the open park/neutral
position switch sense circuit to ground as required. If
87 NORMALLY OPEN
not OK with an automatic transmission, check for an
87A NORMALLY CLOSED open or shorted park/neutral position switch sense
circuit to the park/neutral position switch and repair,
as required. If the park/neutral position switch sense
Fig. 13 Starter Relay
circuit checks OK, refer to Park/Neutral Position
RELAY CIRCUIT TEST Switch in the index of this service manual for the
(1) The relay common feed terminal cavity (30) is location of the proper park/neutral position switch
connected to battery voltage and should be hot at all diagnosis and testing procedures.
times. If OK, go to Step 2. If not OK, repair the open
circuit to the fused B(+) fuse in the PDC as required.
(2) The relay normally closed terminal (87A) is REMOVAL AND INSTALLATION
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3. STARTER MOTOR
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener- REMOVAL
gized position. This terminal supplies battery voltage
2.5L ENGINE
to the starter solenoid field coil. There should be con-
tinuity between the cavity for relay terminal 87 and (1) Disconnect and isolate the battery negative
the starter solenoid terminal at all times. If OK, go cable.
to Step 4. If not OK, repair the open engine starter (2) Raise and support the vehicle.
motor relay output circuit to the starter solenoid as (3) While supporting the starter motor with one
required. hand, use the other hand to remove the two screws
(4) The coil battery terminal (86) is connected to that secure the starter motor to the engine block
the electromagnet in the relay. It is energized when (Fig. 14).
the ignition switch is held in the Start position. On (4) Lower the starter motor from the engine block
vehicles with a manual transmission, the clutch far enough to access and remove the nut that secures
pedal must be blocked in the fully depressed position the battery positive cable eyelet terminal to the
for this test. Check for battery voltage at the cavity starter solenoid B(+) terminal stud (Fig. 15). Always
for relay terminal 86 with the ignition switch in the support the starter motor during this process. Do not
Start position, and no voltage when the ignition let the starter motor hang from the wire harness.
switch is released to the On position. If OK, go to (5) Remove the battery positive cable eyelet termi-
Step 5. If not OK with a manual transmission, dis- nal from the starter solenoid B(+) terminal stud.
connect the clutch pedal position switch wire harness Always support the starter motor during this process.
connector and install a jumper wire between the two Do not let the starter motor hang from the wire har-
cavities in the body half of the connector and check ness.
for battery voltage again at the cavity for relay ter-
minal 86. If now OK, replace the faulty clutch pedal
position switch. If still not OK with a manual trans-

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 8B - 12 STARTING SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
during this process. Do not let the starter motor
hang from the wire harness.
(7) Remove the starter motor and any starter
motor shims (if used) from the engine block.

4.0L ENGINE
(1) Disconnect and isolate the battery negative
cable.
(2) Raise and support the vehicle.
(3) Remove the lower screw (forward facing) that
secures the starter motor to the manual transmission
clutch housing or the automatic transmission torque
converter housing (Fig. 16).

Fig. 14 Starter Motor Remove/Install - 2.5L Engine

1 – STARTER MOTOR
2 – SCREW (2)
3 – SHIM

Fig. 16 Starter Motor Remove/Install - 4.0L Engine

1 – SCREW
2 – STARTER MOTOR
3 – SCREW

(4) While supporting the starter motor with one

hand, use the other hand to remove the upper screw
(rearward facing) that secures the starter motor to
the manual transmission clutch housing or the auto-
matic transmission torque converter housing.
(5) Lower the starter motor from the front of the
manual transmission clutch housing or automatic
Fig. 15 Starter Connections Remove/Install - Typical transmission torque converter housing far enough to
1 – STARTER MOTOR access and remove the nut that secures the battery
2 – SOLENOID B(+) TERMINAL STUD positive cable eyelet terminal to the starter solenoid
3 – BATTERY POSITIVE CABLE EYELET TERMINAL B(+) terminal stud (Fig. 15). Always support the
4 – NUT starter motor during this process. Do not let the
5 – SOLENOID TERMINAL WIRE HARNESS CONNECTOR starter motor hang from the wire harness.
6 – SOLENOID TERMINAL CONNECTOR RECEPTACLE (6) Remove the battery positive cable eyelet termi-
nal from the solenoid B(+) terminal stud. Always
(6) Disconnect the solenoid terminal wire harness support the starter motor during this process. Do not
connector from the connector receptacle on the let the starter motor hang from the wire harness.
starter solenoid. Always support the starter motor (7) Disconnect the solenoid terminal wire harness
connector from the connector receptacle on the

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 XJ STARTING SYSTEMS 8B - 13
REMOVAL AND INSTALLATION (Continued)
starter solenoid. Always support the starter motor Always support the starter motor during this process.
during this process. Do not let the starter motor Do not let the starter motor hang from the wire har-
hang from the wire harness. ness.
(8) Remove the starter motor from the manual (4) Install and tighten the nut that secures the
transmission clutch housing or automatic transmis- battery positive cable eyelet terminal to the starter
sion torque converter housing. solenoid B(+) terminal stud. Tighten the nut to 11.3
N·m (100 in. lbs.). Always support the starter motor
INSTALLATION during this process. Do not let the starter motor
hang from the wire harness.
2.5L ENGINE (5) Position the starter motor to the manual trans-
(1) Position the starter motor to the engine block. mission clutch housing or automatic transmission
(2) Reconnect the solenoid terminal wire harness torque converter housing. Loosely install the two
connector to the connector receptacle on the starter starter motor mounting screws to secure the starter
solenoid. Always support the starter motor during motor to the manual transmission clutch housing or
this process. Do not let the starter motor hang from automatic transmission torque converter housing.
the wire harness. (6) Tighten the lower (forward facing) screw that
(3) Install the battery positive cable eyelet termi- secures the starter motor to the manual transmission
nal onto the starter solenoid B(+) terminal stud. clutch housing or automatic transmission torque con-
Always support the starter motor during this process. verter housing. Tighten the screw to 40.7 N·m (30 ft.
Do not let the starter motor hang from the wire har- lbs.).
ness. (7) Tighten the upper (rearward facing) screw that
(4) Install and tighten the nut that secures the secures the starter motor to the manual transmission
battery positive cable eyelet terminal to the starter clutch housing or automatic transmission torque con-
solenoid B(+) terminal stud. Tighten the nut to 11.3 verter housing. Tighten the screw to 47.5 N·m (35 ft.
N·m (100 in. lbs.). Always support the starter motor lbs.).
during this process. Do not let the starter motor (8) Lower the vehicle.
hang from the wire harness. (9) Reconnect the battery negative cable.
(5) Position the starter motor and any starter
motor shims that were removed during the starter STARTER RELAY
motor removal procedure to the engine block. Loosely
install the two starter motor mounting screws to REMOVAL
secure the starter motor and shims to the engine (1) Disconnect and isolate the battery negative
block. cable.
(2) Remove the cover from the Power Distribution
NOTE: Shim thickness available is 0.381 mm (0.015 Center (PDC) (Fig. 17).
in.). Refer to Starter Motor Noise - 2.5L Engine in (3) See the fuse and relay layout label affixed to
the index of this service manual for the location of the underside of the PDC cover for starter relay iden-
the proper starter motor noise diagnosis and test- tification and location.
ing procedures. (4) Remove the starter relay from the PDC.
(6) Tighten the two screws that secure the starter INSTALLATION
motor and shims to the engine block. Tighten the
(1) See the fuse and relay layout label affixed to
screws to 44.7 N·m (33 ft. lbs.).
the underside of the PDC cover for the proper starter
(7) Lower the vehicle.
relay location.
(8) Reconnect the battery negative cable.
(2) Position the starter relay in the proper recep-
4.0L ENGINE tacle in the PDC.
(3) Align the starter relay terminals with the ter-
(1) Position the starter motor to the manual trans-
minal cavities in the PDC receptacle.
mission clutch housing or automatic transmission
(4) Push down firmly on the starter relay until the
torque converter housing.
terminals are fully seated in the terminal cavities in
(2) Reconnect the solenoid terminal wire harness
the PDC receptacle.
connector to the connector receptacle on the starter
(5) Install the cover onto the PDC.
solenoid. Always support the starter motor during
(6) Reconnect the battery negative cable.
this process. Do not let the starter motor hang from
the wire harness.
(3) Install the battery positive cable eyelet termi-
nal onto the starter solenoid B(+) terminal stud.

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 8B - 14 STARTING SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
• Ignition Switch Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections. Clean corroded
connections as required. Refer to Wiring Diagrams
in the index of this service manual for the location of
the proper wiring repair or connector and terminal
service procedures. Refer to Ignition Switch and
Key Lock Cylinder in the index of this service
manual for the location of the proper ignition switch
service procedures.
• Clutch Pedal Position Switch If the vehicle is
equipped with a manual transmission, visually
inspect the clutch pedal position switch for indica-
tions of physical damage and loose or corroded wire
harness connections. Clean corroded connections as
required. Refer to Wiring Diagrams in the index of
this service manual for the location of the proper wir-
ing repair or connector and terminal service proce-
dures. Refer to Clutch Hydraulic Linkage in the
index of this service manual for the location of the
proper clutch pedal position switch service proce-
dures.
Fig. 17 Power Distribution Center • Park/Neutral Position Switch If the vehicle is
1 – RIGHT FENDER equipped with an automatic transmission, visually
2 – BATTERY inspect the park/neutral position switch for indica-
3 – POWER DISTRIBUTION CENTER tions of physical damage and loose or corroded wire
harness connections. Clean corroded connections as
required. Refer to Wiring Diagrams in the index of
CLEANING AND INSPECTION this service manual for the location of the proper wir-
ing repair or connector and terminal service proce-
STARTING SYSTEM dures. Refer to Park/Neutral Position Switch in
The following components of the starting system the index of this service manual for the location of
should be carefully inspected whenever any starting the proper park/neutral position switch service proce-
system problem is encountered. dures.
• Starter Relay Visually inspect the starter relay
WARNING: ON VEHICLES EQUIPPED WITH AIR-
for indications of physical damage and loose or cor-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
roded wire harness connections. Clean corroded con-
ATTEMPTING ANY STEERING WHEEL, STEERING
nections as required. Refer to Wiring Diagrams in
COLUMN, OR INSTRUMENT PANEL COMPONENT
the index of this service manual for the location of
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
the proper wiring repair or connector and terminal
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
service procedures. Refer to Starter Relay in the
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
index of this service manual for the location of the
TEM CAPACITOR TO DISCHARGE BEFORE PER-
proper starter relay service procedures.
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
• Starter Motor Visually inspect the starter motor
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
for indications of physical damage and loose or cor-
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
roded wire harness connections. Clean corroded con-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
nections as required. Refer to Wiring Diagrams in
BAG DEPLOYMENT AND POSSIBLE PERSONAL
the index of this service manual for the location of
INJURY.
the proper wiring repair or connector and terminal
• Battery Visually inspect the battery for indica- service procedures. If the problem being diagnosed
tions of physical damage and loose or corroded cable involves improper starter engagement, disengage-
connections. Determine the state-of-charge and ment or noise complaints the starter motor should be
cranking capacity of the battery. Charge or replace removed. With the starter motor removed, inspect
the battery, if required. Refer to Battery in the index the starter pinion and ring gears for damaged or
of this service manual for the location of the proper missing teeth. Replace faulty components as
battery cleaning and inspection procedures. required. Refer to Starter Motor in the index of this

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 XJ STARTING SYSTEMS 8B - 15
CLEANING AND INSPECTION (Continued)
service manual for the location of the proper starter • Wiring Visually inspect the starting system wire
motor removal and installation procedures. harnesses for indications of physical damage. Repair
• Starter Solenoid Visually inspect the starter or replace any faulty wiring, as required. Refer to
solenoid for indications of physical damage and loose Starting System in the index of this service manual
or corroded wire harness connections. Clean corroded for the location of complete starting system wiring
connections as required. Refer to Wiring Diagrams diagrams. Refer to Wiring Diagrams in the index of
in the index of this service manual for the location of this service manual for the location of the proper wir-
the proper wiring repair or connector and terminal ing repair or connector and terminal service proce-
service procedures. Refer to Starter Motor in the dures.
index of this service manual for the location of the
proper starter solenoid service procedures.

SPECIFICATIONS

STARTING SYSTEM

Starter Motor and Solenoid

Manufacturer Mitsubishi
Engine Application 2.5L, 4.0L
2.5L - 1.2 Kilowatt (1.6 Horsepower)
Power Rating
4.0L - 1.4 Kilowatt (1.9 Horsepower)
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.2 Volts
Free Running Test Maximum Amperage Draw 90 Amperes
2.5L - 2600 rpm
Free Running Test Minimum Speed
4.0L - 2500 rpm
Solenoid Closing Maximum Voltage Required 7.8 Volts
2.5L - 130 Amperes
*Cranking Amperage Draw Test
4.0L - 160 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.

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 XJ STARTING SYSTEMS 8B - 1

STARTING SYSTEMS
TABLE OF CONTENTS

page page

REMOVAL AND INSTALLATION SPECIFICATIONS

STARTER — LHD (DIESEL) . . . . . . . . . . . . . . . . . 1 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
STARTER — RHD (DIESEL). . . . . . . . . . . . . . . . . 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 4
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 3

REMOVAL AND INSTALLATION (5) Remove the turbocharger oil return hose from
engine block and plug (Fig. 2).
STARTER — LHD (DIESEL)
Removal
(1) Disconnect the negative battery cable.
(2) Remove the innercooler inlet hose from turbo-
charger and position it out of the way (Fig. 1).

Fig. 2 Turbocharger Oil Return Hose — Position &

Orientation
1 – VEHICLE UNDERBODY
2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT
3 – TURBOCHARGER OIL RETURN HOSE
4 – EXHAUST MANIFOLD DOWNPIPE
5 – TURBOCHARGER
Fig. 1 LHD Engine Compartment — Diesel
1 – INTAKE MANIFOLD ELBOW
2 – BREATHER HOSE (6) Remove the right engine mount through bolt
3 – INNERCOOLER OUTLET HOSE nut only (Fig. 2). Do not remove the bolt at this time.
4 – AIR FILTER COVER (7) Position a jack stand and raise the weight off
5 – AIR FILTER OUTLET (FRESH AIR) HOSE the right engine mount.
6 – INNERCOOLER INLET HOSE (8) Remove the (2) right engine mount lower sill
7 – HEATER CORE COOLANT SUPPLY HOSES
plate bolts.
(9) Remove the (4) right engine mount bracket to
(3) Remove the (2) right engine mount upper sill engine block retaining bolts.
plate nuts. (10) Remove the engine mount throughbolt.
(4) Raise the vehicle on a hoist. (11) Remove the engine mount and the engine
mount bracket from the vehicle.

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 8B - 2 STARTING SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(12) Remove the starter motor support bracket.
(13) Disconnect the starter motor electrical connec-
tors.

CAUTION: Heatshields are very sharp. Wear gloves

to prevent injury.

(14) Remove the starter heatshield.

(15) Remove the (3) starter motor retaining bolts.
(16) Remove the starter motor from the vehicle.

Installation
(1) Position the starter motor and install retaining
bolts. Torque bolts to 27 N·m (20 ft. lbs.).
(2) Connect the starter motor electrical. Torque
(B+) nut to 27 N·m (20 ft. lbs.).

CAUTION: Heatshields are very sharp. Wear gloves

to prevent injury.

(3) Install the starter heatshield.

(4) Install the starter motor support bracket.
Torque nuts to 10 N·m (90 in. lbs.). Fig. 3 Turbocharger Oil Return Line
(5) Install the engine mount and engine mount 1 – VEHICLE UNDERBODY
bracket in the vehicle, making sure sill plate studs 2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT
are through engine mount. 3 – TURBOCHARGER OIL RETURN HOSE
(6) Install the engine mount throughbolt and nut 4 – EXHAUST MANIFOLD DOWNPIPE
leaving them loose at this time. 5 – TURBOCHARGER
(7) Install the (4) engine mount bracket to engine
block bolts. Torque bolts to 61 N·m (45 ft. lbs.). (6) Remove the right engine mount through bolt
(8) Tighten, but do not torque (2) right engine nut only (Fig. 3). Do not remove the bolt at this time.
mount lower bolts. (7) Remove the engine mount upper sill plate nuts.
(9) Remove the jack stand. (8) Position a jack stand and raise weight off right
(10) Torque the (2) lower engine mount bolts to 54 engine mount.
N·m (40 ft. lbs.). (9) Remove the track bar support bracket retain-
(11) Torque throughbolt nut to 65 N·m (48 ft. lbs.). ing bolts and remove bracket.
(12) Install the oil return line on the engine block (10) Remove the remaining lower engine mount
nipple. bolt from the sill plate.
(13) Lower the vehicle from the hoist. (11) Remove the (4) engine mount bracket bolts.
(14) Install the (2) engine mount upper sill plate (12) Remove the engine mount throughbolt.
nuts. Torque nuts to 41 N·m (30 ft. lbs.). (13) Remove the engine mount and engine mount
(15) Install the innercooler inlet hose on turbo- bracket from the vehicle.
charger. (14) Remove the starter motor support bracket.
(16) Connect the negative battery cable.
CAUTION: Heatshield is very sharp. Wear gloves to
STARTER — RHD (DIESEL) prevent injury.

REMOVAL (15) Remove the starter heat shield.

(1) Disconnect the negative battery cable. (16) Disconnect the starter motor electrical connec-
(2) Make sure steering wheel is in the unlocked tors.
position. (17) Remove the (3) stater motor retaining bolts.
(3) Raise the vehicle on a hoist. (18) Remove the starter motor from the vehicle.
(4) Rotate the front wheels to access and remove
the steering shaft pinch bolt, slide shaft straight off Installation
gearbox input shaft and position steering shaft aside. (1) Position the starter motor. Torque retaining
(5) Remove the turbocharger oil return line from bolts to 27 N·m (20 ft. lbs.).
engine block and plug (Fig. 3).

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 XJ STARTING SYSTEMS 8B - 3
REMOVAL AND INSTALLATION (Continued)
(2) Reconnect the starter motor electrical. Torque (13) Torque the engine mount throughbolt nut to
(B+) nut to 27 N·m (20 ft. lbs.). 65 N·m (48 ft. lbs.).
(14) Install the oil return line on the engine block
CAUTION: Heatshield is very sharp. Wear gloves to nipple.
prevent injury. (15) Install steering shaft pinch bolt. Torque to 49
N·m (36 ft. lbs.).
(3) Install the starter heat shield. (16) Lower the vehicle from the hoist.
(4) Install the starter motor support bracket. (17) Connect the negative battery cable.
Torque bolt to 47 N·m (35 ft. lbs.). Torque nuts to 10
N·m (90 in. lbs.). STARTER RELAY
(5) Install the engine mount and engine mount
(1) Disconnect and isolate the battery negative
bracket in the vehicle.
cable.
(6) Install the engine mount throughbolt and nut
(2) Remove the cover from the Power Distribution
leaving them loose at this time.
Center (PDC).
(7) Install, but do not torque the engine mount
(3) Refer to the label on the PDC for starter relay
and track bar support bracket bolts
identification and location.
(8) Install the (4) engine mount bracket to engine
(4) Unplug the starter relay from the PDC.
block bolts. Torque bolts to 61 N·m (45 ft. lbs.).
(5) Install the starter relay by aligning the relay
(9) Remove the jack stand.
terminals with the cavities in the PDC and pushing
(10) Install and torque the upper engine mount sill
the relay firmly into place.
plate nuts to 41 N·m (30 ft. lbs.).
(6) Install the PDC cover.
(11) Torque the lower engine mount retaining bolts
(7) Connect the battery negative cable.
to 54 N·m (40 ft. lbs.).
(8) Test the relay operation.
(12) Torque the larger track bar support bracket
bolts to 125 N·m (92 ft. lbs.).

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 8B - 4 STARTING SYSTEMS XJ

SPECIFICATIONS

STARTING SYSTEM

Starter and Solenoid

Engine Application 2.5L Diesel
Power Rating 2.2 Kilowatt
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.5 Volts
Free Running Test Maximum
160 Amperes
Amperage Draw
Free Running Test Minimum
5500 rpm
Speed
Solenoid Closing Maximum
7.8 Volts
Voltage
*Cranking Amperage Draw
350 Amperes
test
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will
increase starter amperage draw.

TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Engine Mount Throughbolt . . . . 65 N·m (48 ft. lbs.)
Engine Mount Upper Sill Plate Nuts . . . . . 41 N·m
(30 ft. lbs.)
Engine Mount to Engine Mounting Bolts . . 61 N·m
(45 ft. lbs.)
Lower Engine Mount Bolts . . . . 54 N·m (40 ft. lbs.)
Stater Motor (B+) Terminal . . . . 27 N·m (20 ft. lbs.)
Starter Motor Retaining Bolts . . 27 N·m (20 ft. lbs.)
Starter Motor Support Bracket Nuts . . . . . . 10 N·m
(90 in. lbs.)
Steering Shaft Pinch Bolt . . . . . 49 N·m (36 ft. lbs.)
Track Bar Support Bracket Bolts . . . . . . . 125 N·m
(92 ft. lbs.)

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 XJ CHARGING SYSTEM 8C - 1

CHARGING SYSTEM
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION

CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 1 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BATTERY TEMPERATURE SENSOR . . . . . . . . . . . 5
BATTERY TEMPERATURE SENSOR . . . . . . . . . . . 2 SPECIFICATIONS
ELECTRONIC VOLTAGE REGULATOR . . . . . . . . . . 2 GENERATOR RATINGS . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 2
ON-BOARD DIAGNOSTIC TEST FOR
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3

DESCRIPTION AND OPERATION ture. This temperature data, along with data from
monitored line voltage, is used by the PCM to vary
CHARGING SYSTEM the battery charging rate. This is done by cycling the
ground path to control the strength of the rotor mag-
DESCRIPTION netic field. The PCM then compensates and regulates
The charging system consists of: generator current output accordingly.
• Generator All vehicles are equipped with On-Board Diagnos-
• Electronic Voltage Regulator (EVR) circuitry tics (OBD). All OBD-sensed systems, including EVR
within the Powertrain Control Module (PCM) (field control) circuitry, are monitored by the PCM.
• Ignition switch (refer to Group 8D, Ignition Sys- Each monitored circuit is assigned a Diagnostic Trou-
tem for information) ble Code (DTC). The PCM will store a DTC in elec-
• Battery (refer to Group 8A, Battery for informa- tronic memory for certain failures it detects. Refer to
tion) On-Board Diagnostics in Group 25, Emission Control
• Battery temperature sensor System for more DTC information.
• Generator Lamp (if equipped) The Check Gauges Lamp (if equipped) monitors:
• Check Gauges Lamp (if equipped) charging system voltage, engine coolant tempera-
• Voltmeter (refer to Group 8E, Instrument Panel ture and engine oil pressure. If an extreme condition
and Gauges for information) is indicated, the lamp will be illuminated. This is
• Wiring harness and connections (refer to Group done as reminder to check the three gauges. The sig-
8W, Wiring for information) nal to activate the lamp is sent via the CCD bus cir-
cuits. The lamp is located on the instrument panel.
OPERATION Refer to Group 8E, Instrument Panel and Gauges for
The charging system is turned on and off with the additional information.
ignition switch. The system is on when the engine is
running and the ASD relay is energized. When the GENERATOR
ASD relay is on, voltage is supplied to the ASD relay
sense circuit at the PCM. This voltage is connected DESCRIPTION
through the PCM and supplied to one of the genera- The generator is belt-driven by the engine using a
tor field terminals (Gen. Source +) at the back of the serpentine type drive belt. It is serviced only as a
generator. complete assembly. If the generator fails for any rea-
The amount of DC current produced by the gener- son, the entire assembly must be replaced.
ator is controlled by the EVR (field control) circuitry
contained within the PCM. This circuitry is con- OPERATION
nected in series with the second rotor field terminal As the energized rotor begins to rotate within the
and ground. generator, the spinning magnetic field induces a cur-
A battery temperature sensor, located in the bat- rent into the windings of the stator coil. Once the
tery tray housing, is used to sense battery tempera-

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 8C - 2 CHARGING SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
generator begins producing sufficient current, it also OPERATION
provides the current needed to energize the rotor. The amount of DC current produced by the gener-
The Y type stator winding connections deliver the ator is controlled by EVR circuitry contained within
induced AC current to 3 positive and 3 negative the PCM. This circuitry is connected in series with
diodes for rectification. From the diodes, rectified DC the generators second rotor field terminal and its
current is delivered to the vehicle electrical system ground.
through the generator battery terminal. Voltage is regulated by cycling the ground path to
Although the generators appear the same exter- control the strength of the rotor magnetic field. The
nally, different generators with different output rat- EVR circuitry monitors system line voltage (B+) and
ings are used on this vehicle. Be certain that the battery temperature (refer to Battery Temperature
replacement generator has the same output rating Sensor for more information). It then determines a
and part number as the original unit. Refer to Gen- target charging voltage. If sensed battery voltage is
erator Ratings in the Specifications section at the 0.5 volts or lower than the target voltage, the PCM
back of this group for amperage ratings and part grounds the field winding until sensed battery volt-
numbers. age is 0.5 volts above target voltage. A circuit in the
Noise emitting from the generator may be caused PCM cycles the ground side of the generator field up
by: worn, loose or defective bearings; a loose or defec- to 100 times per second (100Hz), but has the capabil-
tive drive pulley; incorrect, worn, damaged or misad- ity to ground the field control wire 100% of the time
justed fan drive belt; loose mounting bolts; a (full field) to achieve the target voltage. If the charg-
misaligned drive pulley or a defective stator or diode. ing rate cannot be monitored (limp-in), a duty cycle
of 25% is used by the PCM in order to have some
BATTERY TEMPERATURE SENSOR generator output. Also refer to Charging System
Operation for additional information.
DESCRIPTION
The Battery Temperature Sensor (BTS) is attached
to the battery tray located under the battery. DIAGNOSIS AND TESTING

OPERATION CHARGING SYSTEM

The BTS is used to determine the battery temper- The following procedures may be used to diagnose
ature and control battery charging rate. This temper- the charging system if:
ature data, along with data from monitored line • the generator lamp (if equipped) is illuminated
voltage, is used by the PCM to vary the battery with the engine running
charging rate. System voltage will be higher at colder • the voltmeter (if equipped) does not register
temperatures and is gradually reduced at warmer properly
temperatures. • an undercharged or overcharged battery condi-
The PCM sends 5 volts to the sensor and is tion occurs.
grounded through the sensor return line. As temper- Remember that an undercharged battery is often
ature increases, resistance in the sensor decreases caused by:
and the detection voltage at the PCM increases. • accessories being left on with the engine not
The BTS is also used for OBD II diagnostics. Cer- running
tain faults and OBD II monitors are either enabled • a faulty or improperly adjusted switch that
or disabled, depending upon BTS input (for example, allows a lamp to stay on. See Ignition-Off Draw Test
disable purge and enable Leak Detection Pump in Group 8A, Battery for more information.
(LDP) and O2 sensor heater tests). Most OBD II
monitors are disabled below 20°F. INSPECTION
To perform a complete test of the charging system,
ELECTRONIC VOLTAGE REGULATOR refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRB scan tool. Per-
DESCRIPTION form the following inspections before attaching the
The Electronic Voltage Regulator (EVR) is not a scan tool.
separate component. It is actually a voltage regulat- (1) Inspect the battery condition. Refer to Group
ing circuit located within the Powertrain Control 8A, Battery for procedures.
Module (PCM). The EVR is not serviced separately. If (2) Inspect condition of battery cable terminals,
replacement is necessary, the PCM must be replaced. battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.

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 XJ CHARGING SYSTEM 8C - 3
DIAGNOSIS AND TESTING (Continued)
(3) Inspect all fuses in both the fuseblock and (1) Disconnect negative battery cable at battery.
Power Distribution Center (PDC) for tightness in (2) Remove generator drive belt. Refer to Group 7,
receptacles. They should be properly installed and Cooling System for procedures.
tight. Repair or replace as required. (3) Left Hand Drive (LHD) Vehicles Only: Remove
(4) Inspect generator mounting bolts for tightness. generator pivot and mounting bolts/nut (Fig. 1) or
Replace or tighten bolts if required. Refer to the Gen- (Fig. 2). Position generator for access to wire connec-
erator Removal/Installation section of this group for tors.
torque specifications. (4) Right Hand Drive (RHD) Vehicles Only:
(5) Inspect generator drive belt condition and ten- Remove upper nut (generator adjustment nut) and
sion. Tighten or replace belt as required. Refer to both belt adjustment bolts (Fig. 3). Remove generator
Belt Tension Specifications in Group 7, Cooling Sys- lower nut/bolt. Position generator for access to wire
tem. connectors.
(6) Inspect automatic belt tensioner (if equipped). (5) If equipped, unsnap plastic cover from B+ ter-
Refer to Group 7, Cooling System for information. minal.
(7) Inspect generator electrical connections at gen- (6) Remove B+ terminal mounting nut at rear of
erator field, battery output, and ground terminal (if generator (Fig. 4). Disconnect terminal from genera-
equipped). Also check generator ground wire connec- tor.
tion at engine (if equipped). They should all be clean (7) Disconnect field wire connector at rear of gen-
and tight. Repair as required. erator by pushing on connector tab.
(8) Remove generator from vehicle.
ON-BOARD DIAGNOSTIC TEST FOR CHARGING
SYSTEM
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some circuits are checked continu-
ously and some are checked only under certain con-
ditions.
For DTC information, refer to Diagnostic Trouble
Codes in Group 25, Emission Control System. This
will include a complete list of DTC’s including DTC’s
for the charging system.

REMOVAL AND INSTALLATION

GENERATOR
REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM Fig. 1 Remove/Install Generator—2.5L Engine
BATTERY BEFORE REMOVING BATTERY OUTPUT 1 – UPPER MOUNTING BRACKET
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO 2 – GENERATOR
DO SO CAN RESULT IN INJURY OR DAMAGE TO 3 – UPPER BOLT
ELECTRICAL SYSTEM. 4 – LOWER BOLT

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 8C - 4 CHARGING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 4 Generator Connectors—Typical Denso

1 – FIELD WIRES
2 – B+ (OUTPUT TERMINAL)
Fig. 2 Remove/Install Generator—4.0L Engine—LHD 3 – FIELD WIRE CONNECTOR
1 – UPPER MOUNTING BRACKET
2 – GENERATOR (3) If equipped, snap plastic cover to B+ terminal.
3 – UPPER BOLT
(4) LHD Vehicles: Install generator fasteners and
4 – LOWER BOLT
tighten as follows:
• Generator upper mounting bolt-55 N·m (41 ft.
INSTALLATION lbs.) torque.
(1) Position generator to engine and snap field • Generator lower pivot bolt/nut-55 N·m (41 ft.
wire connector into rear of generator. lbs.) torque.
(2) Install B+ terminal to generator mounting
stud. Tighten mounting nut to 8.5 N·m (75 in. lbs.) CAUTION: Never force a belt over a pulley rim
torque. using a screwdriver. The synthetic fiber of the belt
can be damaged.

CAUTION: When installing a serpentine accessory

drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Group
7, Cooling System.

(5) LHD Vehicles: Install generator drive belt.

Refer to Group 7, Cooling System for procedures.
(6) RHD Vehicles: Install upper nut (generator
adjustment nut) and both belt adjustment bolts.
Install generator lower nut/bolt.
(7) RHD Vehicles: On vehicles equipped with RHD,
the generator is used to adjust the serpentine belt.
Fig. 3 Remove/Install Generator—4.0L Engine—RHD Refer to Group 7, Cooling System for belt routing,
1 – UPPER NUT
belt adjustment and bolt tightening procedures.
2 – LOWER BOLT (8) Install negative battery cable to battery.
3 – GENERATOR
4 – BELT ADJUSTMENT BOLTS

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 XJ CHARGING SYSTEM 8C - 5
REMOVAL AND INSTALLATION (Continued)

BATTERY TEMPERATURE SENSOR REMOVAL

The battery temperature sensor is located under (1) Remove battery. Refer to Group 8A, Battery for
vehicle battery (Fig. 5) and is attached to a mounting procedures.
hole on battery tray. (2) Disconnect sensor pigtail harness from engine
wire harness.
(3) Pry sensor straight up from battery tray
mounting hole.

INSTALLATION
(1) Feed pigtail harness through hole in top of bat-
tery tray and press sensor into top of battery tray.
(2) Connect pigtail harness.
(3) Install battery. Refer to Group 8A, Battery for
procedures.

Fig. 5 Battery Temperature Sensor

1 – BATTERY TEMPERATURE SENSOR
2 – BATTERY TRAY

SPECIFICATIONS
GENERATOR RATINGS

TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56041685AA 117 4.0L 88
DENSO 56041565AA 81 4.0L 57
DENSO 56005684AB 81 2.5L 57
DENSO 56005685AC 117 2.5L 88
DENSO 56041822AA 124 2.5L/4.0L 90

TORQUE CHART Description Torque

Right Hand Drive= RHD, Left Hand Drive= LHD. Ground Terminal Nut—LHD or
RHD . . . . . . . . . . . . . . . . . . 8.5 N·m (75 in. lbs.)
Description Torque Harness Hold-down Nut—LHD or
Generator Mounting Bolt—LHD—2.5L/4.0L RHD . . . . . . . . . . . . . . . . . . 8.5 N·m (75 in. lbs.)
Engine . . . . . . . . . . . . . . . . . . 55 N·m (41 ft. lbs.) Field Terminal Nuts—LHD or
Generator Pivot Bolt/Nut—LHD—2.5L/4.0L RHD . . . . . . . . . . . . . . . . . . 2.8 N·m (25 in. lbs.)
Engine . . . . . . . . . . . . . . . . . . 55 N·m (41 ft. lbs.)
Battery Terminal Nut—LHD or
RHD . . . . . . . . . . . . . . . . . . 8.5 N·m (75 in. lbs.)

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 XJ CHARGING SYSTEM 8C - 1

CHARGING SYSTEM
TABLE OF CONTENTS

page page

REMOVAL AND INSTALLATION SPECIFICATIONS

GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2

REMOVAL AND INSTALLATION

GENERATOR
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE FROM GENERATOR. FAILURE TO DO SO
CAN RESULT IN INJURY.

CAUTION: Never force a belt over a pulley rim

using a screwdriver. The synthetic fiber of the belt
can be damaged.

CAUTION: When installing a serpentine accessory

drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Group
7, Cooling System.

(1) Disconnect negative battery cable. Fig. 1 Generator Electrical

(2) Remove generator drive belt. Refer to Group 7, 1 – GENERATOR FIELD WIRE CONNECTOR
2 – GENERATOR B+ CONNECTION
Cooling System for procedure.
(3) Remove the nut securing battery output cable
to B+ terminal at rear of generator (Fig. 1). • Upper Generator Mounting Bolt—27.5 N·m (20
(4) Unplug field terminal connector at rear of gen- ft. lbs.)
erator (Fig. 1). • Lower Generator Mounting Bolt—47 N·m (35 ft.
(5) Remove upper generator mounting bolt (Fig. 2). lbs.)
(6) Remove lower generator mounting bolt (Fig. 2) • Battery Terminal (generator B+ terminal) Nut—
and remove generator from vehicle. 8.5 N·m (75 in. lbs.)
(7) Reverse the removal procedures for installa-
tion. Tighten hardware in order as follows:

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 8C - 2 CHARGING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
SPECIFICATIONS
Battery Terminal
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 N·m
Lower Generator Mounting
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 N·m
Upper Generator Mounting
Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5 N·m
Vacuum Pump Oil Feed Hose
Banjo Bolt . . . . . . . . . . . . . . . . . . . . . . . . 15 N·m

Fig. 2 Generator Mounting Bolts

1 – GENERATOR MOUNTING BOLTS

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 XJ IGNITION SYSTEM 8D - 1

IGNITION SYSTEM
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 10

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 1 IGNITION COIL—2.5L ENGINE. . . . . . . . . . . . . . 12
DISTRIBUTOR-2.5L ENGINE. . . . . . . . . . . . . . . . . 2 IGNITION COIL—4.0L ENGINE. . . . . . . . . . . . . . 12
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CRANKSHAFT POSITION (CKP) SENSOR . . . . . 13
SPARK PLUG CABLES-2.5L ENGINE . . . . . . . . . . 2 CAMSHAFT POSITION SENSOR—2.5L
IGNITION COIL-2.5L ENGINE . . . . . . . . . . . . . . . . 3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IGNITION COIL—4.0L ENGINE. . . . . . . . . . . . . . . 3 CAMSHAFT POSITION SENSOR—4.0L
CRANKSHAFT POSITION SENSOR. . . . . . . . . . . . 4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CAMSHAFT POSITION SENSOR-2.5L ENGINE. . . 4 DISTRIBUTOR—2.5L ENGINE . . . . . . . . . . . . . . 17
CAMSHAFT POSITION SENSOR—4.0L IGNITION SWITCH AND KEY CYLINDER . . . . . . 20
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SHIFTER/IGNITION INTERLOCK . . . . . . . . . . . . . 22
IGNITION SWITCH AND KEY LOCK SPECIFICATIONS
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IGNITION TIMING. . . . . . . . . . . . . . . . . . . . . . . . 23
DIAGNOSIS AND TESTING ENGINE FIRING ORDER—2.5L 4-CYLINDER
DISTRIBUTOR CAP-2.5L ENGINE. . . . . . . . . . . . . 6 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DISTRIBUTOR ROTOR-2.5L ENGINE . . . . . . . . . . 6 ENGINE FIRING ORDER—4.0L 6-CYLINDER
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . . 7 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPARK PLUG CONDITIONS . . . . . . . . . . . . . . . . . 8 SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 23
IGNITION SWITCH AND KEY LOCK SPARK PLUG CABLE RESISTANCE . . . . . . . . . . 23
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 IGNITION COIL RESISTANCE—2.5L ENGINE . . 23
REMOVAL AND INSTALLATION IGNITION COIL RESISTANCE—4.0L ENGINE . . 23
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . . 10 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 24

DESCRIPTION AND OPERATION 4.0L 6–Cylinder Engine:

The 4.0L 6–cylinder engine uses a one-piece coil
IGNITION SYSTEM rail containing three independent coils. Although cyl-
inder firing order is the same as 4.0L engines of pre-
DESCRIPTION vious years, spark plug firing is not. The 3 coils dual-
Two different ignition systems are used. One type fire the spark plugs on cylinders 1–6, 2–5 and/or 3–4.
is used for the 2.5L 4–cylinder engine. The other is When one cylinder is being fired (on compression
used for the 4.0L 6–cylinder engine. stroke), the spark to the opposite cylinder is being
wasted (on exhaust stroke). The one-piece coil bolts
OPERATION directly to the cylinder head. Rubber boots seal the
2.5L 4–Cylinder Engine: secondary terminal ends of the coils to the top of all
The ignition system is controlled by the Powertrain 6 spark plugs. One electrical connector (located at
Control Module (PCM). the rear end of the coil rail) is used for all three coils.
The ignition system consists of: Because of coil design, spark plug cables (second-
• Spark Plugs ary cables) are not used on either engine. A distrib-
• Ignition Coil utor is not used with the 4.0L engine.
• Secondary Ignition Cables The ignition system is controlled by the Powertrain
• Distributor (contains rotor and camshaft position Control Module (PCM).
sensor) The ignition system consists of:
• Powertrain Control Module (PCM) • Spark Plugs
• Crankshaft Position, Camshaft Position, Throt- • Ignition Coil(s)
tle Position and MAP Sensors • Powertrain Control Module (PCM)

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 8D - 2 IGNITION SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
• Crankshaft Position Sensor SPARK PLUGS
• Camshaft Position Sensor
• The MAP, TPS, IAC and ECT also have an effect DESCRIPTION
on the control of the ignition system. Resistor type spark plugs are used.
Spark plug resistance values range from 6,000 to
DISTRIBUTOR-2.5L ENGINE 20,000 ohms (when checked with at least a 1000 volt
spark plug tester). Do not use an ohmmeter to
DESCRIPTION check the resistance values of the spark plugs.
The 2.5L engine is equipped with a camshaft Inaccurate readings will result.
driven mechanical distributor (Fig. 1) containing a
shaft driven distributor rotor. The distributor is also OPERATION
equipped with an internal camshaft position (fuel To prevent possible pre-ignition and/or mechanical
sync) sensor (Fig. 1). engine damage, the correct type/heat range/number
spark plug must be used.
Always use the recommended torque when tighten-
ing spark plugs. Incorrect torque can distort the
spark plug and change plug gap. It can also pull the
plug threads and do possible damage to both the
spark plug and the cylinder head.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. A sin-
gle plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O, Lubrication and Maintenance
Spark plugs that have low mileage may be cleaned
and reused if not otherwise defective, carbon or oil
Fig. 1 Distributor and Camshaft Position Sensor-
fouled. Also refer to Spark Plug Conditions.
2.5L Engine
1 – SYNC SIGNAL GENERATOR
CAUTION: Never use a motorized wire wheel brush
2 – CAMSHAFT POSITION SENSOR
to clean the spark plugs. Metallic deposits will
3 – PULSE RING
4 – DISTRIBUTOR ASSEMBLY
remain on the spark plug insulator and will cause
plug misfire.

OPERATION
The distributor does not have built in centrifugal SPARK PLUG CABLES-2.5L ENGINE
or vacuum assisted advance. Base ignition timing
and all timing advance is controlled by the Power- DESCRIPTION
train Control Module (PCM). Because ignition timing Spark plug cables are used only on the 2.5L
is controlled by the PCM, base ignition timing is engine. They are sometimes referred to as secondary
not adjustable. ignition wires.
The distributor is locked in place by a fork with a
slot located on the distributor housing base. The dis- OPERATION
tributor holddown clamp bolt passes through this slot The spark plug cables transfer electrical current
when installed. Because the distributor position is from the ignition coil(s) and/or distributor, to individ-
locked when installed, its rotational position can not ual spark plugs at each cylinder. The resistive spark
be changed. Do not attempt to modify the dis- plug cables are of nonmetallic construction. The
tributor housing to get distributor rotation. cables provide suppression of radio frequency emis-
Distributor position will have no effect on igni- sions from the ignition system.
tion timing. The position of the distributor will
determine fuel synchronization only.
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing.
The seal is not serviceable.

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 XJ IGNITION SYSTEM 8D - 3
DESCRIPTION AND OPERATION (Continued)

IGNITION COIL-2.5L ENGINE

DESCRIPTION
A single ignition coil is used with the 2.5L 4–cylin-
der engine. The coil is not oil filled. The coil windings
are embedded in an epoxy compound. This provides
heat and vibration resistance that allows the coil to
be mounted on the engine.

OPERATION
The Powertrain Control Module (PCM) opens and
closes the ignition coil ground circuit for ignition coil
operation.
Battery voltage is supplied to the ignition coil pos-
itive terminal from the ASD relay. If the PCM does
not see a signal from the crankshaft and camshaft
sensors (indicating the ignition key is ON but the
engine is not running), it will shut down the ASD cir-
cuit.
Base ignition timing is not adjustable. By con-
trolling the coil ground circuit, the PCM is able to set Fig. 2 Ignition Coil Assembly—4.0L 6–Cylinder
the base timing and adjust the ignition timing Engine
advance. This is done to meet changing engine oper- 1 – CYL. #6
ating conditions. 2 – CYL. #5
3 – CYL. #4
IGNITION COIL—4.0L ENGINE 4 – CYL. #3
5 – CYL. #2
DESCRIPTION 6 – CYL. #1
7 – COILS (3)
A one-piece coil rail assembly containing three
8 – MOUNTING BOLTS (4)
individual coils is used on the 4.0L 6–cylinder engine
9 – BOLT BASES (4)
(Fig. 2). The coil rail must be replaced as one assem- 10 – RUBBER BOOTS (6)
bly. The bottom of the coil is equipped with 6 individ-
ual rubber boots (Fig. 2) to seal the 6 spark plugs to
the coil. Inside each rubber boot is a spring. The
spring is used for a mechanical contact between the
coil and the top of the spark plug. These rubber boots
and springs are a permanent part of the coil and are
not serviced separately.
(1) The coil is bolted directly to the cylinder head
(Fig. 3). One electrical connector (located at rear of
coil) is used for all three coils.

OPERATION
Although cylinder firing order is the same as 4.0L
Jeep engines of previous years, spark plug firing is
not. The 3 coils dual-fire the spark plugs on cylinders
1–6, 2–5 and/or 3–4. When one cylinder is being fired
(on compression stroke), the spark to the opposite
cylinder is being wasted (on exhaust stroke).
Battery voltage is supplied to the three ignition Fig. 3 Coil Location—4.0L Engine
coils from the ASD relay. The Powertrain Control 1 – COIL RAIL
2 – COIL MOUNTING BOLTS (4)
Module (PCM) opens and closes the ignition coil
3 – COIL
ground circuit for ignition coil operation.
4 – COIL ELECTRICAL CONNECTION
Base ignition timing is not adjustable. By con-
trolling the coil ground circuit, the PCM is able to set
the base timing and adjust the ignition timing

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 8D - 4 IGNITION SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
advance. This is done to meet changing engine oper-
ating conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
Because of coil design, spark plug cables (second-
ary cables) are not used. The cables are integral
within the coil rail.

CRANKSHAFT POSITION SENSOR

DESCRIPTION
The Crankshaft Position (CKP) sensor is located
near the outer edge of the flywheel (starter ringear).

OPERATION
Engine speed and crankshaft position are provided
through the CKP sensor. The sensor generates pulses
that are the input sent to the Powertrain Control
Module (PCM). The PCM interprets the sensor input
to determine the crankshaft position. The PCM then Fig. 4 Sensor Operation—2.5L 4-Cyl. Engine
uses this position, along with other inputs, to deter- 1 – CRANKSHAFT POSITION SENSOR
mine injector sequence and ignition timing. 2 – NOTCHES
The sensor is a hall effect device combined with an 3 – FLYWHEEL
internal magnet. It is also sensitive to steel within a
certain distance from it.
The flywheel/drive plate has groups of four notches
at its outer edge. On 2.5L 4-cylinder engines there
are two sets of notches (Fig. 4). On 4.0L 6-cylinder
engines there are three sets of notches (Fig. 5).
The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM. For each engine revolution there are two
groups of four pulses generated on 2.5L 4-cylinder
engines. There are 3 groups of four pulses generated
on 4.0L 6-cylinder engines.
The trailing edge of the fourth notch, which causes
the pulse, is four degrees before top dead center
(TDC) of the corresponding piston.
The engine will not operate if the PCM does not
receive a CKP sensor input.

CAMSHAFT POSITION SENSOR-2.5L ENGINE

DESCRIPTION
On the 2.5L 4–cylinder engine the Camshaft Posi-
tion (CMP) sensor is located in the distributor. Fig. 5 Sensor Operation—4.0L 6-Cyl. Engine
1 – CRANKSHAFT POSITION SENSOR
OPERATION 2 – FLYWHEEL
The sensor contains a hall effect device called a 3 – FLYWHEEL NOTCHES
sync signal generator to generate a fuel sync signal.
This sync signal generator detects a rotating pulse shaft Position (CKP) sensor to differentiate between
ring (shutter) on the distributor shaft. The pulse ring fuel injection and spark events. It is also used to syn-
rotates 180 degrees through the sync signal genera- chronize the fuel injectors with their respective cylin-
tor. Its signal is used in conjunction with the Crank- ders.

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 XJ IGNITION SYSTEM 8D - 5
DESCRIPTION AND OPERATION (Continued)
When the leading edge of the pulse ring (shutter)
enters the sync signal generator, the following occurs:
The interruption of magnetic field causes the voltage
to switch high resulting in a sync signal of approxi-
mately 5 volts.
When the trailing edge of the pulse ring (shutter)
leaves the sync signal generator, the following occurs:
The change of the magnetic field causes the sync sig-
nal voltage to switch low to 0 volts.

CAMSHAFT POSITION SENSOR—4.0L ENGINE

DESCRIPTION
The Camshaft Position Sensor (CMP) on the 4.0L
6–cylinder engine is bolted to the top of the oil pump
drive shaft assembly (Fig. 6). The sensor and drive
shaft assembly is located on the right side of the
engine near the oil filter (Fig. 7).

Fig. 7 CMP Location—4.0L Engine

1 – OIL FILTER
2 – CAMSHAFT POSITION SENSOR
3 – CLAMP BOLT
4 – HOLD-DOWN CLAMP
5 – MOUNTING BOLTS (2)
6 – ELEC. CONNECTOR

pulse ring (shutter) on the oil pump drive shaft (Fig.

6). The pulse ring rotates 180 degrees through the
sync signal generator. Its signal is used in conjunc-
tion with the crankshaft position sensor to differenti-
ate between fuel injection and spark events. It is also
used to synchronize the fuel injectors with their
respective cylinders.
When the leading edge of the pulse ring (shutter)
enters the sync signal generator, the following occurs:
The interruption of magnetic field causes the voltage
to switch high resulting in a sync signal of approxi-
mately 5 volts.
When the trailing edge of the pulse ring (shutter)
leaves the sync signal generator, the following occurs:
The change of the magnetic field causes the sync sig-
Fig. 6 CMP and Oil Pump Drive Shaft—4.0L Engine nal voltage to switch low to 0 volts.
1 – CAMSHAFT POSITION SENSOR
2 – MOUNTING BOLTS (2) IGNITION SWITCH AND KEY LOCK CYLINDER
3 – PULSE RING
4 – DRIVE GEAR (TO CAMSHAFT)
DESCRIPTION
5 – OIL PUMP DRIVESHAFT
6 – SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
The electrical ignition switch is located on the
steering column. It is used as the main on/off switch-
ing device for most electrical components. The
OPERATION mechanical key lock cylinder is used to engage/disen-
The CMP sensor contains a hall effect device called gage the electrical ignition switch.
a sync signal generator to generate a fuel sync sig-
nal. This sync signal generator detects a rotating

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 8D - 6 IGNITION SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
OPERATION DIAGNOSIS AND TESTING
Vehicles equipped with an automatic trans-
mission and a floor mounted shifter: a cable is DISTRIBUTOR CAP-2.5L ENGINE
used to connect the interlock device in the steering Remove the distributor cap and wipe it clean with
column assembly, to the transmission floor shift a dry lint free cloth. Visually inspect the cap for
lever. This interlock device is used to lock the trans- cracks, carbon paths, broken towers or damaged
mission shifter in the PARK position when the key rotor button (Fig. 8) or (Fig. 9). Also check for white
lock cylinder is rotated to the LOCKED or ACCES- deposits on the inside (caused by condensation enter-
SORY position. The interlock device within the steer- ing the cap through cracks). Replace any cap that
ing column is not serviceable. If repair is necessary, displays charred or eroded terminals. The machined
the steering column assembly must be replaced. surface of a terminal end (faces toward rotor) will
Refer to Group 19, Steering for procedures. indicate some evidence of erosion from normal oper-
If the ignition key is difficult to rotate to or from ation. Examine the terminal ends for evidence of
the LOCK or ACCESSORY position, it may not be mechanical interference with the rotor tip.
the fault of the key cylinder or the steering column
components. The brake transmission shift interlock
cable may be out of adjustment. Refer to Brake
Transmission Shift Interlock Cable Adjustment in
Group 21, Transmissions for adjustment procedures.
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the steering col-
umn. This interlock device is used to lock the trans-
mission shifter in the PARK position when the key
lock cylinder is in the LOCKED or ACCESSORY
position. If it is difficult to rotate the key to or from
the LOCK or ACCESSORY position, the interlock
device within the steering column may be defective.
This device is not serviceable. If repair is necessary,
the steering column assembly must be replaced.
Refer to Group 19, Steering for procedures.
Vehicles equipped with a manual transmis-
sion and a floor mounted shifter: on certain mod- Fig. 8 Cap Inspection—External—Typical
1 – BROKEN TOWER
els, a lever is located on the steering column behind
2 – DISTRIBUTOR CAP
the ignition key lock cylinder. The lever must be
3 – CARBON PATH
manually operated to allow rotation of the ignition 4 – CRACK
key lock cylinder to the LOCK or ACCESSORY posi-
tion. If it is difficult to rotate the key to the LOCK or
ACCESSORY position, the lever mechanism may be DISTRIBUTOR ROTOR-2.5L ENGINE
defective. This mechanism is not serviceable. If Visually inspect the rotor (Fig. 10) for cracks, evi-
repair is necessary, the steering column assembly dence of corrosion or the effects of arcing on the
must be replaced. Refer to Group 19, Steering for metal tip. Also check for evidence of mechanical
procedures. interference with the cap. Some charring is normal
On other models, the ignition key cylinder must be on the end of the metal tip. The silicone-dielectric-
depressed to allow it to be rotated into the LOCK or varnish-compound applied to the rotor tip for radio
ACCESSORY position. If it is difficult to rotate the interference noise suppression, will appear charred.
key to the LOCK or ACCESSORY position, the lock This is normal. Do not remove the charred com-
mechanism within the steering column may be defec- pound. Test the spring for insufficient tension.
tive. This mechanism is not serviceable. If repair is Replace a rotor that displays any of these adverse
necessary, the steering column assembly must be conditions.
replaced. Refer to Group 19, Steering for procedures.

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 XJ IGNITION SYSTEM 8D - 7
DIAGNOSIS AND TESTING (Continued)
Clean high voltage ignition cables with a cloth
moistened with a non-flammable solvent. Wipe the
cables dry. Check for brittle or cracked insulation.
When testing secondary cables for damage with an
oscilloscope, follow the instructions of the equipment
manufacturer.
If an oscilloscope is not available, spark plug cables
may be tested as follows:

CAUTION: Do not leave any one spark plug cable

disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.

With the engine running, remove spark plug cable

Fig. 9 Cap Inspection—Internal—Typical from spark plug (one at a time) and hold next to a
1 – CHARRED OR ERODED TERMINALS good engine ground. If the cable and spark plug are
2 – WORN OR DAMAGED ROTOR BUTTON in good condition, the engine rpm should drop and
3 – CARBON PATH the engine will run poorly. If engine rpm does not
drop, the cable and/or spark plug may not be operat-
ing properly and should be replaced. Also check
engine cylinder compression.
With the engine not running, connect one end of a
test probe to a good ground. Start the engine and run
the other end of the test probe along the entire
length of all spark plug cables. If cables are cracked
or punctured, there will be a noticeable spark jump
from the damaged area to the test probe. The cable
running from the ignition coil to the distributor cap
can be checked in the same manner. Cracked, dam-
aged or faulty cables should be replaced with resis-
tance type cable. This can be identified by the words
ELECTRONIC SUPPRESSION printed on the cable
jacket.
Use an ohmmeter to test for open circuits, excessive
resistance or loose terminals. Remove the distributor
cap from the distributor. Do not remove cables from
cap. Remove cable from spark plug. Connect ohmme-
ter to spark plug terminal end of cable and to corre-
Fig. 10 Rotor Inspection—Typical sponding electrode in distributor cap. Resistance
1 – INSUFFICIENT SPRING TENSION should be 250 to 1000 Ohms per inch of cable. If not,
2 – CRACKS remove cable from distributor cap tower and connect
3 – EVIDENCE OF PHYSICAL CONTACT WITH CAP ohmmeter to the terminal ends of cable. If resistance
4 – ROTOR TIP CORRODED is not within specifications as found in the SPARK
PLUG CABLE RESISTANCE chart, replace the
SPARK PLUG CABLES cable. Test all spark plug cables in this manner.
SPARK PLUG CABLE RESISTANCE
TESTING
Check the spark plug cable connections for good MINIMUM MAXIMUM
contact at the coil(s), distributor cap towers, and 250 Ohms Per Inch 1000 Ohms Per Inch
spark plugs. Terminals should be fully seated. The 3000 Ohms Per Foot 12,000 Ohms Per Foot
insulators should be in good condition and should fit
tightly on the coil, distributor and spark plugs. Spark
plug cables with insulators that are cracked or torn To test ignition coil-to-distributor cap cable, do not
must be replaced. remove the cable from the cap. Connect ohmmeter to
rotor button (center contact) of distributor cap and

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 8D - 8 IGNITION SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)
terminal at ignition coil end of cable. If resistance is two plugs in a set may be caused by sticking valves
not within specifications as found in the Spark Plug or defective spark plug cables. Cold (carbon) fouling
Cable Resistance chart, remove the cable from the of the entire set of spark plugs may be caused by a
distributor cap. Connect the ohmmeter to the termi- clogged air cleaner element or repeated short operat-
nal ends of the cable. If resistance is not within spec- ing times (short trips).
ifications as found in the Spark Plug Cable
Resistance chart, replace the cable. Inspect the igni- WET FOULING OR GAS FOULING
tion coil tower for cracks, burns or corrosion. A spark plug coated with excessive wet fuel or oil
is wet fouled. In older engines, worn piston rings,
SPARK PLUG CONDITIONS leaking valve guide seals or excessive cylinder wear
can cause wet fouling. In new or recently overhauled
NORMAL OPERATING engines, wet fouling may occur before break-in (nor-
The few deposits present on the spark plug will mal oil control) is achieved. This condition can usu-
probably be light tan or slightly gray in color. This is ally be resolved by cleaning and reinstalling the
evident with most grades of commercial gasoline fouled plugs.
(Fig. 11). There will not be evidence of electrode
burning. Gap growth will not average more than OIL OR ASH ENCRUSTED
approximately 0.025 mm (.001 in) per 3200 km (2000 If one or more spark plugs are oil or oil ash
miles) of operation. Spark plugs that have normal encrusted (Fig. 12), evaluate engine condition for the
wear can usually be cleaned, have the electrodes cause of oil entry into that particular combustion
filed, have the gap set and then be installed. chamber.

Fig. 11 Normal Operation and Cold (Carbon) Fouling

1 – NORMAL
2 – DRY BLACK DEPOSITS
3 – COLD (CARBON) FOULING

Some fuel refiners in several areas of the United Fig. 12 Oil or Ash Encrusted
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT ELECTRODE GAP BRIDGING
causes the entire tip of the spark plug to be coated Electrode gap bridging may be traced to loose
with a rust colored deposit. This rust color can be deposits in the combustion chamber. These deposits
misdiagnosed as being caused by coolant in the com- accumulate on the spark plugs during continuous
bustion chamber. Spark plug performance may be stop-and-go driving. When the engine is suddenly
affected by MMT deposits. subjected to a high torque load, deposits partially liq-
uefy and bridge the gap between electrodes (Fig. 13).
COLD FOULING/CARBON FOULING This short circuits the electrodes. Spark plugs with
Cold fouling is sometimes referred to as carbon electrode gap bridging can be cleaned using standard
fouling. The deposits that cause cold fouling are basi- procedures.
cally carbon (Fig. 11). A dry, black deposit on one or

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 XJ IGNITION SYSTEM 8D - 9
DIAGNOSIS AND TESTING (Continued)
severe detonation can also separate the insulator
from the center electrode (Fig. 15). Spark plugs with
this condition must be replaced.

Fig. 13 Electrode Gap Bridging

1 – GROUND ELECTRODE
2 – DEPOSITS
3 – CENTER ELECTRODE Fig. 15 Chipped Electrode Insulator
1 – GROUND ELECTRODE
2 – CENTER ELECTRODE
SCAVENGER DEPOSITS
3 – CHIPPED INSULATOR
Fuel scavenger deposits may be either white or yel-
low (Fig. 14). They may appear to be harmful, but this
is a normal condition caused by chemical additives in PREIGNITION DAMAGE
certain fuels. These additives are designed to change Preignition damage is usually caused by excessive
the chemical nature of deposits and decrease spark combustion chamber temperature. The center elec-
plug misfire tendencies. Notice that accumulation on trode dissolves first and the ground electrode dis-
the ground electrode and shell area may be heavy, but solves somewhat latter (Fig. 16). Insulators appear
the deposits are easily removed. Spark plugs with relatively deposit free. Determine if the spark plug
scavenger deposits can be considered normal in condi- has the correct heat range rating for the engine.
tion and can be cleaned using standard procedures. Determine if ignition timing is over advanced or if
other operating conditions are causing engine over-
heating. (The heat range rating refers to the operat-
ing temperature of a particular type spark plug.
Spark plugs are designed to operate within specific
temperature ranges. This depends upon the thick-
ness and length of the center electrodes porcelain
insulator.)

SPARK PLUG OVERHEATING

Overheating is indicated by a white or gray center
electrode insulator that also appears blistered (Fig.
17). The increase in electrode gap will be consider-
ably in excess of 0.001 inch per 2000 miles of opera-
tion. This suggests that a plug with a cooler heat
range rating should be used. Over advanced ignition
Fig. 14 Scavenger Deposits timing, detonation and cooling system malfunctions
1 – GROUND ELECTRODE COVERED WITH WHITE OR
YELLOW DEPOSITS can also cause spark plug overheating.
2 – CENTER ELECTRODE
IGNITION SWITCH AND KEY LOCK CYLINDER
CHIPPED ELECTRODE INSULATOR ELECTRICAL DIAGNOSIS
A chipped electrode insulator usually results from For ignition switch electrical schematics, refer to
bending the center electrode while adjusting the Ignition Switch in Group 8W, Wiring Diagrams.
spark plug electrode gap. Under certain conditions,

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 8D - 10 IGNITION SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)
Transmission Shift Interlock Cable Adjustment in
Group 21, Transmissions for adjustment procedures.
Vehicles equipped with an automatic trans-
mission and a steering column mounted shifter:
an interlock device is located within the steering col-
umn. This interlock device is used to lock the trans-
mission shifter in the PARK position when the key
lock cylinder is in the LOCKED or ACCESSORY
position. If it is difficult to rotate the key to or from
the LOCK or ACCESSORY position, the interlock
device within the steering column may be defective.
This device is not serviceable. If repair is necessary,
the steering column assembly must be replaced.
Refer to Group 19, Steering for procedures.
Vehicles equipped with a manual transmis-
Fig. 16 Preignition Damage sion and a floor mounted shifter: on certain mod-
1 – GROUND ELECTRODE STARTING TO DISSOLVE els, a lever is located on the steering column behind
2 – CENTER ELECTRODE DISSOLVED the ignition key lock cylinder. The lever must be
manually operated to allow rotation of the ignition
key lock cylinder to the LOCK or ACCESSORY posi-
tion. If it is difficult to rotate the key to the LOCK or
ACCESSORY position, the lever mechanism may be
defective. This mechanism is not serviceable. If
repair is necessary, the steering column assembly
must be replaced. Refer to Group 19, Steering for
procedures.
On other models, the ignition key cylinder must be
depressed to allow it to be rotated into the LOCK or
ACCESSORY position. If it is difficult to rotate the
key to the LOCK or ACCESSORY position, the lock
mechanism within the steering column may be defec-
tive. This mechanism is not serviceable. If repair is
necessary, the steering column assembly must be
replaced. Refer to Group 19, Steering for procedures.
Fig. 17 Spark Plug Overheating
1 – BLISTERED WHITE OR GRAY COLORED INSULATOR
REMOVAL AND INSTALLATION
MECHANICAL DIAGNOSIS (KEY DIFFICULT TO SPARK PLUG CABLES
ROTATE)
Vehicles equipped with an automatic trans- REMOVAL
mission and a floor mounted shifter: a cable is
used to connect the interlock device in the steering CAUTION: When disconnecting a high voltage
column assembly, to the transmission floor shift cable from a spark plug or from the distributor cap,
lever. This interlock device is used to lock the trans- twist the rubber boot slightly (1/2 turn) to break it
mission shifter in the PARK position when the key loose (Fig. 18). Grasp the boot (not the cable) and
lock cylinder is rotated to the LOCKED or ACCES- pull it off with a steady, even force.
SORY position. The interlock device within the steer-
ing column is not serviceable. If repair is necessary,
INSTALLATION
the steering column assembly must be replaced.
Push the cable firmly onto the sparkplug.
Refer to Group 19, Steering for procedures.
If the ignition key is difficult to rotate to or from
the LOCK or ACCESSORY position, it may not be
SPARK PLUGS
the fault of the key cylinder or the steering column
components. The brake transmission shift interlock
PLUG REMOVAL
On the 4.0L 6–cylinder engine the spark plugs are
cable may be out of adjustment. Refer to Brake
located below the coil rail assembly. To gain access to

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 XJ IGNITION SYSTEM 8D - 11
REMOVAL AND INSTALLATION (Continued)

Fig. 18 Cable Removal

1 – SPARK PLUG CABLE AND BOOT
2 – SPARK PLUG BOOT PULLER
3 – TWIST AND PULL
4 – SPARK PLUG

Fig. 19 Setting Spark Plug Gap—Typical

any/all spark plug(s), refer to Ignition Coil-4.0L
1 – GAUGE
Engine Removal/Installation.
2 – SPARK PLUG
(1) 2.5L 4–Cylinder Engine: Always remove spark
plug or ignition coil cables by grasping at the cable
boot (Fig. 18). Turn the cable boot 1/2 turn and pull SPARK PLUG GAP
straight back in a steady motion. Never pull directly • 2.5L 4-Cylinder Engine Spark Plug Gap:.89 mm
on the cable. Internal damage to cable will result. (.035 in).
(2) Prior to removing the spark plug, spray com- • 4.0L 6-Cylinder Engine Spark Plug Gap:.89 mm
pressed air around the spark plug hole and the area (.035 in).
around the spark plug. This will help prevent foreign
material from entering the combustion chamber. PLUG INSTALLATION
(3) Remove the spark plug using a quality socket Always tighten spark plugs to the specified torque.
with a rubber or foam insert. Over tightening can cause distortion. This may result
(4) Inspect the spark plug condition. Refer to in a change in the spark plug gap, or a cracked por-
Spark Plugs Conditions. celain insulator.
When replacing the spark plug and ignition coil
PLUG CLEANING cables, route the cables correctly and secure them in
The plugs may be cleaned using commercially the appropriate retainers. Failure to route the cables
available spark plug cleaning equipment. After clean- properly can cause the radio to reproduce ignition
ing, file the center electrode flat with a small point noise. It could cause cross ignition of the spark plugs,
file or jewelers file before adjusting gap. or short circuit the cables to ground.
(1) Start the spark plug into the cylinder head by
CAUTION: Never use a motorized wire wheel brush hand to avoid cross threading.
to clean the spark plugs. Metallic deposits will (2) Tighten the spark plugs to 35-41 N·m (26-30 ft.
remain on the spark plug insulator and will cause lbs.) torque.
plug misfire. (3) 2.5L 4–Cylinder Engine: Install spark plug
cables over spark plugs.
(4) 4.0L 6–Cylinder Engine: Install coil rail. Refer
PLUG GAP ADJUSTMENT to Ignition Coil-4.0L Engine Removal/Installation.
Check the spark plug gap with a gap gauge tool. If
the gap is not correct, adjust it by bending the
ground electrode (Fig. 19). Never attempt to adjust
the gap by bending the center electrode.

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 8D - 12 IGNITION SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

IGNITION COIL—2.5L ENGINE ber boots (Fig. 21) to seal the 6 spark plugs to the
coil. Inside each rubber boot is a spring. The spring
REMOVAL is used for an electrical contact between the coil and
The ignition coil is an epoxy filled type. If the coil the top of the spark plug. These rubber boots and
is replaced, it must be replaced with the same type. springs are a permanent part of the coil and are not
On the 2.5L 4-cylinder engine, the ignition coil is serviced separately.
mounted to a bracket on side of engine (to rear of (1) Disconnect negative battery cable at battery.
distributor) (Fig. 20). (2) The coil is bolted directly to the cylinder head.
Remove 4 coil mounting bolts (Fig. 22).
(3) Carefully pry up coil assembly from spark
plugs. Do this by prying alternately at each end of
coil until rubber boots have disengaged from all
spark plugs. If boots will not release from spark
plugs, use a commercially available spark plug boot
removal tool. Twist and loosen a few boots from a few
spark plugs to help remove coil.
(4) After coil has cleared spark plugs, position coil
for access to primary electrical connector. Disconnect
connector from coil by pushing slide tab outwards to
right side of vehicle (Fig. 23). After slide tab has been
positioned outwards, push in on secondary release
lock (Fig. 23) on side of connector and pull connector
from coil.
(5) Remove coil from vehicle.

Fig. 20 Ignition Coil—2.5L Engine

1 – IGNITION COIL
2 – ELECTRICAL CONNECTOR
3 – MOUNTING BOLTS (2)
4 – SECONDARY CABLE

(1) Disconnect ignition coil secondary cable from

ignition coil.
(2) Disconnect engine harness connector from igni-
tion coil.
(3) Remove ignition coil mounting bolts (nuts are
used on back side of bracket on some coils).
(4) Remove coil from vehicle.

INSTALLATION
(1) Install ignition coil to bracket on cylinder block
with mounting bolts (and nuts if equipped). If
equipped with nuts and bolts, tighten to 11 N·m (100 Fig. 21 Ignition Coil Assembly—4.0L 6–Cylinder
in. lbs.) torque. If equipped with bolts only, tighten to Engine
5 N·m (50 in. lbs.) torque. 1 – CYL. #6
(2) Connect engine harness connector to coil. 2 – CYL. #5
(3) Connect ignition coil cable to ignition coil. 3 – CYL. #4
4 – CYL. #3
IGNITION COIL—4.0L ENGINE 5 – CYL. #2
6 – CYL. #1
REMOVAL 7 – COILS (3)
A one-piece coil rail assembly containing three 8 – MOUNTING BOLTS (4)
individual coils is used on the 4.0L engine (Fig. 21). 9 – BOLT BASES (4)
The coil rail must be replaced as one assembly. The 10 – RUBBER BOOTS (6)
bottom of the coil is equipped with 6 individual rub-

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 XJ IGNITION SYSTEM 8D - 13
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Position ignition coil rubber boots to all spark
plugs. Push down on coil assembly until bolt bases
have contacted cylinder head
(2) Install 4 coil mounting bolts. Loosely tighten 4
bolts just enough to allow bolt bases to contact cylin-
der head. Do a final tightening of each bolt in steps
down to 29 N·m (250 in. lbs.) torque. Do not apply
full torque to any bolt first.
(3) Connect engine harness connector to coil by
snapping into position. Move slide tab towards
engine (Fig. 23) for a positive lock.
(4) Connect negative battery cable to battery.

CRANKSHAFT POSITION (CKP) SENSOR

Fig. 22 Ignition Coil Rail Location—4.0L 6–Cylinder REMOVAL
Engine The crankshaft position (CKP) sensor is mounted
1 – COIL RAIL
to the transmission bellhousing at the left/rear side
2 – COIL MOUNTING BOLTS (4)
of the engine block.
3 – COIL
4 – COIL ELECTRICAL CONNECTION
The sensor may be mounted to the transmission
with one of the following three different configura-
tions:
• with one bolt (Fig. 24). If sensor is equipped
with one mounting bolt, it is adjustable..
• with two nuts (Fig. 25).
• with two bolts (Fig. 26).

Fig. 23 Ignition Coil Electrical Connector—4.0L

6–Cylinder Engine Fig. 24 Crankshaft Position Sensor—One-Bolt
1 – REAR OF VALVE COVER Mounting
2 – COIL RAIL 1 – SENSOR PIGTAIL
3 – SLIDE TAB 2 – CRANKSHAFT POSITION SENSOR
4 – RELEASE LOCK 3 – MOUNTING BOLT
5 – COIL CONNECTOR 4 – TRANSMISSION HOUSING
5 – PAPER SPACER
6 – SLOTTED HOLE

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 8D - 14 IGNITION SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 25 Crankshaft Position Sensor—Two-Nut Fig. 26 Crankshaft Position Sensor—Two-Bolt

Mounting Mounting
1 – TRANSMISSION BELLHOUSING 1 – TRANSMISSION BELLHOUSING
2 – MOUNTING NUTS (2) 2 – MOUNTING BOLTS (2)
3 – CRANKSHAFT POSITION SENSOR 3 – CRANKSHAFT POSITION SENSOR
4 – MOUNTING STUDS (2) 4 – RUBBER GROMMET
5 – RUBBER GROMMET 5 – SENSOR PIGTAIL
6 – SENSOR PIGTAIL
spacer will be ground off the first time engine is
(1) Near left-rear side of engine, disconnect sensor started. If spacer is not used, sensor will be broken
pigtail harness (electrical connector) from main elec- the first time engine is started.
trical harness connector. These connectors are (4) New Sensors: Be sure paper spacer is installed
attached to a bracket which is attached to the left- to bottom of sensor. If not, obtain spacer
front side of the transmission. PN05252229.
(2) Depending upon application, remove either sen- (5) Used Sensors: Clean bottom of sensor and
sor mounting bolt(s) or nuts. install spacer PN05252229.
(3) Remove sensor from engine. (6) Install sensor into transmission bellhousing
hole.
INSTALLATION (7) Push sensor against flywheel/drive plate. With
Sensor With 2–Bolt Mounting: sensor pushed against flywheel/drive plate, tighten
(1) Install sensor flush against opening in trans- mounting bolt to 7 N·m (60 in. lbs.) torque.
mission housing. (8) Connect sensor pigtail harness electrical con-
(2) Install and tighten two sensor mounting bolts nector to main wiring harness connector.
to 19 N·m (14 ft. lbs.) torque. The two sensor mount-
ing bolts are specially machined to correctly space CAMSHAFT POSITION SENSOR—2.5L ENGINE
unit to flywheel. Do not attempt to install any other On 2.5L engines, the camshaft position sensor is
bolts. located in the distributor (Fig. 27).
Sensor With 2–Nut Mounting:
(3) Install and tighten two sensor mounting nuts REMOVAL
to 19 N·m (14 ft. lbs.) torque. Distributor removal is not necessary to remove
Sensor With One-Bolt Mounting: camshaft position sensor.
New replacement sensors will be equipped with a (1) Disconnect negative battery cable at battery.
paper spacer glued to bottom of sensor. If installing (2) Remove distributor cap from distributor (two
(returning) a used sensor to vehicle, a new paper screws).
spacer must be installed to bottom of sensor. This (3) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.

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 XJ IGNITION SYSTEM 8D - 15
REMOVAL AND INSTALLATION (Continued)

Fig. 27 Camshaft Position Sensor—2.5L Engine

1 – SYNC SIGNAL GENERATOR
2 – CAMSHAFT POSITION SENSOR
3 – PULSE RING
4 – DISTRIBUTOR ASSEMBLY

(4) Remove distributor rotor from distributor shaft.

(5) Lift camshaft position sensor assembly from
distributor housing (Fig. 27).

INSTALLATION Fig. 28 CMP and Oil Pump Drive Shaft—4.0L Engine

(1) Install camshaft position sensor to distributor. 1 – CAMSHAFT POSITION SENSOR
Align sensor into notch on distributor housing. 2 – MOUNTING BOLTS (2)
(2) Connect wiring harness. 3 – PULSE RING
(3) Install rotor. 4 – DRIVE GEAR (TO CAMSHAFT)
(4) Install distributor cap. Tighten mounting 5 – OIL PUMP DRIVESHAFT
screws. 6 – SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)

CAMSHAFT POSITION SENSOR—4.0L ENGINE REMOVAL—SENSOR ONLY

The Camshaft Position Sensor (CMP) on the 4.0L (1) Disconnect electrical connector at CMP sensor
6–cylinder engine is bolted to the top of the oil pump (Fig. 29).
drive shaft assembly (Fig. 28). The sensor and drive (2) Remove 2 sensor mounting bolts (Fig. 28) or
shaft assembly is located on the right side of the (Fig. 29).
engine near the oil filter (Fig. 29). (3) Remove sensor from oil pump drive.
The rotational position of oil pump drive deter-
mines fuel synchronization only. It does not deter- INSTALLATION—SENSOR ONLY
mine ignition timing. (1) Install sensor to oil pump drive.
(2) Install 2 sensor mounting bolts and tighten to
NOTE: Do not attempt to rotate the oil pump drive
2 N·m (15 in. lbs.) torque.
to modify ignition timing.
(3) Connect electrical connector to CMP sensor.
Two different procedures are needed for
removal and installation. The first procedure will REMOVAL—OIL PUMP DRIVE AND SENSOR
detail removal and installation of the sensor only. If the CMP and oil pump drive are to be
The second procedure will detail removal and instal- removed and installed, do not allow engine
lation of the sensor and oil pump drive shaft assem- crankshaft or camshaft to rotate. CMP sensor
bly. The second procedure is to be used if the engine relationship will be lost.
has been disassembled. (1) Disconnect electrical connector at CMP sensor
An internal oil seal is used in the drive shaft hous- (Fig. 29).
ing that prevents engine oil at the bottom of the sen- (2) Remove 2 sensor mounting bolts (Fig. 28) or
sor. The seal is not serviceable. (Fig. 29).
(3) Remove sensor from oil pump drive.

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 8D - 16 IGNITION SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 29 CMP Location—4.0L Engine Fig. 31 Align Timing Marks—4.0L Engine

1 – OIL FILTER 1 – CRANKSHAFT VIBRATION DAMPER TIMING MARK
2 – CAMSHAFT POSITION SENSOR
3 – CLAMP BOLT
4 – HOLD-DOWN CLAMP (4) Before proceeding to next step, mark and note
5 – MOUNTING BOLTS (2) rotational position of oil pump drive in relationship
6 – ELEC. CONNECTOR to engine block. After installation, the CMP sensor
should face rear of engine 0°.
(5) Remove hold-down bolt and clamp (Fig. 29).
(6) While pulling assembly from engine, note direc-
tion and position of pulse ring (Fig. 28). After
removal, look down into top of oil pump and note
direction and position of slot at top of oil pump gear.
(7) Remove and discard old oil pump drive-to-en-
gine block gasket.

INSTALLATION—OIL PUMP DRIVE AND SENSOR

(1) Clean oil pump drive mounting hole area of
engine block.
(2) Install new oil pump drive-to-engine block gas-
ket.
(3) Temporarily install a toothpick or similar tool
through access hole at side of oil pump drive housing.
Align toothpick into mating hole on pulse ring (Fig.
30).
(4) Install oil pump drive into engine while align-
ing into slot on oil pump. Rotate oil pump drive back
to its original position and install hold-down clamp
and bolt. Finger tighten bolt. Do not do a final tight-
ening of bolt at this time.
(5) If engine crankshaft or camshaft has been
Fig. 30 CMP Pulse Ring Alignment—4.0L Engine
rotated, such as during engine tear-down, CMP sen-
1 – PULSE RING (SHUTTER)
2 – TOOTHPICK
sor relationship must be reestablished.
3 – SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY) (a) Remove ignition coil rail assembly. Refer to
Ignition Coil Removal/Installation.

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 XJ IGNITION SYSTEM 8D - 17
REMOVAL AND INSTALLATION (Continued)
(b) Remove cylinder number 1 spark plug. on ignition timing. All ignition timing values are con-
(c) Hold a finger over the open spark plug hole. trolled by powertrain control module (PCM).
Rotate engine at vibration dampener bolt until (15) Tighten hold-down clamp bolt to 23 N·m (17
compression (pressure) is felt. ft. lbs.) torque.
(d) Slowly continue to rotate engine. Do this
until timing index mark on vibration damper pul- DISTRIBUTOR—2.5L ENGINE
ley aligns with top dead center (TDC) mark (0 The distributor contains an internal oil seal that
degree) on timing degree scale (Fig. 31). Always prevents oil from entering the distributor housing.
rotate engine in direction of normal rotation. Do The seal is not serviceable.
not rotate engine backward to align timing marks. Factory replacement distributors are equipped with
(e) Install oil pump drive into engine while a plastic alignment pin already installed. The pin is
aligning into slot on oil pump. If pump drive will located in an access hole on the bottom of the distrib-
not drop down flush to engine block, the oil pump utor housing (Fig. 32). It is used to temporarily lock
slot is not aligned. Remove oil pump drive and the rotor to the cylinder number 1 position during
align slot in oil pump to shaft at bottom of drive. installation. The pin must be removed after install-
Install into engine. Rotate oil pump drive back to ing the distributor.
its original position and install hold-down clamp
and bolt. Finger tighten bolt. Do not do a final
tightening of bolt at this time.
(f) Remove toothpick from housing.
(6) Install sensor to oil pump drive. After installa-
tion, the CMP sensor should face rear of engine 0°.
(7) Install 2 sensor mounting bolts and tighten to
2 N·m (15 in. lbs.) torque.
(8) Connect electrical connector to CMP sensor.
(9) If removed, install spark plug and ignition coil
rail.
To verify correct rotational position of oil pump
drive, the DRB scan tool must be used.

WARNING: WHEN PERFORMING THE FOLLOWING

TEST, THE ENGINE WILL BE RUNNING. BE CARE-
FUL NOT TO STAND IN LINE WITH THE FAN
BLADES OR FAN BELT. DO NOT WEAR LOOSE
CLOTHING.
Fig. 32 Plastic Alignment Pin—2.5L Engine
(10) Connect DRB scan tool to data link connector.
1 – PLASTIC ALIGNMENT PIN
The data link connector is located in passenger com-
partment, below and to left of steering column.
(11) Gain access to SET SYNC screen on DRB. The camshaft position sensor is located in the dis-
(12) Follow directions on DRB screen and start tributor (Fig. 33). For removal/installation proce-
engine. Bring to operating temperature (engine must dures, refer to Camshaft Position Sensor. Distributor
be in “closed loop” mode). removal is not necessary for sensor removal.
(13) With engine running at idle speed, the words Refer to (Fig. 33) for an exploded view of the dis-
IN RANGE should appear on screen along with 0°. tributor.
This indicates correct position of oil pump drive. A fork with a slot is supplied on the bottom of the
(14) If a plus (+) or a minus (-) is displayed next to distributor housing where the housing base seats
degree number, and/or the degree displayed is not against the engine block (Fig. 33). The centerline of
zero, loosen but do not remove hold-down clamp bolt. the slot aligns with the distributor holddown bolt
Rotate oil pump drive until IN RANGE appears on hole in the engine block. Because of the fork, the dis-
screen. Continue to rotate oil pump drive until tributor cannot be rotated. Distributor rotation is not
achieving as close to 0° as possible. necessary as all ignition timing requirements are
The degree scale on SET SYNC screen of DRB is handled by the Powertrain Control Module (PCM).
referring to fuel synchronization only. It is not The position of the distributor determines fuel syn-
referring to ignition timing. Because of this, do chronization only. It does not determine ignition tim-
not attempt to adjust ignition timing using this ing.
method. Rotating oil pump drive will have no effect

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 8D - 18 IGNITION SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
(7) Slowly continue to rotate engine. Do this until
timing index mark on vibration damper pulley aligns
with Top Dead Center (TDC) mark (0 degree) on tim-
ing degree scale (Fig. 34). Always rotate engine in
direction of normal rotation. Do not rotate engine
backward to align timing marks.
(8) On models equipped with A/C, remove electri-
cal cooling fan and shroud assembly from radiator.
Refer to Group 7, Cooling System for procedures.
(9) This will provide room to turn engine crank-
shaft with a socket and ratchet using vibration
damper bolt.

Fig. 33 Distributor—2.5L Engine—Typical

1 – CAP
2 – CAMSHAFT POSITION SENSOR
3 – HOUSING
4 – FORK WITH SLOT
5 – DRIVE GEAR
6 – ROLL PIN
7 – WASHER
8 – GASKET
9 – HOLDDOWN CLAMP Fig. 34 Align Timing Marks—2.5L Engine
10 – HOLDDOWN BOLT 1 – CRANKSHAFT VIBRATION DAMPER TIMING MARK
11 – SHAFT
12 – PULSE RING
(10) Remove distributor holddown bolt and clamp.
13 – ROTOR
(11) Remove distributor from engine by slowly lift-
ing straight up.
NOTE: Do not attempt to modify this fork to attain (12) Note that rotor will rotate slightly in a coun-
ignition timing. terclockwise direction while lifting up distributor.
The oil pump gear will also rotate slightly in a coun-
terclockwise direction while lifting up distributor.
REMOVAL This is due to the helical cut gears on distributor and
(1) Disconnect negative battery cable at battery. camshaft.
(2) Disconnect coil secondary cable at coil. (13) Note removed position of rotor during distrib-
(3) Remove distributor cap from distributor (2 utor removal. During installation, this will be
screws). Do not remove cables from cap. Do not referred to as the Pre-position.
remove rotor. (14) Observe slot in oil pump gear through hole on
(4) Disconnect distributor wiring harness from side of engine. It should be slightly before (counter-
main engine harness. clockwise of) 10 o’clock position (Fig. 35).
(5) Remove cylinder number 1 spark plug. (15) Remove and discard the old distributor-to-en-
(6) Hold a finger over open spark plug hole. Rotate gine block gasket.
engine at vibration dampener bolt until compression
(pressure) is felt.

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 XJ IGNITION SYSTEM 8D - 19
REMOVAL AND INSTALLATION (Continued)

Fig. 35 Slot At 10 O’clock Position—2.5L Engine

1 – 10 0’CLOCK POSITION
2 – OIL PUMP SLOT

INSTALLATION
(1) If engine crankshaft has been rotated after dis-
Fig. 36 Pin Alignment Holes—2.5L Engine
tributor removal, cylinder number 1 must be
1 – DISTRIBUTOR HOUSING (TOP VIEW)
returned to its proper firing stroke. Refer to previous
2 – PULSE RING
REMOVAL Step 5 and Step 6. These steps must be 3 – 4.0L 6–CYLINDER ENGINE ALIGN. HOLE
done before installing distributor. 4 – 2.5L 4–CYLINDER ENGINE ALIGN. HOLE
(2) Check position of slot on oil pump gear. On the 5 – MATING ACCESS HOLE IN DISTRIBUTOR HOUSING
2.5L engine, it should be just slightly before (counter- 6 – PLASTIC RING
clockwise of) 10 o’clock position (Fig. 35). If not, place
a flat blade screwdriver into oil pump gear and
(10) Install rotor to distributor shaft.
rotate it into proper position.
(11) Pre-position distributor into engine while
(3) Factory replacement distributors are equipped
holding centerline of base slot in 1 o’clock position
with a plastic alignment pin already installed (Fig.
(Fig. 37). Continue to engage distributor into engine.
32). This pin is used to temporarily hold rotor to cyl-
The rotor and distributor will rotate clockwise during
inder number 1 firing position during distributor
installation. This is due to the helical cut gears on
installation. If pin is in place, proceed to Step 8. If
distributor and camshaft. When distributor is fully
not, proceed to next step.
seated to engine block, the centerline of base slot
(4) If original distributor is to be reinstalled, such
should be aligned to clamp bolt mounting hole on
as during engine overhaul, the plastic pin will not be
engine (Fig. 38). The rotor should also be pointed
available. A 3/16 inch drift pin punch tool may be
slightly past (clockwise of) 3 o’clock position.
substituted for plastic pin.
It may be necessary to rotate rotor and distributor
(5) Remove camshaft position sensor from distrib-
shaft (very slightly) to engage distributor shaft with
utor housing. Lift straight up.
slot in oil pump gear. The same may have to be done
(6) Four different alignment holes are provided on
to engage distributor gear with camshaft gear.
plastic ring (Fig. 36). Note that 2.5L and 4.0L
engines have different alignment holes (Fig.
36).
(7) Rotate distributor shaft and install pin punch
tool through proper alignment hole in plastic ring
(Fig. 36) and into mating access hole in distributor
housing. This will prevent distributor shaft and rotor
from rotating.
(8) Clean distributor mounting hole area of engine
block.
(9) Install new distributor-to-engine block gasket
(Fig. 33).

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 8D - 20 IGNITION SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
The distributor is correctly installed when:
• rotor is pointed at 3 o’clock position.
• plastic alignment pin (or pin punch tool) is still
installed to distributor.
• number 1 cylinder piston is set at top dead cen-
ter (TDC) (compression stroke).
• centerline of slot at base of distributor is aligned
to centerline of distributor holddown bolt hole on
engine. In this position, the holddown bolt should
easily pass through slot and into engine.
No adjustments are necessary. Proceed to next
step.
(12) Install distributor holddown clamp and bolt.
Tighten bolt to 23 N·m (17 ft. lbs.) torque.
(13) Remove pin punch tool from distributor. Or, if
plastic alignment pin was used, remove it straight
down from bottom of distributor. Discard plastic pin.
(14) If removed, install camshaft position sensor to
distributor. Align wiring harness grommet to notch in
distributor housing.
(15) Install rotor.
Fig. 37 Distributor Pre-position—2.5L Engine CAUTION: If the distributor cap is incorrectly posi-
1 – 1 O’CLOCK POSITION tioned on distributor housing, cap or rotor may be
2 – BASE SLOT damaged when engine is started.
3 – DISTRIBUTOR BASE
(16) Install distributor cap. Tighten distributor cap
holddown screws to 3 N·m (26 in. lbs.) torque.
(17) If removed, install spark plug cables to dis-
tributor cap. For proper firing order, refer to Engine
Firing Order.
(18) Connect distributor wiring harness to main
engine harness.
(19) Connect battery cable to battery.

IGNITION SWITCH AND KEY CYLINDER

The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.

KEY CYLINDER REMOVAL

(1) Disconnect negative battery cable at battery.
(2) If equipped with an automatic transmission,
place shifter in PARK position.
(3) Rotate key to ON position.
(4) A release tang is located on bottom of key cyl-
inder (Fig. 39).
(5) Position a small screwdriver or pin punch into
tang access hole on bottom of steering column lower
Fig. 38 Distributor Engaged Position—2.5L Engine cover (Fig. 40).
1 – DISTRIBUTOR BASE SLOT (6) Push the pin punch up while pulling key cylin-
2 – CLAMP BOLT MOUNTING HOLE (ON ENGINE)
der from steering column.
3 – DISTRIBUTOR BASE

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 XJ IGNITION SYSTEM 8D - 21
REMOVAL AND INSTALLATION (Continued)

Fig. 39 Key Cylinder Release Tang

1 – KEY CYLINDER
2 – RELEASE TANG

Fig. 41 Ignition Switch Lock Tab

1 – LOCK TAB
2 – IGNITION SWITCH
3 – SCREWDRIVER

Fig. 42 Switch In ON Position

Fig. 40 Key Cylinder and Cover Removal
1 – IGNITION SWITCH
1 – LOWER COVER
2 – ROTATE TO ON POSITION
2 – ACCESS HOLE
3 – PIN PUNCH
4 – COVER SCREWS (3) (4) Using a small screwdriver, push on locking tab
(Fig. 41) and remove switch from steering column.
IGNITION SWITCH REMOVAL (5) Disconnect two electrical connectors at rear of
ignition switch (Fig. 43).
(1) Remove key cylinder. Refer to previous steps.
(2) Remove lower steering column cover screws
and remove cover (Fig. 40).
(3) Remove ignition switch mounting screw (Fig.
43). Use tamper proof torx bit (Snap-Ont SDMTR10
or equivalent) to remove the screw.

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 8D - 22 IGNITION SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
KEY CYLINDER INSTALLATION
(1) If equipped with an automatic transmission,
place shifter in PARK position.
(2) Position key cylinder into steering column as it
would normally be in the ON position.
(3) Press key cylinder into column until it snaps
into position.
(4) Check mechanical operation of switch. Auto-
matic Transmission: Be sure transmission lever is
locked in PARK position after key removal. If key is
difficult to rotate or is difficult to remove, the shift
lever-to-steering column cable may be out of adjust-
ment or defective. Refer to Group 21, Transmission
for procedures. Manual Transmission: Be sure key
cannot be removed until release lever is operated. If
key can be removed, release lever mechanism may be
defective. Release lever mechanism is not serviced
separately. If repair is necessary, the steering column
must be replaced. Refer to Group 19, Steering for
procedures.
(5) Connect negative cable to battery.
(6) Check electrical operation of switch.
Fig. 43 Ignition Switch Removal/Installation
1 – TAMPER PROOF SCREW SHIFTER/IGNITION INTERLOCK
2 – IGNITION SWITCH
3 – ELECTRICAL CONNECTORS
REMOVAL/INSTALLATION
On models equipped with an automatic transmis-
IGNITION SWITCH INSTALLATION sion, a cable connects the ignition switch with the
(1) Before installing ignition switch, rotate the slot floor shift lever. The shifter will be locked in the
in the switch to the ON position (Fig. 42). PARK position when the ignition key is in the LOCK
(2) Connect two electrical connectors to rear of or ACCESSORY positions. The cable can be adjusted
ignition switch. Make sure that locking tabs are fully or replaced. Refer to Group 21, Transmissions for
seated into wiring connectors. procedures. The ignition interlock device within the
(3) Position switch to column and install tamper steering column is not serviceable. If service is nec-
proof screw. Tighten screw to 3 N·m (26 in. lbs.). essary, the steering column must be replaced. Refer
(4) Install steering column lower cover. to Group 19, Steering for procedures.

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 XJ IGNITION SYSTEM 8D - 23

SPECIFICATIONS ENGINE FIRING ORDER—4.0L 6-CYLINDER

ENGINE
IGNITION TIMING
Ignition timing is not adjustable on any engine.

ENGINE FIRING ORDER—2.5L 4-CYLINDER

ENGINE

SPARK PLUGS

ENGINE PLUG TYPE ELECTRODE GAP

2.5L RC12ECC 0.89 mm (0.035 in.)
4.0L RC12ECC 0.89 mm (0.035 in.)

SPARK PLUG CABLE RESISTANCE

MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot

IGNITION COIL RESISTANCE—2.5L ENGINE

COIL PRIMARY RESISTANCE @ SECONDARY RESISTANCE @ 21-27°C

MANUFACTURER 21-27°C (70-80°F) (70-80°F)
Diamond 0.97 - 1.18 Ohms 11,300 - 15,300 Ohms
Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms

IGNITION COIL RESISTANCE—4.0L ENGINE

PRIMARY RESISTANCE
21-27°C (70-80°F)
0.71 - 0.88 Ohms

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 8D - 24 IGNITION SYSTEM XJ
SPECIFICATIONS (Continued)

TORQUE CHART
DESCRIPTION TORQUE
Camshaft Position Sensor–to–base
bolts—4.0L . . . . . . . . . . . . . . 28 N·m (15 in. lbs.)
Crankshaft Position Sensor Bolts
(sensor mounted with 2 bolts) . . . . . . . . . 19 N·m
(14 ft. lbs.)
Crankshaft Position Sensor Nuts
(sensor mounted with 2 nuts) . . . . . . . . . 19 N·m
(14 ft. lbs.)
Crankshaft Position Sensor Bolt
(sensor mounted with 1 bolt) . . 7 N·m (60 in. lbs.)
Distributor Hold Down Bolt—2.5L . . . . . . . 23 N·m
(17 ft. lbs.)
Distributor Cap Screws—2.5L . . 3 N·m (26 in. lbs.)
Ignition Coil Mounting (if tapped
bolts are used)—2.5L . . . . . . . 5 N·m (50 in. lbs.)
Ignition Coil Mounting (if nuts/bolts
are used)—2.5L . . . . . . . . . . 11 N·m (100 in. lbs.)
Ignition Coil Rail Mounting Bolts—4.0L . . . 29 N·m
(250 in. lbs.)
Oil Pump Drive Hold-down Bolt—4.0L . . . . 23 N·m
(17 ft. lbs.)
Spark Plugs (all engines) . . . . . 41 N·m (30 ft. lbs.)

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 1

INSTRUMENT PANEL SYSTEMS

TABLE OF CONTENTS

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DESCRIPTION AND OPERATION INSTRUMENT PANEL ACCESSORY SWITCH

INSTRUMENT PANEL SYSTEM . . . . . . . . . . . . . . 1 BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . 1 CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . . . 16
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 2 CLUSTER BEZEL. . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTRUMENT PANEL CIGAR LIGHTER . . . . . . . . 3 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 17
CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . . . . 4 INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . 18
INSTRUMENT PANEL POWER OUTLET . . . . . . . . 4 INSTRUMENT CLUSTER COMPONENTS . . . . . . 19
DIAGNOSIS AND TESTING INSTRUMENT PANEL TOP COVER. . . . . . . . . . . 21
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 5 GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INSTRUMENT PANEL CIGAR LIGHTER . . . . . . . 11 GLOVE BOX COMPONENTS . . . . . . . . . . . . . . . . 23
CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . . . 12 GLOVE BOX LATCH STRIKER . . . . . . . . . . . . . . 24
INSTRUMENT PANEL POWER OUTLET . . . . . . . 12 INSTRUMENT PANEL END CAP . . . . . . . . . . . . . 25
REMOVAL AND INSTALLATION INSTRUMENT PANEL CENTER SUPPORT
STEERING COLUMN OPENING COVER . . . . . . . 13 BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
KNEE BLOCKER . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTRUMENT PANEL ASSEMBLY . . . . . . . . . . . 26
INSTRUMENT PANEL CENTER BEZEL . . . . . . . . 14

DESCRIPTION AND OPERATION mounted on or in the instrument panel. If you cannot

locate a listing for the component or system you are
INSTRUMENT PANEL SYSTEM servicing in the table of contents for this group, or if
you are uncertain as to which vehicle system a com-
DESCRIPTION ponent belongs to, it is suggested that you refer to
The instrument panel serves as the command cen- the alphabetical Component and System Index
ter of the vehicle, which necessarily makes it a very found at the back of this service manual.
complex unit. The instrument panel is designed to
NOTE: This group covers both Left-Hand Drive
house the controls and monitors for standard and
(LHD) and Right-Hand Drive (RHD) versions of this
optional powertrains, climate control systems, audio
model. Whenever required and feasible, the RHD
systems, lighting systems, safety systems and many
versions of affected vehicle components have been
other comfort or convenience items. The instrument
constructed as mirror-image of the LHD versions.
panel is also designed so that all of the various con-
While most of the illustrations used in this group
trols can be safely reached and the monitors can be
represent only the LHD version, the diagnostic and
easily viewed by the vehicle operator when driving,
service procedures outlined can generally be
while still allowing relative ease of access to each of
applied to either version. Exceptions to this rule
these items for service. See the owner’s manual in
have been clearly identified as LHD or RHD, if a
the vehicle glove box for more information on the fea-
special illustration or procedure is required.
tures, use and operation of all of the instrument
panel components and systems.
This group is responsible for covering service infor- INSTRUMENT PANEL
mation for the vehicle instrument panel systems.
However, complete service information coverage for DESCRIPTION
all of the systems and components housed in the This instrument panel uses a full-width structural
instrument panel in a single section of the service plastic foundation as its primary support. When the
manual would not be practical. Therefore, the service two primary molded plastic components of this struc-
information for any component will be found in the ture are vibration welded together they provide supe-
group designated to cover the vehicle system that the rior instrument panel stiffness and integrity to help
component belongs to, even though the component is

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 8E - 2 INSTRUMENT PANEL SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
reduce buzzes, squeaks, and rattles even on the The low-line cluster includes the following analog
bumpiest roads. gauges:
This type of construction also provides improved • Fuel gauge
energy absorption which, in conjunction with the • Speedometer.
dual airbag modules and seat belts, helps to improve This cluster also includes provisions for the follow-
occupant protection. This foundation structure also ing indicator lamps:
serves as the air duct for the heating and air condi- • Airbag indicator lamp
tioning system panel outlets, which greatly reduces • Anti-lock brake system lamp
the number of components used over conventional • Brake warning lamp
instrument panel construction. • Coolant temperature warning lamp
Modular instrument panel construction allows all • Cruise-on indicator lamp
of the gauges and controls to be serviced from the • Four-wheel drive (Part Time and/or Full Time)
front of the panel. In addition, most of the instru- indicator lamps
ment panel electrical components can be accessed • Headlamp high beam indicator lamp
without complete instrument panel removal. If neces- • Low oil pressure warning lamp
sary, the instrument panel can be removed from the • Low washer fluid warning lamp
vehicle as an assembly. • Malfunction Indicator Lamp (MIL)
Removal of the steering column opening cover and • Seat belt reminder lamp
knee blocker provides access to the steering column • Sentry Key Immobilizer System (SKIS) indicator
mounts, the steering column wiring, the headlamp lamp
switch, the electronic combination flasher, and much • Turn signal indicator lamps
of the instrument panel wiring. Removal of the glove • Upshift indicator lamp (manual transmission)
box provides access to the heating and air condition- • Voltage warning lamp.
ing electrical and vacuum harnesses, the blower The high-line cluster replaces some of the indicator
motor relay, the radio antenna coaxial cable, the lamps found in the low-line cluster with analog
lower passenger side airbag mounts, and additional gauges. The high-line cluster includes the following
instrument panel wiring. analog gauges:
Removal of the instrument panel center bezel • Coolant temperature gauge
allows access to the radio, the heating and air condi- • Fuel gauge
tioning controls, the accessory switches, the cigar • Oil pressure gauge
lighter, and the accessory power outlet. Removal of • Speedometer
the instrument cluster bezel allows access to the • Tachometer
instrument cluster. Removal of the cluster assembly • Voltmeter.
allows access to the cluster illumination and indica- The high-line cluster also adds a check gauges
tor lamp bulbs, and more of the instrument panel lamp and a low fuel warning lamp to the remaining
wiring. indicator lamps found in the low-line cluster.
Removal of the instrument panel top cover allows Both instrument clusters feature circuitry that has
access to the upper passenger side airbag mounts. a self-diagnostic actuator test capability, which will
Instrument panel removal is required for service of test each of the CCD bus message-controlled func-
most internal components of the heating and air con- tions of the cluster by lighting the appropriate indi-
ditioning system housing. cator lamps and positioning the gauge needles at
several predetermined locations on the gauge faces in
INSTRUMENT CLUSTER a prescribed sequence. For more information on this
function, refer to Instrument Cluster in the Diag-
DESCRIPTION nosis and Testing section of this group.
Two basic instrument clusters are offered on this The instrument cluster circuitry also integrates a
model: low-line, or high-line. Both clusters are elec- chime tone generator and a timer circuit. These
tromechanical units that utilize integrated circuitry items replace the chime or buzzer module, and the
and information carried on the Chrysler Collision separate timer circuit for the rear window defogger
Detection (CCD) data bus network for control of all system. Refer to Chime Warning System in the
gauges and many of the indicator lamps. These clus- Description and Operation section of Group 8U -
ters also incorporate a digital Vacuum Fluorescent Chime/Buzzer Warning Systems for more information
Display (VFD) for the odometer/trip odometer display on the chime functions of the instrument cluster.
functions. Some variations of each cluster exist due Refer to Rear Window Defogger System in the
to optional equipment and regulatory requirements. Description and Operation section of Group 8N -

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 3
DESCRIPTION AND OPERATION (Continued)
Electrically Heated Systems for more information on The seat belt reminder lamp is controlled by the
the timer function of the instrument cluster. instrument cluster programming. The Malfunction
The instrument clusters for this model are serviced Indicator Lamp (MIL) is normally controlled by CCD
only as complete units. If a cluster gauge or the clus- data bus messages from the Powertrain Control Mod-
ter circuit board are faulty, the entire cluster must be ule (PCM); however, if the instrument cluster detects
replaced. The cluster lens, the cluster hood and a loss of CCD data bus communication, the cluster
mask, the rear cluster housing cover, the odometer will automatically turn the MIL on and display the
reset knob boot and the incandescent lamp bulbs and message “NO BUS” in the odometer VFD until CCD
holders are available for service replacement. data bus communication is restored. The instrument
cluster circuitry uses CCD data bus messages from
OPERATION the Powertrain Control Module (PCM), Airbag Con-
trol Module (ACM), and the Sentry Key Immobilizer
GAUGE Module (SKIM) to control all of the remaining indi-
With the ignition switch in the On or Start posi- cator lamps.
tions, voltage is supplied to all gauges through the Each of the indicator lamps in the instrument clus-
instrument cluster electronic circuit board. With the ter uses incandescent bulbs and holders, which are
ignition switch in the Off position, voltage is not sup- available for service replacement.
plied to the gauges. The gauges do not accurately
indicate any vehicle condition unless the ignition CLUSTER ILLUMINATION LAMP
switch is in the On or Start positions. The cluster illumination lamps are hard wired in
All of the instrument cluster gauges, except the the instrument cluster. When the park or head lamps
odometer, are air core magnetic units. Two fixed elec- are turned on, the cluster illumination lamps light.
tromagnetic coils are located within the gauge. These Illumination brightness is adjusted by rotating the
coils are wrapped at right angles to each other headlamp switch knob (clockwise to dim, counter-
around a movable permanent magnet. The movable clockwise to brighten). The instrument cluster illumi-
magnet is suspended within the coils on one end of a nation lamps receive battery feed from the panel
shaft. The gauge needle is attached to the other end dimmer rheostat in the headlamp switch through a
of the shaft. fuse in the fuseblock module.
One of the coils has a fixed current flowing The instrument cluster electronic circuitry also
through it to maintain a constant magnetic field monitors the cluster illumination lamp dimming level
strength. Current flow through the second coil whenever the park or head lamps are turned on. The
changes, which causes changes in its magnetic field instrument cluster electronic circuitry responds by
strength. The current flowing through the second coil adjusting the dimming level of the odometer Vacuum
is changed by the instrument cluster electronic cir- Fluorescent Display (VFD), and sending dimming
cuitry in response to messages received on the level messages over the Chrysler Collision Detection
Chrysler Collision Detection (CCD) data bus network. (CCD) data bus network. When the park lamps or
The gauge needle moves as the movable permanent headlamps are turned off, the VFD is illuminated at
magnet aligns itself to the changing magnetic fields full brightness for improved daylight visibility.
created around it by the electromagnets. The instru- Each of the cluster illumination lamps is located on
ment cluster circuitry is programmed to move all of the instrument cluster circuit board. Each cluster
the gauge needles back to the low end of their respec- illumination lamp has a replaceable bulb and bulb
tive scales after the ignition switch is turned to the holder.
Off position.
INSTRUMENT PANEL CIGAR LIGHTER
INDICATOR LAMP
Indicator lamps are located in the instrument clus- DESCRIPTION
ter and are served by the cluster circuit board and A cigar lighter is standard equipment on this
connectors. Many of the indicator lamps in the model. The cigar lighter is installed in the instru-
instrument cluster are controlled by the instrument ment panel accessory switch bezel, which is located
cluster circuitry in response to messages received near the bottom of the instrument panel center bezel
over the Chrysler Collision Detection (CCD) data bus area, below the heater and air conditioner controls.
network. The cigar lighter base is secured by a snap fit within
The anti-lock brake system lamp, brake warning the accessory switch bezel.
lamp, four-wheel drive indicator lamps, headlamp The cigar lighter receptacle is serviced only as a
high beam indicator lamp, low washer fluid warning part of the accessory switch bezel unit. If the cigar
lamp and turn signal indicator lamps are hard wired. lighter base is faulty or damaged, the accessory

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 8E - 4 INSTRUMENT PANEL SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
switch bezel unit must be replaced. The cigar lighter panel below the instrument panel in the passenger
knob and heating element unit is available for ser- compartment.
vice. This component cannot be repaired and, if The cigar lighter relay is a International Standards
faulty or damaged, it must be replaced. Organization (ISO) relay. Relays conforming to the
ISO specifications have common physical dimensions,
OPERATION current capacities, terminal patterns, and terminal
The cigar lighter consists of two major components: functions.
a knob and heating element unit, and the cigar The cigar lighter relay cannot be repaired or
lighter base or receptacle shell. The receptacle shell adjusted and, if faulty or damaged, it must be
is connected to ground, and an insulated contact in replaced.
the bottom of the shell is connected to battery cur-
rent. The cigar lighter receives battery voltage from a OPERATION
fuse in the junction block through the cigar lighter The ISO relay consists of an electromagnetic coil, a
relay only when the ignition switch is in the Acces- resistor or diode, and three (two fixed and one mov-
sory or On positions. Refer to Cigar Lighter Relay able) electrical contacts. The movable (common feed)
in the Description and Operation section of this relay contact is held against one of the fixed contacts
group for more information on this component. (normally closed) by spring pressure. When the elec-
The cigar lighter knob and heating element are tromagnetic coil is energized, it draws the movable
encased within a spring-loaded housing, which also contact away from the normally closed fixed contact,
features a sliding protective heat shield. When the and holds it against the other (normally open) fixed
knob and heating element are inserted in the recep- contact.
tacle shell, the heating element resistor coil is When the electromagnetic coil is de-energized,
grounded through its housing to the receptacle shell. spring pressure returns the movable contact to the
If the cigar lighter knob is pushed inward, the heat normally closed position. The resistor or diode is con-
shield slides up toward the knob exposing the heat- nected in parallel with the electromagnetic coil in the
ing element, and the heating element extends from relay, and helps to dissipate voltage spikes that are
the housing toward the insulated contact in the bot- produced when the coil is de-energized.
tom of the receptacle shell.
Two small spring-clip retainers are located on INSTRUMENT PANEL POWER OUTLET
either side of the insulated contact inside the bottom
of the receptacle shell. These clips engage and hold DESCRIPTION
the heating element against the insulated contact An accessory power outlet is standard equipment
long enough for the resistor coil to heat up. When the on this model. The power outlet is installed in the
heating element is engaged with the contact, battery instrument panel accessory switch bezel, which is
current can flow through the resistor coil to ground, located near the bottom of the instrument panel cen-
causing the resistor coil to heat. ter bezel area, below the heater and air conditioner
When the resistor coil becomes sufficiently heated, controls. The power outlet base is secured by a snap
excess heat radiates from the heating element caus- fit within the accessory switch bezel. A plastic protec-
ing the spring-clips to expand. Once the spring-clips tive cap snaps into the power outlet base when the
expand far enough to release the heating element, power outlet is not being used, and hangs from the
the spring-loaded housing forces the knob and heat- power outlet base mount by an integral bail strap
ing element to pop back outward to their relaxed while the power outlet is in use.
position. When the cigar lighter knob and element The power outlet receptacle unit and the accessory
are pulled out of the receptacle shell, the protective power outlet protective cap are serviced only as a
heat shield slides downward on the housing so that part of the accessory switch bezel unit. If the power
the heating element is recessed and shielded around outlet base is faulty or damaged, the entire accessory
its circumference for safety. switch bezel unit must be replaced.

CIGAR LIGHTER RELAY OPERATION

The power outlet base or receptacle shell is con-
DESCRIPTION nected to ground, and an insulated contact in the
The cigar lighter relay is an electromechanical bottom of the shell is connected to battery current.
device that switches fused battery current to the The power outlet receives battery voltage from a fuse
cigar lighter when the ignition switch is turned to in the junction block at all times.
the Accessory or On positions. The cigar lighter relay While the power outlet is very similar to a cigar
is located in the junction block, on the right cowl side lighter base unit, it does not include the two small

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 5
DESCRIPTION AND OPERATION (Continued)
spring-clip retainers inside the bottom of the recepta- (6) Turn the ignition switch to the On position and
cle shell that are used to secure the cigar lighter check for battery voltage at the fused ignition switch
heating element to the insulated contact. output (run/start) fuse in the junction block. If OK,
go to Step 7. If not OK, repair the open fused ignition
switch output (run/start) circuit to the ignition switch
DIAGNOSIS AND TESTING as required.
(7) Turn the ignition switch to the Off position.
INSTRUMENT CLUSTER Disconnect and isolate the battery negative cable.
If all of the gauges and/or indicator lamps are inop- Install the instrument cluster. Connect the battery
erative, perform the Preliminary Diagnosis. If an negative cable. Turn the ignition switch to the On
individual gauge or Chrysler Collision Detection position. Set the park brake. The red brake warning
(CCD) data bus message-controlled indicator lamp is lamp should light. If OK, go to Step 8. If not OK, go
inoperative, go directly to the Actuator Test. If an to Step 9.
individual hard wired indicator lamp is inoperative, (8) Turn the ignition switch to the Off position.
refer to Instrument Cluster - Hard Wired Lamp Turn on the park lamps and adjust the panel lamps
Diagnosis in the Diagnosis and Testing section of dimmer rheostat in the headlamp switch to the full
this group for the procedures to diagnosis that lamp. bright position. The cluster illumination lamps
For complete circuit diagrams, refer to Instrument should light. If OK, refer to Instrument Cluster -
Cluster in the Contents of Group 8W - Wiring Dia- Actuator Test in the Diagnosis and Testing section
grams. of this group. If not OK, go to Step 10.
(9) Turn the ignition switch to the Off position.
WARNING: ON VEHICLES EQUIPPED WITH AIR- Disconnect and isolate the battery negative cable.
BAGS, REFER TO GROUP 8M - PASSIVE Remove the instrument cluster. Connect the battery
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY negative cable. Turn the ignition switch to the On
STEERING WHEEL, STEERING COLUMN, OR position. Check for battery voltage at the fused igni-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR tion switch output (run/start) circuit cavity of the
SERVICE. FAILURE TO TAKE THE PROPER PRE- instrument cluster wire harness connector A. If OK,
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- refer to Instrument Cluster - Actuator Test in the
BAG DEPLOYMENT AND POSSIBLE PERSONAL Diagnosis and Testing section of this group. If not
INJURY. OK, repair the open fused ignition switch output
(run/start) circuit to the fuse in the junction block as
required.
PRELIMINARY DIAGNOSIS
(10) Disconnect and isolate the battery negative
(1) If the indicator lamps operate, but none of the
cable. Remove the instrument cluster. Check for con-
gauges operate, go to Step 2. If all of the gauges and
tinuity between the ground circuit cavity of the
the data bus message-controlled indicator lamps are
instrument cluster wire harness connector A and a
inoperative, go to Step 5.
good ground. There should be continuity. If OK, refer
(2) Check the fused B(+) fuse in the Power Distri-
to Instrument Cluster - Actuator Test in the
bution Center (PDC). If OK, go to Step 3. If not OK,
Diagnosis and Testing section of this group. If not
repair the shorted circuit or component as required
OK, repair the open ground circuit to ground as
and replace the faulty fuse.
required.
(3) Check for battery voltage at the fused B(+) fuse
in the PDC. If OK, go to Step 4. If not OK, repair the
ACTUATOR TEST
open fused B(+) circuit to the battery as required.
The instrument cluster actuator test will put the
(4) Disconnect and isolate the battery negative
instrument cluster into its self-diagnostic mode. In
cable. Remove the instrument cluster. Connect the
this mode the instrument cluster can perform a self-
battery negative cable. Check for battery voltage at
diagnostic test that will confirm that the instrument
the fused B(+) circuit cavity of the instrument cluster
cluster circuitry, the gauges, and the CCD data bus
wire harness connector A. If OK, refer to Instru-
message controlled indicator lamps are capable of
ment Cluster - Actuator Test in the Diagnosis and
operating as designed. During the actuator test the
Testing section of this group. If not OK, repair the
instrument cluster circuitry will position each of the
open fused B(+) circuit to the fuse in the PDC as
gauge needles at various specified calibration points,
required.
and turn all of the CCD data bus message-controlled
(5) Check the fused ignition switch output (run/
lamps on and off at specified time intervals (Fig. 1)
start) fuse in the junction block. If OK, go to Step 6.
or (Fig. 2).
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.

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 8E - 6 INSTRUMENT PANEL SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
Successful completion of the actuator test will con- SERVICE. FAILURE TO TAKE THE PROPER PRE-
firm that the instrument cluster is operational. How- CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
ever, there may still be a problem with the CCD data BAG DEPLOYMENT AND POSSIBLE PERSONAL
bus, the Powertrain Control Module (PCM), the Air- INJURY.
bag Control Module (ACM), the Sentry Key Immobi-
lizer Module (SKIM) or the inputs to one of these
electronic control modules. Use a DRB scan tool and ANTI-LOCK BRAKE SYSTEM LAMP
the proper Diagnostic Procedures manual for testing The diagnosis found here addresses an inoperative
of these components. Anti-lock Brake System (ABS) lamp condition. If the
If an individual gauge does not respond properly, ABS lamp stays on with the ignition switch in the
or does not respond at all during the actuator test, On position, or comes on and stays on while driving,
the instrument cluster should be removed. However, refer to Antilock Brakes in the Diagnosis and Test-
check that the gauge mounting screws on the instru- ing section of Group 5 - Brakes for diagnosis. If no
ment cluster electronic circuit board for proper tight- ABS problem is found, the following procedure will
ness before considering instrument cluster help locate a short or open in the ABS lamp circuit.
replacement. If the gauge mounting screws check For complete circuit descriptions, refer to Instru-
OK, replace the faulty cluster. ment Cluster in the Contents of Group 8W - Wiring
If an individual indicator lamp does not illuminate Diagrams.
during the actuator test, the instrument cluster (1) Check the fused ignition switch output (run/
should be removed. However, check that the incan- start) fuse in the junction block. If OK, go to Step 2.
descent lamp bulb is not faulty and that the bulb If not OK, repair the shorted circuit or component as
holder is properly installed on the instrument cluster required and replace the faulty fuse.
electronic circuit board before considering instrument (2) Turn the ignition switch to the On position.
cluster replacement. If the bulb and bulb holder Check for battery voltage at the fused ignition switch
check OK, replace the faulty instrument cluster. output (run/start) fuse in the junction block. If OK,
(1) Begin the test with the ignition switch in the go to Step 3. If not OK, repair the open fused ignition
Off position. switch output (run/start) circuit to the ignition switch
(2) Depress the trip odometer reset button. as required.
(3) While holding the trip odometer reset button (3) Turn the ignition switch to the Off position.
depressed, turn the ignition switch to the On posi- Disconnect and isolate the battery negative cable.
tion, but do not start the engine. Remove the instrument cluster. Connect the battery
(4) Release the trip odometer reset button. negative cable. Turn the ignition switch to the On
(5) Compare the operation of the suspect gauge(s) position and within five seconds check for continuity
and/or indicator lamp(s) with the Instrument Cluster between the ABS warning indicator driver circuit
Actuator Test chart (Fig. 1) or (Fig. 2). cavity of the instrument cluster wire harness connec-
(6) The instrument cluster will automatically exit tor A and a good ground. There should be continuity
the self-diagnostic mode and return to normal opera- for five seconds after ignition On, and then an open
tion at the completion of the test, if the ignition circuit. If OK, replace the faulty bulb. If not OK, go
switch is turned to the Off position during the test, to Step 4.
or if a vehicle speed message indicating that the (4) Turn the ignition switch to the Off position.
vehicle is moving is received from the PCM on the Disconnect and isolate the battery negative cable.
CCD data bus during the test. Disconnect the Controller Anti-lock Brake (CAB) wire
(7) Go back to Step 1 to repeat the test, if harness connector. Check for continuity between the
required. ABS warning indicator driver circuit cavity of the
instrument cluster wire harness connector A and a
HARD WIRED LAMP DIAGNOSIS good ground. There should be no continuity. If OK, go
Each of the lamps found in this section depends to Step 5. If not OK, repair the shorted ABS warning
upon a hard wired circuit input to the instrument indicator driver circuit as required.
cluster for proper operation. The following procedures (5) Check for continuity between the ABS warning
will help to diagnose conditions that may cause an indicator driver circuit cavities of the instrument
inoperative hard wired lamp circuit condition. cluster wire harness connector A and the CAB wire
harness connector. There should be continuity. If OK,
WARNING: ON VEHICLES EQUIPPED WITH AIR- refer to Antilock Brakes in the Diagnosis and Test-
BAGS, REFER TO GROUP 8M - PASSIVE ing section of Group 5 - Brakes for diagnosis of the
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY CAB. If not OK, repair the open ABS warning indi-
STEERING WHEEL, STEERING COLUMN, OR cator driver circuit as required.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 7
DIAGNOSIS AND TESTING (Continued)

Fig. 1 Low-Line Instrument Cluster Actuator Test

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 8E - 8 INSTRUMENT PANEL SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)

Fig. 2 High-Line Instrument Cluster Actuator Test

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 9
DIAGNOSIS AND TESTING (Continued)
BRAKE WARNING LAMP ground. There should be continuity. If OK, go to Step
The diagnosis found here addresses an inoperative 8. If not OK, repair the open red brake warning indi-
brake warning lamp condition. If the brake warning cator driver circuit to the ignition switch as required.
lamp stays on with the ignition switch in the On (8) Turn the ignition switch to the Off position.
position and the park brake released, or comes on Remove the instrument cluster. Check for continuity
while driving, refer Base Brake System for vehicles between the red brake warning indicator driver cir-
not equipped with the four wheel anti-lock brake sys- cuit cavity of the instrument cluster wire harness
tem, or refer to Antilock Brakes for vehicles connector A and a good ground. There should be no
equipped with the four wheel anti-lock brake system continuity. If OK, go to Step 9. If not OK, repair the
in the Diagnosis and Testing section of Group 5 - shorted red brake warning indicator driver circuit as
Brakes for further diagnosis. If no brake system required.
problem is found, the following procedure will help (9) Check for continuity between the red brake
locate a short or open circuit, or a faulty switch. For warning indicator driver circuit cavities of the instru-
complete circuit diagrams, refer to Instrument ment cluster wire harness connector A and the brake
Cluster in the Contents of Group 8W - Wiring Dia- warning switch wire harness connector. There should
grams. be continuity. If OK, replace the faulty bulb. If not
(1) Check the fused ignition switch output (run/ OK, repair the open red brake warning indicator
start) fuse in the junction block. If OK, go to Step 2. driver circuit as required.
If not OK, repair the shorted circuit or component as
required and replace the faulty fuse. FOUR-WHEEL DRIVE INDICATOR LAMP - FULL TIME
(2) Turn the ignition switch to the On position. The diagnosis found here addresses an inoperative
Check for battery voltage at the fused ignition switch four-wheel drive indicator lamp condition. If the
output (run/start) fuse in the junction block. If OK, problem being diagnosed is related to lamp accuracy,
go to Step 3. If not OK, repair the open fused ignition be certain to confirm that the problem is with the
switch output (run/start) circuit to the ignition switch lamp or switch and not with a damaged or inopera-
as required. tive transfer case or transfer case linkage. Refer to
(3) Turn the ignition switch to the Off position. NV242 Diagnosis in the Diagnosis and Testing sec-
Disconnect and isolate the battery negative cable. tion of Group 21 - Transmission for more informa-
Disconnect the wire harness connector at the park tion. If no transfer case problem is found, the
brake switch. With the park brake released, check for following procedure will help locate a short or open
continuity between the park brake switch terminal in the indicator lamp circuit. For complete circuit
and a good ground. There should be no continuity. If diagrams, refer to Instrument Cluster in the Con-
OK, go to Step 4. If not OK, adjust or replace the tents of Group 8W - Wiring Diagrams.
faulty park brake switch. (1) Check the fused ignition switch output (run/
(4) Disconnect the wire harness connector at the start) fuse in the junction block. If OK, go to Step 2.
brake warning switch. Check for continuity between If not OK, repair the shorted circuit or component as
the two terminals of the brake warning switch. There required and replace the faulty fuse.
should be continuity. If OK, go to Step 5. If not OK, (2) Turn the ignition switch to the On position.
replace the faulty brake warning switch. Check for battery voltage at the fused ignition switch
(5) Check for continuity between each of the two output (run/start) fuse in the junction block. If OK,
brake warning switch terminals and a good ground. go to Step 3. If not OK, repair the open fused ignition
In each case, there should be no continuity. If OK, go switch output (run/start) circuit to the ignition switch
to Step 6. If not OK, replace the faulty brake warn- as required.
ing switch. (3) Turn the ignition switch to the Off position.
(6) With both the park brake switch and the brake Disconnect and isolate the battery negative cable.
warning switch wire harness connectors still discon- Disconnect the transfer case switch wire harness con-
nected, check for continuity between the red brake nector. Check for continuity between the ground cir-
warning indicator driver circuit cavity of the park cuit cavity of the transfer case switch wire harness
brake switch wire harness connector and a good connector and a good ground. There should be conti-
ground. There should be no continuity. If OK, go to nuity. If OK, go to Step 4. If not OK, repair the open
Step 7. If not OK, repair the shorted red brake warn- ground circuit to ground as required.
ing indicator driver circuit as required. (4) Connect the battery negative cable. Turn the
(7) With the ignition switch held in the Start posi- ignition switch to the On position. Install a jumper
tion, check for continuity between the red brake wire between the full time four wheel drive indicator
warning indicator driver circuit cavity of the park lamp driver circuit cavity of the transfer case switch
brake switch wire harness connector and a good wire harness connector and a good ground. The full

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 8E - 10 INSTRUMENT PANEL SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
time four-wheel drive indicator lamp should light. If lamp driver circuit cavity of the transfer case switch
OK, replace the faulty transfer case switch. If not wire harness connector and a good ground. The part
OK, go to Step 5. time four-wheel drive indicator lamp should light. If
(5) Turn the ignition switch to the Off position. OK, replace the faulty transfer case switch. If not
Disconnect and isolate the battery negative cable. OK, go to Step 5.
Remove the instrument cluster. With the transfer (5) Turn the ignition switch to the Off position.
case switch wire harness connector still disconnected, Disconnect and isolate the battery negative cable.
check for continuity between the full time four wheel Remove the instrument cluster. With the transfer
drive indicator lamp driver circuit cavity of the case switch wire harness connector still disconnected,
instrument cluster wire harness connector B and a check for continuity between the part time four
good ground. There should be no continuity. If OK, go wheel drive indicator lamp driver circuit cavity of the
to Step 6. If not OK, repair the shorted full time four instrument cluster wire harness connector B and a
wheel drive indicator lamp driver circuit as required. good ground. There should be no continuity. If OK, go
(6) Check for continuity between the full time four to Step 6. If not OK, repair the shorted part time
wheel drive indicator lamp driver circuit cavities of four wheel drive indicator lamp driver circuit as
the instrument cluster wire harness connector B and required.
the transfer case switch wire harness connector. (6) Check for continuity between the part time
There should be continuity. If OK, replace the faulty four wheel drive indicator lamp driver circuit cavities
bulb. If not OK, repair the open full time four wheel of the instrument cluster wire harness connector B
drive indicator lamp driver circuit as required. and the transfer case switch wire harness connector.
There should be continuity. If OK, replace the faulty
FOUR-WHEEL DRIVE INDICATOR LAMP - PART TIME bulb. If not OK, repair the open part time four wheel
The diagnosis found here addresses an inoperative drive indicator lamp driver circuit as required.
four-wheel drive indicator lamp condition. If the
problem being diagnosed is related to lamp accuracy, HEADLAMP HIGH BEAM INDICATOR LAMP
be certain to confirm that the problem is with the The diagnosis found here addresses an inoperative
lamp or switch and not with a damaged or inopera- headlamp high beam indicator lamp condition. If the
tive transfer case or transfer case linkage. Refer to problem being diagnosed is related to inoperative
NV231 Diagnosis or NV242 Diagnosis in the Diag- headlamp high beams, refer to Headlamp Diagno-
nosis and Testing section of Group 21 - Transmission sis in the Diagnosis and Testing section of Group 8L
for more information. If no transfer case problem is - Lamps for diagnosis of the headlamp system. If no
found, the following procedure will help locate a headlamp system problems are found, the following
short or open in the indicator lamp circuit. For com- procedure will help locate an open in the high beam
plete circuit diagrams, refer to Instrument Cluster indicator lamp circuit. For complete circuit diagrams,
in the Contents of Group 8W - Wiring Diagrams. refer to Instrument Cluster in the Contents of
(1) Check the fused ignition switch output (run/ Group 8W - Wiring Diagrams.
start) fuse in the junction block. If OK, go to Step 2. (1) Disconnect and isolate the battery negative
If not OK, repair the shorted circuit or component as cable. Remove the instrument cluster.
required and replace the faulty fuse. (2) Connect the battery negative cable. Turn the
(2) Turn the ignition switch to the On position. headlamps on and select the high beams with the
Check for battery voltage at the fused ignition switch multi-function switch stalk. Check for battery voltage
output (run/start) fuse in the junction block. If OK, at the high beam indicator driver circuit cavity of the
go to Step 3. If not OK, repair the open fused ignition instrument cluster wire harness connector A. If OK,
switch output (run/start) circuit to the ignition switch replace the faulty bulb. If not OK, repair the open
as required. high beam indicator driver circuit to the headlamp
(3) Turn the ignition switch to the Off position. dimmer (multi-function) switch as required.
Disconnect and isolate the battery negative cable.
Disconnect the transfer case switch wire harness con- LOW WASHER FLUID WARNING LAMP
nector. Check for continuity between the ground cir- The diagnosis found here addresses an inoperative
cuit cavity of the transfer case switch wire harness low washer fluid warning lamp condition. If the prob-
connector and a good ground. There should be conti- lem being diagnosed is related to lamp accuracy, be
nuity. If OK, go to Step 4. If not OK, repair the open certain to confirm that the problem is with the lamp
ground circuit to ground as required. or washer fluid level sensor and not with a damaged
(4) Connect the battery negative cable. Turn the or empty washer fluid reservoir. Inspect the reservoir
ignition switch to the On position. Install a jumper for proper fluid level and signs of damage or distor-
wire between the part time four wheel drive indicator tion that could affect sensor performance before you

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 11
DIAGNOSIS AND TESTING (Continued)
proceed with lamp diagnosis. Refer to Washer Sys- ing Systems for further diagnosis. If no turn signal or
tem in the Diagnosis and Testing section of Group hazard warning system problem is found, the follow-
8K - Wiper and Washer Systems for more informa- ing procedure will help locate a short or open in the
tion. For complete circuit diagrams, refer to Instru- indicator lamp circuit. For complete circuit diagrams,
ment Cluster in the Contents of Group 8W - Wiring refer to Instrument Cluster in the Contents of
Diagrams. Group 8W - Wiring Diagrams.
(1) Check the fused ignition switch output (run/ (1) Disconnect and isolate the battery negative
start) fuse in the junction block. If OK, go to Step 2. cable. Remove the instrument cluster.
If not OK, repair the shorted circuit or component as (2) Connect the battery negative cable. Activate
required and replace the faulty fuse. the hazard warning system by moving the hazard
(2) Turn the ignition switch to the On position. warning switch button to the On position. Check for
Check for battery voltage at the fused ignition switch battery voltage at the inoperative (right or left) turn
output (run/start) fuse in the junction block. If OK, signal circuit cavity of the instrument cluster wire
go to Step 3. If not OK, repair the open fused ignition harness connector (connector A - left, or connector B -
switch output (run/start) circuit to the ignition switch right). There should be a switching (on and off) bat-
as required. tery voltage signal. If OK, replace the faulty (right or
(3) Turn the ignition switch to the Off position. left) indicator lamp bulb. If not OK, repair the open
Disconnect the wire harness connector from the (right or left) turn signal circuit to the turn signal/
washer fluid level sensor. Install a jumper wire hazard warning (multi-function) switch as required.
between the two cavities of the washer fluid level
sensor wire harness connector. Turn the ignition INSTRUMENT PANEL CIGAR LIGHTER
switch to the On position. About thirty seconds after For complete circuit diagrams, refer to Horn/Ci-
the ignition switch is turned to the On position, the gar Lighter in the Contents of Group 8W - Wiring
low washer fluid warning lamp should light. Remove Diagrams.
the jumper wire and the lamp should go off. If OK,
replace the faulty washer fluid level sensor. If not WARNING: ON VEHICLES EQUIPPED WITH AIR-
OK, go to Step 4. BAGS, REFER TO GROUP 8M - PASSIVE
(4) Turn the ignition switch to the Off position. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
Check for continuity between the ground circuit cav- STEERING WHEEL, STEERING COLUMN, OR
ity of the washer fluid level sensor wire harness con- INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
nector and a good ground. There should be SERVICE. FAILURE TO TAKE THE PROPER PRE-
continuity. If OK, go to Step 5. If not OK, repair the CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
open ground circuit to ground as required. BAG DEPLOYMENT AND POSSIBLE PERSONAL
(5) Disconnect and isolate the battery negative INJURY.
cable. Remove the instrument cluster. The washer
fluid level sensor wire harness connector is still dis- (1) Remove the cigar lighter knob and element
connected. Check for continuity between the low from the cigar lighter receptacle shell. Check for con-
washer fluid level sense circuit cavity of the instru- tinuity between the inside circumference of the cigar
ment cluster wire harness connector B and a good lighter receptacle shell and a good ground. there
ground. There should be no continuity. If OK, go to should be continuity. If OK, go to Step 2. If not OK,
Step 6. If not OK, repair the shorted low washer go to Step 3.
fluid level sense circuit as required. (2) Turn the ignition switch to the On position.
(6) Check for continuity between the low washer Check for battery voltage at the insulated contact
fluid level sense circuit cavities of the instrument located at the back of the cigar lighter receptacle
cluster wire harness connector B and the washer shell. If OK, replace the faulty cigar lighter knob and
fluid level sensor wire harness connector. There element. If not OK, go to Step 3.
should be continuity. If OK, replace the faulty bulb. (3) Turn the ignition switch to the Off position.
If not OK, repair the open low washer fluid level Disconnect and isolate the battery negative cable.
sense circuit as required. Remove the instrument panel accessory switch bezel.
Check for continuity between the ground circuit cav-
TURN SIGNAL INDICATOR LAMP ity of the cigar lighter wire harness connector and a
The diagnosis found here addresses an inoperative good ground. There should be continuity. If OK, go to
turn signal indicator lamp condition. For any other Step 4. If not OK, repair the open ground circuit to
turn signal problem, refer to Turn Signal and Haz- ground as required.
ard Warning Systems in the Diagnosis and Testing (4) Connect the battery negative cable. Turn the
section of Group 8J - Turn Signal and Hazard Warn- ignition switch to the Accessory or On positions.
Check for battery voltage at the cigar lighter relay

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 8E - 12 INSTRUMENT PANEL SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
output circuit cavity of the cigar lighter wire harness
connector. If OK, replace the faulty cigar lighter
receptacle (instrument panel accessory switch bezel
unit). If not OK, refer to Cigar Lighter Relay in
the Diagnosis and Testing section of this group for
further diagnosis.

CIGAR LIGHTER RELAY

The cigar lighter relay (Fig. 3) is located in the
junction block, on the right cowl side inner panel
below the instrument panel in the passenger com-
partment. For complete circuit diagrams, refer to TERMINAL LEGEND
Horn/Cigar Lighter in the Contents of Group 8W -
NUMBER IDENTIFICATION
Wiring Diagrams.
30 COMMON FEED
WARNING: ON VEHICLES EQUIPPED WITH AIR- 85 COIL GROUND
BAGS, REFER TO GROUP 8M - PASSIVE
86 COIL BATTERY
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR 87 NORMALLY OPEN
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR 87A NORMALLY CLOSED
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL Fig. 3 Cigar Lighter Relay
INJURY. the ignition switch. There should be continuity
between the junction block cavity for relay terminal
(1) Remove the cigar lighter relay from the junc-
87 and the cigar lighter relay output circuit cavity of
tion block. Refer to Cigar Lighter Relay in the
the cigar lighter wire harness connector at all times.
Removal and Installation section of this group for the
If OK, go to Step 4. If not OK, repair the open cigar
procedures.
lighter relay output circuit to the cigar lighter wire
(2) A relay in the de-energized position should
harness connector as required.
have continuity between terminals 87A and 30, and
(4) The coil battery terminal (86) is connected to
no continuity between terminals 87 and 30. If OK, go
the electromagnet in the relay. It receives battery
to Step 3. If not OK, replace the faulty relay.
feed to energize the cigar lighter relay when the igni-
(3) Resistance between terminals 85 and 86 (elec-
tion switch is in the Accessory or On positions. Turn
tromagnet) should be 75 6 5 ohms. If OK, go to Step
the ignition switch to the On position. Check for bat-
4. If not OK, replace the faulty relay.
tery voltage at the fused ignition switch output (acc/
(4) Connect a battery to terminals 85 and 86.
run) circuit cavity for relay terminal 86 in the
There should now be continuity between terminals
junction block. If OK, go to Step 5. If not OK, repair
30 and 87, and no continuity between terminals 87A
the open fused ignition switch output (acc/run) circuit
and 30. If OK, perform the Relay Circuit Test that
to the ignition switch as required.
follows. If not OK, replace the faulty relay.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. The junction block
RELAY CIRCUIT TEST cavity for this terminal should have continuity to
(1) The relay common feed terminal cavity (30) of
ground at all times. If not OK, repair the open
the junction block is connected to battery voltage and
ground circuit to ground as required.
should be hot at all times. Check for battery voltage
at the fused B(+) circuit cavity of the accessory relay
INSTRUMENT PANEL POWER OUTLET
wire harness connector. If OK, go to Step 2. If not
For complete circuit diagrams, refer to Horn/Ci-
OK, repair the fused B(+) circuit to the fuse in the
gar Lighter in the Contents of Group 8W - Wiring
junction block as required.
Diagrams.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the cigar lighter when the relay is energized by

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 13
DIAGNOSIS AND TESTING (Continued)
WARNING: ON VEHICLES EQUIPPED WITH AIR- REMOVAL
BAGS, REFER TO GROUP 8M - PASSIVE (1) Disconnect and isolate the battery negative
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY cable.
STEERING WHEEL, STEERING COLUMN, OR (2) If the vehicle is so equipped, move the tilt
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR steering column to the fully raised position.
SERVICE. FAILURE TO TAKE THE PROPER PRE- (3) Remove the three screws that secure the lower
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- edge of the steering column opening cover to the
BAG DEPLOYMENT AND POSSIBLE PERSONAL lower instrument panel reinforcement (Fig. 4).
INJURY.

(1) Check the fused B(+) fuse in the junction block.

If OK, go to Step 2. If not OK, repair the shorted cir-
cuit or component as required and replace the faulty
fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the junction block. If OK, go to Step 3. If not OK,
repair the open fused B(+) circuit to the Power Dis-
tribution Center (PDC) as required.
(3) Remove the plastic protective cap from the
power outlet receptacle. Check for continuity between
the inside circumference of the power outlet recepta-
cle and a good ground. There should be continuity. If
OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta- Fig. 4 Steering Column Opening Cover Remove/
cle. If not OK, go to Step 5. Install
1 – INSTRUMENT PANEL
(5) Disconnect and isolate the battery negative
2 – SNAP CLIPS
cable. Remove the instrument panel accessory switch
3 – STEERING COLUMN OPENING COVER
bezel. Check for continuity between the ground cir- 4 – SCREW
cuit cavity of the power outlet wire harness connector
and a good ground. There should be continuity. If
OK, go to Step 6. If not OK, repair the open ground (4) Using a trim stick or another suitable wide
circuit to ground as required. flat-bladed tool, gently pry the upper edge of the
(6) Connect the battery negative cable. Check for steering column opening cover just below the cluster
battery voltage at the fused B(+) circuit cavity of the bezel on each side of the steering column away from
power outlet wire harness connector. If OK, replace the instrument panel far enough to disengage the
the faulty power outlet receptacle (instrument panel two snap clip retainers from the receptacles in the
accessory switch bezel unit). If not OK, repair the instrument panel.
open fused B(+) circuit to the junction block fuse as (5) Remove the steering column opening cover
required. from the instrument panel.

INSTALLATION
REMOVAL AND INSTALLATION (1) Position the steering column opening cover to
the instrument panel.
STEERING COLUMN OPENING COVER (2) Align the snap clip retainers on the steering
column opening cover with the receptacles in the
WARNING: ON VEHICLES EQUIPPED WITH AIR- instrument panel.
BAGS, REFER TO GROUP 8M - PASSIVE (3) Press firmly on the steering column opening
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY cover over the snap clip locations until each of the
STEERING WHEEL, STEERING COLUMN, OR snap clips is fully engaged in its receptacle.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (4) Install and tighten the three screws that secure
SERVICE. FAILURE TO TAKE THE PROPER PRE- the lower edge of the steering column opening cover
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- to the lower instrument panel reinforcement. Tighten
BAG DEPLOYMENT AND POSSIBLE PERSONAL the screws to 2.2 N·m (20 in. lbs.).
INJURY. (5) Reconnect the battery negative cable.

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 8E - 14 INSTRUMENT PANEL SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

KNEE BLOCKER the mounting screws are located in the screw hole on
each side of the steering column that is closest to the
WARNING: ON VEHICLES EQUIPPED WITH AIR- driver side front door of the vehicle (Fig. 6).
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the steering column opening cover Fig. 6 Knee Blocker Mounting Screw Location
from the instrument panel. Refer to Steering Col- 1 – KNEE BLOCKER
umn Opening Cover in the Removal and Installa- 2 – RIGHT-HAND DRIVE
3 – SCREWS
tion section of this group for the procedures.
4 – LEFT-HAND DRIVE
(3) Remove the two screws that secure the knee
blocker to the instrument panel (Fig. 5).
(3) Install the steering column opening cover onto
the instrument panel. Refer to Steering Column
Opening Cover in the Removal and Installation sec-
tion of this group for the procedures.
(4) Reconnect the battery negative cable.

INSTRUMENT PANEL CENTER BEZEL

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
Fig. 5 Knee Blocker Remove/Install BAG DEPLOYMENT AND POSSIBLE PERSONAL
1 – KNEE BLOCKER INJURY.
2 – SCREW
3 – TAB
4 – SLOT REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(4) Pull the upper edge of the knee blocker away
(2) Using a trim stick or another suitable wide
from the instrument panel far enough to disengage
flat-bladed tool, gently pry the instrument panel cen-
the two lower mounting tabs from the mounting slots
ter bezel away from the instrument panel far enough
in the lower instrument panel reinforcement.
to disengage the six snap clip retainers that secure it
(5) Remove the knee blocker from the instrument
from the receptacles in the instrument panel (Fig. 7).
panel.
(3) Remove the center bezel from the instrument
panel.
INSTALLATION
(1) Position the knee blocker to the instrument INSTALLATION
panel.
(1) Position the center bezel to the instrument
(2) Install and tighten the four screws that secure
panel.
the knee blocker to the instrument panel. Tighten
(2) Align the snap clips on the center bezel with
the screws to 2.2 N·m (20 in. lbs.). Be certain that
the receptacles in the instrument panel.

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 15
REMOVAL AND INSTALLATION (Continued)

Fig. 8 Instrument Panel Accessory Switch Bezel

Remove/Install
1 – ACCESSORY SWITCH BEZEL
2 – SCREW

(4) Pull the accessory switch bezel away from the

Fig. 7 Instrument Panel Center Bezel Remove/Install instrument panel far enough to access the instru-
1 – INSTRUMENT PANEL ment panel wire harness connectors.
2 – CENTER BEZEL (5) Disconnect the instrument panel wire harness
connectors from the connector receptacles, the acces-
sory switches, the cigar lighter and the accessory
(3) Press firmly on the center bezel over each of
power outlet on the back of the accessory switch
the snap clip locations until each of the six snap clips
bezel.
is fully engaged in its receptacle on the instrument
(6) Remove the accessory switch bezel from the
panel.
instrument panel.
(4) Reconnect the battery negative cable.
INSTALLATION
INSTRUMENT PANEL ACCESSORY SWITCH (1) Position the accessory switch bezel to the
BEZEL instrument panel.
(2) Reconnect the instrument panel wire harness
WARNING: ON VEHICLES EQUIPPED WITH AIR- connectors to the connector receptacles, the accessory
BAGS, REFER TO GROUP 8M - PASSIVE switches, the cigar lighter and the accessory power
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY outlet on the back of the accessory switch bezel.
STEERING WHEEL, STEERING COLUMN, OR (3) Position the accessory switch bezel onto the
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR instrument panel.
SERVICE. FAILURE TO TAKE THE PROPER PRE- (4) Install and tighten the three screws that secure
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- the accessory switch bezel to the instrument panel.
BAG DEPLOYMENT AND POSSIBLE PERSONAL Tighten the screws to 2.2 N·m (20 in. lbs.).
INJURY. (5) Install the center bezel onto the instrument
panel. Refer to Instrument Panel Center Bezel in
REMOVAL the Removal and Installation section of this group for
the procedures.
(1) Disconnect and isolate the battery negative
(6) Reconnect the battery negative cable.
cable.
(2) Remove the center bezel from the instrument
panel. Refer to Instrument Panel Center Bezel in
the Removal and Installation section of this group for
the procedures.
(3) Remove the three screws that secure the acces-
sory switch bezel to the instrument panel (Fig. 8).

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 8E - 16 INSTRUMENT PANEL SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

CIGAR LIGHTER RELAY (4) Remove the screw located above the fuse access
opening that secures the right cowl side trim to the
WARNING: ON VEHICLES EQUIPPED WITH AIR- right cowl side inner panel.
BAGS, REFER TO GROUP 8M - PASSIVE (5) Remove the screw that secures the right door
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY sill trim and the right cowl side trim to the right
STEERING WHEEL, STEERING COLUMN, OR door opening sill.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (6) Remove the right cowl side trim panel from the
SERVICE. FAILURE TO TAKE THE PROPER PRE- vehicle.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (7) Refer to Junction Block in the Contents of
BAG DEPLOYMENT AND POSSIBLE PERSONAL Group 8W - Wiring Diagrams for cigar lighter relay
INJURY. identification and location.
(8) Remove the cigar lighter relay from the recep-
tacle in the junction block.
REMOVAL
(1) Disconnect and isolate the battery negative INSTALLATION
cable. (1) Refer to Junction Block in the Contents of
(2) Remove the fuse access panel by unsnapping it Group 8W - Wiring Diagrams for the proper cigar
from the right cowl side trim panel. lighter relay location.
(3) Remove the stamped nut that secures the right (2) Position the cigar lighter relay to the receptacle
cowl side trim to the junction block stud (Fig. 9). in the junction block.
(3) Align the terminals of the cigar lighter relay
with the cavities in the junction block receptacle.
(4) Push on the cigar lighter relay case firmly and
evenly until all of the relay terminals are fully seated
within the cavities of the junction block receptacle.
(5) Position the right cowl side trim to the right
door sill trim.
(6) Install and tighten the screw that secures the
right cowl side trim to the right door sill trim.
Tighten the screw to 2.2 N·m (20 in. lbs.).
(7) Position the right cowl side trim to the right
cowl side inner panel.
(8) Install and tighten the screw that secures the
right cowl side trim to the right cowl side inner
panel. Tighten the screw to 2.2 N·m (20 in. lbs.).
(9) Install the stamped nut that secures the right
cowl side trim to the junction block stud.
(10) Install the fuse access panel by snapping it
onto the right cowl side trim panel.
(11) Reconnect the battery negative cable.

CLUSTER BEZEL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
Fig. 9 Right Cowl Side Trim Remove/Install SERVICE. FAILURE TO TAKE THE PROPER PRE-
1 – RIGHT FRONT DOOR SILL
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
2 – COWL SIDE TRIM PANEL BAG DEPLOYMENT AND POSSIBLE PERSONAL
3 – SCREW INJURY.
4 – SILL TRIM
5 – FUSE ACCESS PANEL
6 – PUSH-NUT REMOVAL
(1) Disconnect and isolate the battery negative
cable.

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 17
REMOVAL AND INSTALLATION (Continued)
(2) Remove the knee blocker from the instrument (2) Align the snap clips on the cluster bezel with
panel. Refer to Knee Blocker in the Removal and the receptacles in the instrument panel.
Installation section of this group for the procedures. (3) Press firmly on the cluster bezel over each of
(3) Remove the center bezel from the instrument the snap clip locations until each of the snap clips is
panel. Refer to Instrument Panel Center Bezel in fully engaged in its receptacle.
the Removal and Installation section of this group for (4) Engage the two ends of the steering column
the procedures. sight shield with each other at the connector located
(4) Remove the four screws exposed by the center below the lower steering column shroud.
bezel removal that secure the cluster bezel to the (5) Install the headlamp switch knob and shaft
instrument panel. onto the headlamp switch. Refer to Headlamp
(5) Remove the headlamp switch knob and shaft Switch in the Removal and Installation section of
from the headlamp switch. Refer to Headlamp this group for the procedures.
Switch in the Removal and Installation section of (6) Install and tighten the four screws that secure
this group for the procedures. the cluster bezel to the instrument panel beneath the
(6) Disengage the two ends of the steering column instrument panel center bezel. Tighten the screws to
sight shield from each other at the connector located 2.2 N·m (20 in. lbs.).
below the lower steering column shroud (Fig. 10). (7) Install the center bezel onto the instrument
panel. Refer to Instrument Panel Center Bezel in
the Removal and Installation section of this group for
the procedures.
(8) Install the knee blocker onto the instrument
panel. Refer to Knee Blocker in the Removal and
Installation section of this group for the procedures.
Be certain that the two ends of the steering column
sight shield connector are engaged with each other
before installing the knee blocker.
(9) Reconnect the battery negative cable.

HEADLAMP SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
Fig. 10 Cluster Bezel Remove/Install CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
1 – INSTRUMENT PANEL BAG DEPLOYMENT AND POSSIBLE PERSONAL
2 – CLUSTER BEZEL INJURY.
3 – SCREW
4 – STEERING COLUMN SIGHT SHIELD CONNECTOR
5 – HEADLAMP SWITCH KNOB AND SHAFT WARNING: IF THE HEADLAMP SWITCH WAS ON,
WAIT FIVE MINUTES TO ALLOW THE CERAMIC
DIMMER RESISTOR TO COOL. IF THE CERAMIC
(7) If the vehicle is so equipped, set the tilt steer-
DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT
ing column in its lowest position.
CAN BURN YOUR FINGERS.
(8) Using a trim stick or another suitable wide
flat-bladed tool, gently pry around the perimeter of
the cluster bezel to disengage the five snap clips from REMOVAL
their receptacles in the instrument panel. (1) Disconnect and isolate the battery negative
(9) Remove the cluster bezel from the instrument cable.
panel. (2) Remove the knee blocker from the instrument
panel. Refer to Knee Blocker in the Removal and
INSTALLATION Installation section of this group for the procedures.
(1) Position the cluster bezel to the instrument (3) Pull the headlamp switch control knob out to
panel. the On position stop.

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 8E - 18 INSTRUMENT PANEL SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(4) Reach up under the instrument panel through (5) Insert the shaft of the headlamp switch control
the outboard side of the steering column opening to knob and shaft unit through the opening in the span-
access and depress the headlamp switch control knob ner nut and into the headlamp switch.
and shaft release button on the inboard side of the (6) Push the headlamp switch control knob and
switch body. shaft unit all the way into the headlamp switch body.
(5) While holding the release button depressed, (7) Install the knee blocker onto the instrument
pull the headlamp switch control knob and shaft out panel. Refer to Knee Blocker in the Removal and
of the headlamp switch. Installation section of this group for the procedures.
(6) Remove the spanner nut that secures the head- (8) Reconnect the battery negative cable.
lamp switch to the instrument panel (Fig. 11).
INSTRUMENT CLUSTER
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cluster bezel from the instrument
panel. Refer to Cluster Bezel in the Removal and
Installation section of this group for the procedures.
(3) Remove the four screws that secure the instru-
Fig. 11 Headlamp Switch Remove/Install ment cluster to the instrument panel (Fig. 12).
1 – WIRE HARNESS CONNECTORS
2 – HEADLAMP SWITCH
3 – NUT
4 – INSTRUMENT PANEL

(7) Pull the headlamp switch into the steering col-

umn opening area of the instrument panel far
enough to access the instrument panel wire harness
connectors.
(8) Disconnect the two instrument panel wire har-
ness connectors from the headlamp switch.
(9) Remove the headlamp switch from the instru-
ment panel.

INSTALLATION
(1) Position the headlamp switch to the instru-
ment panel steering column opening.
Fig. 12 Instrument Cluster Remove/Install
(2) Reconnect the two instrument panel wire har-
1 – INSTRUMENT PANEL
ness connectors to the headlamp switch. 2 – SELF-DOCKING WIRE HARNESS CONNECTORS
(3) Position the headlamp switch behind its 3 – INSTRUMENT CLUSTER
mounting hole on the instrument panel. 4 – SCREW
(4) Install and tighten the spanner nut that
secures the headlamp switch to the instrument
panel. Tighten the nut to 2.7 N·m (24 in. lbs.). (4) Pull the instrument cluster rearward far
enough to disengage the two self-docking instrument
panel wire harness connectors from the connector

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 19
REMOVAL AND INSTALLATION (Continued)
receptacles on the back of the cluster housing. Do reinstalled in the correct position. Always use the
not pull on the instrument cluster by the lens correct bulb size and type for replacement. An incor-
or mask sections, or the cluster components rect bulb size or type may overheat and cause dam-
may become separated. age to the instrument cluster, the electronic circuit
(5) Remove the instrument cluster from the instru- board and/or the gauges.
ment panel. (1) Disconnect and isolate the battery negative
cable.
INSTALLATION (2) Remove the instrument cluster from the instru-
(1) Position the instrument cluster to the instru- ment panel. Refer to Instrument Cluster in the
ment panel. Removal and Installation section of this group for the
(2) Align the instrument cluster with the cluster procedures.
opening in the instrument panel and push the cluster (3) Turn the bulb holder counterclockwise about
firmly and evenly into place. The instrument panel sixty degrees on the cluster electronic circuit board.
has two self-docking wire harness connectors that (4) Pull the bulb and bulb holder unit straight
will be automatically aligned with, and connected to back to remove it from the bulb mounting hole in the
the cluster connector receptacles when the cluster is cluster electronic circuit board (Fig. 13).
installed in the instrument panel.
(3) Install and tighten the four screws that secure
the instrument cluster to the instrument panel.
Tighten the screws to 2.2 N·m (20 in. lbs.).
(4) Install the cluster bezel onto the instrument
panel. Refer to Cluster Bezel in the Removal and
Installation section of this group for the procedures.
(5) Reconnect the battery negative cable.

INSTRUMENT CLUSTER COMPONENTS

Some of the components for the instrument cluster
used in this vehicle are serviced individually. The
serviced components include: the incandescent
instrument cluster indicator lamp and illumination Fig. 13 Cluster Bulb Locations
lamp bulbs (including the integral bulb holders), the 1 – CLUSTER ILLUMINATION BULBS
odometer reset knob boot, the cluster lens, the clus-
ter hood and mask unit, and the instrument cluster CLUSTER LENS
housing rear cover. Following are the service proce- (1) Disconnect and isolate the battery negative
dures for the instrument cluster components. cable.
(2) Remove the instrument cluster from the instru-
WARNING: ON VEHICLES EQUIPPED WITH AIR-
ment panel. Refer to Instrument Cluster in the
BAGS, REFER TO GROUP 8M - PASSIVE
Removal and Installation section of this group for the
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
procedures.
STEERING WHEEL, STEERING COLUMN, OR
(3) Work around the perimeter of the cluster hous-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
ing to disengage each of the latches that secure the
SERVICE. FAILURE TO TAKE THE PROPER PRE-
cluster lens to the cluster housing (Fig. 14).
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(4) Gently pull the cluster lens away from the clus-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
ter housing.
INJURY.
ODOMETER RESET KNOB BOOT
REMOVAL (1) Disconnect and isolate the battery negative
cable.
CLUSTER BULB (2) Remove the instrument cluster from the instru-
This procedure applies to each of the incandescent ment panel. Refer to Instrument Cluster in the
cluster illumination lamp or indicator lamp bulb and Removal and Installation section of this group for the
bulb holder units. However, the illumination lamps procedures.
and the indicator lamps use different bulb and bulb (3) Remove the cluster lens from the cluster hous-
holder unit sizes. They must never be interchanged. ing. Refer to Instrument Cluster Components -
Be certain that any bulb and bulb holder unit Cluster Lens in the Removal and Installation sec-
removed from the cluster electronic circuit board is tion of this group for the procedures.

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 8E - 20 INSTRUMENT PANEL SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 14 Instrument Cluster Components

1 – CLUSTER REAR COVER 4 – ODOMETER RESET KNOB BOOT
2 – CLUSTER HOOD AND MASK 5 – INSTRUMENT CLUSTER HOUSING
3 – CLUSTER LENS

(4) Remove the odometer reset knob boot by pull- Removal and Installation section of this group for the
ing it out of the cluster lens. procedures.
(3) Work around the perimeter of the cluster hous-
CLUSTER HOOD AND MASK ing to disengage each of the latches that secure the
(1) Disconnect and isolate the battery negative rear cover to the cluster housing (Fig. 14).
cable. (4) Gently pull the rear cover away from the back
(2) Remove the instrument cluster from the instru- of the cluster housing.
ment panel. Refer to Instrument Cluster in the
Removal and Installation section of this group for the INSTALLATION
procedures.
(3) Remove the cluster lens from the cluster hous- CLUSTER BULB
ing. Refer to Instrument Cluster Components - This procedure applies to each of the incandescent
Cluster Lens in the Removal and Installation sec- cluster illumination lamp or indicator lamp bulb and
tion of this group for the procedures. bulb holder units. However, the illumination lamps
(4) Work around the perimeter of the cluster hous- and the indicator lamps use different bulb and bulb
ing to disengage each of the latches that secure the holder unit sizes. They must never be interchanged.
cluster hood and mask unit to the cluster housing Be certain that any bulb and bulb holder unit
(Fig. 14). removed from the cluster electronic circuit board is
(5) Gently pull the cluster hood and mask unit reinstalled in the correct position.
away from the cluster housing.
CAUTION: Always use the correct bulb size and
CLUSTER HOUSING REAR COVER type for replacement. An incorrect bulb size or type
(1) Disconnect and isolate the battery negative may overheat and cause damage to the instrument
cable. cluster, the electronic circuit board and/or the
(2) Remove the instrument cluster from the instru- gauges.
ment panel. Refer to Instrument Cluster in the

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 21
REMOVAL AND INSTALLATION (Continued)
(1) Insert the bulb and bulb holder unit straight Removal and Installation section of this group for the
into the correct bulb mounting hole in the cluster procedures.
electronic circuit board. (6) Reconnect the battery negative cable.
(2) With the bulb holder fully seated against the
cluster electronic circuit board, turn the bulb holder CLUSTER HOUSING REAR COVER
clockwise about sixty degrees to lock it into place. (1) Position the rear cover to the back of the clus-
(3) Install the instrument cluster onto the instru- ter housing.
ment panel. Refer to Instrument Cluster in the (2) Press firmly and evenly on the rear cover until
Removal and Installation section of this group for the each of the latches that secure the rear cover to the
procedures. cluster housing is fully engaged.
(4) Reconnect the battery negative cable. (3) Install the instrument cluster onto the instru-
ment panel. Refer to Instrument Cluster in the
CLUSTER LENS Removal and Installation section of this group for the
(1) Align the cluster lens with the cluster hood and procedures.
mask unit. (4) Reconnect the battery negative cable.
(2) Press firmly and evenly on the cluster lens to
install it onto the cluster housing. INSTRUMENT PANEL TOP COVER
(3) Work around the perimeter of the cluster hous-
ing to be certain that each of the latches that secure WARNING: ON VEHICLES EQUIPPED WITH AIR-
the cluster lens to the cluster housing is fully BAGS, REFER TO GROUP 8M - PASSIVE
engaged. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
(4) Install the instrument cluster onto the instru- STEERING WHEEL, STEERING COLUMN, OR
ment panel. Refer to Instrument Cluster in the INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
Removal and Installation section of this group for the SERVICE. FAILURE TO TAKE THE PROPER PRE-
procedures. CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(5) Reconnect the battery negative cable. BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
ODOMETER RESET KNOB BOOT
(1) Position the odometer reset knob to the mount-
ing hole from the back of the cluster lens. REMOVAL
(2) Pull the odometer reset knob into the mounting (1) Disconnect and isolate the battery negative
hole from the face of the cluster lens. cable.
(3) Install the cluster lens onto the cluster hous- (2) Remove the cluster bezel from the instrument
ing. Refer to Instrument Cluster Components - panel. Refer to Cluster Bezel in the Removal and
Cluster Lens in the Removal and Installation sec- Installation section of this group for the procedures.
tion of this group for the procedures. (3) Using a trim stick or another suitable wide
(4) Install the instrument cluster onto the instru- flat-bladed tool, gently pry the rear edge (farthest
ment panel. Refer to Instrument Cluster in the from the windshield) of the instrument panel top
Removal and Installation section of this group for the cover up and away from the instrument panel far
procedures. enough to disengage the seven snap clip retainers
(5) Reconnect the battery negative cable. from their receptacles in the instrument panel (Fig.
15).
CLUSTER HOOD AND MASK (4) Pull the top cover sharply rearwards (away
(1) Align the hood and mask unit with the cluster from the windshield) to disengage the four snap clip
housing. retainers that secure the forward edge of the top
(2) Press firmly and evenly on the hood and mask cover from their receptacles in the instrument panel
unit to install it onto the cluster housing. near the base of the windshield.
(3) Work around the perimeter of the cluster hous- (5) Remove the top cover from the instrument
ing to be certain that each of the latches that secure panel.
the hood and mask unit to the cluster housing is
fully engaged. INSTALLATION
(4) Install the cluster lens onto the cluster hous- (1) Position the top cover onto the instrument
ing. Refer to Instrument Cluster Components - panel.
Cluster Lens in the Removal and Installation sec- (2) Align the four snap clips on the forward edge
tion of this group for the procedures. (nearest the windshield) of the top cover with the
(5) Install the instrument cluster onto the instru- snap clip receptacles in the instrument panel.
ment panel. Refer to Instrument Cluster in the

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 8E - 22 INSTRUMENT PANEL SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 15 Instrument Panel Top Cover Remove/Install

1 – INSTRUMENT PANEL Fig. 16 Glove Box Stop Bumpers Remove/Install
2 – TOP COVER 1 – GLOVE BOX OPENING UPPER REINFORCEMENT
3 – FRONT EDGE 2 – GLOVE BOX LATCH STRIKER
4 – REAR EDGE 3 – STOP BUMPERS
4 – GLOVE BOX DOOR

(3) Press firmly downward on the top cover over

each of the four forward snap clip locations until (4) Remove the two glove box stop bumpers by
each of the snap clips is fully seated in their recep- sliding them downward and out of the slots in the
tacles in the instrument panel. instrument panel upper glove box opening reinforce-
(4) Align the seven snap clips on the rear edge ment.
(farthest from the windshield) of the top cover with (5) Roll the glove box downward so that the stops
the snap clip receptacles in the instrument panel. molded into the glove box bin pass through the stop
(5) Press firmly downward on the top cover over bumper slots in the instrument panel upper glove
each of the seven rearward snap clip locations until box opening reinforcement.
each of the snap clips is fully seated in their recep- (6) Reverse the roll down procedure to roll the
tacles in the instrument panel. glove box back up into the instrument panel.
(6) Install the cluster bezel onto the instrument
panel. Refer to Cluster Bezel in the Removal and REMOVAL
Installation section of this group for the procedures. (1) Disconnect and isolate the battery negative
(7) Reconnect the battery negative cable. cable.
(2) Remove the three screws that secure the glove
GLOVE BOX box hinge to the instrument panel lower glove box
opening reinforcement (Fig. 17).
WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) Release the glove box latch.
BAGS, REFER TO GROUP 8M - PASSIVE (4) Remove the glove box from the instrument
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY panel.
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR INSTALLATION
SERVICE. FAILURE TO TAKE THE PROPER PRE- (1) Position the glove box to the instrument panel
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- with the bin inserted in the glove box opening far
BAG DEPLOYMENT AND POSSIBLE PERSONAL enough so that the stops on each side of the glove
INJURY. box bin are located behind the rubber stop bumpers
located on the instrument panel upper glove box
opening reinforcement.
ROLL DOWN (2) Align the screw holes in the glove box hinge
(1) Disconnect and isolate the battery negative with the mounting holes in the instrument panel
cable. lower glove box opening reinforcement.
(2) Open the glove box. (3) Install and tighten the three screws that secure
(3) Locate the two rubber stop bumpers on the the glove box hinge to the instrument panel lower
upper edge of the instrument panel glove box open- glove box opening reinforcement. Tighten the screws
ing (Fig. 16). to 2.2 N·m (20 in. lbs.).

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 23
REMOVAL AND INSTALLATION (Continued)

Fig. 17 Glove Box Remove/Install

1 – GLOVE BOX
2 – LATCH
3 – SCREWS

(4) Reconnect the battery negative cable. Fig. 18 Glove Box Components Remove/Install
1 – OUTER DOOR
GLOVE BOX COMPONENTS 2 – STOPS
The glove box hinge, bin, inner door and latch are 3 – INNER DOOR
serviced only as a complete unit. The glove box outer 4 – LATCH
door and lock cylinder are serviced separately. 5 – BIN
6 – HINGE
WARNING: ON VEHICLES EQUIPPED WITH AIR- 7 – SCREWS
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY Removal and Installation section of this group for the
STEERING WHEEL, STEERING COLUMN, OR procedures.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (3) Remove the seven screws that secure the inner
SERVICE. FAILURE TO TAKE THE PROPER PRE- glove box door to the outer glove box door (Fig. 18).
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (4) Remove the outer glove box door from the inner
BAG DEPLOYMENT AND POSSIBLE PERSONAL glove box door unit.
INJURY.
GLOVE BOX LOCK CYLINDER
(1) Insert the key into the glove box lock cylinder
REMOVAL and turn the lock cylinder to the unlocked position.
(2) Open the glove box.
GLOVE BOX HINGE, BIN, INNER DOOR AND LATCH
(3) With the key still in the lock cylinder, insert a
(1) Disconnect and isolate the battery negative small pin punch or a stiff wire into the lock cylinder
cable. release hole (Fig. 19) and depress the lock cylinder
(2) Remove the glove box from the instrument retaining tumbler.
panel. Refer to Glove Box - Removal in the (4) While holding the retaining tumbler depressed,
Removal and Installation section of this group for the rotate the key in the lock cylinder clockwise and
procedures. press outward on the back of the lock cylinder from
(3) Remove the seven screws that secure the inner the inside of the glove box door until the lock cylin-
glove box door to the outer glove box door (Fig. 18). der comes out of the glove box latch lock cylinder
(4) Remove the inner glove box door unit from the bore.
outer glove box door.
INSTALLATION
GLOVE BOX OUTER DOOR
(1) Disconnect and isolate the battery negative GLOVE BOX HINGE, BIN, INNER DOOR AND LATCH
cable. (1) Position the inner glove box door unit onto the
(2) Remove the glove box from the instrument outer glove box door.
panel. Refer to Glove Box - Removal in the

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 8E - 24 INSTRUMENT PANEL SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Open the glove box.
(3) Remove the passenger side airbag module from
Fig. 19 Glove Box Lock Cylinder Remove/Install the instrument panel. Refer to Passenger Side Air-
1 – LOCK CYLINDER bag Module in the Removal and Installation section
2 – LATCH HANDLE of Group 8M - Passive Restraint Systems for the pro-
3 – RELEASE HOLE cedures.
(4) Remove the two screws that secure the latch
striker to the instrument panel glove box opening
(2) Install and tighten the seven screws that
upper reinforcement (Fig. 20).
secure the inner glove box door to the outer glove box
door. Tighten the screws to 2.2 N·m (20 in. lbs.).
(3) Install the glove box onto the instrument panel.
Refer to Glove Box - Installation in the Removal
and Installation section of this group for the proce-
dures.
(4) Reconnect the battery negative cable.

GLOVE BOX OUTER DOOR

(1) Position the outer glove box door onto the inner
glove box door unit.
(2) Install and tighten the seven screws that
secure the inner glove box door to the outer glove box
door. Tighten the screws to 2.2 N·m (20 in. lbs.).
(3) Install the glove box onto the instrument panel. Fig. 20 Glove Box Latch Striker Remove/Install
Refer to Glove Box - Installation in the Removal 1 – GLOVE BOX OPENING UPPER REINFORCEMENT
and Installation section of this group for the proce- 2 – SCREWS
dures. 3 – LATCH STRIKER
4 – STOP BUMPER SLOTS
(4) Reconnect the battery negative cable.

GLOVE BOX LOCK CYLINDER (5) Remove the latch striker from the instrument
(1) To install the lock cylinder, insert the key into panel glove box opening upper reinforcement.
the cylinder and align the lock cylinder tumblers
with the ramp in the glove box latch lock cylinder INSTALLATION
bore. The ramp is located at about the 7 o’clock posi- (1) Position the latch striker onto the instrument
tion. panel glove box opening upper reinforcement.
(2) Push the glove box lock cylinder firmly into the (2) Install and tighten the two screws that secure
lock cylinder bore while rotating the key and cylinder the latch striker to the instrument panel glove box
counterclockwise to the 6 o’clock position, where the opening upper reinforcement. Tighten the screws to
lock cylinder retaining tumbler will snap back into 2.2 N·m (20 in. lbs.).
place. (3) Install the passenger side airbag module onto
the instrument panel. Refer to Passenger Side Air-
GLOVE BOX LATCH STRIKER bag Module in the Removal and Installation section
of Group 8M - Passive Restraint Systems for the pro-
WARNING: ON VEHICLES EQUIPPED WITH AIR- cedures.
BAGS, REFER TO GROUP 8M - PASSIVE (4) Close the glove box.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (5) Reconnect the battery negative cable.
STEERING WHEEL, STEERING COLUMN, OR

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 25
REMOVAL AND INSTALLATION (Continued)

INSTRUMENT PANEL END CAP Removal and Installation section of this group for the
procedures.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) Remove the top cover from the instrument
BAGS, REFER TO GROUP 8M - PASSIVE panel. Refer to Instrument Panel Top Cover in the
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY Removal and Installation section of this group for the
STEERING WHEEL, STEERING COLUMN, OR procedures.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (4) Remove the passenger side airbag module from
SERVICE. FAILURE TO TAKE THE PROPER PRE- the instrument panel. Refer to Passenger Side Air-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- bag Module in the Removal and Installation section
BAG DEPLOYMENT AND POSSIBLE PERSONAL of Group 8M - Passive Restraint Systems for the pro-
INJURY. cedures.
(5) Remove the six screws that secure the end cap
to the instrument panel (Fig. 21).
REMOVAL (6) Remove the end cap from the instrument
panel.
DRIVER SIDE
(1) Disconnect and isolate the battery negative INSTALLATION
cable.
(2) Remove the knee blocker from the instrument DRIVER SIDE
panel. Refer to Knee Blocker in the Removal and (1) Position the end cap to the instrument panel.
Installation section of this group for the procedures. (2) Install and tighten the five screws that secure
(3) Remove the top cover from the instrument the end cap to the instrument panel. Tighten the
panel. Refer to Instrument Panel Top Cover in the screws to 2.2 N·m (20 in. lbs.).
Removal and Installation section of this group for the (3) Install the top cover onto the instrument panel.
procedures. Refer to Instrument Panel Top Cover in the
(4) Remove the five screws that secure the end cap Removal and Installation section of this group for the
to the instrument panel (Fig. 21). procedures.
(4) Install the knee blocker onto the instrument
panel. Refer to Knee Blocker in the Removal and
Installation section of this group for the procedures.
(5) Reconnect the battery negative cable.

PASSENGER SIDE
(1) Position the end cap to the instrument panel.
(2) Install and tighten the six screws that secure
the end cap to the instrument panel. Tighten the
screws to 2.2 N·m (20 in. lbs.).
(3) Install the passenger side airbag module onto
the instrument panel. Refer to Passenger Side Air-
bag Module in the Removal and Installation section
of Group 8M - Passive Restraint Systems for the pro-
cedures.
(4) Install the top cover onto the instrument panel.
Fig. 21 Instrument Panel End Cap Remove/Install Refer to Instrument Panel Top Cover in the
1 – END CAP Removal and Installation section of this group for the
2 – INSTRUMENT PANEL
procedures.
3 – SCREW
(5) Roll up the glove box into the instrument
panel. Refer to Glove Box - Roll Down in the
(5) Remove the end cap from the instrument Removal and Installation section of this group for the
panel. procedures.
(6) Reconnect the battery negative cable.
PASSENGER SIDE
(1) Disconnect and isolate the battery negative
cable.
(2) Roll down the glove box from the instrument
panel. Refer to Glove Box - Roll Down in the

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 8E - 26 INSTRUMENT PANEL SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

INSTRUMENT PANEL CENTER SUPPORT (6) Remove the two nuts that secure the instru-
ment panel center support bracket to the studs on
BRACKET
the floor panel transmission tunnel.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (7) Remove the center support bracket from the
BAGS, REFER TO GROUP 8M - PASSIVE instrument panel.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR INSTALLATION
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (1) Position the center support bracket to the
SERVICE. FAILURE TO TAKE THE PROPER PRE- instrument panel.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (2) Install and tighten the two nuts that secure
BAG DEPLOYMENT AND POSSIBLE PERSONAL the instrument panel center support bracket to the
INJURY. studs on the floor panel transmission tunnel. Tighten
the nuts to 28 N·m (250 in. lbs.).
(3) Install and tighten the two nuts that secure
REMOVAL the center support bracket to the studs on the instru-
(1) Disconnect and isolate the battery negative ment panel. Tighten the nuts to 28 N·m (250 in. lbs.).
cable. (4) Position the floor carpet back onto the front of
(2) Remove the center bezel from the instrument the floor panel transmission tunnel.
panel. Refer to Instrument Panel Center Bezel in (5) Install the floor console onto the floor panel
the Removal and Installation section of this group for transmission tunnel. Refer to Floor Console in the
the procedures. Removal and Installation section of Group 23 - Body
(3) Remove the floor console from the floor panel for the procedures.
transmission tunnel. Refer to Floor Console in the (6) Install the center bezel onto the instrument
Removal and Installation section of Group 23 - Body panel. Refer to Instrument Panel Center Bezel in
for the procedures. the Removal and Installation section of this group for
(4) Pull the floor carpet back from the front of the the procedures.
floor panel transmission tunnel far enough to access (7) Reconnect the battery negative cable.
the instrument panel center support bracket mount-
ing nuts. INSTRUMENT PANEL ASSEMBLY
(5) Remove the two nuts that secure the center
support bracket to the studs on the instrument panel WARNING: ON VEHICLES EQUIPPED WITH AIR-
(Fig. 22). BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

REMOVAL
NOTE: Before starting this procedure, be certain to
turn the steering wheel until the front wheels are in
the straight-ahead position.

(1) Disconnect and isolate the battery negative

Fig. 22 Instrument Panel Center Support Bracket cable.
Remove/Install (2) Remove the trim from the left and right cowl
1 – INSTRUMENT PANEL
side inner panels. Refer to Lower A-Pillar Cowl
2 – NUT Trim in the Removal and Installation section of
3 – BRACKET Group 23 - Body for the procedures.
4 – FLOOR PAN TRANSMISSION TUNNEL (3) Remove the knee blocker from the instrument
5 – STUDS panel. Refer to Knee Blocker in the Removal and
Installation section of this group for the procedures.

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 27
REMOVAL AND INSTALLATION (Continued)
(4) Remove the top cover from the instrument ness connector at the floor panel transmission tunnel
panel. Refer to Instrument Panel Top Cover in the under the instrument panel.
Removal and Installation section of this group for the (10) Roll down the glove box from the instrument
procedures. panel. Refer to Glove Box - Roll Down in the
(5) Remove the center support bracket from the Removal and Installation section of this group for the
instrument panel. Refer to Instrument Panel Cen- procedures.
ter Support Bracket in the Removal and Installa- (11) Reach through the inboard side of the instru-
tion section of this group for the procedures. ment panel glove box opening to disconnect the two
(6) Remove the steering column from the vehicle. halves of the heater-A/C system vacuum harness con-
Refer to Steering Column in the Removal and nector.
Installation section of Group 19 - Steering for the (12) Reach under the right end of the instrument
procedures. panel to access and disconnect the two halves of the
(7) Remove the screws from the centers of the radio antenna coaxial cable connector. On Left-Hand
instrument panel-to-body and the instrument panel- Drive models only, also disengage the retainer on the
to-headlamp and dash wire harness connectors near radio half of the coaxial cable from the heater-A/C
the left cowl side inner panel and disconnect both housing kick cover.
connectors. (13) Loosen the right and left instrument panel
(8) Remove the screw from the center of the cowl side roll down screws about 6 mm (0.25 inch)
instrument panel-to-floor wire harness connector (Fig. 23).
near the floor panel transmission tunnel under the (14) Remove the four screws and two nuts that
instrument panel and disconnect the connector. secure the top of the instrument panel to the top of
(9) Disconnect the two wire harness connectors the dash panel near the base of the windshield.
located near the instrument panel-to-floor wire har- (15) With the aid of an assistant, lift the top of the
instrument panel assembly off of the two dash panel

Fig. 23 Instrument Panel Assembly Remove/Install

1 – SCREW 3 – INSTRUMENT PANEL COWL SIDE ROLL DOWN SCREWS
2 – NUT

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 8E - 28 INSTRUMENT PANEL SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
studs. Then pull the lower instrument panel rear- ness connector at the floor panel transmission tunnel
ward to clear the cowl side roll down screws. under the instrument panel.
(16) Remove the instrument panel assembly from (8) Reconnect the instrument panel-to-floor wire
the vehicle. harness connector near the floor panel transmission
tunnel under the instrument panel and tighten the
INSTALLATION connector screw. Tighten the screw to 4 N·m (35 in.
(1) With the aid of an assistant, position the lbs.).
instrument panel assembly onto the cowl side roll (9) Reconnect the instrument panel-to-body and
down screws and the dash panel studs in the vehicle. the instrument panel-to-headlamp and dash wire
(2) Install and tighten the four screws and two harness connectors near the left cowl side inner
nuts that secure the top of the instrument panel to panel and tighten the connector screws. Tighten the
the top of the dash panel near the base of the wind- screws to 4 N·m (35 in. lbs.).
shield. Tighten the screws and nuts to 7 N·m (60 in. (10) Install the steering column into the vehicle.
lbs.). Refer to Steering Column in the Removal and
(3) Tighten the right and left instrument panel Installation section of Group 19 - Steering for the
cowl side roll down screws. Tighten the screws to 28 procedures.
N·m (250 in. lbs.). (11) Install the center support bracket onto the
(4) Reach under the right end of the instrument instrument panel. Refer to Instrument Panel Cen-
panel to access and reconnect the two halves of the ter Support Bracket in the Removal and Installa-
radio antenna coaxial cable connector. On Left-Hand tion section of this group for the procedures.
Drive models only, also engage the retainer on the (12) Install the top cover onto the instrument
radio half of the coaxial cable onto the heater-A/C panel. Refer to Instrument Panel Top Cover in the
housing kick cover. Removal and Installation section of this group for the
(5) Reach through the inboard side of the instru- procedures.
ment panel glove box opening to reconnect the two (13) Install the knee blocker onto the instrument
halves of the heater-A/C system vacuum harness con- panel. Refer to Knee Blocker in the Removal and
nector. Installation section of this group for the procedures.
(6) Roll up the glove box into the instrument (14) Install the trim onto the left and right cowl
panel. Refer to Glove Box - Roll Down in the side inner panels. Refer to Lower A-Pillar Cowl
Removal and Installation section of this group for the Trim in the Removal and Installation section of
procedures. Group 23 - Body for the procedures.
(7) Reconnect the two wire harness connectors (15) Reconnect the battery negative cable.
located near the instrument panel-to-floor wire har-

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 XJ INSTRUMENT PANEL SYSTEMS 8E - 1

INSTRUMENT PANEL SYSTEMS

TABLE OF CONTENTS

page page

REMOVAL AND INSTALLATION REAR FOG LAMP SWITCH. . . . . . . . . . . . . . . . . . 1

HEADLAMP LEVELING SWITCH. . . . . . . . . . . . . . 1

REMOVAL AND INSTALLATION INSTALLATION

(1) Install the instrument panel center bezel on
HEADLAMP LEVELING SWITCH the I. P. Be certain headlamp leveling switch electri-
cal harness is inserted through the hole in center
REMOVAL bezel.
(2) Connect the headlamp leveling switch electri-
cal.
(3) Verify switch / system operation.
(4) Install the headlamp leveling switch in the
instrument panel center bezel by gently pushing
straight in.
(5) Connect the negative battery cable.

REAR FOG LAMP SWITCH

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Disconnect and isolate the battery negative

cable.
Fig. 1 Headlamp Leveling Switch Position & (2) Using a trim stick or another suitable wide
Orientation flat-bladed tool, gently pry the instrument panel cen-
1 – INSTRUMENT PANEL CNETER BEZEL ter bezel away from the instrument panel to release
2 – HEADLAMP LEVELING SWITCH the six snap clip retainers.
(3) Remove the center bezel from the vehicle.
(1) Disconnect and isolate the negative battery (4) Remove the three screws that secure the acces-
cable. sory switch bezel to the instrument panel
(2) Using a trim stick or another suitable wide (5) Pull the accessory switch bezel out from the
flat-bladed tool, gently pry the instrument panel cen- instrument panel far enough to unplug the wire har-
ter bezel away from the instrument panel to release ness connectors (Fig. 2).
the four snap clip retainers (Fig. 1). (6) Remove the accessory switch bezel from the
(3) Pull the center bezel away from the instrument instrument panel.
panel far enough to disconnect the wiring harness (7) Carefully pry the snap retainers at the top and
from the headlamp leveling switch. bottom of the rear fog lamp switch receptacle on the
(4) Depress the switch retaining tabs to remove back of the accessory switch bezel with a small thin-
the switch from the center bezel. bladed screwdriver and pull the switch out of the
receptacle.

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 8E - 2 INSTRUMENT PANEL SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
receptacle on the back of the accessory switch bezel
are fully engaged. Tighten the mounting screws to
2.2 N·m (20 in. lbs.).

Fig. 2 Accessory Switch Bezel Remove/Install

1 – ACCESSORY SWITCH BEZEL
2 – SCREW

(8) Reverse the removal procedures to install. Be

certain that both of the switch snap retainers in the

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 XJ AUDIO SYSTEMS 8F - 1

AUDIO SYSTEMS
TABLE OF CONTENTS

page page

GENERAL INFORMATION SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 1 RADIO FREQUENCY INTERFERENCE . . . . . . . . . . 6
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
RADIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 RADIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . . . . 1 AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RADIO NOISE SUPPRESSION . . . . . . . . . . . . . . . 2 RADIO NOISE SUPPRESSION COMPONENTS . . 11
DIAGNOSIS AND TESTING SPECIAL TOOLS
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2 AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . 12
RADIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

GENERAL INFORMATION DESCRIPTION AND OPERATION

INTRODUCTION RADIO
An audio system is standard factory-installed Available factory-installed radio receivers for this
equipment on this model, unless the vehicle is model include an AM/FM (RAL sales code), an
ordered with an available radio delete option. Refer AM/FM/cassette (RAS sales code), and an AM/FM/
to 8W-47 Audio System in Group 8W - Wiring Dia- CD/cassette/3-band graphic equalizer (RAZ sales
grams for complete circuit descriptions and diagrams. code). All factory-installed radio receivers are stereo
Electronically Tuned Radios (ETR), and include an
NOTE: This group covers both Left-Hand Drive electronic digital clock function.
(LHD) and Right-Hand Drive (RHD) versions of this The radio can only be serviced by an authorized
model. Whenever required and feasible, the RHD radio repair station. Refer to the latest Warranty Pol-
versions of affected vehicle components have been icies and Procedures manual for a current listing of
constructed as mirror-image of the LHD versions. authorized radio repair stations.
While most of the illustrations used in this group For more information on radio features, setting
represent only the LHD version, the diagnostic and procedures, and control functions refer to the owner’s
service procedures outlined can generally be manual in the vehicle glove box.
applied to either version. Exceptions to this rule
have been clearly identified as LHD or RHD, if a IGNITION-OFF DRAW FUSE
special illustration or procedure is required. All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is removed when the vehicle is
shipped from the factory. This fuse feeds various
AUDIO SYSTEM accessories that require battery current when the
Several combinations of radio receivers and ignition switch is in the Off position, including the
speaker systems are offered on this model. The stan- clock and radio station preset memory functions. The
dard equipment audio system includes an AM/FM fuse is removed to prevent battery discharge during
(RAL sales code) receiver, and speakers in two loca- vehicle storage.
tions. When removing or installing the IOD fuse, it is
Following are general descriptions of the major important that the ignition switch be in the Off posi-
components in the standard and optional factory-in- tion. Failure to place the ignition switch in the Off
stalled audio systems. Refer to the owner’s manual in position can cause the radio display to become scram-
the vehicle glove box for more information on the fea- bled when the IOD fuse is removed and replaced.
tures, use and operation of each of the available Removing and replacing the IOD fuse again, with the
audio systems.

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 8F - 2 AUDIO SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
ignition switch in the Off position, will correct the nect allows the instrument panel assembly to be
scrambled display condition. removed and installed without removing the radio.
The IOD fuse should be checked if the radio is The factory-installed Electronically Tuned Radios
inoperative. The IOD fuse is located in the Power (ETRs) automatically compensate for radio antenna
Distribution Center (PDC). Refer to the PDC label for trim. Therefore, no antenna trimmer adjustment is
IOD fuse identification and location. required or possible when replacing the receiver or
the antenna.
SPEAKER
The standard equipment speaker system includes RADIO NOISE SUPPRESSION
two 13.3 centimeter (5.25 inch) diameter full-range
speakers. Each speaker is mounted to the lower front DESCRIPTION
corner of the front door inner panel behind the door Radio Frequency Interference (RFI) and Electro-
trim panel. Magnetic Interference (EMI) noise suppression is
The four speaker option adds two 13.3 centimeter accomplished primarily through circuitry internal to
(5.25 inch) diameter full-range speakers to the stan- the radio receivers. These internal suppression
dard speaker system, for a total of four speakers. devices are only serviced as part of the radio receiver.
Each of the additional speakers is mounted behind a External suppression devices that are used on this
grille installed on the outboard ends of a speaker vehicle to control RFI or EMI noise include the fol-
support structure, which is integral to the headliner lowing:
and located just forward of the upper liftgate opening • Radio antenna base ground
reinforcement near the rear of the vehicle cargo area. • Radio receiver chassis ground wire or strap
The premium speaker option upgrades all of the • Engine-to-body ground strap
speakers to Infinity models, and includes a 100 watt • Resistor-type spark plugs
Infinity amplifier. Each front door has two separate • Radio suppression-type secondary ignition wir-
Infinity speakers: a woofer mounted low in the door, ing.
and a tweeter mounted behind the door flag trim For more information on the spark plugs and sec-
panel. Infinity coaxial speakers are mounted in the ondary ignition components, refer to Ignition Sys-
headliner speaker support structure. The Infinity tem in the Description and Operation section of
amplifier is mounted to the floor panel under the left Group 8D - Ignition System.
rear seat cushion.

ANTENNA DIAGNOSIS AND TESTING

All models use a fixed-length stainless steel rod-
type antenna mast, installed at the right front fender AUDIO SYSTEM
of the vehicle. The antenna mast is connected to the
center wire of the coaxial antenna cable, and is not WARNING: ON VEHICLES EQUIPPED WITH AIR-
grounded to any part of the vehicle. BAGS, REFER TO GROUP 8M - PASSIVE
To eliminate static, the antenna base must have a RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
good ground. The coaxial antenna cable shield (the STEERING WHEEL, STEERING COLUMN, OR
outer wire mesh of the cable) is grounded to the INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
antenna base and the radio chassis. SERVICE. FAILURE TO TAKE THE PROPER PRE-
The antenna coaxial cable has an additional dis- CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
connect, located near the right cowl side inner panel BAG DEPLOYMENT AND POSSIBLE PERSONAL
behind the instrument panel. This additional discon- INJURY.

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 XJ AUDIO SYSTEMS 8F - 3
DIAGNOSIS AND TESTING (Continued)

Audio System Diagnosis

CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. Fuse faulty. 1. Check radio fuses in junction block. Replace fuses, if required.
2. Radio connector 2. Check for loose or corroded radio connector. Repair, if
faulty. required.
3. Wiring faulty. 3. Check for battery voltage at radio connector. Repair wiring, if
4. Ground faulty. required.
5. Radio faulty. 4. Check for continuity between radio chassis and a known good
6. Speakers faulty. ground. There should be continuity. Repair ground, if required.
7. Amplifier faulty (if 5. See Radio in the Diagnosis and Testing section of this group.
equipped). 6. See Speaker in the Diagnosis and Testing section of this
group.
7. See Speaker in the Diagnosis and Testing section of this
group.
NO DISPLAY. 1. Fuse faulty. 1. Check radio fuses in junction block. Replace fuses, if required.
2. Radio connector 2. Check for loose or corroded radio connector. Repair, if
faulty. required.
3. Wiring faulty. 3. Check for battery voltage at radio connector. Repair wiring, if
4. Ground faulty. required.
5. Radio faulty. 4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. See Radio in the Diagnosis and Testing section of this group.
CLOCK WILL 1. Fuse faulty. 1. Check ignition-off draw fuse. Replace fuse, if required.
NOT KEEP SET 2. Radio connector 2. Check for loose or corroded radio connector. Repair, if
TIME. faulty. required.
3. Wiring faulty. 3. Check for battery voltage at radio connector. Repair wiring, if
4. Ground faulty. required.
5. Radio faulty. 4. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
5. See Radio in the Diagnosis and Testing section of this group.
POOR RADIO 1. Antenna faulty. 1. See Antenna in the Diagnosis and Testing section of this
RECEPTION. 2. Ground faulty. group.
3. Radio faulty. 2. Check for continuity between radio chassis and a known good
ground. There should be continuity. Repair ground, if required.
3. See Radio in the Diagnosis and Testing section of this group.
NO/POOR TAPE 1. Faulty tape. 1. Insert known good tape and test operation.
OPERATION. 2. Foreign objects 2. Remove foreign objects and test operation.
behind tape door. 3. Clean head with Mopar Cassette Head Cleaner.
3. Dirty cassette tape 4. Exchange or replace radio, if required.
head.
4. Faulty tape deck.
NO COMPACT 1. Faulty CD. 1. Insert known good CD and test operation.
DISC 2. Foreign material on 2. Clean CD and test operation.
OPERATION CD. 3. Allow temperature of vehicle interior to stabilize and test
3. Condensation on CD operation.
or optics. 4. Exchange or replace radio, if required.
4. Faulty CD player.

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 8F - 4 AUDIO SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)

RADIO WARNING: ON VEHICLES EQUIPPED WITH AIR-

For circuit descriptions and diagrams, refer to BAGS, REFER TO GROUP 8M - PASSIVE
8W-47 - Audio System in Group 8W - Wiring Dia- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
grams. STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
WARNING: ON VEHICLES EQUIPPED WITH AIR- SERVICE. FAILURE TO TAKE THE PROPER PRE-
BAGS, REFER TO GROUP 8M - PASSIVE CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY BAG DEPLOYMENT AND POSSIBLE PERSONAL
STEERING WHEEL, STEERING COLUMN, OR INJURY.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTION: The speaker output of the radio is a
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
“floating ground” system. Do not allow any speaker
BAG DEPLOYMENT AND POSSIBLE PERSONAL
lead to short to ground, as damage to the radio
INJURY.
may result.

CAUTION: The speaker output of the radio is a (1) Turn the ignition switch to the On position.
“floating ground” system. Do not allow any speaker Turn the radio on. Adjust the balance and fader con-
lead to short to ground, as damage to the radio trols to check the performance of each individual
may result. speaker. Note the speaker locations that are not per-
forming correctly. Go to Step 2.
(1) Check the fuse(s) in the junction block and the (2) Turn the radio off. Turn the ignition switch to
Power Distribution Center (PDC). If OK, go to Step the Off position. Disconnect and isolate the battery
2. If not OK, repair the shorted circuit or component negative cable. Remove the radio from the instru-
as required and replace the faulty fuse(s). ment panel. If the vehicle is equipped with the Infin-
(2) Check for battery voltage at the fuse in the ity speaker package, also unplug the wire harness
PDC. If OK, go to Step 3. If not OK, repair the open connectors at the amplifier. Check both the speaker
circuit to the battery as required. feed (+) circuit and return (–) circuit cavities for the
(3) Turn the ignition switch to the On position. inoperative speaker location(s) at the radio wire har-
Check for battery voltage at the fuse in the junction ness connectors for continuity to ground. In each
block. If OK, go to Step 4. If not OK, repair the open case, there should be no continuity. If OK, go to Step
circuit to the ignition switch as required. 3. If not OK, repair the shorted speaker circuit(s) as
(4) Turn the ignition switch to the Off position. required.
Disconnect and isolate the battery negative cable. (3) If the vehicle is equipped with the Infinity
Remove the radio, but do not unplug the radio wire speaker package, go to Step 6. If the vehicle is
harness connectors. Check for continuity between the equipped with the standard speaker system, check
radio chassis and a good ground. There should be the resistance between the speaker feed (+) circuit
continuity. If OK, go to Step 5. If not OK, repair the and return (–) circuit cavities of the radio wire har-
open radio chassis ground circuit as required. ness connectors for the inoperative speaker loca-
(5) Connect the battery negative cable. Turn the tion(s). The meter should read between 2 and 12
ignition switch to the On position. Check for battery ohms (speaker resistance). If OK, go to Step 4. If not
voltage at the fused ignition switch output (accesso- OK, go to Step 5.
ry/run) circuit cavity of the left (gray) radio wire har- (4) Install a known good radio. Connect the bat-
ness connector. If OK, go to Step 6. If not OK, repair tery negative cable. Turn the ignition switch to the
the open circuit as required. On position. Turn on the radio and test the speaker
(6) Turn the ignition switch to the Off position. operation. If OK, replace the faulty radio. If not OK,
Check for battery voltage at the fused B(+) circuit turn the radio off, turn the ignition switch to the Off
cavity of the left (gray) radio wire harness connector. position, disconnect and isolate the battery negative
If OK, replace the faulty radio. If not OK, repair the cable, remove the test radio, and go to Step 5.
open circuit to the Ignition-Off Draw (IOD) fuse as (5) Unplug the speaker wire harness connector at
required. the inoperative speaker. Check for continuity
between the speaker feed (+) circuit cavities of the
SPEAKER radio wire harness connector and the speaker wire
For circuit descriptions and diagrams, refer to harness connector. Repeat the check between the
8W-47 - Audio System in Group 8W - Wiring Dia- speaker return (–) circuit cavities of the radio wire
grams. harness connector and the speaker wire harness con-
nector. In each case, there should be continuity. If

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 XJ AUDIO SYSTEMS 8F - 5
DIAGNOSIS AND TESTING (Continued)
OK, replace the faulty speaker. If not OK, repair the the amplified return (–) circuit cavities of the speaker
open circuit(s) as required. wire harness connector and the amplifier wire har-
(6) For each inoperative speaker location, check for ness connector. In each case there should be continu-
continuity between the speaker feed (+) circuit cavi- ity. If OK, replace the faulty speaker. If not OK,
ties of the radio wire harness connectors and the repair the open circuit as required.
amplifier wire harness connectors. Repeat the check
for each inoperative speaker location between the ANTENNA
speaker return (–) circuit cavities of the radio wire
harness connectors and the amplifier wire harness WARNING: ON VEHICLES EQUIPPED WITH AIR-
connectors. In each case, there should be continuity. BAGS, REFER TO GROUP 8M - PASSIVE
If OK, go to Step 7. If not OK, repair the open circuit RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
as required. STEERING WHEEL, STEERING COLUMN, OR
(7) Check for continuity between the two ground INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
circuit cavities of the amplifier wire harness connec- SERVICE. FAILURE TO TAKE THE PROPER PRE-
tor and a good ground. There should be continuity. If CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
OK, go to Step 8. If not OK, repair the open circuit(s) BAG DEPLOYMENT AND POSSIBLE PERSONAL
as required. INJURY.
(8) Check the amplifier fuse in the junction block.
If OK, go to Step 9. If not OK, repair the shorted cir- The following four tests are used to diagnose the
cuit or component as required and replace the faulty antenna with an ohmmeter:
fuse. • Test 1 - Mast to ground test
(9) Install the radio. Connect the battery negative • Test 2 - Tip-of-mast to tip-of-conductor test
cable. Check for battery voltage at the amplifier fuse • Test 3 - Body ground to battery ground test
in the junction block. If OK, go to Step 10. If not OK, • Test 4 - Body ground to coaxial shield test.
repair the open circuit to the PDC as required. The ohmmeter test lead connections for each test
(10) Check for battery voltage at the two fused are shown in Antenna Tests (Fig. 1).
B(+) circuit cavities of the amplifier wire harness
NOTE: This model has a two-piece antenna coaxial
connector. If OK, go to Step 11. If not OK, repair the
cable. Tests 2 and 4 must be conducted in two
open circuit to the fuse in the junction block as
steps to isolate a coaxial cable problem; from the
required.
coaxial cable connection under the right end of the
(11) Turn the ignition switch to the On position.
instrument panel near the right cowl side inner
Turn the radio on. Check for battery voltage at the
panel to the antenna base, and then from the coax-
radio 12 volt output circuit cavity of the amplifier
ial cable connection to the radio chassis connec-
wire harness connector. If OK, go to Step 12. If not
tion.
OK, repair the open circuit to the radio as required.
(12) Turn the radio off. Turn the ignition switch to
the Off position. Disconnect and isolate the battery
negative cable. For each inoperative speaker location,
check both the amplified feed (+) circuit and the
amplified return (–) circuit cavities of the amplifier
wire harness connectors for continuity to ground. In
each case there should be no continuity. If OK, go to
Step 13. If not OK, repair the short circuit as
required.
(13) For each inoperative speaker location, check
the resistance between the amplified feed (+) circuit
and the amplified return (–) circuit cavities of the
amplifier wire harness connectors. The meter should
read between 2 and 12 ohms (speaker resistance). If
OK, replace the faulty amplifier. If not OK, go to
Step 14.
(14) Unplug the speaker wire harness connector at
the inoperative speaker. Check for continuity
between the amplified feed (+) circuit cavities of the
speaker wire harness connector and the amplifier
wire harness connector. Repeat the check between Fig. 1 Antenna Tests

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 8F - 6 AUDIO SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
TEST 1 RADIO FREQUENCY INTERFERENCE
Test 1 determines if the antenna mast is insulated
from the base. Proceed as follows: WARNING: ON VEHICLES EQUIPPED WITH AIR-
(1) Unplug the antenna coaxial cable connector BAGS, REFER TO GROUP 8M - PASSIVE
from the radio chassis and isolate. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
(2) Connect one ohmmeter test lead to the tip of STEERING WHEEL, STEERING COLUMN, OR
the antenna mast. Connect the other test lead to the INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
antenna base. Check for continuity. SERVICE. FAILURE TO TAKE THE PROPER PRE-
(3) There should be no continuity. If continuity is CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
found, replace the faulty or damaged antenna base BAG DEPLOYMENT AND POSSIBLE PERSONAL
and cable assembly. INJURY.

TEST 2 For complete circuit diagrams, see Group 8W -

Test 2 checks the antenna for an open circuit as Wiring Diagrams. Inspect the ground paths and con-
follows: nections at the following locations:
(1) Unplug the antenna coaxial cable connector • Blower motor
from the radio chassis. • Electric fuel pump
(2) Connect one ohmmeter test lead to the tip of • Engine-to-body ground strap
the antenna mast. Connect the other test lead to the • Generator
center pin of the antenna coaxial cable connector. • Ignition module
(3) Continuity should exist (the ohmmeter should • Radio antenna base ground
only register a fraction of an ohm). High or infinite • Radio receiver chassis ground wire or strap
resistance indicates damage to the base and cable • Wiper motor.
assembly. Replace the faulty base and cable, if If the source of RFI or EMI noise is identified as a
required. component on the vehicle (i.e., generator, blower
motor, etc.), the ground path for that component
TEST 3 should be checked. If excessive resistance is found in
Test 3 checks the condition of the vehicle body any ground circuit, clean, tighten, or repair the
ground connection. This test should be performed ground circuits or connections to ground as required
with the battery positive cable removed from the bat- before considering any component replacement.
tery. Disconnect both battery cables, the negative For service and inspection of secondary ignition
cable first. Reconnect the battery negative cable and components, refer to the Diagnosis and Testing sec-
perform the test as follows: tion of Group 8D - Ignition Systems. Inspect the fol-
(1) Connect one ohmmeter test lead to the vehicle lowing secondary ignition system components:
fender. Connect the other test lead to the battery • Distributor cap and rotor
negative post. • Ignition coil
(2) The resistance should be less than one ohm. • Spark plugs
(3) If the resistance is more than one ohm, check • Spark plug wire routing and condition.
the braided ground strap connected to the engine and Reroute the spark plug wires or replace the faulty
the vehicle body for being loose, corroded, or dam- components as required.
aged. Repair the ground strap connection, if required. If the source of the RFI or EMI noise is identified
as two-way mobile radio or telephone equipment,
TEST 4 check the equipment installation for the following:
Test 4 checks the condition of the ground between • Power connections should be made directly to
the antenna base and the vehicle body as follows: the battery, and fused as closely to the battery as
(1) Connect one ohmmeter test lead to the vehicle possible.
fender. Connect the other test lead to the outer crimp • The antenna should be mounted on the roof or
on the antenna coaxial cable connector. toward the rear of the vehicle. Remember that mag-
(2) The resistance should be less then one ohm. netic antenna mounts on the roof panel can adversely
(3) If the resistance is more then one ohm, clean affect the operation of an overhead console compass,
and/or tighten the antenna base to fender mounting if the vehicle is so equipped.
hardware. • The antenna cable should be fully shielded coax-
ial cable, should be as short as is practical, and
should be routed away from the factory-installed
vehicle wire harnesses whenever possible.

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 XJ AUDIO SYSTEMS 8F - 7
DIAGNOSIS AND TESTING (Continued)
• The antenna and cable must be carefully
matched to ensure a low Standing Wave Ratio
(SWR).
Fleet vehicles are available with an extra-cost RFI-
suppressed Powertrain Control Module (PCM). This
unit reduces interference generated by the PCM on
some radio frequencies used in two-way radio com-
munications. However, this unit will not resolve com-
plaints of RFI in the commercial AM or FM radio
frequency ranges.

REMOVAL AND INSTALLATION

RADIO
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- Fig. 2 Center Bezel Remove/Install
BAG DEPLOYMENT AND POSSIBLE PERSONAL 1 – INSTRUMENT PANEL
INJURY. 2 – CENTER BEZEL

(1) Disconnect and isolate the battery negative

cable.
(2) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the instrument panel cen-
ter bezel away from the instrument panel to release
the six snap clip retainers (Fig. 2).
(3) Remove the center bezel from the instrument
panel.
(4) Remove the two screws that secure the radio to
the instrument panel (Fig. 3).
(5) Pull the radio out from the instrument panel
far enough to access the wire harness connectors and
the antenna coaxial cable connector (Fig. 4).
(6) Unplug the wire harness connectors and the
antenna coaxial cable connector from the rear of the
radio.
(7) Remove the radio from the instrument panel.
(8) Reverse the removal procedures to install. Fig. 3 Radio Remove/Install
Tighten the radio mounting screws to 3.9 N·m (35 in. 1 – RADIO
lbs.). 2 – SCREW

AMPLIFIER (4) Unplug the two wire harness connectors from

(1) Disconnect and isolate the battery negative the amplifier (Fig. 5).
cable. (5) Remove the three screws that secure the ampli-
(2) Disengage the rear seat cushion latch by pull- fier to the floor panel.
ing upward on the release strap. Tilt the seat cush- (6) Remove the amplifier from the floor panel.
ion forward. (7) Reverse the removal procedures to install.
(3) Lift the carpeting in the left under-seat area as Tighten the amplifier mounting screws to 2.8 N·m
required to access the amplifier. (25 in. lbs.).

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 8F - 8 AUDIO SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 6 Window Regulator Crank Handle Remove -

Fig. 4 Radio Connections - Typical Typical
1 – ANTENNA CABLE 1 – DOOR HANDLE REMOVAL TOOL
2 – RADIO 2 – WINDOW CRANK
3 – INSTRUMENT PANEL WIRING
4 – GROUND WIRE

Fig. 7 Front Door Trim Panel Remove/Install -

Fig. 5 Amplifier Remove/Install Manual Window
1 – AMPLIFIER 1 – U-NUT
2 – WIRE HARNESS CONNECTORS 2 – DOOR
3 – REAR FLOOR PAN 3 – TRIM PANEL
4 – SCREW 4 – WINDOW CRANK
5 – SPACER
6 – PUSH-IN FASTENER
SPEAKER
(4) Using a trim stick or another suitable wide
FRONT DOOR
flat-bladed tool, gently pry the front door trim panel
LOWER away from the door around the perimeter to release
the trim panel retainers.
(1) Disconnect and isolate the battery negative
cable. NOTE: To aid in the removal of the trim panel, start
(2) If the vehicle is so equipped, remove the man- at the bottom of the panel.
ual window regulator crank handle with a removal
tool (Fig. 6). (5) Lift the front door trim panel upwards and
(3) Remove the screws that secure the front door away from the inner door panel far enough to disen-
trim panel to the inner door panel (Fig. 7) or (Fig. 8).

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 XJ AUDIO SYSTEMS 8F - 9
REMOVAL AND INSTALLATION (Continued)

Fig. 8 Front Door Trim Panel Remove/Install - Power Fig. 9 Front Door Lower Speaker Remove/Install
Window 1 – SPEAKER
1 – U-NUT 2 – WIRE HARNESS CONNECTORS
2 – DOOR 3 – NUT
3 – TRIM PANEL 4 – SCREW
4 – PUSH-IN FASTENER

gage the top of the panel from the inner belt weath-
erstrip.
(6) Pull the front door trim panel away from the
inner door panel far enough to access the inside door
latch release and lock linkage rods near the back of
the inside door remote controls.
(7) Unsnap the plastic retainer clips from the
inside door remote control ends of the latch release
and lock linkage rods, and remove the rod ends from
the inside door remote controls.
(8) If the vehicle is so equipped, unplug the wire
harness connectors from the door power switch mod-
ule and, on the driver side only, the power mirror
switch.
(9) Set the front door trim panel aside.
(10) Remove the two screws that secure the
speaker to the lower front corner of the inner door
panel (Fig. 9).
(11) Pull the speaker away from the inner door Fig. 10 Front Door Flag Trim Panel Remove/Install
panel far enough to access and unplug the speaker 1 – FRONT DOOR
2 – DOOR FLAG TRIM PANEL
wire harness connector.
3 – RETAINER
(12) Remove the speaker from the door.
4 – SCREW
(13) Reverse the removal procedures to install. 5 – UPPER SPEAKER WIRE HARNESS
Tighten the speaker mounting screws to 1.1 N·m (10
in. lbs.). Tighten the trim panel mounting screws to
2.2 N·m (20 in. lbs.). (3) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the door flag trim away
UPPER from the inner door to release the trim panel
(1) Remove the front door trim panel from the retainer.
front door. See Speaker, Front Door, Lower in this (4) Pull the front door flag trim away from the
group for the procedures. inner door panel far enough to access and unplug the
(2) Remove the one screw that secures the front upper speaker wire harness connector.
door flag trim to the inner door panel (Fig. 10). (5) Unsnap the speaker from the retainers molded
into the back side of the front door flag trim panel.

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 8F - 10 AUDIO SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(6) Reverse the removal procedures to install. ANTENNA
Tighten the mounting screw to 2.2 N·m (20 in. lbs.).
WARNING: ON VEHICLES EQUIPPED WITH AIR-
REAR HEADLINER BAGS, REFER TO GROUP 8M - PASSIVE
The rear headliner speakers can be serviced with- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
out removing the headliner using the procedures that STEERING WHEEL, STEERING COLUMN, OR
follow. The headliner speaker support structure is INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
integral to the headliner assembly. Refer to Group 23 SERVICE. FAILURE TO TAKE THE PROPER PRE-
- Body for the headliner service procedures. CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(1) Disconnect and isolate the battery negative BAG DEPLOYMENT AND POSSIBLE PERSONAL
cable. INJURY.
(2) Using a trim stick or another suitable wide
flat-bladed tool, gently pry around the perimeter (1) Disconnect and isolate the battery negative
edge of the rear headliner speaker grille to release cable.
the five snap retainers that secure the grille to the (2) Remove the right front fender inner splash
headliner speaker support structure (Fig. 11). shield. Refer to Group 23 - Body for the procedures.
(3) Reach under the right end of the instrument
panel to unplug the antenna coaxial cable connector
(Fig. 12). Unplug the connector by pulling it apart
while twisting the metal connector halves. Do not
pull on the cable.

Fig. 11 Rear Headliner Speaker Remove/Install

1 – CARGO LAMP
2 – HEADLINER
3 – WIRE HARNESS CONNECTOR
4 – SPEAKER
5 – SCREWS
6 – SPEAKER GRILLE

(3) Remove the speaker grille from the headliner.

(4) Remove the two screws that secure the speaker
to the headliner speaker support structure.
(5) Lower the speaker from the headliner far Fig. 12 Antenna Cable Routing
enough to access and unplug the speaker wire har- 1 – INSTRUMENT PANEL
ness connector. 2 – ANTENNA COAXIAL CABLE
3 – ANTENNA COAXIAL CABLE
(6) Remove the speaker from the headliner.
4 – HEATER-A/C HOUSING KICK COVER
(7) Reverse the removal procedures to install.
5 – INSTRUMENT PANEL
Tighten the mounting screws to 2.2 N·m (20 in. lbs.).

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 XJ AUDIO SYSTEMS 8F - 11
REMOVAL AND INSTALLATION (Continued)
(4) Unscrew the antenna mast from the antenna
body (Fig. 13).

Fig. 13 Antenna Mast Remove/Install - Typical

1 – ANTENNA MAST
2 – ADAPTER
3 – CAP NUT

(5) Remove the antenna cap nut and adapter using

an antenna nut wrench (Special Tool C-4816) (Fig.
14).

Fig. 15 Antenna Mounting

1 – NUT
2 – MAST
3 – RIGHT FRONT FENDER
4 – ANTENNA BODY AND CABLE
5 – GROMMET
6 – ADAPTER

(9) Remove the antenna body and cable from the

vehicle.
(10) Reverse the removal procedures to install.
Tighten the antenna cap nut to 6.2 N·m (55 in. lbs.).
Tighten the antenna mast to 3.3 N·m (30 in. lbs.).

RADIO NOISE SUPPRESSION COMPONENTS

WARNING: ON VEHICLES EQUIPPED WITH AIR-
Fig. 14 Antenna Cap Nut and Adapter Remove/ BAGS, REFER TO GROUP 8M - PASSIVE
Install - Typical RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
1 – CAP NUT STEERING WHEEL, STEERING COLUMN, OR
2 – ANTENNA ADAPTER INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
3 – TOOL
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(6) Lower the antenna body and cable assembly BAG DEPLOYMENT AND POSSIBLE PERSONAL
through the top of the fender far enough to access INJURY.
the antenna body by reaching up into the rear of the
right front fender wheel housing (Fig. 15).
(7) Disengage the coaxial cable grommet from the REMOVAL
hole in the right cowl side outer panel.
(8) Pull the coaxial cable out through the right ENGINE-TO-BODY GROUND STRAP
cowl side outer panel. (1) Remove the screw that secures the engine-to-
body ground strap eyelet to the dash panel (Fig. 16).

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 8F - 12 AUDIO SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(4) Remove the engine-to-body ground strap from
the engine compartment.

INSTALLATION
ENGINE-TO-BODY GROUND STRAP
(1) Position the engine-to-body ground strap in the
engine compartment.
(2) Position the engine-to-body ground strap eyelet
over the stud on the left upper rear corner of the
engine cylinder head.
(3) Install and tighten the nut that secures the
engine-to-body ground strap eyelet to the stud on the
left upper rear corner of the engine cylinder head.
Tighten the nut to 27 N·m (20 ft. lbs.).
(4) Install and tighten the screw that secures the
engine-to-body ground strap eyelet to the dash panel.
Tighten the screw to 27 N·m (20 ft. lbs.).

Fig. 16 Engine-To-Body Ground Strap Remove/

Install SPECIAL TOOLS
1 – SCREW
2 – DASH PANEL AUDIO SYSTEMS
3 – ENGINE CYLINDER HEAD
4 – STUD
5 – NUT
6 – GROUND STRAP

(2) Remove the nut that secures the engine-to-body

ground strap eyelet to the stud on the left upper rear
corner of the engine cylinder head.
(3) Remove the engine-to-body ground strap eyelet Antenna Nut Wrench C-4816
from the stud on the left upper rear corner of the
engine cylinder head.

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 XJ HORN SYSTEMS 8G - 1

HORN SYSTEMS
TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

HORN SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DESCRIPTION AND OPERATION Refer to the owner’s manual in the vehicle glove
box for more information on the features, use and
HORN SYSTEM operation of the horn system.

REMOTE KEYLESS ENTRY RECEIVER

DESCRIPTION
A dual-note electric horn system is standard facto- The Remote Keyless Entry (RKE) receiver can also
ry-installed equipment on this model. The standard operate the horn system. An RKE receiver is used on
equipment horn system features one low-note horn this vehicle when it is equipped with the optional
unit and one high-note horn unit. The horn system RKE system. The RKE receiver controls and inte-
uses a non-switched source of battery current so that grates the additional electronic functions and fea-
the system will remain functional, regardless of the tures included on models with this option. A
ignition switch position. The horn system includes customer programmable feature of the RKE system
the following components: enables the RKE receiver to momentarily energize
• Clockspring the horn relay through a hard wired circuit as an
• Horns audible verification that the receiver has received a
• Horn relay valid lock request from the RKE transmitter.
• Horn switch Refer to Remote Keyless Entry System in the
• Remote Keyless Entry (RKE) receiver (only with Description and Operation section of Group 8P -
the RKE system) Power Lock Systems for more information on this
Refer to Clockspring in the Description and Oper- feature.
ation section of Group 8M - Passive Restraint Sys-
tems for more information on this component. Refer HORN
to Remote Keyless Entry System in the Descrip-
tion and Operation section of Group 8P - Power Lock DESCRIPTION
Systems for more information on this component. The dual electromagnetic diaphragm-type horns
Refer to Horn/Cigar Lighter in the Contents of are standard equipment on this model. The low-note
Group 8W - Wiring Diagrams for complete circuit horn is secured with a bracket to the left radiator
diagrams. Following are general descriptions of the closure panel brace, behind the front bumper. The
remaining major components in the horn system. high-note horn is secured with a bracket to the right
radiator closure panel brace, behind the front
OPERATION bumper. Both horns are grounded through their
The horn system is activated by a horn switch con- mounting brackets and receives battery feed through
cealed beneath the driver side airbag module trim its wire harness connector and circuit from the closed
cover in the center of the steering wheel. Depressing contacts of the horn relay.
the center of the driver side airbag module trim cover The horns cannot be repaired or adjusted and, if
closes the horn switch. Closing the horn switch acti- faulty or damaged, they must be individually
vates the horn relay. The activated horn relay then replaced.
switches the battery current needed to energize the
horns.

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 8G - 2 HORN SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
OPERATION When the electromagnetic coil is de-energized,
Within the two halves of the molded plastic horn spring pressure returns the movable contact to the
housing are a flexible diaphragm, a plunger, an elec- normally closed position. The resistor or diode is con-
tromagnetic coil and a set of contact points. The dia- nected in parallel with the electromagnetic coil in the
phragm is secured in suspension around its relay, and helps to dissipate voltage spikes that are
perimeter by the mating surfaces of the horn hous- produced when the coil is de-energized.
ing. The plunger is secured to the center of the dia-
phragm and extends into the center of the HORN SWITCH
electromagnet. The contact points control the current
flow through the electromagnet. DESCRIPTION
When the horn is energized, electrical current A center-blow, normally open, resistive membrane-
flows through the closed contact points to the electro- type horn switch is secured with heat stakes to the
magnet. The resulting electromagnetic field draws back side of the driver side airbag module trim cover
the plunger and diaphragm toward it until that in the center of the steering wheel (Fig. 1). The
movement mechanically opens the contact points. switch consists of two plastic membranes, one that is
When the contact points open, the electromagnetic flat and one that is slightly convex. These two mem-
field collapses allowing the plunger and diaphragm to branes are secured to each other around the perime-
return to their relaxed positions and closing the con- ter. Inside the switch, the centers of the facing
tact points again. This cycle continues repeating at a surfaces of these membranes each has a grid made
very rapid rate producing the vibration and move- with an electrically conductive material applied to it.
ment of air that creates the sound that is directed One of the grids is connected to a circuit that pro-
through the horn outlet. vides it with continuity to ground at all times. The
grid of the other membrane is connected to the horn
HORN RELAY relay control circuit.

DESCRIPTION
The horn relay is a electromechanical device that
switches battery current to the horn when the horn
switch grounds the relay coil. The horn relay is
located in the junction block on the right cowl side
inner panel below the instrument panel in the pas-
senger compartment. If a problem is encountered
with a continuously sounding horn, it can usually be
quickly resolved by removing the horn relay from the
junction block until further diagnosis is completed.
Refer to Junction Block in the Contents of Group
8W - Wiring Diagrams for horn relay identification
and location.
The horn relay is a International Standards Orga-
nization (ISO) relay. Relays conforming to the ISO
specifications have common physical dimensions, cur-
rent capacities, terminal patterns, and terminal func- Fig. 1 Driver Side Airbag Module Trim Cover and
tions. Horn Switch
The horn relay cannot be repaired or adjusted and, 1 – RETAINER SLOTS
if faulty or damaged, it must be replaced. 2 – TRIM COVER
3 – LOCKING BLOCKS
OPERATION 4 – RETAINER SLOTS
The ISO relay consists of an electromagnetic coil, a 5 – HORN SWITCH
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed) The steering wheel and steering column must be
relay contact is held against one of the fixed contacts properly grounded in order for the horn switch to
(normally closed) by spring pressure. When the elec- function properly. The horn switch is only serviced as
tromagnetic coil is energized, it draws the movable a part of the driver side airbag module trim cover. If
contact away from the normally closed fixed contact, the horn switch is damaged or faulty, or if the driver
and holds it against the other (normally open) fixed side airbag is deployed, the driver side airbag module
contact.

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 XJ HORN SYSTEMS 8G - 3
DESCRIPTION AND OPERATION (Continued)
trim cover and horn switch must be replaced as a
unit.

OPERATION
When the center area of the driver side airbag trim
cover is depressed, the electrically conductive grids
on the facing surfaces of the horn switch membranes
contact each other, closing the switch circuit. The
completed horn switch circuit provides a ground for
the control coil side of the horn relay, which activates
the relay. When the horn switch is released, the
TERMINAL LEGEND
resistive tension of the convex membrane separates
the two electrically conductive grids and opens the NUMBER IDENTIFICATION
switch circuit. 30 COMMON FEED
85 COIL GROUND

DIAGNOSIS AND TESTING 86 COIL BATTERY

87 NORMALLY OPEN
HORN RELAY 87A NORMALLY CLOSED
The horn relay (Fig. 2) is located in the junction
block on the right cowl side inner panel below the Fig. 2 Horn Relay
instrument panel in the passenger compartment. If a RELAY CIRCUIT TEST
problem is encountered with a continuously sounding
(1) The relay common feed terminal cavity (30) is
horn, it can usually be quickly resolved by removing
connected to battery voltage and should be hot at all
the horn relay from the junction block until further
times. If OK, go to Step 2. If not OK, repair the open
diagnosis is completed. Refer to Junction Block in
circuit to the fuse in the junction block as required.
the Contents of Group 8W - Wiring Diagrams for
(2) The relay normally closed terminal (87A) is
horn relay identification and location. For complete
connected to terminal 30 in the de-energized position,
circuit diagrams, refer to Horn/Cigar Lighter in the
but is not used for this application. Go to Step 3.
Contents of Group 8W - Wiring Diagrams.
(3) The relay normally open terminal (87) is con-
WARNING: ON VEHICLES EQUIPPED WITH AIR- nected to the common feed terminal (30) in the ener-
BAGS, REFER TO GROUP 8M - PASSIVE gized position. This terminal supplies battery voltage
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY to the horn(s). There should be continuity between
STEERING WHEEL, STEERING COLUMN, OR the cavity for relay terminal 87 and the horn relay
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR output circuit cavity of each horn wire harness con-
SERVICE. FAILURE TO TAKE THE PROPER PRE- nector at all times. If OK, go to Step 4. If not OK,
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- repair the open circuit to the horn(s) as required.
BAG DEPLOYMENT AND POSSIBLE PERSONAL (4) The coil battery terminal (86) is connected to
INJURY. the electromagnet in the relay. It is connected to bat-
tery voltage and should be hot at all times. Check for
(1) Remove the horn relay from the junction block. battery voltage at the cavity for relay terminal 86. If
Refer to Horn Relay in the Removal and Installa- OK, go to Step 5. If not OK, repair the open circuit to
tion section of this group for the procedures. the fuse in the junction block as required.
(2) A relay in the de-energized position should (5) The coil ground terminal (85) is connected to
have continuity between terminals 87A and 30, and the electromagnet in the relay. It is grounded
no continuity between terminals 87 and 30. If OK, go through the horn switch when the horn switch is
to Step 3. If not OK, replace the faulty relay. depressed. On vehicles equipped with the Remote
(3) Resistance between terminals 85 and 86 (elec- Keyless Entry (RKE) system, the horn relay coil
tromagnet) should be 75 6 5 ohms. If OK, go to Step ground terminal can also be grounded by the RKE
4. If not OK, replace the faulty relay. receiver in response to certain inputs related to the
(4) Connect a battery to terminals 85 and 86. RKE system. Check for continuity to ground at the
There should now be continuity between terminals cavity for relay terminal 85. There should be conti-
30 and 87, and no continuity between terminals 87A nuity with the horn switch depressed, and no conti-
and 30. If OK, perform the Relay Circuit Test that nuity with the horn switch released. If not OK, refer
follows. If not OK, replace the faulty relay. to Horn Switch in the Diagnosis and Testing section
of this group.

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 8G - 4 HORN SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)

HORN SWITCH HORN

For complete circuit diagrams, refer to Horn/Ci- For complete circuit diagrams, refer to Horn/Ci-
gar Lighter in the Contents of Group 8W - Wiring gar Lighter in the Contents of Group 8W - Wiring
Diagrams. Diagrams.
(1) Measure the resistance between the horn(s)
WARNING: ON VEHICLES EQUIPPED WITH AIR- mounting bracket(s) and a good ground. There should
BAGS, REFER TO GROUP 8M - PASSIVE be no measurable resistance. If OK, go to Step 2. If
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY not OK, clean and tighten the horn mounting hard-
STEERING WHEEL, STEERING COLUMN, OR ware as required.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (2) Disconnect the wire harness connector(s) from
SERVICE. FAILURE TO TAKE THE PROPER PRE- the horn connector receptacle(s). Check for battery
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- voltage at the horn relay output circuit cavity of the
BAG DEPLOYMENT AND POSSIBLE PERSONAL horn(s) wire harness connector(s). There should be
INJURY. zero volts. If OK, go to Step 3. If not OK, repair the
shorted horn relay output circuit or replace the
(1) Disconnect and isolate the battery negative faulty horn relay as required.
cable. Remove the knee blocker from the instrument (3) Depress the horn switch. There should now be
panel. battery voltage at the horn relay output circuit cavity
(2) Check for continuity between the metal steer- of the horn(s) wire harness connector(s). If OK,
ing column jacket and a good ground. There should replace the faulty horn(s). If not OK, repair the open
be continuity. If OK, go to Step 3. If not OK, refer to horn relay output circuit to the horn relay as
Steering Column in the Removal and Installation required.
section of Group 19 - Steering for proper installation
of the steering column.
(3) Remove the driver side airbag module from the REMOVAL AND INSTALLATION
steering wheel. Disconnect the horn switch wire har-
ness connectors from the driver side airbag module. HORN RELAY
(4) Remove the horn relay from the junction block.
Check for continuity between the steering column REMOVAL
half of the horn switch feed wire harness connector (1) Disconnect and isolate the battery negative
and a good ground. There should be no continuity. If cable.
OK, go to Step 5. If not OK, repair the shorted horn (2) Remove the fuse access panel by unsnapping it
relay control circuit to the horn relay in the junction from the right cowl side inner trim panel (Fig. 3).
block as required. (3) Remove the push nut that secures the right
(5) Check for continuity between the steering col- cowl side inner trim panel to the junction block stud.
umn half of the horn switch feed wire harness con- (4) Remove the screw located above the fuse access
nector and the horn relay control circuit cavity for opening that secures the trim panel to the right cowl
the horn relay in the junction block. There should be side inner panel.
continuity. If OK, go to Step 6. If not OK, repair the (5) Remove the screw that secures the right cowl
open horn relay control circuit to the horn relay in side inner trim panel and right front door sill trim to
the junction block as required. the door opening sill.
(6) Check for continuity between the horn switch (6) Remove the trim from the right cowl side inner
feed wire and the horn switch ground wire on the panel.
driver side airbag module. There should be no conti- (7) Refer to Junction Block in the Contents of
nuity. If OK, go to Step 7. If not OK, replace the Group 8W - Wiring Diagrams for horn relay identifi-
faulty horn switch. cation and location.
(7) Depress the center of the driver side airbag (8) Remove the horn relay from the junction block.
module trim cover and check for continuity between
the horn switch feed wire and the horn switch INSTALLATION
ground wire on the driver side airbag module. There (1) Refer to Junction Block in the Contents of
should now be continuity. If not OK, replace the Group 8W - Wiring Diagrams for proper horn relay
faulty horn switch. location.
(2) Position the horn relay in the proper receptacle
in the junction block.
(3) Align the horn relay terminals with the termi-
nal cavities in the junction block receptacle.

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 XJ HORN SYSTEMS 8G - 5
REMOVAL AND INSTALLATION (Continued)

HORN
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Raise and support the vehicle.
(3) Remove the front underbody splash shield.

NOTE: Remove the horn and its mounting bracket

from the vehicle as a unit. Do not remove the horn
from its mounting bracket.

(4) Remove the screw that secures the horn and

mounting bracket unit to the radiator closure panel
brace (Fig. 4).

Fig. 3 Right Cowl Side Inner Trim Remove/Install

1 – RIGHT FRONT DOOR SILL
2 – COWL SIDE TRIM PANEL
3 – SCREW
4 – SILL TRIM
5 – FUSE ACCESS PANEL
6 – PUSH-NUT

(4) Push down firmly on the horn relay until the

terminals are fully seated in the terminal cavities in
the junction block receptacle.
(5) Position the trim onto the right cowl side inner
panel.
(6) Install and tighten the screw that secures the
right cowl side inner trim panel and right front door
sill trim to the door opening sill. Tighten the screw to
2.2 N·m (20 in. lbs.).
Fig. 4 Horns Remove/Install
1 – MOUNTING BOLT
(7) Install and tighten the screw located above the
2 – HORN
fuse access opening that secures the trim panel to
the right cowl side inner panel. Tighten the screw to
2.2 N·m (20 in. lbs.). (5) Lower the horn and mounting bracket unit far
(8) Install the push nut that secures the right cowl enough to access and disconnect the wire harness
side inner trim panel onto the junction block stud. connector from the horn connector receptacle.
(9) Install the fuse access panel by snapping it (6) Remove the horn and mounting bracket unit
onto the right cowl side inner trim panel. from behind the front bumper.
(10) Reconnect the battery negative cable.

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 8G - 6 HORN SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION sure panel brace. Tighten the screw to 28.5 N·m (21
(1) Position the horn and mounting bracket unit ft. lbs.).
behind the front bumper. (5) Install the front underbody splash shield.
(2) Reconnect the wire harness connector to the (6) Lower the vehicle.
horn connector receptacle. (7) Reconnect the battery negative cable.
(3) Position the horn and mounting bracket unit to
the radiator closure panel brace.
(4) Install and tighten the screw that secures the
horn and mounting bracket unit to the radiator clo-

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 XJ SPEED CONTROL SYSTEM 8H - 1

SPEED CONTROL SYSTEM

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING

SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . 1 ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPEED CONTROL SERVO. . . . . . . . . . . . . . . . . . . 2 VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . . . . . 4
SPEED CONTROL SOLENOID CIRCUITS . . . . . . . 2 REMOVAL AND INSTALLATION
SPEED CONTROL SWITCHES . . . . . . . . . . . . . . . 2 SPEED CONTROL SERVO. . . . . . . . . . . . . . . . . . . 5
BRAKE LAMP SWITCH. . . . . . . . . . . . . . . . . . . . . 3 SPEED CONTROL SWITCH. . . . . . . . . . . . . . . . . . 5
SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . . 3 VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . . 6
VEHICLE SPEED SENSOR (SPEED CONTROL SPECIFICATIONS
OPERATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DESCRIPTION AND OPERATION • Depressing the clutch pedal (if equipped).

NOTE: Depressing the OFF switch or turning off

SPEED CONTROL SYSTEM
the ignition switch will erase the set speed stored
in the PCM.
DESCRIPTION
The speed control system is electronically con- For added safety, the speed control system is pro-
trolled and vacuum operated. Electronic control of grammed to disengage for any of the following condi-
the speed control system is integrated into the Pow- tions:
ertrain Control Module (PCM). The controls consist • An indication of Park or Neutral
of two steering wheel mounted switches. The • A rapid increase rpm (indicates that the clutch
switches are labeled: ON/OFF, RES/ACCEL, SET, has been disengaged)
COAST, and CANCEL. • Excessive engine rpm (indicates that the trans-
The system is designed to operate at speeds above mission may be in a low gear)
30 mph (50 km/h). • The speed signal increases at a rate of 10 mph
per second (indicates that the coefficient of friction
WARNING: THE USE OF SPEED CONTROL IS NOT
between the road surface and tires is extremely low)
RECOMMENDED WHEN DRIVING CONDITIONS DO
• The speed signal decreases at a rate of 10 mph
NOT PERMIT MAINTAINING A CONSTANT SPEED,
per second (indicates that the vehicle may have
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
decelerated at an extremely high rate)
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
Once the speed control has been disengaged,
PERY.
depressing the RES/ACCEL switch (when speed is
greater than 30 mph) restores the vehicle to the tar-
OPERATION get speed that was stored in the PCM.
When speed control is selected by depressing the While the speed control is engaged, the driver can
ON switch, the PCM allows a set speed to be stored increase the vehicle speed by depressing the RES/AC-
in PCM RAM for speed control. To store a set speed, CEL switch. The new target speed is stored in the
depress the SET switch while the vehicle is moving PCM when the RES/ACCEL is released. The PCM
at a speed between 35 and 85 mph. In order for the also has a “tap-up9 feature in which vehicle speed
speed control to engage, the brakes cannot be increases at a rate of approximately 2 mph for each
applied, nor can the gear selector be indicating the momentary switch activation of the RES/ACCEL
transmission is in Park or Neutral. switch.
The speed control can be disengaged manually by:
• Stepping on the brake pedal
• Depressing the OFF switch
• Depressing the CANCEL switch.

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 8H - 2 SPEED CONTROL SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
A “tap down” feature is used to decelerate without SPEED CONTROL SOLENOID CIRCUITS
disengaging the speed control system. To decelerate
from an existing recorded target speed, momentarily OPERATION
depress the COAST switch. For each switch activa- When all of the speed control parameters are met,
tion, speed will be lowered approximately 1 mph. and the SET button is pressed, the PCM actuates the
vent solenoid and “duty-cycles” the vacuum solenoid
SPEED CONTROL SERVO to open the throttle and bring the vehicle up to tar-
get speed. When the vehicle is at target speed, it will
DESCRIPTION actuate the vent solenoid with the vacuum solenoid
The servo unit consists of a solenoid valve body, de-activated to maintain the vehicle at target speed.
and a vacuum chamber. The solenoid valve body con- When the vehicle is above target speed, the PCM will
tains three solenoids: “duty-cycle” the vent solenoid with the vacuum sole-
• Vacuum noid still de-activated to close the throttle to return
• Vent to target speed.
• Dump
The vacuum chamber contains a diaphragm with a SPEED CONTROL SWITCHES
cable attached to control the throttle linkage.
DESCRIPTION
OPERATION There are two separate switch pods that operate
The Powertrain Control Module (PCM) controls the the speed control system. The steering-wheel-
solenoid valve body. The solenoid valve body controls mounted switches use multiplexed circuits to provide
the application and release of vacuum to the dia- inputs to the PCM for ON, OFF, RESUME, ACCEL-
phragm of the vacuum servo. The servo unit cannot ERATE, SET, DECEL and CANCEL modes. Refer to
be repaired and is serviced only as a complete assem- the owner’s manual for more information on speed
bly. control switch functions and setting procedures.
Power is supplied to the servo’s by the PCM The individual switches cannot be repaired. If one
through the brake switch. The PCM controls the switch fails, the entire switch module must be
ground path for the vacuum and vent solenoids. replaced.
The dump solenoid is energized anytime it receives
power. If power to the dump solenoid is interrupted, OPERATION
the solenoid dumps vacuum in the servo. This pro- When speed control is selected by depressing the
vides a safety backup to the vent and vacuum sole- ON, OFF switch, the PCM allows a set speed to be
noids. stored in its RAM for speed control. To store a set
The vacuum and vent solenoids must be grounded speed, depress the SET switch while the vehicle is
at the PCM to operate. When the PCM grounds the moving at a speed between approximately 35 and 85
vacuum servo solenoid, the solenoid allows vacuum mph. In order for the speed control to engage, the
to enter the servo and pull open the throttle plate brakes cannot be applied, nor can the gear selector
using the cable. When the PCM breaks the ground, be indicating the transmission is in Park or Neutral.
the solenoid closes and no more vacuum is allowed to The speed control can be disengaged manually by:
enter the servo. The PCM also operates the vent sole- • Stepping on the brake pedal
noid via ground. The vent solenoid opens and closes a • Depressing the OFF switch
passage to bleed or hold vacuum in the servo as • Depressing the CANCEL switch.
required. The speed control can be disengaged also by any of
The PCM duty cycles the vacuum and vent sole- the following conditions:
noids to maintain the set speed, or to accelerate and • An indication of Park or Neutral
decelerate the vehicle. To increase throttle opening, • The VSS signal increases at a rate of 10 mph
the PCM grounds the vacuum and vent solenoids. To per second (indicates that the co-efficient of friction
decrease throttle opening, the PCM removes the between the road surface and tires is extremely low)
grounds from the vacuum and vent solenoids. When • Depressing the clutch pedal.
the brake is released, if vehicle speed exceeds 30 • Excessive engine rpm (indicates that the trans-
mph to resume, 35 mph to set, and the RES/ACCEL mission may be in a low gear)
switch has been depressed, ground for the vent and • The VSS signal decreases at a rate of 10 mph
vacuum circuits is restored. per second (indicates that the vehicle may have
decelerated at an extremely high rate)
• If the actual speed is not within 20 mph of the
set speed

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 XJ SPEED CONTROL SYSTEM 8H - 3
DESCRIPTION AND OPERATION (Continued)
The previous disengagement conditions are pro- Refer to the Brake section for more information on
grammed for added safety. brake lamp switch service and adjustment proce-
Once the speed control has been disengaged, dures.
depressing the ACCEL switch restores the vehicle to The brake switch is equipped with three sets of
the target speed that was stored in the PCM’s RAM. contacts, one normally open and the other two nor-
mally closed (brakes disengaged). The PCM sends a
NOTE: Depressing the OFF switch will erase the 12 volt signal to one of the normally closed contacts
set speed stored in the PCM’s RAM. in the brake switch, which is returned to the PCM as
a brake switch state signal. With the contacts closed,
If, while the speed control is engaged, the driver the 12 volt signal is pulled to ground causing the sig-
wishes to increase vehicle speed, the PCM is pro- nal to go low. The low voltage signal, monitored by
grammed for an acceleration feature. With the the PCM, indicates that the brakes are not applied.
ACCEL switch held closed, the vehicle accelerates When the brakes are applied, the contacts open,
slowly to the desired speed. The new target speed is causing the PCM’s output brake signal to go high,
stored in the PCM’s RAM when the ACCEL switch is disengaging the speed control, cutting off PCM power
released. The PCM also has a “tap-up” feature in to the speed control solenoids.
which vehicle speed increases at a rate of approxi- The second set of normally closed contacts supplies
mately 2 mph for each momentary switch activation 12 volts from the PCM any time speed control is
of the ACCEL switch. turned on. Through the brake switch, current is
The PCM also provides a means to decelerate with- routed to the speed control servo solenoids. The
out disengaging speed control. To decelerate from an speed control solenoids (vacuum, vent and dump) are
existing recorded target speed, depress and hold the provided this current any time the speed control is
COAST switch until the desired speed is reached. ON and the brakes are disengaged.
Then release the switch. The ON, OFF switch oper- When the driver applies the brakes, the contacts
ates two components: the PCM’s ON, OFF input, and open and current is interrupted to the solenoids. The
the battery voltage to the brake switch, which powers normally open contacts are fed battery voltage. When
the speed control servo. the brakes are applied, battery voltage is supplied to
the brake lamps.
Multiplexing
The PCM sends out 5 volts through a fixed resistor SERVO CABLE
and monitors the voltage change between the fixed
resistor and the switches. If none of the switches are DESCRIPTION
depressed, the PCM will measure 5 volts at the sen-
The speed control servo cable is connected between
sor point (open circuit). If a switch with no resistor is
the speed control vacuum servo diaphragm and the
closed, the PCM will measure 0 volts (grounded cir-
throttle body control linkage.
cuit). Now, if a resistor is added to a switch, then the
PCM will measure some voltage proportional to the OPERATION
size of the resistor. By adding a different resistor to
This cable causes the throttle control linkage to
each switch, the PCM will see a different voltage
open or close the throttle valve in response to move-
depending on which switch is pushed.
ment of the vacuum servo diaphragm.
Another resistor has been added to the ’at rest cir-
cuit’ causing the PCM to never see 5 volts. This was
done for diagnostic purposes. If the switch circuit
VACUUM RESERVOIR
should open (bad connection), then the PCM will see
DESCRIPTION
the 5 volts and know the circuit is bad. The PCM will
The vacuum reservoir is a plastic storage tank con-
then set an open circuit fault.
nected to an engine vacuum source by vacuum lines.
BRAKE LAMP SWITCH OPERATION
The vacuum reservoir is used to supply the vac-
DESCRIPTION
uum needed to maintain proper speed control opera-
The switch is mounted on the brake pedal mount-
tion when engine vacuum drops, such as in climbing
ing bracket under the instrument panel.
a grade while driving. A one-way check valve is used
in the vacuum line between the reservoir and the
OPERATION
vacuum source. This check valve is used to trap
Vehicles equipped with the speed control option use
engine vacuum in the reservoir. On certain vehicle
a dual function brake lamp switch. The PCM moni-
applications, this reservoir is shared with the heat-
tors the state of the dual function brake lamp switch.

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 8H - 4 SPEED CONTROL SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
ing/air-conditioning system. The vacuum reservoir • Smooth operation of throttle linkage and throttle
cannot be repaired and must be replaced if faulty. body air valve.
• Failed speed control servo. Do the servo vacuum
VEHICLE SPEED SENSOR (SPEED CONTROL test.
OPERATION)
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
DESCRIPTION
not to damage connector, terminals or seals. If
The Vehicle Speed Sensor (VSS) is mounted to an
these components are damaged, intermittent or
adapter near the transmission output shaft. The sen-
complete system failure may occur.
sor is driven through the adapter by a speedometer
pinion gear.
VACUUM SUPPLY TEST
OPERATION (1) Disconnect vacuum hose at speed control servo
The VSS is a pulse generator. The VSS pulse sig- and install a vacuum gauge into the disconnected
nal to the speedometer/odometer is monitored by the hose.
PCM speed control circuitry to determine vehicle (2) Start engine and observe gauge at idle. Vac-
speed and to maintain speed control set speed. uum gauge should read at least ten inches of mer-
cury.
DIAGNOSIS AND TESTING (3) If vacuum is less than ten inches of mercury,
determine source of leak. Check vacuum line to
ROAD TEST engine for leaks. Also check actual engine intake
Perform a vehicle road test to verify reports of manifold vacuum. If manifold vacuum does not meet
speed control system malfunction. The road test this requirement, check for poor engine performance
should include attention to the speedometer. Speed- and repair as necessary.
ometer operation should be smooth and without flut- (4) If vacuum line to engine is not leaking, check
ter at all speeds. for leak at vacuum reservoir. To locate and gain
Flutter in the speedometer indicates a problem access to reservoir, refer to Vacuum Reservoir Remov-
which might cause surging in the speed control sys- al/Installation in this group. Disconnect vacuum line
tem. The cause of any speedometer problems should at reservoir and connect a hand-operated vacuum
be corrected before proceeding. Refer to Group 8E, pump to reservoir fitting. Apply vacuum. Reservoir
Instrument Panel and Gauges for speedometer diag- vacuum should not bleed off. If vacuum is being lost,
nosis. replace reservoir.
If a road test verifies a system problem and the (5) Verify operation of one-way check valve and
speedometer operates properly, check for: check it for leaks.
• A Diagnostic Trouble Code (DTC). If a DTC (a) Locate one-way check valve. The valve is
exists, conduct tests per the Powertrain Diagnostic located in vacuum line between vacuum reservoir
Procedures service manual. and engine vacuum source. Disconnect vacuum
• A misadjusted brake (stop) lamp switch. This hoses (lines) at each end of valve.
could also cause an intermittent problem. (b) Connect a hand-operated vacuum pump to
• Loose, damaged or corroded electrical connec- reservoir end of check valve. Apply vacuum. Vac-
tions at the servo. Corrosion should be removed from uum should not bleed off. If vacuum is being lost,
electrical terminals and a light coating of Mopar replace one-way check valve.
MultiPurpose Grease, or equivalent, applied. (c) Connect a hand-operated vacuum pump to
• Leaking vacuum reservoir. vacuum source end of check valve. Apply vacuum.
• Loose or leaking vacuum hoses or connections. Vacuum should flow through valve. If vacuum is
• Defective one-way vacuum check valve. not flowing, replace one-way check valve. Seal the
• Secure attachment of both ends of the speed con- fitting at opposite end of valve with a finger and
trol servo cable. apply vacuum. If vacuum will not hold, diaphragm
within check valve has ruptured. Replace valve.

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 XJ SPEED CONTROL SYSTEM 8H - 5

REMOVAL AND INSTALLATION

SPEED CONTROL SERVO
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Disconnect vacuum line at servo (Fig. 1).
(3) Disconnect electrical connector at servo.
(4) Disconnect servo cable at throttle body. Refer to
Servo Cable Removal/Installation.
(5) Remove 2 mounting nuts holding servo cable
sleeve to bracket (Fig. 2).
(6) Pull speed control cable sleeve and servo away
from servo mounting bracket to expose cable retain-
ing clip (Fig. 2) and remove clip. Note: The servo
mounting bracket displayed in (Fig. 2) is a typical
bracket and may/may not be applicable to this model Fig. 2 Servo Cable Clip Remove/Install—Typical
vehicle. 1 – SERVO MOUNTING NUTS (2)
2 – SERVO
3 – CABLE RETAINING CLIP
4 – SERVO CABLE AND SLEEVE

INSTALLATION
(1) Position servo to mounting bracket.
(2) Align hole in cable connector with hole in servo
pin. Install cable-to-servo retaining clip.
(3) Insert servo mounting studs through holes in
servo mounting bracket.
(4) Install servo mounting nuts and tighten to 8.5
N·m (75 in. lbs.).
(5) Connect vacuum line at servo.
(6) Connect electrical connector at servo.
(7) Connect servo cable to throttle body. Refer to
Servo Cable Removal/Installation.
(8) Connect negative battery cable to battery.
(9) Before starting engine, operate accelerator
Fig. 1 Speed Control Servo Location pedal to check for any binding.
1 – R. F. FENDER
2 – SPEED CONTROL SERVO SPEED CONTROL SWITCH
3 – ELECTRICAL CONNECTOR
4 – MOUNTING BRACKET WARNING: BEFORE ATTEMPTING TO DIAGNOSE,
5 – VACUUM LINE REMOVE OR INSTALL ANY AIRBAG SYSTEM OR
RELATED STEERING WHEEL AND STEERING COL-
UMN COMPONENTS YOU MUST FIRST DISCON-
(7) Remove servo from mounting bracket. While
NECT AND ISOLATE THE BATTERY NEGATIVE
removing, note orientation of servo to bracket.
(GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM
CAPACITOR TO DISCHARGE BEFORE FURTHER
SYSTEM SERVICE. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.

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 8H - 6 SPEED CONTROL SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL (5) Disconnect servo cable at servo. Refer to Speed
(1) Disconnect and isolate negative battery cable Control Servo Removal/Installation.
from battery.
(2) Remove airbag module. Refer to Group 8M,
Passive Restraint Systems.
(3) From underside of steering wheel, remove
speed control switch mounting screw (Fig. 3).

Fig. 4 Speed Control Servo Cable at Throttle Body

1 – ACCELERATOR CABLE
Fig. 3 Speed Control Switch Remove/Install
2 – OFF
1 – MOUNTING SCREW
3 – OFF
2 – SPEED CONTROL SWITCH
4 – THROTTLE BODY BELLCRANK
5 – SPEED CONTROL CABLE
(4) Remove switch from steering wheel and unplug 6 – RELEASE TABS
electrical connector. 7 – BRACKET

INSTALLATION INSTALLATION
(1) Plug electrical connector into switch. (1) Attach end of cable to speed control servo.
(2) Position switch to steering wheel. Refer to Speed Control Servo Removal/Installation.
(3) Install switch mounting screw and tighten to (2) Install cable into cable bracket (snaps in).
1.5 N·m (14 in. lbs.) torque. (3) Install cable connector at throttle body
(4) Install airbag module. Refer to Group 8M, Pas- bellcrank pin (snaps on).
sive Restraint Systems. (4) Clip cable to cable guide at valve cover.
(5) Connect negative battery cable to battery. (5) Connect negative battery cable to battery.
(6) Before starting engine, operate accelerator
SERVO CABLE pedal to check for any binding.
REMOVAL VACUUM RESERVOIR
(1) Disconnect negative battery cable at battery.
(2) Using finger pressure only, remove cable con- REMOVAL
nector by pushing connector off the throttle body The vacuum reservoir is located behind right front
bellcrank pin (Fig. 4). DO NOT try to pull cable bumper end cap on vehicles equipped with LHD (Left
connector off perpendicular to the bellcrank Hand Drive) (Fig. 5). It is located behind left front
pin. Connector will be broken. bumper end cap on vehicles equipped with RHD
(3) Two release tabs are located on sides of speed (Right Hand Drive).
control cable at cable bracket (Fig. 4). Squeeze tabs (1) Remove front bumper end cap. Refer to Front
together and push cable out of bracket. Bumper End Cap Removal/Installation.
(4) Unclip cable from cable guide at valve cover. (2) Remove vacuum line at reservoir (Fig. 6).

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 XJ SPEED CONTROL SYSTEM 8H - 7
REMOVAL AND INSTALLATION (Continued)
(3) Remove 2 reservoir mounting screws.
(4) Remove reservoir from bumper bar.

Fig. 6 Vacuum Reservoir Removal/Installation

1 – VACUUM LINE
2 – RESERVOIR SCREWS
Fig. 5 Vacuum Reservoir Location
3 – VACUUM RESERVOIR
1 – BUMPER END CAP
2 – VACUUM RESERVOIR
SPECIFICATIONS
INSTALLATION
(1) Position reservoir to bumper bar and install TORQUE CHART
mounting screws. Tighten screws to 8 N·m (72 in.
lbs.) torque. Description Torque
(2) Install vacuum line to reservoir Servo Mounting Bracket-to-Servo Nuts . . . 8.5 N·m
(3) Install front bumper end cap. Refer to Front (75 in. lbs.)
Bumper End Cap Removal/Installation. Servo Mounting Bracket-to-Body Bolts . . . . . 2 N·m
(20 in. lbs.)
Speed Control Switch Mounting Screws . . . 1.5 N·m
(14 in. lbs.)
Vacuum Reservoir Mounting Bolts . . . . . . . . 8 N·m
(72 in. lbs.)

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 XJ VEHICLE SPEED CONTROL SYSTEM 8H - 1

VEHICLE SPEED CONTROL SYSTEM

TABLE OF CONTENTS

page

DESCRIPTION AND OPERATION

DIESEL ENGINE SPEED CONTROL SYSTEM . . . . 1

DESCRIPTION AND OPERATION speed control functions are used. The outputs from
these switches are filtered into one input. The MSA
DIESEL ENGINE SPEED CONTROL SYSTEM determines which output has been applied through
Unique features for the 2.5L diesel engine will be resistive multiplexing. The input circuit voltage is
covered in this section. measured by the MSA to determine which switch
• Models equipped with the 2.5L diesel engine do function has been selected.
not use a vacuum reservoir to retain engine vacuum • A speed control indicator lamp, located on the
for speed control operation. There are no vaccum-op- instrument panel cluster is energized by the MSA via
erated speed control servos used in vehicles with the the CCD Bus. This occurs when speed control system
2.5L diesel engine. power has been turned ON, and the engine is run-
• The range of the speed control system operation ning.
is restricted to speeds between 56 km/h (35 MPH) to • The two switch modules are labeled: ON/OFF,
145 km/h (90 MPH). SET, RESUME/ACCEL, CANCEL and COAST. Refer
• Inputs to the MSA that allow speed control oper- to the owner’s manual for more information on speed
ation are from the vehicle speed sensor and the control switch functions and setting procedures. The
Speed Control Switch. individual switches cannot be repaired. If one indi-
• Two separate speed control switch modules are vidual switch fails, the switch module must be
mounted on the steering wheel to the left and right replaced.
side of the driver’s airbag module. Switch features
are:
• Within the two switch modules, five momen-
tary contact switches, supporting seven different

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 XJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1

TURN SIGNAL AND HAZARD WARNING SYSTEMS

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION TURN SIGNAL SWITCH AND HAZARD

TURN SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . 1 WARNING SWITCH . . . . . . . . . . . . . . . . . . . . . . 5
HAZARD WARNING SYSTEM . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
TURN SIGNAL SWITCH AND HAZARD COMBINATION FLASHER . . . . . . . . . . . . . . . . . . . 5
WARNING SWITCH . . . . . . . . . . . . . . . . . . . . . . 2 TURN SIGNAL SWITCH AND HAZARD
TURN SIGNAL CANCELLING CAM . . . . . . . . . . . . 3 WARNING SWITCH . . . . . . . . . . . . . . . . . . . . . . 6
COMBINATION FLASHER . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
TURN SIGNAL AND HAZARD WARNING
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DESCRIPTION AND OPERATION lamp and rear tail/stop/turn signal lamp to flash on
and off. If the exterior lamps are turned off, the front
TURN SIGNAL SYSTEM park/turn signal lamp and the front side marker
lamp will flash in unison. If the exterior lamps are
DESCRIPTION turned on, the front park/turn signal lamp and the
A turn signal system is standard factory-installed front side marker lamp will flash alternately.
safety equipment on this model. The turn signal sys- See the owner’s manual in the vehicle glove box for
tem uses ignition switched battery current, and will more information on the features, use and operation
operate only when the ignition switch is in the On or of the turn signal system.
Accessory positions. The turn signal system includes
the following components: HAZARD WARNING SYSTEM
• Combination flasher
• Front side marker lamps DESCRIPTION
• Turn signal cancelling cam A hazard warning system is standard factory-in-
• Turn signal indicator lamps stalled safety equipment on this model. Unlike the
• Turn signal lamps turn signal system, the hazard warning system uses
• Turn signal switch. a non-switched source of battery current so that the
Refer to Lamp in the proper section of Group 8L - system will operate regardless of the ignition switch
Lamps for more information on the exterior turn sig- position. The hazard warning system includes the fol-
nal lamps. Refer to Instrument Cluster in the lowing components:
proper section of Group 8E - Instrument Panel Sys- • Combination flasher
tems for more information on the turn signal indica- • Front side marker lamps
tor lamps. Following are general descriptions of the • Hazard warning switch
major components in the turn signal system. For • Turn signal indicator lamps
complete circuit diagrams, refer to Turn Signals in • Turn signal lamps.
the Contents of Group 8W - Wiring Diagrams. Refer to Lamp in the proper section of Group 8L -
Lamps for more information on the exterior turn sig-
OPERATION nal lamps. Refer to Instrument Cluster in the
With the ignition switch in the On or Accessory proper section of Group 8E - Instrument Panel Sys-
position, and the turn signal (multi-function) switch tems for more information on the turn signal indica-
control stalk moved up (right turn) or down (left tor lamps. Following are general descriptions of the
turn), the turn signal system is activated. When the major components in the hazard warning system. For
turn signal system is activated, the circuitry of the complete circuit diagrams, refer to Turn Signals in
turn signal switch and the combination flasher will the Contents of Group 8W - Wiring Diagrams.
cause the selected (right or left) turn signal indicator
lamp, front park/turn signal lamp, front side marker

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 8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
OPERATION
With the hazard warning switch in the On posi-
tion, the hazard warning system is activated. When
the hazard warning system is activated, the circuitry
of the hazard warning switch and the combination
flasher will cause both the right side and the left side
turn signal indicator lamps, front park/turn signal
lamps, front side marker lamps and rear tail/stop/
turn signal lamps to flash on and off. If the exterior
lamps are turned off, the front park/turn signal
lamps and the front side marker lamps will flash in
unison. If the exterior lamps are turned on, the front
park/turn signal lamps and the front side marker
lamps will flash alternately.
See the owner’s manual in the vehicle glove box for
more information on the features, use and operation
of the hazard warning system. Fig. 1 Multi-Function Switch
1 – HAZARD WARNING BUTTON
TURN SIGNAL SWITCH AND HAZARD 2 – CANCEL ACTUATOR
3 – CONTROL STALK
WARNING SWITCH
DESCRIPTION OPERATION
The turn signal and hazard warning switches are
integral to the multi-function switch unit, which is TURN SIGNAL SWITCH
secured to the left side of the steering column (Fig. The multi-function switch control stalk that
1). The only visible parts of the multi-function switch extends from the left side of the steering column just
are the control stalk that extends from the left side below the steering wheel is moved up or down to
of the steering column, and the hazard warning activate the turn signal switch. When the control
switch button that protrudes from the top of the stalk is moved in the upward direction, the right
steering column. The multi-function switch control turn signal switch circuitry is activated; and, when
stalk has international control symbols on it, which the control stalk is moved in the downward direction,
identify its functions. The hazard warning switch the left turn signal switch circuitry is activated. The
button is identified with a double triangle, which is turn signal switch has a detent position in each
the international control symbol for hazard warning. direction that provides turn signals with automatic
The remainder of the multi-function switch is con- cancellation, and an intermediate momentary posi-
cealed beneath the steering column shrouds. tion in each direction that provides turn signals only
The multi-function switch also contains circuitry until the multi-function switch control stalk is
for the following functions: released.
• Headlamp beam selection When the turn signal switch is in a detent posi-
• Headlamp optical horn tion, it is turned off by one of two turn signal cancel-
The information contained in this group addresses ling cam lobes that are integral to the rotor of the
only the multi-function switch turn signal and haz- clockspring mechanism. Turning the steering wheel
ard warning functions. For information relative to causes the turn signal cancelling cam lobes to contact
the other systems that are controlled by and circuits a cancel actuator in the multi-function switch, and
that are integral to the multi-function switch, see the the turn signal switch automatically returns to the
group in this service manual that covers that system. off position.
However, the turn signal and hazard warning
switches cannot be repaired. If these switches or any HAZARD WARNING SWITCH
other circuit or component of the multi-function The hazard warning switch is controlled by the
switch unit is faulty or damaged, the entire multi- hazard warning switch button. Slide the switch but-
function switch unit must be replaced. ton to the left to turn the switch on and activate the
hazard warning system, and slide the button to the
right again to turn the switch and the hazard warn-
ing system off.

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 XJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3
DESCRIPTION AND OPERATION (Continued)

TURN SIGNAL CANCELLING CAM outputs or functions. The combination flasher should
never be substituted for an ISO-relay or replaced
DESCRIPTION with an ISO-relay, or else component and vehicle
The turn signal cancelling cam is concealed within damage may occur.
the steering column below the steering wheel. The Because of the active electronic elements within
turn signal cancelling cam consists of two lobes that the combination flasher, it cannot be tested with con-
are integral to the lower surface of the clockspring ventional automotive electrical test equipment. If the
rotor. The clockspring mechanism provides turn sig- combination flasher is believed to be faulty, test the
nal cancellation as well as a constant electrical con- turn signal system and hazard warning system cir-
nection between the horn switch, driver side airbag cuits as described in this group. Then replace the
module and speed control switches on the steering combination flasher with a known good unit to con-
wheel and the instrument panel wire harness on the firm system operation.
steering column. The housing of the clockspring is The combination flasher has five blade-type termi-
secured to the steering column and remains station- nals intended for the following inputs and outputs:
ary. The rotor of the clockspring, including the turn fused B(+), fused ignition switch output, ground, turn
signal cancelling cam lobes rotate with the steering signal circuit, and hazard warning circuit. Constant
wheel. battery voltage and ground are supplied to the
The turn signal cancelling cam is integral to the flasher so that it can perform the hazard warning
clockspring and cannot be repaired. If faulty or dam- function, and ignition switched battery voltage is
aged, the entire clockspring assembly must be supplied for the turn signal function. Refer to Turn
replaced. Refer to Clockspring in the Removal and Signals in the Contents of Group 8W - Wiring Dia-
Installation section of Group 8M - Passive Restraint grams for complete circuit diagrams.
Systems for the clockspring service procedures. The combination flasher is located in a wire har-
ness connector which is secured to the diagnostics
OPERATION splice block bracket outboard of the steering column
The turn signal cancelling cam has two lobes opening underneath the instrument panel. The com-
molded into the lower surface of the clockspring bination flasher cannot be repaired or adjusted and,
rotor. When the turn signals are activated by moving if faulty or damaged, it must be replaced.
the multi-function switch control stalk to a detent
position, a turn signal cancel actuator is extended OPERATION
from the inside surface of the multi-function switch The IC within the combination flasher (Fig. 2) con-
housing toward the clockspring rotor. When the tains the logic that controls the flasher operation and
steering wheel is rotated during the turn, one of the the flash rate. Pin 6 of the IC receives a sense volt-
two turn signal cancelling cam lobes will contact the age from the hazard warning circuit of the multi-
turn signal cancel actuator, releasing the multi-func- function switch. When the hazard warning switch is
tion switch control stalk from its detent and cancel- turned on, the 9hazard on sense” voltage will become
ling the turn signal event. low due to the circuit being grounded through the
turn signal bulbs. This low voltage sense signals the
COMBINATION FLASHER IC to energize the flash control Positive-Negative-
Positive (PNP) transistor at a pre-calibrated flash
DESCRIPTION rate or frequency. Each time the PNP transistor ener-
The combination flasher is a smart relay that func- gizes the hazard warning circuit, the pin 6 “hazard
tions as both the turn signal system and the hazard on sense” voltage will become high and the IC signals
warning system flasher. The combination flasher con- the PNP transistor to de-energize the circuit. This
tains active electronic Integrated Circuitry (IC) ele- cycling will continue until the hazard warning switch
ments. This flasher is designed to handle the current is turned off.
flow requirements of the factory-installed lighting. If Likewise, pin 8 of the IC receives a sense voltage
supplemental lighting is added to the turn signal from the turn signal circuits of the multi-function
lamp circuits, such as when towing a trailer with switch. When the left or right turn signal switch is
lights, the combination flasher will automatically try turned on, the “turn signal on sense” voltage will
to compensate to keep the flash rate the same. become low due to the circuit being grounded
While the combination flasher has a International through the turn signal bulbs. This low voltage sense
Standards Organization (ISO)-type relay terminal signals the IC to energize the flash control PNP tran-
configuration or footprint, the internal circuitry is sistor at a pre-calibrated flash rate or frequency.
much different. The combination flasher does not use Each time the PNP transistor energizes the turn sig-
standard ISO-relay inputs or provide ISO-relay type nal circuit, the pin 8 “turn signal on sense” voltage

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 8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
If the problem being diagnosed is related to a fail-
ure of the turn signals to automatically cancel follow-
ing completion of a turn, inspect the multi-function
switch for a faulty or damaged cancel actuator and
inspect the turn signal cancelling cam lobes on the
clockspring mechanism for damage or improper
installation. For complete circuit diagrams, refer to
Turn Signals in the Contents of Group 8W - Wiring
Diagrams.

WARNING: ON VEHICLES EQUIPPED WITH AIR-

BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 2 Combination Flasher - Typical
(1) Turn the ignition switch to the On position.
will become high and the IC signals the PNP transis- Actuate the turn signal switch or the hazard warning
tor to de-energize the circuit. This cycling will con- switch. Observe the turn signal indicator lamp(s) in
tinue until the right or left turn signal switch is the instrument cluster. If the flash rate is very high,
turned off. check for a turn signal bulb that is not lit or is very
A special design feature of the combination flasher dimly lit. Repair the circuits to that lamp or replace
allows it to “sense” that a turn signal circuit or bulb the faulty bulb, as required. If the turn signal indi-
is not operating, and provide the driver an indication cator(s) fail to light, go to Step 2.
of the condition by flashing the remaining bulbs in (2) Turn the ignition switch to the Off position.
the affected circuit at a higher rate (120 flashes-per- Check the turn signal fuse in the junction block
minute or higher). Conventional flashers either con- and/or the hazard warning fuse in the Power Distri-
tinue flashing at their typical rate (heavy-duty type), bution Center (PDC). If OK, go to Step 3. If not OK,
or discontinue flashing the affected circuit entirely repair the shorted circuit or component as required
(standard-duty type). During turn signal operation, and replace the faulty fuse(s).
the combination flasher IC compares normal battery (3) Check for battery voltage at the hazard warn-
voltage input on pin 2 with the shunt resistor voltage ing fuse in the PDC. If OK, go to Step 4. If not OK,
input on pin 7. If the IC “senses” that the voltage dif- repair the open fused B(+) circuit to the battery as
ference between pin 2 and pin 7 is different than the required.
pre-calibrated value of the IC, it will increase the (4) Turn the ignition switch to the On position.
rate at which it signals the PNP transistor to ener- Check for battery voltage at the turn signal fuse in
gize the pin 1 output. Thus, the inoperative half (left the fuseblock module. If OK, go to Step 5. If not OK,
or right side) of the turn signal circuit will flash repair the open fused ignition switch output (accesso-
faster. ry/run) circuit to the ignition switch as required.
(5) Turn the ignition switch to the Off position.
DIAGNOSIS AND TESTING Disconnect and isolate the battery negative cable.
Remove the combination flasher from its wire har-
ness connector and replace it with a known good
TURN SIGNAL AND HAZARD WARNING unit. Connect the battery negative cable. Test the
SYSTEMS operation of the turn signal and hazard warning sys-
When diagnosing the turn signal or hazard warn- tems. If OK, discard the faulty combination flasher.
ing circuits, remember that high generator output If not OK, remove the test flasher and go to Step 6.
can burn out bulbs rapidly and repeatedly. If this is a (6) Turn the ignition switch to the On position.
problem on the vehicle being diagnosed, refer to Check for battery voltage at the fused ignition switch
Charging System in the Diagnosis and Testing sec- output (accessory/run) circuit cavity in the combina-
tion of Group 8C - Charging System for further diag- tion flasher wire harness connector. If OK, go to Step
nosis of a possible generator overcharging condition. 7. If not OK, go to Step 9.

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 XJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5
DIAGNOSIS AND TESTING (Continued)
(7) Turn the ignition switch to the Off position. shown in the Multi-Function Switch Continuity chart
Place the hazard warning switch in the On position. (Fig. 3).
Check for battery voltage again at the fused B+ cir-
SWITCH POSITION CONTINUITY
cuit cavity in the combination flasher wire harness BETWEEN
connector. If OK, go to Step 8. If not OK, go to Step 9. TURN HAZARD
SIGNAL WARNING
(8) Disconnect and isolate the battery negative
cable. Check for continuity between the ground cir- NEUTRAL OFF F and H
F and K
cuit cavity of the combination flasher wire harness
A and E
connector and a good ground. There should be conti-
nuity. If OK, go to Step 9. If not OK, repair the open LEFT OFF F and H
C and K
ground circuit to ground as required.
C and I
(9) Disconnect the instrument panel wire harness A and E
connector from the multi-function switch connector
RIGHT OFF F and K
receptacle. Check for continuity between the turn sig- C and H
nal output circuit cavities in the combination flasher C and J
wire harness connector and in the instrument panel A and E
wire harness connector for the multi-function switch. NEUTRAL ON B and E
There should be continuity. If OK, go to Step 10. If C and H
not OK, repair the open turn signal output circuit as C and K
required. C and I
C and J
(10) Check for continuity between the hazard
warning output circuit cavities in the combination
flasher wire harness connector and in the instrument Fig. 3 Multi-Function Switch Continuity
panel wire harness connector for the multi-function
switch. There should be continuity. If OK, refer to (3) If the turn signal switch or hazard warning
Turn Signal Switch and Hazard Warning Switch switch fails any of the continuity checks, replace the
in the Diagnosis and Testing section of this group. If faulty multi-function switch assembly as required. If
not OK, repair the open hazard warning output cir- the switch circuits are OK, repair the lighting cir-
cuit as required. cuits as required.

TURN SIGNAL SWITCH AND HAZARD REMOVAL AND INSTALLATION

WARNING SWITCH
The turn signal switch and the hazard warning COMBINATION FLASHER
switch are integral to the multi-function switch.
Refer to Turn Signal and Hazard Warning Sys- WARNING: ON VEHICLES EQUIPPED WITH AIR-
tems in the Diagnosis and Testing section of this BAGS, REFER TO GROUP 8M - PASSIVE
group before testing the multi-function switch. For RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
complete circuit diagrams, refer to Turn Signals in STEERING WHEEL, STEERING COLUMN, OR
the Contents of Group 8W - Wiring Diagrams. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
WARNING: ON VEHICLES EQUIPPED WITH AIR- CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT BAG DEPLOYMENT AND POSSIBLE PERSONAL
SYSTEMS BEFORE ATTEMPTING ANY STEERING INJURY.
WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
FAILURE TO TAKE THE PROPER PRECAUTIONS REMOVAL
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY- (1) Disconnect and isolate the battery negative
MENT AND POSSIBLE PERSONAL INJURY. cable.
(2) Remove the knee blocker from the instrument
(1) Disconnect and isolate the battery negative panel. Refer to Knee Blocker in the Removal and
cable. Disconnect the instrument panel wire harness Installation section of Group 8E - Instrument Panel
connector from the multi-function switch connector Systems for the procedures.
receptacle. (3) Reach through the outboard side of the steer-
(2) Using an ohmmeter, perform the switch conti- ing column opening to access and disengage the com-
nuity checks at the connector receptacle terminals as bination flasher wire harness connector retainer from

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 8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
the instrument panel diagnostics mounting bracket TURN SIGNAL SWITCH AND HAZARD
(Fig. 4).
WARNING SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT
SYSTEMS BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE.
FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the knee blocker from the instrument
panel. Refer to Knee Blocker in the Removal and
Installation section of Group 8E - Instrument Panel
Systems for the procedures.
(3) Remove the three screws that secure the lower
Fig. 4 Combination Flasher Remove/Install
steering column shroud to the upper shroud (Fig. 5).
1 – DIAGNOSTICS MOUNTING BRACKET
2 – DIAGNOSTICS SPLICE BLOCK
3 – INSTRUMENT PANEL COURTESY LAMP
4 – DATA LINK CONNECTOR
5 – OUTBOARD STEERING COLUMN OPENING
6 – COMBINATION FLASHER AND CONNECTOR

(4) Pull the combination flasher into the instru-

ment panel steering column opening far enough to
access the wire harness connector.
(5) Remove the combination flasher from the wire
harness connector.
(6) Remove the combination flasher from under
the instrument panel.

INSTALLATION
(1) Position the combination flasher under the
instrument panel.
(2) Align the combination flasher terminals with
the terminal cavities in the wire harness connector.
(3) Push in firmly on the combination flasher until
the terminals are fully seated in the terminal cavities
in the wire harness connector.
(4) Install the combination flasher wire harness
connector retainer into the mounting hole of the
instrument panel diagnostics mounting bracket. Fig. 5 Steering Column Shrouds Remove/Install
(5) Install the knee blocker onto the instrument 1 – UPPER SHROUD
panel. Refer to Knee Blocker in the Removal and 2 – SCREW (3)
Installation section of Group 8E - Instrument Panel 3 – LOWER SHROUD
Systems for the procedures. 4 – STEERING WHEEL
(6) Reconnect the battery negative cable.
(4) If the vehicle is equipped with a standard non-
tilt steering column, loosen the two upper steering
column mounting nuts. If the vehicle is equipped

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 XJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7
REMOVAL AND INSTALLATION (Continued)
with the optional tilt steering column, move the tilt (8) Gently pull the lower mounting tab of the
steering column to the fully lowered position. multi-function switch water shield bracket away from
(5) Remove both the upper and lower shrouds from the steering column far enough to clear the screw
the steering column. boss below the multi-function switch control stalk.
(6) Remove the two screws that secure the multi- (9) Lift the water shield and bracket with the
function switch water shield and bracket to the top of multi-function switch off of the left side of the steer-
the steering column (Fig. 6). ing column far enough to access the two multi-func-
tion switch wire harness connectors. If the vehicle is
equipped with the optional tilt steering column, lift-
ing gently upward on the tilt release lever will pro-
vide additional clearance to ease multi-function
switch removal.
(10) Disconnect the two instrument panel wire
harness connectors from the multi-function switch
connector receptacles.
(11) Remove the multi-function switch and water
shield from the steering column as a unit.
(12) Gently and carefully remove the water shield
from the switch by pulling it over the hazard warn-
ing switch button and the multi-function switch con-
trol stalk.

INSTALLATION
Fig. 6 Water Shield Upper Screws Remove/Install (1) Gently and carefully install the water shield
1 – MOUNTING SCREWS
onto the switch by pulling it over the hazard warning
2 – HAZARD WARNING SWITCH KNOB switch button and the multi-function switch control
3 – MULTI-FUNCTION SWITCH LEVER stalk.
4 – WATER SHIELD AND BRACKET (2) Position the multi-function switch and water
5 – WIPER SWITCH LEVER shield near its mounts on the steering column as a
unit.
(3) Reconnect the two instrument panel wire har-
(7) Remove the one screw located below the multi-
ness connectors to the multi-function switch connec-
function switch control stalk that secures the multi-
tor receptacles.
function switch water shield and bracket to the
(4) Position the multi-function switch onto its
steering column (Fig. 7).
mounts on the left side of the steering column. If the
vehicle is equipped with the optional tilt steering col-
umn, lifting gently upward on the tilt release lever
will provide additional clearance to ease multi-func-
tion switch installation.
(5) Position the lower mounting tab of the multi-
function switch water shield bracket to the steering
column screw boss below the multi-function switch
control stalk.
(6) Install and tighten the one screw located below
the multi-function switch control stalk that secures
the multi-function switch water shield and bracket to
the steering column. Tighten the screw to 1.1 N·m
(10 in. lbs.).
(7) Install and tighten the two screws that secure
the multi-function switch water shield and bracket to
the top of the steering column. Tighten the screws to
Fig. 7 Water Shield Lower Screw Remove/Install 2.2 N·m (20 in. lbs.).
1 – MULTI-FUNCTION SWITCH LEVER (8) Position both the upper and lower shrouds onto
2 – WATER SHIELD AND BRACKET the steering column.
3 – LOWER MOUNTING SCREW
4 – LOWER MOUNTING TAB

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 8J - 8 TURN SIGNAL AND HAZARD WARNING SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(9) Install and tighten the three screws that secure (11) Install the knee blocker onto the instrument
the lower steering column shroud to the upper panel. Refer to Knee Blocker in the Removal and
shroud. Tighten the screws to 2 N·m (18 in. lbs.). Installation section of Group 8E - Instrument Panel
(10) If the vehicle is so equipped, tighten the two Systems for the procedures.
nuts that secure the non-tilt steering column upper (12) Reconnect the battery negative cable.
mounting bracket to the dash panel steering column
support bracket studs. Tighten the nuts to 22 N·m
(200 in. lbs.).

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 XJ WIPER AND WASHER SYSTEMS 8K - 1

WIPER AND WASHER SYSTEMS

TABLE OF CONTENTS

page page

GENERAL INFORMATION WASHER NOZZLE AND PLUMBING . . . . . . . . . . . 4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING
WINDSHIELD WIPER SYSTEM . . . . . . . . . . . . . . 1 WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WINDSHIELD WASHER SYSTEM . . . . . . . . . . . . . 1 WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR WIPER AND WASHER SYSTEM . . . . . . . . 2 WIPER SWITCH AND WASHER SWITCH. . . . . . . 7
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION
WIPER ARM AND BLADE. . . . . . . . . . . . . . . . . . . 2 WIPER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIPER LINKAGE AND PIVOT. . . . . . . . . . . . . . . . 2 WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . 2 WIPER LINKAGE AND PIVOT. . . . . . . . . . . . . . . . 9
WIPER SWITCH AND WASHER SWITCH. . . . . . . 3 WIPER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WASHER RESERVOIR . . . . . . . . . . . . . . . . . . . . . 3 WIPER SWITCH AND WASHER SWITCH. . . . . . 11
WASHER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 13
WASHER FLUID LEVEL SENSOR . . . . . . . . . . . . . 4

GENERAL INFORMATION The intermittent wipe mode delay times are driver
adjustable from about one second to about fifteen sec-
INTRODUCTION onds. The intermittent wipe mode is provided by
Windshield wiper and washer systems are stan- delay logic and relay control circuitry contained
dard factory-installed equipment on this model. A within the intermittent wiper/washer switch. The
rear wiper and washer system is optional factory-in- intermittent wipe relay is also contained within the
stalled equipment. Following is general information switch.
about the available wiper and washer systems for The windshield wipers will operate only when the
this vehicle. Refer to 8W-53 - Wipers in Group 8W - ignition switch is in the Accessory or On positions. A
Wiring Diagrams for complete circuit descriptions circuit breaker located in the junction block protects
and diagrams. the circuitry of the windshield wiper system. Refer to
the owner’s manual in the vehicle glove box for more
NOTE: This group covers both Left-Hand Drive information on the features, use and operation of the
(LHD) and Right-Hand Drive (RHD) versions of this windshield wiper system.
model. Whenever required and feasible, the RHD
versions of affected vehicle components have been WINDSHIELD WASHER SYSTEM
constructed as mirror-image of the LHD versions. An electrically operated windshield washer system
While most of the illustrations used in this group is standard equipment. The washer reservoir is
represent only the LHD version, the diagnostic and located between the inner and outer front fenders,
service procedures outlined can generally be above and forward of the left front wheel housing.
applied to either version. Exceptions to this rule The reservoir filler neck is located in the engine com-
have been clearly identified as LHD or RHD, if a partment on the left inner fender shield.
special illustration or procedure is required. The washer reservoir holds the washer fluid, which
is pressurized by a pump when the windshield
washer switch lever is actuated. The windshield
WINDSHIELD WIPER SYSTEM washer pump feeds the pressurized washer fluid
An intermittent windshield wiper system is stan- through the washer system plumbing to the wind-
dard equipment on this model. The intermittent shield washer nozzles.
wiper system lets the driver select from either of two A low washer fluid warning lamp is standard
wiper speeds, low or high, or the intermittent wipe equipment on all models equipped with the optional
delay mode. rear wiper and washer system. The low washer fluid
warning lamp in the instrument cluster will warn

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 8K - 2 WIPER AND WASHER SYSTEMS XJ
GENERAL INFORMATION (Continued)
the driver when the washer fluid level needs to be The blades are mounted to spring-loaded wiper
checked. Refer to Group 8E - Instrument Panel Sys- arms. The spring tension of the wiper arms controls
tems for more information on this feature. the pressure applied to the blades on the glass. The
The washers will operate only when the ignition windshield wiper arms are secured by an integral
switch is in the Accessory or On positions. If the wip- latch to the two wiper pivots on the cowl plenum cov-
ers are not already turned on when the washers are er/grille panel at the base of the windshield. The rear
activated, the wipers will be automatically cycled for wiper arm is secured by a nut directly to the rear
one or two wipes, then be turned off. A fuse located wiper motor output shaft on the liftgate below the
in the junction block protects the circuitry of the liftgate glass.
washer system. Refer to the owner’s manual in the The wiper arms and blades cannot be adjusted or
vehicle glove box for more information on the fea- repaired. If faulty or damaged, they must be
tures, use and operation of the windshield washer replaced.
system.
WIPER LINKAGE AND PIVOT
REAR WIPER AND WASHER SYSTEM The wiper linkage and pivot module is secured
A rear wiper and washer system is an available with screws to the cowl top panel beneath the cowl
option on this model. The rear wiper system is a plenum cover/grille panel. The wiper motor is
fixed-cycle wiper system. A single switch in the secured with screws to the center of the linkage and
instrument panel accessory switch bezel controls both pivot module bracket. The wiper pivots are secured
the rear wiper and washer functions. The rear to the ends of the module bracket.
washer system shares the reservoir of the windshield The two wiper pivot crank arms and the wiper
washer system, but has its own dedicated washer motor crank arm each have ball studs on their ends.
pump and plumbing. The left pivot ball stud is the longer of the three. A
The rear wiper and washer systems will operate connecting link with a plastic socket-type bushing in
only when the ignition switch is in the Accessory or the right end, and a plastic sleeve-type bushing in
On positions. A fuse in the junction block protects the the left end, is fit over the pivot ball studs to join the
circuitry of both the rear wiper and washer systems. two pivots.
Refer to the owner’s manual in the vehicle glove The wiper drive link has a plastic socket-type
box for more information on the features, use and bushing on each end. One end of the drive link is
operation of the rear wiper and washer system. snap-fit over the exposed end of the longer left pivot
ball stud, while the other end is snap-fit over the ball
stud on the wiper motor crank arm.
DESCRIPTION AND OPERATION The wiper linkage, pivots, bushings, motor, crank
arm, and mounting bracket are only serviced as a
WIPER ARM AND BLADE complete unit. If any part of this assembly is faulty
All Cherokee models have two 45.72-centimeter or damaged, the entire unit must be replaced.
(18-inch) windshield wiper blades with non-replace-
able rubber elements (squeegees). The optional rear WIPER MOTOR
wiper uses a single 33.0-centimeter (13-inch) wiper
blade with a non-replaceable rubber element (squee- FRONT
gee). The two-speed permanent magnet wiper motor has
Caution should be exercised to protect the rubber an integral transmission and park switch. The motor
squeegees from any petroleum-based cleaners or con- also contains an internal automatic resetting circuit
taminants, which will rapidly deteriorate the rubber. breaker to protect the motor from overloads.
If the squeegees are damaged, worn, or contami- The motor is secured to the wiper linkage and
nated, the entire wiper blade assembly must be pivot module bracket with three screws and is pro-
replaced. tected by a rubber boot. The wiper motor output
Wiper squeegees exposed to the elements for a long shaft passes through a hole in the module bracket,
time tend to lose their wiping effectiveness. Periodic where a nut secures the wiper motor crank arm to
cleaning of the squeegees is suggested to remove the motor output shaft. A reinforcement and stud
deposits of salt and road film. The wiper blades, plate with a rubber-isolated mounting bracket
arms, and windshield or rear glass should be cleaned extends from the cowl plenum side of the dash panel
with a sponge or cloth and windshield washer fluid, a to the motor mounting bracket to provide additional
mild detergent, or a non-abrasive cleaner. If the support.
squeegees continue to streak or smear, the wiper Wiper speed is controlled by current flow to the
blades should be replaced. proper set of brushes. The wiper motor completes its

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 XJ WIPER AND WASHER SYSTEMS 8K - 3
DESCRIPTION AND OPERATION (Continued)
wipe cycle when the windshield wiper switch stalk is
moved to the Off position, and parks the blades in
the lowest portion of the wipe pattern.
The windshield wiper motor cannot be repaired. If
faulty or damaged, the entire wiper linkage and pivot
module unit must be replaced. The reinforcement
bracket and stud plate are available for service.

REAR
The rear wiper motor is secured to a bracket that
is fastened to the liftgate inner panel, below the lift-
gate glass and behind the liftgate trim panel. The
motor output shaft passes through the liftgate outer
panel where a rubber gasket and plastic bezel unit,
and a nut seal and secure the unit to the liftgate
outer panel. The rear wiper arm is secured directly Fig. 1 Windshield Wiper Switch and Washer Switch
to the motor output shaft with a nut.
The rear wiper motor unit provides three operating instrument panel center bezel area, below the heater
modes: and air conditioner controls. The rear wiper and
• Constant wipe that operates when the rear washer switch controls the rear wiper and washer
wiper switch is turned to the On position. functions.
• Constant wipe that operates when the rear The toggle-type switch features a detent in the On
washer switch is depressed. position, and a momentary Wash position. The rear
• A park mode that operates the wiper motor until wiper and washer switch also has an integral illumi-
the blade reaches its park position when either the nation lamp with a serviceable bulb. The switch knob
rear wiper switch or the ignition switch is placed in is pushed down to its detent to activate the rear
the Off position. wiper system, and down again to the momentary
The rear wiper motor cannot be repaired. If faulty position to activate the rear washer system. Both the
or damaged, the entire rear wiper motor assembly rear wiper and rear washer motors will operate con-
must be replaced. tinuously for as long as the switch is held in the
momentary Wash position.
The rear wiper and washer switch cannot be
WIPER SWITCH AND WASHER SWITCH
repaired and, if faulty or damaged, the entire switch
unit must be replaced.
FRONT
The windshield wiper and washer switches are
mounted on the right side of the steering column
WASHER RESERVOIR
(Fig. 1). The switch stalk is moved up or down to A single washer fluid reservoir is used for both the
select the wiper switch mode, and pulled towards the standard front and optional rear washer systems.
steering wheel to activate the washer system. An The washer fluid reservoir is secured between the
intermittent wipe system control knob on the end of left front inner and outer fender panels, above and in
the switch stalk is rotated to select the desired delay front of the left front wheel house.
interval. The windshield wiper and washer switch Each washer pump and motor unit has a barbed
contains circuitry for the following functions: nipple, which is installed through a rubber grommet
• Windshield wipers seal inserted in a hole near the bottom of the reser-
• Intermittent wiper delay relay control and logic voir. The washer pumps are retained by an interfer-
• Intermittent wipe relay ence fit between the barbed nipple and the grommet
• Windshield washers. seal, which is a light press fit.
The windshield wiper and washer switch cannot be The washer reservoir has a separate filler neck
repaired. If any function of the switch is faulty, or if and grommet seal. The filler neck snaps into the res-
the switch is damaged, the entire switch unit must ervoir from the engine compartment side of the left
be replaced. inner fender shield. A snap-fit filler cap with an inte-
gral bail strap is fit to the reservoir filler neck. On
REAR models so equipped, the reservoir also has a hole pro-
The single two-function rear wiper and washer vided for a washer fluid level sensor.
switch is installed in the instrument panel accessory The washer reservoir, filler neck, grommet seal,
switch bezel, which is located near the bottom of the and filler cap are each available for service.

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 8K - 4 WIPER AND WASHER SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)

WASHER PUMP Located at the highest point of the supply hose

The washer pumps and motors are mounted near routing, beneath the liftgate opening upper header
the bottom of the washer reservoir. A barbed nipple garnish moulding, the hose connects to a check valve.
on the pump housing passes through a rubber grom- The check valve prevents washer fluid drain-back or
met seal installed in a hole near the bottom of the siphoning from occurring. From the check valve,
reservoir. The washer pump is retained by an inter- another single hose is routed through a grommet to
ference fit between the barbed pump nipple and the the liftgate, where it is connected to a nipple that
grommet seal, which is a light press fit. protrudes from the inside of the rear wiper motor
A permanently lubricated and sealed motor is cou- output shaft bezel.
pled to a rotor-type pump. Washer fluid is gravity-fed The washer fluid passes through the bezel nipple
from the reservoir to the pump. When the motor is to the outside of the liftgate. There a single hose is
energized, the pump pressurizes the washer fluid connected to a nipple on the outside of the rear wiper
and forces it through the plumbing to the nozzles. motor output shaft bezel. The hose is routed through
On vehicles with the optional rear wiper/washer a plastic trough-like guard snapped to the underside
system, the front washer pump and motor is always of the rear wiper arm. The hose is then attached to
mounted in the lower hole of the reservoir. The the single rear washer nozzle. The nozzle snaps into
washer pump and motor unit cannot be repaired. If place on the rear wiper arm.
faulty, the entire washer pump and motor unit must The rear washer nozzle cannot be adjusted. The
be replaced. nozzle, bezel, check valve, and hose fittings cannot be
repaired and, if faulty or damaged, they must be
WASHER FLUID LEVEL SENSOR replaced.
The washer fluid level sensor is mounted near the
front of the washer reservoir, above the two washer DIAGNOSIS AND TESTING
pumps. A barbed nipple on the sensor is press-fit into
a rubber grommet seal installed in a hole in the front
WIPER SYSTEM
of the reservoir.
When the fluid level in the reservoir falls below
FRONT
the pivoting float on the sensor, the float changes
For circuit descriptions and diagrams, refer to
position and closes the internal switch contacts of the
8W-53 - Wipers in Group 8W - Wiring Diagrams.
sensor. Refer to Group 8E - Instrument Panel Sys-
tems for diagnosis of the low washer fluid warning WARNING: ON VEHICLES EQUIPPED WITH AIR-
lamp and circuit, including the sensor. BAGS, REFER TO GROUP 8M - PASSIVE
The washer fluid level sensor cannot be repaired. If RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
faulty or damaged, the sensor unit must be replaced. STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
WASHER NOZZLE AND PLUMBING SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
FRONT BAG DEPLOYMENT AND POSSIBLE PERSONAL
Pressurized washer fluid is fed through a single INJURY.
hose, attached to a barbed nipple on the front washer
pump. The hose is routed to a tee fitting located in (1) Check the circuit breaker in the junction block.
the cowl plenum area, beneath the cowl plenum cov- If OK, go to Step 2. If not OK, replace the faulty cir-
er/grille panel. Hoses from the tee fitting are routed cuit breaker.
to the two nozzles, which are riveted into openings in (2) Disconnect and isolate the battery negative
the cowl plenum cover/grille panel below the wind- cable. Unplug the windshield wiper switch wire har-
shield. ness connector. Connect the battery negative cable.
The two fluidic washer nozzles are not adjustable. Turn the ignition switch to the On position. Check
The nozzles and hose fittings cannot be repaired and, for battery voltage at the fused ignition switch out-
if faulty or damaged, they must be replaced. put (run/acc) circuit cavity of the wiper switch wire
harness connector. If OK, go to Step 3. If not OK,
REAR repair the open circuit to the junction block as
Pressurized washer fluid is fed through a single required.
hose, attached to a barbed nipple on the rear washer (3) If the problem being diagnosed involves only
pump. The hose is routed from the front of the vehi- the pulse wipe, wipe-after-wash, or intermittent wipe
cle to the liftgate with the body wire harness. modes, go to Step 4. If not, go to Step 5.

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 XJ WIPER AND WASHER SYSTEMS 8K - 5
DIAGNOSIS AND TESTING (Continued)
(4) Turn the ignition switch to the Off position. STEERING WHEEL, STEERING COLUMN, OR
Disconnect and isolate the battery negative cable. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
Check for continuity between the ground circuit cav- SERVICE. FAILURE TO TAKE THE PROPER PRE-
ity of the wiper switch wire harness connector and a CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
good ground. There should be continuity. If OK, BAG DEPLOYMENT AND POSSIBLE PERSONAL
replace the faulty switch. If not OK, repair the open INJURY.
circuit to ground as required.
(5) Turn the ignition switch to the Off position. (1) Check the fuse in the junction block. If OK, go
Disconnect and isolate the battery negative cable. to Step 2. If not OK, repair the shorted circuit or
Remove the windshield wiper and washer switch and component as required and replace the faulty fuse.
check the switch continuity. See Wiper Switch and (2) Disconnect and isolate the battery negative
Washer Switch in the Diagnosis and Testing section cable. Remove the accessory switch bezel and unplug
of this group for the procedures. If OK, go to Step 6. the wire harness connector from the rear wiper and
If not OK, replace the faulty switch. washer switch. Connect the battery negative cable.
(6) Unplug the windshield wiper motor wire har- Turn the ignition switch to the On position. Check
ness connector. Check for continuity between the for battery voltage at the fused ignition switch out-
ground circuit cavity in the body half of the wiper put circuit cavity of the rear wiper and washer
motor wire harness connector and a good ground. switch wire harness connector. If OK, go to Step 3. If
There should be continuity. If OK, go to Step 7. If not not OK, repair the open circuit to the junction block
OK, repair the open circuit to ground as required. as required.
(7) Connect the battery negative cable. Turn the (3) Turn the ignition switch to the Off position.
ignition switch to the On position. Check for battery Disconnect and isolate the battery negative cable.
voltage at the fused ignition switch output (run/acc) Check for continuity between the ground circuit cav-
circuit cavity in the body half of the wiper motor wire ity of the rear wiper and washer switch wire harness
harness connector. If OK, go to Step 8. If not OK, connector and a good ground. There should be conti-
repair the open circuit to the junction block as nuity. If OK, go to Step 4. If not OK, repair the open
required. circuit to ground as required.
(8) Turn the ignition switch to the Off position. (4) Test the rear wiper and washer switch continu-
Disconnect and isolate the battery negative cable. ity. See Wiper Switch and Washer Switch in the
With the windshield wiper and washer switch wire Diagnosis and Testing section of this group for the
harness connector still unplugged, check the cavities procedures. If OK, go to Step 5. If not OK, replace
for each of the following circuits in the body half of the faulty switch.
the wiper motor wire harness connector for continu- (5) Remove the liftgate trim panel and unplug the
ity to ground. In each case, there should be no conti- rear wiper motor wire harness connector. Connect
nuity. If OK, go to Step 9. If not OK, repair the short the battery negative cable. Turn the ignition switch
circuit as required. to the On position. Check for battery voltage at the
• Wiper park switch sense fused ignition switch output (run) circuit cavity of
• Wiper switch low speed output the rear wiper motor wire harness connector. If OK,
• Wiper switch high speed output. go to Step 6. If not OK, repair the open circuit to the
(9) Check for continuity between the cavities in junction block as required.
the body half of the wiper motor wire harness con- (6) Turn the ignition switch to the Off position.
nector and the cavities in the windshield wiper and Disconnect and isolate the battery negative cable.
washer switch wire harness connector for each of the Check for continuity between the ground circuit cav-
following circuits. In each case, there should be con- ity of the rear wiper motor wire harness connector
tinuity. If OK, replace the faulty wiper motor. If not and a good ground. There should be continuity. If
OK, repair the open circuit as required. OK, go to Step 7. If not OK, repair the open circuit to
• Wiper park switch sense ground as required.
• Wiper switch low speed output (7) Check for continuity between the rear wiper
• Wiper switch high speed output. motor control circuit cavity of the rear wiper motor
wire harness connector and a good ground. There
REAR should be no continuity. If OK, go to Step 8. If not
For circuit descriptions and diagrams, refer to OK, repair the short circuit as required.
8W-53 - Wipers in Group 8W - Wiring Diagrams. (8) Check for continuity between the rear wiper
motor control circuit cavities of the rear wiper motor
WARNING: ON VEHICLES EQUIPPED WITH AIR- wire harness connector and the rear wiper and
BAGS, REFER TO GROUP 8M - PASSIVE washer switch wire harness connector. There should
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY

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 8K - 6 WIPER AND WASHER SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
be continuity. If OK, replace the faulty rear wiper tinuity. If OK, replace the faulty switch. If not OK,
motor. If not OK, repair the open circuit as required. repair the open circuit as required.

WASHER SYSTEM REAR

The diagnosis found here addresses an inoperative
FRONT rear washer pump. If the washer pump operates, but
The diagnosis found here addresses an inoperative no washer fluid is emitted from the washer nozzle, be
front washer pump. If the washer pump operates, certain to check the fluid level in the reservoir. Check
but no washer fluid is emitted from the washer noz- for ice or other foreign material in the reservoir, and
zles, be certain to check the fluid level in the reser- for pinched, disconnected, broken, or incorrectly
voir. Check for ice or other foreign material in the routed washer system plumbing. For circuit descrip-
reservoir, and for pinched, disconnected, broken, or tions and diagrams, refer to 8W-53 - Wipers in Group
incorrectly routed washer system plumbing. For cir- 8W - Wiring Diagrams.
cuit descriptions and diagrams, refer to 8W-53 - Wip-
ers in Group 8W - Wiring Diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
WARNING: ON VEHICLES EQUIPPED WITH AIR- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
BAGS, REFER TO GROUP 8M - PASSIVE STEERING WHEEL, STEERING COLUMN, OR
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
STEERING WHEEL, STEERING COLUMN, OR SERVICE. FAILURE TO TAKE THE PROPER PRE-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
SERVICE. FAILURE TO TAKE THE PROPER PRE- BAG DEPLOYMENT AND POSSIBLE PERSONAL
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- INJURY.
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. (1) Turn the ignition switch to the On position.
Place the rear wiper/washer switch in the Wipe posi-
(1) Turn the ignition switch to the On position. tion. Check whether the rear wiper is operating. If
Turn the wiper switch to the Low or High speed posi- OK, go to Step 2. If not OK, see the Wiper System
tion. Check whether the wipers operate. If OK, go to diagnosis in this group.
Step 2. If not OK, see the Wiper System diagnosis in (2) Turn the ignition switch to the Off position.
this group. Disconnect and isolate the battery negative cable.
(2) Turn the ignition switch to the Off position. Unplug the rear washer pump wire harness connec-
Disconnect and isolate the battery negative cable. tor. Check for continuity between the ground circuit
Unplug the front washer pump wire harness connec- cavity of the rear washer pump wire harness connec-
tor. Check for continuity between the ground circuit tor and a good ground. There should be continuity. If
cavity of the front washer pump wire harness connec- OK, go to Step 3. If not OK, repair the open circuit to
tor and a good ground. There should be continuity. If ground as required.
OK, go to Step 3. If not OK, repair the open circuit to (3) Connect the battery negative cable. Turn the
ground as required. ignition switch to the On position. Check for battery
(3) Connect the battery negative cable. Turn the voltage at the rear washer motor control circuit cav-
ignition switch to the On position. Check for battery ity of the rear washer pump wire harness connector
voltage at the front washer switch output circuit cav- while the rear washer switch is actuated. If OK,
ity of the front washer pump wire harness connector replace the faulty pump. If not OK, go to Step 4.
while actuating the washer switch. If OK, replace the (4) Turn the ignition switch to the Off position.
faulty washer pump. If not OK, go to Step 4. Disconnect and isolate the battery negative cable.
(4) Turn the ignition switch to the Off position. Unplug the rear wiper/washer switch wire harness
Disconnect and isolate the battery negative cable. connector. Check for continuity between the rear
Unplug the windshield wiper/washer switch wire washer motor control circuit cavity of the rear
harness connector. Check for continuity between the washer pump wire harness connector and a good
front washer switch output circuit cavity of the front ground. There should be no continuity. If OK, go to
washer pump wire harness connector and a good Step 5. If not OK, repair the short circuit as
ground. There should be no continuity. If OK, go to required.
Step 5 If not OK, repair the short circuit as required. (5) Check for continuity between the rear washer
(5) Check for continuity between the front washer motor control circuit cavities of the rear washer
switch output circuit cavities of the front washer pump wire harness connector and the rear wiper/
pump wire harness connector and the wiper/washer washer switch wire harness connector. There should
switch wire harness connector. There should be con-

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 XJ WIPER AND WASHER SYSTEMS 8K - 7
DIAGNOSIS AND TESTING (Continued)
be continuity. If OK, replace the faulty switch. If not the wiper system and/or washer system wire harness
OK, repair the open circuit as required. circuits as required.

WIPER SWITCH AND WASHER SWITCH REAR

Perform the diagnosis for the rear wiper system
FRONT and/or washer system as described in this group
Perform the diagnosis for the front wiper system before testing the rear wiper and washer switch. For
and/or washer system as described in this group circuit descriptions and diagrams, see 8W-53 - Wip-
before testing the front wiper and washer switch. For ers in Group 8W - Wiring Diagrams.
circuit descriptions and diagrams, see 8W-53 - Wip-
ers in Group 8W - Wiring Diagrams. WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
WARNING: ON VEHICLES EQUIPPED WITH AIR- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
BAGS, REFER TO GROUP 8M - PASSIVE STEERING WHEEL, STEERING COLUMN, OR
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
STEERING WHEEL, STEERING COLUMN, OR SERVICE. FAILURE TO TAKE THE PROPER PRE-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
SERVICE. FAILURE TO TAKE THE PROPER PRE- BAG DEPLOYMENT AND POSSIBLE PERSONAL
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- INJURY.
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. (1) Remove the accessory switch bezel from the
instrument panel and unplug the rear wiper and
(1) Disconnect and isolate the battery negative washer switch wire harness connector.
cable. (2) Using an ohmmeter, check the rear wiper and
(2) Remove the front wiper and washer switch washer switch continuity at the switch terminals as
from the steering column and unplug the wire har- shown in the Rear Wiper Switch and Washer Switch
ness connector from the switch. Continuity chart (Fig. 3).
(3) Using an ohmmeter, perform the switch conti-
nuity checks at the switch terminals as shown in the
Windshield Wiper Switch and Washer Switch Conti-
nuity chart (Fig. 2).

SWITCH POSITION CONTINUITY BETWEEN

SWITCH POSITION CONTINUITY BETWEEN
OFF PIN P2 AND PIN L OFF 1 AND 4
LOW PIN P1 AND PIN L WIPE 4 AND 5

HIGH PIN P1 AND PIN H WASH 2 AND 5, 4 AND 5

ILLUMINATION LAMP 1 AND 3
WASH PIN P1 AND PIN W
INTERMITTENT CANNOT BE CHECKED
Fig. 3 Rear Wiper Switch and Washer Switch
Continuity
(3) If the switch fails any of the continuity checks,
replace the faulty switch. If the switch is OK, repair
Fig. 2 Windshield Wiper Switch and Washer Switch the rear wiper system and/or washer system wire
Continuity harness circuits as required.
(4) If the switch fails any of the continuity checks,
replace the faulty switch. If the switch is OK, repair

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 8K - 8 WIPER AND WASHER SYSTEMS XJ

REMOVAL AND INSTALLATION (3) To install the wiper blade on the wiper arm,
slide the blade retainer into the U-shaped formation
WIPER BLADE on the tip of the wiper arm until the release tab
snaps into its locked position. Be certain that the
FRONT notched retainer for the wiper element is oriented
towards the end of the wiper blade that is nearest to
NOTE: The notched retainer end of the wiper ele- the rear wiper motor output shaft.
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot. WIPER ARM
(1) Lift the wiper arm to raise the wiper blade and CAUTION: The use of a screwdriver or other prying
element off of the windshield glass. tool to remove a wiper arm may distort it. This dis-
(2) To remove the wiper blade from the wiper arm, tortion could allow the arm to come off of the pivot
push the release tab under the arm tip and slide the shaft, regardless of how carefully it is installed.
blade away from the tip towards the pivot end of the
arm (Fig. 4).
FRONT
(1) Lift the wiper arm to permit the latch to be
pulled out to its holding position, then release the
arm (Fig. 5). The arm will remain off the windshield
with the latch in this position.

Fig. 4 Wiper Blade Remove/Install - Typical

1 – RELEASE TAB

(3) To install the wiper blade on the wiper arm,

slide the blade retainer into the U-shaped formation
on the tip of the wiper arm until the release tab
snaps into its locked position. Be certain that the
notched retainer for the wiper element is oriented
towards the end of the wiper blade that is nearest to
the wiper pivot. Fig. 5 Wiper Arm Remove/Install
1 – LOCKING LATCH
REAR 2 – ARM

NOTE: The notched retainer end of the wiper ele-

(2) Remove the arm from the pivot using a rocking
ment should always be oriented towards the end of
motion.
the wiper blade that is nearest to the wiper pivot.
(3) Install the arm and blade with the wiper motor
(1) Lift the rear wiper arm to raise the wiper blade in the Park position. See the Front Wiper Arm
and element off of the rear liftglass. Installation illustration (Fig. 6).
(2) To remove the wiper blade from the wiper arm, (4) Mount the arms on the pivot shafts so that the
push the release tab under the arm tip and slide the distance from the lower edge of the wiper arm tip to
blade away from the tip towards the rear wiper the upper edge of the lower windshield moulding is:
motor output shaft end of the arm (Fig. 4). • 23 to 52 mm (0.90 to 2.04 inch) on the driver
side

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 XJ WIPER AND WASHER SYSTEMS 8K - 9
REMOVAL AND INSTALLATION (Continued)

Fig. 7 Rear Wiper Arm Remove/Install

1 – PIVOT COVER
Fig. 6 Front Wiper Arm Installation 2 – WIPER ARM RETAINING NUT
• 33 to 62 mm (1.29 to 2.44 inch) on the passenger
side.
(5) Lift the wiper arm away from the windshield
slightly to relieve the spring tension on the latch.
Push the latch into the locked position and slowly
release the arm until the wiper blade rests on the
windshield.
(6) Operate the wipers with the windshield glass
wet, then turn the wiper switch to the Off position.
Check for the correct wiper arm positioning and
readjust if required.

REAR
(1) Disconnect the washer nozzle hose and clip
from the external nipple of the rear wiper motor out- Fig. 8 Rear Wiper Arm Installation
put shaft bezel. 1 – IN PARKED POSITION —27 TO 35 mm (1.06 TO 1.38 INCH)
ABOVE UPPER EDGE OF LOWER GLASS SEAL AT TIP OF
(2) Lift the wiper arm pivot cover and remove the WIPER BLADE
retaining nut (Fig. 7).
(3) Remove the wiper arm from the motor output
shaft using a rocking motion. (7) Tighten the wiper arm retaining nut to 18 N·m
(4) Install the rear wiper arm with the wiper (160 in. lbs.) and close the pivot cover.
motor in the Park position. Place the rear wiper
blade on the glass so that it is parallel to the liftgate WIPER LINKAGE AND PIVOT
glass opening, and install the wiper arm retaining The wiper linkage and pivots can only be removed
nut. from or installed in the vehicle as a unit with the
(5) Operate the rear wiper with the liftgate glass wiper motor. See Wiper Motor in this group for the
wet, then turn the rear wiper switch to the Off posi- service procedures.
tion so that the blade moves to the Park position.
(6) The measurement from the tip of the blade WIPER MOTOR
should now be from 27 to 35 mm (1.06 to 1.38 inch)
above the upper edge of the lower liftgate glass seal FRONT
(Fig. 8). Check for the correct wiper arm positioning (1) Disconnect and isolate the battery negative
and readjust if required. cable.

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 8K - 10 WIPER AND WASHER SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(2) Remove the wiper arms from the wiper pivots.
See Wiper Arm in this group for the procedures.
(3) Remove the eight screws that secure the cowl
plenum cover/grille panel and screen to the cowl top
panel (Fig. 9).

Fig. 10 Wiper Linkage Module Remove/Install

1 – BRACKET AND GROMMET
2 – SCREW
3 – NUT
4 – LINKAGE AND PIVOT MODULE
Fig. 9 Cowl Plenum Cover/Grille Panel Remove/
Install • Wiper module mounting screws - 6 N·m (50 in.
1 – SCREW lbs.)
2 – SCREW
• Wiper module mounting bracket and reinforce-
3 – GRILLE PANEL
ment nuts - 6 N·m (50 in. lbs.).
4 – SCREEN
5 – WASHER HOSE
6 – NUT
REAR
7 – BRACKET (1) Disconnect and isolate the battery negative
8 – NUT cable.
(2) From the outside of the liftgate glass, remove
the rear wiper arm from the rear wiper motor output
(4) Carefully lift the cowl plenum cover/grille panel
shaft. See Wiper Arm in this group for the proce-
and screen from the vehicle far enough to access the
dures.
windshield washer plumbing. Use care so as not to
(3) From the outside of the liftgate, remove the
damage the paint around the pivot openings of the
rear wiper motor output shaft nut (Fig. 11).
panel.
(4) Pull the rear wiper motor output shaft bezel
(5) Disconnect the windshield washer supply hose
and rubber gasket away from the liftgate far enough
and the passenger side washer nozzle hose from the
to access the washer supply hose.
washer nozzle supply hose tee fitting.
(5) Disconnect the washer supply hose from the
(6) Remove the cowl plenum cover/grille panel and
internal nipple on the bezel.
screen from the vehicle.
(6) Remove the bezel and rubber gasket from the
(7) Reach into the cowl plenum and unplug the
motor output shaft.
wiper motor wire harness connector.
(7) Remove the liftgate trim panel from the lift-
(8) Open and support the hood
gate. Refer to Group 23 - Body for the procedures.
(9) Remove the two nuts that secure the studs of
(8) Unplug the rear wiper motor wire harness con-
the wiper module mounting bracket and reinforce-
nector.
ment to the dash panel (Fig. 10).
(9) Remove the two screws that secure the rear
(10) Remove the four screws near the wiper pivots
wiper motor mounting bracket to the liftgate inner
that secure the wiper module to the cowl plenum
panel.
panel.
(10) Remove the rear wiper motor and mounting
(11) Remove the wiper module from the cowl ple-
bracket from the liftgate as a unit.
num as a unit.
(11) Reverse the removal procedures to install.
(12) Reverse the removal procedures to install.
Tighten the mounting hardware as follows:
Tighten the mounting hardware as follows:
• Rear wiper motor mounting bracket screws - 5
N·m (45 in. lbs.)

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 XJ WIPER AND WASHER SYSTEMS 8K - 11
REMOVAL AND INSTALLATION (Continued)
(3) Remove the three screws that secure the lower
steering column shroud to the upper shroud (Fig. 12).

Fig. 11 Rear Wiper Motor Remove/Install

1 – LIFTGATE
2 – ARM
3 – NUT
4 – NUT
5 – SCREW
Fig. 12 Steering Column Shrouds Remove/Install
6 – MOTOR AND BRACKET
1 – UPPER SHROUD
7 – BLADE
2 – SCREW (3)
8 – BEZEL
3 – LOWER SHROUD
9 – CLIP
4 – STEERING WHEEL
10 – HOSE

(4) If the vehicle is equipped with a standard non-

• Rear wiper motor output shaft retaining nut - 3
tilt steering column, loosen the two upper steering
N·m (27 in. lbs.).
column mounting nuts. If the vehicle is equipped
with the optional tilt steering column, move the tilt
WIPER SWITCH AND WASHER SWITCH steering column to the fully lowered position.
(5) Remove both the upper and lower shrouds from
FRONT the steering column.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (6) Remove the two screws that secure the switch
BAGS, REFER TO GROUP 8M - PASSIVE water shield and bracket to the top of the steering
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY column (Fig. 13).
STEERING WHEEL, STEERING COLUMN, OR (7) Remove the one screw located below the multi-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR function switch lever that secures the switch water
SERVICE. FAILURE TO TAKE THE PROPER PRE- shield and bracket to the steering column (Fig. 14).
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (8) Gently pull the lower mounting tab of the
BAG DEPLOYMENT AND POSSIBLE PERSONAL switch water shield bracket away from the steering
INJURY. column far enough to clear the screw boss below the
multi-function switch lever.
(1) Disconnect and isolate the battery negative (9) Lift the water shield and bracket with the
cable. multi-function switch off of the left side of the steer-
(2) Remove the knee blocker from the instrument ing column as a unit and move it out of the way. If
panel. See Knee Blocker in Group 8E - Instrument the vehicle is equipped with the optional tilt steering
Panel Systems for the procedures. column, lifting gently upward on the tilt release lever

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 8K - 12 WIPER AND WASHER SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(13) Reverse the removal procedures to install.
Tighten the upper switch mounting screws to 2.2
N·m (20 in. lbs.). Tighten the lower switch water
shield and bracket screw to 1.1 N·m (10 in. lbs.).
Tighten the non-tilt steering column mounting nuts
to 22 N·m (200 in. lbs.) and the steering column
shroud mounting screws to 2 N·m (18 in. lbs.).

REAR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
Fig. 13 Water Shield Upper Screws Remove/Install CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
1 – MOUNTING SCREWS BAG DEPLOYMENT AND POSSIBLE PERSONAL
2 – HAZARD WARNING SWITCH KNOB INJURY.
3 – MULTI-FUNCTION SWITCH LEVER
4 – WATER SHIELD AND BRACKET (1) Disconnect and isolate the battery negative
5 – WIPER SWITCH LEVER cable.
(2) Remove the center bezel from the instrument
panel. See Instrument Panel Center Bezel in Group
8E - Instrument Panel Systems for the procedures.
(3) Remove the three screws that secure the acces-
sory switch bezel to the instrument panel (Fig. 15).

Fig. 14 Water Shield Lower Screw Remove/Install

1 – MULTI-FUNCTION SWITCH LEVER
2 – WATER SHIELD AND BRACKET
3 – LOWER MOUNTING SCREW
Fig. 15 Accessory Switch Bezel Remove/Install
4 – LOWER MOUNTING TAB
1 – ACCESSORY SWITCH BEZEL
2 – SCREW
will provide additional clearance to ease multi-func-
tion switch removal.
(4) Pull the accessory switch bezel out from the
(10) Gently pull the windshield wiper and washer
instrument panel far enough to access the wire har-
switch up and away from the right side of the steer-
ness connectors.
ing column far enough to access the wire harness
(5) Unplug the wire harness connectors from the
connector.
rear of the accessory switches, the cigar lighter and
(11) Unplug the wire harness connector from the
the power outlet.
windshield wiper and washer switch.
(6) Remove the accessory switch bezel from the
(12) Remove the windshield wiper and washer
instrument panel.
switch from the steering column.
(7) With a small thin-bladed screwdriver, gently
pry the snap clips at the top and bottom of the rear

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 XJ WIPER AND WASHER SYSTEMS 8K - 13
REMOVAL AND INSTALLATION (Continued)
wiper and washer switch receptacle on the back of
the accessory switch bezel and pull the switch out of
the bezel.
(8) Reverse the removal procedures to install. Be
certain that both of the switch snap clip retainers in
the receptacle on the back of the accessory switch
bezel are fully engaged. Tighten the mounting screws
to 2.2 N·m (20 in. lbs.).

WASHER SYSTEM
WASHER RESERVOIR
(1) Disconnect and isolate the battery negative
cable.
(2) The washer reservoir filler neck is held in the
reservoir by an interference fit. Remove the filler
neck from the reservoir using a combination of pull-
ing, rocking and twisting actions (Fig. 16).

Fig. 17 Washer Reservoir Remove/Install

1 – SCREW
2 – FENDER
3 – WASHER RESERVOIR
4 – FILLER NECK
5 – SCREW
6 – FLUID LEVEL SENSOR
7 – REAR WASHER PUMP
8 – FRONT WASHER PUMP
9 – HOOK

(11) Reverse the removal procedures to install.

Tighten the reservoir mounting screws to 3 N·m (26
Fig. 16 Washer Reservoir Filler Neck Remove/Install in. lbs.).
1 – RESERVOIR
2 – LEFT FENDER WASHER PUMP
3 – FILLER NECK AND CAP (1) Disconnect and isolate the battery negative
cable.
(3) Remove the engine air filter housing. Refer to (2) Raise and support the vehicle.
Group 14 - Fuel System for the procedures. (3) Remove the left front inner wheelhouse splash
(4) Remove the two screws that secure the washer shield. Refer to Group 23 - Body for the procedures.
reservoir to the inner fender shield (Fig. 17). (4) Remove the washer supply hose(s) from the
(5) Raise and support the vehicle. barbed outlet nipple of the washer pump(s) and drain
(6) Remove the left front inner wheelhouse splash the washer fluid from the reservoir into a clean con-
shield. Refer to Group 23 - Body for the procedures. tainer for reuse.
(7) Remove the washer supply hose(s) from the (5) Unplug the wire harness connectors from the
washer pump(s) and drain the washer fluid from the washer pump(s).
reservoir into a clean container for reuse. (6) Using a trim stick or another suitable wide
(8) Unplug the wire harness connectors from the flat-bladed tool, gently pry the barbed inlet nipple of
washer pump(s) and the washer fluid level sensor. the washer pump out of the rubber grommet seal in
(9) Slide the reservoir slightly towards the rear of the reservoir. Care must be taken not to damage the
the vehicle to release the two hooks from the inner reservoir.
fender ledge slots. (7) Remove the rubber grommet seal from the res-
(10) Lower the front of the washer reservoir and ervoir and discard.
slide the unit forward to remove it from the vehicle.

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 8K - 14 WIPER AND WASHER SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(8) Reverse the removal procedures to install. (3) Carefully lift the cowl plenum cover/grille panel
Always use a new rubber grommet seal on the reser- and screen from the vehicle far enough to access the
voir. windshield washer plumbing. Use care so as not to
damage the paint around the pivot openings of the
WASHER FLUID LEVEL SENSOR panel.
(1) Remove the washer reservoir from the vehicle. (4) Disconnect the windshield washer supply hose
See Washer Reservoir in this group for the proce- and the passenger side washer nozzle hose from the
dures. washer nozzle supply hose tee fitting.
(5) Remove the cowl plenum cover/grille panel and
NOTE: The pivoting float of the washer fluid sensor screen from the vehicle.
must be in a horizontal position within the reservoir (6) From the underside of the cowl plenum cover/
in order to be removed. With the reservoir empty grille panel, disconnect the washer hose from the
and in an upright position, the pivoting float will ori- nozzle fitting.
ent itself to the horizontal position when the sensor (7) From the underside of the cowl plenum cover/
connector is pointed straight downwards. grille panel, remove the rivet that secures the nozzle
to the opening in the cowl plenum cover/grille panel.
(2) Using a trim stick or another suitable wide (8) Remove the washer nozzle from the cowl ple-
flat-bladed tool, gently pry the washer fluid level sen- num cover/grille panel.
sor out of the rubber grommet seal. Care must be (9) Reverse the removal procedures to install.
taken not to damage the reservoir.
(3) Remove the rubber grommet seal from the res- REAR
ervoir and discard. (1) Unsnap the rear washer nozzle from the rear
(4) Reverse the removal procedures to install. wiper arm (Fig. 19).
Always use a new rubber grommet seal on the reser-
voir.

WASHER NOZZLE
FRONT
(1) Remove the wiper arms from the wiper pivots.
See Wiper Arm in this group for the procedures.
(2) Remove the eight screws that secure the cowl
plenum cover/grille panel and screen to the cowl top
panel (Fig. 18).

Fig. 19 Rear Washer Nozzle Remove/Install

1 – TO CHECK VALVE AND BODY SUPPLY HOSE
2 – LIFTGATE
Fig. 18 Front Washer Nozzles Remove/Install 3 – GROMMET
4 – NOZZLE
1 – RIVET
5 – GUARD
2 – GRILLE PANEL
6 – HOSE
3 – SCREW
7 – CLIP
4 – SCREEN
8 – BEZEL
5 – WASHER HOSE
9 – LIFTGATE SUPPLY HOSE
6 – TEE
7 – NOZZLE

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 XJ WIPER AND WASHER SYSTEMS 8K - 15
REMOVAL AND INSTALLATION (Continued)
(2) Disconnect the washer supply hose from the (7) When reinstalling the check valve, be certain
barbed rear washer nozzle nipple. the valve is properly oriented within the system flow
(3) Reverse the removal procedures to install. (Fig. 20).

CHECK VALVE
(1) Remove the four screws that secure the liftgate
opening upper garnish moulding to the upper liftgate
opening reinforcement.
(2) Using a trim stick or another suitable wide-
bladed flat tool, gently pry the liftgate opening upper
garnish moulding away from the upper liftgate open-
ing reinforcement to release the snap clip retainers.
(3) Remove the garnish moulding from the upper
liftgate opening. Fig. 20 Rear Washer System Check Valve
(4) Disconnect the liftgate half of the washer sup- 1 – TO RESERVOIR
ply hose from the barbed nipple of the rear washer 2 – CHECKBALL
system check valve. 3 – SPRING
(5) Disconnect the body half of the washer supply 4 – TO NOZZLE
hose from the other barbed nipple of the rear washer
system check valve. (8) Reverse the remaining removal procedures to
(6) Remove the check valve from the vehicle. complete the installation.

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 XJ LAMPS 8L - 1

LAMPS
TABLE OF CONTENTS

page page

LAMP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 LAMP SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 3 LAMP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . . 6 BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . . . 20
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . . . 10

LAMP SYSTEMS

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 2

LAMP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DESCRIPTION AND OPERATION instrument cluster illumination. The headlamp

switch also contains a rheostat for controlling the
LAMP SYSTEMS illumination level of the instrument cluster lamps.
Each vehicle is equipped with various lamp assem-
OPERATION
blies. A good ground is necessary for proper lighting
operation. Grounding is provided through a separate The headlamp switch has an off position, a parking
ground wire. lamp position, and a headlamp on position. High
When changing lamp bulbs check the socket for beams are controlled by the multifunction switch on
corrosion. If corrosion is present, clean it with a wire the steering column. The headlamp switch cannot be
brush and coat the inside of the socket lightly with repaired. It must be replaced. Refer to Group 8E for
Mopart Multi-Purpose Grease or equivalent. removal and installation procedures, and Group 8W
for wiring.
HEADLAMPS
SENTINEL HEADLAMP DELAY MODULE
DESCRIPTION
DESCRIPTION
Headlamps on the Cherokee are sealed beam units.
Each module contains a low beam filament and a The Headlamp Module delays the de-activation of
high beam filament. the headlamps for 45 6 15 seconds after the ignition
switch is turned OFF.
OPERATION
OPERATION
The headlamps are controlled by the headlamp
switch and the high beams by the multifunction The driver engages the module by turning the igni-
switch. Each headlamp unit can be serviced individ- tion switch OFF, then turning the headlamps OFF.
ually. The module is mounted to a bracket attached to the
inside of the instrument panel.
HEADLAMP SWITCH
TAIL/TURN SIGNAL/STOP/BACK-UP LAMP
DESCRIPTION
DESCRIPTION
The headlamp switch is located on the instrument
panel. The headlamp switch controls the parking The rear tail lamp modules contains three bulbs, a
lamps, the headlamps, the interior lamps, and lens, and a housing. One bulb is a two filament bulb

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 8L - 2 LAMPS XJ
DESCRIPTION AND OPERATION (Continued)
used for tail light and stop lamp functions. One sin- ada only. A separate module, mounted on the cowl,
gle filament bulb is for turn signal functions. The controls the DRL.
other bulb is a single filament bulb used for back-up
light illumination. OPERATION
The headlamps are illuminated when the ignition
OPERATION switch is turned to the ON position. The DRL module
Each tail lamp module can be serviced separately. receives a vehicle-moving signal from the vehicle
Each bulb can also be serviced separately. The head- speed sensor. This provides a constant head-
lamp switch controls tail lamp operation. The multi- lamps-on condition as long as the vehicle is moving.
function switch on the steering column controls turn The lamps are illuminated at less than 50 percent of
signal operation, and the back-up light switch con- normal intensity.
trols the back-up light operation. The brake lamp
switch controls the stop lamp function. SAFETY PRECAUTIONS
FRONT TURN SIGNAL/PARKING LAMP WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
DESCRIPTION SONAL INJURY CAN RESULT.
The front turn signal and parking lamp module
contains a housing, a lens, and two bulbs.
CAUTION: Do not touch the glass of halogen bulbs
OPERATION with fingers or other possibly oily surface, reduced
The parking lamp function is controlled by the bulb life will result.
headlamp switch. The turn signal function is con- Do not use bulbs with higher candle power than
trolled by the multifunction switch on the steering indicated in the Bulb Application table at the end of
column. Each bulb can be serviced separately. this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
CHMSL (CENTER HIGH MOUNTED STOP LAMP) Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
DESCRIPTION fuse panel or in the Owners Manual.
The center high mounted stop lamp (CHMSL) is
When it is necessary to remove components to ser-
mounted on the liftgate. The module consists of a
vice another, it should not be necessary to apply
housing, a lens, and a single filament bulb.
excessive force or bend a component to remove it.
OPERATION Before damaging a trim component, verify hidden
The CHMSL is controlled by the brake lamp fasteners or captured edges are not holding the com-
switch. ponent in place.

DAYTIME RUNNING LAMPS

DESCRIPTION
The Daytime Running Lights (Headlamps) System
is installed on vehicles manufactured for sale in Can-

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 XJ LAMPS 8L - 3

LAMP DIAGNOSIS

TABLE OF CONTENTS
page page

DIAGNOSIS AND TESTING SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 3

DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 3

DIAGNOSIS AND TESTING SYSTEM DIAGNOSIS

DIAGNOSTIC PROCEDURES HEADLAMP
When a vehicle experiences problems with the Always begin any diagnosis by testing all of the
headlamp system, verify the condition of the battery fuses and circuit breakers in the system. Refer to
connections, fuses, charging system, headlamp bulbs, Group 8W, Wiring Diagrams.
wire connectors, relay, high beam switch, dimmer Conventional and halogen headlamps are inter-
switch, and headlamp switch. Refer to Group 8W, changeable. It is recommended that they not be
Wiring Diagrams for component locations and circuit intermixed on a given vehicle.
information.

CONDITION POSSIBLE CAUSES CORRECTION

HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
WITH ENGINE IDLING and posts.
OR IGNITION TURNED 2. Loose or worn generator drive 2. Adjust or replace generator drive belt.
OFF belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of-charge,
refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.

HEADLAMP BULBS BURN 1. Charging system output too high. 1. Test and repair charging system, refer to
OUT Group 8A.
FREQUENTLY 2. Loose or corroded terminals or 2. Inspect and repair all connectors and
splices in circuit. splices, refer to Group 8W.

HEADLAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system, refer to
WITH ENGINE RUNNING Group 8A.
ABOVE IDLE* 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
3. High resistance in headlamp 3. Test amperage draw of headlamp circuit.
circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.

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 8L - 4 LAMPS XJ
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

HEADLAMPS FLASH 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
RANDOMLY locations, refer to Group 8W.
2. High resistance in headlamp 2. Test amperage draw of headlamp circuit.
circuit. Should not exceed 30 amps.
3. Faulty headlamp switch. 3. Replace headlamp switch. Refer to
Group 8E.
4. Loose or corroded terminals or 4. Inspect and repair all connectors and
splices in circuit. splices, refer to Group 8W.

HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to

ILLUMINATE Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch. Refer to
Group 8E.
4. Faulty headlamp dimmer 4. Replace multi-function switch.
(multi-function) switch.
5. Broken connector terminal or wire 5. Repair connector terminal or wire splice.
splice in headlamp circuit.

*Canada vehicles must have lamps ON.

FOG LAMP

CONDITION POSSIBLE CAUSES CORRECTION

FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
WITH ENGINE IDLING OR and posts.
IGNITION TURNED OFF. 2. Loose or worn generator drive 2. Adjust or replace generator drive belt.
belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.

FOG LAMP BULBS BURN 1. Charging system output too high. 1. Test and repair charging system. Refer to
OUT FREQUENTLY Group 8A.

2. Loose or corroded terminals or 2. Inspect and repair all connectors and

splices in circuit. splices. Refer to Group 8W.

FOG LAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system. Refer to
WITH ENGINE RUNNING Group 8A.
ABOVE IDLE 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.

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 XJ LAMPS 8L - 5
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION

FOG LAMPS FLASH 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
RANDOMLY locations. Refer to Group 8W.
2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Loose or corroded terminals or 4. Inspect and repair all connectors and
splices in circuit. splices. Refer to Group 8W.

FOG LAMPS DO NOT 1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group 8W.
ILLUMINATE 2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to Group
8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or wire 4. Repair connector terminal or wire splice.
splice in fog lamp circuit.
5. Defective or burned out bulb. 5. Replace bulb.

HEADLAMP DELAY MODULE body ground. The voltmeter should indicate battery
voltage. If not, repair the open circuit in the wire
DELAY FUNCTION INOPERATIVE harness from ignition switch to HDLP delay module.
(1) Ensure headlamps operate before proceeding. (5) Turn headlamps on and measure voltage at
(2) Remove, inspect and test the HDLP delay 10 delay module connector, terminal 6. The voltmeter
amp fuse in junction box. Replace if defective. should indicate battery voltage. If not repair open cir-
(3) With the key off and the connector discon- cuit between L2 and HDLP delay module.
nected, measure the resistance from the delay mod- (6) Measure the voltage between the delay module
ule connector, terminal 4 to vehicle body ground. The connector, terminal 2 and vehicle body ground. The
ohmmeter should indicate zero ohms. If not, repair voltmeter should indicate battery voltage. If not,
the open circuit in the wire harness to vehicle body repair the open circuit in the wire harness to the
ground. HDLP fuse in the PDC.
(4) With the key on measure the voltage between (7) If steps 1 through 6 prove out good, replace
the delay module connector, terminal 8 and vehicle headlamp delay module.

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 8L - 6 LAMPS XJ

HEADLAMP ALIGNMENT

TABLE OF CONTENTS
page page

SERVICE PROCEDURES HEADLAMP ADJUSTMENT . . . . . . . . . . . . . . . . . . 6

HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . . 6 FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . . . . . 8
LAMP ALIGNMENT SCREEN PREPARATION . . . . . 6 SPECIAL TOOLS
VEHICLE PREPARATION FOR HEADLAMP HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . . 9
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE PROCEDURES (6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
HEADLAMP ALIGNMENT gallon of missing fuel.
Headlamps can be aligned using the screen method
provided in this section. Alignment Tool C-4466-A or HEADLAMP ADJUSTMENT
equivalent can also be used. Refer to instructions Headlamps can be aligned using the screen
provided with the tool for proper procedures. method. The Headlamp Alignment Tool C-4466-A or
equivalent can also be used. Refer to instructions
LAMP ALIGNMENT SCREEN PREPARATION provided with the tool for proper procedures.
(1) Position vehicle on a level surface perpendicu- A properly aimed low beam will project the top
lar to a flat wall 7.62 meters (25 ft) away from front edge of the beam intensity pattern on the screen
of headlamp lens (Fig. 1). from 25 mm (1 in.) above to 75 mm (3 in.) below
(2) If necessary, tape a line on the floor 7.62 headlamp centerline. The side-to-side left edge of the
meters (25 ft) away from and parallel to the wall. beam intensity pattern should be from 50 mm (2 in.)
(3) Measure from the floor up 1.27 meters (5 ft) left to 50 mm (2 in.) right of headlamp centerline
and tape a line on the wall at the centerline of the (Fig. 2).
vehicle. Sight along the centerline of the vehicle (1) Remove screws and both headlamp bezels.
(from rear of vehicle forward) to verify accuracy of (2) Clean front of the headlamps.
the line placement. (3) Place headlamps on LOW beam.
(4) Rock vehicle side-to-side three times to allow (4) Cover front of the headlamp that is not being
suspension to stabilize. adjusted.
(5) Jounce front suspension three times by pushing (5) Turn vertical adjustment screw (Fig. 3) until
downward on front bumper and releasing. the headlamp beam pattern on screen/wall is similar
(6) Measure the distance from the center of head- to the pattern depicted in the alignment screen fig-
lamp lens to the floor. Transfer measurement to the ure.
alignment screen (with tape). Use this line for
NOTE: When using a headlamp aiming screen,
up/down adjustment reference.
adjust the headlamps so that:
(7) Measure distance from the centerline of the
vehicle to the center of each headlamp being aligned. • The left edge of the beam intensity pattern is
Transfer measurements to screen (with tape) to each positioned within 50 mm (2 in.) left to 50 mm (2 in.)
side of vehicle centerline. Use these lines for left/ right of the vertical centerline (Fig. 2).
right adjustment reference. • The top edge of the beam intensity pattern is
positioned within 25 mm (1 in.) above or 75 mm (3
VEHICLE PREPARATION FOR HEADLAMP in.) below the headlamp horizontal centerline (Fig.
ALIGNMENT 2).
(1) Verify headlamp dimmer switch and high beam (6) Cover front of the headlamp and adjust the
indicator operation. other headlamp beam as instructed below.
(2) Correct defective components that could hinder (7) Rotate the adjustment screws until the beam
proper headlamp alignment. intensity pattern on the aiming screen/wall is aligned
(3) Verify proper tire inflation. within the headlamp the alignment screen target
(4) Clean headlamp lenses. (Fig. 2).
(5) Verify that luggage area is not heavily loaded.

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 XJ LAMPS 8L - 7
SERVICE PROCEDURES (Continued)

Fig. 1 Headlamp Alignment Screen—Typical

1 – CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS 4 – FRONT OF HEADLAMP
2 – FLOOR TO CENTER OF HEADLAMP LENS 5 – VEHICLE CENTERLINE
3 – 7.62 METERS (25 FEET)

(8) Cover front of headlamp that has been adjusted

and adjust the other headlamp beam as instructed
above.
(9) Install headlamp bezels. Tighten the screws
securely.

Fig. 3 Headlamp Beam Adjustment Screws

1 – LEFT/RIGHT ADJUSTMENT SCREW
2 – UP/DOWN ADJUSTMENT SCREW
3 – HEADLAMP

Fig. 2 Headlamp Alignment Screen Target

1 – LOW BEAM INTENSITY PATTERN (ISO-CANDELA CURVE)

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 8L - 8 LAMPS XJ
SERVICE PROCEDURES (Continued)

Fig. 4 Fog Lamp Alignment —Typical

1 – VEHICLE CENTERLINE 5 – 100 mm (4 in.)
2 – CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS 6 – 7.62 METERS (25 FEET)
3 – HIGH-INTENSITY AREA 7 – FRONT OF FOG LAMP
4 – FLOOR TO CENTER OF FOG LAMP LENS

FOG LAMP ADJUSTMENT

Prepare an alignment screen. A properly aligned
fog lamp will project a pattern on the alignment
screen 100 mm (4 in.) below the fog lamp centerline
and straight ahead (Fig. 4).
Rotate the adjustment screw to adjust beam height
(Fig. 5).

Fig. 5 Fog Lamp Adjustment

1 – ADJUSTMENT SCREW
2 – MOUNTING BRACKET
3 – FOG LAMP

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 XJ LAMPS 8L - 9

SPECIAL TOOLS
HEADLAMP ALIGNMENT

Headlamp Aiming Kit C-4466–A

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 8L - 10 LAMPS XJ

LAMP BULB SERVICE

TABLE OF CONTENTS
page page

REMOVAL AND INSTALLATION LICENSE PLATE LAMP BULB . . . . . . . . . . . . . . . 12

HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 10 CENTER HIGH MOUNTED STOP LAMP
FOG LAMP BULB. . . . . . . . . . . . . . . . . . . . . . . . . 10 (CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . . . 12
FRONT PARK/TURN SIGNAL LAMP BULB . . . . . . 11 UNDERHOOD LAMP BULB . . . . . . . . . . . . . . . . . 12
SIDE MARKER LAMP BULB . . . . . . . . . . . . . . . . . 11 CARGO LAMP BULB . . . . . . . . . . . . . . . . . . . . . . 13
BACK-UP/BRAKE/REAR TURN SIGNAL/TAIL MAP READING LAMP BULB. . . . . . . . . . . . . . . . . 13
LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 VISOR VANITY LAMP BULB. . . . . . . . . . . . . . . . . 13

REMOVAL AND INSTALLATION (3) Position retaining ring on sealed beam and
install screws.
HEADLAMP BULB (4) Install headlamp bezel.

REMOVAL FOG LAMP BULB

(1) Remove the screws attaching the bezel to the
grille opening panel (Fig. 1). REMOVAL
(2) Remove screws attaching the retaining ring to (1) Remove the screws attaching the access cover
the headlamp canister. to the bottom of the fog lamp (Fig. 2).
(3) Disconnect the headlamp bulb wire harness (2) Remove spring clip securing bulb to fog lamp.
connector. (3) Disconnect bulb wire connector.
(4) Separate the sealed beam from the vehicle. (4) Remove bulb element from fog lamp.

Fig. 1 Headlamp Bezel Fig. 2 Fog Lamp Components

1 – HEADLAMP ADJUSTMENT 1 – FOG LAMP
2 – NUT 2 – CLIP
3 – HEADLAMP 3 – BULB
4 – BEZEL 4 – ACCESS COVER
5 – PARK/TURN LAMP 5 – BULB SOCKET
6 – SPRING
7 – BUMPER
INSTALLATION

INSTALLATION CAUTION: Do not touch the bulb glass with fingers

(1) Connect wire harness connector. or other oily surfaces. Reduced bulb life will result.
(2) Position bulb in canister. (1) Position bulb element in fog lamp.

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 XJ LAMPS 8L - 11
REMOVAL AND INSTALLATION (Continued)
(2) Connect bulb wire connector.
(3) Install spring clip securing bulb to fog lamp.
(4) Install screws attaching the access cover to the
bottom of the fog lamp.

FRONT PARK/TURN SIGNAL LAMP BULB

REMOVAL
(1) Remove headlamp bezel.
(2) Remove screws attaching park/turn signal
lamp housing to grille opening panel.
(3) Rotate bulb socket one-third turn counter-clock-
wise and remove it from lamp housing (Fig. 3).
(4) Pull bulb from socket.

Fig. 4 Side Marker Lamp

1 – SIDE MARKER LAMP HOUSING
2 – SIDE MARKER LAMP BULB
3 – BULB SOCKET

BACK-UP/BRAKE/REAR TURN SIGNAL/TAIL

LAMP BULB
REMOVAL
(1) Remove tail lamp housing.
(2) Rotate bulb socket one-third turn counter-clock-
wise and remove bulb socket from lamp housing (Fig.
5).
(3) Pull bulb from socket.
Fig. 3 Park/Turn Signal Lamp Bulb
1 – BULB SOCKET
2 – PARK LAMP HOUSING
3 – PARK LAMP BULB

INSTALLATION
(1) Install bulb in socket.
(2) Install socket in lamp housing.
(3) Install park/turn signal lamp housing.
(4) Install headlamp bezel.

SIDE MARKER LAMP BULB

REMOVAL
(1) Remove screws attaching side marker lamp
housing.
(2) Rotate bulb socket counter-clockwise and pull Fig. 5 Bulb Socket Removal
from back side of lamp housing (Fig. 4). 1 – TAIL LAMP BULB
(3) Pull bulb from socket. 2 – BULB SOCKET
3 – TAIL LAMP HOUSING
INSTALLATION
(1) Install bulb in socket.
(2) Install bulb and socket in back of side marker
INSTALLATION
(1) Install bulb in socket.
lamp housing.
(2) Install bulb and socket in lamp housing.
(3) Install side marker lamp housing.
(3) Install lamp housing.

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 8L - 12 LAMPS XJ
REMOVAL AND INSTALLATION (Continued)

LICENSE PLATE LAMP BULB UNDERHOOD LAMP BULB

REMOVAL REMOVAL
(1) Remove screws attaching license plate lamp (1) Insert a small flat blade in the access slot
housing to liftgate. between the lamp base and lamp lens.
(2) Rotate bulb socket counter-clockwise and (2) Pry the lamp lens upward and remove the
remove bulb socket from lamp housing. lamp lens (Fig. 7).
(3) Pull bulb from socket. (3) Depress the bulb terminal inward (Fig. 8) to
release the bulb.
INSTALLATION
(1) Install bulb in lamp socket.
(2) Install bulb socket in lamp housing.
(3) Install screws attaching license plate lamp
housing to liftgate.

CENTER HIGH MOUNTED STOP LAMP

(CHMSL) BULB
REMOVAL
(1) Remove the screws attaching the lamp housing
to the liftgate.
(2) Rotate bulb socket 1/4 turn counter-clockwise
and pull from housing (Fig. 6).
(3) Pull bulb from socket.

Fig. 7 Underhood Lamp Lens

1 – LAMP
2 – LAMP LENS

Fig. 6 CHMSL Bulb

1 – CHMSL BULB
2 – BULB SOCKET
3 – CHMSL LAMP HOUSING

INSTALLATION Fig. 8 Underhood Lamp Bulb

1 – BULB
(1) Push bulb into socket.
2 – DEPRESS TERMINAL INWARD
(2) Position socket in lamp and rotate 1/4 turn
3 – BULB WIRE LOOP
clockwise. 4 – LAMP BASE
(3) Install screws attaching lamp housing to the
liftgate.
INSTALLATION
(1) Engage the replacement bulb wire loop to the
terminal closest to the lamp base wire connector.

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 XJ LAMPS 8L - 13
REMOVAL AND INSTALLATION (Continued)
(2) Depress the opposite terminal inward and MAP READING LAMP BULB
engage the remaining bulb wire loop.
(3) Position the lamp lens on the lamp base and REMOVAL
press into place. (1) Insert a flat blade screwdriver in slot at front
of lens (Fig. 10).
CARGO LAMP BULB (2) Rotate the screwdriver until lens snaps out of
the housing.
REMOVAL (3) Remove lens from housing.
(1) Insert a small flat blade into the access slots (4) Remove bulb from terminals.
(Fig. 9).
(2) Carefully pry the lens from the lamp.
(3) Grasp bulb and pull from lamp.

Fig. 10 Reading Lamp Bulb

1 – LENS
2 – FLAT BLADE
Fig. 9 Cargo Lamp Lens
3 – CONSOLE
1 – HOUSING
2 – SCREWDRIVER SLOTS
3 – CARGO LAMP INSTALLATION
4 – LENS (1) Insert bulb into reading lamp terminals.
(2) Replace lens by holding lens level and pushing
INSTALLATION rearward into housing.
(1) Position bulb in lamp and snap into place. (3) Push lens up to snap into housing.
(2) Position the lens at the lamp housing and force
it upward into the housing until the mounting tabs VISOR VANITY LAMP BULB
are seated on the lamp mounting pins.
REMOVAL
(1) Using a small flat blade, carefully pry each cor-
ner of lens outward from lamp.
(2) Separate lens from lamp.
(3) Grasp bulb and pull outward.

INSTALLATION
(1) Position bulb in socket and push into place.
(2) Position lens on lamp and snap into place.

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 8L - 14 LAMPS XJ

LAMP SERVICE

TABLE OF CONTENTS
page page

REMOVAL AND INSTALLATION CENTER HIGH MOUNTED STOP LAMP

HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 (CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FOG LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 LICENSE PLATE LAMP . . . . . . . . . . . . . . . . . . . . 16
FRONT PARK/TURN SIGNAL LAMP . . . . . . . . . . . 15 UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . . . 16
SIDE MARKER LAMP. . . . . . . . . . . . . . . . . . . . . . 15 CARGO LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
BACK-UP/BRAKE/REAR TURN SIGNAL/TAIL MAP/READING LAMP . . . . . . . . . . . . . . . . . . . . . 17
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 VISOR VANITY LAMP. . . . . . . . . . . . . . . . . . . . . . 18

REMOVAL AND INSTALLATION

HEADLAMP
REMOVAL
(1) Remove the screws attaching the bezel to the
grille opening panel
(2) Remove the screws attaching the retaining ring
to the headlamp bucket.
(3) Disconnect the headlamp bulb wire harness
connector (Fig. 1).
(4) Separate the bulb from the vehicle.
(5) Remove the spring attaching the headlamp
bucket to the grille opening panel (Fig. 2).
(6) Slide the headlamp bucket downward to disen-
gage it from the headlamp adjusting screws.
Fig. 2 Headlamp
1 – HEADLAMP ADJUSTMENT
2 – NUT
3 – HEADLAMP
4 – BEZEL
5 – PARK/TURN LAMP
6 – SPRING
7 – BUMPER

INSTALLATION
(1) Position the headlamp bucket in the grille
opening panel and slide the headlamp bucket upward
to engage it with the headlamp adjusting screws.
(2) Install the spring attaching the headlamp
bucket to the grille opening panel.
(3) Connect the wire harness connector.
(4) Position the bulb in the bucket.
Fig. 1 Headlamp Connector (5) Position retaining ring on the headlamp bulb
1 – HEADLAMP CONNECTOR
and install screws.
2 – PARK/TURN LAMP BULB
3 – SIDE MARKER LAMP BULB
(6) Install the headlamp bezel.

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 XJ LAMPS 8L - 15
REMOVAL AND INSTALLATION (Continued)

FOG LAMP
REMOVAL
(1) Disconnect the fog lamp wire harness connec-
tor.
(2) Remove the screws attaching the fog lamp to
the support (Fig. 3).
(3) Separate the fog lamp from the vehicle.

Fig. 4 Park/Turn Signal Lamp

1 – NUT
2 – BEZEL
3 – PARK/TURN LAMP
4 – BUMPER

(2) Remove bulb and socket from back side of

lamp.

Fig. 3 Fog Lamp

1 – FOG LAMP
2 – BUMPER

INSTALLATION
(1) Position the fog lamp in the support bracket
and install the screws.
(2) Connect the fog lamp wire harness connector.

FRONT PARK/TURN SIGNAL LAMP

REMOVAL
(1) Remove the headlamp bezel.
(2) Remove the screws attaching the park/turn sig-
nal lamp housing to the grille opening panel (Fig. 4).
Fig. 5 Side Marker Lamp
(3) Remove the bulb sockets and separate from the
1 – GRILLE OPENING PANEL
vehicle. 2 – FENDER
3 – SIDE MARKER LAMP
INSTALLATION
(1) Install bulbs and sockets in the lamp housing.
(2) Position the park/turn signal lamp housing on INSTALLATION
the grille opening panel and install the screws. (1) Install bulb and socket in back of side marker
(3) Install the headlamp bezel. lamp.
(2) Install side marker lamp in grille opening
SIDE MARKER LAMP panel.

REMOVAL
(1) Remove screws attaching side marker lamp
lens to grille opening panel (Fig. 5).

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 8L - 16 LAMPS XJ
REMOVAL AND INSTALLATION (Continued)

BACK-UP/BRAKE/REAR TURN SIGNAL/TAIL

LAMP
REMOVAL
(1) Open the liftgate.
(2) Remove the bolts attaching the tail lamp hous-
ing to the quarter panel (Fig. 6).
(3) Grasp the lamp and pull to disengage it from
the grommet at the base of the lamp.
(4) Rotate the bulb sockets one-third turn and
remove the bulb sockets from the lamp housing.

Fig. 7 Center High Mounted Stop lamp

1 – U-NUT
2 – LIFTGATE
3 – CHMSL

(3) Install the screws attaching the CHMSL to the

liftgate.

LICENSE PLATE LAMP

REMOVAL
Fig. 6 Tail Lamp (1) Remove screws attaching the license plate
1 – TAIL LAMP lamp to the liftgate.
2 – REAR BUMPER
(2) Remove the bulb from the lamp socket.
3 – GROMMET

INSTALLATION
INSTALLATION (1) Install bulb in the lamp socket.
(1) Install the bulb and sockets in the lamp hous- (2) Position the license plate lamp on the liftgate
ing. and install screws.
(2) Position the lamp housing in the quarter panel
and push to engage the grommet. UNDERHOOD LAMP
(3) Install the lamp housing screws. Tighten the The underhood lamp is installed on the hood inner
screws securely. panel. The lamp illuminates when the hood is
(4) Install the bolts attaching the tail lamp hous- opened. A switch that is integral with the lamp base
ing to the quarter panel. controls the operation. The switch provides automatic
(5) Close the liftgate. ON/OFF functions each time the hood is opened and
closed.
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) REMOVAL
(1) Disconnect the wire harness connector from the
REMOVAL lamp.
(1) Remove the screws attaching the CHMSL to (2) Remove lamp lens.
the liftgate (Fig. 7). (3) Remove bulb.
(2) Disconnect the wire harness connector. (4) Remove screw attaching underhood lamp to the
(3) Separate the CHMSL from the vehicle. inner hood panel.
(5) Separate underhood lamp from vehicle.
INSTALLATION
(1) Connect the wire harness connector.
(2) Position the CHMSL on the liftgate.

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 XJ LAMPS 8L - 17
REMOVAL AND INSTALLATION (Continued)

Fig. 9 Cargo Lamp

Fig. 8 Underhood Lamp 1 – HOUSING
1 – HOOD 2 – SCREWDRIVER SLOTS
2 – UNDERHOOD LAMP/SWITCH 3 – CARGO LAMP
4 – LENS

INSTALLATION
(1) Position underhood lamp on hood inner panel.
Ensure anti-rotation tab is positioned in slot on hood
inner panel.
(2) Install the attaching screw through the lamp
and into the hood panel (Fig. 8). Tighten the screw
securely.
(3) Fold lamp housing over and firmly press onto
base to snap into place.
(4) Connect the wire harness connector to the
lamp.

CARGO LAMP
REMOVAL
(1) Insert a small flat blade into the access slots
(Fig. 9).
(2) Carefully pry the lens from the lamp. Fig. 10 Cargo Lamp Lens
(3) Disengage the lens mounting tabs from the 1 – MOUNTING PIN ON UNDERSIDE
lamp mounting pins (Fig. 10). 2 – BULB
(4) Remove the fasteners attaching the lamp to the 3 – MOUNTING PIN
4 – MOUNTING TAB
roof.
5 – TAB “A”
(5) Remove the lamp housing from the headliner
6 – MOUNTING TAB
cavity. 7 – SLOT “B”
(6) Disconnect the wire harness connector.

INSTALLATION MAP/READING LAMP

(1) Position the dome lamp housing at the head- The map/reading lamp can be serviced by removing
liner cavity. the overhead console. Refer to Group 8C, Overhead
(2) Connect the wire harness connector. Console for removal/installation procedures.
(3) Install the fasteners attaching the lamp to the
roof.
(4) Position the lens at the lamp housing and force
it upward into the housing until the mounting tabs
are seated on the lamp mounting pins.

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 8L - 18 LAMPS XJ
REMOVAL AND INSTALLATION (Continued)

VISOR VANITY LAMP INSTALLATION

(1) Position visor lamp at visor and connect visor
REMOVAL lamp wire connector.
(1) Fold down sunvisor. (2) Position visor lamp in visor and press into
(2) Starting at the base of the lamp assembly and place.
working right-to-left, use a small flat blade, carefully
pry lamp from visor.
(3) Disconnect visor lamp wire connector and
remove from vehicle.

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 XJ LAMPS 8L - 19

LAMP SYSTEMS

TABLE OF CONTENTS
page page

REMOVAL AND INSTALLATION DAYTIME RUNNING LAMP MODULE . . . . . . . . . . 19

SENTINEL HEADLAMP DELAY MODULE . . . . . . . 19

REMOVAL AND INSTALLATION DAYTIME RUNNING LAMP MODULE

SENTINEL HEADLAMP DELAY MODULE REMOVAL
The Daytime Running Lights (DRL) module is
REMOVAL located on the right fender inner panel adjacent to
(1) Remove the knee blocker. the dash panel (Fig. 2).
(2) Remove the screw that attaches the module to
the inside of the instrument panel (Fig. 1).
(3) Disconnect the wire harness connector and
remove the module from the instrument panel.

Fig. 1 Headlamp Delay Module

1 – BRACKET
2 – HEADLAMP DELAY MODULE Fig. 2 Daytime Running Lamp Module
1 – DAYTIME RUNNING LIGHT MODULE

INSTALLATION
(1) Disconnect the wire harness connector from the
(1) Position the module inside the I/P and connect
module.
the wire harness connector to the module.
(2) Remove the screws that attach the module to
(2) Install the screw that attaches the module to
the fender inner panel.
the inside of the instrument panel.
(3) Remove the module from the fender inner
(3) Install the knee blocker.
panel.

INSTALLATION
(1) Position the module on the right fender inner
panel.
(2) Install the attaching screws. Tighten the
screws securely.
(3) Connect the wire harness connector to the mod-
ule.

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 8L - 20 LAMPS XJ

BULB APPLICATION

TABLE OF CONTENTS
page page

SPECIFICATIONS INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . 20

EXTERIOR LAMPS. . . . . . . . . . . . . . . . . . . . . . . . 20

SPECIFICATIONS LAMP BULB

Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
EXTERIOR LAMPS Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Dome/Reading . . . . . . . . . . . . . . . . . . . . . . . . . . 906
CAUTION: Do not use bulbs that have a higher can- Overhead Console . . . . . . . . . . . . . . . . . . . . . . . 912
dle power than the bulb listed in the Bulb Applica- Under Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
tion Table. Damage to lamp can result. Do not touch Vanity Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
halogen bulbs with fingers or other oily surfaces. Underpanel Courtesy . . . . . . . . . . . . . . . . . . . . 168
Bulb life will be reduced.
INDICATOR LAMPS
The following Bulb Application Table lists the lamp
title on the left side of the column and trade number LAMP BULB
or part number on the right. A/C Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Airbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
LAMP BULB Anti-lock Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3157 Brake Warning . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Center High Mounted Stoplamp . . . . . . . . . . . . 921 Check Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fog lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3 Check Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Front Side Marker . . . . . . . . . . . . . . . . . . . . . . 168 Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Headlamp/Sealed Beam . . . . . . . . . . . . . . 6054BLL Coolant Temp High . . . . . . . . . . . . . . . . . . . . . . 194
License Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Cruise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Park/Turn Signal . . . . . . . . . . . . . . . . . . . . . . . 3157 Fasten Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . 74
Tail/Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3157 Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . 74
Rear Turn Signal . . . . . . . . . . . . . . . . . . . . . . . 3157 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Heater Control . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INTERIOR LAMPS High Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the Bulb Applica- Low Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
tion Table. Damage to lamp can result. Low Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . 194
Low Washer Fluid . . . . . . . . . . . . . . . . . . . . . . . . 74
Service procedures for most of the lamps in the Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASC
instrument panel, Instrument cluster and switches Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
are located in Group 8E, Instrument Panel and Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . 658
Gauges. Some components have lamps that can only Transmission Floor Shift . . . . . . . . . . . . . . . . . . 658
be serviced by an Authorized Service Center (ASC) Turn Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
after the component is removed from the vehicle. Upshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
The following Bulb Application Tables lists the
lamp title on the left side of the column and trade
number or part number on the right.

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 XJ LAMPS 8L - 1

LAMPS
TABLE OF CONTENTS

page page

LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 1 LAMP SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

HEADLAMP AND FOG LAMP ALIGNMENT. . . . . . . 3 BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . . . 11
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . . . . 6

LAMP DIAGNOSIS

TABLE OF CONTENTS
page page

DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . 2

HEADLAMP LEVELING MOTOR. . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . 1

DESCRIPTION AND OPERATION

HEADLAMP LEVELING MOTOR
DESCRIPTION
Vehicles equipped with a remote headlamp leveling
system use two leveling motors attached to each
headlamp mounting bracket. They are located just
behind the headlamp assemblies and must be
accessed from underneath the vehicle.

OPERATION
This system allows the driver to adjust the vertical
headlamp aim from the interior of the vehicle to com-
pensate for passenger or cargo load. A headlamp lev-
eling switch is located in the instrument panel and
controls the headlamp leveling motor function.

DIAGNOSIS AND TESTING

DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the Fig. 1 Headlamp Leveling Motor Position &
headlamp system, verify the condition of the battery Orientation
connections, fuses, charging system, headlamp bulbs, 1 – HEADLAMP LEVELING MOTOR
wire connectors, relay, high beam switch, dimmer 2 – FRONT STABILIZER BAR
switch, and headlamp switch. Refer to Group 8W,
Wiring Diagrams for component locations and circuit
information.

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 8L - 2 LAMPS XJ
DIAGNOSIS AND TESTING (Continued)

DIAGNOSIS AND TESTING

HEADLAMP LEVELING MOTOR DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

ONE MOTOR DOES NOT 1. Poor connection at motor. 1. Secure connector on motor.
OPERATE
2. No voltage at motor. 2. Repair circuit. Refer to Group 8W,
Wiring.
3. Defective motor. 3. Replace motor.

BOTH MOTORS DO NOT 1. No voltage at headlamp leveling 1. Repair circuit or replace fuse. Refer to
OPERATE switch. Group 8W, Wiring.
2. No voltage at both motors. 2. Repair circuit or replace fuse. Refer to
Group 8W, Wiring.
3. Poor connection at motors. 3. Secure connectors on motors.
4. Both motors defective. 4. Replace motors.

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 XJ LAMPS 8L - 3

HEADLAMP AND FOG LAMP ALIGNMENT

TABLE OF CONTENTS
page page

SERVICE PROCEDURES ADJUSTMENTS

HEADLAMP ALIGNMENT PREPARATION. . . . . . . . 3 HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN . . . . . . . . . . . . . . . . . . . . 3

SERVICE PROCEDURES (5) Rock vehicle side-to-side three times and allow
suspension to stabilize.
HEADLAMP ALIGNMENT PREPARATION (6) Jounce front suspension three times by pushing
(1) Verify headlamp are on low beam setting. downward on front bumper and releasing.
(2) Verify that the headlamp leveling switch is in (7) Measure the distance from the center of head-
the “0” position. lamp lens to the floor. Transfer measurement to the
(3) Inspect and correct damaged or defective com- alignment screen (with tape). Use this line for
ponents that could interfere with proper headlamp up/down adjustment reference.
alignment. (8) Place a tape line 130 mm below and parallel to
(4) Verify proper tire inflation. the center of headlamp line.
(5) Clean headlamp lenses. (9) Measure distance from the centerline of the
(6) Verify that luggage area is loaded as the vehi- vehicle to the center of each headlamp being aligned.
cle is routinely used. Transfer measurements to screen (with tape) to each
(7) Fuel tank should be FULL. Add 2.94 kg (6.5 side of vehicle centerline. Use these lines for left/
lbs.) of weight over the fuel tank for each estimated right adjustment reference.
gallon of missing fuel.
HEADLAMP ADJUSTMENT
A properly aimed low beam headlamp will project a
ADJUSTMENTS high intensity light pattern on the screen with the
horizontal cut-off line aligned with the tape line 130
HEADLAMP/FOG LAMP ADJUSTMENT USING mm (5.12 in.) below the headlamp centerline (Fig. 1).
ALIGNMENT SCREEN The intersection of the horizontal and 15 degree cut-
off lines in the projected pattern should align to the
ALIGNMENT SCREEN PREPARATION intersection of the headlamp centerline vertical tape
(1) Position vehicle on a level surface perpendicu- line and the tape line 130 mm (5.12 in.) below the
lar to a flat wall 10 meters (32.8 ft.) away from front headlamp horizontal centerline. The high beams on a
of headlamp lens (Fig. 1). vehicle with aero headlamps cannot be aligned. The
(2) Place 75 kg in the driver’s seat to simulate the high beam pattern should be correct when the low
ride height of the vehicle when driven. beams are aligned properly.
(3) If necessary, tape a line on the floor 10 meters To adjust headlamp alignment, rotate alignment
(32.8 ft) away from and parallel to the wall. screws (Fig. 2) to achieve the specified low beam hot
(4) From the floor up 1.27 meters (5 ft), tape a line spot pattern.
on the wall at the centerline of the vehicle. Sight
along the centerline of the vehicle (from rear of vehi-
cle forward) to verify accuracy of the line placement.

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 8L - 4 LAMPS XJ
ADJUSTMENTS (Continued)

Fig. 1 Headlamp Alignment Screen—Typical

1 – CENTER OF VEHICLE 5 – 10 METERS (32.8 ft.)
2 – CENTER OF HEADLAMPS 6 – HORIZONTAL CUT-OFF LINE
3 – 15° CUT-OFF LINE 7 – 130mm
4 – FRONT OF HEADLAMP

FOG LAMP ALIGNMENT

Prepare an alignment screen. Refer to the Align-
ment Screen Preparation paragraph in this section. A
properly aligned fog lamp will project a pattern on
the alignment screen 200 mm (8 in.) below the fog
lamp centerline and straight ahead (Fig. 3). To
improve visual interpretation of the fog lamp pattern
on the alignment screen, disable the headlamps by
disengaging the wire connectors from the headlamp
bulbs.
To adjust fog lamp alignment, rotate alignment
screws (Fig. 4) to achieve the specified pattern.

Fig. 2 Headlamp Beam Adustment Screws

1 – LEFT/RIGHT ADJUSTMENT SCREW
2 – UP/DOWN ADJUSTMENT SCREW
3 – HEADLAMP

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 XJ LAMPS 8L - 5
ADJUSTMENTS (Continued)

Fig. 3 Fog Lamp Alignment-Typical

1 – HIGH INTENSITY AREA 5 – 200mm (8 in.)
2 – CENTER OF VEHICLE 6 – FRONT OF FOG LAMP
3 – VERTICAL CENTER OF FOG LAMP 7 – 10 METERS (32.8 ft.)
4 – HORIZONTAL CENTER OF FOG LAMP

Fig. 4 Fog Lamp Beam Adjustment Screws

1 – ADJUSTMENT SCREW
2 – MOUNTING BRACKET
3 – FOG LAMP

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 8L - 6 LAMPS XJ

LAMP BULB SERVICE

TABLE OF CONTENTS
page page

REMOVAL AND INSTALLATION REAR FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . 7

FRONT POSITION LAMP BULB . . . . . . . . . . . . . . . 6 LICENSE PLATE LAMP BULB . . . . . . . . . . . . . . . . 7
SIDE REPEATER LAMP BULB . . . . . . . . . . . . . . . . 6

REMOVAL AND INSTALLATION (3) Pull the front position lamp straight from
headlamp (Fig. 3).
FRONT POSITION LAMP BULB
REMOVAL
(1) Remove the 2 screws holding the headlamp
bezel in place and remove bezel (Fig. 1).

Fig. 3 Front Position Lamp Grommet & Socket

Location
1 – GROMMET
2 – SOCKET

Fig. 1 Headlight Bezel Retaining Screws (4) Remove the front position lamp bulb from
(2) Remove the 4 screws holding the headlamp socket.
(Fig. 2).
INSTALLATION
(1) Install the front position lamp bulb in lamp
socket.
(2) Verify lamp operation.
(3) Install front position lamp in headlamp.
(4) Connect headlamp electrical connector.
(5) Position the headlamp, headlamp retaining
ring and install the retaining screws.
(6) Position the headlamp bezel and install retain-
ing screws.

SIDE REPEATER LAMP BULB

REMOVAL
Fig. 2 Headlamp Retaining Screws (1) Grip the side repeater lamp assembly and pull
straight from the fender.
(2) Rotate and pull the socket from the housing
(Fig. 4).
(3) Pull the bulb straight from the socket.

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 XJ LAMPS 8L - 7
REMOVAL AND INSTALLATION (Continued)

Fig. 4 Side Repeater Lamp Fig. 5 Rear Lamp Replacement

INSTALLATION (3) Install the remaining three lamp sockets in the
(1) Align the side repeater lamp bulb to the socket taillamp assembly.
(Fig. 4). (4) Position the taillamp assembly and install the
(2) Push the bulb into the socket. retaining screws.
(3) Verify lamp operation.
(4) Push and rotate the socket into the housing. LICENSE PLATE LAMP BULB
(5) Press the lamp assembly into the fender
mounting hole. REMOVAL
(1) Remove the appropriate license plate lamp
REAR FOG LAMP BULB retaining screws.
(2) Pull lamp housing from rear liftgate. Lamp
REMOVAL must be positioned properly to allow removal without
(1) There are 3 mounting bolts attaching the tail- removing license plate.
light assembly. When removing, unfasten the 3 bolts (3) Rotate the lamp socket counter clockwise and
located on the top and side. Lift up and out to pull straight from lamp housing.
remove the assembly. (4) Pull the lamp bulb straight from its socket.
(2) Turn the socket assembly 1/3 turn and pull the
socket from the housing (Fig. 5). INSTALLATION
(3) Pull the rear fog lamp straight from its socket. (1) Install bulb in lamp socket.
(2) Verify lamp operation.
INSTALLATION (3) Install lamp socket in lamp housing.
(1) Install rear fog lamp bulb in its socket. (4) Install license plate lamp assembly in liftgate
(2) Verify lamp operation. and install retaining screws.

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 8L - 8 LAMPS XJ

LAMP SERVICE

TABLE OF CONTENTS
page page

REMOVAL AND INSTALLATION FRONT FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . 9

HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REAR TURN SIGNAL, BACKUP, TAILLAMP
HEADLAMP LEVELING MOTOR. . . . . . . . . . . . . . . 8 AND FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 9
SIDE REPEATER LAMP . . . . . . . . . . . . . . . . . . . . . 9 LICENSE PLATE LAMP . . . . . . . . . . . . . . . . . . . . . 9

REMOVAL AND INSTALLATION INSTALLATION

(1) Install front position lamp in headlamp.
HEADLAMP (2) Connect headlamp electrical connector.
(3) Position the headlamp, headlamp retaining
REMOVAL ring and install the retaining screws.
(1) Remove the 2 screws holding the headlamp (4) Position the headlamp bezel and install retain-
bezel in place and remove bezel (Fig. 1). ing screws.

HEADLAMP LEVELING MOTOR

REMOVAL
(1) Open the hood and disconnect the negative bat-
tery cable.
(2) Raise the vehicle on a hoist or position a
creeper under the front of the vehicle.
(3) Remove the appropriate side front splash
shield. Located just in front of the front wheel.

Fig. 1 Headlight Bezel Retaining Screws

(2) Remove the 4 screws holding the headlamp
(Fig. 2).
(3) Pull the front position lamp straight from
headlamp.
(4) Disconnect the headlamp electrical connector
by pulling straight off.
(5) Remove the headlamp from the vehicle.

Fig. 3 Headlamp Leveling Motor

1 – HEADLAMP LEVELING MOTOR
2 – FRONT STABILIZER BAR
Fig. 2 Headlamp Retaining Screws

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 XJ LAMPS 8L - 9
REMOVAL AND INSTALLATION (Continued)
(4) Disconnect the headlamp leveling motor electri- FRONT FOG LAMP
cal connector.
(5) Rotate the leveling motor 90 degrees until REMOVAL
motor is loose in mounting bracket. 1. Remove the 2 screws from the bottom cover of
(6) Tilt motor upwards to disconnect motor push the lamp body.
rod from the headlamp leveling linkage. 2. Disconnect the 2 wires from the lamp element.
(7) Remove the headlamp leveling motor from the 3. Remove the lamp element from the housing.
vehicle (Fig. 3).
INSTALLATION
INSTALLATION 1. Install the new lamp element in the housing
(1) Install leveling motor push rod through hole in and reinstall the lower housing.
mounting bracket and connect push rod on leveling
linkage. The proper angle must be achieved to con- REAR TURN SIGNAL, BACKUP, TAILLAMP AND
nect the push rod onto the leveling linkage.
(2) Once the push rod is connected, rotate motor
FOG LAMP
until tabs line up with tabs in mounting bracket.
Once the tabs are lined up push and rotate the motor
REMOVAL
(1) There are 3 mounting bolts attaching the tail-
90 degrees to lock in place.
light assembly. When removing, unfasten the 3 bolts
(3) Connect the headlamp leveling motor electrical
located on the top and side. Lift up and out to
connector.
remove the assembly.
(4) Position the front splash shield.
(5) Lower the vehicle and connect the negative
battery cable.

SIDE REPEATER LAMP

REMOVAL
(1) Grip the side repeater lamp assembly and pull
straight from the fender.

Fig. 5 Rear Lamp Replacement

(2) Turn the socket assembly 1/3 turn and pull the
socket from the housing (Fig. 5).

INSTALLATION
(1) Install the four lamp sockets in the taillamp
assembly.
(2) Verify lamp operation.
Fig. 4 Side Repeater Lamp (3) Position the taillamp assembly and install the
retaining screws.
(2) Rotate and pull the socket from the housing
(Fig. 4).
LICENSE PLATE LAMP
INSTALLATION
(1) Push and rotate the socket into the housing.
REMOVAL
(2) Verify lamp operation. (1) Remove the appropriate license plate lamp
(3) Press the lamp assembly into the fender retaining screws.
mounting hole. (2) Pull lamp housing from rear liftgate. Lamp
must be positioned properly to allow removal without
removing license plate.
(3) Rotate the lamp socket counter clockwise and
pull straight from lamp housing.

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 8L - 10 LAMPS XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install lamp socket in lamp housing.
(2) Verify lamp operation.
(3) Install license plate lamp assembly in liftgate
and install retaining screws.

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 XJ LAMPS 8L - 11

BULB APPLICATION

TABLE OF CONTENTS
page

SPECIFICATIONS
REPLACEMENT BULBS . . . . . . . . . . . . . . . . . . . . 11

SPECIFICATIONS Interior Lamps Bulb Type

Ashtray Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 1891
REPLACEMENT BULBS Cigarette Lighter Lamp . . . . . . . . . . . . . . . . . . . 53
Auto. Trans. Floor Shift Lamp . . . . . . . . . . . . . 658
Exterior Lamps Bulb Type Cargo Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H4 Climate Control Lamp (2) . . . . . . . . . . . . . . . . . . 74
Front Position . . . . . . . . . . . . . . . . . . . . . . . . . T4W Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Front Turn Signal . . . . . . . . . . . . . . . . . . . . P27/7W Dome/Reading Lamp . . . . . . . . . (1) 561 and (2) 906
Side Turn Signal . . . . . . . . . . . . . . . . . . . . . . W3W Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . 194
License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . W5W Lighted Vanity Mirror (2) . . . . . . . . . . . . . . . . . . 74
Rear Position and Stop . . . . . . . . . . . . . . . . P27/7W Map Reading Light in Overhead Console (4) . . . 912
Rear Turn Signal . . . . . . . . . . . . . . . . . . . . P27/7W Rocker Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . P27/7W Transfer Case Lamp . . . . . . . . . . . . . . . . . . . . . 658
Rear Fog . . . . . . . . . . . . . . . . . . . . . . . . . . . P27/7W Underpanel Courtesy lamps (2) . . . . . . . . . . . . 168
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . W5W NOTE: Numbers refer to commercial bulb types
Underhood Retractable Lamp . . . . . . . . . . . . . . 105 that can be purchased from your local Jeep dealer.
Front Fog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3
CHMSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . W16W

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 XJ PASSIVE RESTRAINT SYSTEMS 8M - 1

PASSIVE RESTRAINT SYSTEMS

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION DRIVER SIDE AIRBAG MODULE TRIM

AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1 COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DRIVER SIDE AIRBAG MODULE . . . . . . . . . . . . . 2 PASSENGER SIDE AIRBAG MODULE. . . . . . . . . . 9
PASSENGER SIDE AIRBAG MODULE. . . . . . . . . . 3 PASSENGER SIDE AIRBAG DOOR . . . . . . . . . . . 11
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . . 3 AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . 12
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING ADJUSTMENTS
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 4 CLOCKSPRING CENTERING . . . . . . . . . . . . . . . . 15
SERVICE PROCEDURES SPECIAL TOOLS
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 5 PASSIVE RESTRAINT SYSTEMS . . . . . . . . . . . . 16
REMOVAL AND INSTALLATION
DRIVER SIDE AIRBAG MODULE . . . . . . . . . . . . . 6

DESCRIPTION AND OPERATION • Airbag indicator lamp

• Clockspring
AIRBAG SYSTEM • Driver and passenger side airbag modules
(including the airbag inflators)
DESCRIPTION • Driver and passenger side knee blockers
A dual front airbag system is standard factory-in- • Wire harness and connections.
stalled safety equipment on this model. The primary This group provides complete service information
passenger restraints in this vehicle are the standard for the ACM, both airbag modules, and the clock-
equipment factory-installed seat belts, which require spring. Complete service information for the other
active use by the vehicle occupants. The airbag sys- airbag system components can be located as follows:
tem is a supplemental passive restraint that was • Refer to Instrument Cluster in the proper sec-
designed and is intended to enhance the protection tion of Group 8E - Instrument Panel Systems for
for the front seat occupants of the vehicle only when complete service information for the airbag indicator
used in conjunction with the seat belts. See the own- lamp.
er’s manual in the vehicle glove box for more infor- • Refer to Knee Blocker in the Removal and
mation on the features, use and operation of all of Installation section of Group 8E - Instrument Panel
the factory-installed passenger restraints, including Systems for complete service information on the
the airbag system. driver side knee blocker.
• Refer to Glove Box in the Removal and Instal-
NOTE: This group covers both Left-Hand Drive lation section of Group 8E - Instrument Panel Sys-
(LHD) and Right-Hand Drive (RHD) versions of this tems for complete service information on the
model. Whenever required and feasible, the RHD passenger side knee blocker.
versions of affected vehicle components have been • Refer to Airbag System in the Contents of
constructed as mirror-image of the LHD versions. Group 8W - Wiring Diagrams for complete service
While most of the illustrations used in this group information and circuit diagrams for the airbag sys-
represent only the LHD version, the diagnostic and tem wiring components.
service procedures outlined can generally be See the proper Diagnostic Procedures manual to
applied to either version. Exceptions to this rule test or diagnose a problem with any component of
have been clearly identified as LHD or RHD, if a the airbag system.
special illustration or procedure is required.
OPERATION
The dual front airbag system consists of the follow- The airbag system electrical circuits are continu-
ing components: ously monitored and controlled by a microprocessor
• Airbag Control Module (ACM) and software contained within the Airbag Control

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 8M - 2 PASSIVE RESTRAINT SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
Module (ACM). The ACM also contains an impact WITH ACID, WATER, OR HEAVY METALS MAY PRO-
sensor and a safing sensor, which are monitored by DUCE HARMFUL AND IRRITATING GASES (SODIUM
the ACM to determine when an impact occurs that is HYDROXIDE IS FORMED IN THE PRESENCE OF
severe enough to require airbag system protection. MOISTURE) OR COMBUSTIBLE COMPOUNDS. THE
When a frontal impact is severe enough, the ACM PASSENGER AIRBAG MODULE CONTAINS ARGON
signals the inflator units of both airbag modules to GAS PRESSURIZED TO OVER 2500 PSI. DO NOT
deploy the airbags. ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR
An airbag indicator lamp in the instrument cluster TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE,
lights for about seven seconds as a bulb test, each INCINERATE, OR BRING INTO CONTACT WITH
time the ignition switch is turned to the On or Start ELECTRICITY. DO NOT STORE AT TEMPERATURES
positions. Following the bulb test, the airbag indica- EXCEEDING 93° C (200° F).
tor lamp is turned on or off by the ACM to indicate • REPLACE AIRBAG SYSTEM COMPONENTS
the status of the airbag system. If the airbag indica- ONLY WITH PARTS SPECIFIED IN THE CHRYSLER
tor lamp comes on at any time other than during the MOPAR PARTS CATALOG. SUBSTITUTE PARTS
bulb test, it indicates that there is a problem in the MAY APPEAR INTERCHANGEABLE, BUT INTERNAL
airbag system circuits. Such a problem may cause DIFFERENCES MAY RESULT IN INFERIOR OCCU-
the airbags not to deploy when required, or to deploy PANT PROTECTION.
when not required. • THE FASTENERS, SCREWS, AND BOLTS ORIG-
The driver side airbag module includes an inflat- INALLY USED FOR THE AIRBAG SYSTEM COMPO-
able airbag and an inflator unit behind a trim cover NENTS HAVE SPECIAL COATINGS AND ARE
in the hub area of the steering wheel. The passenger SPECIFICALLY DESIGNED FOR THE AIRBAG SYS-
side airbag module includes a second inflatable air- TEM. THEY MUST NEVER BE REPLACED WITH ANY
bag and an inflator unit behind an airbag door in the SUBSTITUTES. ANY TIME A NEW FASTENER IS
instrument panel above the glove box. NEEDED, REPLACE IT WITH THE CORRECT FAS-
During a frontal vehicle impact, the knee blockers TENERS PROVIDED IN THE SERVICE PACKAGE OR
work in concert with properly adjusted seat belts to SPECIFIED IN THE CHRYSLER MOPAR PARTS CAT-
restrain the driver and front seat passenger in the ALOG.
proper position for an airbag deployment. The knee • WHEN A STEERING COLUMN HAS AN AIRBAG
blockers also work to absorb and distribute the crash MODULE ATTACHED, NEVER PLACE THE COLUMN
energy from the driver and front seat passenger to ON THE FLOOR OR ANY OTHER SURFACE WITH
the structure of the instrument panel. The driver THE STEERING WHEEL OR AIRBAG MODULE FACE
side knee blocker is a stamped metal reinforcement DOWN.
located behind the instrument panel steering column
opening cover. The passenger side knee blocker is
integral to the glove box door. DRIVER SIDE AIRBAG MODULE
Following are general descriptions of the major
components in the airbag system. DESCRIPTION
The driver side airbag module protective trim cover
WARNING: is the most visible part of the driver side airbag sys-
• THE AIRBAG SYSTEM IS A SENSITIVE, COM- tem. The driver side airbag module is mounted
PLEX ELECTROMECHANICAL UNIT. BEFORE directly to the steering wheel. Located under the air-
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- bag module trim cover are the horn switch, the
BAG SYSTEM OR RELATED STEERING WHEEL, folded airbag cushion, and the airbag cushion sup-
STEERING COLUMN, OR INSTRUMENT PANEL porting components. The resistive membrane-type
COMPONENTS YOU MUST FIRST DISCONNECT horn switch is secured with heat stakes to the inside
AND ISOLATE THE BATTERY NEGATIVE (GROUND) surface of the airbag module trim cover, between the
CABLE. THEN WAIT TWO MINUTES FOR THE SYS- trim cover and the folded airbag cushion.
TEM CAPACITOR TO DISCHARGE BEFORE FUR- The driver side airbag module cannot be repaired,
THER SYSTEM SERVICE. THIS IS THE ONLY SURE and must be replaced if deployed or in any way dam-
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE aged. The driver side airbag module trim cover and
TO DO THIS COULD RESULT IN ACCIDENTAL AIR- the horn switch are available as a unit for service
BAG DEPLOYMENT AND POSSIBLE PERSONAL replacement.
INJURY.
• THE DRIVER SIDE AIRBAG MODULE INFLATOR OPERATION
ASSEMBLY CONTAINS SODIUM AZIDE AND POTAS- The driver side airbag module includes a stamped
SIUM NITRATE. THESE MATERIALS ARE POISON- metal housing to which the cushion and an inflator
OUS AND EXTREMELY FLAMMABLE. CONTACT

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 XJ PASSIVE RESTRAINT SYSTEMS 8M - 3
DESCRIPTION AND OPERATION (Continued)
unit are attached and sealed. The conventional pyro- charge the gas it produces directly into the cushion
technic-type inflator assembly is mounted to studs on when supplied with the proper electrical signal. Fol-
the back of the airbag module housing. The inflator lowing an airbag deployment, the airbag cushion
seals the hole in the airbag cushion so it can dis- quickly deflates by venting this gas through the
charge the gas it produces directly into the cushion porous fabric material used on each end panel of the
when supplied with the proper electrical signal. Fol- airbag cushion.
lowing an airbag deployment, the airbag cushion The molded plastic passenger side airbag door is
quickly deflates by venting this gas towards the secured to extruded tabs at the top and bottom rear
instrument panel through the porous fabric material of the airbag module housing by keyed openings in
used on the steering wheel side of the airbag cushion. the upper and lower mounting flange returns of the
The protective trim cover is fitted to the front of airbag door. The upper and lower airbag door mount-
the airbag module and forms a decorative cover in ing flanges are then secured to the instrument panel
the center of the steering wheel. The inside of the structural support and the upper glove box opening
trim cover has locking blocks molded into it that reinforcement with screws. The airbag door has pre-
engage a lip on the airbag module metal housing. determined breakout lines concealed beneath its dec-
Two stamped metal retainers then fit over the infla- orative cover. Upon airbag deployment, the airbag
tor mounting studs on the back of the airbag module door will split at the breakout lines and the door will
housing and are engaged in slots on the inside of the fold back over the top of the instrument panel, out of
cover, securely locking the trim cover into place. The the way.
trim cover will split at predetermined breakout lines,
then fold back out of the way along with the horn AIRBAG CONTROL MODULE
switch upon airbag deployment.
DESCRIPTION
PASSENGER SIDE AIRBAG MODULE The Airbag Control Module (ACM) is secured with
nuts to weld-studs on the ACM mounting bracket.
DESCRIPTION The ACM mounting bracket is secured with screws to
The passenger side airbag door on the instrument the floor panel transmission tunnel underneath the
panel above the glove box is the most visible part of center floor console and behind the park brake mech-
the passenger side airbag system. Located under the anism in the passenger compartment of the vehicle.
airbag door are the passenger side airbag cushion The ACM contains an electronic microprocessor, an
and the airbag cushion supporting components. electronic impact sensor, an electromechanical safing
The passenger side airbag module includes an sensor, and an energy storage capacitor.
extruded aluminum housing within which the cush- The ACM cannot be repaired or adjusted and, if
ion and inflator are mounted and sealed. Two damaged or faulty, it must be replaced.
stamped metal brackets, one on each end of the hous-
ing, enclose the cushion and inflator and also serve OPERATION
as the mounting brackets for the module. The two The microprocessor in the ACM contains the airbag
mounting brackets at the top front of the airbag mod- system logic. The airbag system logic includes
ule are secured with screws to the top of the instru- On-Board Diagnostics (OBD), and the ability to com-
ment panel structural support beneath the municate with the instrument cluster circuitry over
instrument panel top cover. The two mounting brack- the Chrysler Collision Detection (CCD) data bus to
ets at the bottom front of the airbag module are control the airbag indicator lamp. The microprocessor
secured with screws to the instrument panel struc- continuously monitors all of the airbag system elec-
tural support over the glove box. trical circuits to determine the system readiness. If
Following a passenger side airbag deployment, the the ACM detects a monitored system fault, it sends
passenger side airbag module and the passenger side messages to the instrument cluster over the CCD
airbag door must be replaced. The passenger side air- data bus to turn on the airbag indicator lamp. Refer
bag module cannot be repaired, and must be replaced to Instrument Cluster in the proper section of
if deployed or in any way damaged. The passenger Group 8E - Instrument Panel Systems for more infor-
side airbag door is available as a separate service mation on the airbag indicator lamp.
item. One electronic impact sensor is used in this airbag
system. The impact sensor is an accelerometer that
OPERATION senses the rate of vehicle deceleration, which pro-
The hybrid-type inflator assembly includes a small vides verification of the direction and severity of an
canister of highly compressed argon gas. The inflator impact. The impact sensor is calibrated for the spe-
seals the hole in the airbag cushion so it can dis- cific vehicle, and is only serviced as a unit with the

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 8M - 4 PASSIVE RESTRAINT SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
ACM. A pre-programmed decision algorithm in the However, if the clockspring is removed for service or
ACM microprocessor determines when the decelera- if the steering column is disconnected from the steer-
tion rate as signaled by the impact sensor indicates ing gear allowing the clockspring tape to change posi-
an impact that is severe enough to require airbag tion relative to the other steering components, it
system protection. When the programmed conditions must be re-centered following completion of the ser-
are met, the ACM sends an electrical signal to deploy vice or it may be damaged. Refer to Clockspring
the airbags. Centering in the Adjustments section of this group
In addition to the electronic impact sensor, there is for the proper centering procedures.
an electromechanical sensor within the ACM called a Service replacement clocksprings are shipped pre-
safing sensor. The safing sensor is a normally open centered and with a locking pin installed. This lock-
series switch located in the airbag deployment circuit ing pin should not be removed until the clockspring
of the ACM. This sensor detects impact energy of a has been installed on the steering column. If the
lesser magnitude than the electronic impact sensor, locking pin is removed before the clockspring is
and must be closed in order for the airbags to deploy. installed on a steering column, the clockspring cen-
The ACM also contains an energy-storage capaci- tering procedure must be performed.
tor. This capacitor stores enough electrical energy to
deploy the airbags for up to one second following a
battery disconnect or failure during an impact. The DIAGNOSIS AND TESTING
purpose of the capacitor is to provide airbag system
protection in a severe secondary impact, if the initial AIRBAG SYSTEM
impact has damaged or disconnected the battery, but A DRB scan tool is required for diagnosis of the
was not severe enough to deploy the airbags. airbag system. See the proper Diagnostic Procedures
manual for more information.
CLOCKSPRING (1) Connect the DRB scan tool to the 16-way data
link wire harness connector. The connector is located
DESCRIPTION on the driver side lower edge of the instrument
The clockspring assembly is secured with two inte- panel, outboard of the steering column (Fig. 1).
gral plastic latches onto the steering column lock
housing near the top of the steering column behind
the steering wheel. The clockspring is used to main-
tain a continuous electrical circuit between the fixed
clockspring wire harness on the steering column and
several electrical components that rotate with the
steering wheel. The rotating components include the
driver side airbag module, the horn switch and, if the
vehicle is so equipped, the vehicle speed control
switches.
The clockspring cannot be repaired. If the clock-
spring is faulty, damaged, or if the driver side airbag
has been deployed, the clockspring must be replaced.

OPERATION
The clockspring assembly consists of a plastic case
which contains a flat, ribbon-like, electrically conduc-
tive tape that winds and unwinds like a clockspring
with the steering wheel rotation. The electrically con-
ductive tape consists of several fine gauge copper
wire leads sandwiched between two narrow strips of
plastic film.
Like the clockspring in a timepiece, the clockspring Fig. 1 16-Way Data Link Connector - Typical
tape has travel limits and can be damaged by being 1 – 16–WAY DATA LINK CONNECTOR
wound too tightly. To prevent this from occurring, the 2 – BOTTOM OF INSTRUMENT PANEL
clockspring is centered when it is installed on the
steering column. Centering the clockspring indexes
(2) Turn the ignition switch to the On position.
the clockspring tape to other steering components so
Exit the vehicle with the DRB. Be certain that the
that it can operate within its designed travel limits.

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 XJ PASSIVE RESTRAINT SYSTEMS 8M - 5
DIAGNOSIS AND TESTING (Continued)
DRB contains the latest version of the proper DRB DISPOSAL OF NON-DEPLOYED AIRBAG MODULES
software. All damaged or faulty and non-deployed driver side
(3) Using the DRB, read and record the active or passenger side airbag modules which are replaced
Diagnostic Trouble Code (DTC) data. on vehicles are to be returned. If an airbag module
(4) Read and record any stored DTC data. assembly is faulty or damaged and non-deployed,
(5) See the proper Diagnostic Procedures manual if refer to the parts return list in the current Chrysler
any DTC is found in Step 3 or Step 4. Corporation Warranty Policies and Procedures man-
(6) After completing the necessary repairs, try to ual for the proper handling and disposal procedures.
erase the stored DTC data. If any problems remain,
the stored DTC data will not erase. See the proper DEPLOYED
Diagnostic Procedures manual for the procedures to Any vehicle which is to be returned to use after an
diagnose any stored DTC that will not erase. airbag deployment, must have both airbag modules,
(7) With the ignition switch still in the On posi- the passenger side airbag module door and the clock-
tion, check to be certain that nobody is in the vehicle. spring replaced. These components will be damaged
(8) From outside of the vehicle (away from the air- or weakened as a result of an airbag deployment,
bags in case of an accidental deployment) turn the which may or may not be obvious during a visual
ignition switch to the Off position for about ten sec- inspection, and are not intended for reuse.
onds, and then back to the On position. Observe the Other vehicle components should be closely
airbag indicator lamp in the instrument cluster. It inspected, but are to be replaced only as required by
should light for six to eight seconds, and then go out. the extent of the visible damage incurred.
This indicates that the airbag system is functioning
normally. STORAGE
An airbag module must be stored in its original,
NOTE: If the airbag indicator lamp fails to light, or special container until used for service. Also, it must
lights and stays on, there is an airbag system mal- be stored in a clean, dry environment; away from
function. See the proper Diagnostic Procedures sources of extreme heat, sparks, and high electrical
manual to diagnose the problem. energy. Always place or store an airbag module on a
surface with its trim cover or airbag side facing up,
to minimize movement in case of an accidental
SERVICE PROCEDURES deployment.

AIRBAG SYSTEM CLEANUP PROCEDURE

Following an airbag system deployment, the vehi-
NON-DEPLOYED cle interior will contain a powdery residue. This res-
At no time should any source of electricity be per- idue consists primarily of harmless particulate
mitted near the inflator on the back of an airbag by-products of the small pyrotechnic charge used to
module. When carrying a non-deployed airbag mod- initiate the airbag deployment propellant. However,
ule, the trim cover or airbag side of the module this residue will also contain traces of sodium
should be pointed away from the body to minimize hydroxide powder, a chemical by-product of the pro-
injury in the event of an accidental deployment. If pellant material that is used to generate the nitrogen
the module is placed on a bench or any other surface, gas that inflates the airbag. Since sodium hydroxide
the trim cover or airbag side of the module should be powder can irritate the skin, eyes, nose, or throat, be
face up to minimize movement in the event of an sure to wear safety glasses, rubber gloves, and a
accidental deployment. long-sleeved shirt during cleanup (Fig. 2).
In addition, the airbag system should be disarmed
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
whenever any steering wheel, steering column, or
DURING CLEANUP, RUN COOL WATER OVER THE
instrument panel components require diagnosis or
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
service. Failure to observe this warning could result
IRRITATION OF THE NOSE OR THROAT, EXIT THE
in accidental airbag deployment and possible per-
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
sonal injury. Refer to Group 8E - Instrument
CEASES. IF IRRITATION CONTINUES, SEE A PHYSI-
Panel Systems for additional service procedures on
CIAN.
the instrument panel components. Refer to Group
19 - Steering for additional service procedures on Begin the cleanup by removing the airbag modules
the steering wheel and steering column components. from the vehicle. Refer to Driver Side Airbag Mod-
ule and Passenger Side Airbag Module in the

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 8M - 6 PASSIVE RESTRAINT SYSTEMS XJ
SERVICE PROCEDURES (Continued)
driver side airbag has been deployed, the clockspring
must also be replaced. Refer to Clockspring in the
Removal and Installation section of this group for the
additional service procedures for the clockspring.

WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
Fig. 2 Wear Safety Glasses and Rubber Gloves - WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
Typical TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
Removal and Installation section of this group for the BAG DEPLOYMENT AND POSSIBLE PERSONAL
procedures. INJURY.
Use a vacuum cleaner to remove any residual pow- • WHEN REMOVING A DEPLOYED AIRBAG MOD-
der from the vehicle interior. Clean from outside the ULE, RUBBER GLOVES, EYE PROTECTION, AND A
vehicle and work your way inside, so that you avoid LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
kneeling or sitting on a non-cleaned area. MAY BE DEPOSITS ON THE AIRBAG MODULE AND
Be sure to vacuum the heater and air conditioning OTHER INTERIOR SURFACES. IN LARGE DOSES,
outlets as well (Fig. 3). Run the heater and air con- THESE DEPOSITS MAY CAUSE IRRITATION TO THE
ditioner blower on the lowest speed setting and vac- SKIN AND EYES.
uum any powder expelled from the outlets. You may
need to vacuum the interior of the vehicle a second
time to recover all of the powder.
REMOVAL
(1) Disconnect and isolate the battery negative
cable. If either of the airbags has not been deployed,
wait two minutes for the system capacitor to dis-
charge before further service.
(2) From the underside of the steering wheel,
remove the two screws that secure the driver side
airbag module to the steering wheel (Fig. 4).
(3) Pull the airbag module away from the steering
wheel far enough to access the two wire harness con-
nectors on the back of the airbag module.
(4) Disconnect the clockspring horn switch wire
harness connector from the horn switch feed wire
connector, which is located on the back of the airbag
module.
(5) The clockspring airbag wire harness connector
is a tight snap-fit into the airbag module connector
receptacle, which is located on the airbag inflator on
Fig. 3 Vacuum Heater and A/C Outlets - Typical the back of the airbag module. Firmly grasp and pull
Place the deployed airbag modules in your vehicu- or gently pry on the clockspring airbag wire harness
lar scrap pile. connector to disconnect it from the airbag module.
Do not pull on the clockspring wire harness to
disengage the connector from the airbag mod-
REMOVAL AND INSTALLATION ule connector receptacle.
(6) Remove the driver side airbag module from the
DRIVER SIDE AIRBAG MODULE steering wheel.
The following procedure is for replacement of a (7) If the driver side airbag has been deployed, the
faulty or damaged driver side airbag module. If the clockspring must be replaced. Refer to Clockspring

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 XJ PASSIVE RESTRAINT SYSTEMS 8M - 7
REMOVAL AND INSTALLATION (Continued)
(2) Reconnect the clockspring horn switch wire
harness connector to the horn switch feed wire con-
nector, which is located on the back of the airbag
module.
(3) Carefully position the driver side airbag mod-
ule in the steering wheel. Be certain that the clock-
spring wire harnesses in the steering wheel hub area
are not pinched between the airbag module and the
steering wheel.
(4) From the underside of the steering wheel,
install and tighten the two driver side airbag module
mounting screws. Tighten the screws to 10.2 N·m (90
in. lbs.).
(5) Do not reconnect the battery negative cable at
this time. Refer to Airbag System in the Diagnosis
Fig. 4 Driver Side Airbag Module Remove/Install and Testing section of this group for the proper pro-
1 – CLOCKSPRING cedures.
2 – SCREW
3 – HORN SWITCH WIRE
DRIVER SIDE AIRBAG MODULE TRIM COVER
4 – NUT
5 – DRIVER AIRBAG MODULE
The horn switch is integral to the driver side air-
6 – STEERING WHEEL bag module trim cover. If either component is faulty
7 – SPEED CONTROL WIRE or damaged, the entire driver side airbag module
8 – AIRBAG WIRE trim cover and horn switch unit must be replaced.

WARNING:
in the Removal and Installation section of this group • THE AIRBAG SYSTEM IS A SENSITIVE, COM-
for the clockspring service procedures. PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
INSTALLATION BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
WARNING:
COMPONENTS YOU MUST FIRST DISCONNECT
• USE EXTREME CARE TO PREVENT ANY FOR-
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
EIGN MATERIAL FROM ENTERING THE DRIVER
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
SIDE AIRBAG MODULE, OR BECOMING
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
ENTRAPPED BETWEEN THE AIRBAG CUSHION
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
AND THE DRIVER SIDE AIRBAG TRIM COVER.
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
FAILURE TO OBSERVE THIS WARNING COULD
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
RESULT IN OCCUPANT INJURIES UPON AIRBAG
BAG DEPLOYMENT AND POSSIBLE PERSONAL
DEPLOYMENT.
INJURY.
• THE DRIVER SIDE AIRBAG MODULE TRIM
• THE HORN SWITCH IS INTEGRAL TO THE AIR-
COVER MUST NEVER BE PAINTED. REPLACEMENT
BAG MODULE TRIM COVER. SERVICE OF THIS
TRIM COVERS ARE SERVICED IN THE ORIGINAL
COMPONENT SHOULD BE PERFORMED ONLY BY
COLORS. PAINT MAY CHANGE THE WAY IN WHICH
CHRYSLER-TRAINED AND AUTHORIZED DEALER
THE MATERIAL OF THE TRIM COVER RESPONDS
SERVICE TECHNICIANS. FAILURE TO TAKE THE
TO AN AIRBAG DEPLOYMENT. FAILURE TO
PROPER PRECAUTIONS OR TO FOLLOW THE
OBSERVE THIS WARNING COULD RESULT IN
PROPER PROCEDURES COULD RESULT IN ACCI-
OCCUPANT INJURIES UPON AIRBAG DEPLOY-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
MENT.
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
(1) When installing the driver side airbag module, RIES.
reconnect the clockspring airbag wire harness con-
nector to the airbag module connector receptacle by REMOVAL
pressing straight in on the connector. You can be cer-
(1) Disconnect and isolate the battery negative
tain that the connector is fully engaged by listening
cable. If either of the airbags has not been deployed,
carefully for a distinct audible click as the connector
wait two minutes for the system capacitor to dis-
snaps into place.
charge before further service.

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 8M - 8 PASSIVE RESTRAINT SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(2) Remove the driver side airbag module from the
steering wheel. Refer to Driver Side Airbag Mod-
ule in the Removal and Installation section of this
group for the procedures.
(3) Remove the plastic horn switch feed wire
retainer from the stud on the back of the driver side
airbag housing (Fig. 5).

Fig. 6 Driver Side Airbag Trim Cover Retainers

Remove/Install
1 – UPPER RETAINER
2 – AIRBAG HOUSING
3 – NUT (4)
4 – RETAINER SLOTS
Fig. 5 Horn Switch Feed Wire Remove/Install 5 – LOWER RETAINER
1 – HORN SWITCH FEED WIRE 6 – TRIM COVER
2 – HORN SWITCH GROUND WIRE 7 – STUDS
3 – WIRE RETAINER 8 – INFLATOR

(4) Remove the four nuts that secure the upper

and lower trim cover retainers to the studs on the
back of the driver side airbag housing (Fig. 6).
(5) Remove the upper and lower trim cover retain-
ers from the airbag housing studs.
(6) Remove the horn switch ground wire eyelet
from the upper airbag housing stud.
(7) Disengage the four trim cover locking blocks
from the lip around the outside edge of the driver
side airbag housing and remove the housing from the
cover (Fig. 7).

INSTALLATION
WARNING:
• USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE DRIVER
SIDE AIRBAG MODULE, OR BECOMING Fig. 7 Driver Side Airbag Trim Cover Remove/Install
ENTRAPPED BETWEEN THE AIRBAG CUSHION 1 – RETAINER SLOTS
2 – TRIM COVER
AND THE DRIVER SIDE AIRBAG TRIM COVER.
3 – LOCKING BLOCKS
FAILURE TO OBSERVE THIS WARNING COULD
4 – RETAINER SLOTS
RESULT IN OCCUPANT INJURIES UPON AIRBAG 5 – HORN SWITCH
DEPLOYMENT.
• THE DRIVER SIDE AIRBAG MODULE TRIM
COVER MUST NEVER BE PAINTED. REPLACEMENT OBSERVE THIS WARNING COULD RESULT IN
TRIM COVERS ARE SERVICED IN THE ORIGINAL OCCUPANT INJURIES UPON AIRBAG DEPLOY-
COLORS. PAINT MAY CHANGE THE WAY IN WHICH MENT.
THE MATERIAL OF THE TRIM COVER RESPONDS
TO AN AIRBAG DEPLOYMENT. FAILURE TO (1) Carefully position the driver side airbag mod-
ule in the trim cover. Be certain that the horn switch

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 XJ PASSIVE RESTRAINT SYSTEMS 8M - 9
REMOVAL AND INSTALLATION (Continued)
feed and ground wires are not pinched between the the passenger side airbag module has been deployed,
airbag housing and the trim cover locking blocks. the passenger side airbag door must also be replaced.
(2) Engage the upper and lower trim cover locking Refer to Passenger Side Airbag Door in the
blocks with the lip of the driver side airbag housing, Removal and Installation section of this group for the
then engage the locking blocks on each side of the additional service procedures for the passenger side
trim cover with the lip of the housing. Be certain airbag door.
that each of the locking blocks is fully engaged on
the lip of the airbag housing (Fig. 8). WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MOD-
ULE, RUBBER GLOVES, EYE PROTECTION, AND A
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
MAY BE DEPOSITS ON THE AIRBAG MODULE AND
OTHER INTERIOR SURFACES. IN LARGE DOSES,
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
SKIN AND EYES.

Fig. 8 Driver Side Airbag Trim Cover Locking REMOVAL

Blocks Engaged (1) Disconnect and isolate the battery negative
1 – LIP cable. If either of the airbags has not been deployed,
2 – TRIM COVER wait two minutes for the system capacitor to dis-
3 – HORN SWITCH charge before further service.
4 – AIRBAG HOUSING (2) Remove the top cover from the instrument
5 – LOCKING BLOCK
panel. Refer to Instrument Panel Top Cover in the
Removal and Installation section of Group 8E -
(3) Install the horn switch ground wire eyelet over Instrument Panel Systems for the procedures.
the upper airbag housing stud. (3) Disconnect the passenger side airbag module
(4) Install the upper and lower airbag trim cover wire harness connector from the instrument panel
retainers over the airbag housing studs. Be certain wire harness. This connector is located on the top of
that the tabs on each retainer are engaged in the the instrument panel structural support between the
retainer slots of the upper and lower trim cover lock- airbag module and the windshield (Fig. 9).
ing blocks (Fig. 7). (4) Disengage the passenger side airbag module
(5) Install and tighten the trim cover retainer wire harness connector retainer from the mounting
mounting nuts on the airbag housing studs. Tighten hole on the top of the instrument panel structural
the nuts to 10 N·m (90 in. lbs.). support.
(6) Install the driver side airbag module onto the (5) Remove the four screws that secure the upper
steering wheel. Refer to Driver Side Airbag Mod- flange of the passenger side airbag door to the
ule in the Removal and Installation section of this instrument panel structural support (Fig. 10).
group for the procedures. (6) Remove the two screws that secure the passen-
ger side airbag module upper mounting brackets to
PASSENGER SIDE AIRBAG MODULE the top of the instrument panel structural support.
The following procedure is for replacement of a (7) Roll down the glove box from the instrument
faulty or damaged passenger side airbag module. If panel. Refer to Glove Box - Roll Down in the

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 8M - 10 PASSIVE RESTRAINT SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(11) Remove the passenger side airbag door from
the airbag module. Refer to Passenger Side Airbag
Door in the Removal and Installation section of this
group for the procedures.

INSTALLATION
WARNING: USE EXTREME CARE TO PREVENT
ANY FOREIGN MATERIAL FROM ENTERING THE
PASSENGER SIDE AIRBAG MODULE, OR BECOM-
ING ENTRAPPED BETWEEN THE AIRBAG CUSHION
AND THE PASSENGER SIDE AIRBAG DOOR. FAIL-
URE TO OBSERVE THIS WARNING COULD RESULT
Fig. 9 Passenger Side Airbag Module Connector
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
1 – AIRBAG DOOR
MENT.
2 – PASSENGER SIDE AIRBAG WIRE HARNESS CONNECTOR
3 – AIRBAG HOUSING
(1) Install the passenger side airbag door onto the
airbag module. Refer to Passenger Side Airbag
Door in the Removal and Installation section of this
group for the procedures.
(2) Carefully position the passenger side airbag
module and airbag door in the instrument panel as a
unit.
(3) Reach through and above the instrument panel
glove box opening to install and tighten the two
screws that secure the passenger side airbag module
lower mounting brackets to the instrument panel
structural support. Tighten the screws to 11.8 N·m
(105 in. lbs.).
(4) Install and tighten the four screws that secure
the lower flange of the passenger side airbag door to
the instrument panel upper glove box opening rein-
forcement. Tighten the screws to 2.2 N·m (20 in.
lbs.).
Fig. 10 Passenger Side Airbag Module Remove/ (5) Install the glove box into the instrument panel.
Install Refer to Glove Box - Roll Down in the Removal
1 – INSTRUMENT PANEL and Installation section of Group 8E - Instrument
2 – SCREW Panel Systems for the procedures.
3 – PASSENGER AIRBAG MODULE (6) Install and tighten the two screws that secure
4 – SCREW the passenger side airbag module upper mounting
5 – GLOVE BOX DOOR brackets to the top of the instrument panel struc-
tural support. Tighten the screws to 11.8 N·m (105
Removal and Installation section of Group 8E - in. lbs.).
Instrument Panel Systems for the procedures. (7) Install and tighten the four screws that secure
(8) Remove the four screws that secure the lower the upper flange of the passenger side airbag door to
flange of the passenger side airbag door to the the instrument panel structural support. Tighten the
instrument panel upper glove box opening reinforce- screws to 2.2 N·m (20 in. lbs.).
ment. (8) Engage the passenger side airbag module wire
(9) Reach through and above the instrument panel harness connector retainer in the mounting hole on
glove box opening to access and remove the two the top of the instrument panel structural support.
screws that secure the passenger side airbag module (9) Reconnect the passenger side airbag module
lower mounting brackets to the instrument panel wire harness connector to the instrument panel wire
structural support. harness. Be certain that the connector is fully
(10) Remove the passenger side airbag module and engaged and latched.
airbag door from the instrument panel as a unit. (10) Install the top cover onto the instrument
panel. Refer to Instrument Panel Top Cover in the

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 XJ PASSIVE RESTRAINT SYSTEMS 8M - 11
REMOVAL AND INSTALLATION (Continued)
Removal and Installation section of Group 8E -
Instrument Panel Systems for the procedures.
(11) Do not reconnect the battery negative cable at
this time. Refer to Airbag System in the Diagnosis
and Testing section of this group for the proper pro-
cedures.

PASSENGER SIDE AIRBAG DOOR

WARNING:
• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
Fig. 11 Passenger Side Airbag Door Remove/Install
STEERING COLUMN, OR INSTRUMENT PANEL
1 – CONNECTOR
COMPONENTS YOU MUST FIRST DISCONNECT
2 – AIRBAG MODULE HOUSING
AND ISOLATE THE BATTERY NEGATIVE (GROUND) 3 – AIRBAG DOOR FLANGE
CABLE. THEN WAIT TWO MINUTES FOR THE SYS- 4 – AIRBAG DOOR
TEM CAPACITOR TO DISCHARGE BEFORE FUR- 5 – TABS
THER SYSTEM SERVICE. THIS IS THE ONLY SURE 6 – KEYED SLOTS
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL INSTALLATION
INJURY.
WARNING:
• WHEN REMOVING A DEPLOYED AIRBAG MOD-
• USE EXTREME CARE TO PREVENT ANY FOR-
ULE, RUBBER GLOVES, EYE PROTECTION, AND A
EIGN MATERIAL FROM ENTERING THE PASSEN-
LONG-SLEEVED SHIRT SHOULD BE WORN. THERE
GER SIDE AIRBAG MODULE, OR BECOMING
MAY BE DEPOSITS ON THE AIRBAG MODULE AND
ENTRAPPED BETWEEN THE AIRBAG CUSHION
OTHER INTERIOR SURFACES. IN LARGE DOSES,
AND THE PASSENGER SIDE AIRBAG DOOR. FAIL-
THESE DEPOSITS MAY CAUSE IRRITATION TO THE
URE TO OBSERVE THIS WARNING COULD RESULT
SKIN AND EYES.
IN OCCUPANT INJURIES UPON AIRBAG DEPLOY-
MENT.
REMOVAL • THE PASSENGER SIDE AIRBAG DOOR MUST
(1) Disconnect and isolate the battery negative NEVER BE PAINTED. REPLACEMENT AIRBAG
cable. If either of the airbags has not been deployed, DOORS ARE SERVICED IN THE ORIGINAL COL-
wait two minutes for the system capacitor to dis- ORS. PAINT MAY CHANGE THE WAY IN WHICH THE
charge before further service. MATERIAL OF THE AIRBAG DOOR RESPONDS TO
(2) Remove the passenger side airbag module from AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE
the instrument panel. Refer to Passenger Side Air- THIS WARNING COULD RESULT IN OCCUPANT
bag Module in the Removal and Installation section INJURIES UPON AIRBAG DEPLOYMENT.
of this group for the procedures.
(1) Position the passenger side airbag door over
(3) Place the passenger side airbag module on a
the airbag module.
suitable work surface. Slide the passenger side air-
(2) Engage the keyed holes in the returns of the
bag door sideways on the airbag module until the
upper and lower airbag door mounting flanges with
keyed holes in the returns of the upper and lower
the three tabs on the top and the bottom of the pas-
airbag door mounting flanges clear the three tabs on
senger side airbag module housing.
the top and the bottom of the airbag module housing
(3) Slide the passenger side airbag door sideways
(Fig. 11).
until the keyed holes in the returns of the upper and
(4) Disengage the keyed holes in the returns of the
lower airbag door mounting flanges are locked onto
upper and lower airbag door mounting flange returns
the three tabs on the top and the bottom of the air-
from the three tabs on the top and the bottom of the
bag module housing.
passenger side airbag module housing.
(4) Install the passenger side airbag module onto
(5) Remove the passenger side airbag door from
the instrument panel. Refer to Passenger Side Air-
the airbag module.
bag Module in the Removal and Installation section
of this group for the procedures.

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 8M - 12 PASSIVE RESTRAINT SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

AIRBAG CONTROL MODULE (a) Squeeze the two connector latch tabs
between the thumb and forefinger.
WARNING: (b) Pull the connector straight away from the
• THE AIRBAG CONTROL MODULE CONTAINS ACM connector receptacle.
THE IMPACT SENSOR, WHICH ENABLES THE SYS-
TEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPT-
ING TO DIAGNOSE OR SERVICE ANY AIRBAG
SYSTEM OR RELATED STEERING WHEEL, STEER-
ING COLUMN, OR INSTRUMENT PANEL COMPO-
NENTS YOU MUST FIRST DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
• NEVER STRIKE OR KICK THE AIRBAG CON-
TROL MODULE, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. IF AN AIR-
BAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT. Fig. 12 Airbag Control Module Remove/Install
ALWAYS REINSTALL THE AIRBAG CONTROL MOD- 1 – NUT AND WASHER (3)
ULE PROTECTIVE COVER. FAILURE TO OBSERVE 2 – INSTRUMENT PANEL WIRE HARNESS CONNECTOR
THIS WARNING COULD RESULT IN ACCIDENTAL, 3 – ACM MOUNTING BRACKET
4 – SCREW (4)
INCOMPLETE, OR IMPROPER AIRBAG DEPLOY-
5 – AIRBAG CONTROL MODULE
MENT AND POSSIBLE OCCUPANT INJURIES.

(7) Remove the three nuts that secure the ACM to

REMOVAL the weld studs on the ACM mounting bracket on the
(1) Disconnect and isolate the battery negative floor panel transmission tunnel.
cable. If either of the airbags has not been deployed, (8) Remove the ACM from the ACM mounting
wait two minutes for the system capacitor to dis- bracket on the floor panel transmission tunnel.
charge before further service.
(2) Remove the center floor console from the floor INSTALLATION
panel transmission tunnel. Refer to Full Floor Con- (1) Carefully position the ACM onto the ACM
sole in the index of this service manual for the loca- mounting bracket on the floor panel transmission
tion of the proper center floor console removal tunnel. When the ACM is correctly positioned the
procedures. arrow on the ACM label will be pointed forward in
(3) Remove the console rear duct from the floor the vehicle.
panel transmission tunnel. Refer to Ducts And Out- (2) Install and tighten the three nuts that secure
lets in the index of this service manual for the loca- the ACM to the weld studs on the ACM mounting
tion of the proper console rear duct removal bracket on the floor panel transmission tunnel.
procedures. Tighten the nuts to 7.3 N·m (65 in. lbs.).
(4) Remove the three screws that secure the center (3) Reconnect the instrument panel wire harness
floor console rear mounting bracket to the floor panel connector to the ACM connector receptacle. Be cer-
transmission tunnel. tain that the connector latches are fully engaged.
(5) Remove the center floor console rear mounting (4) Position the center floor console rear mounting
bracket from the floor panel transmission tunnel. bracket onto the floor panel transmission tunnel over
(6) Disconnect the instrument panel wire harness the ACM.
connector from the Airbag Control Module (ACM) (5) Install and tighten the three screws that secure
(Fig. 12). To disconnect the instrument panel wire the center floor console rear mounting bracket to the
harness connector from the ACM: floor panel transmission tunnel. Tighten the screws
to 1.1 N·m (10 in. lbs.).

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 XJ PASSIVE RESTRAINT SYSTEMS 8M - 13
REMOVAL AND INSTALLATION (Continued)
(6) Install the console rear duct onto the floor (5) Pull the steering wheel off of the steering col-
panel transmission tunnel. Refer to Ducts And Out- umn upper shaft spline using a steering wheel puller
lets in the index of this service manual for the loca- (Special Tool C-3428-B).
tion of the proper console rear duct installation (6) Remove the steering column opening cover
procedures. from the instrument panel. Refer to Steering Col-
(7) Install the center floor console onto the floor umn Opening Cover in the Removal and Installa-
panel transmission tunnel. Refer to Full Floor Con- tion section of Group 8E - Instrument Panel Systems
sole in the index of this service manual for the loca- for the procedures.
tion of the proper center floor console installation (7) If the vehicle is so equipped, move the tilt
procedures. steering column to the fully raised position.
(8) Do not reconnect the battery negative cable at (8) Remove the three screws that secure the lower
this time. Refer to Airbag System in the Diagnosis steering column shroud to the upper shroud (Fig. 13).
and Testing section of this group for the proper pro-
cedures.

CLOCKSPRING
The clockspring cannot be repaired. It must be
replaced if faulty or damaged, or if the driver side
airbag has been deployed.

WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,

COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

REMOVAL
Fig. 13 Steering Column Shrouds Remove/Install
NOTE: Before starting this procedure, be certain to 1 – UPPER SHROUD
turn the steering wheel until the front wheels are in 2 – SCREW (3)
the straight-ahead position. 3 – LOWER SHROUD
4 – STEERING WHEEL
(1) Place the front wheels in the straight-ahead
position.
(2) Remove the driver side airbag module from the (9) If the vehicle is equipped with a standard non-
steering wheel. Refer to Driver Side Airbag Mod- tilt steering column, loosen the two upper steering
ule in the Removal and Installation section of this column mounting nuts. If the vehicle is equipped
group for the procedures. with the optional tilt steering column, move the tilt
(3) If the vehicle is so equipped, disconnect the steering column to the fully lowered position.
upper clockspring wire harness connector from the (10) Remove both the upper and lower shrouds
steering wheel wire harness for the vehicle speed from the steering column.
control switches located within the hub cavity of the (11) Disconnect the two instrument panel wire
steering wheel. harness connectors from the lower clockspring con-
(4) Remove the nut that secures the steering wheel nector receptacles (Fig. 14).
armature to the steering column upper shaft, which (12) The multi-function switch water shield
is located within the hub cavity of the steering wheel. bracket on the top of the steering column has a small
access window which allows access to the upper

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 8M - 14 PASSIVE RESTRAINT SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
replaced if faulty or damaged, or if the driver side
airbag has been deployed.
(14) If the removed clockspring is to be reused,
lock the clockspring rotor to the clockspring case to
maintain clockspring centering until it is reinstalled
on the steering column. This can be done by inserting
a stiff wire through the small index hole located at
about the 11 o’clock position in the centered clock-
spring rotor and case. Refer to Clockspring Center-
ing in the Adjustments section of this group for an
illustration of the clockspring index hole. Bend the
wire over after it has been inserted through the
index hole to prevent it from falling out.

INSTALLATION
If the clockspring is not properly centered in rela-
Fig. 14 Clockspring Remove/Install tion to the steering wheel, steering shaft and steer-
1 – CLOCKSPRING ing gear, it may be damaged. Refer to Clockspring
2 – LATCHES Centering in the Adjustments section of this group
3 – WIRE HARNESS before installing or reinstalling a clockspring.
4 – TURN SIGNAL SWITCH LEVER Service replacement clocksprings are shipped pre-
5 – WATER SHIELD BRACKET
centered and with a locking pin installed. This lock-
6 – STEERING COLUMN
ing pin should not be removed until the clockspring
7 – WIPER SWITCH LEVER
has been installed on the steering column. If the
locking pin is removed before the clockspring is
clockspring latch with a small screwdriver (Fig. 15). installed on a steering column, the clockspring cen-
Gently pry both plastic latches of the clockspring tering procedure must be performed.
assembly to release them from the steering column
upper housing. NOTE: Before starting this procedure, be certain
that the front wheels are still in the straight-ahead
NOTE: If the clockspring plastic latches are broken, position.
be certain to remove the broken pieces from the
steering column upper housing. (1) If the removed clockspring is being reused,
remove the wire from the index hole that is locking
the clockspring rotor to the clockspring case to main-
tain clockspring centering.
(2) Be certain that the turn signal switch stalk is
in the neutral position, then carefully slide the cen-
tered clockspring down over the steering column
upper shaft until the clockspring latches engage the
steering column upper housing.
(3) If a new clockspring has been installed, remove
the locking pin that is securing the clockspring rotor
to the clockspring case and maintaining clockspring
centering.
(4) Reconnect the two instrument panel wire har-
ness connectors to the lower clockspring connector
receptacles. Be certain that the connector latches are
fully engaged.
Fig. 15 Upper Clockspring Latch Access Window (5) Position the steering column shrouds on the
1 – UPPER CLOCKSPRING LATCH ACCESS WINDOW steering column.
2 – CLOCKSPRING (6) Install and tighten the three screws that secure
3 – WATER SHIELD AND BRACKET the lower steering column shroud to the upper
shroud. Tighten the screws to 2 N·m (18 in. lbs.).
(13) Remove the clockspring from the steering col- (7) Install the steering column opening cover onto
umn. The clockspring cannot be repaired. It must be the instrument panel. Refer to Steering Column
Opening Cover in the Removal and Installation sec-

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 XJ PASSIVE RESTRAINT SYSTEMS 8M - 15
REMOVAL AND INSTALLATION (Continued)
tion of Group 8E - Instrument Panel Systems for the AND ISOLATE THE BATTERY NEGATIVE (GROUND)
procedures. CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
(8) Install the steering wheel onto the steering col- TEM CAPACITOR TO DISCHARGE BEFORE FUR-
umn upper shaft. Be certain to index the flats on the THER SYSTEM SERVICE. THIS IS THE ONLY SURE
hub of the steering wheel with the formations on the WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
inside of the clockspring rotor. Pull the upper clock- TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
spring wire harnesses through the lower hole in the BAG DEPLOYMENT AND POSSIBLE PERSONAL
steering wheel armature. INJURY.
(9) Install and tighten the steering wheel mount-
ing nut. Tighten the nut to 61 N·m (45 ft. lbs.). Be
certain not to pinch the wire harnesses between the NOTE: Before starting this procedure, be certain to
steering wheel and the nut. turn the steering wheel until the front wheels are in
(10) If the vehicle is so equipped, reconnect the the straight-ahead position.
upper clockspring wire harness connector to the
(1) Place the front wheels in the straight-ahead
steering wheel wire harness for the vehicle speed
position.
control switches.
(2) Remove the clockspring from the steering col-
(11) Install the driver side airbag module onto the
umn. Refer to Clockspring in the Removal and
steering wheel. Refer to Driver Side Airbag Mod-
Installation section of this group for the procedures.
ule in the Removal and Installation section of this
(3) Hold the clockspring case in one hand so that it
group for the procedures.
is oriented as it would be when it is installed on the
steering column (Fig. 16).
ADJUSTMENTS
CLOCKSPRING CENTERING
The clockspring is designed to wind and unwind
when the steering wheel is rotated, but is only
designed to rotate the same number of turns (about
five complete rotations) as the steering wheel can be
turned from stop to stop. Centering the clockspring
indexes the clockspring tape to other steering compo-
nents so that it can operate within its designed
travel limits. The rotor of a centered clockspring can
be rotated two and one-half turns in either direction
from the centered position, without damaging the
clockspring tape.
However, if the clockspring is removed for service
or if the steering column is disconnected from the
steering gear, the clockspring tape can change posi-
tion relative to the other steering components. The
clockspring must then be re-centered following com-
pletion of the service or the clockspring tape may be
damaged.
Service replacement clocksprings are shipped pre- Fig. 16 Clockspring
centered and with a locking pin installed. This lock- 1 –
LOCKING PIN
ing pin should not be removed until the clockspring 2 –
ROTOR FLATS
has been installed on the steering column. If the 3 –
CASE
locking pin is removed before the clockspring is 4 –
UPPER CLOCKSPRING WIRE HARNESSES (WIRES NOT
SHOWN)
installed on a steering column, the clockspring cen- 5 – ROTOR
tering procedure must be performed. 6 – INDEX HOLE

WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,

COMPLEX ELECTROMECHANICAL UNIT. BEFORE (4) Use your other hand to rotate the clockspring
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- rotor clockwise to the end of its travel. Do not apply
BAG SYSTEM OR RELATED STEERING WHEEL, excessive torque.
STEERING COLUMN, OR INSTRUMENT PANEL (5) From the end of the clockwise travel, rotate the
COMPONENTS YOU MUST FIRST DISCONNECT rotor about two and one-half turns counterclockwise,

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 8M - 16 PASSIVE RESTRAINT SYSTEMS XJ
ADJUSTMENTS (Continued)
until the rotor flats are horizontal. If the upper clock- SPECIAL TOOLS
spring wire harnesses are not oriented towards the
bottom of the clockspring, rotate the rotor another PASSIVE RESTRAINT SYSTEMS
one-half turn in the counterclockwise direction.
(6) The clockspring is now centered. Lock the
clockspring rotor to the clockspring case to maintain
clockspring centering until it is reinstalled on the
steering column. This can be done by inserting a stiff
wire through the small index hole located at about
the 11 o’clock position in the centered clockspring
rotor and case. Bend the wire over after it has been
inserted through the index hole to prevent it from
falling out.
(7) The front wheels should still be in the straight-
ahead position. Install the clockspring onto the steer- Puller C-3428-B
ing column. Refer to Clockspring in the Removal
and Installation section of this group for the proce-
dures.

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 1

ELECTRICALLY HEATED SYSTEMS

TABLE OF CONTENTS

page page

REAR WINDOW DEFOGGER SYSTEM . . . . . . . . . . 1 HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . 8

REAR WINDOW DEFOGGER SYSTEM

TABLE OF CONTENTS
page page

GENERAL INFORMATION REAR GLASS HEATING GRID . . . . . . . . . . . . . . . .4

INTRODUCTION . . . . . . . . . . . . . . . . . .........1 DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . . .4
REAR WINDOW DEFOGGER SYSTEM .........1 DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . . .4
DESCRIPTION AND OPERATION INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . .5
REAR GLASS HEATING GRID . . . . . . . . . . . . . . . .2 SERVICE PROCEDURES
OUTSIDE MIRROR HEATING GRID . . . . . . . . . . . .2 REAR GLASS HEATING GRID REPAIR .........6
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . . .2 REMOVAL AND INSTALLATION
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . .2 DEFOGGER SWITCH . . . . . . . . . . . . . .........6
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . . .3 DEFOGGER RELAY . . . . . . . . . . . . . . . .........7
DIAGNOSIS AND TESTING
DEFOGGER SYSTEM . . . . . . . . . . . . . .........3

GENERAL INFORMATION REAR WINDOW DEFOGGER SYSTEM

The rear window defogger system will only operate
INTRODUCTION when the ignition switch is in the On position. When
An electrically heated rear window defogger and the defogger switch is in the On position, an electric
electrically heated outside rear view mirrors are heater grid on the rear window glass is energized.
available factory-installed options on this model. Vehicles with the heated mirror options also have
Refer to 8W-48 - Rear Window Defogger and 8W-62 - heater grids located behind the outside rear view
Power Mirrors in Group 8W - Wiring Diagrams for mirror glass. Each of these grids produce heat to help
complete circuit descriptions and diagrams. clear the rear window glass and outside rear view
mirrors of ice, snow, or fog.
NOTE: This group covers both Left-Hand Drive The defogger system is controlled by a switch
(LHD) and Right-Hand Drive (RHD) versions of this installed in the instrument panel accessory switch
model. Whenever required and feasible, the RHD bezel, which is located near the bottom of the instru-
versions of affected vehicle components have been ment panel center bezel area, below the heater and
constructed as mirror-image of the LHD versions. air conditioner controls. An amber indicator lamp in
While most of the illustrations used in this group the switch button will light to indicate when the
represent only the LHD version, the diagnostic and defogger system is turned on. The instrument cluster
service procedures outlined can generally be circuitry, which contains the defogger system timer
applied to either version. Exceptions to this rule logic, monitors the state of the defogger switch
have been clearly identified as LHD or RHD, if a through a hard-wired input. The instrument cluster
special illustration or procedure is required. circuitry controls the defogger system through a
hard-wired control output to the defogger relay.
The defogger system will be automatically turned
off after a programmed time interval of about ten
minutes. After the initial time interval has expired, if

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 8N - 2 ELECTRICALLY HEATED SYSTEMS XJ
GENERAL INFORMATION (Continued)
the defogger switch is turned on again during the window heating grid is operating as designed, refer
same ignition cycle, the defogger system will auto- to Power Mirror in the Diagnosis and Testing section
matically turn off after about five minutes. of Group 8T - Power Mirror Systems for diagnosis of
The defogger system will automatically shut off if the mirror heating grids.
the ignition switch is turned to the Off position, or it The heating grid behind each outside mirror glass
can be turned off manually by depressing the instru- cannot be repaired and, if faulty or damaged, the
ment panel switch. Following are general descrip- entire power mirror unit must be replaced. Refer to
tions of the major components in the defogger Power Mirror in the Removal and Installation section
system. Refer to the owner’s manual in the vehicle of Group 8T - Power Mirror Systems for the service
glove box for more information on the features, use procedures.
and operation of the defogger system.
DEFOGGER SWITCH
The rear window defogger switch is installed in the
DESCRIPTION AND OPERATION instrument panel accessory switch bezel, which is
located near the bottom of the instrument panel cen-
REAR GLASS HEATING GRID ter bezel area, below the heater and air conditioner
The heated rear window glass has two electrically controls. The momentary-type switch provides a
conductive vertical bus bars and a series of horizon- hard-wired ground signal to the instrument cluster
tal grid lines made of a silver-ceramic material, each time it is depressed. The instrument cluster
which is baked on and bonded to the inside surface of rear window defogger timer and logic circuitry
the glass. The grid lines and bus bars comprise a responds by energizing or de-energizing the rear win-
parallel electrical circuit. dow defogger relay.
When the rear window defogger switch is placed in Energizing the rear window defogger relay pro-
the On position, electrical current is directed to the vides electrical current to the rear window defogger
rear window grid lines through the bus bars. The grid and, if the vehicle is so equipped, the outside
grid lines heat the rear window to clear the surface rear view mirror heating grids. An amber indicator
of fog or snow. Protection for the heated grid circuit lamp in the defogger switch, which lights to indicate
is provided by a fuse in the Power Distribution Cen- when the defogger system is turned On, is also pow-
ter (PDC). ered by the defogger relay output.
The grid lines and bus bars are highly resistant to The defogger switch illumination lamp and indica-
abrasion. However, it is possible for an open circuit tor lamp bulbs are serviceable. The defogger switch
to occur in an individual grid line, resulting in no cannot be repaired and, if faulty or damaged, it must
current flow through the line. be replaced.
The grid lines can be damaged or scraped off with
sharp instruments. Care should be taken when clean- INSTRUMENT CLUSTER
ing the glass or removing foreign materials, decals, The instrument cluster is an electromechanical
or stickers from the glass. Normal glass cleaning sol- unit that contains integrated circuitry and internal
vents or hot water used with rags or toweling is rec- programming to perform a variety of functions. The
ommended. instrument cluster circuitry monitors hard-wired
A repair kit is available to repair the grid lines and switch inputs, as well as message inputs received
bus bars, or to reinstall the heated glass pigtail from other vehicle electronic control modules on the
wires. Chrysler Collision Detection (CCD) data bus network.
The instrument cluster uses these many inputs
OUTSIDE MIRROR HEATING GRID along with its internal programming and integral
Vehicles equipped with the optional heated mirror timer and logic circuitry to perform the functions of
package have an electric heating grid located behind the rear window defogger timer on this model. The
the mirror glass of each outside rear view mirror. instrument cluster circuitry also has a self-diagnostic
The heated mirrors are controlled by the rear win- capability. Refer to Instrument Cluster in Group 8E -
dow defogger switch. Electrical current is directed to Instrument Panel Systems for more information on
the heating grid inside the mirror only when the rear this feature.
window defogger switch is in the On position. However, there are no diagnostics available for the
If the outside mirror heating grids and the rear rear window defogger timer and logic circuitry.
window heating grid are all inoperative, diagnosis of Therefore, the diagnosis for this system consists of
the rear window defogger system should be per- confirming the presence of a rear window defogger
formed as described in this group. If the outside mir- switch input signal at the instrument cluster connec-
ror heating grids are inoperative, but the rear tor, and the resulting rear window defogger relay

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 3
DESCRIPTION AND OPERATION (Continued)
control output signal at the defogger relay. For diag-
nosis of the CCD data bus and the data bus message
inputs, a DRB scan tool and the proper Diagnostic
Procedures manual are recommended.
Refer to Instrument Cluster in Group 8E - Instru-
ment Panel Systems for the service procedures for
the instrument cluster. The rear window defogger
timer and logic circuitry cannot be adjusted or
repaired and, if faulty or damaged, the instrument
cluster assembly must be replaced.

DEFOGGER RELAY
The rear window defogger relay is a International
Standards Organization (ISO)-type relay. The rear
window defogger relay is a electromechanical device
that switches fused battery current to the rear glass Fig. 1 Rear Window Glass Grid Test
and outside mirror heating grids, and the indicator 1 – TERMINAL “A”
2 – TERMINAL “B”
lamp of the defogger switch, when the instrument
3 – FEED WIRE
cluster rear window defogger timer and logic cir-
4 – MID-POINT “C” (TYPICAL)
cuitry grounds the relay coil. See Defogger Relay in 5 – HEATED REAR WINDOW DEFOGGER GRID
the Diagnosis and Testing section of this group for 6 – GROUND WIRE
more information.
The rear window defogger relay is located in the
junction block, on the right cowl side inner panel The above checks will confirm system operation.
below the instrument panel in the passenger com- Illumination of the defogger switch indicator lamp
partment. The rear window defogger relay cannot be means that there is electrical current available at the
repaired and, if faulty or damaged, it must be output of the defogger relay, but does not confirm
replaced. that the electrical current is reaching the rear glass
heating grid lines.
If the defogger system does not operate, the prob-
DIAGNOSIS AND TESTING lem should be isolated in the following manner:
(1) Confirm that the ignition switch is in the On
DEFOGGER SYSTEM position.
For circuit descriptions and diagrams, refer to (2) Ensure that the rear glass heating grid feed
8W-48 - Rear Window Defogger or 8W-62 Power Mir- and ground wires are connected to the glass. Confirm
rors in Group 8W - Wiring Diagrams. The operation that the ground wire has continuity to ground.
of the electrically heated rear window defogger sys- (3) Check the fuses in the Power Distribution Cen-
tem can be confirmed in one of the following man- ter (PDC) and in the junction block. The fuses must
ners: be tight in their receptacles and all electrical connec-
1. Turn the ignition switch to the On position. tions must be secure.
While monitoring the instrument panel voltmeter, set When the above steps have been completed and the
the defogger switch in the On position. When the rear glass or outside rear view mirror heating grid is
defogger switch is turned On, a distinct voltmeter still inoperative, one or more of the following is
needle deflection should be noted. faulty:
2. Turn the ignition switch to the On position. Set • Defogger switch
the defogger switch in the On position. The rear win- • Defogger relay
dow defogger operation can be checked by feeling the • Instrument cluster circuitry
rear window or outside rear view mirror glass. A dis- • Rear window grid lines (all grid lines would
tinct difference in temperature between the grid lines have to be broken or one of the feed wires discon-
and the adjacent clear glass or the mirror glass can nected for the entire system to be inoperative)
be detected within three to four minutes of operation. • Outside rear view mirror heating grid.
3. Using a 12-volt DC voltmeter, contact the rear If setting the defogger switch to the On position
glass heating grid terminal A (right side) with the produces a severe voltmeter deflection, check for a
negative lead, and terminal B (left side) with the pos- short circuit between the defogger relay output and
itive lead (Fig. 1). The voltmeter should read battery the rear glass or outside rear view mirror heating
voltage. grids.

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 8N - 4 ELECTRICALLY HEATED SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)

REAR GLASS HEATING GRID (3) Check for continuity between the ground cir-
For circuit descriptions and diagrams, refer to cuit terminal and the rear window defogger switch
8W-48 - Rear Window Defogger in Group 8W - Wir- sense circuit terminal on the back of the defogger
ing Diagrams. To detect breaks in the grid lines, the switch housing (Fig. 2). There should be momentary
following procedure is required: continuity as the defogger switch button is depressed,
(1) Turn the ignition switch to the On position. Set and then no continuity. If OK, see the diagnosis for
the defogger switch in the On position. The indicator the Instrument Cluster in this group. If not OK,
lamp should light. If OK, go to Step 2. If not OK, see replace the faulty switch.
the Defogger Relay diagnosis in this group.
(2) Using a 12-volt DC voltmeter, contact the ver-
tical bus bar on the right side of the vehicle with the
negative lead. With the positive lead, contact the ver-
tical bus bar on the left side of the vehicle. The volt-
meter should read battery voltage. If OK, go to Step
3. If not OK, repair the open circuit to the defogger
relay as required.
(3) With the negative lead of the voltmeter, contact
a good body ground point. The voltage reading should
not change. If OK, go to Step 4. If not OK, repair the
circuit to ground as required.
(4) Connect the negative lead of the voltmeter to
the right side bus bar and touch each grid line at SWITCH POSITION CONTINUITY BETWEEN
midpoint C with the positive lead. A reading of OFF LAMPS
approximately six volts indicates a line is good. A
ON MOMENTARY 1 AND 2
reading of zero volts indicates a break in the grid
line between midpoint C and the left side bus bar. A ILLUMINATION LAMP 1 AND 4
reading of ten to fourteen volts indicates a break INDICATOR LAMP 1 AND 3
between midpoint C and the right side bus bar. Move
the positive lead on the grid line towards the break
and the voltage reading will change as soon as the Fig. 2 Defogger Switch Continuity
break is crossed. DEFOGGER RELAY
DEFOGGER SWITCH WARNING: ON VEHICLES EQUIPPED WITH AIR-
For circuit descriptions and diagrams, refer to BAGS, REFER TO GROUP 8M - PASSIVE
8W-48 - Rear Window Defogger in Group 8W - Wir- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
ing Diagrams. STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
WARNING: ON VEHICLES EQUIPPED WITH AIR- SERVICE. FAILURE TO TAKE THE PROPER PRE-
BAGS, REFER TO GROUP 8M - PASSIVE CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY BAG DEPLOYMENT AND POSSIBLE PERSONAL
STEERING WHEEL, STEERING COLUMN, OR INJURY.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- RELAY TEST
BAG DEPLOYMENT AND POSSIBLE PERSONAL The defogger relay (Fig. 3) is located in the junc-
INJURY. tion block, on the right cowl side inner panel below
the instrument panel in the passenger compartment.
(1) Disconnect and isolate the battery negative Remove the defogger relay from the junction block to
cable. Remove the accessory switch bezel from the perform the following tests:
instrument panel and unplug the defogger switch (1) A relay in the de-energized position should
wire harness connector. have continuity between terminals 87A and 30, and
(2) Check for continuity between the ground cir- no continuity between terminals 87 and 30. If OK, go
cuit cavity of the defogger switch wire harness con- to Step 2. If not OK, replace the faulty relay.
nector and a good ground. There should be (2) Resistance between terminals 85 and 86 (elec-
continuity. If OK, go to Step 3. If not OK, repair the tromagnet) should be 75 6 10 ohms. If OK, go to
open circuit as required. Step 3. If not OK, replace the faulty relay.

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 5
DIAGNOSIS AND TESTING (Continued)
(3) Connect a battery to terminals 85 and 86. is turned On. Be certain that you depress the defog-
There should now be continuity between terminals ger switch at least twice to confirm that the system
30 and 87, and no continuity between terminals 87A is turned on during this test. If OK, go to Step 5. If
and 30. If OK, see the Relay Circuit Test in this not OK, repair the open circuit to the instrument
group. If not OK, replace the faulty relay. cluster as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. It is connected to
fused ignition switch output voltage and should be
hot when the ignition switch is in the On position.
Check for battery voltage at the cavity for relay ter-
minal 86 with the ignition switch in the On position.
If OK, see the diagnosis for Instrument Cluster in
this group. If not OK, repair the open circuit to the
fuse in the junction block as required.

INSTRUMENT CLUSTER
Before performing this test, complete the Defogger
TERMINAL LEGEND Switch and the Defogger Relay tests as described in
NUMBER IDENTIFICATION this group. For circuit descriptions and diagrams,
30 COMMON FEED refer to 8W-48 - Rear Window Defogger in Group 8W
- Wiring Diagrams.
85 COIL GROUND
86 COIL BATTERY WARNING: ON VEHICLES EQUIPPED WITH AIR-
87 NORMALLY OPEN BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
87A NORMALLY CLOSED
STEERING WHEEL, STEERING COLUMN, OR
Fig. 3 Defogger Relay INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
RELAY CIRCUIT TEST CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(1) The relay common feed terminal cavity (30) is BAG DEPLOYMENT AND POSSIBLE PERSONAL
connected to battery voltage and should be hot at all INJURY.
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required. (1) Disconnect and isolate the battery negative
(2) The relay normally closed terminal (87A) is cable. Remove the defogger relay from the junction
connected to terminal 30 in the de-energized position, block and unplug the defogger switch wire harness
but is not used for this application. Go to Step 3. connector.
(3) The relay normally open terminal (87) is con- (2) Remove the instrument cluster from the instru-
nected to the common feed terminal (30) in the ener- ment panel. Refer to Instrument Cluster in Group 8E
gized position. This terminal supplies battery voltage - Instrument Panel Systems for the procedures.
to the rear glass and outside rear view mirror heat- (3) Check for continuity between the rear window
ing grids and the defogger switch indicator lamp. defogger switch sense circuit cavity of the right
There should be continuity between the cavity for instrument cluster wire harness connector (connector
relay terminal 87 and the rear window defogger relay B) and a good ground. There should be no continuity.
output circuit cavities of the rear glass heating grid If OK, go to Step 4. If not OK, repair the short circuit
connector, both outside rear view mirror heating grid as required.
connectors, and the defogger switch connector at all (4) Check for continuity between the rear window
times. If OK, go to Step 4. If not OK, repair the open defogger switch sense circuit cavities of the right
circuit(s) as required. instrument cluster wire harness connector (connector
(4) The coil ground terminal (85) is connected to B) and the defogger switch wire harness connector.
the electromagnet in the relay. This terminal is pro- There should be continuity. If OK, go to Step 5. If not
vided with ground by the instrument cluster rear OK, repair the open circuit as required.
window defogger timer and logic circuitry to energize (5) Check for continuity between the rear window
the defogger relay. There should be continuity to defogger relay control circuit cavity of the right
ground at the cavity for relay terminal 85 when the instrument cluster wire harness connector (connector
defogger switch is turned On. However, with the B) and a good ground. There should be no continuity.
defogger relay removed, the defogger switch indicator If OK, go to Step 6. If not OK, repair the short circuit
lamp will not light to show that the defogger system as required.

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 8N - 6 ELECTRICALLY HEATED SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
(6) Check for continuity between the rear window (2) Follow the instructions in the repair kit for
defogger relay control circuit cavities of the right preparing the damaged area.
instrument cluster wire harness connector (connector (3) Remove the package separator clamp and mix
B) and the defogger relay receptacle (the cavity for the two conductive epoxy components thoroughly
ISO relay terminal 85) in the junction block. There within the packaging. Fold the package in half and
should be continuity. If OK, replace the faulty instru- cut the center corner to dispense the epoxy.
ment cluster. If not OK, repair the open circuit as (4) For grid line repairs, mask the area to be
required. repaired with masking tape or a template.
(5) Apply the epoxy through the slit in the mask-
ing tape or template. Overlap both ends of the break
SERVICE PROCEDURES by at least 19 millimeters (0.75 inch).
(6) For a terminal or pigtail wire replacement,
REAR GLASS HEATING GRID REPAIR mask the adjacent areas so the epoxy can be
Repair of the rear glass heating grid lines, bus extended onto the adjacent grid line as well as the
bars, terminals or pigtail wires can be accomplished bus bar. Apply a thin layer of epoxy to the area
using a Mopar Rear Window Defogger Repair Kit where the terminal or pigtail wire was fastened and
(Part Number 4267922) or equivalent. onto the adjacent grid line.
(7) Apply a thin layer of conductive epoxy to the
WARNING: MATERIALS CONTAINED IN THE terminal or bare wire end of the pigtail and place it
REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION. in the proper location on the bus bar. To prevent the
THE KIT CONTAINS EPOXY RESIN AND AMINE terminal or pigtail wire from moving while the epoxy
TYPE HARDENER, WHICH ARE HARMFUL IF SWAL- is curing, it must be wedged or clamped.
LOWED. AVOID CONTACT WITH THE SKIN AND (8) Carefully remove the masking tape or tem-
EYES. FOR SKIN CONTACT, WASH THE AFFECTED plate.
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER. CAUTION: Do not allow the glass surface to exceed
DO NOT TAKE INTERNALLY. IF TAKEN INTER- 204° C (400° F) or the glass may fracture.
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA- (9) Allow the epoxy to cure 24 hours at room tem-
TION. DO NOT USE NEAR FIRE OR FLAME. CON- perature, or use a heat gun with a 260° to 371° C
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE (500° to 700° F) range for fifteen minutes. Hold the
REACH OF CHILDREN. heat gun approximately 25.4 centimeters (10 inches)
from the repair.
(1) Mask the repair area so that the conductive (10) After the conductive epoxy is properly cured,
epoxy can be applied neatly. Extend the epoxy appli- remove the wedge or clamp from the terminal or pig-
cation onto the grid line or the bus bar on each side tail wire. Do not attach the wire harness connectors
of the break (Fig. 4). until the curing process is complete.
(11) Check the operation of the rear window defog-
ger glass heating grid.

REMOVAL AND INSTALLATION

DEFOGGER SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO GROUP 8M - PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL COM-
PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
Fig. 4 Grid Line Repair - Typical PERSONAL INJURY.
1 – BREAK
2 – GRID LINE (1) Disconnect and isolate the battery negative
3 – MASKING TAPE
cable.

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 7
REMOVAL AND INSTALLATION (Continued)
(2) Remove the center bezel from the instrument (3) Remove the stamped nut that secures the right
panel. See Instrument Panel Center Bezel in Group cowl side trim to the junction block stud (Fig. 6).
8E - Instrument Panel Systems for the procedures.
(3) Remove the three screws that secure the acces-
sory switch bezel to the instrument panel (Fig. 5).

Fig. 5 Accessory Switch Bezel Remove/Install

1 – ACCESSORY SWITCH BEZEL
2 – SCREW

(4) Pull the accessory switch bezel out from the

instrument panel far enough to access the wire har-
ness connectors.
(5) Unplug the wire harness connectors from the
rear of the accessory switches and the cigar lighter/
power outlet.
(6) Remove the accessory switch bezel from the Fig. 6 Right Cowl Side Trim Remove/Install
instrument panel. 1 – RIGHT FRONT DOOR SILL
(7) With a small thin-bladed screwdriver, gently pry 2 – COWL SIDE TRIM PANEL
the snap clips at the top and bottom of the rear window 3 – SCREW
defogger switch receptacle on the back of the accessory 4 – SILL TRIM
switch bezel and pull the switch out of the bezel. 5 – FUSE ACCESS PANEL
(8) Reverse the removal procedures to install. Be 6 – PUSH-NUT
certain that both of the switch snap retainers in the
receptacle on the back of the accessory switch bezel (4) Remove the screw located above the fuse access
are fully engaged. Tighten the mounting screws to opening that secures the right cowl side trim to the
2.2 N·m (20 in. lbs.). right cowl side inner panel.
(5) Remove the screw that secures the right door
DEFOGGER RELAY sill trim and the right cowl side trim to the right
door opening sill.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, (6) Remove the right cowl side trim panel from the
REFER TO GROUP 8M - PASSIVE RESTRAINT SYS- vehicle.
TEMS BEFORE ATTEMPTING ANY STEERING WHEEL, (7) Unplug the rear window defogger relay from
STEERING COLUMN, OR INSTRUMENT PANEL COM- the junction block.
PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE (8) Install the defogger relay by aligning the relay
THE PROPER PRECAUTIONS COULD RESULT IN terminals with the cavities in the junction block and
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE pushing the relay firmly into place.
PERSONAL INJURY. (9) Connect the battery negative cable.
(10) Test the relay operation.
(1) Disconnect and isolate the battery negative cable. (11) Reinstall the right cowl side trim and the fuse
(2) Remove the fuse access panel by unsnapping it access panel. Tighten the mounting screws to 2.2
from the right cowl side trim panel. N·m (20 in. lbs.).

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 8N - 8 ELECTRICALLY HEATED SYSTEMS XJ

HEATED SEAT SYSTEM

TABLE OF CONTENTS
page page

GENERAL INFORMATION HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . . . . 10

INTRODUCTION . . . . . . . . . . . . . . . . . . ........8 HEATED SEAT ELEMENT and SENSOR. . . . . . . . 11
DESCRIPTION AND OPERATION HEATED SEAT RELAY . . . . . . . . . . . . . . . . . . . . . 11
HEATED SEAT SWITCH. . . . . . . . . . . . . . . . . . . . .8 SEAT HEAT INTERFACE MODULE. . . . . . . . . . . . 12
SEAT HEAT INTERFACE MODULE. . . . . . . . . . . . .9 REMOVAL AND INSTALLATION
HEATED SEAT RELAY . . . . . . . . . . . . . . . . . . . . . .9 HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . . . . 12
HEATED SEAT ELEMENT and SENSOR . . . . . . . .9 SEAT HEAT INTERFACE MODULE. . . . . . . . . . . . 12
DIAGNOSIS AND TESTING HEATED SEAT RELAY . . . . . . . . . . . . . . . . . . . . . 12
HEATED SEAT SYSTEM . . . . . . . . . . . . ........9

GENERAL INFORMATION N-FET Transistor within the SHIM energizes the

heating elements in the seat cushion and back. When
INTRODUCTION the sensor input indicates the correct temperature
Individually controlled electrically heated front set point has been achieved, the SHIM de-energizes
seats are available factory-installed optional equip- the N-FET. The SHIM will continue to cycle the
ment on this model. The seat heaters will only oper- N-FET as needed to maintain the temperature set
ate when the ignition switch is in the ON position, point.
and the surface temperature at the front seat heating The SHIM will automatically turn off the heating
element sensors is below the designed temperature elements if it detects a short or an open in the heat-
set points of the system. The heated seat system will ing element or a sensor out of range. These condi-
not operate in ambient temperatures greater than tions will also cause the SHIM to notify the occupant
about 32° C (90° F). of the failure via flashing the heated seat switch
There are separate momentary, tactile, two-direc- LED’s as discussed later.
tional rocker switches located in the center console Switched battery power to the SHIM is supplied by
with center NEUTRAL, HI and LO positions for each the heated seat relay mounted to the seat cushion
front seat. Depressing the rocker switch to its frame with the SHIM under the right front seat. The
momentary HI or LO position signals the Seat Heat battery feed is protected by a circuit breaker located
Interface Module (SHIM) to power the selected in the junction block.
heated seat and maintain the requested temperature Following are general descriptions of the major
setting (HI or LO). Each switch has a HI and LO components in the heated seat system. Refer to
Light-Emitting Diode (LED) which, via the SHIM, 8W-63 - Power Seat With Heated Seats in Group 8W
illuminates to give a visual indication that the sys- - Wiring Diagrams for complete circuit descriptions
tem is in the HI or LO mode. The LO heat set point and diagrams.
is about 32° C (90° F), and the HI heat set point is
about 38° C (100° F). The system shall be deactivated DESCRIPTION AND OPERATION
whenever the same set position is depressed a second
time and shall change states directly when switching
HEATED SEAT SWITCH
from HI to LO or vice versa. The system shall be
The heated seat switch assembly is located on the
deactivated whenever the ignition switch is placed in
center console where the ashtray is normally located
the off position. When the ignition switch is placed
(Fig. 1). The two momentary, two-directional rocker
back in the run position, the heated seat system
switches, one switch for each front seat, provide a
shall remain deactivated until a momentary switch is
resistor-multiplexed signal to the Seat Heat Interface
depressed. When a seat heater is turned on, a sensor
Module (SHIM). Each switch has center NEUTRAL,
located near the seat cushion electric heater element
and momentary LO and HI positions so that both the
provides the SHIM with input indicating the surface
driver and the front seat passenger can select a pre-
temperature of the seat cushion. If the surface tem-
ferred seat heating mode.
perature input is below the temperature set point of
Each switch has two telltales (LED’s) which indi-
the SHIM for the selected temperature setting, an
cate the mode of the heater of the respective seat.

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 9
DESCRIPTION AND OPERATION (Continued)

HEATED SEAT ELEMENT and SENSOR

Two heated seat heating elements are used in each
front seat, one for the seat cushion and the other for
the seat back. The two elements for each seat are
connected in series with the SHIM.
The temperature sensor is a Negative Temperature
Coefficient (NTC) thermistor. One temperature sen-
sor is used for each seat, and it is integral to the seat
cushion heating element.
The heating elements are sewn into the seat cush-
ion cover and seat back cover assemblies, which are
serviced individually. The heating elements and tem-
perature sensor cannot be repaired and, if faulty or
damaged, the affected seat cover assembly must be
replaced. Refer to Group 23 - Body for the seat cush-
ion cover and seat back cover Removal and Installa-
tion.

Fig. 1 Heated Seat Switch Location DIAGNOSIS AND TESTING

1 – ASH RECEIVER
2 – HEATED SEAT SWITCHES & BEZEL
3 – WIRE HARNESS CONNECTORS
HEATED SEAT SYSTEM
4 – FLOOR CONSOLE For circuit descriptions and diagrams, refer to 8W -
63 - Power Seat With Heated Seats in Group 8W -
Wiring Diagrams.
The switches also have LED’s which provide back-
lighting when the ignition switch is in the ON posi- WARNING: ON VEHICLES EQUIPPED WITH AIR-
tion. The LED’s cannot be repaired. If the LED is BAGS, REFER TO GROUP 8M - PASSIVE
faulty, the individual switch must be replaced. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
SEAT HEAT INTERFACE MODULE INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
The Seat Heat Interface Module (SHIM) is an elec- SERVICE. FAILURE TO TAKE THE PROPER PRE-
tronic microprocessor controlled device designed to CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
operate the electric seat heater elements. The SHIM BAG DEPLOYMENT AND POSSIBLE PERSONAL
is located under the right front seat cushion. Inputs INJURY.
to the module include the console mounted resistor
multiplexed switch signals, seat cushion temperature The heated seat system is capable of performing
sensors, a relay-switched battery feed, and a ground. some self-diagnostics. The following table depicts the
The SHIM outputs are the feed for the seat heating various failure modes which will be reported to the
elements and sensors, and the switch telltale circuits. occupant via flashing the momentary switch telltales.
The SHIM cannot be repaired and, if faulty or dam- The switch telltales will flash on the driver’s switch
aged, it must be replaced. if the failure exists in the driver’s seat portion of the
system, similarly with the passenger’s switch. The
HEATED SEAT RELAY telltale will illuminate for approximately a 1⁄2second
The heated seat relay is located under the right on, 1⁄2second off pulse for a duration of one minute.
front seat cushion near the SHIM. Ignition and bat- This process will repeat every time the system is ini-
tery power is fed to the relay, which then provides a tiated via the switches until the problem has been
switched battery feed to the SHIM. The heated seat corrected.
relay cannot be repaired and, if faulty or damaged, it
must be replaced.

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 8N - 10 ELECTRICALLY HEATED SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
SEAT HEAT INTERFACE MODULE DIAGNOSTIC ROUTINES

FAILURE MODE SWITCH “HI” TELLTALE SWITCH “LO” TELLTALE

Shorted Heating Element Flashing Flashing
Open Heating Element Flashing Off
NTC Value Out of Range Off Flashing

Before testing the individual components in the suspect switch. Check for continuity between the
heated seat system, check the following: ground circuit cavity of the 6-way heated seat switch
• If the heated seat switch backlighting does not wire harness connector and a good ground. There
illuminate with the ignition switch in the ON posi- should be continuity. If OK, go to Step 3. If not OK,
tion, check the fuse in the junction block. If the fuse repair the open circuit as required.
is OK, see Heated Seat Switch Backlighting in the (3) Connect the battery negative cable. Turn the
Diagnosis and Testing section of this group. If not ignition switch to the ON position. Check for battery
OK, repair the shorted circuit or component as voltage at the fused ignition switch output circuit
required and replace the faulty fuse. cavity of the 6-way heated seat switch wire harness
• If the heated seat switch telltales do not illumi- connector. If OK, turn the ignition switch to the OFF
nate with the ignition switch in the ON position, but position, disconnect and isolate the battery negative
the heating elements do heat, see Heated Seat cable, and replace the heated seat switch. If not OK,
Switch Telltales in the Diagnosis and Testing section repair the open circuit as required.
of this group.
• If the heated seat switch backlighting illumi- TELLTALES
nates with the ignition switch in the ON position, (1) Replace the heated seat switch with a known
but the heating elements do not heat and the tell- good unit and test the operation of the switch tell-
tales do not illuminate, check the circuit breaker in tales. If OK, discard the faulty heated seat switch. If
the junction block. If the circuit breaker is OK, see not OK, see Seat Heat Interface Module in the Diag-
Heated Seat Switch Multiplexed Resistances in the nosis and Testing section of this group.
Diagnosis and Testing section of this group. If not
OK, replace the faulty circuit breaker. MULTIPLEXED RESISTANCES
• If the heated seat switch backlighting illumi- (1) Disconnect and isolate the battery negative
nates and the telltales illuminate, but the heating cable.
elements do not heat; see Heated Seat Element in (2) Remove the heated seat switch assembly from
the Diagnosis and Testing section of this group. the center console. Remove the connector from the
suspect switch.
HEATED SEAT SWITCH (3) With the suspect heated seat switch in the
For circuit descriptions and diagrams, refer to 8W - NEUTRAL position, using an ohmmeter, measure the
63 - Power Seat With Heated Seats in Group 8W - resistance between the fused ignition switch output
Wiring Diagrams. circuit terminal and the heated seat switch output
circuit terminal in the 6-way connector receptacle on
WARNING: ON VEHICLES EQUIPPED WITH AIR- the back of the switch. The resistance reading should
BAGS, REFER TO GROUP 8M - PASSIVE be about 2.2. Kohms. If OK, go to Step 4. If not OK,
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY replace the faulty switch.
STEERING WHEEL, STEERING COLUMN, OR (4) Hold the suspect heated seat switch in the LO
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR position. Using an ohmmeter, check the resistance
SERVICE. FAILURE TO TAKE THE PROPER PRE- between the fused ignition switch output circuit ter-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- minal and the heated seat switch output circuit ter-
BAG DEPLOYMENT AND POSSIBLE PERSONAL minal in the 6-way connector receptacle on the back
INJURY. of the switch. The resistance reading should be about
414 Ohms. If OK, go to Step 5. If not OK, replace the
faulty switch.
BACKLIGHTING (5) Hold the suspect heated seat switch in the HI
(1) Disconnect and isolate the battery negative position. Using an ohmmeter, check the resistance
cable between the fused ignition switch output circuit ter-
(2) Remove the heated seat switch assembly from minal and the heated seat switch output circuit ter-
the center console. Remove the connector from the minal in the 6-way connector receptacle on the back

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 11
DIAGNOSIS AND TESTING (Continued)
of the switch. The resistance reading should be about (1) Disconnect and isolate the battery negative
32.5 Ohms. If OK, see Heated Seat Relay in the cable. Unplug the 4-way heated seat cushion wire
Diagnosis and Testing section of this group. If not harness connector.
OK, replace the faulty switch. (2) Using an ohmmeter, check the resistance
between the heated seat sensor input circuit cavity
HEATED SEAT ELEMENT and SENSOR and the heated seat sensor feed circuit cavity of the
The wire harness connectors for the seat cushion seat cushion cover half of the heated seat cushion
and seat back heating elements are located under the wire harness connector. The sensor resistance should
seat, near the rear edge of the seat cushion frame. be between 1 Kohm and 200 Kohms. If OK, see
For circuit descriptions and diagrams, refer to 8W - Heated Seat Relay in the Diagnosis and Testing sec-
63 - Power Seat With Heated Seats in Group 8W - tion of this group. If not OK, replace the faulty seat
Wiring Diagrams. cushion cover.

SEAT CUSHION HEATED SEAT RELAY

(1) Disconnect and isolate the battery negative For circuit descriptions and diagrams, refer to 8W -
cable. Unplug the 4-way heated seat cushion wire 63 - Power Seat With Heated Seats in Group 8W -
harness connector. Wiring Diagrams.
(2) Check for continuity between the two heated (1) Disconnect and isolate the battery negative
seat element circuit cavities of the seat cushion cover cable. Unplug the 8-way heated seat relay connector.
half of the heated seat cushion wire harness connec- (2) Check for continuity between the ground cir-
tor. There should be continuity. If OK, go to Step 3. If cuit cavity of the 8-way heated seat relay wire har-
not OK, replace the faulty seat cushion cover. ness connector and a good ground. There should be
(3) Check for continuity between one of the heated continuity. If OK, go to Step 3. If not OK, repair the
seat element circuit cavities of the seat cushion cover open circuit as required.
half of the heated seat cushion wire harness connec- (3) Connect the battery negative cable. Check for
tor and the seat cushion frame. There should be no battery voltage at the battery feed circuit cavity (pin
continuity. If OK, see Seat Back in the Diagnosis and 8) of the 8-way heated seat relay wire harness con-
Testing section of this group. If not OK, replace the nector. If OK, go to Step 4. If not OK, repair the open
faulty seat cushion cover. circuit as required.
(4) Turn the ignition switch to the ON position.
SEAT BACK Check for battery voltage at the fused ignition switch
(1) Disconnect and isolate the battery negative output circuit cavity of the 8-way heated seat relay
cable. Unplug the 2-way heated seat back wire har- wire harness connector. If OK, turn the ignition
ness connector. switch to the OFF position, disconnect and isolate
(2) Check for continuity between the heated seat the battery negative cable, and go to Step 5. If not
element circuit cavity and the ground circuit cavity of OK, repair the open circuit as required.
the seat back cover half of the heated seat back wire (5) Unplug the 14-way seat heat interface module
harness connector. There should be continuity. If OK, (SHIM) connector. Check for continuity between the
go to Step 3. If not OK, replace the faulty seat back two switched battery feed cavities of the 14-way
cover. SHIM wire harness connector and the switched bat-
(3) Check for continuity between the heated seat tery feed cavity of the 8-way heated seat relay wire
element circuit cavity of the seat back cover half of harness connector. If OK, reconnect the heated seat
the heated seat back wire harness connector and the relay wire harness connector, and go to Step 6. If not
seat back frame. There should be no continuity. If OK, repair the open circuit as required.
OK, see Heated Seat Sensor in the Diagnosis and (6) Connect the battery negative cable. Turn the
Testing section of this group. If not OK, replace the ignition switch to the ON position. Check for battery
faulty seat back cover. voltage at the switched battery feed cavities of the
14-way SHIM wire harness connector. If OK, turn
HEATED SEAT SENSOR the ignition switch to the OFF position, disconnect
The wire harness connector for the seat cushion and isolate the battery negative cable, and see Seat
heating element and sensor are located under the Heat Interface Module in the diagnosis and testing
seat, near the rear edge of the seat cushion frame. section of this group. If not OK, replace the heated
For circuit descriptions and diagrams, refer to 8W - seat relay.
63 - Power Seat With Heated Seats in Group 8W -
Wiring Diagrams.

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 8N - 12 ELECTRICALLY HEATED SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)

SEAT HEAT INTERFACE MODULE (4) Pull back the seat cushion to allow access to
Before testing the seat heat interface module, test the Seat Heat Interface Module (SHIM).
the heated seat switch, the heated seat elements, and (5) Pull the SHIM upward to release the two
the heated seat sensor as described in the Diagnosis mounting fasteners from either the module or the
and Testing section of this group. If testing of the mounting bracket. Unplug the wire harness connec-
heated seat switch, elements, and sensor reveals no tor from the module (Fig. 2).
problems, proceed as follows. For circuit descriptions
WARNING: THERE ARE MANY SHARP METAL
and diagrams, refer to 8W - 63 - Power Seat With
EDGES ON THE SEAT CUSHION FRAME AND SEAT
Heated Seats in Group 8W - Wiring Diagrams.
ADJUSTER RAILS UNDER THE SEAT. WHEN PER-
(1) Replace the seat heat interface module with a
FORMING THIS SERVICE, A LONG-SLEEVED SHIRT
known good unit and test the operation of the heated
AND GLOVES SHOULD BE WORN IN ORDER TO
seats. If OK, discard the faulty seat heat interface
AVOID UNNECESSARY CUTS AND ABRASIONS TO
module. If not OK, go to Step 2.
EXPOSED SKIN.
(2) Test each of the circuits from the heated seat
switch, heated seat relay, heated seat elements, and
heated seat sensor to the seat heat interface module.
Repair any short or open circuits as required.

REMOVAL AND INSTALLATION

HEATED SEAT SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Disconnect and isolate the battery negative

cable.
(2) Using a trim stick or another suitable wide Fig. 2 Seat Heat Interface Module Remove/Install
flat-bladed tool, gently pry around the perimeter 1 – SEAT CUSHION FRAME
edges of the heated switch assembly bezel to release 2 – SEAT HEAT INTERFACE MODULE
3 – WIRE HARNESS CONNECTOR
the assembly from the console. Remove the assembly
4 – POWER SEAT TRACK FRONT BRACKET
from the console.
(3) Pull the switch assembly out from the console
far enough to access and unplug the wire harness (6) Reverse the removal procedures to install. Be
connectors. certain that the SHIM terminals are aligned with the
(4) Remove the heated seat switch assembly from cavities in the wire harness connector before pushing
the console. the module firmly into place.
(5) Remove the heated seat switch(es) from the
heated seat switch assembly. HEATED SEAT RELAY
(6) Reverse the removal procedures to install. (1) Move the right power seat adjuster to its full
up and full rear stop positions.
SEAT HEAT INTERFACE MODULE (2) Disconnect and isolate the battery negative
(1) Move the right power seat adjuster to its full cable.
up and full rear stop positions. (3) Unhook the seat cushion cover retainer from
(2) Disconnect and isolate the battery negative the seat cushion frame and pull back the seat cush-
cable. ion cover.
(3) Unhook the seat cushion cover retainer from (4) Pull back the seat cushion to allow access to
the seat cushion frame and pull back the seat cush- the Heated Seat Relay.
ion cover.

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 13
REMOVAL AND INSTALLATION (Continued)
(5) Cut the Christmas tree fastener to remove the
Heated Seat Relay fastener from the mounting
bracket. Unplug the wire harness connector from the
relay (Fig. 3).
(6) Reverse the removal procedures to install. A
new Christmas tree fastener must be used to mount
the relay. Be certain that the relay terminals are
aligned with the cavities in the wire harness connec-
tor before pushing the relay firmly into place.

Fig. 3 Heated Seat Relay Remove/Install

1 – HEATED SEAT RELAY
2 – SEAT CUSHION FRAME
3 – WIRE HARNESS CONNECTOR
4 – POWER SEAT TRACK FRONT BRACKET

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 1

ELECTRICALLY HEATED SYSTEMS

TABLE OF CONTENTS

page page

REAR WINDOW DEFOGGER SYSTEM . . . . . . . . . . 1 HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . 8

REAR WINDOW DEFOGGER SYSTEM

TABLE OF CONTENTS
page page

GENERAL INFORMATION REAR GLASS HEATING GRID . . . . . . . . . . . . . . . .4

INTRODUCTION . . . . . . . . . . . . . . . . . .........1 DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . . .4
REAR WINDOW DEFOGGER SYSTEM .........1 DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . . .4
DESCRIPTION AND OPERATION INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . .5
REAR GLASS HEATING GRID . . . . . . . . . . . . . . . .2 SERVICE PROCEDURES
OUTSIDE MIRROR HEATING GRID . . . . . . . . . . . .2 REAR GLASS HEATING GRID REPAIR .........6
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . . .2 REMOVAL AND INSTALLATION
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . .2 DEFOGGER SWITCH . . . . . . . . . . . . . .........6
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . . .3 DEFOGGER RELAY . . . . . . . . . . . . . . . .........7
DIAGNOSIS AND TESTING
DEFOGGER SYSTEM . . . . . . . . . . . . . .........3

GENERAL INFORMATION REAR WINDOW DEFOGGER SYSTEM

The rear window defogger system will only operate
INTRODUCTION when the ignition switch is in the On position. When
An electrically heated rear window defogger and the defogger switch is in the On position, an electric
electrically heated outside rear view mirrors are heater grid on the rear window glass is energized.
available factory-installed options on this model. Vehicles with the heated mirror options also have
Refer to 8W-48 - Rear Window Defogger and 8W-62 - heater grids located behind the outside rear view
Power Mirrors in Group 8W - Wiring Diagrams for mirror glass. Each of these grids produce heat to help
complete circuit descriptions and diagrams. clear the rear window glass and outside rear view
mirrors of ice, snow, or fog.
NOTE: This group covers both Left-Hand Drive The defogger system is controlled by a switch
(LHD) and Right-Hand Drive (RHD) versions of this installed in the instrument panel accessory switch
model. Whenever required and feasible, the RHD bezel, which is located near the bottom of the instru-
versions of affected vehicle components have been ment panel center bezel area, below the heater and
constructed as mirror-image of the LHD versions. air conditioner controls. An amber indicator lamp in
While most of the illustrations used in this group the switch button will light to indicate when the
represent only the LHD version, the diagnostic and defogger system is turned on. The instrument cluster
service procedures outlined can generally be circuitry, which contains the defogger system timer
applied to either version. Exceptions to this rule logic, monitors the state of the defogger switch
have been clearly identified as LHD or RHD, if a through a hard-wired input. The instrument cluster
special illustration or procedure is required. circuitry controls the defogger system through a
hard-wired control output to the defogger relay.
The defogger system will be automatically turned
off after a programmed time interval of about ten
minutes. After the initial time interval has expired, if

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 8N - 2 ELECTRICALLY HEATED SYSTEMS XJ
GENERAL INFORMATION (Continued)
the defogger switch is turned on again during the window heating grid is operating as designed, refer
same ignition cycle, the defogger system will auto- to Power Mirror in the Diagnosis and Testing section
matically turn off after about five minutes. of Group 8T - Power Mirror Systems for diagnosis of
The defogger system will automatically shut off if the mirror heating grids.
the ignition switch is turned to the Off position, or it The heating grid behind each outside mirror glass
can be turned off manually by depressing the instru- cannot be repaired and, if faulty or damaged, the
ment panel switch. Following are general descrip- entire power mirror unit must be replaced. Refer to
tions of the major components in the defogger Power Mirror in the Removal and Installation section
system. Refer to the owner’s manual in the vehicle of Group 8T - Power Mirror Systems for the service
glove box for more information on the features, use procedures.
and operation of the defogger system.
DEFOGGER SWITCH
The rear window defogger switch is installed in the
DESCRIPTION AND OPERATION instrument panel accessory switch bezel, which is
located near the bottom of the instrument panel cen-
REAR GLASS HEATING GRID ter bezel area, below the heater and air conditioner
The heated rear window glass has two electrically controls. The momentary-type switch provides a
conductive vertical bus bars and a series of horizon- hard-wired ground signal to the instrument cluster
tal grid lines made of a silver-ceramic material, each time it is depressed. The instrument cluster
which is baked on and bonded to the inside surface of rear window defogger timer and logic circuitry
the glass. The grid lines and bus bars comprise a responds by energizing or de-energizing the rear win-
parallel electrical circuit. dow defogger relay.
When the rear window defogger switch is placed in Energizing the rear window defogger relay pro-
the On position, electrical current is directed to the vides electrical current to the rear window defogger
rear window grid lines through the bus bars. The grid and, if the vehicle is so equipped, the outside
grid lines heat the rear window to clear the surface rear view mirror heating grids. An amber indicator
of fog or snow. Protection for the heated grid circuit lamp in the defogger switch, which lights to indicate
is provided by a fuse in the Power Distribution Cen- when the defogger system is turned On, is also pow-
ter (PDC). ered by the defogger relay output.
The grid lines and bus bars are highly resistant to The defogger switch illumination lamp and indica-
abrasion. However, it is possible for an open circuit tor lamp bulbs are serviceable. The defogger switch
to occur in an individual grid line, resulting in no cannot be repaired and, if faulty or damaged, it must
current flow through the line. be replaced.
The grid lines can be damaged or scraped off with
sharp instruments. Care should be taken when clean- INSTRUMENT CLUSTER
ing the glass or removing foreign materials, decals, The instrument cluster is an electromechanical
or stickers from the glass. Normal glass cleaning sol- unit that contains integrated circuitry and internal
vents or hot water used with rags or toweling is rec- programming to perform a variety of functions. The
ommended. instrument cluster circuitry monitors hard-wired
A repair kit is available to repair the grid lines and switch inputs, as well as message inputs received
bus bars, or to reinstall the heated glass pigtail from other vehicle electronic control modules on the
wires. Chrysler Collision Detection (CCD) data bus network.
The instrument cluster uses these many inputs
OUTSIDE MIRROR HEATING GRID along with its internal programming and integral
Vehicles equipped with the optional heated mirror timer and logic circuitry to perform the functions of
package have an electric heating grid located behind the rear window defogger timer on this model. The
the mirror glass of each outside rear view mirror. instrument cluster circuitry also has a self-diagnostic
The heated mirrors are controlled by the rear win- capability. Refer to Instrument Cluster in Group 8E -
dow defogger switch. Electrical current is directed to Instrument Panel Systems for more information on
the heating grid inside the mirror only when the rear this feature.
window defogger switch is in the On position. However, there are no diagnostics available for the
If the outside mirror heating grids and the rear rear window defogger timer and logic circuitry.
window heating grid are all inoperative, diagnosis of Therefore, the diagnosis for this system consists of
the rear window defogger system should be per- confirming the presence of a rear window defogger
formed as described in this group. If the outside mir- switch input signal at the instrument cluster connec-
ror heating grids are inoperative, but the rear tor, and the resulting rear window defogger relay

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 3
DESCRIPTION AND OPERATION (Continued)
control output signal at the defogger relay. For diag-
nosis of the CCD data bus and the data bus message
inputs, a DRB scan tool and the proper Diagnostic
Procedures manual are recommended.
Refer to Instrument Cluster in Group 8E - Instru-
ment Panel Systems for the service procedures for
the instrument cluster. The rear window defogger
timer and logic circuitry cannot be adjusted or
repaired and, if faulty or damaged, the instrument
cluster assembly must be replaced.

DEFOGGER RELAY
The rear window defogger relay is a International
Standards Organization (ISO)-type relay. The rear
window defogger relay is a electromechanical device
that switches fused battery current to the rear glass Fig. 1 Rear Window Glass Grid Test
and outside mirror heating grids, and the indicator 1 – TERMINAL “A”
2 – TERMINAL “B”
lamp of the defogger switch, when the instrument
3 – FEED WIRE
cluster rear window defogger timer and logic cir-
4 – MID-POINT “C” (TYPICAL)
cuitry grounds the relay coil. See Defogger Relay in 5 – HEATED REAR WINDOW DEFOGGER GRID
the Diagnosis and Testing section of this group for 6 – GROUND WIRE
more information.
The rear window defogger relay is located in the
junction block, on the right cowl side inner panel The above checks will confirm system operation.
below the instrument panel in the passenger com- Illumination of the defogger switch indicator lamp
partment. The rear window defogger relay cannot be means that there is electrical current available at the
repaired and, if faulty or damaged, it must be output of the defogger relay, but does not confirm
replaced. that the electrical current is reaching the rear glass
heating grid lines.
If the defogger system does not operate, the prob-
DIAGNOSIS AND TESTING lem should be isolated in the following manner:
(1) Confirm that the ignition switch is in the On
DEFOGGER SYSTEM position.
For circuit descriptions and diagrams, refer to (2) Ensure that the rear glass heating grid feed
8W-48 - Rear Window Defogger or 8W-62 Power Mir- and ground wires are connected to the glass. Confirm
rors in Group 8W - Wiring Diagrams. The operation that the ground wire has continuity to ground.
of the electrically heated rear window defogger sys- (3) Check the fuses in the Power Distribution Cen-
tem can be confirmed in one of the following man- ter (PDC) and in the junction block. The fuses must
ners: be tight in their receptacles and all electrical connec-
1. Turn the ignition switch to the On position. tions must be secure.
While monitoring the instrument panel voltmeter, set When the above steps have been completed and the
the defogger switch in the On position. When the rear glass or outside rear view mirror heating grid is
defogger switch is turned On, a distinct voltmeter still inoperative, one or more of the following is
needle deflection should be noted. faulty:
2. Turn the ignition switch to the On position. Set • Defogger switch
the defogger switch in the On position. The rear win- • Defogger relay
dow defogger operation can be checked by feeling the • Instrument cluster circuitry
rear window or outside rear view mirror glass. A dis- • Rear window grid lines (all grid lines would
tinct difference in temperature between the grid lines have to be broken or one of the feed wires discon-
and the adjacent clear glass or the mirror glass can nected for the entire system to be inoperative)
be detected within three to four minutes of operation. • Outside rear view mirror heating grid.
3. Using a 12-volt DC voltmeter, contact the rear If setting the defogger switch to the On position
glass heating grid terminal A (right side) with the produces a severe voltmeter deflection, check for a
negative lead, and terminal B (left side) with the pos- short circuit between the defogger relay output and
itive lead (Fig. 1). The voltmeter should read battery the rear glass or outside rear view mirror heating
voltage. grids.

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 8N - 4 ELECTRICALLY HEATED SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)

REAR GLASS HEATING GRID (3) Check for continuity between the ground cir-
For circuit descriptions and diagrams, refer to cuit terminal and the rear window defogger switch
8W-48 - Rear Window Defogger in Group 8W - Wir- sense circuit terminal on the back of the defogger
ing Diagrams. To detect breaks in the grid lines, the switch housing (Fig. 2). There should be momentary
following procedure is required: continuity as the defogger switch button is depressed,
(1) Turn the ignition switch to the On position. Set and then no continuity. If OK, see the diagnosis for
the defogger switch in the On position. The indicator the Instrument Cluster in this group. If not OK,
lamp should light. If OK, go to Step 2. If not OK, see replace the faulty switch.
the Defogger Relay diagnosis in this group.
(2) Using a 12-volt DC voltmeter, contact the ver-
tical bus bar on the right side of the vehicle with the
negative lead. With the positive lead, contact the ver-
tical bus bar on the left side of the vehicle. The volt-
meter should read battery voltage. If OK, go to Step
3. If not OK, repair the open circuit to the defogger
relay as required.
(3) With the negative lead of the voltmeter, contact
a good body ground point. The voltage reading should
not change. If OK, go to Step 4. If not OK, repair the
circuit to ground as required.
(4) Connect the negative lead of the voltmeter to
the right side bus bar and touch each grid line at SWITCH POSITION CONTINUITY BETWEEN
midpoint C with the positive lead. A reading of OFF LAMPS
approximately six volts indicates a line is good. A
ON MOMENTARY 1 AND 2
reading of zero volts indicates a break in the grid
line between midpoint C and the left side bus bar. A ILLUMINATION LAMP 1 AND 4
reading of ten to fourteen volts indicates a break INDICATOR LAMP 1 AND 3
between midpoint C and the right side bus bar. Move
the positive lead on the grid line towards the break
and the voltage reading will change as soon as the Fig. 2 Defogger Switch Continuity
break is crossed. DEFOGGER RELAY
DEFOGGER SWITCH WARNING: ON VEHICLES EQUIPPED WITH AIR-
For circuit descriptions and diagrams, refer to BAGS, REFER TO GROUP 8M - PASSIVE
8W-48 - Rear Window Defogger in Group 8W - Wir- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
ing Diagrams. STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
WARNING: ON VEHICLES EQUIPPED WITH AIR- SERVICE. FAILURE TO TAKE THE PROPER PRE-
BAGS, REFER TO GROUP 8M - PASSIVE CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY BAG DEPLOYMENT AND POSSIBLE PERSONAL
STEERING WHEEL, STEERING COLUMN, OR INJURY.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- RELAY TEST
BAG DEPLOYMENT AND POSSIBLE PERSONAL The defogger relay (Fig. 3) is located in the junc-
INJURY. tion block, on the right cowl side inner panel below
the instrument panel in the passenger compartment.
(1) Disconnect and isolate the battery negative Remove the defogger relay from the junction block to
cable. Remove the accessory switch bezel from the perform the following tests:
instrument panel and unplug the defogger switch (1) A relay in the de-energized position should
wire harness connector. have continuity between terminals 87A and 30, and
(2) Check for continuity between the ground cir- no continuity between terminals 87 and 30. If OK, go
cuit cavity of the defogger switch wire harness con- to Step 2. If not OK, replace the faulty relay.
nector and a good ground. There should be (2) Resistance between terminals 85 and 86 (elec-
continuity. If OK, go to Step 3. If not OK, repair the tromagnet) should be 75 6 10 ohms. If OK, go to
open circuit as required. Step 3. If not OK, replace the faulty relay.

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 5
DIAGNOSIS AND TESTING (Continued)
(3) Connect a battery to terminals 85 and 86. is turned On. Be certain that you depress the defog-
There should now be continuity between terminals ger switch at least twice to confirm that the system
30 and 87, and no continuity between terminals 87A is turned on during this test. If OK, go to Step 5. If
and 30. If OK, see the Relay Circuit Test in this not OK, repair the open circuit to the instrument
group. If not OK, replace the faulty relay. cluster as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. It is connected to
fused ignition switch output voltage and should be
hot when the ignition switch is in the On position.
Check for battery voltage at the cavity for relay ter-
minal 86 with the ignition switch in the On position.
If OK, see the diagnosis for Instrument Cluster in
this group. If not OK, repair the open circuit to the
fuse in the junction block as required.

INSTRUMENT CLUSTER
Before performing this test, complete the Defogger
TERMINAL LEGEND Switch and the Defogger Relay tests as described in
NUMBER IDENTIFICATION this group. For circuit descriptions and diagrams,
30 COMMON FEED refer to 8W-48 - Rear Window Defogger in Group 8W
- Wiring Diagrams.
85 COIL GROUND
86 COIL BATTERY WARNING: ON VEHICLES EQUIPPED WITH AIR-
87 NORMALLY OPEN BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
87A NORMALLY CLOSED
STEERING WHEEL, STEERING COLUMN, OR
Fig. 3 Defogger Relay INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
RELAY CIRCUIT TEST CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(1) The relay common feed terminal cavity (30) is BAG DEPLOYMENT AND POSSIBLE PERSONAL
connected to battery voltage and should be hot at all INJURY.
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required. (1) Disconnect and isolate the battery negative
(2) The relay normally closed terminal (87A) is cable. Remove the defogger relay from the junction
connected to terminal 30 in the de-energized position, block and unplug the defogger switch wire harness
but is not used for this application. Go to Step 3. connector.
(3) The relay normally open terminal (87) is con- (2) Remove the instrument cluster from the instru-
nected to the common feed terminal (30) in the ener- ment panel. Refer to Instrument Cluster in Group 8E
gized position. This terminal supplies battery voltage - Instrument Panel Systems for the procedures.
to the rear glass and outside rear view mirror heat- (3) Check for continuity between the rear window
ing grids and the defogger switch indicator lamp. defogger switch sense circuit cavity of the right
There should be continuity between the cavity for instrument cluster wire harness connector (connector
relay terminal 87 and the rear window defogger relay B) and a good ground. There should be no continuity.
output circuit cavities of the rear glass heating grid If OK, go to Step 4. If not OK, repair the short circuit
connector, both outside rear view mirror heating grid as required.
connectors, and the defogger switch connector at all (4) Check for continuity between the rear window
times. If OK, go to Step 4. If not OK, repair the open defogger switch sense circuit cavities of the right
circuit(s) as required. instrument cluster wire harness connector (connector
(4) The coil ground terminal (85) is connected to B) and the defogger switch wire harness connector.
the electromagnet in the relay. This terminal is pro- There should be continuity. If OK, go to Step 5. If not
vided with ground by the instrument cluster rear OK, repair the open circuit as required.
window defogger timer and logic circuitry to energize (5) Check for continuity between the rear window
the defogger relay. There should be continuity to defogger relay control circuit cavity of the right
ground at the cavity for relay terminal 85 when the instrument cluster wire harness connector (connector
defogger switch is turned On. However, with the B) and a good ground. There should be no continuity.
defogger relay removed, the defogger switch indicator If OK, go to Step 6. If not OK, repair the short circuit
lamp will not light to show that the defogger system as required.

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 8N - 6 ELECTRICALLY HEATED SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
(6) Check for continuity between the rear window (2) Follow the instructions in the repair kit for
defogger relay control circuit cavities of the right preparing the damaged area.
instrument cluster wire harness connector (connector (3) Remove the package separator clamp and mix
B) and the defogger relay receptacle (the cavity for the two conductive epoxy components thoroughly
ISO relay terminal 85) in the junction block. There within the packaging. Fold the package in half and
should be continuity. If OK, replace the faulty instru- cut the center corner to dispense the epoxy.
ment cluster. If not OK, repair the open circuit as (4) For grid line repairs, mask the area to be
required. repaired with masking tape or a template.
(5) Apply the epoxy through the slit in the mask-
ing tape or template. Overlap both ends of the break
SERVICE PROCEDURES by at least 19 millimeters (0.75 inch).
(6) For a terminal or pigtail wire replacement,
REAR GLASS HEATING GRID REPAIR mask the adjacent areas so the epoxy can be
Repair of the rear glass heating grid lines, bus extended onto the adjacent grid line as well as the
bars, terminals or pigtail wires can be accomplished bus bar. Apply a thin layer of epoxy to the area
using a Mopar Rear Window Defogger Repair Kit where the terminal or pigtail wire was fastened and
(Part Number 4267922) or equivalent. onto the adjacent grid line.
(7) Apply a thin layer of conductive epoxy to the
WARNING: MATERIALS CONTAINED IN THE terminal or bare wire end of the pigtail and place it
REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION. in the proper location on the bus bar. To prevent the
THE KIT CONTAINS EPOXY RESIN AND AMINE terminal or pigtail wire from moving while the epoxy
TYPE HARDENER, WHICH ARE HARMFUL IF SWAL- is curing, it must be wedged or clamped.
LOWED. AVOID CONTACT WITH THE SKIN AND (8) Carefully remove the masking tape or tem-
EYES. FOR SKIN CONTACT, WASH THE AFFECTED plate.
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER. CAUTION: Do not allow the glass surface to exceed
DO NOT TAKE INTERNALLY. IF TAKEN INTER- 204° C (400° F) or the glass may fracture.
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA- (9) Allow the epoxy to cure 24 hours at room tem-
TION. DO NOT USE NEAR FIRE OR FLAME. CON- perature, or use a heat gun with a 260° to 371° C
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE (500° to 700° F) range for fifteen minutes. Hold the
REACH OF CHILDREN. heat gun approximately 25.4 centimeters (10 inches)
from the repair.
(1) Mask the repair area so that the conductive (10) After the conductive epoxy is properly cured,
epoxy can be applied neatly. Extend the epoxy appli- remove the wedge or clamp from the terminal or pig-
cation onto the grid line or the bus bar on each side tail wire. Do not attach the wire harness connectors
of the break (Fig. 4). until the curing process is complete.
(11) Check the operation of the rear window defog-
ger glass heating grid.

REMOVAL AND INSTALLATION

DEFOGGER SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
REFER TO GROUP 8M - PASSIVE RESTRAINT SYS-
TEMS BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL COM-
PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
Fig. 4 Grid Line Repair - Typical PERSONAL INJURY.
1 – BREAK
2 – GRID LINE (1) Disconnect and isolate the battery negative
3 – MASKING TAPE
cable.

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 7
REMOVAL AND INSTALLATION (Continued)
(2) Remove the center bezel from the instrument (3) Remove the stamped nut that secures the right
panel. See Instrument Panel Center Bezel in Group cowl side trim to the junction block stud (Fig. 6).
8E - Instrument Panel Systems for the procedures.
(3) Remove the three screws that secure the acces-
sory switch bezel to the instrument panel (Fig. 5).

Fig. 5 Accessory Switch Bezel Remove/Install

1 – ACCESSORY SWITCH BEZEL
2 – SCREW

(4) Pull the accessory switch bezel out from the

instrument panel far enough to access the wire har-
ness connectors.
(5) Unplug the wire harness connectors from the
rear of the accessory switches and the cigar lighter/
power outlet.
(6) Remove the accessory switch bezel from the Fig. 6 Right Cowl Side Trim Remove/Install
instrument panel. 1 – RIGHT FRONT DOOR SILL
(7) With a small thin-bladed screwdriver, gently pry 2 – COWL SIDE TRIM PANEL
the snap clips at the top and bottom of the rear window 3 – SCREW
defogger switch receptacle on the back of the accessory 4 – SILL TRIM
switch bezel and pull the switch out of the bezel. 5 – FUSE ACCESS PANEL
(8) Reverse the removal procedures to install. Be 6 – PUSH-NUT
certain that both of the switch snap retainers in the
receptacle on the back of the accessory switch bezel (4) Remove the screw located above the fuse access
are fully engaged. Tighten the mounting screws to opening that secures the right cowl side trim to the
2.2 N·m (20 in. lbs.). right cowl side inner panel.
(5) Remove the screw that secures the right door
DEFOGGER RELAY sill trim and the right cowl side trim to the right
door opening sill.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, (6) Remove the right cowl side trim panel from the
REFER TO GROUP 8M - PASSIVE RESTRAINT SYS- vehicle.
TEMS BEFORE ATTEMPTING ANY STEERING WHEEL, (7) Unplug the rear window defogger relay from
STEERING COLUMN, OR INSTRUMENT PANEL COM- the junction block.
PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE (8) Install the defogger relay by aligning the relay
THE PROPER PRECAUTIONS COULD RESULT IN terminals with the cavities in the junction block and
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE pushing the relay firmly into place.
PERSONAL INJURY. (9) Connect the battery negative cable.
(10) Test the relay operation.
(1) Disconnect and isolate the battery negative cable. (11) Reinstall the right cowl side trim and the fuse
(2) Remove the fuse access panel by unsnapping it access panel. Tighten the mounting screws to 2.2
from the right cowl side trim panel. N·m (20 in. lbs.).

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 8N - 8 ELECTRICALLY HEATED SYSTEMS XJ

HEATED SEAT SYSTEM

TABLE OF CONTENTS
page page

GENERAL INFORMATION HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . . . . 10

INTRODUCTION . . . . . . . . . . . . . . . . . . ........8 HEATED SEAT ELEMENT and SENSOR. . . . . . . . 11
DESCRIPTION AND OPERATION HEATED SEAT RELAY . . . . . . . . . . . . . . . . . . . . . 11
HEATED SEAT SWITCH. . . . . . . . . . . . . . . . . . . . .8 SEAT HEAT INTERFACE MODULE. . . . . . . . . . . . 12
SEAT HEAT INTERFACE MODULE. . . . . . . . . . . . .9 REMOVAL AND INSTALLATION
HEATED SEAT RELAY . . . . . . . . . . . . . . . . . . . . . .9 HEATED SEAT SWITCH . . . . . . . . . . . . . . . . . . . . 12
HEATED SEAT ELEMENT and SENSOR . . . . . . . .9 SEAT HEAT INTERFACE MODULE. . . . . . . . . . . . 12
DIAGNOSIS AND TESTING HEATED SEAT RELAY . . . . . . . . . . . . . . . . . . . . . 12
HEATED SEAT SYSTEM . . . . . . . . . . . . ........9

GENERAL INFORMATION N-FET Transistor within the SHIM energizes the

heating elements in the seat cushion and back. When
INTRODUCTION the sensor input indicates the correct temperature
Individually controlled electrically heated front set point has been achieved, the SHIM de-energizes
seats are available factory-installed optional equip- the N-FET. The SHIM will continue to cycle the
ment on this model. The seat heaters will only oper- N-FET as needed to maintain the temperature set
ate when the ignition switch is in the ON position, point.
and the surface temperature at the front seat heating The SHIM will automatically turn off the heating
element sensors is below the designed temperature elements if it detects a short or an open in the heat-
set points of the system. The heated seat system will ing element or a sensor out of range. These condi-
not operate in ambient temperatures greater than tions will also cause the SHIM to notify the occupant
about 32° C (90° F). of the failure via flashing the heated seat switch
There are separate momentary, tactile, two-direc- LED’s as discussed later.
tional rocker switches located in the center console Switched battery power to the SHIM is supplied by
with center NEUTRAL, HI and LO positions for each the heated seat relay mounted to the seat cushion
front seat. Depressing the rocker switch to its frame with the SHIM under the right front seat. The
momentary HI or LO position signals the Seat Heat battery feed is protected by a circuit breaker located
Interface Module (SHIM) to power the selected in the junction block.
heated seat and maintain the requested temperature Following are general descriptions of the major
setting (HI or LO). Each switch has a HI and LO components in the heated seat system. Refer to
Light-Emitting Diode (LED) which, via the SHIM, 8W-63 - Power Seat With Heated Seats in Group 8W
illuminates to give a visual indication that the sys- - Wiring Diagrams for complete circuit descriptions
tem is in the HI or LO mode. The LO heat set point and diagrams.
is about 32° C (90° F), and the HI heat set point is
about 38° C (100° F). The system shall be deactivated DESCRIPTION AND OPERATION
whenever the same set position is depressed a second
time and shall change states directly when switching
HEATED SEAT SWITCH
from HI to LO or vice versa. The system shall be
The heated seat switch assembly is located on the
deactivated whenever the ignition switch is placed in
center console where the ashtray is normally located
the off position. When the ignition switch is placed
(Fig. 1). The two momentary, two-directional rocker
back in the run position, the heated seat system
switches, one switch for each front seat, provide a
shall remain deactivated until a momentary switch is
resistor-multiplexed signal to the Seat Heat Interface
depressed. When a seat heater is turned on, a sensor
Module (SHIM). Each switch has center NEUTRAL,
located near the seat cushion electric heater element
and momentary LO and HI positions so that both the
provides the SHIM with input indicating the surface
driver and the front seat passenger can select a pre-
temperature of the seat cushion. If the surface tem-
ferred seat heating mode.
perature input is below the temperature set point of
Each switch has two telltales (LED’s) which indi-
the SHIM for the selected temperature setting, an
cate the mode of the heater of the respective seat.

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 9
DESCRIPTION AND OPERATION (Continued)

HEATED SEAT ELEMENT and SENSOR

Two heated seat heating elements are used in each
front seat, one for the seat cushion and the other for
the seat back. The two elements for each seat are
connected in series with the SHIM.
The temperature sensor is a Negative Temperature
Coefficient (NTC) thermistor. One temperature sen-
sor is used for each seat, and it is integral to the seat
cushion heating element.
The heating elements are sewn into the seat cush-
ion cover and seat back cover assemblies, which are
serviced individually. The heating elements and tem-
perature sensor cannot be repaired and, if faulty or
damaged, the affected seat cover assembly must be
replaced. Refer to Group 23 - Body for the seat cush-
ion cover and seat back cover Removal and Installa-
tion.

Fig. 1 Heated Seat Switch Location DIAGNOSIS AND TESTING

1 – ASH RECEIVER
2 – HEATED SEAT SWITCHES & BEZEL
3 – WIRE HARNESS CONNECTORS
HEATED SEAT SYSTEM
4 – FLOOR CONSOLE For circuit descriptions and diagrams, refer to 8W -
63 - Power Seat With Heated Seats in Group 8W -
Wiring Diagrams.
The switches also have LED’s which provide back-
lighting when the ignition switch is in the ON posi- WARNING: ON VEHICLES EQUIPPED WITH AIR-
tion. The LED’s cannot be repaired. If the LED is BAGS, REFER TO GROUP 8M - PASSIVE
faulty, the individual switch must be replaced. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
SEAT HEAT INTERFACE MODULE INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
The Seat Heat Interface Module (SHIM) is an elec- SERVICE. FAILURE TO TAKE THE PROPER PRE-
tronic microprocessor controlled device designed to CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
operate the electric seat heater elements. The SHIM BAG DEPLOYMENT AND POSSIBLE PERSONAL
is located under the right front seat cushion. Inputs INJURY.
to the module include the console mounted resistor
multiplexed switch signals, seat cushion temperature The heated seat system is capable of performing
sensors, a relay-switched battery feed, and a ground. some self-diagnostics. The following table depicts the
The SHIM outputs are the feed for the seat heating various failure modes which will be reported to the
elements and sensors, and the switch telltale circuits. occupant via flashing the momentary switch telltales.
The SHIM cannot be repaired and, if faulty or dam- The switch telltales will flash on the driver’s switch
aged, it must be replaced. if the failure exists in the driver’s seat portion of the
system, similarly with the passenger’s switch. The
HEATED SEAT RELAY telltale will illuminate for approximately a 1⁄2second
The heated seat relay is located under the right on, 1⁄2second off pulse for a duration of one minute.
front seat cushion near the SHIM. Ignition and bat- This process will repeat every time the system is ini-
tery power is fed to the relay, which then provides a tiated via the switches until the problem has been
switched battery feed to the SHIM. The heated seat corrected.
relay cannot be repaired and, if faulty or damaged, it
must be replaced.

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 8N - 10 ELECTRICALLY HEATED SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
SEAT HEAT INTERFACE MODULE DIAGNOSTIC ROUTINES

FAILURE MODE SWITCH “HI” TELLTALE SWITCH “LO” TELLTALE

Shorted Heating Element Flashing Flashing
Open Heating Element Flashing Off
NTC Value Out of Range Off Flashing

Before testing the individual components in the suspect switch. Check for continuity between the
heated seat system, check the following: ground circuit cavity of the 6-way heated seat switch
• If the heated seat switch backlighting does not wire harness connector and a good ground. There
illuminate with the ignition switch in the ON posi- should be continuity. If OK, go to Step 3. If not OK,
tion, check the fuse in the junction block. If the fuse repair the open circuit as required.
is OK, see Heated Seat Switch Backlighting in the (3) Connect the battery negative cable. Turn the
Diagnosis and Testing section of this group. If not ignition switch to the ON position. Check for battery
OK, repair the shorted circuit or component as voltage at the fused ignition switch output circuit
required and replace the faulty fuse. cavity of the 6-way heated seat switch wire harness
• If the heated seat switch telltales do not illumi- connector. If OK, turn the ignition switch to the OFF
nate with the ignition switch in the ON position, but position, disconnect and isolate the battery negative
the heating elements do heat, see Heated Seat cable, and replace the heated seat switch. If not OK,
Switch Telltales in the Diagnosis and Testing section repair the open circuit as required.
of this group.
• If the heated seat switch backlighting illumi- TELLTALES
nates with the ignition switch in the ON position, (1) Replace the heated seat switch with a known
but the heating elements do not heat and the tell- good unit and test the operation of the switch tell-
tales do not illuminate, check the circuit breaker in tales. If OK, discard the faulty heated seat switch. If
the junction block. If the circuit breaker is OK, see not OK, see Seat Heat Interface Module in the Diag-
Heated Seat Switch Multiplexed Resistances in the nosis and Testing section of this group.
Diagnosis and Testing section of this group. If not
OK, replace the faulty circuit breaker. MULTIPLEXED RESISTANCES
• If the heated seat switch backlighting illumi- (1) Disconnect and isolate the battery negative
nates and the telltales illuminate, but the heating cable.
elements do not heat; see Heated Seat Element in (2) Remove the heated seat switch assembly from
the Diagnosis and Testing section of this group. the center console. Remove the connector from the
suspect switch.
HEATED SEAT SWITCH (3) With the suspect heated seat switch in the
For circuit descriptions and diagrams, refer to 8W - NEUTRAL position, using an ohmmeter, measure the
63 - Power Seat With Heated Seats in Group 8W - resistance between the fused ignition switch output
Wiring Diagrams. circuit terminal and the heated seat switch output
circuit terminal in the 6-way connector receptacle on
WARNING: ON VEHICLES EQUIPPED WITH AIR- the back of the switch. The resistance reading should
BAGS, REFER TO GROUP 8M - PASSIVE be about 2.2. Kohms. If OK, go to Step 4. If not OK,
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY replace the faulty switch.
STEERING WHEEL, STEERING COLUMN, OR (4) Hold the suspect heated seat switch in the LO
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR position. Using an ohmmeter, check the resistance
SERVICE. FAILURE TO TAKE THE PROPER PRE- between the fused ignition switch output circuit ter-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- minal and the heated seat switch output circuit ter-
BAG DEPLOYMENT AND POSSIBLE PERSONAL minal in the 6-way connector receptacle on the back
INJURY. of the switch. The resistance reading should be about
414 Ohms. If OK, go to Step 5. If not OK, replace the
faulty switch.
BACKLIGHTING (5) Hold the suspect heated seat switch in the HI
(1) Disconnect and isolate the battery negative position. Using an ohmmeter, check the resistance
cable between the fused ignition switch output circuit ter-
(2) Remove the heated seat switch assembly from minal and the heated seat switch output circuit ter-
the center console. Remove the connector from the minal in the 6-way connector receptacle on the back

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 11
DIAGNOSIS AND TESTING (Continued)
of the switch. The resistance reading should be about (1) Disconnect and isolate the battery negative
32.5 Ohms. If OK, see Heated Seat Relay in the cable. Unplug the 4-way heated seat cushion wire
Diagnosis and Testing section of this group. If not harness connector.
OK, replace the faulty switch. (2) Using an ohmmeter, check the resistance
between the heated seat sensor input circuit cavity
HEATED SEAT ELEMENT and SENSOR and the heated seat sensor feed circuit cavity of the
The wire harness connectors for the seat cushion seat cushion cover half of the heated seat cushion
and seat back heating elements are located under the wire harness connector. The sensor resistance should
seat, near the rear edge of the seat cushion frame. be between 1 Kohm and 200 Kohms. If OK, see
For circuit descriptions and diagrams, refer to 8W - Heated Seat Relay in the Diagnosis and Testing sec-
63 - Power Seat With Heated Seats in Group 8W - tion of this group. If not OK, replace the faulty seat
Wiring Diagrams. cushion cover.

SEAT CUSHION HEATED SEAT RELAY

(1) Disconnect and isolate the battery negative For circuit descriptions and diagrams, refer to 8W -
cable. Unplug the 4-way heated seat cushion wire 63 - Power Seat With Heated Seats in Group 8W -
harness connector. Wiring Diagrams.
(2) Check for continuity between the two heated (1) Disconnect and isolate the battery negative
seat element circuit cavities of the seat cushion cover cable. Unplug the 8-way heated seat relay connector.
half of the heated seat cushion wire harness connec- (2) Check for continuity between the ground cir-
tor. There should be continuity. If OK, go to Step 3. If cuit cavity of the 8-way heated seat relay wire har-
not OK, replace the faulty seat cushion cover. ness connector and a good ground. There should be
(3) Check for continuity between one of the heated continuity. If OK, go to Step 3. If not OK, repair the
seat element circuit cavities of the seat cushion cover open circuit as required.
half of the heated seat cushion wire harness connec- (3) Connect the battery negative cable. Check for
tor and the seat cushion frame. There should be no battery voltage at the battery feed circuit cavity (pin
continuity. If OK, see Seat Back in the Diagnosis and 8) of the 8-way heated seat relay wire harness con-
Testing section of this group. If not OK, replace the nector. If OK, go to Step 4. If not OK, repair the open
faulty seat cushion cover. circuit as required.
(4) Turn the ignition switch to the ON position.
SEAT BACK Check for battery voltage at the fused ignition switch
(1) Disconnect and isolate the battery negative output circuit cavity of the 8-way heated seat relay
cable. Unplug the 2-way heated seat back wire har- wire harness connector. If OK, turn the ignition
ness connector. switch to the OFF position, disconnect and isolate
(2) Check for continuity between the heated seat the battery negative cable, and go to Step 5. If not
element circuit cavity and the ground circuit cavity of OK, repair the open circuit as required.
the seat back cover half of the heated seat back wire (5) Unplug the 14-way seat heat interface module
harness connector. There should be continuity. If OK, (SHIM) connector. Check for continuity between the
go to Step 3. If not OK, replace the faulty seat back two switched battery feed cavities of the 14-way
cover. SHIM wire harness connector and the switched bat-
(3) Check for continuity between the heated seat tery feed cavity of the 8-way heated seat relay wire
element circuit cavity of the seat back cover half of harness connector. If OK, reconnect the heated seat
the heated seat back wire harness connector and the relay wire harness connector, and go to Step 6. If not
seat back frame. There should be no continuity. If OK, repair the open circuit as required.
OK, see Heated Seat Sensor in the Diagnosis and (6) Connect the battery negative cable. Turn the
Testing section of this group. If not OK, replace the ignition switch to the ON position. Check for battery
faulty seat back cover. voltage at the switched battery feed cavities of the
14-way SHIM wire harness connector. If OK, turn
HEATED SEAT SENSOR the ignition switch to the OFF position, disconnect
The wire harness connector for the seat cushion and isolate the battery negative cable, and see Seat
heating element and sensor are located under the Heat Interface Module in the diagnosis and testing
seat, near the rear edge of the seat cushion frame. section of this group. If not OK, replace the heated
For circuit descriptions and diagrams, refer to 8W - seat relay.
63 - Power Seat With Heated Seats in Group 8W -
Wiring Diagrams.

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 8N - 12 ELECTRICALLY HEATED SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)

SEAT HEAT INTERFACE MODULE (4) Pull back the seat cushion to allow access to
Before testing the seat heat interface module, test the Seat Heat Interface Module (SHIM).
the heated seat switch, the heated seat elements, and (5) Pull the SHIM upward to release the two
the heated seat sensor as described in the Diagnosis mounting fasteners from either the module or the
and Testing section of this group. If testing of the mounting bracket. Unplug the wire harness connec-
heated seat switch, elements, and sensor reveals no tor from the module (Fig. 2).
problems, proceed as follows. For circuit descriptions
WARNING: THERE ARE MANY SHARP METAL
and diagrams, refer to 8W - 63 - Power Seat With
EDGES ON THE SEAT CUSHION FRAME AND SEAT
Heated Seats in Group 8W - Wiring Diagrams.
ADJUSTER RAILS UNDER THE SEAT. WHEN PER-
(1) Replace the seat heat interface module with a
FORMING THIS SERVICE, A LONG-SLEEVED SHIRT
known good unit and test the operation of the heated
AND GLOVES SHOULD BE WORN IN ORDER TO
seats. If OK, discard the faulty seat heat interface
AVOID UNNECESSARY CUTS AND ABRASIONS TO
module. If not OK, go to Step 2.
EXPOSED SKIN.
(2) Test each of the circuits from the heated seat
switch, heated seat relay, heated seat elements, and
heated seat sensor to the seat heat interface module.
Repair any short or open circuits as required.

REMOVAL AND INSTALLATION

HEATED SEAT SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Disconnect and isolate the battery negative

cable.
(2) Using a trim stick or another suitable wide Fig. 2 Seat Heat Interface Module Remove/Install
flat-bladed tool, gently pry around the perimeter 1 – SEAT CUSHION FRAME
edges of the heated switch assembly bezel to release 2 – SEAT HEAT INTERFACE MODULE
3 – WIRE HARNESS CONNECTOR
the assembly from the console. Remove the assembly
4 – POWER SEAT TRACK FRONT BRACKET
from the console.
(3) Pull the switch assembly out from the console
far enough to access and unplug the wire harness (6) Reverse the removal procedures to install. Be
connectors. certain that the SHIM terminals are aligned with the
(4) Remove the heated seat switch assembly from cavities in the wire harness connector before pushing
the console. the module firmly into place.
(5) Remove the heated seat switch(es) from the
heated seat switch assembly. HEATED SEAT RELAY
(6) Reverse the removal procedures to install. (1) Move the right power seat adjuster to its full
up and full rear stop positions.
SEAT HEAT INTERFACE MODULE (2) Disconnect and isolate the battery negative
(1) Move the right power seat adjuster to its full cable.
up and full rear stop positions. (3) Unhook the seat cushion cover retainer from
(2) Disconnect and isolate the battery negative the seat cushion frame and pull back the seat cush-
cable. ion cover.
(3) Unhook the seat cushion cover retainer from (4) Pull back the seat cushion to allow access to
the seat cushion frame and pull back the seat cush- the Heated Seat Relay.
ion cover.

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 XJ ELECTRICALLY HEATED SYSTEMS 8N - 13
REMOVAL AND INSTALLATION (Continued)
(5) Cut the Christmas tree fastener to remove the
Heated Seat Relay fastener from the mounting
bracket. Unplug the wire harness connector from the
relay (Fig. 3).
(6) Reverse the removal procedures to install. A
new Christmas tree fastener must be used to mount
the relay. Be certain that the relay terminals are
aligned with the cavities in the wire harness connec-
tor before pushing the relay firmly into place.

Fig. 3 Heated Seat Relay Remove/Install

1 – HEATED SEAT RELAY
2 – SEAT CUSHION FRAME
3 – WIRE HARNESS CONNECTOR
4 – POWER SEAT TRACK FRONT BRACKET

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 XJ POWER DISTRIBUTION SYSTEMS 8O - 1

POWER DISTRIBUTION SYSTEMS

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . . . . 5

POWER DISTRIBUTION SYSTEM. . . . . . . . . . . . . 1 JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER DISTRIBUTION CENTER . . . . . . . . . . . . . 2 DISASSEMBLY AND ASSEMBLY
IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . . . . 2 POWER DISTRIBUTION CENTER . . . . . . . . . . . . . 7
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS
REMOVAL AND INSTALLATION POWER DISTRIBUTION SYSTEMS . . . . . . . . . . 10
POWER DISTRIBUTION CENTER . . . . . . . . . . . . . 4

DESCRIPTION AND OPERATION NOTE: This group covers both Left-Hand Drive
(LHD) and Right-Hand Drive (RHD) versions of this
POWER DISTRIBUTION SYSTEM model. Whenever required and feasible, the RHD
versions of affected vehicle components have been
DESCRIPTION constructed as mirror-image of the LHD versions.
This group covers the various standard and While most of the illustrations used in this group
optional power distribution components used on this represent only the LHD version, the diagnostic and
model. The power distribution system for this vehicle service procedures outlined can generally be
consists of the following components: applied to either version. Exceptions to this rule
• Power Distribution Center (PDC) have been clearly identified as LHD or RHD, if a
• Junction Block (JB). special illustration or procedure is required.
The power distribution system also incorporates
various types of circuit control and protection fea-
OPERATION
tures, including:
The power distribution system for this vehicle is
• Automatic resetting circuit breakers
designed to provide safe, reliable, and centralized dis-
• Blade-type fuses
tribution points for the electrical current required to
• Maxi fuse-type fusible links
operate all of the many standard and optional facto-
• Relays.
ry-installed electrical and electronic powertrain,
Following are general descriptions of the major
chassis, safety, security, comfort and convenience sys-
components in the power distribution system. See the
tems. At the same time, the power distribution sys-
owner’s manual in the vehicle glove box for more
tem was designed to provide ready access to these
information on the features and use of all of the
electrical distribution points for the vehicle techni-
power distribution system components. Refer to the
cian to use when conducting diagnosis and repair of
index in this service manual for the location of com-
faulty circuits. The power distribution system can
plete circuit diagrams for the various power distribu-
also prove useful for the sourcing of additional elec-
tion system components.
trical circuits that may be required to provide the
electrical current needed to operate many accessories
that the vehicle owner may choose to have installed
in the aftermarket.

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 8O - 2 POWER DISTRIBUTION SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)

POWER DISTRIBUTION CENTER replacement. The PDC main housing unit, the fuse
wedges, the fuse cassette and the bus bars cannot be
DESCRIPTION repaired and are only serviced as a unit with the
headlamp and dash wire harness. If the PDC main
housing unit, fuse wedges, fuse cassette or the bus
bars are faulty or damaged, the headlamp and dash
wire harness unit must be replaced.

OPERATION
All of the current from the battery and the gener-
ator output enters the PDC through two cables and
eyelets that are secured with a nut to the PDC B(+)
terminal stud located on one end of the PDC housing.
The PDC B(+) terminal stud cover is unlatched and
removed to access the battery and generator output
connection B(+) terminal stud. The PDC cover is
unlatched and opened or removed to access the fuses
or relays. Internal connection of all of the PDC cir-
cuits is accomplished by an intricate combination of
hard wiring and bus bars. Refer to Power Distribu-
tion in the index of this service manual for the loca-
tion of complete PDC circuit diagrams.

Fig. 1 Power Distribution Center Location IGNITION-OFF DRAW FUSE

1 – LEFT FENDER
2 – BATTERY DESCRIPTION
3 – POWER DISTRIBUTION CENTER

All of the electrical current distributed throughout

this vehicle is directed through the standard equip-
ment Power Distribution Center (PDC) (Fig. 1). The
molded plastic PDC housing is located on the right
side of the engine compartment, just behind the bat-
tery. The PDC houses up to fourteen blade-type maxi
fuses, which replace all in-line fusible links. The PDC
also houses up to twelve blade-type mini fuses, and
up to eight International Standards Organization
(ISO) relays (four standard-type and four micro-type).
The PDC housing is secured to a stamped sheet
metal bracket in the engine compartment by mount-
ing slots and tabs that are integral to the PDC hous-
ing. The PDC mounting bracket is secured with two
screws to the right front inner fender shield above
the right front wheel house. The PDC housing has a
molded plastic cover that includes two integral hinge
tabs on the inboard side, and an integral latch on the
outboard side. The PDC cover is easily opened or
removed for service access and has a convenient fuse
and relay layout map integral to the inside surface of Fig. 2 Ignition-Off Draw Fuse
the cover to ensure proper component identification. 1 – POWER DISTRIBUTION CENTER
A separate molded plastic B(+) terminal stud cover is 2 – IGNITION-OFF DRAW FUSE
secured by two integral tabs and a latch to one end
of the PDC housing. All vehicles are equipped with an Ignition-Off
The PDC cover, the PDC housing lower cover, the Draw (IOD) fuse (Fig. 2) that is removed from its
PDC B(+) terminal stud cover, the PDC relay wedges cavity in the Power Distribution Center (PDC) when
and the PDC relay cassettes are available for service the vehicle is shipped from the factory. Dealer per-

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 XJ POWER DISTRIBUTION SYSTEMS 8O - 3
DESCRIPTION AND OPERATION (Continued)
sonnel are to remove the IOD fuse from the storage Battery in the index of this service manual for the
location and install it into PDC fuse cavity 16 as part location of additional service information covering
of the preparation procedures performed just prior to the battery.
new vehicle delivery.
The PDC has a molded plastic cover that can be JUNCTION BLOCK
removed to provide service access to all of the fuses
and relays in the PDC. An integral latch and hinge DESCRIPTION
tabs are molded into the PDC cover for easy removal.
A fuse layout map is integral to the underside of the
PDC cover to ensure proper fuse and relay identifica-
tion. The IOD fuse is a 15 ampere mini blade-type
fuse and, when removed, it is stored in a plastic fuse
holder formation that is molded into the underside of
the PDC cover.

OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
many of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion, Fig. 3 Junction Block Location
while still allowing vehicle operation so that the 1 – JUNCTION BLOCK
vehicle can be loaded, unloaded and moved as needed 2 – FUSE ACCESS PANEL
by both vehicle transportation company and dealer 3 – RIGHT COWL SIDE INNER TRIM PANEL
personnel.
The IOD fuse is removed from PDC fuse cavity 16 An electrical Junction Block (JB) is concealed
when the vehicle is shipped from the assembly plant. behind the right cowl side inner trim panel in the
Dealer personnel must install the IOD fuse when the passenger compartment of the vehicle (Fig. 3). The
vehicle is being prepared for delivery in order to JB combines the functions previously provided by a
restore full electrical system operation. Once the separate fuseblock module and relay center. The JB
vehicle is prepared for delivery, the IOD function of serves to simplify and centralize numerous electrical
this fuse becomes transparent and the fuse that has components, as well as to distribute electrical current
been assigned the IOD designation becomes only to many of the accessory systems in the vehicle. It
another Fused B(+) circuit fuse. The IOD fuse serves also eliminates the need for numerous splice connec-
no useful purpose to the dealer technician in the ser- tions and serves in place of a bulkhead connector
vice or diagnosis of any vehicle system or condition, between many of the engine compartment, instru-
other than the same purpose as that of any other ment panel, and body wire harnesses. The JB houses
standard circuit protection device. up to twenty-seven blade-type fuses (three standard-
The IOD fuse can be used by the vehicle owner as type and twenty-four mini-type), up to three blade-
a convenient means of reducing battery depletion type automatic resetting circuit breakers, and four
when a vehicle is to be stored for periods not to International Standards Organization (ISO) relays
exceed about thirty days. However, it must be (three standard-type and one micro-type).
remembered that removing the IOD fuse will not The molded plastic JB housing has integral mount-
eliminate IOD, but only reduce this normal condition. ing brackets that are secured with three nuts to
If a vehicle will be stored for more than about thirty studs on the right cowl side inner panel below the
days, the battery negative cable should be discon- instrument panel. The right cowl side inner trim
nected to eliminate normal IOD; and, the battery panel is secured to a stud on the JB with a push nut.
should be tested and recharged at regular intervals A snap-fit fuse access panel can be removed for ser-
during the vehicle storage period to prevent the bat- vice of the JB fuses and also conceals the push nut. A
tery from becoming discharged or damaged. Refer to finger recess is molded into the front of the fuse

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 8O - 4 POWER DISTRIBUTION SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
access panel for easy removal, and a fuse puller and
spare fuse holders are located on the back of the fuse
access panel.
The JB unit cannot be repaired and is only ser-
viced as an assembly. If any internal circuit or the JB
housing is faulty or damaged, the entire JB unit
must be replaced.

OPERATION
All of the circuits entering and leaving the JB do
so through up to ten wire harness connectors, which
are connected to the JB through integral connector
receptacles molded into the JB housing. Internal con-
nection of all of the JB circuits is accomplished by an
intricate combination of hard wiring and bus bars.
Refer to Junction Block in the index of this service
manual for the location of complete JB circuit dia-
grams.

Fig. 4 Power Distribution Center Connections

REMOVAL AND INSTALLATION 1 – COVER
2 – NUT
POWER DISTRIBUTION CENTER 3 – POWER DISTRIBUTION CENTER
The Power Distribution Center (PDC) main hous- 4 – BATTERY
ing unit, the PDC fuse wedges, the PDC fuse cassette 5 – BATTERY WIRE HARNESS PDC TAKE-OUTS
and the PDC bus bars cannot be repaired and are
only serviced as a unit with the headlamp and dash
(7) Remove the battery wire harness PDC take out
wire harness. If the PDC main housing unit, the fuse
eyelets from the B(+) terminal stud.
wedge, the fuse cassette or the bus bars are faulty or
(8) Disengage the latches on the PDC mounting
damaged, the entire PDC and headlamp and dash
bracket from the tabs on the PDC housing, and pull
wire harness unit must be replaced.
the PDC housing upward to disengage the mounting
slots from the stanchions of the mounting bracket
REMOVAL
(Fig. 5).
(1) Disconnect and isolate the battery negative
(9) Remove the PDC and the headlamp and dash
cable.
wire harness from the engine compartment as a unit.
(2) Disconnect each of the headlamp and dash wire
(10) Remove the two screws that secure the PDC
harness connectors. Refer to Connector Locations
mounting bracket to the right front inner fender (Fig.
in the index of this service manual for the location of
6).
more information on the headlamp and dash wire
(11) Remove the PDC mounting bracket from the
harness connector locations.
right front inner fender.
(3) Remove all of the fasteners that secure each of
the headlamp and dash wire harness ground eyelets INSTALLATION
to the vehicle body and chassis components. Refer to
Connector Locations in the index of this service NOTE: If the PDC is being replaced with a new unit,
manual for the location of more information on the be certain to transfer each of the fuses and relays
ground eyelet locations. from the faulty PDC to the proper cavities of the
(4) Disengage each of the retainers that secure the replacement PDC. Refer to Power Distribution in the
headlamp and dash wire harness to the vehicle body index of this service manual for the location of
and chassis components. Refer to Connector Loca- complete PDC circuit diagrams and cavity assign-
tions in the index of this service manual for the loca- ments.
tion of more information on the headlamp and dash
wire harness retainer locations. (1) Position the PDC mounting bracket onto the
(5) Unlatch and remove the B(+) terminal stud right front inner fender.
cover from the end of the PDC (Fig. 4). (2) Install and tighten the two screws that secure
(6) Remove the nut that secures the eyelets of the the PDC mounting bracket to the right front inner
battery wire harness PDC take outs to the PDC B(+) fender. Tighten the screws to 8.1 N·m (72 in. lbs.).
terminal stud.

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 XJ POWER DISTRIBUTION SYSTEMS 8O - 5
REMOVAL AND INSTALLATION (Continued)
(5) Install the eyelets of the battery wire harness
PDC take outs onto the PDC B(+) terminal stud.
(6) Install and tighten the nut that secures the
eyelet of the battery wire harness PDC take outs to
the B(+) terminal stud. Tighten the nut to 10.8 N·m
(95 in. lbs.).
(7) Engage the tabs on the lower edge of the B(+)
terminal stud cover in the slots on the PDC housing,
then engage the latch on the top of the cover with
the latch receptacle on the PDC housing.
(8) Engage each of the retainers that secure the
headlamp and dash wire harness to the vehicle body
and chassis components. Refer to Connector Loca-
tions in the index of this service manual for the loca-
tion of more information on the headlamp and dash
wire harness retainer locations.
(9) Install all of the fasteners that secure each of
the headlamp and dash wire harness ground eyelets
to the vehicle body and chassis components. Refer to
Fig. 5 Power Distribution Center Remove/Install Connector Locations in the index of this service
1 – RIGHT FENDER manual for the location of more information on the
2 – POWER DISTRIBUTION CENTER ground eyelet locations.
3 – BRACKET
(10) Reconnect each of the headlamp and dash
wire harness connectors. Refer to Connector Loca-
tions in the index of this service manual for the loca-
tion of more information on the headlamp and dash
wire harness connector locations.
(11) Reconnect the battery negative cable.

IGNITION-OFF DRAW FUSE

The Ignition-Off Draw (IOD) fuse is removed from
Power Distribution Center (PDC) fuse cavity 16 (Fig.
7) when the vehicle is shipped from the assembly
plant. Dealer personnel must install the IOD fuse
when the vehicle is being prepared for delivery in
order to restore full electrical system operation.

NOTE: When removing or installing the IOD fuse, it

is important that the ignition switch be in the Off
position. Failure to place the ignition switch in the
Off position can cause the radio display to become
scrambled when the IOD fuse is installed. Remov-
ing and installing the IOD fuse again with the igni-
Fig. 6 PDC Mounting Bracket Remove/Install tion switch in the Off position will usually correct
1 – RIGHT FRONT INNER FENDER the scrambled radio display condition.
2 – PDC MOUNTING BRACKET
3 – SCREW
REMOVAL
(3) Position the PDC and the headlamp and dash (1) Turn the ignition switch to the Off position.
wire harness unit in the engine compartment. (2) Unlatch and remove the cover from the PDC.
(4) Engage the mounting slots on the PDC housing (3) Remove the IOD fuse from fuse cavity 16 of the
with the stanchions of the PDC mounting bracket PDC.
and push the unit downward until the mounting (4) Store the removed IOD fuse by inserting the
bracket latches engage the mounting tabs on the terminal blades of the fuse into the plastic fuse
PDC housing. holder formation that is molded into the underside of
the PDC cover.
(5) Install and latch the cover onto the PDC.

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 8O - 6 POWER DISTRIBUTION SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the fuse access panel by unsnapping it
from the right cowl side inner trim panel (Fig. 8).

Fig. 7 Ignition-Off Draw Fuse

1 – POWER DISTRIBUTION CENTER
2 – IGNITION-OFF DRAW FUSE

INSTALLATION
(1) Turn the ignition switch to the Off position.
(2) Unlatch and remove the cover from the PDC.
(3) Remove the stored IOD fuse from the plastic
fuse holder formation that is molded into the under-
side of the PDC cover.
(4) Align the terminal blades of the IOD fuse with
the terminal receptacles in fuse cavity 16 of the PDC.
(5) Use a thumb to press the IOD fuse firmly down Fig. 8 Right Cowl Side Inner Trim Remove/Install
1 – RIGHT FRONT DOOR SILL
into PDC fuse cavity 16.
2 – COWL SIDE TRIM PANEL
(6) Install and latch the cover onto the PDC.
3 – SCREW
4 – SILL TRIM
JUNCTION BLOCK 5 – FUSE ACCESS PANEL
6 – PUSH-NUT
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING (3) Remove the push nut that secures the right
COLUMN, OR INSTRUMENT PANEL COMPONENT cowl side inner trim panel to the mounting stud on
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- the Junction Block (JB).
LATE THE BATTERY NEGATIVE (GROUND) CABLE, (4) Remove the screw located above the fuse access
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- opening that secures the trim panel to the right cowl
TEM CAPACITOR TO DISCHARGE BEFORE PER- side inner panel.
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS (5) Remove the screw that secures the right cowl
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG side inner trim panel and right front door sill trim to
SYSTEM. FAILURE TO TAKE THE PROPER PRE- the door opening sill.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (6) Remove the trim from the right cowl side inner
BAG DEPLOYMENT AND POSSIBLE PERSONAL panel.
INJURY. (7) Remove the screw that secures the lower
instrument panel wire harness connector to the JB.
(8) Disconnect all of the wire harness connectors
from the connector receptacles on the JB.

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 XJ POWER DISTRIBUTION SYSTEMS 8O - 7
REMOVAL AND INSTALLATION (Continued)
(9) Remove the three nuts that secure the JB to sill trim to the door opening sill. Tighten the screw to
the mounting studs on the right cowl side inner 2.2 N·m (20 in. lbs.).
panel (Fig. 9). (7) Install and tighten the screw located above the
fuse access opening that secures the trim panel to
the right cowl side inner panel. Tighten the screw to
2.2 N·m (20 in. lbs.).
(8) Install the push nut that secures the right cowl
side inner trim panel to the mounting stud on the
JB.
(9) Install the fuse access panel by snapping it
onto the right cowl side inner trim panel.
(10) Reconnect the battery negative cable.

DISASSEMBLY AND ASSEMBLY

POWER DISTRIBUTION CENTER
The Power Distribution Center (PDC) cover, the
PDC housing lower cover, the PDC relay wedges, the
PDC relay cassettes and the PDC B(+) terminal stud
cover are available for service replacement (Fig. 10).
The PDC cover and B(+) terminal stud cover can be
Fig. 9 Junction Block Remove/Install simply unlatched and removed from the PDC housing
1 – JUNCTION BLOCK
without the PDC being removed or disassembled.
2 – STUD Service of the remaining PDC components requires
3 – RIGHT COWL SIDE INNER PANEL that the PDC be removed from its mounting and dis-
4 – NUT assembled. Refer to Wiring Repair in the index of
this service manual for the location of the wiring
repair procedures.
(10) Remove the JB from the mounting studs on
the right cowl side inner panel.
DISASSEMBLY
INSTALLATION PDC HOUSING LOWER COVER
NOTE: If the Junction Block (JB) is being replaced (1) Disconnect and isolate the battery negative
with a new unit, be certain to transfer each of the cable.
fuses, circuit breakers and relays from the faulty JB (2) Unlatch and remove the cover from the PDC.
to the proper cavities of the replacement JB. Refer (3) Unlatch and remove the B(+) terminal stud
to Junction Block in the index of this service man- cover from the PDC.
ual for the location of complete circuit diagrams (4) Remove the nut that secures the two battery
and cavity assignments for the JB. wire harness PDC take out eyelets to the B(+) termi-
nal stud of the PDC.
(1) Position the JB onto the mounting studs (5) Remove the battery wire harness PDC take out
located on the right cowl side inner panel. eyelets from the PDC B(+) terminal stud.
(2) Install and tighten the three nuts that secure (6) Disengage the latches on the PDC mounting
the JB to the mounting studs on the right cowl side bracket from the tabs on the PDC housing, and pull
inner panel. Tighten the nuts to 2.7 N·m (24 in. lbs.). the PDC housing upward to disengage the mounting
(3) Reconnect all of the wire harness connectors to slots from the stanchions of the mounting bracket.
the proper connector receptacles on the JB. (7) Using a trim stick or another suitable wide
(4) Install and tighten the screw that secures the flat-bladed tool, gently pry the latches on each side
lower instrument panel wire harness connector to the and one end of the PDC housing that secure the
JB connector receptacle. Tighten the screw to 3.5 housing lower cover to the PDC and remove the
N·m (31 in. lbs.). housing lower cover (Fig. 11).
(5) Position the trim onto the right cowl side inner
panel. PDC RELAY WEDGE
(6) Install and tighten the screw that secures the (1) Remove the PDC housing lower cover.
right cowl side inner trim panel and right front door (2) Remove each of the relays from the PDC relay
wedge to be removed.

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 8O - 8 POWER DISTRIBUTION SYSTEMS XJ
DISASSEMBLY AND ASSEMBLY (Continued)

Fig. 11 PDC Housing Lower Cover Remove/Install

Fig. 10 Power Distribution Center Components
1 – PDC HOUSING
1 – LATCH
2 – TAB
2 – COVER
3 – PDC HOUSING LOWER COVER
3 – LATCH
4 – LATCH
4 – B(+) TERMINAL STUD COVER
5 – PDC HOUSING
6 – HOUSING LOWER COVER (TYPICAL)
7 – WIRE HARNESS
8 – RELAY CASSETTE (TYPICAL)
9 – RELAY WEDGE (TYPICAL)
10 – HINGE TABS

(3) From the bottom of the PDC housing, use a

small screwdriver or a terminal pick tool (Special
Tool Kit 6680) to release the two latches (yellow) that
secure the relay wedge to the PDC relay cassette.
(4) From the top of the PDC housing, remove the
relay wedge from the PDC relay cassette (Fig. 12).

PDC RELAY CASSETTE

(1) Remove the relay wedge from the PDC relay
cassette to be removed.

NOTE: It may be necessary to remove relay cas-

settes that are not being serviced from the PDC
housing in order to obtain sufficient clearance to
service the faulty relay cassette. The same service
procedure is repeated as necessary to remove each
of the interfering relay wedges and relay cassettes
from the PDC housing. Fig. 12 PDC Relay Wedge Remove/Install
1 – RELAY WEDGE (TYPICAL)
(2) From the top of the PDC housing, use a small 2 – PDC HOUSING
screwdriver or a terminal pick tool (Special Tool Kit
6680) to release the two latches that secure the relay (3) Gently and evenly press the relay cassette
cassette in the PDC (Fig. 13). down through the PDC housing.

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 XJ POWER DISTRIBUTION SYSTEMS 8O - 9
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
PDC RELAY CASSETTE
(1) Move the faulty PDC relay cassette with its
wiring away from the bottom of the PDC housing far
enough to allow the replacement relay cassette to be
installed into the PDC.
(2) Using the faulty relay cassette as a guide, be
certain that the replacement relay cassette is cor-
rectly oriented before installing it into the PDC hous-
ing.
(3) From the bottom of the PDC housing, align and
insert the replacement relay cassette into the PDC.
Press the relay cassette up into the PDC until both
of the latches are fully engaged.

CAUTION: Proper care must be taken to be certain

that the wiring and terminals from the faulty PDC
relay cassette are installed in the correct terminal
Fig. 13 PDC Relay Cassette Latches cavities of the replacement relay cassette. To pre-
1 – LATCHES vent mistakes it is recommended that the wiring
2 – FROM SPECIAL TOOL KIT 6680 and terminals be removed from the faulty relay cas-
3 – PDC RELAY CASSETTES (TYPICAL)
sette one cavity at a time, repaired or spliced as
necessary, then installed securely into the correct
(4) From the bottom of the PDC housing, remove cavity of the replacement relay cassette. If you are
the relay cassette from the PDC (Fig. 14). not absolutely certain into which cavity a terminal
should be installed, refer to Power Distribution in
the index of this service manual for the location of
complete circuit diagrams covering the PDC.

(4) While pulling gently on the wire from the bot-

tom of the faulty PDC relay cassette, use a terminal
pick tool (Special Tool Kit 6680) from the top of the
relay cassette to release the latch that secures the
terminal in the relay cassette terminal cavity (Fig.
15).
(5) From the bottom of the faulty PDC relay cas-
sette, remove the wire and terminal from the relay
cassette terminal cavity.
(6) Make all necessary repairs and splices to the
wire for the removed terminal. Refer to Wiring
Repair in the index of this service manual for the
location of the wiring repair procedures.
(7) From the bottom of the PDC housing, align and
insert the removed wire and terminal into the correct
terminal cavity of the replacement relay cassette.
Fig. 14 PDC Relay Cassette Remove/Install Push the wire and terminal up into the relay cassette
1 – PDC HOUSING terminal cavity until it is fully engaged by the latch.
2 – PDC RELAY CASSETTE (TYPICAL)
(8) Repeat Step 4, Step 5, Step 6 and Step 7 one
3 – LATCHES
wire and terminal at a time until each of the wires
and terminals have been transferred from the faulty
CAUTION: Do not remove the wiring and terminals PDC relay cassette into the replacement relay cas-
from the terminal cavities of the faulty PDC relay sette.
cassette at this time. Refer to the Assembly proce- (9) Install the PDC relay wedge into the replace-
dure that follows for the proper procedures for ment PDC relay cassette.
transferring the wiring and terminals to the replace-
ment PDC relay cassette.

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 8O - 10 POWER DISTRIBUTION SYSTEMS XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(2) Press the PDC housing lower cover gently and
evenly onto the PDC until each of the latches that
secure the cover to the PDC is fully engaged.
(3) Engage the mounting slots on the PDC housing
with the stanchions of the PDC mounting bracket
and push the unit downward until the mounting
bracket latches fully engage the mounting tabs on
the PDC housing.
(4) Install the battery wire harness PDC take out
eyelets over the PDC B(+) terminal stud.
(5) Install and tighten the nut that secures the
eyelets of the battery wire harness PDC take outs to
the B(+) terminal stud. Tighten the nut to 10.8 N·m
(95 in. lbs.).
(6) Install the B(+) terminal stud cover onto the
PDC.
(7) Install the cover onto the PDC.
(8) Reconnect the battery negative cable.

Fig. 15 PDC Relay Cassette Terminal Remove/Install

1 – TERMINAL CAVITIES (TYPICAL) SPECIAL TOOLS
2 – PDC RELAY CASSETTE (TYPICAL)
3 – TERMINAL LATCHES (TYPICAL) POWER DISTRIBUTION SYSTEMS
4 – FROM SPECIAL TOOL KIT 6680

PDC RELAY WEDGE

(1) From the top of the PDC housing, align and
insert the PDC relay wedge latch arms into the cor-
rect cavities in the relay cassette.
(2) Gently and evenly press the PDC relay wedge
down into the relay cassette until both of the latches
are fully engaged.
(3) Install each of the removed relays into the
proper cavities of the PDC relay wedge.
(4) Install the PDC housing lower cover.

PDC HOUSING LOWER COVER

(1) Align the PDC housing lower cover to the bot-
tom of the PDC. Terminal Pick Kit 6680

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 XJ POWER LOCK SYSTEMS 8P - 1

POWER LOCK SYSTEMS

TABLE OF CONTENTS

page page

GENERAL INFORMATION POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . . . 4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOTE KEYLESS ENTRY TRANSMITTER . . . . . 5
POWER LOCK SYSTEM . . . . . . . . . . . . . . . . . . . . 1 REMOTE KEYLESS ENTRY RECEIVER . . . . . . . . . 5
REMOTE KEYLESS ENTRY SYSTEM . . . . . . . . . . 1 SERVICE PROCEDURES
DESCRIPTION AND OPERATION REMOTE KEYLESS ENTRY TRANSMITTER
POWER LOCK SWITCH . . . . . . . . . . . . . . . . . . . . 2 BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . 6
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOTE KEYLESS ENTRY TRANSMITTER
POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . . . 2 PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE KEYLESS ENTRY TRANSMITTER . . . . . 2 REMOTE KEYLESS ENTRY RECEIVER
REMOTE KEYLESS ENTRY RECEIVER . . . . . . . . . 2 PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING REMOVAL AND INSTALLATION
POWER LOCK SYSTEM AND REMOTE DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 7
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . . . . . 3 POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . . . 7
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REMOTE KEYLESS ENTRY RECEIVER . . . . . . . . . 8

GENERAL INFORMATION through a fuse in the junction block, independent of

the ignition switch.
INTRODUCTION The power lock system includes a lock inhibit fea-
Power locks are optional factory-installed equip- ture, which prevents the doors from being locked by
ment on this model. The power window system and the power lock system if the driver door is open with
the power mirror system are included on vehicles the key in the ignition switch or with the headlamp
equipped with the power lock option. The Remote switch in the On position. However, the lock inhibit
Keyless Entry (RKE) system is an additional option feature will not prevent manual locking of the vehicle
available on vehicles equipped with the power lock using the manual lock buttons or the key cylinders.
option. Refer to 8W-61 - Power Door Locks in Group The power lock system includes the front door
8W - Wiring Diagrams for complete circuit descrip- power lock switches integral to the driver and pas-
tions and diagrams. senger door modules, and the power lock motors
mounted in each door and the liftgate. The power
NOTE: This group covers both Left-Hand Drive lock control circuitry and the power lock and unlock
(LHD) and Right-Hand Drive (RHD) versions of this relays are integral to the Passenger Door Module
model. Whenever required and feasible, the RHD (PDM).
versions of affected vehicle components have been Following are general descriptions of the major
constructed as mirror-image of the LHD versions. components in the power lock system. Refer to the
While most of the illustrations used in this group owner’s manual in the vehicle glove box for more
represent only the LHD version, the diagnostic and information on the features, use and operation of the
service procedures outlined can generally be power lock system.
applied to either version. Exceptions to this rule
have been clearly identified as LHD or RHD, if a REMOTE KEYLESS ENTRY SYSTEM
special illustration or procedure is required. The Remote Keyless Entry (RKE) system is a radio
frequency system that allows the use of a remote bat-
tery-powered radio transmitter to control the power
POWER LOCK SYSTEM lock system. On vehicles with the RKE option, the
The power lock system allows all of the doors and power locks can be operated by depressing the Lock
the liftgate to be locked or unlocked electrically by or Unlock buttons of the RKE transmitter. The RKE
operating the switch on either front door trim panel. system includes an illuminated entry feature, which
This system operates with battery power supplied turns on the courtesy lamps for a timed interval

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 8P - 2 POWER LOCK SYSTEMS XJ
GENERAL INFORMATION (Continued)
(about thirty seconds), when the power locks are PDM contains the control circuitry and the power
unlocked using the RKE transmitter. lock and unlock relays for the entire power lock sys-
The RKE system for this vehicle also features a tem.
customer programmable horn chirp feature. This fea- In its role as the power lock control module, the
ture allows the customer the option of enabling or PDM receives inputs from the battery, the ignition
disabling the horn chirp request that the RKE switch, the DDM, the driver door ajar switch, the
receiver issues as an audible indication that a valid key-in ignition switch, and the headlamp switch. It
Lock signal has been received from the RKE trans- also receives a hard-wired input from the remote
mitter. See Remote Keyless Entry Receiver Program- Keyless Entry (RKE) receiver, if the vehicle is so
ming in this group for more information on this equipped. In response to these inputs, the PDM
feature. sends the proper outputs to control the power lock
The RKE system can retain the vehicle access motors through its integral power lock and unlock
codes of up to four transmitters. The transmitter relays.
codes are retained in memory, even if the battery is The DDM and the PDM are mounted to their
disconnected. If a transmitter is faulty or lost, new respective front door trim panels. The DDM and
transmitter vehicle access codes can be programmed PDM are serviced individually and cannot be
into the system using a DRB scan tool and the repaired. If the DDM or PDM, or any of the switches
proper Diagnostic Procedures manual. and circuitry that they contain are faulty or dam-
The RKE system consists of the remote key fob aged, the complete DDM or PDM unit must be
transmitter and a radio receiver with program logic. replaced.
The RKE receiver is installed in an RKE housing on
the headliner of the vehicle, or in the housing of the POWER LOCK MOTOR
optional overhead console, depending upon how the In the power lock and Remote Keyless Entry
vehicle is equipped. (RKE) systems, the locks are actuated by a reversible
Following are general descriptions of the major electric motor mounted within each door and the lift-
components in the RKE system. Refer to the owner’s gate. The power lock motor direction is controlled by
manual in the vehicle glove box for more information the battery and ground feeds from the power lock
on the features, use and operation of the RKE sys- and unlock relays integral to the Passenger Door
tem. Module (PDM).
The power lock motors cannot be repaired and, if
faulty or damaged, the entire motor must be
DESCRIPTION AND OPERATION replaced.

POWER LOCK SWITCH REMOTE KEYLESS ENTRY TRANSMITTER

The power locks are controlled by a two-way switch The Remote Keyless Entry (RKE) system transmit-
that is integral to the Driver Door Module (DDM) ter is equipped with two buttons, labeled Lock and
and the Passenger Door Module (PDM) mounted in Unlock. It is also equipped with a key ring and is
the trim panel of its respective front door. Each designed to serve as a key fob. The operating range
switch is illuminated by a light-emitting diode when of the transmitter radio signal is up to 7 meters (23
the ignition switch is turned to the On position. The feet) from the RKE receiver.
power lock switches provide a hard-wired lock or Each transmitter has a different vehicle access
unlock signal to the power lock system control cir- code, which must be programmed into the memory of
cuitry, which is located in the PDM. the RKE receiver in the vehicle in order to operate
The power lock switches and their lamps cannot be the RKE system. See Remote Keyless Entry Trans-
repaired. If the switches are damaged or faulty, the mitter Programming in this group for more informa-
entire PDM or DDM unit must be replaced. tion.
The transmitter operates on two Panasonic
DOOR MODULE CR2016 (or equivalent) batteries. Typical battery life
A Driver Door Module (DDM) and a Passenger is from one to two years. The transmitter cannot be
Door Module (PDM) are used on all models equipped repaired and, if faulty or damaged, it must be
with power locks and power windows. Each door replaced.
module houses both the front door power lock and
power window switches. In addition to the switches REMOTE KEYLESS ENTRY RECEIVER
for its own door, the DDM houses individual switches On models with the Remote Keyless Entry (RKE)
for each passenger door power window, a power win- option, an RKE receiver is mounted in an RKE hous-
dow lockout switch and the power mirror switch. The ing, or in the overhead console housing on the vehicle

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 XJ POWER LOCK SYSTEMS 8P - 3
DESCRIPTION AND OPERATION (Continued)
headliner. The RKE receiver is a radio frequency unit transmitter, see the Power Lock Motor diagnosis in
that also contains the RKE system program logic. this group.
The RKE receiver also performs as a smart relay for • If the RKE and power lock systems are function-
the illuminated entry feature. ing, but the illuminated entry system fails to operate,
The RKE receiver has a memory function to retain see the Remote Keyless Entry Receiver diagnosis in
the vehicle access codes of at least one, but no more this group.
than four RKE transmitters. The receiver is designed
to retain the transmitter codes in memory, even if DOOR MODULE
the battery is disconnected. If the power lock system is inoperative with either
The RKE receiver receives inputs from the battery, front door power lock switch, test the Passenger Door
the driver door ajar switch, and the Chrysler Colli- Module (PDM). If the power lock system is inopera-
sion Detection (CCD) data bus. It also receives the tive with only the driver side front door power lock
radio signal input from the RKE transmitter. In switch, test the Driver Door Module (DDM). For cir-
response to those inputs, it is programmed to control cuit descriptions and diagrams, refer to 8W-61 -
outputs to the power lock motors, the courtesy lamp Power Door Locks in Group 8W - Wiring Diagrams.
circuits, and the vehicle horn.
The RKE system for this vehicle also features a DRIVER DOOR MODULE
customer programmable horn chirp feature. This fea- The only function of the Driver Door Module
ture allows the customer the option of enabling or (DDM) in the power lock system is to provide a Lock
disabling the horn chirp request that the RKE or Unlock signal to the power lock system control cir-
receiver issues as an audible indication that a valid cuitry contained within the Passenger Door Module
Lock signal has been received from the RKE trans- (PDM). The DDM signals the PDM by providing a
mitter. See Remote Keyless Entry Receiver Program- hard-wired ground path through the DDM ground
ming in this group for more information on this circuit and the driver side power lock switch contacts
feature. to the lock request or unlock request terminals of the
The RKE receiver cannot be repaired and, if faulty PDM. The DDM power lock switch function can be
or damaged, it must be replaced. tested as follows:
(1) Disconnect and isolate the battery negative
cable. Remove the driver side front door trim panel
DIAGNOSIS AND TESTING and unplug the 12-way DDM wire harness connector
(C-2) from the DDM. Check for continuity between
POWER LOCK SYSTEM AND REMOTE the ground circuit cavity of the 12-way DDM wire
KEYLESS ENTRY SYSTEM harness connector and a good ground. There should
On models without the Remote Keyless Entry be continuity. If OK, go to Step 2. If not OK, repair
(RKE) option, proceed directly to the Door Module the open circuit to ground as required.
diagnosis. As a preliminary diagnosis for models with (2) If the problem being diagnosed is inoperative
the RKE system, note the power lock system and power lock switch illumination, proceed as follows. If
illuminated entry system operation while you actuate the problem is not power lock switch illumination, go
both the Lock and Unlock functions with the power to Step 4. Connect the battery negative cable. Turn
lock switches and the RKE transmitter. Then, pro- the ignition switch to the Accessory or On positions.
ceed as follows: Check for battery voltage at both sides of the power
• If the entire power lock system fails to function window circuit breaker in the junction block. If OK,
with either the power lock switches or the RKE go to Step 3. If not OK, replace the faulty circuit
transmitter, unplug the wire harness connector from breaker.
the RKE receiver and test the power lock system (3) With the ignition switch still in the On or
operation again using the power lock switches. If the Accessory position, check for battery voltage at the
power lock system now operates, see the Remote fused ignition switch output circuit cavity of the
Keyless Entry Receiver diagnosis in this group. If the 12-way DDM wire harness connector. If OK, replace
power lock system still fails to operate, see the Door the faulty DDM. If not OK, repair the open circuit to
Module diagnosis in this group. the junction block as required.
• If the power lock system functions with both (4) Test the power lock switch continuity through
power lock switches, but not with the RKE transmit- the DDM 12-way wire harness connector receptacle.
ter, see the Remote Keyless Entry Transmitter diag- See the DDM Power Lock Switch Continuity chart
nosis in this group. (Fig. 1) to determine if the continuity is correct in
• If one power lock motor fails to operate with both the Lock and Unlock switch positions. If OK,
both of the power lock switches and/or the RKE repair the lock request circuit and/or the unlock

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 8P - 4 POWER LOCK SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
request circuit between the DDM and the PDM as to Step 5. Connect the battery negative cable. Turn
required. If not OK, replace the faulty DDM. the ignition switch to the Accessory or On positions.
Check for battery voltage at both sides of the power
window circuit breaker in the junction block. If OK,
go to Step 4. If not OK, replace the faulty circuit
breaker.
(4) With the ignition switch still in the Accessory
or On positions, check for battery voltage at the
fused ignition switch output circuit cavity of the
8-way PDM wire harness connector. If OK, replace
the faulty PDM. If not OK, repair the open circuit to
the junction block as required.
(5) If the problem being diagnosed is an inopera-
SWITCH POSITION CONTINUITY BETWEEN tive door lock inhibit feature or a power lock system
LOCK 7&8 that responds to an Unlock command, but not a Lock
command, proceed as follows. Otherwise, go to Step
UNLOCK 11 & 8
7. With the driver side front door closed, check for
continuity between the door ajar/key-in circuit cavity
Fig. 1 DDM Power Lock Switch Continuity of the 8-way PDM wire harness connector and a good
PASSENGER DOOR MODULE ground. There should be no continuity. If OK, go to
The Passenger Door Module (PDM) contains the Step 6. If not OK, repair the shorted door ajar and/or
passenger side front door power lock switch and the key-in ignition circuits as required. Refer to Group
power lock system control circuitry. In its role as a 8U - Chime/Buzzer Warning Systems for more infor-
power lock switch, it provides the power lock system mation.
control circuitry with a ground path through the (6) Open the driver side front door with the key in
PDM ground circuit and the driver side power lock the ignition switch or with the headlamp switch in
switch contacts to indicate a lock request or unlock the On position. Check for continuity between the
request. door ajar/key-in circuit cavity of the 8-way PDM wire
In its role as the power lock control module, the harness connector and a good ground. There should
PDM receives inputs from the battery, the ignition be continuity. If OK, go to Step 8. If not OK, repair
switch, the DDM, the driver door ajar switch, the the open door ajar and/or key-in ignition circuits as
key-in ignition switch, and the headlamp switch. It required. Refer to Group 8U - Chime/Buzzer Warning
also receives a hard-wired input from the RKE Systems for more information.
receiver, if the vehicle is so equipped. In response to (7) Connect the battery negative cable. Check for
these inputs, the PDM sends the proper outputs to battery voltage at the fused B(+) circuit cavity of the
control the power lock motors through its integral 8-way PDM wire harness connector. If OK, go to Step
power lock and unlock relays. The PDM power lock 8. If not OK, repair the open circuit to the fuse in the
system functions can be tested as outlined below. If junction block as required.
the power lock system operates, but the RKE system (8) Test the PDM power lock switch continuity
lock and/or unlock functions are inoperative, see the through the two PDM wire harness connector recep-
diagnosis for the Remote Keyless Entry Transmitter tacles. See the PDM Power Lock Switch Continuity
in this group. chart (Fig. 2) to determine if the continuity is correct
(1) Check the fuse in the junction block. If OK, go in both the Lock and Unlock switch positions. If OK,
to Step 2. If not OK, repair the shorted circuit or see the diagnosis for Power Lock Motors in this
component as required and replace the faulty fuse. group. If not OK, replace the faulty PDM.
(2) Disconnect and isolate the battery negative
cable. Remove the passenger side front door trim POWER LOCK MOTOR
panel and unplug the 8-way PDM wire harness con- Before you proceed with this diagnosis, confirm
nector (C-1) from the PDM. Check for continuity proper power door lock switch operation. See Door
between the ground circuit cavity of the 8-way PDM Module in this group for the diagnostic procedures.
wire harness connector and a good ground. There Remember, the Passenger Door Module (PDM) cir-
should be continuity. If OK, go to Step 3. If not OK, cuitry controls the output to each of the power lock
repair the open circuit to ground as required. motors. For circuit descriptions and diagrams, refer
(3) If the problem being diagnosed is inoperative to 8W-61 - Power Door Locks in Group 8W - Wiring
power lock switch illumination, proceed as follows. If Diagrams.
the problem is not power lock switch illumination, go

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 XJ POWER LOCK SYSTEMS 8P - 5
DIAGNOSIS AND TESTING (Continued)
(3) Once it is determined which power lock motor
is inoperative, that motor can be tested as follows.
Unplug the wire harness connector at the inoperative
power lock motor. Apply 12 volts to the motor termi-
nals to check its operation in one direction. Reverse
the polarity to check the operation in the other direc-
tion. If OK, repair the short or open circuits between
the power lock motor and the PDM as required. If
not OK, replace the faulty power lock motor.

REMOTE KEYLESS ENTRY TRANSMITTER

(1) Replace the Remote Keyless Entry (RKE)
transmitter batteries. See Remote Keyless Entry
Transmitter Battery Replacement in this group for
LEFT-HAND DRIVE (LHD) the procedures. Test each of the transmitter func-
tions. If OK, discard the faulty batteries. If not OK,
SWITCH POSITION CONTINUITY BETWEEN
go to Step 2.
LOCK C1 PIN 3 & C1 PIN 6 (2) Perform the Remote Keyless Entry Transmitter
C1 PIN 3 & C2 PIN 1 Programming procedure with the suspect transmitter
C1 PIN 3 & C2 PIN 5 and another known good transmitter. Use a DRB
scan tool, as described in the proper Diagnostic Pro-
UNLOCK C1 PIN 6 & C1 PIN 7
cedures manual.
C1 PIN 7 & C2 PIN 1 (3) Test the RKE system operation with both
C1 PIN 7 & C2 PIN 5 transmitters. If both transmitters fail to operate the
power lock system, see the diagnosis for the Remote
RIGHT-HAND DRIVE (RHD) Keyless Entry Receiver in this group. If the known
SWITCH POSITION CONTINUITY BETWEEN good transmitter operates the power locks and the
suspect transmitter does not, replace the faulty
LOCK C1 PIN 7& C1 PIN 6 transmitter.
C1 PIN 7 & C2 PIN 1
C1 PIN 7 & C2 PIN 5 NOTE: Be certain to perform the Remote Keyless
Entry Transmitter Programming procedure again
UNLOCK C1 PIN 6 & C1 PIN 3
following this test. This procedure will erase the
C1 PIN 3 & C2 PIN 1 access code of the test transmitter from the RKE
C1 PIN 3 & C2 PIN 5 receiver.

Fig. 2 PDM Power Lock Switch Continuity REMOTE KEYLESS ENTRY RECEIVER
(1) Check each power lock motor for correct opera- If the problem being diagnosed is an inoperative
tion while moving the power lock switch to both the Remote Keyless Entry (RKE) horn chirp feature, be
Lock and Unlock positions. If all of the power lock certain that the horn chirp feature has not been dis-
motors are inoperative, go to Step 2. If one power abled. See Remote Keyless Entry Receiver Program-
lock motor is inoperative, go to Step 3. ming in this group for the procedures. Also be certain
(2) If all of the power lock motors are inoperative, that the vehicle horn system is operational. Refer to
the problem may be caused by one shorted motor. Group 8G - Horn Systems for more information.
Unplugging a shorted power lock motor from the If the problem being diagnosed is an inoperative
power lock circuit will allow the good power lock RKE illuminated entry system, be certain that the
motor to operate. Unplug each power lock motor wire interior courtesy lamp system is operational. Refer to
harness connector, one at a time, and recheck both Group 8L - Lamps for more information.
the lock and unlock functions by operating the power Before you proceed with diagnosis of the RKE
lock switch. If all of the power lock motors are still receiver, see the diagnosis for Remote Keyless Entry
inoperative after the above test, check for a short or Transmitter in this group. For circuit descriptions
open circuit between the power lock motors and the and diagrams, refer to 8W-61 - Power Door Locks in
PDM. If unplugging one power lock motor causes the Group 8W - Wiring Diagrams.
other motors to become functional, go to Step 3 to (1) Check the fuses in the Power Distribution Cen-
test the unplugged motor. ter (PDC) and the junction block. If OK, go to Step 2.

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 8P - 6 POWER LOCK SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
If not OK, repair the shorted circuit or component as no continuity. If OK, go to Step 11. If not OK, repair
required and replace the faulty fuse. the short circuit to the horn relay as required.
(2) Disconnect and isolate the battery negative (11) Check for continuity between the horn relay
cable. Remove the Remote Keyless Entry (RKE) output circuit cavity of the RKE receiver wire har-
receiver from the headliner. Unplug the wire harness ness connector and the junction block cavity for the
connector from the RKE receiver. horn relay coil ground terminal (85). There should be
(3) Check the wire harness connector and the continuity. If OK, replace the faulty RKE receiver. If
receptacle in the RKE receiver for loose, corroded, or not OK, repair the open circuit to the junction block
damaged terminals and pins. If OK, go to Step 4. If as required.
not OK, repair as required.
(4) Check for continuity between each of the two
ground circuit cavities of the RKE receiver wire har- SERVICE PROCEDURES
ness connector and a good ground. In each case,
there should be continuity. If OK, go to Step 5. If not REMOTE KEYLESS ENTRY TRANSMITTER
OK, repair the circuit to ground as required. BATTERY REPLACEMENT
(5) Connect the battery negative cable. Check for The Remote Keyless Entry (RKE) transmitter case
battery voltage at each of the two fused B(+) circuit snaps open and shut for battery access. To replace
cavities of the RKE receiver wire harness connector. the RKE transmitter batteries:
If OK, go to Step 6. If not OK, repair the open circuit (1) Using a trim stick or another suitable wide
to the PDC or the junction block as required. flat-bladed tool, gently pry at the center seam of the
(6) If the problem being diagnosed involves only transmitter case halves near the key ring until the
the RKE horn chirp feature, go to Step 10. If the two halves unsnap.
problem being diagnosed involves only the RKE illu- (2) Lift the back half of the transmitter case off of
minated entry feature, go to Step 9. If the problem the transmitter.
being diagnosed involves only the RKE power lock (3) Remove the two batteries from the transmitter.
feature, go to Step 7. (4) Replace the two batteries with new Panasonic
(7) Disconnect and isolate the battery negative CR2016, or their equivalent. Be certain that the bat-
cable. Unplug the 8-way Passenger Door Module teries are installed with their polarity correctly ori-
(PDM) wire harness connector. Check for continuity ented.
between the lock request circuit cavity of the RKE (5) Align the two transmitter case halves with
receiver wire harness connector and a good ground. each other, and squeeze them firmly together until
Repeat the test between the unlock request circuit they snap back into place.
cavity of the RKE receiver wire harness connector
and a good ground. In each case, there should be no REMOTE KEYLESS ENTRY TRANSMITTER
continuity. If OK, go to Step 8. If not OK, repair the PROGRAMMING
shorted circuit as required. To program the Remote Keyless Entry (RKE)
(8) Check for continuity between the lock request transmitter access codes into the RKE receiver
circuit cavities of the RKE receiver wire harness con- requires the use of a DRB scan tool. Refer to the
nector and the 8-way PDM wire harness connector. proper Diagnostic Procedures manual for more infor-
Repeat the test between the unlock request circuit mation.
cavities of the RKE receiver wire harness connector
and the 8-way PDM wire harness connector. In each
REMOTE KEYLESS ENTRY RECEIVER
case, there should be continuity. If OK, replace the
faulty RKE receiver. If not OK, repair the open cir- PROGRAMMING
cuit as required. The optional Remote Keyless Entry (RKE) system
(9) Check for continuity between the door ajar cir- for this vehicle has a customer programmable horn
cuit cavity of the RKE receiver wire harness connec- chirp feature. The horn chirp is requested by the
tor and a good ground with the driver door closed. RKE receiver through a hard-wired circuit to the
There should be no continuity until the driver door is horn relay, whenever a valid Lock message is
opened. If OK, replace the faulty RKE receiver. If not received from a programmed RKE radio transmitter.
OK, repair the circuit or replace the faulty driver The purpose of the horn chirp is to provide the
door ajar switch as required. vehicle operator with an audible verification that the
(10) Unplug the horn relay from the junction Lock request has been received by the RKE receiver.
block. Check for continuity between the horn relay However, for any number of reasons, some customers
output circuit cavity of the RKE receiver wire har- may prefer that this feature be disabled. This RKE
ness connector and a good ground. There should be system allows them that option.

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 XJ POWER LOCK SYSTEMS 8P - 7
SERVICE PROCEDURES (Continued)
To program the Remote Keyless Entry (RKE) (5) Pull the front door trim panel away from the
receiver so that the horn chirp feature is disabled, inner door panel far enough to access the inside door
proceed as follows: latch release and lock linkage rods near the back of
(1) While within the reception range of the RKE the inside door remote controls.
receiver, press and hold the Lock button of a pro- (6) Unsnap the plastic retainer clips from the
grammed RKE transmitter depressed for five to ten inside door remote control ends of the latch release
seconds. and lock linkage rods, and remove the rod ends from
(2) While holding the RKE transmitter Lock but- the inside door remote controls.
ton depressed, press and release the RKE transmit- (7) Unplug the wire harness connectors from the
ter Unlock button. door module.
(3) The RKE horn chirp feature is now disabled. (8) Remove the trim panel from the front door.
Repeating the preceding steps will again enable (9) Remove the three screws that secure the door
the RKE horn chirp feature. module to the front door trim panel (Fig. 4).

REMOVAL AND INSTALLATION

DOOR MODULE
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the screws that secure the front door
trim panel to the inner door panel (Fig. 3).

Fig. 4 Door Module Remove/Install

1 – INSIDE DOOR LATCH AND LOCK REMOTE CONTROLS
2 – CONNECTOR 1 RECEPTACLE
3 – DOOR MODULE
4 – CONNECTOR 2 RECEPTACLE
5 – SCREWS
6 – DOOR TRIM PANEL

(10) Remove the door module from the front door

trim panel.
(11) Reverse the removal procedures to install.
Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
Fig. 3 Front Door Trim Panel Remove/Install
1 – U-NUT
POWER LOCK MOTOR
2 – DOOR
3 – TRIM PANEL FRONT DOOR
4 – PUSH-IN FASTENER The front door power lock motor is integral to the
front door latch unit. If the front door power lock
motor is faulty or damaged, the entire latch unit
(3) Using a trim stick or another suitable wide must be replaced. Refer to Group 23 - Body for the
flat-bladed tool, gently pry the front door trim panel front door latch service procedures.
away from the door around the perimeter to release
the trim panel retainers. REAR DOOR
The rear door power lock motor is integral to the
NOTE: To aid in the removal of the trim panel, start
rear door latch unit. If the rear door power lock
at the bottom of the panel.
motor is faulty or damaged, the entire latch unit
(4) Lift the front door trim panel upwards and must be replaced. Refer to Group 23 - Body for the
away from the inner door panel far enough to disen- rear door latch service procedures.
gage the top of the panel from the inner belt weath-
erstrip.

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 8P - 8 POWER LOCK SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
LIFTGATE cotton clothing, not synthetic fabric clothing; and,
(1) Disconnect and isolate the battery negative should ground themselves before and during all
cable. handling and service procedures. Electrically con-
(2) Open the liftgate. ductive wrist or heel straps are recommended, or
(3) Remove the liftgate trim panel from the lift- static dissipating shoes are also acceptable. Work
gate. Refer to Group 23 - Body for the procedures. and storage areas should be free of static genera-
(4) Reach through the liftgate inner panel access tive materials such as: dry air, glass, nylon, wool,
hole and disconnect the link from the clip on the fur, silk, rayon, acrylic, polystyrene foam, polyester,
power lock motor (Fig. 5). saran, polyethylene, polypropylene, PVC, and
teflon.

MINI-DOME MOUNTED TYPE

(1) Disconnect and isolate the battery negative
cable.
(2) Remove the two screws that secure the Remote
Keyless Entry (RKE) mini-dome housing to the roof
panel reinforcement (Fig. 6).

Fig. 5 Liftgate Power Lock Motor Remove/Install

1 – CLIPS
2 – LOCK LEVER
3 – LINK
4 – MOTOR
5 – LIFTGATE INNER PANEL
6 – SCREW
7 – CONNECTORS
Fig. 6 Mini-Dome Housing Remove/Install
1 – MOUNTING TAB
(5) Remove the two screws that secure the power
2 – HEADLINER
lock motor to the liftgate inner panel.
3 – REINFORCEMENT
(6) Pull the power lock motor out through the lift- 4 – SCREW
gate inner panel access hole far enough to access the 5 – MINI-DOME HOUSING
wire harness connector.
(7) Unplug the wire harness connector from the
power lock motor. (3) Lower the front of the mini-dome housing and
(8) Remove the power lock motor from the liftgate. slide the unit forward to disengage the rear mount-
(9) Reverse the removal procedures to install. ing tab from the headliner.
Tighten the power lock motor mounting screws to 3 (4) Lower the mini-dome housing far enough to
N·m (28 in. lbs.). access the RKE receiver wire harness connector.
(5) Unplug the wire harness connector from the
REMOTE KEYLESS ENTRY RECEIVER RKE receiver.
(6) Remove the RKE mini-dome unit from the
CAUTION: A discharge of static electricity may headliner.
damage this unit. At no time should any source of (7) Reverse the removal procedures to install.
static electricity be permitted near this unit. Techni- Tighten the mounting screws to 2.8 N·m (24 in. lbs.).
cians handling or servicing the unit should wear

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 XJ POWER LOCK SYSTEMS 8P - 9
REMOVAL AND INSTALLATION (Continued)
OVERHEAD CONSOLE MOUNTED TYPE
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the overhead console from the head-
liner. Refer to Overhead Console in Group 8V - Over-
head Console Systems for the procedures.
(3) Remove the six screws that secure the rear
overhead console housing to the overhead console
bezel (Fig. 7).
(4) Gently flex the sides of the overhead console
bezel far enough to clear the tabs on the rear console
housing and remove the housing from the bezel.
(5) Remove the two screws that secure the RKE
receiver circuit board to the rear overhead console Fig. 7 RKE Receiver Remove/Install
housing. 1 – REAR OVERHEAD CONSOLE HOUSING
(6) Remove the RKE circuit board from the rear 2 – RKE RECEIVER
overhead console housing. 3 – TABS
(7) Reverse the removal procedures to install. 4 – OVERHEAD CONSOLE BEZEL
Tighten the mounting screws to 2.2 N·m (20 in. lbs.). 5 – SCREWS

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 XJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1

VEHICLE THEFT/SECURITY SYSTEMS

TABLE OF CONTENTS

page page

GENERAL INFORMATION DIAGNOSIS AND TESTING

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SENTRY KEY IMMOBILIZER SYSTEM . . . . . . . . . 3
SENTRY KEY IMMOBILIZER SYSTEM . . . . . . . . . 1 SERVICE PROCEDURES
DESCRIPTION AND OPERATION SENTRY KEY IMMOBILIZER SYSTEM
SENTRY KEY IMMOBILIZER MODULE. . . . . . . . . 1 TRANSPONDER PROGRAMMING . . . . . . . . . . . 4
SENTRY KEY IMMOBILIZER TRANSPONDER . . . 2 REMOVAL AND INSTALLATION
SENTRY KEY IMMOBILIZER SYSTEM SENTRY KEY IMMOBILIZER MODULE. . . . . . . . . 4
INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . 3

GENERAL INFORMATION malfunction is detected. The SKIS can be diagnosed,

and any stored DTC can be retrieved using a
INTRODUCTION DRBIIIt scan tool as described in the proper Diag-
The Sentry Key Immobilizer System (SKIS) is nostic Procedures manual.
available factory-installed optional equipment for this
model. Following are some general descriptions of the DESCRIPTION AND OPERATION
features and components of the SKIS. Refer to the
vehicle owner’s manual for more information on the
SENTRY KEY IMMOBILIZER MODULE
use and operation of the SKIS. Refer to 8W-30 - Fuel/
The Sentry Key Immobilizer Module (SKIM) con-
Ignition System in Group 8W - Wiring Diagrams for
tains a Radio Frequency (RF) transceiver and a cen-
complete circuit descriptions and diagrams.
tral processing unit, which includes the Sentry Key
Immobilizer System (SKIS) program logic. The SKIS
SENTRY KEY IMMOBILIZER SYSTEM programming enables the SKIM to program and
The Sentry Key Immobilizer System (SKIS) is
retain in memory the codes of at least one, but no
designed to provide passive protection against unau-
more than eight electronically coded Sentry Key
thorized vehicle use by preventing the engine from
transponders. The SKIS programming also enables
operating while the system is armed. The primary
the SKIM to communicate over the Chrysler Collision
components of this system are the Sentry Key Immo-
Detection (CCD) data bus network with the Power-
bilizer Module (SKIM), the Sentry Key transponder,
train Control Module (PCM), the instrument cluster
the SKIS indicator lamp, and the Powertrain Control
and/or the DRBIIIt scan tool.
Module (PCM).
The SKIM transmits and receives RF signals
The SKIM is installed on the steering column near
through a tuned antenna enclosed within a molded
the ignition lock cylinder. The transponder is located
plastic ring formation that is integral to the SKIM
under the molded rubber cap on the head of the igni-
housing. When the SKIM is properly installed on the
tion key. The SKIS indicator lamp is located in the
steering column, the antenna ring is oriented around
instrument cluster.
the circumference of the ignition lock cylinder hous-
The SKIS includes two valid Sentry Key transponders
ing. This antenna ring must be located within eight
from the factory. If the customer wishes, additional non-
millimeters (0.31 inches) of the Sentry Key in order
coded blank Sentry Keys are available. These blank
to ensure proper RF communication between the
keys can be cut to match a valid ignition key, but the
SKIM and the Sentry Key transponder.
engine will not start unless the key transponder is also
For added system security, each SKIM is pro-
programmed to the vehicle using the Customer Learn
grammed with a unique “Secret Key” code and a
programming procedure or a DRBIIIt scan tool. The
security code (PIN). The SKIM keeps the “Secret
SKIS will recognize no more than eight valid Sentry
Key” code in memory. This “Secret Key” code must be
Key transponders at any one time.
transferred to the PCM memory during the initializa-
The SKIS performs a self-test each time the igni-
tion/programming of the SKIS when the vehicle is
tion switch is turned to the On position, and will
manufactured, and each time the PCM is replaced
store Diagnostic Trouble Codes (DTCs) if a system
during vehicle service by the dealer technician. The

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 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
SKIM also transfers the “Secret Key” code to the For diagnosis or initialization of the SKIM and the
memory of each of the Sentry Key transponders dur- PCM, a DRBIIIt scan tool and the proper Diagnostic
ing new key programming. The security code is used Procedures manual are required. The SKIM cannot
by the assembly plant to access the SKIS for initial- be repaired and, if faulty or damaged, the unit must
ization, or by the dealer technician to access the sys- be replaced.
tem for service. The SKIM also stores in its memory
the Vehicle Identification Number (VIN), which it SENTRY KEY IMMOBILIZER TRANSPONDER
learns through a CCD data bus message from the The Sentry Key Immobilizer System (SKIS) uses a
PCM during initialization. transponder that is integral to each of the two igni-
The SKIM and the PCM both use software that tion keys that are supplied with the vehicle when it
includes a rolling code algorithm strategy, which is shipped from the factory. The transponder chip is
helps to reduce the possibility of unauthorized SKIS insulated within a nylon mount inserted in the head
disarming. The rolling code algorithm ensures secu- of the key, and invisible beneath a molded rubber cap
rity by preventing an override of the SKIS through (Fig. 1).
the unauthorized substitution of the SKIM or the
PCM. However, the use of this strategy also means
that replacement of either the SKIM or the PCM
units will require a system initialization procedure to
restore system operation.
When the ignition switch is turned to the On or Start
positions, the SKIM transmits an RF signal to excite
the Sentry Key transponder. The SKIM then listens for
a return RF signal from the transponder of the Sentry
Key that is inserted in the ignition lock cylinder. If the
SKIM receives an RF signal with valid “Secret Key” and
transponder identification codes, the SKIM sends a
“valid key” message to the PCM over the CCD data bus.
If the SKIM receives an invalid RF signal or no
response, it sends “invalid key” messages to the PCM.
The PCM will enable or disable engine operation based
upon the status of the SKIM messages.
The SKIM also sends messages to the instrument
cluster over the CCD data bus network to control the Fig. 1 Sentry Key Immobilizer Transponder
SKIS indicator lamp. The SKIM sends messages to the 1 – MOLDED CAP
instrument cluster to turn the lamp on for about three 2 – TRANSPONDER
3 – MOLDED CAP REMOVED
seconds when the ignition switch is turned to the On
4 – SENTRY KEY
position as a bulb test. After completion of the bulb test,
the SKIM sends bus messages to keep the lamp off for a
duration of about one second. Then the SKIM sends Each Sentry Key transponder has a unique tran-
messages to turn the lamp on or off based upon the sponder identification code programmed into it by the
results of the SKIS self-tests. If the SKIS indicator manufacturer. The Sentry Key Immobilizer Module
lamp comes on and stays on after the bulb test, it indi- (SKIM) has a unique “Secret Key” code programmed
cates that the SKIM has detected a system malfunction into it by the manufacturer. Each time a new Sentry
and/or that the SKIS has become inoperative. Key transponder is programmed, the SKIM learns
If the SKIM detects an invalid key when the ignition the transponder identification code from the tran-
switch is turned to the On position, it sends messages to sponder, and the transponder learns the “Secret Key”
the instrument cluster to flash the SKIS indicator lamp. code from the SKIM. Each of these codes is stored
The SKIM can also send messages to the instrument within the transponder and in the nonvolatile mem-
cluster to flash the lamp and to generate a single audi- ory of the SKIM. Therefore, blank keys for the SKIS
ble chime tone. These functions serve as an indication must be programmed and their transponder identifi-
to the customer that the SKIS has been placed in its cation codes must be learned by and stored in the
“Customer Learn” programming mode. See Sentry Key SKIM memory, in addition to being cut to match the
Immobilizer System Transponder Programming in this mechanical coding of the ignition lock cylinder. See
group for more information on the “Customer Learn” Sentry Key Immobilizer System Transponder Pro-
programming mode. gramming in this group for more information.

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 XJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3
DESCRIPTION AND OPERATION (Continued)
The Sentry Key transponder is within the range of DIAGNOSIS AND TESTING
the SKIM transceiver antenna ring when it is inserted
in the ignition lock cylinder. When the ignition switch is SENTRY KEY IMMOBILIZER SYSTEM
turned to the Start or On positions, the SKIM trans-
ceiver issues a Radio Frequency (RF) signal that excites WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
the transponder chip. The transponder chip responds by REFER TO GROUP 8M - PASSIVE RESTRAINT SYS-
issuing an RF signal containing its transponder identi- TEMS BEFORE ATTEMPTING ANY STEERING WHEEL,
fication code and the “Secret Key” code. The SKIM STEERING COLUMN, OR INSTRUMENT PANEL COM-
transceiver compares the transponder codes with the PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE
codes stored in its memory to determine whether a valid THE PROPER PRECAUTIONS COULD RESULT IN
key is in the ignition lock cylinder. ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
The Sentry Key transponder cannot be repaired PERSONAL INJURY.
and, if faulty or damaged, it must be replaced.

SENTRY KEY IMMOBILIZER SYSTEM NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
INDICATOR LAMP
able, efficient, and accurate means to diagnose the
The Sentry Key Immobilizer System (SKIS) indica-
Sentry Key Immobilizer System involves the use of
tor lamp gives an indication when the SKIS is faulty
a DRB scan tool. Refer to the proper Diagnostic
or when the vehicle has been immobilized due to the
Procedures manual for the procedures.
use of an invalid ignition key. The lamp is controlled
by the instrument cluster circuitry based upon mes- The Sentry Key Immobilizer System (SKIS) and
sages received from the Sentry Key Immobilizer the Chrysler Collision Detection (CCD) data bus net-
Module (SKIM) on the Chrysler Collision Detection work should be diagnosed using a DRB scan tool.
(CCD) data bus. The DRB will allow confirmation that the CCD data
The SKIM sends messages to the instrument clus- bus is functional, that the Sentry Key Immobilizer
ter to turn the lamp on for about three seconds when Module (SKIM) is placing the proper messages on the
the ignition switch is turned to the On position as a CCD data bus, and that the Powertrain Control Mod-
bulb test. After completion of the bulb test, the SKIM ule (PCM) and the instrument cluster are receiving
sends bus messages to keep the lamp off for a dura- the CCD data bus messages. Refer to the proper
tion of about one second. Then the SKIM sends mes- Diagnostic Procedures manual for the procedures.
sages to the instrument cluster circuitry to turn the Refer to 8W-39 - Vehicle Theft Security System in
lamp on or off based upon the results of the SKIS Group 8W - Wiring Diagrams for complete circuit
self-tests. If the SKIS indicator lamp comes on and descriptions and diagrams.
stays on after the bulb test, it indicates that the (1) Check the fuses in the fuseblock module. If OK,
SKIM has detected a system malfunction and/or that go to Step 2. If not OK, repair the shorted circuit or
the SKIS has become inoperative. component as required and replace the faulty fuse.
If the SKIM detects an invalid key when the ignition (2) Disconnect and isolate the battery negative
switch is turned to the On position, it sends messages to cable. Unplug the wire harness connector at the
the instrument cluster to flash the SKIS indicator lamp. SKIM. Check for continuity between the ground cir-
The SKIM can also send messages to the instrument cuit cavity of the SKIM wire harness connector and a
cluster to flash the lamp and to generate a single audi- good ground. There should be continuity. If OK, go to
ble chime tone. These functions serve as an indication Step 3. If not OK, repair the open circuit to ground
to the customer that the SKIS has been placed in its as required.
“Customer Learn” programming mode. See Sentry Key (3) Connect the battery negative cable. Check for
Immobilizer System Transponder Programming in this battery voltage at the fused B(+) circuit cavity of the
group for more information on the “Customer Learn” SKIM wire harness connector. If OK, go to Step 4. If
programming mode. not OK, repair the open circuit to the fuse in the
The SKIS indicator lamp uses a replaceable incan- fuseblock module as required.
descent bulb and bulb holder on the instrument clus- (4) Turn the ignition switch to the On position.
ter electronic circuit board. Refer to Group 8E - Check for battery voltage at the fused ignition switch
Instrument Panel Systems for diagnosis and service output (run/start) circuit cavity of the SKIM wire
of a faulty SKIS indicator lamp. If the SKIS indicator harness connector. If OK, use a DRB scan tool and
lamp comes on and stays on after the bulb test func- the proper Diagnostic Procedures manual to complete
tion, diagnosis of the SKIS should be performed with the diagnosis of the SKIS. If not OK, repair the open
a DRB scan tool and the proper Diagnostic Proce- circuit to the fuse in the fuseblock module as
dures manual. required.

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 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS XJ

SERVICE PROCEDURES “Customer Learn” programming mode if it sees a non-

blank Sentry Key transponder when it should see a
SENTRY KEY IMMOBILIZER SYSTEM blank, if it has already programmed eight valid Sentry
Keys, or if the ignition switch is turned to the Off posi-
TRANSPONDER PROGRAMMING tion for more than about fifty seconds.
Two programmed Sentry Key transponders are
included with the Sentry Key Immobilizer System
(SKIS) when it is shipped from the factory. The Sentry REMOVAL AND INSTALLATION
Key Immobilizer Module (SKIM) can be programmed to
recognize up to six additional transponders, for a total SENTRY KEY IMMOBILIZER MODULE
of eight Sentry Keys. The following “Customer Learn”
programming procedure for the programming of addi- WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
tional transponders requires access to at least two of REFER TO GROUP 8M - PASSIVE RESTRAINT SYS-
the valid Sentry Keys. If two valid Sentry Keys are not TEMS BEFORE ATTEMPTING ANY STEERING WHEEL,
available, Sentry Key programming will require the use STEERING COLUMN, OR INSTRUMENT PANEL COM-
of a DRB scan tool and the proper Diagnostic Proce- PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE
dures manual. THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
CUSTOMER LEARN PERSONAL INJURY.
(1) Obtain the additional Sentry Key transponder
blank(s) that are to be programmed for the vehicle. Cut (1) Disconnect and isolate the battery negative
the additional Sentry Key transponder blanks to match cable.
the ignition lock cylinder mechanical key codes. (2) Remove the knee blocker from the instrument
(2) Insert one of the two valid Sentry Key tran- panel. See Knee Blocker in Group 8E - Instrument
sponders into the ignition switch and turn the igni- Panel Systems for the procedures.
tion switch to the On position. (3) Remove the three screws that secure the lower
(3) After the ignition switch has been in the On posi- steering column shroud to the upper shroud (Fig. 2).
tion for about three seconds, but no more than fifteen
seconds later, cycle the ignition switch back to the Off
position. Replace the first valid Sentry Key in the igni-
tion lock cylinder with the second valid Sentry Key and
turn the ignition switch back to the On position.
(4) About ten seconds after the completion of Step
3, the SKIS indicator lamp will start to flash and a
single audible chime tone will sound to indicate that
the system has entered the “Customer Learn” pro-
gramming mode.
(5) Within about fifty seconds of entering the “Cus-
tomer Learn” programming mode, turn the ignition
switch to the Off position, replace the valid Sentry
Key with a blank Sentry Key transponder, and turn
the ignition switch back to the On position.
(6) About ten seconds after the completion of Step
5, a single audible chime tone will sound and the
SKIS indicator lamp will stop flashing and stay on
solid for about three seconds to indicate that the
blank Sentry Key transponder has been successfully
programmed. The SKIS will immediately return to
normal system operation following exit from the
“Customer Learn” programming mode.
(7) Go back to Step 2 and repeat this process for
each additional Sentry Key transponder blank to be Fig. 2 Steering Column Shrouds Remove/Install
programmed. 1 – UPPER SHROUD
If any of the above steps is not completed in the 2 – SCREW (3)
proper sequence, or within the allotted time, the SKIS 3 – LOWER SHROUD
will automatically exit the “Customer Learn” program- 4 – STEERING WHEEL
ming mode. The SKIS will also automatically exit the

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 XJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5
REMOVAL AND INSTALLATION (Continued)

Fig. 3 Sentry Key Immobilizer Module Remove/Install

1 – UPPER SHROUD 5 – IGNITION LOCK CYLINDER
2 – STEERING COLUMN 6 – SCREW
3 – WIRE HARNESS CONNECTOR 7 – LOWER SHROUD
4 – SENTRY KEY IMMOBILIZER MODULE 8 – STEERING WHEEL

(4) If the vehicle is equipped with a standard non- (9) Rotate the SKIM and its mounting bracket
tilt steering column, loosen the two upper steering downwards and then to the side away from the steer-
column mounting nuts. If the vehicle is equipped ing column to slide the SKIM antenna ring from
with the optional tilt steering column, move the tilt around the ignition switch lock cylinder housing.
steering column to the fully lowered position. (10) Remove the SKIM from the vehicle.
(5) Remove both the upper and lower shrouds from (11) Reverse the removal procedures to install.
the steering column. Tighten the non-tilt steering column mounting nuts
(6) Disengage the steering column wire harness to 22 N·m (200 in. lbs.) and the steering column
retainer from the tab on the top of the Sentry Key shroud mounting screws to 2 N·m (18 in. lbs.).
Immobilizer Module (SKIM) mounting bracket (Fig. 3).
(7) Unplug the wire harness connector from the NOTE: If the SKIM is replaced with a new unit, a
SKIM receptacle. DRBIIIT scan tool and the proper Diagnostic Proce-
(8) The SKIM mounting bracket features a clip for- dures manual MUST be used to initialize the new
mation that secures the SKIM to the inboard lower SKIM and to program at least two Sentry Key
flange of the steering column jacket. Pull downward transponders.
on the connector end of the SKIM mounting bracket
to release this clip from the steering column jacket.

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 XJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1

VEHICLE THEFT/SECURITY SYSTEMS

TABLE OF CONTENTS

page page

DESCRIPTION AND OPERATION SERVICE PROCEDURES

SENTRY KEY IMMOBILIZER SYSTEM . . . . . . . . . 1 SENTRY KEY IMMOBILIZER SYSTEM
SENTRY KEY IMMOBILIZER MODULE. . . . . . . . . 1 TRANSPONDER PROGRAMMING . . . . . . . . . . . 3
SENTRY KEY IMMOBILIZER TRANSPONDER . . . 2 REMOVAL AND INSTALLATION
SENTRY KEY IMMOBILIZER SYSTEM SENTRY KEY IMMOBILIZER MODULE. . . . . . . . . 4
INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
SENTRY KEY IMMOBILIZER SYSTEM . . . . . . . . . 3

DESCRIPTION AND OPERATION more than eight electronically coded Sentry Key
transponders. The SKIS programming also enables
SENTRY KEY IMMOBILIZER SYSTEM the SKIM to communicate over the Chrysler Collision
The Sentry Key Immobilizer System (SKIS) is Detection (CCD) data bus network with the Power-
designed to provide passive protection against unau- train Control Module (PCM), the instrument cluster
thorized vehicle use by preventing the engine from and/or the DRB scan tool.
operating. The primary components of this system The SKIM transmits and receives RF signals
are the Sentry Key Immobilizer Module (SKIM), the through a tuned antenna enclosed within a molded
Sentry Key transponder, the SKIS indicator lamp, plastic ring formation that is integral to the SKIM
and the Powertrain Control Module (PCM). housing. When the SKIM is properly installed on the
The SKIM is installed on the steering column near steering column, the antenna ring is oriented around
the ignition lock cylinder. The transponder is located the circumference of the ignition lock cylinder hous-
under the molded rubber cap on the head of the igni- ing. This antenna ring must be located within eight
tion key. The SKIS indicator lamp is located in the millimeters (0.31 inches) of the Sentry Key in order
instrument cluster. to ensure proper RF communication between the
The SKIS includes two valid Sentry Key transpon- SKIM and the Sentry Key transponder.
ders from the factory. If the customer wishes, addi- For added system security, each SKIM is pro-
tional non-coded blank Sentry Keys are available. grammed with a unique “Secret Key” code and a
These blank keys can be cut to match a valid ignition security code. The SKIM keeps the “Secret Key” code
key, but the engine will not start unless the key tran- in memory and sends the code over the CCD data
sponder is also programmed to the vehicle. The SKIS bus to the PCM, which also keeps this code in its
will recognize no more than eight valid Sentry Key memory. The SKIM also sends the “Secret Key” code
transponders at any one time. to each of the programmed Sentry Key transponders.
The SKIS performs a self-test each time the igni- The security code is used by the assembly plant to
tion switch is turned to the On position, and will access the SKIS for initialization, or by the dealer
store Diagnostic Trouble Codes (DTCs) if a system technician to access the system for service. The
malfunction is detected. The SKIS can be diagnosed, SKIM also stores in its memory the Vehicle Identifi-
and any stored DTC can be retrieved using a DRB cation Number (VIN), which it learns through a CCD
scan tool as described in the proper Diagnostic Pro- data bus message from the PCM during initializa-
cedures manual. tion.
The SKIM and the PCM both use software that
SENTRY KEY IMMOBILIZER MODULE includes a rolling code algorithm strategy, which
The Sentry Key Immobilizer Module (SKIM) con- helps to reduce the possibility of unauthorized SKIS
tains a Radio Frequency (RF) transceiver and a cen- disarming. The rolling code algorithm ensures secu-
rity by preventing an override of the SKIS through
tral processing unit, which includes the Sentry Key
Immobilizer System (SKIS) program logic. The SKIS the unauthorized substitution of the SKIM or the
PCM. However, the use of this strategy also means
programming enables the SKIM to program and
that replacement of either the SKIM or the PCM
retain in memory the codes of at least two, but no

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 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
units will require a system initialization procedure to
restore system operation.
When the ignition switch is turned to the On or
Start positions, the SKIM transmits an RF signal to
excite the Sentry Key transponder. The SKIM then
listens for a return RF signal from the transponder
of the Sentry Key that is inserted in the ignition lock
cylinder. If the SKIM receives an RF signal with
valid “Secret Key” and transponder identification
codes, the SKIM sends a “valid key” message to the
PCM over the CCD data bus. If the SKIM receives
an invalid RF signal or no response, it sends “invalid
key” messages to the PCM. The PCM will enable or
disable engine operation based upon the status of the
SKIM messages.
The SKIM also sends messages to the instrument
cluster over the CCD data bus network to control the
SKIS indicator lamp. The SKIM sends messages to Fig. 1 Sentry Key Immobilizer Transponder
the instrument cluster to turn the lamp on for about 1 – MOLDED CAP
three seconds when the ignition switch is turned to 2 – TRANSPONDER
the On position as a bulb test. After completion of 3 – MOLDED CAP REMOVED
the bulb test, the SKIM sends bus messages to keep 4 – SENTRY KEY
the lamp off for a duration of about one second. Then
the SKIM sends messages to turn the lamp on or off these codes is stored within the transponder and in
based upon the results of the SKIS self-tests. If the the nonvolatile memory of the SKIM. Therefore,
SKIS indicator lamp comes on and stays on after the blank keys for the SKIS must be programmed by and
bulb test, it indicates that the SKIM has detected a into the SKIM, in addition to being cut to match the
system malfunction and/or that the SKIS has become mechanical coding of the ignition lock cylinder. See
inoperative. Sentry Key Immobilizer System Transponder Pro-
If the SKIM detects an invalid key or transponder gramming in this group for more information.
fault when the ignition switch is turned to the On The Sentry Key transponder is within the range of
position, it sends messages to the instrument cluster the SKIM transceiver antenna ring when it is
to flash the SKIS indicator lamp. inserted in the ignition lock cylinder. When the igni-
For diagnosis or initialization of the SKIM and the tion switch is turned to the Start or On positions, the
PCM, a DRB scan tool and the proper Diagnostic SKIM transceiver issues a Radio Frequency (RF) sig-
Procedures manual are required. The SKIM cannot nal that excites the transponder chip. The transpon-
be repaired and, if faulty or damaged, the unit must der chip responds by issuing an RF signal containing
be replaced. its transponder identification code and the “Secret
Key” code. The SKIM transceiver compares the tran-
SENTRY KEY IMMOBILIZER TRANSPONDER sponder codes with the codes stored in its memory to
The Sentry Key Immobilizer System (SKIS) uses a determine whether a valid key is in the ignition lock
transponder that is integral to each of the two igni- cylinder.
tion keys that are supplied with the vehicle when it The Sentry Key transponder cannot be repaired
is shipped from the factory. The transponder chip is and, if faulty or damaged, it must be replaced.
insulated within a nylon mount inserted in the head
of the key, and invisible beneath a molded rubber cap SENTRY KEY IMMOBILIZER SYSTEM
(Fig. 1).
Each Sentry Key transponder has a unique tran- INDICATOR LAMP
sponder identification code programmed into it by the The Sentry Key Immobilizer System (SKIS) indica-
manufacturer. The Sentry Key Immobilizer Module tor lamp gives an indication when the SKIS is faulty
(SKIM) has a unique “Secret Key” code programmed or when the vehicle has been immobilized due to the
into it by the manufacturer. When a Sentry Key use of an invalid ignition key. The lamp is controlled
transponder is programmed into the memory of the by the instrument cluster circuitry based upon mes-
SKIM, the SKIM learns the transponder identifica- sages received from the Sentry Key Immobilizer
tion code from the transponder, and the transponder Module (SKIM) on the Chrysler Collision Detection
learns the “Secret Key” code from the SKIM. Each of (CCD) data bus.

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 XJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3
DESCRIPTION AND OPERATION (Continued)
The SKIM sends messages to the instrument clus- work should be diagnosed using a DRB scan tool.
ter to turn the lamp on for about three seconds when The DRB will allow confirmation that the CCD data
the ignition switch is turned to the On position as a bus is functional, that the Sentry Key Immobilizer
bulb test. After completion of the bulb test, the SKIM Module (SKIM) is placing the proper messages on the
sends bus messages to keep the lamp off for a dura- CCD data bus, and that the Powertrain Control Mod-
tion of about one second. Then the SKIM sends mes- ule (PCM) and the instrument cluster are receiving
sages to the instrument cluster circuitry to turn the the CCD data bus messages. Refer to the proper
lamp on or off based upon the results of the SKIS Diagnostic Procedures manual for the procedures.
self-tests. If the SKIS indicator lamp comes on and Refer to 8W-30 - Fuel/Ignition System in Group 8W -
stays on after the bulb test, it indicates that the Wiring Diagrams for complete circuit descriptions
SKIM has detected a system malfunction and/or that and diagrams.
the SKIS has become inoperative. If the SKIM (1) Check the fuses in the fuseblock module. If OK,
detects an invalid key or transponder fault when the go to Step 2. If not OK, repair the shorted circuit or
ignition switch is turned to the On position, it sends component as required and replace the faulty fuse.
messages to the instrument cluster to flash the SKIS (2) Disconnect and isolate the battery negative
indicator lamp. cable. Unplug the wire harness connector at the
The SKIS indicator lamp uses a replaceable incan- SKIM. Check for continuity between the ground cir-
descent bulb and bulb holder on the instrument clus- cuit cavity of the SKIM wire harness connector and a
ter electronic circuit board. Refer to Group 8E - good ground. There should be continuity. If OK, go to
Instrument Panel Systems for diagnosis and service Step 3. If not OK, repair the open circuit to ground
of a faulty SKIS indicator lamp. If the SKIS indicator as required.
lamp comes on and stays on after the bulb test func- (3) Connect the battery negative cable. Check for
tion, diagnosis of the SKIS should be performed with battery voltage at the fused B(+) circuit cavity of the
a DRB scan tool and the proper Diagnostic Proce- SKIM wire harness connector. If OK, go to Step 4. If
dures manual. not OK, repair the open circuit to the fuse in the
fuseblock module as required.
(4) Turn the ignition switch to the On position.
DIAGNOSIS AND TESTING Check for battery voltage at the fused ignition switch
output (run/start) circuit cavity of the SKIM wire
SENTRY KEY IMMOBILIZER SYSTEM harness connector. If OK, use a DRB scan tool and
the proper Diagnostic Procedures manual to complete
WARNING: ON VEHICLES EQUIPPED WITH AIR- the diagnosis of the SKIS. If not OK, repair the open
BAGS, REFER TO GROUP 8M - PASSIVE circuit to the fuse in the fuseblock module as
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY required.
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- SERVICE PROCEDURES
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL SENTRY KEY IMMOBILIZER SYSTEM
INJURY. TRANSPONDER PROGRAMMING
Two programmed Sentry Key transponders are
NOTE: The following tests may not prove conclu- included with the Sentry Key Immobilizer System
sive in the diagnosis of this system. The most reli- (SKIS) when it is shipped from the factory. The Sen-
able, efficient, and accurate means to diagnose the try Key Immobilizer Module (SKIM) can be pro-
Sentry Key Immobilizer System involves the use of grammed to recognize up to six additional
a DRB scan tool. Refer to the proper Diagnostic transponders, for a total of eight Sentry Keys. Sentry
Procedures manual for the procedures. Key programming will require the use of a DRB scan
tool and the proper Diagnostic Procedures manual.
The Sentry Key Immobilizer System (SKIS) and
the Chrysler Collision Detection (CCD) data bus net-

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 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS XJ

REMOVAL AND INSTALLATION (5) While holding the retaining tumbler depressed,
pull the ignition lock cylinder and key out of the igni-
SENTRY KEY IMMOBILIZER MODULE tion lock housing.
(6) Remove the three screws that secure the lower
WARNING: ON VEHICLES EQUIPPED WITH AIR- steering column shroud to the upper shroud.
BAGS, REFER TO GROUP 8M - PASSIVE (7) If the vehicle is so equipped, move the tilt
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY steering column to the fully lowered position.
STEERING WHEEL, STEERING COLUMN, OR (8) If the vehicle is so equipped, loosen the two
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR nuts that secure the non-tilt steering column upper
SERVICE. FAILURE TO TAKE THE PROPER PRE- mounting bracket to the dash panel steering column
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- support bracket studs. Lower the column far enough
BAG DEPLOYMENT AND POSSIBLE PERSONAL to remove the upper steering column shroud.
INJURY. (9) Remove both the upper and lower shrouds from
the steering column.
(1) Disconnect the negative battery cable. (10) Disengage the steering column wire harness
(2) Remove the knee blocker from the instrument retainer from the tab on the top of the Sentry Key
panel. See Knee Blocker in Group 8E - Instrument Immobilizer Module (SKIM) mounting bracket (Fig.
Panel Systems for the procedures. 3).
(3) Insert the key in the ignition lock cylinder and (11) Unplug the wire harness connector from the
turn the ignition switch to the On position. SKIM receptacle.
(4) Insert a small screwdriver or pin punch (12) The SKIM mounting bracket features a clip
through the access hole in the lower steering column formation that secures the SKIM to the inboard
shroud and depress the ignition lock cylinder retain- lower flange of the steering column jacket. Pull
ing tumbler (Fig. 2). downward on the connector end of the SKIM mount-
ing bracket to release this clip from the steering col-
umn jacket.
(13) Rotate the SKIM and its mounting bracket
downwards and then to the side away from the steer-
ing column to slide the SKIM antenna ring from
around the ignition switch lock cylinder housing.

Fig. 2 Steering Column Shrouds Remove/Install

1 – LOWER SHROUD
2 – ACCESS HOLE
3 – STEERING WHEEL
4 – PIN PUNCH
5 – SCREWS (3)

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 XJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5
REMOVAL AND INSTALLATION (Continued)

Fig. 3 Sentry Key Immobilizer Module Remove/Install

1 – UPPER SHROUD 5 – IGNITION LOCK CYLINDER
2 – STEERING COLUMN 6 – SCREW
3 – WIRE HARNESS CONNECTOR 7 – LOWER SHROUD
4 – SENTRY KEY IMMOBILIZER MODULE 8 – STEERING WHEEL

(14) Remove the SKIM from the vehicle. (16) If the SKIM is replaced with a new unit, a
(15) Reverse the removal procedures to install. DRB scan tool and the proper Diagnostic Procedures
Tighten the non-tilt steering column mounting nuts manual MUST be used to initialize the new SKIM
to 22 N·m (200 in. lbs.) and the steering column and to program at least two Sentry Key
shroud mounting screws to 2 N·m (18 in. lbs.). transponders.

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 XJ POWER SEAT SYSTEMS 8R - 1

POWER SEAT SYSTEMS

TABLE OF CONTENTS

page page

GENERAL INFORMATION DIAGNOSIS AND TESTING

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 POWER SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . 2
POWER SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . 1 CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION POWER SEAT ADJUSTER AND MOTORS . . . . . . 2
POWER SEAT SWITCH. . . . . . . . . . . . . . . . . . . . . 1 POWER SEAT SWITCH. . . . . . . . . . . . . . . . . . . . . 2
POWER SEAT ADJUSTER AND MOTORS . . . . . . 1 REMOVAL AND INSTALLATION
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . 2 POWER SEAT SWITCH. . . . . . . . . . . . . . . . . . . . . 3
POWER SEAT ADJUSTER AND MOTORS . . . . . . 3

GENERAL INFORMATION tem. Refer to the owner’s manual in the vehicle glove
box for more information on the features, use and
INTRODUCTION operation of the power seat system.
Six-way power seats are an available factory-in-
stalled option for Left-Hand Drive (LHD) versions of DESCRIPTION AND OPERATION
this model. Refer to 8W-63 - Power Seat in Group 8W
- Wiring Diagrams for complete circuit descriptions
POWER SEAT SWITCH
and diagrams.
The power seat can be adjusted in six different
NOTE: This group covers both Left-Hand Drive ways using the power seat switch. The switch is
(LHD) and Right-Hand Drive (RHD) versions of this located on the lower outboard side of the seat cushion
model. Whenever required and feasible, the RHD on the seat cushion side shield. Refer to the owner’s
versions of affected vehicle components have been manual for more information on the power seat
constructed as mirror-image of the LHD versions. switch functions and the seat adjusting procedures.
While most of the illustrations used in this group The individual switches in the power seat switch
represent only the LHD version, the diagnostic and unit cannot be repaired. If one switch is damaged or
service procedures outlined can generally be faulty, the entire power seat switch unit must be
applied to either version. Exceptions to this rule replaced.
have been clearly identified as LHD or RHD, if a
special illustration or procedure is required. POWER SEAT ADJUSTER AND MOTORS
There are three reversible motors that operate the
power seat adjuster. The motors are connected to
POWER SEAT SYSTEM worm-drive gearboxes that move the seat adjuster
The power seat system option allows the front through a combination of screw-type drive units.
seating positions to be electrically adjusted for opti- The front and rear of a seat are operated by differ-
mum control and comfort using the power seat ent motors. They can be raised or lowered indepen-
switches located on the outboard seat cushion side dently of each other. When the center seat switch is
shield. The power seat system allows the seating pushed to the Up or Down position, both the front
position to be adjusted forward, rearward, front up, and rear motors operate in unison, moving the entire
front down, rear up, or rear down. The power seat seat up or down. The forward-rearward motor is
system receives battery current through a fuse in the operated by pushing the center seat switch to the
Power Distribution Center and a circuit breaker in Forward or Rearward position.
the junction block, regardless of the ignition switch When a switch is actuated, a battery feed and a
position. ground path are applied through the switch contacts
The power seat system includes the power seat to the motor(s). The motor(s) and drives operate to
adjuster and motors unit, the power seat switch, and move the seat in the selected direction until the
the circuit breaker. Following are general descrip- switch is released, or until the travel limit of the
tions of the major components in the power seat sys- power seat adjuster is reached. When the switch is

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 8R - 2 POWER SEAT SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
moved in the opposite direction, the battery feed and from the Power Distribution Center (PDC) as
ground path to the motor(s) are reversed through the required.
switch contacts. This causes the motor to run in the
opposite direction. POWER SEAT ADJUSTER AND MOTORS
Each motor contains a self-resetting circuit breaker For circuit descriptions and diagrams, refer to
to protect it from overload. Consecutive or frequent 8W-63 - Power Seat in Group 8W - Wiring Diagrams.
resetting of the circuit breakers must not be allowed Operate the power seat switch to move all three
to continue, or the motors may be damaged. Make seat motors in each direction. The seat should move
the necessary repairs. in each of the selected directions. If the power seat
The power seat adjuster and motors cannot be adjuster fails to operate in only one direction, move
repaired, and are serviced only as a complete unit. If the adjuster a short distance in the opposite direction
any component in this unit is faulty or damaged, the and test again to be certain that the adjuster is not
entire power seat adjuster and motors assembly must at its travel limit. If the power seat adjuster still
be replaced. fails to operate in only one direction, see Power Seat
Switch in the Diagnosis and Testing section of this
CIRCUIT BREAKER group. If the power seat adjuster fails to operate in
An automatic resetting circuit breaker in the junc- more than one direction, proceed as follows:
tion block is used to protect the power seat system (1) Test the circuit breaker in the junction block as
circuit. The circuit breaker can protect the system described in this group. If OK, go to Step 2. If not
from a short circuit, or from an overload condition OK, replace the faulty circuit breaker.
caused by an obstructed or stuck seat adjuster. (2) Remove the power seat switch from the seat.
The circuit breaker cannot be repaired and, if Check for battery voltage at the fused B(+) circuit
faulty or damaged, it must be replaced. cavity of the power seat switch wire harness connec-
tor. If OK, go to Step 3. If not OK, repair the open
circuit to the junction block as required.
DIAGNOSIS AND TESTING (3) Check for continuity between the ground cir-
cuit cavity of the power seat switch wire harness con-
POWER SEAT SYSTEM nector and a good ground. There should be
Before any testing of the power seat system is continuity. If OK, go to Step 4. If not OK, repair the
attempted, the battery should be fully-charged and open circuit to ground as required.
all wire harness connections and pins cleaned and (4) Test the power seat switch as described in this
tightened to ensure proper continuity and grounds. group. If the switch tests OK, check the wire harness
For circuit descriptions and diagrams, refer to 8W-63 for the inoperative power seat motor(s) between the
- Power Seat in Group 8W - Wiring Diagrams. power seat switch and the motor for shorts or opens.
With the dome lamp on, apply the power seat If the circuits check OK, replace the faulty power
switch in the direction of the failure. If the dome seat adjuster and motors assembly. If the circuits are
lamp dims, the seat may be jamming. Check under not OK, repair the wire harness as required.
and behind the seat for binding or obstructions. If
the dome lamp does not dim, proceed with testing of POWER SEAT SWITCH
the individual components and circuits. For circuit descriptions and diagrams, refer to
8W-63 - Power Seat in Group 8W - Wiring Diagrams.
CIRCUIT BREAKER (1) Disconnect and isolate the battery negative
For circuit descriptions and diagrams, refer to cable.
8W-63 - Power Seat in Group 8W - Wiring Diagrams. (2) Remove the power seat switch from the power
(1) Locate the correct circuit breaker in the junc- seat.
tion block. Pull out the circuit breaker slightly, but (3) Use an ohmmeter to test the continuity of the
be certain that the circuit breaker terminals still con- power seat switches in each position. See the Power
tact the terminals in the junction block cavities. Seat Switch Continuity chart (Fig. 1). If OK, see the
(2) Connect the negative lead of a 12-volt DC volt- diagnosis for the Power Seat Adjuster and Motors in
meter to a good ground. this group. If not OK, replace the faulty power seat
(3) With the voltmeter positive lead, check both switch module.
terminals of the circuit breaker for battery voltage.
If only one terminal has battery voltage, the circuit
breaker is faulty and must be replaced. If neither ter-
minal has battery voltage, repair the open circuit

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 XJ POWER SEAT SYSTEMS 8R - 3
DIAGNOSIS AND TESTING (Continued)

REMOVAL AND INSTALLATION

POWER SEAT SWITCH
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three screws that secure the seat
cushion side shield to the outboard seat cushion
frame.
(3) Pull the seat cushion side shield away from the
POWER SEAT SWITCH
seat cushion frame far enough to access the power
LEFT SEAT SWITCH seat switch wire harness connector.
SWITCH POSITION CONTINUITY BETWEEN (4) Unplug the wire harness connector from the
power seat switch.
Off B-E, B-J, B-K, B-L, (5) Remove the seat cushion side shield from the
B-M, B-N seat.
Vertical Up A-J, A-M, B-E, B-N (6) Remove the two screws that secure the power
seat switch to the inside of the seat cushion side
Vertical Down A-E, A-N, B-J, B-M shield (Fig. 2).
Horizontal Forward A-L, B-K
Horizontal Rearward A-K, B-L
Front Tilt Up A-M, B-N
Front Tilt Down A-N, B-M
Rear Tilt Up A-J, B-E
Rear Tilt Down A-E, B-J

RIGHT SEAT SWITCH

SWITCH POSITION CONTINUITY BETWEEN
Off A-E, A-J, A-K, A-L,
A-M, A-N
Vertical Up A-J, A-N, B-E, B-M
Vertical Down A-E, A-M, B-J, B-N Fig. 2 Power Seat Switch Remove/Install
1 – SEAT SIDE SHIELD
Horizontal Forward A-L, B-K 2 – POWER SEAT SWITCH
3 – SCREWS
Horizontal Rearward A-K, B-L
Front Tilt Up A-N, B-M
(7) Remove the power seat switch from the seat
Front Tilt Down A-M, B-N cushion side shield.
Rear Tilt Up A-J, B-E (8) Reverse the removal procedures to install.
Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
Rear Tilt Down A-E, B-J
POWER SEAT ADJUSTER AND MOTORS
(1) Move the seat to its fully raised and fully for-
ward position, if possible.
(2) Disconnect and isolate the battery negative
Fig. 1 Power Seat Switch Continuity cable.
(3) For the driver side power seaat only, unplug
the seat belt switch wire harness connector from the
driver side seat belt buckle half on the inboard side
of the seat (Fig. 3).
(4) Unplug the power seat wire harness connector
from the body wire harness connector.

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 8R - 4 POWER SEAT SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
(7) Remove the nut that secures the inboard rear
of the seat adjuster frame to the stud on the floor
panel.
(8) Remove the seat and the power seat adjuster
and motors assembly from the vehicle as a unit.
(9) Remove the four nuts that secure the power
seat adjuster and motors assembly to the seat cush-
ion frame (Fig. 5).

Fig. 3 Driver Seat Belt Switch Connector

1 – DRIVER SIDE FRONT SEAT
2 – SEAT BELT SWITCH CONNECTOR
3 – BODY WIRE HARNESS CONNECTOR

(5) Remove the two screws that secure the front of

the seat adjuster frame to the floor panel seat
mounting reinforcement (Fig. 4).

Fig. 5 Power Seat Adjuster and Motors Remove/

Install
1 – POWER SEAT ADJUSTER AND MOTORS
2 – SEAT CUSHION FRAME
3 – SEAT CUSHION FRAME

(10) Remove the power seat switch from the out-

board side of the seat. Refer to Power Seat Switch
in the index of this service manual for the location of
the proper power seat switch removal and installa-
tion procedures.
(11) Disengage the power seat switch wire harness
and connector from the seat cushion frame.
(12) Remove the power seat adjuster and motors
assembly from the seat cushion frame.
Fig. 4 Power Seat Remove/Install (13) Reverse the removal procedures to install.
1 – NUT Tighten the seat mounting hardware as follows:
2 – DRIVER SIDE FRONT SEAT • Seat adjuster to seat cushion frame nuts - 25
3 – SCREW N·m (18 ft. lbs.)
4 – STUD • Seat adjuster to floor panel screws - 27 N·m (20
5 – SCREW
ft. lbs.)
• Seat adjuster to floor panel nut - 40 N·m (30 ft.
(6) Remove the screw that secures the outboard lbs.).
rear of the seat adjuster frame to the floor panel.

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 XJ POWER WINDOW SYSTEMS 8S - 1

POWER WINDOW SYSTEMS

TABLE OF CONTENTS

page page

GENERAL INFORMATION CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . 3

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 3
POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . . 1 POWER WINDOW SWITCH . . . . . . . . . . . . . . . . . 4
DESCRIPTION AND OPERATION POWER WINDOW MOTOR. . . . . . . . . . . . . . . . . . 4
POWER WINDOW SWITCH . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER WINDOW MOTOR. . . . . . . . . . . . . . . . . . 2 POWER WINDOW SWITCH . . . . . . . . . . . . . . . . . 5
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . 2 POWER WINDOW MOTOR. . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION the junction block, only when the ignition switch is
in the On or Accessory positions.
INTRODUCTION The power window system includes the power win-
Power windows are available as factory-installed dow switches on each door trim panel, the circuit
optional equipment on this model. The power lock breaker in the junction block, and the power window
system and power mirror system are included on motors inside each door. This group covers diagnosis
vehicles equipped with the power window option. and service of only the electrical components in the
Refer to 8W-60 - Power Windows in Group 8W - Wir- power window system. For service of mechanical
ing Diagrams for complete circuit descriptions and components, such as the regulator, lift plate, window
diagrams. tracks, or glass refer to Group 23 - Body.
Following are general descriptions of the major
NOTE: This group covers both Left-Hand Drive components in the power window system. Refer to
(LHD) and Right-Hand Drive (RHD) versions of this the owner’s manual in the vehicle glove box for more
model. Whenever required and feasible, the RHD information on the features, use and operation of the
versions of affected vehicle components have been power window system.
constructed as mirror-image of the LHD versions.
While most of the illustrations used in this group
represent only the LHD version, the diagnostic and
DESCRIPTION AND OPERATION
service procedures outlined can generally be
applied to either version. Exceptions to this rule POWER WINDOW SWITCH
have been clearly identified as LHD or RHD, if a The individual power windows are controlled by a
special illustration or procedure is required. two-way momentary switch mounted on the trim
panel of the passenger side front door trim panel
and, on four-door models, on each of the rear door
POWER WINDOW SYSTEM trim panels. Two-way momentary master switches on
The power window system allows all of the door the driver side front door trim panel control all of the
windows to be raised and lowered electrically by power windows in the vehicle. The driver side front
actuating a switch on the trim panel of each respec- door trim panel also has a two-position power win-
tive door. Additionally, a set of master switches on dow lockout switch.
the driver side front door trim panel allows the The front door power window switches and the
driver to raise or lower each of the passenger door power window lockout switch are integral to the
windows. A power window lockout switch on the Driver Door Module (DDM) or Passenger Door Mod-
driver side front door trim panel can prevent the pas- ule (PDM), respectively. The rear door power window
senger door windows from being operated, except switches are stand-alone units.
from the master switches. The power window system Each power window switch controls its power win-
receives battery current through a circuit breaker in dow motor by switching battery current and ground

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 8S - 2 POWER WINDOW SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
between the terminals of the power window motor. In addition, each power window motor is equipped
The passenger side front door and, on four-door mod- with an integral self-resetting circuit breaker to pro-
els, both rear door power window switches receive tect the motor from overloads. The power window
their battery feed through the power window lockout motor and gearbox assembly cannot be repaired and,
switch or through the master switches in the DDM. if faulty or damaged, the entire power window regu-
Also, each of the individual power window switches lator assembly must be replaced.
receives its ground through the DDM. When the lock-
out switch is placed in the Lock position, the individ- CIRCUIT BREAKER
ual power window switches become inoperative An automatic resetting circuit breaker in the junc-
because they have no battery current available to tion block is used to protect the power window sys-
them. However, the master switches are unaffected tem circuit. The circuit breaker can protect the
by the lockout switch position. system from a short circuit, or from an overload con-
Each power window switch, except the lockout dition caused by an obstructed or stuck window glass
switch, is illuminated by a Light-Emitting Diode or regulator.
(LED) when the ignition switch is turned to the On The circuit breaker cannot be repaired and, if
position. However, when the power window lockout faulty, it must be replaced.
switch is placed in the Lock position, the LED for the
locked-out passenger side front and, on four-door
models, the rear passenger door power window DIAGNOSIS AND TESTING
switches is turned off.
The front door power window switches and their POWER WINDOW SYSTEM
lamps cannot be repaired and, if faulty or damaged, For circuit descriptions and diagrams, refer to
the entire door module must be replaced. The rear 8W-60 - Power Windows in Group 8W - Wiring Dia-
door power window switches and their lamps cannot grams.
be repaired but, if faulty or damaged, only the
affected switch unit must be replaced. ALL WINDOWS INOPERATIVE
(1) Check the circuit breaker in the junction block,
DOOR MODULE as described in this group. If OK, go to Step 2. If not
A Driver Door Module (DDM) and a Passenger OK, replace the faulty circuit breaker.
Door Module (PDM) are used on all models equipped (2) Disconnect and isolate the battery negative
with power locks and power windows. Each door cable. Remove the driver side front door trim panel
module houses both the front door power lock and and unplug the Driver Door Module (DDM) wire har-
power window switches. In addition to the switches ness connectors from the DDM. Check for continuity
for its own door, the DDM houses individual switches between the ground circuit cavity of the 8-way DDM
for each passenger door power window, a power win- wire harness connector and a good ground. If OK, go
dow lockout switch, the power mirror switch, and cir- to Step 3. If not OK, repair the circuit to ground as
cuitry to support the one-touch down feature of the required.
driver side front door power window. The PDM also (3) Connect the battery negative cable. Turn the
houses the control circuitry and the power lock and ignition switch to the On position. Check for battery
unlock relays for the power lock system. voltage at the master switch power feed (run/acc) cir-
The DDM and the PDM are mounted to their cuit cavity of the 12-way DDM wire harness connec-
respective front door trim panels. The DDM and tor. If OK, see the diagnosis for the Door Module in
PDM are serviced individually and cannot be this group. If not OK, repair the open circuit to the
repaired. If the DDM or PDM, or any of the switches circuit breaker in the junction block as required.
and circuitry that they contain are faulty or dam-
aged, the complete DDM or PDM unit must be ONE WINDOW INOPERATIVE
replaced. The window glass must be free to slide up and
down for the power window motor to function prop-
POWER WINDOW MOTOR erly. If the glass is not free to move up and down, the
A permanent magnet reversible motor moves the motor will overload and trip the integral circuit
window regulator through an integral gearbox mech- breaker. To determine if the glass is free, disconnect
anism. A positive and negative battery connection to the regulator plate from the glass. Then slide the
the two motor terminals will cause the motor to window up and down by hand.
rotate in one direction. Reversing the current There is an alternate method to check if the glass
through these same two connections will cause the is free. Position the glass between the up and down
motor to rotate in the opposite direction. stops. Then, shake the glass in the door. Check that

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 XJ POWER WINDOW SYSTEMS 8S - 3
DIAGNOSIS AND TESTING (Continued)
the glass can be moved slightly from side to side, the passenger side front door power window switch
front to rear, and up and down. Then check that the and, on four-door models, the rear door power win-
glass is not bound tight in the tracks. If the glass is dow switches get their battery current through the
free, proceed with the diagnosis that follows. If the power window lockout switch in the Driver Door
glass is not free, refer to Group 23 - Body for the Module (DDM). In addition, each individual power
door window glass and hardware service and adjust- window switch gets its ground through the master
ment procedures. switch in the DDM.
(1) Check the power window switch continuity as The one-touch down feature circuitry within the
described in the diagnosis for the Door Module (front DDM will not operate the power window motor if the
doors) or Power Window Switch (rear doors) in this door glass, window regulator, or gearbox mechanism
group. If OK and the driver side front window is are stuck, obstructed, or binding. If the driver side
inoperative, see the Power Window Motor diagnosis front door power window operates as designed, but
in this group. If OK and the inoperative window is the one-touch down feature is inoperative, replace
other than the driver side front, go to Step 2. If not the faulty DDM.
OK, replace the faulty door module or switch. If the problem being diagnosed is an inoperative
(2) Refer to the circuit diagrams in 8W-60 - Power power window switch illumination lamp, but the
Windows in Group 8W - Wiring Diagrams. Check the power window switch operates as designed, replace
continuity in each circuit between the inoperative the faulty door module. For circuit descriptions and
Passenger Door Module (PDM) or power window diagrams, refer to 8W-60 - Power Windows in Group
switch wire harness connector cavities and the corre- 8W - Wiring Diagrams.
sponding Driver Door Module (DDM) wire harness (1) Disconnect and isolate the battery negative
connector cavities. If OK, see the diagnosis for the cable. Remove the front door trim panel and unplug
Power Window Motor in this group. If not OK, repair the door module wire harness connectors from the
the open circuit(s) as required. door module.
(2) Check the door module power window switch
NOTE: All individual power window switches and/or power window lockout switch continuity in
receive their battery and ground feeds through the each position, as shown in the proper chart (Fig. 1)
Driver Door Module (DDM) and wire harness con- or (Fig. 2). If OK, see the Power Window Motor diag-
nectors. nosis in this group. If not OK, replace the faulty door
module.

CIRCUIT BREAKER
For circuit descriptions and diagrams, refer to
8W-60 - Power Windows in Group 8W - Wiring Dia-
grams.
(1) Locate the circuit breaker in the junction block.
Pull out the circuit breaker slightly, but be certain
that the circuit breaker terminals still contact the
terminals in the junction block cavities.
SWITCH POSITION CONTINUITY BETWEEN
(2) Connect the negative lead of a 12-volt DC volt-
OFF (NORMAL) 1&8,2&8,3&8,4&8,5&8,6&8,10&8,12&8
meter to a good ground.
RIGHT REAR DOWN 1&9,2&8
(3) With the voltmeter positive lead, check both
terminals of the circuit breaker for battery voltage. RIGHT REAR UP 2&9,1&8

If only one terminal has battery voltage, the circuit RIGHT FRONT UP 3&9,6&8

breaker is faulty and must be replaced. If neither ter- LEFT REAR UP 4&9,10&8

minal has battery voltage, repair the open circuit LEFT FRONT UP 5&9,12&8

from the Power Distribution Center (PDC) as RIGHT FRONT DOWN 6&9,3&8

required. If the circuit breaker checks OK, but no LEFT REAR DOWN 10&9,4&8

power windows operate, see Power Window System LEFT FRONT DOWN 12&9,5&8

in the Diagnosis and Testing section of this group.

DOOR MODULE SWITCH POSITION CONTINUITY BETWEEN

The Driver Door Module (DDM) contains the mas- LOCKOUT OFF (UP) C1 PIN 8 & C2 PIN 9

ter switches and the lockout switch in the power win- LOCKOUT ON (DOWN) NO CONTINUITY BETWEEN C1 PIN 8 & C2 PIN 9

dow system. The DDM also contains an integrated

circuit to support the one-touch down feature of the
driver side front door power window. Remember that Fig. 1 DDM Power Window Switch Continuity

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 8S - 4 POWER WINDOW SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)

POWER WINDOW MOTOR

For circuit descriptions and diagrams, refer to
8W-60 - Power Windows in Group 8W - Wiring Dia-
grams. Before you proceed with this diagnosis, con-
firm proper switch operation. See the Door Module
and/or Power Window Switch diagnosis in this group.
POWER WINDOWS
(1) Disconnect and isolate the battery negative
OFF (NORMAL) C2 PIN 2 & C2 PIN 3
cable. Remove the trim panel from the door with the
C2 PIN 4 & C2 PIN 9 inoperative power window.
UP C2 PIN 2 & C2 PIN 3 (2) Unplug the power window motor wire harness
C2 PIN 9 & C2 PIN 10 connector. Apply 12 volts across the motor terminals
DOWN C2 PIN 2 & C2 PIN 10 to check its operation in one direction. Reverse the
C2 PIN 4 & C2 PIN 9 connections across the motor terminals to check the
operation in the other direction. Remember, if the
window is in the full up or full down position, the
Fig. 2 PDM Power Window Switch Continuity motor will not operate in that direction by design. If
POWER WINDOW SWITCH OK, repair the circuits from the power window motor
The diagnosis found here applies only to the rear to the door module or the power window switch as
door power window switches. For diagnosis of the required. If not OK, replace the faulty motor.
front door power window switches, see Door Module (3) If the motor operates in both directions, check
in this group. If the problem being diagnosed is an the operation of the window glass and lift mechanism
inoperative power window switch illumination lamp, through its complete up and down travel. There
but the power window switch operates as designed, should be no binding or sticking of the window glass
replace the faulty switch. For circuit descriptions and or lift mechanism through the entire travel range. If
diagrams, refer to 8W-60 - Power Windows in Group not OK, refer to Group 23 - Body to check the win-
8W - Wiring Diagrams. dow glass, tracks, and regulator for sticking, binding,
(1) Disconnect and isolate the battery negative or improper adjustment.
cable.
(2) Remove the power window switch from the REMOVAL AND INSTALLATION
rear door trim panel.
(3) Check the power window switch continuity in DOOR MODULE
each position as shown in the Rear Door Power Win-
(1) Disconnect and isolate the battery negative
dow Switch Continuity chart (Fig. 3). If OK, see the
cable.
Power Window Motor diagnosis in this group. If not
(2) Remove the screws that secure the front door
OK, replace the faulty switch.
trim panel to the inner door panel (Fig. 4).
(3) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the front door trim panel
away from the door around the perimeter to release
the trim panel retainers.

NOTE: To aid in the removal of the trim panel, start

at the bottom of the panel.

(4) Lift the front door trim panel upwards and

SWITCH POSITION CONTINUITY BETWEEN
away from the inner door panel far enough to disen-
gage the top of the panel from the inner belt weath-
OFF (NORMAL) 1&4
erstrip.
2&5
(5) Pull the front door trim panel away from the
UP 1&6 inner door panel far enough to access the inside door
2&5 latch release and lock linkage rods near the back of
DOWN 1&4 the inside door remote controls.
5&6 (6) Unsnap the plastic retainer clips from the
inside door remote control ends of the latch release
and lock linkage rods, and remove the rod ends from
Fig. 3 Rear Door Power Window Switch Continuity the inside door remote controls.

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 XJ POWER WINDOW SYSTEMS 8S - 5
REMOVAL AND INSTALLATION (Continued)
(2) Remove the screws that secure the door trim
panel to the inner door panel (Fig. 6).

Fig. 4 Front Door Trim Panel Remove/Install

1 – U-NUT
2 – DOOR
3 – TRIM PANEL Fig. 6 Rear Door Trim Panel Remove/Install
4 – PUSH-IN FASTENER 1 – U-NUT
2 – REAR DOOR
3 – TRIM PANEL
(7) Unplug the wire harness connectors from the 4 – PUSH-IN FASTENER
door module.
(8) Remove the trim panel from the front door.
(9) Remove the three screws that secure the door (3) Using a trim stick or another suitable wide
module to the front door trim panel (Fig. 5). flat-bladed tool, gently pry the rear door trim panel
away from the door around the perimeter to release
the trim panel retainers.

NOTE: To aid in the removal of the trim panel, start

at the bottom of the panel.

(4) Lift the rear door trim panel upwards and

away from the inner door panel far enough to disen-
gage the top of the panel from the inner belt weath-
erstrip.
(5) Pull the rear door trim panel away from the
inner door panel far enough to access the inside door
latch release and lock linkage rods near the back of
Fig. 5 Door Module Remove/Install the inside door remote controls.
1 – INSIDE DOOR LATCH AND LOCK REMOTE CONTROLS (6) Unsnap the plastic retainer clips from the
2 – CONNECTOR 1 RECEPTACLE inside door remote control ends of the latch release
3 – DOOR MODULE and lock linkage rods, and remove the rod ends from
4 – CONNECTOR 2 RECEPTACLE the inside door remote controls.
5 – SCREWS (7) Unplug the wire harness connector from the
6 – DOOR TRIM PANEL rear door power window switch.
(8) Remove the trim panel from the rear door.
(10) Remove the door module from the front door (9) With a small thin-bladed screwdriver, gently
trim panel. pry the snap clips at the sides of the power window
(11) Reverse the removal procedures to install. switch receptacle on the back of the rear door trim
Tighten the mounting screws to 2.2 N·m (20 in. lbs.). panel and pull the switch out of the receptacle (Fig.
7).
POWER WINDOW SWITCH (10) Reverse the removal procedures to install. Be
(1) Disconnect and isolate the battery negative certain that both of the switch snap retainers in the
cable. receptacle on the back of the trim panel are fully
engaged.

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 8S - 6 POWER WINDOW SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)
ulator unit. If the front door power window motor or
mechanism is faulty or damaged, the entire power
window regulator unit must be replaced. Refer to
Group 23 - Body for the front door window regulator
service procedures.

REAR DOOR
The rear door power window motor and mechanism
is integral to the rear door power window regulator
unit. If the rear door power window motor or mech-
anism is faulty or damaged, the entire power window
regulator unit must be replaced. Refer to Group 23 -
Body for the rear door window regulator service
procedures.

Fig. 7 Rear Door Power Window Switch Remove/

Install
1 – REAR DOOR POWER WINDOW SWITCH
2 – TRIM PANEL
3 – SWITCH RECEPTACLE

POWER WINDOW MOTOR

FRONT DOOR
The front door power window motor and mecha-
nism is integral to the front door power window reg-

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 XJ POWER MIRROR SYSTEMS 8T - 1

POWER MIRROR SYSTEMS

TABLE OF CONTENTS

page page

GENERAL INFORMATION DIAGNOSIS AND TESTING

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 POWER MIRROR SYSTEM. . . . . . . . . . . . . . . . . . 2
POWER MIRROR SYSTEM. . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
DESCRIPTION AND OPERATION POWER MIRROR SWITCH . . . . . . . . . . . . . . . . . . 3
POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . 1 DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 3
POWER MIRROR SWITCH . . . . . . . . . . . . . . . . . . 1 POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . 4
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION Following are general descriptions of the major

components in the power mirror system. Refer to the
INTRODUCTION owner’s manual in the vehicle glove box for more
Power operated or power operated and heated out- information on the features, use and operation of the
side rear view mirrors are available factory-installed power mirror system.
options on this model. Refer to 8W-62 - Power Mir-
rors in Group 8W - Wiring Diagrams for complete cir- DESCRIPTION AND OPERATION
cuit descriptions and diagrams.

NOTE: This group covers both Left-Hand Drive POWER MIRROR

(LHD) and Right-Hand Drive (RHD) versions of this Each power mirror head contains two electric
model. Whenever required and feasible, the RHD motors, two drive mechanisms, and the mirror glass.
versions of affected vehicle components have been One motor and drive controls mirror up-and-down
constructed as mirror-image of the LHD versions. movement, and the other controls right-and-left
While most of the illustrations used in this group movement.
represent only the LHD version, the diagnostic and The power mirrors in vehicles equipped with the
service procedures outlined can generally be available heated mirror option also include an elec-
applied to either version. Exceptions to this rule tric heating grid located behind the mirror glass.
have been clearly identified as LHD or RHD, if a This heating grid is energized by the rear window
special illustration or procedure is required. defogger relay whenever the rear window defogger
system is turned on. Refer to Group 8N - Electrically
Heated Systems for more information on the opera-
POWER MIRROR SYSTEM tion of the rear window defogger system.
The power operated or power operated and heated The power mirror assembly cannot be repaired.
outside rear view mirrors allow the driver to adjust Only the mirror glass is serviced separately. If any
both outside mirrors electrically from the driver seat other component of the power mirror unit is faulty or
position by operating a switch on the driver side damaged, the entire assembly must be replaced.
front door trim panel. The power mirrors receive bat-
tery current through a fuse in the junction block, and POWER MIRROR SWITCH
will only operate when the ignition switch is in the Both the right and left power outside mirrors are
On or Accessory positions. controlled by a single multi-function switch unit
The heated mirror option includes an electric heat- located on the driver side front door trim panel. Two
ing grid behind the mirror glass in each outside mir- versions of this switch are offered. Models without
ror, which can clear the mirror glass of ice, snow, or power windows or power locks have a stand-alone
fog. The heating grid receives fused battery current switch mounted in the driver side front door trim
through the rear window defogger relay only when panel. Models equipped with power windows and
the rear window defogger system is turned on. Refer power locks have a power mirror switch that is inte-
to Group 8N - Electrically Heated Systems for more gral to the Driver Door Module (DDM).
information on the rear window defogger system. Both versions of the switch are operated in the
same manner. A three position rocker-type mirror

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 8T - 2 POWER MIRROR SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
selector switch is moved right (right mirror control), (4) Turn the ignition switch to the Off position.
left (left mirror control), or center to turn the power Disconnect and isolate the battery negative cable.
mirrors off. Then one of four directional control but- Remove the driver side front door trim panel and
tons is depressed to control movement of the selected unplug the DDM wire harness connectors. Connect
mirror up, down, right, or left. The directional control the battery negative cable. Turn the ignition switch
buttons of the DDM-mounted switch are illuminated to the On position. Check for battery voltage at the
when the ignition switch is in the On or Accessory fused ignition switch output circuit cavity of the
positions. The stand-alone switch is not illuminated. 12-way DDM wire harness connector. If OK, replace
The stand-alone power mirror switch cannot be the faulty DDM. If not OK, repair the open circuit to
repaired and, if faulty or damaged, it must be the power window circuit breaker in the junction
replaced as a complete unit. If the DDM power mir- block as required.
ror switch is faulty or damaged, the entire DDM unit (5) If the problem being diagnosed is an inopera-
must be replaced. tive power mirror electric heating grid, proceed as
follows. If not, go to Step 8. Disconnect and isolate
DOOR MODULE the battery negative cable. Remove the front door
A Driver Door Module (DDM) and a Passenger trim panel on the side of the vehicle with the inoper-
Door Module (PDM) are used on all models equipped ative mirror heating grid. Unplug the wire harness
with power locks and power windows. Each door connector at the mirror. Check for continuity between
module houses both the front door power lock and the ground circuit cavity in the body half of the
power window switches. In addition to the switches power mirror wire harness connector and a good
for its own door, the DDM houses individual switches ground. If OK, go to Step 6. If not OK, repair the
for each passenger door power window, a power win- open circuit to ground as required.
dow lockout switch, the power mirror switch, and cir- (6) Connect the battery negative cable. Turn the
cuitry to support the one-touch down feature of the ignition switch to the On position. Turn on the rear
driver side front door power window. The PDM also window defogger system. Check for battery voltage at
houses the control circuitry and the power lock and the rear window defogger relay output circuit cavity
unlock relays for the power lock system. in the body half of the power mirror wire harness
The DDM and the PDM are mounted to their connector. If OK, go to Step 7. If not OK, repair the
respective front door trim panels. The DDM and open circuit to the rear window defogger relay as
PDM are serviced individually and cannot be required.
repaired. If the DDM or PDM, or any of the switches (7) Check for continuity between the ground cir-
and circuitry that they contain are faulty or dam- cuit and the rear window defogger relay output cir-
aged, the complete DDM or PDM unit must be cuit cavities in the mirror half of the power mirror
replaced. wire harness connector. There should be continuity. If
not OK, replace the faulty power mirror. If OK, check
the resistance through the electric heating grid cir-
DIAGNOSIS AND TESTING cuit. Correct resistance through the electric heating
grid should be from 10 to 16 ohms when measured at
POWER MIRROR SYSTEM an ambient temperature of 21° C (70° F). If not OK,
For circuit descriptions and diagrams, refer to replace the faulty power mirror.
8W-62 - Power Mirrors in Group 8W - Wiring Dia- (8) Disconnect and isolate the battery negative
grams. cable. Remove the stand-alone power mirror switch
(1) Check the fuse in the junction block. If OK, go from the driver side front door trim panel or, with a
to Step 2. If not OK, repair the shorted circuit or DDM-mounted switch, remove the driver side front
component as required and replace the faulty fuse. door trim panel. Unplug the wire harness connector
(2) Turn the ignition switch to the On position. from the stand-alone switch or the 8-way wire har-
Check for battery voltage at the fuse in the junction ness connector from the DDM. Connect the battery
block. If OK, go to Step 3. If not OK, repair the open negative cable. Turn the ignition switch to the On
circuit to the ignition switch as required. position. Check for battery voltage at the fused igni-
(3) If the problem being diagnosed is inoperative tion switch output circuit cavity of the stand-alone
illumination of the power mirror switch directional switch wire harness connector or the 8-way DDM
buttons for the Driver Door Module (DDM)-type wire harness connector. If OK, go to Step 9. If not
switch, proceed as follows. If not, go to Step 5. Check OK, repair the open circuit to the junction block as
the power window circuit breaker in the junction required.
block. If OK, go to Step 4. If not OK, replace the (9) Turn the ignition switch to the Off position.
faulty circuit breaker. Disconnect and isolate the battery negative cable.

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 XJ POWER MIRROR SYSTEMS 8T - 3
DIAGNOSIS AND TESTING (Continued)
Check for continuity between the ground circuit cav-
ity of the stand-alone switch wire harness connector
or the 8-way DDM wire harness connector and a
good ground. There should be continuity. If OK, go to
Step 10. If not OK, repair the circuit to ground as
required.
(10) Check the stand-alone power mirror switch or
DDM-mounted power mirror switch continuity as
shown in (Fig. 1) or (Fig. 2). If OK, go to Step 11. If SELECT RIGHT MIRROR
not OK, replace the faulty stand-alone power mirror SWITCH POSITION CONTINUITY BETWEEN
switch or the faulty DDM.
UP 7 & 3, 2 & 5
DOWN 2 & 3, 7 & 5
RIGHT 4 & 3, 2 & 5
LEFT 2 & 3, 6 & 5

SELECT LEFT MIRROR

SWITCH POSITION CONTINUITY BETWEEN
SELECT RIGHT MIRROR UP 1 & 3, 2 & 5
SWITCH POSITION CONTINUITY BETWEEN DOWN 2 & 3, 1 & 5
OFF 1 & 3, 1 & 4, 1 & 5, 1 & 6 RIGHT 6 & 3, 2 & 5
UP 2 & 4, 1 & 3, 1 & 5, 1 & 6 LEFT 2 & 3, 6 & 5
DOWN 2 & 5, 1 & 3, 1 & 4, 1 & 6
RIGHT 2 & 6, 1 & 3, 1 & 4, 1 & 5
LEFT 2 & 3, 1 & 4, 1 & 5, 1 & 6
Fig. 2 Driver Door Module Power Mirror Switch
SELECT LEFT MIRROR Continuity
SWITCH POSITION CONTINUITY BETWEEN which is integral to the Driver Door Module (DDM).
OFF 1 & 5, 1 & 6, 1 & 7, 1 & 8 See Door Module in this group for the DDM-type
UP 2 & 8, 1 & 5, 1 & 6, 1 & 7 power mirror switch service procedures.
(1) Disconnect and isolate the battery negative
DOWN 2 & 5, 1 & 6, 1 & 7, 1 & 8
cable.
RIGHT 2 & 6, 1 & 5, 1 & 7, 1 & 8
(2) Using a trim stick or another suitable wide
LEFT 2 & 7, 1 & 5, 1 & 6, 1 & 8 flat-bladed tool, gently pry around the perimeter
edge of the switch to release the snap clips that
secure the switch to the trim panel (Fig. 4).
Fig. 1 Stand-Alone Power Mirror Switch Continuity
(3) Pull the power mirror switch away from the
(11) Connect the battery negative cable. Use two trim panel far enough to access the wire harness con-
jumper wires, one connected to a 12-volt battery feed, nector.
and the other connected to a good body ground. See (4) Unplug the power mirror switch from the wire
the Power Mirror Test chart for the correct jumper harness connector.
wire connections at the mirror half of the power mir- (5) Reverse the removal procedures to install.
ror wire harness connector (Fig. 3). If the mirror
reactions are OK, repair the wire harness between DOOR MODULE
the mirror and the stand-alone power mirror switch (1) Disconnect and isolate the battery negative
or the DDM as required. If the mirror reactions are cable.
not OK, replace the faulty power outside mirror (2) Remove the screws that secure the front door
assembly. trim panel to the inner door panel (Fig. 5).
(3) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the front door trim panel
REMOVAL AND INSTALLATION
away from the door around the perimeter to release
the trim panel retainers.
POWER MIRROR SWITCH
This procedure covers removal of the stand-alone NOTE: To aid in the removal of the trim panel, start
type power mirror switch. Vehicles with power win- at the bottom of the panel.
dows and power locks have a power mirror switch

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 8T - 4 POWER MIRROR SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

POWER MIRROR TEST

12 VOLTS GROUND MIRROR
REACTION
PIN 1 PIN 4 UP
PIN 4 PIN 1 DOWN
PIN 2 PIN 3 LEFT Fig. 5 Front Door Trim Panel Remove/Install
PIN 3 PIN 2 RIGHT 1 – U-NUT
PIN 5 PIN 6 HEATER 2 – DOOR
3 – TRIM PANEL
4 – PUSH-IN FASTENER

gage the top of the panel from the inner belt weath-
erstrip.
(5) Pull the front door trim panel away from the
Fig. 3 Power Mirror Test inner door panel far enough to access the inside door
latch release and lock linkage rods near the back of
the inside door remote controls.
(6) Unsnap the plastic retainer clips from the
inside door remote control ends of the latch release
and lock linkage rods, and remove the rod ends from
the inside door remote controls.
(7) Unplug the wire harness connectors from the
door module.
(8) Remove the trim panel from the front door.
(9) Remove the three screws that secure the door
module to the front door trim panel (Fig. 6).
(10) Remove the door module from the front door
trim panel.
(11) Reverse the removal procedures to install.
Tighten the mounting screws to 2.2 N·m (20 in. lbs.).

POWER MIRROR
(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is so equipped, remove the man-
ual window regulator crank handle with a removal
Fig. 4 Stand-Alone Power Mirror Switch Remove/ tool (Fig. 7).
Install (3) Remove the screws that secure the front door
1 – STAND-ALONE POWER MIRROR SWITCH trim panel to the inner door panel (Fig. 8) or (Fig. 9).
2 – CONNECTOR
(4) Using a trim stick or another suitable wide
3 – DOOR TRIM PANEL
flat-bladed tool, gently pry the front door trim panel
away from the door around the perimeter to release
(4) Lift the front door trim panel upwards and the trim panel retainers.
away from the inner door panel far enough to disen-

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 XJ POWER MIRROR SYSTEMS 8T - 5
REMOVAL AND INSTALLATION (Continued)

Fig. 6 Door Module Remove/Install

1 – INSIDE DOOR LATCH AND LOCK REMOTE CONTROLS
2 – CONNECTOR 1 RECEPTACLE
3 – DOOR MODULE
4 – CONNECTOR 2 RECEPTACLE Fig. 8 Front Door Trim Panel Remove/Install -
5 – SCREWS Manual Window
6 – DOOR TRIM PANEL 1 – U-NUT
2 – DOOR
3 – TRIM PANEL
4 – WINDOW CRANK
5 – SPACER
6 – PUSH-IN FASTENER

Fig. 7 Window Regulator Crank Handle Remove -

Typical
1 – DOOR HANDLE REMOVAL TOOL
2 – WINDOW CRANK

NOTE: To aid in the removal of the trim panel, start Fig. 9 Front Door Trim Panel Remove/Install - Power
at the bottom of the panel. Window
1 – U-NUT
(5) Lift the front door trim panel upwards and 2 – DOOR
away from the inner door panel far enough to disen- 3 – TRIM PANEL
gage the top of the panel from the inner belt weath- 4 – PUSH-IN FASTENER
erstrip.
(6) Pull the front door trim panel away from the (8) Unplug the wire harness connectors from the
inner door far enough to access the inside door latch door power switch module or, on the driver side only,
release and lock linkage rods near the back of the the stand-alone power mirror switch.
inside door remote controls. (9) Set the front door trim panel aside.
(7) Unsnap the plastic retainer clips from the (10) Remove the one screw that secures the front
inside door remote control ends of the latch release door flag trim to the inner door panel (Fig. 10).
and lock linkage rods, and remove the rod ends from (11) Using a trim stick or another suitable wide
the inside door remote controls. flat-bladed tool, gently pry the door flag trim away

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 8T - 6 POWER MIRROR SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

Fig. 11 Power Mirror Remove/Install

1 – SIDE VIEW MIRROR
2 – WIRE HARNESS
Fig. 10 Front Door Flag Trim Panel Remove/Install 3 – SEAL
1 – FRONT DOOR 4 – GROMMET
2 – DOOR FLAG TRIM PANEL 5 – DOOR
3 – RETAINER
4 – SCREW
5 – UPPER SPEAKER WIRE HARNESS (15) Pull the mirror and seal from the outside of
the door while feeding the wire harness, grommet,
and connector out through the hole from the inside of
from the inner door to release the trim panel the door.
retainer. (16) Reverse the removal procedures to install.
(12) Unplug the power mirror wire harness con- Tighten the mirror mounting screws to 4.3 N·m (38
nector. in. lbs.). Tighten the door trim mounting screws to
(13) Remove the three screws that secure the 2.2 N·m (20 in. lbs.).
power mirror to the inner door panel (Fig. 11).
(14) Unseat the power mirror wire harness grom-
met by pushing it out through the hole in the door
flag from the inside.

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 XJ CHIME/BUZZER WARNING SYSTEMS 8U - 1

CHIME/BUZZER WARNING SYSTEMS

TABLE OF CONTENTS

page page

GENERAL INFORMATION DIAGNOSIS AND TESTING

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DRIVER DOOR JAMB SWITCH . . . . . . . . . . . . . . 2
CHIME WARNING SYSTEM . . . . . . . . . . . . . . . . . 1 DRIVER SEAT BELT SWITCH . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . . . . . 3
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 1 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 3
DRIVER DOOR JAMB SWITCH . . . . . . . . . . . . . . 2 INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 3
DRIVER SEAT BELT SWITCH . . . . . . . . . . . . . . . . 2 REMOVAL AND INSTALLATION
KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . . . . . 2 CHIME WARNING SYSTEM SWITCHES. . . . . . . . 4
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 2

GENERAL INFORMATION • Overhead console trip computer is reset

• The optional Sentry Key Immobilizer System
INTRODUCTION (SKIS) is in the “customer programming” mode.
This group covers the chime warning system, Following are general descriptions of the major
which is standard factory-installed equipment on this components in the chime warning system. Refer to
model. Refer to 8W-40 Instrument Cluster or 8W-44 - the owner’s manual in the vehicle glove box for more
Interior Lighting in Group 8W - Wiring Diagrams for information on the features, use and operation of the
complete circuit descriptions and diagrams. chime warning system.

NOTE: This group covers both Left-Hand Drive

(LHD) and Right-Hand Drive (RHD) versions of this
DESCRIPTION AND OPERATION
model. Whenever required and feasible, the RHD
versions of affected vehicle components have been INSTRUMENT CLUSTER
constructed as mirror-image of the LHD versions. The instrument cluster is an electromechanical
While most of the illustrations used in this group unit that contains integrated circuitry and internal
represent only the LHD version, the diagnostic and programming to perform a variety of functions. The
service procedures outlined can generally be instrument cluster circuitry monitors hard-wired
applied to either version. Exceptions to this rule switch inputs, as well as message inputs received
have been clearly identified as LHD or RHD, if a from other vehicle electronic modules on the Chrysler
special illustration or procedure is required. Collision Detection (CCD) data bus network.
The instrument cluster uses these many inputs
along with its internal programming and an integral
CHIME WARNING SYSTEM chime tone generator to perform the functions of the
The chime warning system provides an audible chime warning module on this model. The instru-
warning to the driver under the following conditions: ment cluster circuitry also has a self-diagnostic capa-
• Driver side seat belt is not fastened (chimes will bility. Refer to Group 8E - Instrument Panel Systems
sound after the ignition switch is turned to the On for more information on this feature.
position for the duration of the seat belt reminder Hard-wired chime warning system inputs to the
lamp illumination or until the driver side seat belt is instrument cluster include the following:
buckled, whichever occurs first) • Driver door jamb switch
• Engine coolant temperature is high • Driver seat belt switch
• Head or park lamps are turned on with the igni- • Headlamp switch
tion switch Off and the driver side front door open • Key-in ignition switch.
• Key is in the ignition switch with the ignition The only instrument cluster diagnosis found in this
switch Off and the driver side front door open group consists of confirming the viability of the hard-
• Low fuel warning lamp illumination - less than wired chime request inputs to the instrument cluster
about one-eighth tank of fuel remaining circuitry. For diagnosis of the CCD data bus and the

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 8U - 2 CHIME/BUZZER WARNING SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
data bus message inputs, a DRB scan tool and the door is open). The headlamp switch opens the ground
proper Diagnostic Procedures manual are recom- path when the headlamp switch is turned off.
mended. The headlamp switch cannot be repaired and, if
Refer to Group 8E - Instrument Panel Systems for faulty or damaged, it must be replaced. Refer to
the instrument cluster service procedures. The Group 8E - Instrument Panel Systems for the service
instrument cluster chime warning circuitry and procedures.
chime tone generator cannot be repaired and, if
faulty or damaged, the instrument cluster assembly
must be replaced. DIAGNOSIS AND TESTING

DRIVER DOOR JAMB SWITCH DRIVER DOOR JAMB SWITCH

The driver door jamb switch is mounted to the For circuit descriptions and diagrams, refer to
driver side front door hinge pillar. The switch closes 8W-40 - Instrument Cluster or 8W-44 - Interior
a path to ground for the instrument cluster chime Lighting in Group 8W - Wiring Diagrams.
warning circuitry through the key-in ignition switch
and/or the headlamp switch when the driver door is WARNING: ON VEHICLES EQUIPPED WITH AIR-
opened, and opens the ground path when the driver BAGS, REFER TO GROUP 8M - PASSIVE
door is closed. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
The driver door jamb switch cannot be repaired STEERING WHEEL, STEERING COLUMN, OR
and, if faulty or damaged, it must be replaced. Refer INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
to Group 8L - Lamps for the service procedures. SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
DRIVER SEAT BELT SWITCH
INJURY.
The driver seat belt switch is integral to the driver
seat belt buckle-half assembly. The switch is nor- (1) Rotate the headlamp switch knob counterclock-
mally closed, providing a ground path to the instru- wise to ensure that the dome lamps are not switched
ment panel chime warning circuitry. When the tip- off. Open the driver door and note whether the inte-
half of the seat belt is inserted into the seat belt rior lamps light. They should light. If OK, see the
buckle, the switch opens the ground path. diagnosis for the Key-In Ignition Switch or the Head-
The driver seat belt switch cannot be repaired and, lamp Switch in this group. If not OK, go to Step 2.
if faulty or damaged, the entire driver seat belt buck- (2) Disconnect and isolate the battery negative
le-half unit must be replaced. Refer to Group 23 - cable. Unplug the driver door jamb switch from its
Body for the service procedures. wire harness connector. Check for continuity between
the ground circuit cavity of the driver door jamb
KEY-IN IGNITION SWITCH switch wire harness connector and a good ground.
The key-in ignition switch is integral to the igni- There should be continuity. If OK, go to Step 3. If not
tion switch, which is mounted on the left side of the OK, repair the circuit to ground as required.
steering column, opposite the ignition lock cylinder. (3) Check for continuity between the door jamb
It closes a path to ground for the instrument cluster switch ground circuit terminal and the left front door
chime warning circuitry when the ignition key is jamb switch sense terminal of the door jamb switch.
inserted in the ignition lock cylinder and the driver There should be continuity with the switch plunger
door jamb switch is closed (driver door is open). The released, and no continuity with the switch plunger
key-in ignition switch opens the ground path when depressed. If not OK, replace the faulty switch.
the key is removed from the ignition lock cylinder.
The key-in ignition switch cannot be repaired and, DRIVER SEAT BELT SWITCH
if faulty or damaged, the entire ignition switch must For circuit descriptions and diagrams, refer to
be replaced. Refer to Group 8D - Ignition Systems for 8W-40 - Instrument Cluster or 8W-44 - Interior
the service procedures. Lighting in Group 8W - Wiring Diagrams.

HEADLAMP SWITCH
The headlamp switch is located in the instrument
panel, outboard of the steering column. It closes a
path to ground for the instrument cluster chime
warning circuitry when the park or head lamps are
on and the driver door jamb switch is closed (driver

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 XJ CHIME/BUZZER WARNING SYSTEMS 8U - 3
DIAGNOSIS AND TESTING (Continued)
WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) Check for continuity between the left front door
BAGS, REFER TO GROUP 8M - PASSIVE jamb switch sense circuit cavity of the key-in ignition
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY switch wire harness connector and a good ground.
STEERING WHEEL, STEERING COLUMN, OR There should be continuity with the driver door open,
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR and no continuity with the driver door closed. If OK,
SERVICE. FAILURE TO TAKE THE PROPER PRE- see the diagnosis for Instrument Cluster in this
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- group. If not OK, repair the circuit to the driver door
BAG DEPLOYMENT AND POSSIBLE PERSONAL jamb switch as required.
INJURY.
HEADLAMP SWITCH
(1) Disconnect and isolate the battery negative For circuit descriptions and diagrams, refer to
cable. Unplug the driver seat belt switch wire har- 8W-40 - Instrument Cluster or 8W-44 - Interior
ness connector on the floor under the driver seat Lighting in Group 8W - Wiring Diagrams.
near the seat belt buckle-half anchor. Check for con-
tinuity between the seat belt switch sense circuit and WARNING: ON VEHICLES EQUIPPED WITH AIR-
the ground circuit cavities of the seat belt half of the BAGS, REFER TO GROUP 8M - PASSIVE
driver seat belt switch wire harness connector. There RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
should be continuity with the seat belt unbuckled, STEERING WHEEL, STEERING COLUMN, OR
and no continuity with the seat belt buckled. If OK, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
go to Step 2. If not OK, replace the faulty seat belt SERVICE. FAILURE TO TAKE THE PROPER PRE-
buckle-half assembly. CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(2) Check for continuity between the ground cir- BAG DEPLOYMENT AND POSSIBLE PERSONAL
cuit cavity in the body half of the driver seat belt INJURY.
switch wire harness connector and a good ground.
There should be continuity. If OK, see the Instru- (1) Disconnect and isolate the battery negative
ment Cluster diagnosis in this group. If not OK, cable. Remove the headlamp switch from the instru-
repair the circuit to ground as required. ment panel. Refer to Group 8E - Instrument Panel
Systems for the procedures. Unplug the headlamp
KEY-IN IGNITION SWITCH switch wire harness connectors. Check for continuity
For circuit descriptions and diagrams, refer to between the left front door jamb switch sense circuit
8W-40 - Instrument Cluster or 8W-44 - Interior cavity of the headlamp switch wire harness connector
Lighting in Group 8W - Wiring Diagrams. and a good ground. There should be continuity with
the driver door closed, and no continuity with the
WARNING: ON VEHICLES EQUIPPED WITH AIR- driver door open. If OK, go to Step 2. If not OK,
BAGS, REFER TO GROUP 8M - PASSIVE repair the circuit to the driver door jamb switch as
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY required.
STEERING WHEEL, STEERING COLUMN, OR (2) Check for continuity between the key-in switch
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR sense circuit terminal and the left front door jamb
SERVICE. FAILURE TO TAKE THE PROPER PRE- switch sense terminal of the headlamp switch. There
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- should be no continuity with the switch in the Off
BAG DEPLOYMENT AND POSSIBLE PERSONAL position, and continuity with the switch in the park
INJURY. or head lamps On position. If OK, see the diagnosis
for the Instrument Cluster in this group. If not OK,
(1) Disconnect and isolate the battery negative replace the faulty headlamp switch.
cable. Remove the steering column shrouds. Refer to
Group 8D - Ignition Systems for the procedures. INSTRUMENT CLUSTER
Unplug the key-in ignition switch wire harness con- Before performing this test, complete the testing of
nector from the ignition switch. the hard-wired chime warning system switches as
(2) Check for continuity between the key-in switch described in this group. For circuit descriptions and
sense circuit and the left front door jamb switch diagrams, refer to 8W-40 - Instrument Cluster or
sense circuit terminals of the key-in ignition switch. 8W-44 - Interior Lighting in Group 8W - Wiring Dia-
There should be continuity with the key in the igni- grams.
tion lock cylinder, and no continuity with the key
removed from the ignition lock cylinder. If OK, go to
Step 3. If not OK, replace the faulty ignition switch
assembly.

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 8U - 4 CHIME/BUZZER WARNING SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
WARNING: ON VEHICLES EQUIPPED WITH AIR- belt switch sense circuit cavity of the right instru-
BAGS, REFER TO GROUP 8M - PASSIVE ment cluster wire harness connector (connector B)
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY and a good ground. There should be no continuity. If
STEERING WHEEL, STEERING COLUMN, OR OK, go to Step 5. If not OK, repair the short circuit
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR as required.
SERVICE. FAILURE TO TAKE THE PROPER PRE- (5) Check for continuity between the seat belt
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- switch sense circuit cavities of the right instrument
BAG DEPLOYMENT AND POSSIBLE PERSONAL cluster wire harness connector (connector B) and the
INJURY. driver seat belt switch wire harness connector. There
should be continuity. If OK, test the instrument clus-
(1) Disconnect and isolate the battery negative ter as described in Group 8E - Instrument Panel Sys-
cable. Remove the instrument cluster from the tems. If not OK, repair the open circuit as required.
instrument panel. Refer to Group 8E - Instrument
Panel Systems for the procedures.
(2) Unplug the headlamp switch and the key-in REMOVAL AND INSTALLATION
ignition switch wire harness connectors. Check for
continuity between the key-in switch sense circuit CHIME WARNING SYSTEM SWITCHES
cavity of the right instrument cluster wire harness Service procedures for the various hard-wired
connector (connector B) and a good ground. There switches used in the chime warning system can be
should be no continuity. If OK, go to Step 3. If not found in the proper group as follows:
OK, repair the short circuit as required. • Driver door jamb switch - refer to Group 8L -
(3) Check for continuity between the key-in switch Lamps
sense circuit cavities of the right instrument cluster • Driver seat belt switch - refer to Group 23 -
wire harness connector (connector B) and the head- Body
lamp switch wire harness connector. There should be • Headlamp switch - refer to Group 8E - Instru-
continuity. If OK, go to Step 4. If not OK, repair the ment Panel Systems
open circuit as required. • Key-in ignition switch - refer to Group 8D - Igni-
(4) Unplug the driver seat belt switch wire har- tion Systems.
ness connector. Check for continuity between the seat

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 XJ OVERHEAD CONSOLE SYSTEMS 8V - 1

OVERHEAD CONSOLE SYSTEMS

TABLE OF CONTENTS

page page

GENERAL INFORMATION COMPASS CALIBRATION . . . . . . . . . . . . . . . . . . . 5

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 COMPASS DEMAGNETIZING . . . . . . . . . . . . . . . . 6
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
DESCRIPTION AND OPERATION OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . 6
TRIP COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . 1 TRIP COMPUTER, COMPASS, AND
COMPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 THERMOMETER DISPLAY MODULE . . . . . . . . . 7
THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PUSH BUTTON MODULE . . . . . . . . . . . . . . . . . . . 7
READING AND COURTESY LAMP . . . . . . . . . . . . 2 READING AND COURTESY LAMP BULB . . . . . . . 8
GARAGE DOOR OPENER STORAGE BIN . . . . . . . 3 GARAGE DOOR OPENER STORAGE BIN
SUNGLASSES STORAGE BIN. . . . . . . . . . . . . . . . 3 DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING SUNGLASSES STORAGE BIN. . . . . . . . . . . . . . . . 8
TRIP COMPUTER, COMPASS, AND AMBIENT TEMPERATURE SENSOR . . . . . . . . . . . 8
THERMOMETER DISPLAY MODULE . . . . . . . . . 3 SPECIAL TOOLS
THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 4 COMPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE PROCEDURES
COMPASS VARIATION ADJUSTMENT . . . . . . . . . 4

GENERAL INFORMATION door opener storage bin, and a sunglasses storage

bin.
INTRODUCTION On models equipped with the Remote Keyless
An overhead console featuring a mini trip com- Entry (RKE) option, the RKE receiver is also located
puter, an electronic compass, and an outside ambient within the overhead console housing. Refer to Group
temperature thermometer is an available factory-in- 8P - Power Lock Systems for more information on
stalled option on this model. Refer to 8W-49 - Over- this feature.
head Console in Group 8W - Wiring Diagrams for Following are general descriptions of the major
complete circuit descriptions and diagrams. components used in the overhead console. Refer to
the owner’s manual in the vehicle glove box for more
NOTE: This group covers both Left-Hand Drive information on the features, use and operation of the
(LHD) and Right-Hand Drive (RHD) versions of this various overhead console components.
model. Whenever required and feasible, the RHD
versions of affected vehicle components have been
constructed as mirror-image of the LHD versions.
DESCRIPTION AND OPERATION
While most of the illustrations used in this group
represent only the LHD version, the diagnostic and TRIP COMPUTER
service procedures outlined can generally be A mini trip computer is available on this model to
applied to either version. Exceptions to this rule provide several electronic functions and features. The
have been clearly identified as LHD or RHD, if a trip computer contains a central processing unit and
special illustration or procedure is required. interfaces with other modules in the vehicle on the
Chrysler Collision Detection (CCD) data bus network.
The CCD data bus network allows the sharing of
OVERHEAD CONSOLE sensor information. This helps to reduce wire har-
The overhead console for this model includes a ness complexity, reduce internal controller hardware,
mini trip computer, an electronic compass, and an and reduce component sensor current loads. At the
outside ambient temperature thermometer. The over- same time, this system provides increased reliability,
head console also houses two front-mounted and two enhanced diagnostics, and allows the addition of
rear-mounted reading and courtesy lamps, a garage many new feature capabilities.

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 8V - 2 OVERHEAD CONSOLE SYSTEMS XJ
DESCRIPTION AND OPERATION (Continued)
Some of the functions and features that the trip cession flag can exceed the compensating ability of
computer supports and/or controls, include the fol- the compass unit if placed on the roof panel. Mag-
lowing display options: netic bit drivers used on the fasteners that hold the
• Compass and temperature assembly to the roof header can also affect compass
• Trip odometer (ODO) operation. If the vehicle roof should become magne-
• Average fuel economy (AVG ECO) tized, demagnetizing and calibration may be required
• Instant fuel economy (ECO) to restore proper compass operation. See Compass
• Distance to empty (DTE) Calibration or Compass Demagnetizing in the Service
• Elapsed time (ET) Procedures section of this group for these procedures.
• Blank display. The compass, trip computer, and thermometer dis-
Momentarily depressing and releasing the Step play module cannot be repaired, and is only available
button when the ignition switch is in the On position for service as a unit. If faulty or damaged, the com-
will cause the overhead console display to step plete module must be replaced. The push button
sequentially through the listed display options. (Step and U. S./Metric) switch module is serviced
Momentarily depressing and releasing the U. S./Met- separately.
ric button toggles the display between U. S. and Met-
ric measurements. THERMOMETER
The push button (Step and U. S./Metric) switch The thermometer displays the outside ambient
module in the overhead console is hard wired to the temperature. The temperature display can be
trip computer. The compass flux-gate unit is integral changed from Fahrenheit to Celsius using the U.
to the trip computer, compass, and thermometer dis- S./Metric button, located just rearward of the display
play module unit. Data input for all other trip com- module. The displayed temperature is not an instant
puter functions is received through CCD data bus reading of conditions, but an average temperature. It
messages. The trip computer uses its internal pro- may take the thermometer display several minutes
gramming and all of these inputs to calculate and to respond to a major temperature change, such as
display the requested data. If the data displayed is driving out of a heated garage into winter tempera-
incorrect, see Trip Computer, Compass, and Ther- tures.
mometer Display Module - Self-Diagnostic Test in the When the ignition switch is turned to the Off posi-
Diagnosis and Testing section of this group. If these tion, the last displayed temperature reading stays in
tests prove inconclusive, the use of a DRB scan tool the thermometer unit memory. When the ignition
and the proper Diagnostic Procedures manual are switch is turned to the On position again, the ther-
recommended for further testing of the trip computer mometer will display the memory temperature if the
and the CCD data bus. engine coolant temperature is above about 52° C
The trip computer, compass, and thermometer dis- (125° F). If the engine coolant temperature is below
play module cannot be repaired, and is only available about 52° C (125° F), the thermometer will display
for service as a unit. If faulty or damaged, the com- the actual temperature sensed by the ambient tem-
plete module must be replaced. The push button perature sensor. The thermometer temperature dis-
(Step and U. S./Metric) switch module is serviced play update interval varies with the vehicle speed.
separately. The thermometer function is supported by an
ambient temperature sensor. The sensor is mounted
COMPASS outside the passenger compartment near the front
The compass will display the direction in which the and center of the vehicle and is hard-wired to the
vehicle is pointed using the eight major compass module. The ambient temperature sensor is available
headings (Examples: north is N, northeast is NE). It as a separate service item.
does not display the headings in actual degrees. The thermometer, compass, and trip computer dis-
The self-calibrating compass unit requires no play module cannot be repaired, and are only avail-
adjusting in normal use. The only calibration that able for service as a unit. If faulty or damaged, the
may prove necessary is to drive the vehicle in three complete module must be replaced. The push button
complete circles, on level ground, in not less than 48 (Step and U. S./Metric) switch module and ambient
seconds. This will reorient the compass unit to its temperature sensor are serviced separately.
vehicle.
The compass unit also will compensate for magne- READING AND COURTESY LAMP
tism the body of the vehicle may acquire during nor- All reading and courtesy lamps located in the over-
mal use. However, avoid placing anything magnetic head console are activated by the door ajar switches.
directly on the roof of the vehicle. Magnetic mounts When the doors are closed, the lamps can be individ-
for an antenna, a repair order hat, or a funeral pro- ually activated by depressing the corresponding lens.

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 XJ OVERHEAD CONSOLE SYSTEMS 8V - 3
DESCRIPTION AND OPERATION (Continued)
When a door is open, depressing the lamp lens message inputs being received from the instrument
switches will not turn the lamps off. Refer to Group cluster over the Chrysler Collision Detection (CCD)
8L - Lamps, for diagnosis of the reading and courtesy data bus. If the problem is a no-display condition,
lamps. use the following procedures. For circuit descriptions
The reading and courtesy lamp lens, and bulbs are and diagrams, refer to 8W-49 - Overhead Console in
available for service replacement. The reading and Group 8W - Wiring Diagrams.
courtesy lamp holders and switches are only avail- (1) Check the fuses in the junction block and the
able as part of the overhead console wire harness. If Power Distribution Center (PDC). If OK, go to Step
any reading lamp switch is faulty or damaged, the 2. If not OK, repair the shorted circuit or component
wire harness and all four switches must be replaced. as required and replace the faulty fuse(s).
(2) Turn the ignition switch to the On position.
GARAGE DOOR OPENER STORAGE BIN Check for battery voltage at the fused ignition switch
A compartment in the overhead console is designed output fuse in the junction block. If OK, go to Step 3.
to hold most garage door opener remote control If not OK, repair the open circuit to the ignition
transmitters. The transmitter is mounted within the switch as required.
compartment with an adhesive-backed hook and loop (3) Turn the ignition switch to the Off position.
fastener patch. Disconnect and isolate the battery negative cable.
With the transmitter mounted in the storage bin, Remove the overhead console from the headliner.
adapter pegs located on the front of the storage bin Check for continuity between the ground circuit cav-
door are selected and mounted on a post near the ities of the overhead console wire harness connector
center of the storage bin door. The peg(s) selected and a good ground. There should be continuity. If
and/or the post must be long enough to depress the OK, go to Step 4. If not OK, repair the open circuit to
button of the transmitter, when the garage door ground as required.
opener storage bin door is depressed. The pegs may (4) Connect the battery negative cable. Check for
be stacked, if necessary. Refer to the owner’s manual battery voltage at the fused B(+) circuit cavity of the
in the vehicle glove box for more information. overhead console wire harness connector. If OK, go to
A transmitter mounting kit including the adhesive- Step 5. If not OK, repair the open circuit to the junc-
backed hook and loop fastener material and a selec- tion block as required.
tion of pegs is available for service. The garage door (5) Turn the ignition switch to the On position.
opener storage bin door assembly is also available for Check for battery voltage at the fused ignition switch
service replacement. output circuit cavity of the overhead console wire
harness connector. If OK, proceed to the Self-Diag-
SUNGLASSES STORAGE BIN nostic Test in this group for further diagnosis of the
A sunglasses storage bin is included in the over- module and the CCD data bus. If not OK, repair the
head console. The interior of the bin is lined with a open circuit to the junction block as required.
foam rubber padding material to protect the sun-
glasses from being scratched. This bin features a SELF-DIAGNOSTIC TEST
push/push-type latching mechanism, and a viscous A self-diagnostic test is used to determine that the
dampening system for a fluid opening action. trip computer, compass, thermometer, and all of the
The sunglasses storage bin door, latch, viscous display module segments are operating properly elec-
damper, hinge spring and housing are available for trically. Initiate the self-diagnostic test as follows:
service only as a complete module. If any part of this (1) With the ignition switch in the Off position,
unit is faulty or damaged, the entire module must be simultaneously press and hold the Step button and
replaced. the U. S./Metric button.
(2) Turn the ignition switch to the On position.
(3) Continue to hold both buttons until the display
DIAGNOSIS AND TESTING module performs a display segment test. In this test,
all of the vacuum fluorescent display segments are
TRIP COMPUTER, COMPASS, AND lighted. This test will:
THERMOMETER DISPLAY MODULE a. Verify that all display segments are functional
If the problem with the trip computer, compass, b. Check the internal circuitry of the module
and thermometer display module is an inaccurate or c. Check that all of the CCD data bus messages
scrambled display, use the Self-Diagnostic Test proce- needed are being received.
dures. If the problem is incorrect display lighting lev- (4) Respond to the respective test results as fol-
els, use a DRB scan tool and the proper Diagnostic lows. If all tests are passed, the module will automat-
Procedures manual to test for the correct dimming ically return to normal operation.

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 8V - 4 OVERHEAD CONSOLE SYSTEMS XJ
DIAGNOSIS AND TESTING (Continued)
a. In the display segment test, if any segment SENSOR TEST
should fail to light the unit is faulty and must be (1) Turn the ignition switch to the Off position.
replaced. Disconnect and isolate the battery negative cable.
b. If the internal circuitry test is failed, the mod- Unplug the temperature sensor wire harness connec-
ule will display “FAIL”. If “FAIL” is displayed, the tor.
unit is faulty and must be replaced. (2) Measure the resistance of the temperature sen-
c. If the CCD data bus message test is failed, the sor. At -40° C (-40° F), the sensor resistance is 336
module will display “CCD”. If “CCD” is displayed, the kilohms. At 55° C (131° F), the sensor resistance is
use of a DRB scan tool and the proper Diagnostic 2.986 kilohms. The sensor resistance should read
Procedures manual are required for further diagno- between these two values. If OK, go to the Sensor
sis. Circuit Test. If not OK, replace the faulty sensor.
(5) Momentarily depress and release either button
one time to exit the self-diagnostic test mode and SENSOR CIRCUIT TEST
return the trip computer, compass, and thermometer (1) Turn the ignition switch to the Off position.
display module to normal operation. Disconnect and isolate the battery negative cable.
Unplug the ambient temperature sensor wire har-
NOTE: If the compass functions, but accuracy is ness connector and the overhead console wire har-
suspect, it may be necessary to perform a variation ness connector.
adjustment. This procedure allows the compass (2) Connect a jumper wire between the two termi-
unit to accommodate variations in the earth’s mag- nals in the body half of the sensor wire harness con-
netic field strength, based on geographic location. nector.
See the Compass Variation Adjustment procedures, (3) Check for continuity between the sensor return
in this group. circuit and the ambient temperature sensor signal
circuit cavities of the overhead console wire harness
NOTE: If the compass reading has blanked out, and connector. There should be continuity. If OK, go to
only “CAL” appears in the display module, demag- Step 4. If not OK, repair the open circuit as required.
netizing may be necessary to remove excessive (4) Remove the jumper wire from the ambient tem-
residual magnetic fields from the vehicle. See the perature sensor wire harness connector. Check for
Compass Demagnetizing procedure, in this group. continuity between the sensor return circuit cavity of
the overhead console wire harness connector and a
good ground. There should be no continuity. If OK, go
THERMOMETER to Step 5. If not OK, repair the short circuit as
The thermometer function is supported by a ambi- required.
ent temperature sensor, a wiring circuit, and a por- (5) Check for continuity between the ambient tem-
tion of the overhead console trip computer, compass, perature sensor signal circuit cavity of the overhead
and thermometer display module display. The sensor console wire harness connector and a good ground.
is mounted outside the passenger compartment near There should be no continuity. If OK, see the Trip
the front and center of the vehicle. Computer, Compass, and Thermometer Display Mod-
If any portion of the ambient temperature sensor ule diagnosis in this group. If not OK, repair the
circuit fails, the thermometer display will self-diag- short circuit as required.
nose the circuit. An “SC” (short circuit) will appear in
the display in place of the temperature, when the
SERVICE PROCEDURES
sensor is exposed to temperatures above 55° C (131°
F), or if the sensor circuit is shorted. An “OC” (open
circuit) will appear in the display in place of the tem-
COMPASS VARIATION ADJUSTMENT
Variance is the difference between magnetic north
perature, when the sensor is exposed to temperatures
and geographic north. In some geographic locations,
below -40° C (-40° F), or if the sensor circuit is open.
the difference between magnetic and geographic
The ambient temperature sensor circuit can also be
north is great enough to cause the compass to give
diagnosed using the following Sensor Test, and Sen-
false readings. If this problem occurs, the compass
sor Circuit Test. If the temperature sensor and cir-
variance must be set.
cuit are confirmed to be OK, but the temperature
To set the compass variance:
display is inoperative or incorrect, see the Trip Com-
(1) Using the Variance Settings map, find your
puter, Compass, and Thermometer Display Module
geographic location and note the zone number (Fig.
diagnosis in this group. For circuit descriptions and
1).
diagrams, refer to 8W-49 - Overhead Console in
Group 8W - Wiring Diagrams.

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 XJ OVERHEAD CONSOLE SYSTEMS 8V - 5
SERVICE PROCEDURES (Continued)

Fig. 1 Variance Settings

(2) Turn the ignition switch to the On position. If This allows the compass unit to compensate for small
the compass/temperature data is not currently being changes in the residual magnetism that the vehicle
displayed, momentarily depress and release the Step may acquire during normal use. Do not attempt to
button to step through the display options until you calibrate the compass near large metal objects such
have reached the compass/temperature display. as other vehicles, large buildings, or bridges.
(3) Depress both the U. S./Metric, and the Step
buttons. Hold the buttons down until “VAR” appears NOTE: Whenever the compass is calibrated manu-
in the display. This takes about five seconds. ally, the variation number must also be reset. See
(4) Release both of the buttons. The current vari- Compass Variation Adjustment in the Service Pro-
ance zone number setting will appear in the display. cedures section of this group.
(5) Press and release the U. S./Metric button to
step through the zone numbers, until the zone num- Calibrate the compass manually as follows:
ber for your geographic location appears in the dis- (1) Start the engine. If the compass/temperature
play. data is not currently being displayed, momentarily
(6) Press the Step button to enter this zone num- depress and release the Step button to step through
ber into the compass unit memory. the display options until you have reached the com-
(7) Confirm that the correct directions are now pass/temperature display.
indicated by the compass. (2) Depress both the U. S./Metric and the Step
buttons. Hold the buttons down until “CAL” appears
COMPASS CALIBRATION in the display. This takes about ten seconds, and
appears about five seconds after “VAR” is displayed.
CAUTION: Do not place any external magnets, such (3) Release both of the buttons.
as magnetic roof mount antennas, in the vicinity of (4) Drive the vehicle on a level surface, away from
the compass. Do not use magnetic tools when ser- large metal objects, through three or more complete
vicing the overhead console. circles in not less than 48 seconds. The “CAL” mes-
sage will disappear from the display to indicate that
The electronic compass unit features a self-cali- the compass is now calibrated.
brating design, which simplifies the calibration pro-
cedure. This feature automatically updates the
compass calibration while the vehicle is being driven.

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 8V - 6 OVERHEAD CONSOLE SYSTEMS XJ
SERVICE PROCEDURES (Continued)
NOTE: If the “CAL” message remains in the dis-
play, either there is excessive magnetism near the
compass, or the unit is faulty. Repeat the demagne-
tizing and calibration procedures at least one more
time.

NOTE: If the wrong direction is still indicated in the

compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.

COMPASS DEMAGNETIZING
A degaussing tool (Special Tool 6029) is used to
demagnetize, or degauss, the overhead console for-
ward mounting screw(s) and the roof panel. Equiva-
lent units must be rated as continuous duty for 110/
115 volts and 60 Hz. They must also have a field
strength of over 350 gauss at 7 millimeters (0.25
inch) beyond the tip of the probe.
To demagnetize the roof panel and the overhead
console forward mounting screw(s), proceed as fol-
lows:
(1) Be certain that the ignition switch is in the Off
position, before you begin the demagnetizing proce-
dure.
(2) Plug in the degaussing tool, while keeping the
tool at least 61 centimeters (2 feet) away from the
compass unit. Fig. 2 Roof Demagnetizing Pattern
(3) Slowly approach the head of the overhead con-
sole forward mounting screw with the degaussing tool at least 11 centimeters (4 inches) to each side of
tool plugged in. the roof center line, and 28 centimeters (11 inches)
(4) Contact the head of each screw with the plastic back from the windshield header.
coated tip of the degaussing tool for about two sec- (10) With the degaussing tool still energized,
onds. slowly back it away from the roof panel. When the
(5) With the degaussing tool still energized, slowly tip of the tool is at least 61 centimeters (2 feet) from
back it away from the screw. When the tip of the tool the roof panel, unplug the tool.
is at least 61 centimeters (2 feet) from the screw (11) Calibrate the compass and adjust the compass
head, unplug the tool. variance as described in the Service Procedures sec-
(6) Place a piece of paper approximately 22 by 28 tion of this group.
centimeters (8.5 by 11 inches), oriented on the vehicle
lengthwise from front to rear, on the center line of REMOVAL AND INSTALLATION
the roof at the windshield header (Fig. 2). The pur-
pose of the paper is to protect the roof panel from
scratches, and to define the area to be demagnetized.
OVERHEAD CONSOLE
(1) Disconnect and isolate the battery negative
(7) Plug in the degaussing tool, while keeping the
cable.
tool at least 61 centimeters (2 feet) away from the
(2) Remove the two screws located forward of the
compass unit.
display module that secure the overhead console to
(8) Slowly approach the center line of the roof
the upper windshield opening reinforcement (Fig. 3).
panel at the windshield header, with the degaussing
(3) To release the overhead console from the rear
tool plugged in.
mounting bracket, use your fingertips to gently pull
(9) Contact the roof panel with the plastic coated
the sides of the overhead console housing outward
tip of the degaussing tool. Be sure that the template
near the rear mounting bracket.
is in place to avoid scratching the roof panel. Using a
(4) Move the overhead console forward to disen-
slow, back-and-forth sweeping motion, and allowing
gage the rear mounting tab from the headliner.
13 millimeters (0.50 inch) between passes, move the

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 XJ OVERHEAD CONSOLE SYSTEMS 8V - 7
REMOVAL AND INSTALLATION (Continued)

Fig. 3 Overhead Console Remove/Install

Fig. 4 Trip Computer, Compass, and Thermometer
1 – HEADLINER
2 – REAR BRACKET
Display Module Remove/Install
3 – REAR MOUNTING TAB 1 – TRIP COMPUTER, COMPASS AND THERMOMETER
DISPLAY MODULE
4 – OVERHEAD CONSOLE
2 – OVERHEAD CONSOLE HOUSING
5 – SCREW
3 – PUSH BUTTON MODULE CONNECTOR
6 – SCREW
4 – OVERHEAD CONSOLE WIRE HARNESS CONNECTOR
5 – MOUNTING SCREWS
(5) Lower the overhead console far enough to 6 – MOUNTING PINS
access the two wire harness connectors.
(6) Unplug one wire harness connector near the housing far enough to access the two wire harness
push button module towards the front of the over- connectors.
head console. (5) Unplug the overhead console and push button
(7) Unplug one wire harness connector from the module wire harness connectors from the trip com-
Remote Keyless Entry (RKE) receiver near the center puter, compass, and thermometer display module.
of the overhead console, if the vehicle is so equipped. (6) Remove the trip computer, compass, and ther-
(8) Remove the overhead console from the head- mometer display module from the overhead console
liner. housing.
(9) Reverse the removal procedures to install. (7) Reverse the removal procedures to install.
Tighten the overhead console mounting screws to 2.7 Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
N·m (24 in. lbs.).
PUSH BUTTON MODULE
TRIP COMPUTER, COMPASS, AND (1) Remove the overhead console from the vehicle.
THERMOMETER DISPLAY MODULE See Overhead Console in this group for the proce-
(1) Remove the overhead console from the vehicle. dures.
See Overhead Console in this group for the proce- (2) Unplug the push button module wire harness
dures. connector from the trip computer, compass, and ther-
(2) Remove the two screws that secure the forward mometer display module.
end of the trip computer, compass, and thermometer (3) Remove the four screws that secure the push
display module to the overhead console housing (Fig. button module to the overhead console housing (Fig.
4). 5).
(3) Gently flex the sides of the overhead console (4) Remove the push button module from the over-
housing as required to release the trip computer, head console.
compass, and thermometer display module mounting (5) Reverse the removal procedures to install.
pins. Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
(4) Pull the trip computer, compass, and thermom-
eter display module away from the overhead console

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 8V - 8 OVERHEAD CONSOLE SYSTEMS XJ
REMOVAL AND INSTALLATION (Continued)

SUNGLASSES STORAGE BIN

The sunglasses storage bin door and bin, housing,
damper, spring and latch are serviced only as a unit.
Remove the sunglasses storage bin module from the
overhead console as follows:
(1) Remove the overhead console from the vehicle.
See Overhead Console in this group for the proce-
dures.
(2) Disengage the overhead console courtesy lamp
wire harness from the retainers molded into the sun-
glasses storage bin housing.
(3) Remove the six screws that secure the sun-
glasses storage bin module to the overhead console
Fig. 5 Push Button Module Remove/Install housing (Fig. 6).
1 – PUSH BUTTON MODULE
2 – MOUNTING SCREWS

READING AND COURTESY LAMP BULB

(1) Disconnect and isolate the battery negative
cable.
(2) Insert a long, narrow, flat-bladed tool in the
notch on the edge of the reading and courtesy lamp
lens.
(3) Gently pry the lens downward from the over-
head console housing and pivot the lens down. It may
be necessary to move the tool along the edge of the
lens to free the lens from the console housing.
(4) Unsnap the bulb from the bulb holders by pull-
ing the bulb gently downwards.
(5) Install a new bulb by aligning its base with the
Fig. 6 Sunglasses Storage Bin Module Remove/
bulb holders and pushing the bulb firmly into place.
Install
(6) Pivot the lens back up into position and press
1 – SUNGLASSES STORAGE BIN MODULE
upward firmly until it snaps into place. 2 – MOUNTING SCREWS
(7) Connect the battery negative cable. 3 – WIRE HARNESS RETAINERS
(8) Test the lamp by depressing the lens to check
for proper lamp switching and lighting.
(4) Remove the sunglasses storage bin module
GARAGE DOOR OPENER STORAGE BIN DOOR from the overhead console.
(1) Open the garage door opener storage bin door. (5) Reverse the removal procedures to install.
(2) Using a trim stick or another suitable wide Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
flat-bladed tool, gently pry between the door pivot
pin and the pivot hole on one side of the overhead AMBIENT TEMPERATURE SENSOR
console housing until the pivot pin clears the pivot (1) Disconnect and isolate the battery negative
hole. cable.
(3) Use a gentle twisting action to remove the (2) Locate the ambient temperature sensor, below
garage door opener storage bin door from the over- the grille and behind the front bumper on the radia-
head console housing. tor support crossmember (Fig. 7).
(4) To install, insert the pivot pin on one side of (3) Unplug the ambient temperature sensor wire
the door into the pivot hole in the overhead console harness connector.
housing. Gently depress the pivot pin on the other (4) Remove the screw that secures the ambient
side of the door until it clears the side of the garage temperature sensor to the radiator support cross-
door opener storage bin opening of the overhead con- member.
sole housing, and push the door into the opening. (5) Remove the ambient temperature sensor from
Guide the door into the opening so that the second the vehicle.
pivot pin snaps into its pivot hole.

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 XJ OVERHEAD CONSOLE SYSTEMS 8V - 9
REMOVAL AND INSTALLATION (Continued)

SPECIAL TOOLS
COMPASS

Degaussing Tool 6029

Fig. 7 Ambient Temperature Sensor Remove/Install

1 – WIRE HARNESS
2 – SCREW
3 – SENSOR
4 – RADIATOR SUPPORT CROSSMEMBER
5 – CLIPS
6 – HORN

(6) Reverse the removal procedures to install.

Tighten the ambient temperature sensor mounting
screw to 3.4 N·m (30 in. lbs.).

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 XJ WIRING DIAGRAMS 8W - 1

WIRING DIAGRAMS
CONTENTS

page page

AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1 POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1

AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1 POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
ANTI-LOCK BRAKES . . . . . . . . . . . . . . . . . . 8W-35-1 POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1 POWER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1 POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
COMPONENT INDEX . . . . . . . . . . . . . . . . . . 8W-02-1 REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
CONNECTOR LOCATIONS . . . . . . . . . . . . . . 8W-90-1 REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . 8W-80-1 SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . 8W-50-1 SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . 8W-95-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1 STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1
GENERAL INFORMATION . . . . . . . . . . . . . . 8W-01-1 TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1 TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1 TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . 8W-40-1 VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1 VEHICLE THEFT SECURITY SYSTEM . . . . . 8W-39-1
JUNCTION BLOCK. . . . . . . . . . . . . . . . . . . . 8W-12-1 WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . 8W-49-1

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 XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 1

8W-01 GENERAL INFORMATION

INDEX
page page

DESCRIPTION AND OPERATION TROUBLESHOOTING WIRING PROBLEMS . . . . . 10

CIRCUIT FUNCTIONS . . . . . . . . . . . . . . . . . . ....4 SERVICE PROCEDURES
CIRCUIT INFORMATION . . . . . . . . . . . . . . . . ....4 CONNECTOR AND TERMINAL
CONNECTOR INFORMATION . . . . . . . . . . . . ....7 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTROSTATIC DISCHARGE (ESD) CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 12
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . . .8 DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . . . 14
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . .1 TERMINAL REPLACEMENT . . . . . . . . . . . . . . . . . 14
NOTES, CAUTIONS, and WARNINGS . . . . . . . . . .7 TERMINAL/CONNECTOR REPAIR- AUGAT
SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . .5 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . .7 TERMINAL/CONNECTOR REPAIR-MOLEX
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 11
TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 TERMINAL/CONNECTOR REPAIR—THOMAS
TERMINOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . .7 AND BETTS CONNECTORS . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 10
INTERMITTENT AND POOR CONNECTIONS. ....9 SPECIAL TOOLS
TROUBLESHOOTING TESTS . . . . . . . . . . . . ....9 WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . . 15
TROUBLESHOOTING TOOLS . . . . . . . . . . . . ....8

DESCRIPTION AND OPERATION Components are shown two ways. A solid line
around a component indicates that the component is
INTRODUCTION complete. A dashed line around a component indi-
Chrysler wiring diagrams are designed to provide cates that the component being shown is not com-
information regarding the vehicles wiring content. In plete. Incomplete components have a reference
order to effectively use Chrysler wiring diagrams to number to indicate the page where the component is
diagnose and repair a Chrysler vehicle, it is impor- shown complete.
tant to understand all of their features and charac- It is important to realize that no attempt is made
teristics. on the diagrams to represent components and wiring
Diagrams are arranged such that the power (B+) as they appear on the vehicle. For example, a short
side of the circuit is placed near the top of the page, piece of wire is treated the same as a long one. In
and the ground (B-) side of the circuit is placed near addition, switches and other components are shown
the bottom of the page. as simply as possible, with regard to function only.
All switches, components, and modules are shown
in the at rest position with the doors closed and the
key removed from the ignition.

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 8W - 01 - 2 8W - 01 GENERAL INFORMATION XJ
DESCRIPTION AND OPERATION (Continued)

The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.

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 XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 3
DESCRIPTION AND OPERATION (Continued)

The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.

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 8W - 01 - 4 8W - 01 GENERAL INFORMATION XJ
DESCRIPTION AND OPERATION (Continued)

CIRCUIT INFORMATION CIRCUIT FUNCTIONS

Each wire shown in the diagrams contains a code All circuits in the diagrams use an alpha/numeric
which identifies the main circuit, part of the main code to identify the wire and its function. To identify
circuit, gage of wire, and color (Fig. 1). 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 second-
ary codes that may apply to some models.
CIRCUIT IDENTIFICATION CODE CHART

CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS (GAUGES)
Fig. 1 Wire Code Identification H OPEN
1 – COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER)
2 – GAUGE OF WIRE (18 GAUGE)
I NOT USED
3 – PART OF MAIN CIRCUIT (VARIES DEPENDING ON J OPEN
EQUIPMENT)
4 – MAIN CIRCUIT IDENTIFICATION K POWERTRAIN CONTROL MODULE
L EXTERIOR LIGHTING
WIRE COLOR CODE CHART M INTERIOR LIGHTING
N NOT USED
STANDARD O NOT USED
COLOR CODE COLOR TRACER P POWER OPTION (BATTERY FEED)
COLOR
Q POWER OPTIONS (IGNITION FEED)
BL BLUE WT
R PASSIVE RESTRAINT
BK BLACK WT
S SUSPENSION/STEERING
BR BROWN WT
T TRANSMISSION/TRANSAXLE/
DB DARK BLUE WT TRANSFER CASE
DG DARK GREEN WT U OPEN
GY GRAY BK V SPEED CONTROL, WIPER/WASHER
LB LIGHT BLUE BK W OPEN
LG LIGHT GREEN BK X AUDIO SYSTEMS
OR ORANGE BK Y OPEN
PK PINK BK or WT Z GROUNDS
RD RED WT
TN TAN WT
VT VIOLET WT
WT WHITE BK
YL YELLOW BK
* WITH TRACER

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 XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 5
DESCRIPTION AND OPERATION (Continued)

SECTION IDENTIFICATION GROUP TOPIC

The wiring diagrams are grouped into individual 8W-01 thru General Information and Diagram
sections. If a component is most likely found in a par- 8W-09 Overview
ticular group, it will be shown complete (all wires,
connectors, and pins) within that group. For exam- 8W-10 thru Main Sources of Power and Vehicle
ple, the Auto Shutdown Relay is most likely to be 8W-19 Grounding
found in Group 30, so it is shown there complete. It 8W-20 thru Starting and Charging
can, however, be shown partially in another group if 8W-29
it contains some associated wiring. 8W-30 thru Powertrain/Drivetrain Systems
8W-39
SYMBOLS 8W-40 thru Body Electrical items and A/C
International symbols are used throughout the wir-
8W-49
ing diagrams. These symbols are consistent with
those being used around the world 8W-50 thru Exterior Lighting, Wipers, and Trailer
8W-59 Tow
8W-60 thru Power Accessories
8W-69
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-90 Connector Locations (including
grounds)
8W-95 Splice Locations

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 8W - 01 - 6 8W - 01 GENERAL INFORMATION XJ
DESCRIPTION AND OPERATION (Continued)

Wiring Diagram Symbols

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 XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 7
DESCRIPTION AND OPERATION (Continued)

TERMINOLOGY are identified using the name/number on the Dia-

This a list of terms with there definitions used in gram pages.
the wiring diagrams.
SPLICE LOCATIONS
Built-Up-Export . . . . . . . Vehicles Built For Sale In Splice Location charts in Section 8W-70 show the
Markets Other Than North America entire splice, and provide references to other sections
Except-Built-Up-Export . Vehicles Built For Sale In the splice serves.
North America Section 8W-95 contains illustrations that show the
LHD . . . . . . . . . . . . . . . . Left Hand Drive Vehicles general location of the splices in each harness. The
RHD . . . . . . . . . . . . . . . Right Hand Drive Vehicles illustrations show the splice by number, and provide
EATX . . . Electronic Automatic Transmission-Front a written location.
Wheel Drive
ATX . . Automatic Transmission-Front Wheel Drive NOTES, CAUTIONS, and WARNINGS
MTX . . . . Manual Transmission-Front Wheel Drive Throughout this group additional important infor-
A/T . . . . Automatic Transmission-Rear Wheel Drive mation is presented in three ways; Notes, Cautions,
M/T . . . . . Manual Transmission-Rear Wheel Drive and Warnings.
NOTES are used to help describe how switches or
SOHC . . . . . . . . . . . Single Over Head Cam Engine
components operate to complete a particular circuit.
DOHC . . . . . . . . . . . . Dual Over Head Cam Engine
They are also used to indicate different conditions
CONNECTOR INFORMATION that may appear on the vehicle. For example, an
up-to and after condition.
CAUTION: Not all connectors are serviced. Some CAUTIONS are used to indicate information that
connectors are serviced only with a harness. A typ- could prevent making an error that may damage the
ical example might be the Supplemental Restraint vehicle.
System connectors. Always check parts availability WARNINGS provide information to prevent per-
before attempting a repair. sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
IDENTIFICATION
In-line connectors are identified by a number, as WARNING: ALWAYS WEAR SAFETY GLASSES FOR
follows: EYE PROTECTION.
• In-line connectors located on the engine com-
partment harness are C100 series numbers.
• Connectors located on the instrument panel WARNING: USE SAFETY STANDS ANYTIME A PRO-
harness are C200 series numbers. CEDURE REQUIRES BEING UNDER A VEHICLE.
• Connectors located on the body harness are
C300 series numbers. WARNING: BE SURE THAT THE IGNITION SWITCH
• Jumper harness connectors are C400 series ALWAYS IS IN THE OFF POSITION, UNLESS THE
numbers. PROCEDURE REQUIRES IT TO BE ON.
• Grounds and ground connectors are identi-
fied with a “G” and follow the same series number-
ing as the in-line connector. WARNING: SET THE PARKING BRAKE WHEN
Component connectors are identified by the compo- WORKING ON ANY VEHICLE. AN AUTOMATIC
nent name instead of a number. Multiple connectors TRANSMISSION SHOULD BE IN PARK. A MANUAL
on a component use a C1, C2, etc. identifier. TRANSMISSION SHOULD BE IN NEUTRAL.

LOCATIONS
Section 8W-90 contains connector/ground location WARNING: OPERATE THE ENGINE ONLY IN A
illustrations. The illustrations contain the connector WELL-VENTILATED AREA.
name (or number)/ground number and component
identification. Connector/ground location charts in WARNING: KEEP AWAY FROM MOVING PARTS
Section 8W-90 reference the illustration number for WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
components and connectors. FAN AND BELTS.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors

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 8W - 01 - 8 8W - 01 GENERAL INFORMATION XJ
DESCRIPTION AND OPERATION (Continued)
WARNING: TO PREVENT SERIOUS BURNS, AVOID DIAGNOSIS AND TESTING
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA- TROUBLESHOOTING TOOLS
LYTIC CONVERTER, AND MUFFLER. When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
WARNING: DO NOT ALLOW FLAME OR SPARKS are listed and explained below.
NEAR THE BATTERY. GASES ARE ALWAYS • Jumper Wire - This is a test wire used to con-
PRESENT IN AND AROUND THE BATTERY. nect two points of a circuit. It can be used to bypass
an open in a circuit.

WARNING: ALWAYS REMOVE RINGS, WATCHES, WARNING: NEVER USE A JUMPER WIRE ACROSS
LOOSE HANGING JEWELRY, AND LOOSE CLOTH- A LOAD, SUCH AS A MOTOR, CONNECTED
ING. BETWEEN A BATTERY FEED AND GROUND.

• Voltmeter - Used to check for voltage on a cir-

TAKE OUTS cuit. Always connect the black lead to a known good
The abbreviation T/O is used in the component ground and the red lead to the positive side of the
location section to indicate a point in which the wir- circuit.
ing harness branches out to a component.
CAUTION: Most of the electrical components used
in today’s vehicle are solid state. When checking
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
voltages in these circuits use a meter with a 10-me-
DEVICES gohm or greater impedance rating.
All ESD sensitive components are solid state and a
symbol (Fig. 2) is used to indicate this. When han- • Ohmmeter - Used to check the resistance
dling any component with this symbol comply with between two points of a circuit. Low or no resistance
the following procedures to reduce the possibility of in a circuit means good continuity.
electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not CAUTION: - Most of the electrical components used
known whether the part is ESD sensitive, assume in today’s vehicle are Solid State. When checking
that it is. resistance in these circuits use a meter with a
(1) Always touch a known good ground before han- 10-megohm or greater impedance rating. In addi-
dling the part. This should be repeated while han- tion, make sure the power is disconnected from the
dling the part and more frequently after sliding circuit. Circuits that are powered up by the vehicle
across a seat, sitting down from a standing position, electrical system can cause damage to the equip-
or walking a distance. ment and provide false readings.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure. • Probing Tools - These tools are used for probing
(3) When using a voltmeter, be sure to connect the terminals in connectors (Fig. 3). Select the proper
ground lead first. size tool from Special Tool Package 6807, and insert
(4) Do not remove the part from its protective it into the terminal being tested. Use the other end
packing until it is time to install the part. of the tool to insert the meter probe.
(5) Before removing the part from its package,
ground the package to a known good ground on the
vehicle.

Fig. 3 Probing Tool

1 – SPECIAL TOOL 6801
Fig. 2 Electrostatic Discharge Symbol 2 – PROBING END

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 XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 9
DIAGNOSIS AND TESTING (Continued)

INTERMITTENT AND POOR CONNECTIONS

Most intermittent electrical problems are caused
by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a
problem. Before condemning a component or wiring
assembly check the following items.
• Connectors are fully seated
• Spread terminals, or terminal push out
• Terminals in the wiring assembly are fully
seated into the connector/component and locked in
position
• Dirt or corrosion on the terminals. Any amount
of corrosion or dirt could cause an intermittent prob-
lem
• Damaged connector/component casing exposing
the item to dirt and moisture
• Wire insulation that has rubbed through causing
a short to ground
• Some or all of the wiring strands broken inside
of the insulation covering.
• Wiring broken inside of the insulation
Fig. 4 Testing for Voltage Potential
TROUBLESHOOTING TESTS
Before beginning any tests on a vehicles electrical
system use the Wiring Diagrams and study the cir-
cuit. Also refer to the Troubleshooting Wiring Prob-
lems in this section.

TESTING FOR VOLTAGE POTENTIAL

(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 4).
(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri-
ate test procedure.

TESTING FOR CONTINUITY

(1) Remove the fuse for the circuit being checked
or, disconnect the battery.
(2) Connect one lead of the ohmmeter to one side
of the circuit being tested (Fig. 5).
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.
Fig. 5 Testing for Continuity
TESTING FOR A SHORT TO GROUND 1 – FUSE REMOVED FROM CIRCUIT
(1) Remove the fuse and disconnect all items
involved with the fuse. TESTING FOR A SHORT TO GROUND ON FUSES
(2) Connect a test light or a voltmeter across the
terminals of the fuse.
POWERING SEVERAL LOADS
(3) Starting at the fuse block, wiggle the wiring (1) Refer to the wiring diagrams and disconnect or
harness about six to eight inches apart and watch isolate all items on the suspected fused circuits.
the voltmeter/test lamp. (2) Replace the blown fuse.
(4) If the voltmeter registers voltage or the test (3) Supply power to the fuse by turning ON the
lamp glows, there is a short to ground in that gen- ignition switch or re-connecting the battery.
eral area of the wiring harness.

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 8W - 01 - 10 8W - 01 GENERAL INFORMATION XJ
DIAGNOSIS AND TESTING (Continued)
(4) Start connecting the items in the fuse circuit SERVICE PROCEDURES
one at a time. When the fuse blows the circuit with
the short to ground has been isolated. WIRING REPAIR
When replacing or repairing a wire, it is important
TESTING FOR A VOLTAGE DROP that the correct gage be used as shown in the wiring
(1) Connect the positive lead of the voltmeter to diagrams. The wires must also be held securely in
the side of the circuit closest to the battery (Fig. 6). place to prevent damage to the insulation.
(2) Connect the other lead of the voltmeter to the (1) Disconnect battery negative cable
other side of the switch or component. (2) Remove 1 inch of insulation from each end of
(3) Operate the item. the wire.
(4) The voltmeter will show the difference in volt- (3) Place a piece of heat shrink tubing over one
age between the two points. side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wire (example 1). (Fig. 7)
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (example
2) (Fig. 7)
(6) Twist the wires together (example 3) (Fig. 7)
(7) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation
(10) Connect battery and test all affected systems.

Fig. 6 Testing for Voltage Drop

TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
Fig. 7 Wire Repair
(4) Isolate the problem area.
1 – EXAMPLE 1
(5) Repair the problem. 2 – EXAMPLE 2
(6) Verify proper operation. For this step check for 3 – EXAMPLE 3
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams.

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 XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 11
SERVICE PROCEDURES (Continued)

TERMINAL/CONNECTOR REPAIR-MOLEX TERMINAL/CONNECTOR REPAIR—THOMAS

CONNECTORS AND BETTS CONNECTORS
(1) Disconnect battery. (1) Disconnect battery.
(2) Disconnect the connector from its mating half/ (2) Disconnect the connector from its mating half/
component. component.
(3) Insert the terminal releasing special tool 6742 (3) Push in the two lock tabs on the side of the
into the terminal end of the connector (Fig. 8). connector (Fig. 10).

Fig. 8 Molex Connector Repair

1 – CONNECTOR
Fig. 10 Thomas and Betts Connector Lock Release
2 – SPECIAL TOOL 6742 Tabs
1 – LOCK TABS

(4) Using special tool 6742 release the locking fin-

gers on the terminal (Fig. 9). (4) Insert the probe end of special tool 6934 into
(5) Pull on the wire to remove it from the connec- the back of the connector cavity (Fig. 11).
tor. (5) Grasp the wire and tool 6934 and slowly
(6) Repair or replace the connector or terminal, as remove the wire and terminal from the connector.
necessary.

Fig. 9 Using Special Tool 6742

1 – CONNECTOR
2 – SPECIAL TOOL 6742 Fig. 11 Removing Wire Terminal
1 – SPECIAL TOOL 6934

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 8W - 01 - 12 8W - 01 GENERAL INFORMATION XJ
SERVICE PROCEDURES (Continued)
(6) Repair or replace the terminal.
(7) Install the wire and terminal in the connector.
Fully seat the terminal in the connector.
(8) Push in the single lock tab on the side of the
connector (Fig. 12).

Fig. 14 Using Special Tool 6932

1 – SPECIAL TOOL 6932
2 – CONNECTOR

(5) Repair or replace the connector or terminal as

Fig. 12 Single Lock Tab necessary.
1 – SINGLE LOCK TAB (6) When re-assembling the connector, the locking
wedge must be placed in the locked position to pre-
vent terminal push out.
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS CONNECTOR REPLACEMENT
(1) Disconnect battery. (1) Disconnect battery.
(2) Disconnect the connector from its mating half/ (2) Disconnect the connector that is to be repaired
component. from its mating half/component
(3) Push down on the yellow connector locking tab (3) Remove the connector locking wedge, if
to release the terminals (Fig. 13). required (Fig. 15)

Fig. 13 Augat Connector Repair Fig. 15 Connector Locking Wedge

1 – LOCKING TAB 1 – CONNECTOR
2 – CONNECTOR 2 – CONNECTOR LOCKING WEDGE TAB

(4) Using special tool 6932, push the terminal to (4) Position the connector locking finger away from
remove it from the connector (Fig. 14). the terminal using the proper pick from special tool

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 XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 13
SERVICE PROCEDURES (Continued)
kit 6680. Pull on the wire to remove the terminal CONNECTOR AND TERMINAL REPLACEMENT
from the connector (Fig. 16) (Fig. 17). (1) Disconnect battery.
(5) Reset the terminal locking tang, if it has one. (2) Disconnect the connector (that is to be
(6) Insert the removed wire in the same cavity on repaired) from its mating half/component.
the repair connector. (3) Cut off the existing wire connector directly
(7) Repeat steps four through six for each wire in behind the insulator. Remove six inches of tape from
the connector, being sure that all wires are inserted the harness.
into the proper cavities. For additional connector pin- (4) Stagger cut all wires on the harness side at 1/2
out identification, refer to the wiring diagrams. inch intervals (Fig. 18).
(8) Insert the connector locking wedge into the (5) Remove 1 inch of insulation from each wire on
repaired connector, if required. the harness side.
(9) Connect connector to its mating half/component. (6) Stagger cut the matching wires on the repair
(10) Connect battery and test all affected systems. connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 18).

Fig. 16 Terminal Removal

1 – CONNECTOR
2 – FROM SPECIAL TOOL KIT 6680

Fig. 18 Stagger Cutting Wires

1 – REPAIR SIDE WIRES
2 – STAGER CUTS
3 – HARNESS WIRES

(7) Remove 1 inch of insulation from each wire.

(8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
Fig. 17 Terminal Removal Using Special Tool and heat using a heat gun. Heat the joint until the
1 – FROM SPECIAL TOOL KIT 6680 tubing is tightly sealed and sealant comes out of both
2 – CONNECTOR ends of the tubing
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.

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 8W - 01 - 14 8W - 01 GENERAL INFORMATION XJ
SERVICE PROCEDURES (Continued)
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.

TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig. 19).
(3) Remove connector locking wedge, if required
(Fig. 19).

Fig. 21 Terminal Removal Using Special Tool

1 – FROM SPECIAL TOOL KIT 6680
2 – CONNECTOR

(5) Cut the wire 6 inches from the back of the con-
nector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and
remove 1 inch of insulation.
Fig. 19 Connector Locking Wedge Tab (Typical)
(9) Place a piece of heat shrink tubing over one
1 – CONNECTOR
side of the wire. Make sure the tubing will be long
2 – CONNECTOR LOCKING WEDGE TAB
enough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on each
(4) Position the connector locking finger away from part of the exposed wires.
the terminal using the proper pick from special tool (11) Push the two ends of wire together until the
kit 6680. Pull on the wire to remove the terminal strands of wire are close to the insulation.
from the connector (Fig. 20) (Fig. 21). (12) Twist the wires together.
(13) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(15) Insert the repaired wire into the connector.
(16) Install the connector locking wedge, if
required, and reconnect the connector to its mating
half/component.
(17) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(18) Connect battery, and test all affected systems.

DIODE REPLACEMENT
(1) Disconnect the battery.
Fig. 20 Terminal Removal (2) Locate the diode in the harness, and remove
1 – CONNECTOR the protective covering.
2 – FROM SPECIAL TOOL KIT 6680 (3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 22).

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 XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 15
SERVICE PROCEDURES (Continued)

SPECIAL TOOLS
WIRING/TERMINAL

Probing Tool Package 6807

Fig. 22 Diode Identification
1 – CURRENT FLOW
2 – BAND AROUND DIODE INDICATES CURRENT FLOW
3 – DIODE AS SHOWN IN THE DIAGRAMS

(4) Remove the insulation from the wires in the

harness. Only remove enough insulation to solder in
the new diode.
(5) Install the new diode in the harness, making
sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.
(6) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
(7) Tape the diode to the harness using electrical
tape making, sure the diode is completely sealed
from the elements.
(8) Re-connect the battery, and test affected sys- Terminal Pick 6680
tems.

Terminal Removing Tool 6932

Terminal Removing Tool 6934

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 XJ 8W - 02 COMPONENT INDEX 8W - 02 - 1

8W-02 COMPONENT INDEX

Component Page Component Page
1-2 And 3-4 Solenoid . . . . . . . . . . . . . . . . . . . 8W-31 Engine Starter Motor Relay . . . . . . . . . . . . . 8W-21
2-3 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31 Engine Starter Motor . . . . . . . . . . . . . . . . . . 8W-21
A/C Compressor Clutch Relay . . . . . . . . . . . . 8W-42 Evap Leak Detection Pump . . . . . . . . . . . . . . 8W-30
A/C Compressor Clutch . . . . . . . . . . . . . . . . . 8W-42 Extended Idle Switch . . . . . . . . . . . . . . . . . . 8W-30
A/C- Heater Control . . . . . . . . . . . . . . . . . . . 8W-42 Fog Lamp Relays . . . . . . . . . . . . . . . . . . . . . . 8W-50
A/C Pressure Switches . . . . . . . . . . . . . . . . . . 8W-42 Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-50, 51
Accelerator Pedal Position Sensor . . . . . . . . . 8W-30 Forward/Rearward Motor . . . . . . . . . . . . . . . 8W-63
Airbag Control Module . . . . . . . . . . . . . . . . . 8W-43 Front Fog Lamp Switch . . . . . . . . . . . . . . 8W-44, 50
Airbags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43 Front Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Ambient Temperature Sensor . . . . . . . . . . . . 8W-49 Front Wiper Motor . . . . . . . . . . . . . . . . . . . . 8W-53
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Automatic Shut Down Relay . . . . . . . . . . . . . 8W-30 Fuel Injection Pump . . . . . . . . . . . . . . . . . . . 8W-30
Back-Up Lamp Switch . . . . . . . . . . . . . . . . . . 8W-51 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Back-Up Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-51 Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30
Battery Temperature Sensor . . . . . . . . . . . . . 8W-30 Fuel Pump Module . . . . . . . . . . . . . . . . . . . . 8W-30
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Blend Door Actuator . . . . . . . . . . . . . . . . . . . 8W-42 Fuses (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Blower Motor Relay . . . . . . . . . . . . . . . . . . . . 8W-42 Fuses (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Blower Motor Resistor Block . . . . . . . . . . . . . 8W-42 Fusible Link A11 . . . . . . . . . . . . . . . . . . . . . . 8W-10
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42 Fusible Link . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Brake Lamp Switch . . . . . . . . . . . . . . . . . . . . 8W-33 G Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35
Brake Warning Pressure Switch . . . . . . . . . . 8W-40 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Camshaft Position Sensor . . . . . . . . . . . . . . . 8W-30 Glow Plug Assembly . . . . . . . . . . . . . . . . . . . 8W-30
Cargo Lamp/Switch . . . . . . . . . . . . . . . . . . . . 8W-44 Glow Plug Relay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Center High Mounted Stop Lamp . . . . . . . . . 8W-51 Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Cigar Lighter Relay . . . . . . . . . . . . . . . . . . . . 8W-41 Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41 Headlamp Beam Select Switch . . . . . . . . . . . 8W-50
Circuit Breakers (JB) . . . . . . . . . . . . . . . . . . 8W-12 Headlamp Delay Module . . . . . . . . . . . . . . . . 8W-50
City Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50 Headlamp Leveling Motors . . . . . . . . . . . . . . 8W-50
Clockspring . . . . . . . . . . . . . . . . . . 8W-30, 33, 41, 43 Headlamp Leveling Switch . . . . . . . . . . . . . . 8W-50
Cluster Illumination Lamps . . . . . . . . . . . . . 8W-40 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . 8W-50
Clutch Interlock Switch Jumper . . . . . . . . 8W-12, 21 Headlamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-50, 50
Clutch Interlock Switch . . . . . . . . . . . . . . 8W-12, 21 Heated Seat Backs . . . . . . . . . . . . . . . . . . . . 8W-63
Combination Flasher . . . . . . . . . . . . . . . . . . . 8W-52 Heated Seat Cushions . . . . . . . . . . . . . . . . . . 8W-63
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49 Heated Seat Relay . . . . . . . . . . . . . . . . . . . . . 8W-63
Controller Anti-Lock Brake Relay . . . . . . . . . 8W-35 Heated Seat Switches . . . . . . . . . . . . . . . . . . 8W-63
Controller Anti-Lock Brake . . . . . . . . . . . . . . 8W-35 Heater Control . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-44 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Crankshaft Position Sensor . . . . . . . . . . . . . . 8W-30 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Data Link Connector . . . . . . . . . . . . . . . . . . . 8W-30 Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Daytime Running Lamp Module . . . . . . . . . . 8W-50 Idle Air Control Motor . . . . . . . . . . . . . . . . . . 8W-30
Diode Module . . . . . . . . . . . . . . . . . . . . . . . . 8W-51 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Dome Lamps Switch . . . . . . . . . . . . . . . . . . . 8W-44 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Door Jamb Switches . . . . . . . . . . . . . . . . . 8W-39, 44 Input Speed Sensor . . . . . . . . . . . . . . . . . . . . 8W-31
Door Lock Motors . . . . . . . . . . . . . . . . . . . . . 8W-61 Instrument Cluster . . . . . . . . . . . . . . . . . . . . 8W-40
Duty Cycle Evap/Purge Solenoid . . . . . . . . . . 8W-30 Intake Air Temperature Sensor . . . . . . . . . . . 8W-30
Engine Control Module . . . . . . . . . . . . . . . . . 8W-30 Junction Block . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Engine Coolant Temperature Gauge . . . . . . . 8W-40 License Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Engine Coolant Temperature Sensors . . . . . . 8W-30 Liftgate Lock Motor . . . . . . . . . . . . . . . . . . . . 8W-61
Engine Oil Pressure Sensor . . . . . . . . . . . . . . 8W-30 Liftgate Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-30 Lock-Up Solenoid . . . . . . . . . . . . . . . . . . . . . . 8W-31

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 8W - 02 - 2 8W - 02 COMPONENT INDEX XJ

Component Page Component Page

Low Coolant Switch . . . . . . . . . . . . . . . . . . . . 8W-30 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . 8W-53
Manifold Absolute Pressure Sensor . . . . . . . . 8W-30 Rear Wiper/Washer Switch . . . . . . . . . . . . . . 8W-53
Message Center . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Repeater Lamps . . . . . . . . . . . . . . . . . . . . 8W-50, 52
Needle Movement Sensor . . . . . . . . . . . . . . . 8W-30 Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . 8W-40
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40 Seat Heat Interface Module . . . . . . . . . . . . . . 8W-63
Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . 8W-40 Sentry Key Immobilizer Module . . . . . . . . . . 8W-39
Output Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31 Shift Lock Solenoid . . . . . . . . . . . . . . . . . . . . 8W-31
Overhead Module . . . . . . . . . . . . . . . . . . . . . 8W-49 Side Marker Lamps . . . . . . . . . . . . . . . . . 8W-50, 52
Oxygen Sensor Downstream Relay . . . . . . . . 8W-30 Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Oxygen Sensor Upstream Relay . . . . . . . . . . 8W-30 Speed Control Switches . . . . . . . . . . . . . . . . . 8W-33
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Park Brake Switch . . . . . . . . . . . . . . . . . . . . 8W-40 Splice Information . . . . . . . . . . . . . . . . . . . . . 8W-70
Park/Neutral Position Switch . . . . . . . . . . . . 8W-31 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Park/Turn Signal Lamps . . . . . . . . . . . . . 8W-50, 52 Tail/Stop Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-51
Power Amplifier . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Throttle Position Sensor . . . . . . . . . . . . . . . . 8W-30
Power Antenna Relay . . . . . . . . . . . . . . . . . . 8W-47 Torque Converter Clutch Solenoid . . . . . . . . . 8W-31
Power Antenna . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Trailer Tow Connector . . . . . . . . . . . . . . . . . . 8W-54
Power Distribution Center . . . . . . . . . . . . . . . 8W-10 Trailer Tow Electric Brake Provision . . . . . . . 8W-54
Power Lock/Window Switches . . . . . . . 8W-60, 61, 62 Trailer Tow Relays . . . . . . . . . . . . . . . . . . . . . 8W-54
Power Mirror Switch . . . . . . . . . . . . . . . . . . . 8W-62 Transfer Case Switch Illumination . . . . . . . . 8W-44
Power Mirrors . . . . . . . . . . . . . . . . . . . . . 8W-48, 62 Transfer Case Switch . . . . . . . . . . . . . . . . . . 8W-40
Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41 Transmission Control Module . . . . . . . . . . . . 8W-31
Power Seat Motors . . . . . . . . . . . . . . . . . . . . 8W-63 Transmission Range Sensor . . . . . . . . . . . . . . 8W-31
Power Seat Switches . . . . . . . . . . . . . . . . . . . 8W-63 Transmission Solenoid . . . . . . . . . . . . . . . . . . 8W-31
Power Steering Pressure Switch . . . . . . . . . . 8W-30 Trip Reset Switch . . . . . . . . . . . . . . . . . . . . . 8W-40
Power Window Motors . . . . . . . . . . . . . . . . . . 8W-60 Turbo Boost Pressure Sensor . . . . . . . . . . . . . 8W-30
Powertrain Control Module . . . . . . . . . . . 8W-20, 30 Turn Signal Lamps . . . . . . . . . . . . . . . 8W-50, 52, 52
PRNDL Illumination . . . . . . . . . . . . . . . . . . . 8W-44 Turn Signal/Hazard Switch . . . . . . . . . . . . . . 8W-52
Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . 8W-42 Underhood Lamp/Switch . . . . . . . . . . . . . . . . 8W-44
Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . 8W-42 Vehicle Speed Control Servo . . . . . . . . . . . . . 8W-33
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-30
Rail Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Visor/Vanity Lamps . . . . . . . . . . . . . . . . . . . . 8W-44
Rear Fog Lamp Indicator . . . . . . . . . . . . . . . 8W-51 Volt Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Rear Fog Lamp Relay . . . . . . . . . . . . . . . . . . 8W-51 Washer Fluid Level Switch . . . . . . . . . . . . . . 8W-40
Rear Fog Lamp Switch . . . . . . . . . . . . . . . . . 8W-51 Water In Fuel Sensor . . . . . . . . . . . . . . . . . . 8W-30
Rear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63 Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . 8W-35
Rear Washer Pump . . . . . . . . . . . . . . . . . . . . 8W-53 Windshield Washer Pump . . . . . . . . . . . . . . . 8W-53
Rear Window Defogger Relay . . . . . . . . . . . . 8W-48 Wipe/Wash Switch . . . . . . . . . . . . . . . . . . . . . 8W-53
Rear Window Defogger Switch . . . . . . . . . . . 8W-48 Wiper Motor Relay . . . . . . . . . . . . . . . . . . . . 8W-53
Rear Window Defogger . . . . . . . . . . . . . . . . . 8W-48

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 XJ 8W - 10 POWER DISTRIBUTION 8W - 10 - 1

8W-10 POWER DISTRIBUTION

Component Page Component Page
A/C Compressor Clutch . . . . . . . . . . . . . . . 8W-10-22, 32 Fuse 17 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 16
A/C Compressor Clutch Relay . . . . . . . . 8W-10-19, 22, 32 Fuse 17 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-12, 27
Automatic Shut Down Relay . . . . . . . . . 8W-10-19, 23, 34 Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 16
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 13 Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-21 Fuse 19 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Blower Motor Relay . . . . . . . . . . . . . . . 8W-10-11, 21, 26 Fuse 19 (PDC) . . . . . . . . . . . . . . 8W-10-12, 14, 28, 29, 32
Brake Lamp Switch . . . . . . . . . . . . . . . . . 8W-10-32, 33 Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26
Brake Warning Pressure Switch . . . . . . . . . 8W-10-15, 16 Fuse 20 (PDC) . . . . . . . . . . . . . . . . 8W-10-12, 14, 31, 32
Cargo Lamp/Switch . . . . . . . . . . . . . . . . . . 8W-10-27, 30 Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26
Center High Mounted Stop Lamp . . . . . . . . 8W-10-32, 33 Fuse 21 (PDC) . . . . . . . . . . . . . . . . . . . 8W-10-19, 23, 34
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26 Fuse 22 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Cigar Lighter Relay . . . . . . . . . . . . . 8W-10-15, 16, 20, 26 Fuse 22 (PDC) . . . . . . . . . . . . . . . . 8W-10-12, 14, 31, 34
Circuit Breaker 28 (JB) . . . . . . . . . . . . . . . 8W-10-15, 16 Fuse 23 (PDC) . . . . . . . . . . . . . . . . 8W-10-12, 14, 33, 35
Circuit Breaker 29 (JB) . . . . . . . . . . . . . . . 8W-10-20, 26 Fuse 24 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Circuit Breaker 30 (JB) . . . . . . . . . . . . . . . 8W-10-15, 16 Fuse 24 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19
Combination Flasher . . . . . . . . . . . . . . . . . 8W-10-31, 35 Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Compass . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28, 29, 30 Fuse 25 (PDC) . . . . . . . . . . . . . . 8W-10-12, 14, 32, 33, 35
Controller Anti-Lock Brake . . . . . . . . 8W-10-25, 26, 32, 33 Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Data Link Connector . . . . . . . . . . . . . . . . . 8W-10-28, 29 Fuse 26 (PDC) . . . . . . . . . . . . . . . . 8W-10-12, 14, 29, 33
Daytime Running Lamp Module . . . . . . . . . . . 8W-10-22 Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Dome Lamp . . . . . . . . . . . . . . . . . . . . 8W-10-28, 29, 30 Fuse 27 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-22, 32
Dome Lamps Switch . . . . . . . . . . . . . . . 8W-10-28, 29, 30 Fusible Link A11 . . . . . . . . . . . . . . . . . . . 8W-10-11, 13
Driver Door Jamb Switch . . . . . . . . . . . . . . . . 8W-10-17 G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 16
Electronic Vacuum Modulator . . . . . . . . . . . . . 8W-10-34 Generator . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 13
Engine Control Module . . . . . . . . . . . . . . . 8W-10-19, 32 Glow Plug Assembly . . . . . . . . . . . . . . . . . . . 8W-10-19
Engine Starter Motor . . . . . . . . . . . . 8W-10-11, 13, 24, 25 Glow Plug Relay . . . . . . . . . . . . . . . . . . . . 8W-10-19, 34
Engine Starter Motor Relay . . . . . . . . . . . . 8W-10-24, 25 Headlamp Delay Module . . . . . . . . . . . . . . 8W-10-22, 24
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . 8W-10-32, 35 Headlamp Switch . . . . . . . . . . . . 8W-10-17, 22, 24, 28, 29
Fog Lamp Relay No. 2 . . . . . . . . . . . . . . . . . . 8W-10-33 High Note Horn . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-24 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26
Fuel Heater Relay . . . . . . . . . . . . . . . . . . . . . 8W-10-24 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23
Fuel Injection Pump . . . . . . . . . . . . . . . . . 8W-10-19, 34 Ignition Switch . . . . . . . . . . . . . . . . 8W-10-15, 16, 17, 18
Fuel Injector No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-10-23 Instrument Cluster . . . . . . . . . . . . . . . 8W-10-17, 27, 30
Fuel Injector No. 2 . . . . . . . . . . . . . . . . . . . . . 8W-10-23 Junction Block . . 8W-10-15, 16, 17, 18, 20, 24, 25, 26, 27, 30
Fuel Injector No. 3 . . . . . . . . . . . . . . . . . . . . . 8W-10-23 Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-10-27, 30
Fuel Injector No. 4 . . . . . . . . . . . . . . . . . . . . . 8W-10-23 Left Fog Lamp . . . . . . . . . . . . . . . . . . . 8W-10-32, 33, 35
Fuel Injector No. 5 . . . . . . . . . . . . . . . . . . . . . 8W-10-23 Left Tail/Stop Lamp . . . . . . . . . . . . . . . . . 8W-10-32, 33
Fuel Injector No. 6 . . . . . . . . . . . . . . . . . . . . . 8W-10-23 Left Visor/Vanity Lamp . . . . . . . . . . . . . 8W-10-28, 29, 30
Fuel Pump Module . . . . . . . . . . . . . . . . . . . . 8W-10-31 Low Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . 8W-10-31 Overhead Module . . . . . . . . . . . . . . . . . 8W-10-28, 29, 30
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26 Oxygen Sensor 1/1 Upstream . . . . . . . . . . . . . 8W-10-23
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26 Oxygen Sensor 1/2 Downstream . . . . . . . . . . . 8W-10-23
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . 8W-10-11, 13, 15, 19 Oxygen Sensor Downstream Relay . . . . . . . . . 8W-10-27
Fuse 3 (PDC) . . . . . . . . . . . . . . . . . 8W-10-11, 13, 15, 19 Oxygen Sensor Upstream Relay . . . . . . . . . . . 8W-10-27
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . 8W-10-11, 13, 19, 20 Park Brake Switch . . . . . . . . . . . . . . . . . . 8W-10-15, 16
Fuse 5 (PDC) . . . . . . . . . . . . . . . . . 8W-10-11, 13, 16, 21 Passenger Power Lock/Window Switch . . . . . . . 8W-10-17
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . 8W-10-11, 13, 21, 24 Power Amplifier . . . . . . . . . . . . . . . . . . . . 8W-10-33, 34
Fuse 7 (PDC) . . . . . . . . . . . . . . . . . 8W-10-11, 13, 22, 24 Power Antenna Relay . . . . . . . . . . . . . . . . . . . 8W-10-29
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17 Power Distribution Center . . 8W-10-2, 7, 11, 12, 13, 14, 15,
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . 8W-10-11, 13, 23, 24 16, 19, 20, 21, 22, 23, 24, 25, 26, 27,
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17 28, 29, 30, 31, 32, 33, 34, 35
Fuse 9 (PDC) . . . . . . . . . . . . . . . . . 8W-10-11, 13, 22, 26 Powertrain Control Module . . . . . . . . . . 8W-10-19, 23, 31
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17 Radiator Fan Motor . . . . . . . . . . . . . . . . . 8W-10-21, 26
Fuse 10 (PDC) . . . . . . . . . . . . . . . . 8W-10-11, 13, 16, 25 Radiator Fan Relay . . . . . . . . . . . . . . . 8W-10-19, 21, 26
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27, 30
Fuse 11 (PDC) . . . . . . . . . . . . . . . . 8W-10-11, 13, 25, 26 Rail Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18 Rear Window Defogger . . . . . . . . . . . . . . . 8W-10-24, 25
Fuse 12 (PDC) . . . . . . . . . . . . . . . . 8W-10-12, 13, 25, 26 Rear Window Defogger Relay . . . . . . . . 8W-10-18, 24, 25
Fuse 13 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-10-24, 25 Right Courtesy Lamp . . . . . . . . . . . . . . . . 8W-10-27, 30
Fuse 13 (PDC) . . . . . . . . . . . . . . . . 8W-10-12, 14, 25, 26 Right Fog Lamp . . . . . . . . . . . . . . . . . . 8W-10-32, 33, 35
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-10-24, 25 Right Tail/Stop Lamp . . . . . . . . . . . . . . . . 8W-10-32, 33
Fuse 14 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 26 Right Visor/Vanity Lamp . . . . . . . . . . . . 8W-10-28, 29, 30
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26 Sentry Key Immobilizer Module . . . . . . . . . 8W-10-22, 32
Fuse 15 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-10-14, 24 Transmission Control Module . . . . . . . . . . . . . 8W-10-27
Fuse 16 (PDC) . . . . . . . . . . . . . . . . 8W-10-12, 14, 27, 30 Underhood Lamp/Mercury Switch . . . . . . . . 8W-10-27, 30

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 8W - 10 - 2 8W-10 POWER DISTRIBUTION XJ
GAS

POWER DISTRIBUTION CENTER

AUTOMATIC
RADIATOR 13 6 SHUT
FAN DOWN
RELAY D 14 12 10 8 5 2 RELAY
11 4
OXYGEN
ENGINE SENSOR
STARTER DOWNSTREAM
MOTOR 10 9 8 20 19 18 RELAY
RELAY
1 7 11 17
C OXYGEN
2 6 12 16
FUEL SENSOR
PUMP 3 4 5 13 14 15 UPSTREAM
RELAY RELAY

FOG CONTROLLER
LAMP 10 9 8 20 19 18
ANTI-LOCK
RELAY 1 7 11 17 BRAKE
NO. 1 B 2 12 RELAY
6 16
3 4 5 13 14 15
A/C FOG
COMPRESSOR LAMP
CLUTCH RELAY
RELAY F27 10A F24 F21 15A F18 15A NO. 2
1 2 7 8 13 14 19 20
A F26 20A F23 15A F20 15A F17 20A
3 4 9 10 15 16 21 22
F25 15A F22 15A F19 20A F16 15A
5 6 11 12 17 18 23 24

FUSES
8
7 14 21 15 28
30A

6 7 13 20 14 27
30A

5 6 12 19 13 26
40A 20A

4 5 11 18 12 25
40A 40A

3 4 10 17 11 24
50A 30A

2 3 9 16 10 23
40A 20A

1 2 8 15 9 22
40A 20A

M2 M1

GENERATOR BATTERY

J008W-7 XJI01002

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 3
GAS

FUSES

FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT

1 - - -

2 40A A1 12RD A0 6RD

3 40A A2 12PK/BK A0 6RD

4 50A A7 10RD/BK A0 6RD

5 40A F141 12LG/RD A0 6RD

6 40A A111 12RD/LG A0 6RD

A3 14RD/WT
7 30A A0 6RD
A3 14RD/WT

8 30A A16 14RD/LG A0 6RD

A17 16RD/BK
9 20A A0 6RD
A17 16RD/BK

10 20A A41 16YL A0 6RD

11 30A A4 12BK/PK A0 6RD

12 40A A10 12RD/DG A0 6RD

13 20A A20 12RD/DB A0 6RD

14 - - A0 6RD

15 - - A0 6RD

16 15A M1 20PK A0 6RD

17 20A F99 18RD A0 6RD

18 15A A142 18DG/OR A999 16RD

19 20A F34 18TN/BK A0 6RD

20 15A L9 20BK/PK A0 6RD

21 15A F142 18DG/WT A999 16RD

22 15A A61 14DG/BK A0 6RD

23 15A F32 20PK/DB A0 6RD

24 - - -

25 15A F61 20WT/OR A0 6RD

26 20A F75 16VT A0 6RD

27 10A F1 20DB/GY A17 16RD/BK

ABS
DRL
4.0L

XJI01003 J008W-7

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 8W - 10 - 4 8W-10 POWER DISTRIBUTION XJ
GAS
CAVITY CIRCUIT FUNCTION
B1 A17 16RD/BK FUSED B(+)

A/C B2 C3 16DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT

COMPRESSOR
B3 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
CLUTCH
RELAY B4 - -

B5 F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)

CAVITY CIRCUIT FUNCTION

D2 A16 14RD/LG FUSED B(+)

AUTOMATIC D4 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)

SHUT - -
D5
DOWN
RELAY D6 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL

A999 16RD
D8 AUTOMATIC SHUT DOWN RELAY OUTPUT
A999 16RD

CAVITY CIRCUIT FUNCTION

B16 G19 20LG/OR ABS WARNING INDICATOR DRIVER
CONTROLLER
B17 - -
ANTI-LOCK
BRAKE B18 G83 18GY/BK ABS RELAY CONTROL
RELAY
B19 Z1 20BK GROUND

B19 Z1 20BK GROUND

B20 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)

CAVITY CIRCUIT FUNCTION

C6 A41 16YL FUSED B(+)

C7 T40 16BR ENGINE STARTER MOTOR RELAY OUTPUT

C8 F45 20YL/RD FUSED B(+) ENGINE STARTER MOTOR RELAY

ENGINE
STARTER C8 T141 20YL IGNITION SWITCH OUTPUT (START)
MOTOR C9 - -
RELAY
C10 Z1 20BK GROUND

C10 Z1 20BK GROUND

C10 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE

C10 T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE

4.0L ABS EXCEPT DRL 2.5L, 4.0L M/T, RHD 4.0L A/T LHD 4.0 A/T
4.0L M/T LHD 4.0L M/T EXCEPT ABS EXCEPT DRL EXCEPT 4.0L M/T
4.0L A/T

J008W-7 XJI01004

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 5
GAS

CAVITY CIRCUIT FUNCTION

L77 20BR/YL FUSED HEADLAMP SWITCH OUTPUT
B6
FOG L77 20BR/YL FUSED HEADLAMP SWITCH OUTPUT
LAMP
B7 - -
RELAY
NO. 1 Z1 20BK GROUND
B8
Z1 20BK GROUND

B9 L139 20VT FOG LAMP RELAY OUTPUT NO. 1

B10 L33 20RD/WT FUSED B(+)

G34 16RD/GY HIGH BEAM INDICATOR DRIVER

B10
G34 16RD/GY HIGH BEAM INDICATOR DRIVER

CAVITY CIRCUIT FUNCTION

B11 F61 20WT/OR FUSED B(+)
FOG
LAMP B12 L39 20LB FOG LAMP RELAY OUTPUT
RELAY
NO. 2 B13 Z1 20BK GROUND

B14 - -

B15 L92 20PK FOG LAMP SWITCH OUTPUT

CAVITY CIRCUIT FUNCTION

A61 14DG/BK FUSED B(+)
FUEL C1
PUMP A61 16DG/BK FUSED B(+)
RELAY A141 14DG/WT FUEL PUMP RELAY OUTPUT
C2

C3 K31 18BR FUEL PUMP RELAY CONTROL

C4 - -
C5 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)

EXCEPT DRL
DRL
XJI01005 J008W-7

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 8W - 10 - 6 8W-10 POWER DISTRIBUTION XJ
GAS

CAVITY CIRCUIT FUNCTION

F99 18RD FUSED B(+)
C16
F99 18RD FUSED B(+)
OXYGEN A242 18VT/OR OXYGEN SENSOR 1/2 DOWNSTREAM
C17
SENSOR
DOWNSTREAM F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
RELAY C18
F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
(GAS)
F26 18PK/OR FUSED IGNITION SWITCH OUTPUT (ST-RUN)
C18
F26 18PK/OR FUSED IGNITION SWITCH OUTPUT (ST-RUN)

C19 - -

C20 K74 18BR/VT OXYGEN SENSOR DOWNSTREAM RELAY CONTROL

CAVITY CIRCUIT FUNCTION

C11 F99 18RD FUSED B(+)

C12 A42 18DG OXYGEN SENSOR 1/1 UPSTREAM

OXYGEN F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
SENSOR C13
UPSTREAM F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
RELAY F26 18PK/OR FUSED IGNITION SWITCH OUTPUT (ST-RUN)
C13
(GAS)
C14 - -

C15 K73 18BR/OR KNOCK SENSOR SIGNAL (-)

CAVITY CIRCUIT FUNCTION

D10 F141 12LG/RD FUSED B(+)

RADIATOR F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)

D11
FAN F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
RELAY
D12 - -

D13 C27 18DB/PK RADIATOR FAN RELAY CONTROL

D14 C25 12LB RADIATOR FAN RELAY OUTPUT

2.5L, 4.0L A/T FOG EXCEPT DRL

4.0L (A/T DRL), (A/T EXCEPT FOG), (M/T)
J008W-7 XJI01006

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 7
DIESEL

POWER DISTRIBUTION CENTER

13 6
FUEL
ENGINE D 14 12 10 8 5 2 HEATER
STARTER RELAY
MOTOR 11 4
RELAY

13 6
RADIATOR C AUTOMATIC
FAN 14 12 10 8 5 2 SHUT
RELAY DOWN
11 4 RELAY

NOT CONTROLLER
USED 10 9 8 20 19 18 ANTI-LOCK
1 11
BRAKE
7 17 RELAY
B 2 12
6 16
A/C 3 4 5 13 14 15 FOG
COMPRESSOR LAMP
CLUTCH RELAY
RELAY
F27 10A F24 10A F21 20A F18
1 2 7 8 13 14 19 20
A F26 20A F23 15A F20 20A F17
3 4 9 10 15 16 21 22
F25 15A F22 20A F19 15A F16 15A
5 6 11 12 17 18 23 24

FUSES
7 8 14 21 15 28
30A 30A

6 7 13 20 14 27
20A 20A

5 6 12 19 13 26
30A 40A

4 5 11 18 12 25
40A 40A

3 4 10 17 11 24
30A 40A

2 3 9 16 10 23
50A 40A

1 2 8 15 9 22
50A 50A

M2 M1

GENERATOR BATTERY

XJI01007 J008W-7

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 8W - 10 - 8 8W-10 POWER DISTRIBUTION XJ
DIESEL

FUSES

FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT

1 - - -

2 50A A54 12RD/GY A0 6RD

3 50A A54 12RD/GY A0 6RD

4 30A A16 12RD/LG A0 6RD

5 40A A1 12RD A0 6RD

6 30A A61 14LG/RD A0 6RD

7 20A A41 16YL A0 6RD

8 30A A3 14RD/WT A0 6RD

9 50A A7 10RD/BK A0 6RD

10 40A A2 12PK/BK A0 6RD

11 40A A111 12RD/LG A0 6RD

12 40A A10 12RD/DG A0 6RD

13 40A F141 12LG/RD A0 6RD

14 20A A20 12RD/DB A0 6RD

15 30A A4 12BK/PK A0 6RD

M1 20PK
16 15A A0 6RD
M1 20PK

17 - - A0 6RD

18 - - -

19 15A F32 20PK/DB A0 6RD

A17 18RD/BK
20 20A A0 6RD
A17 16RD/BK

21 20A F142 16DG/OR A142 16DG/OR

22 20A F75 16VT A0 6RD

23 15A L9 20BK/PK A0 6RD

24 10A F16 16RD/LG A16 12RD/LG

25 15A F61 20WT/OR A0 6RD

26 20A F34 18TN/BK A0 6RD

27 10A F1 20DB/GY A17 18RD/BK

ABS

J008W-7 XJI01008

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 9
DIESEL

CAVITY CIRCUIT FUNCTION

B1 A17 16RD/BK FUSED B(+)

A/C B2 C3 16DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT

COMPRESSOR
B3 C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
CLUTCH
RELAY B4 - -

B5 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT

CAVITY CIRCUIT FUNCTION

C2 A16 12RD/LG FUSED B(+)

AUTOMATIC C4 A16 12RD/LG FUSED B(+)

SHUT
C5 - -
DOWN
RELAY C6 K51 20DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL

A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT

C8
A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT

CAVITY CIRCUIT FUNCTION

B16 G19 20LG/OR ABS WARNING INDICATOR DRIVER

CONTROLLER B17 - -
ANTI-LOCK
F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
BRAKE B18
RELAY F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)

B19 Z1 20BK GROUND

B20 G83 18GY/BK ABS RELAY CONTROL

XJI01009 J008W-7

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 8W - 10 - 10 8W-10 POWER DISTRIBUTION XJ
DIESEL

CAVITY CIRCUIT FUNCTION

D10 A41 16YL FUSED B(+)
ENGINE
D11 T141 20YL IGNITION SWITCH OUTPUT (START)
STARTER
MOTOR D12 - -
RELAY
Z1 20BK GROUND
D13
Z1 20BK/YL GROUND

D14 T40 16BR ENGINE STARTER MOTOR RELAY OUTPUT

CAVITY CIRCUIT FUNCTION

B11 F61 20WT/OR FUSED B(+)

B12 L39 20LB FOG LAMP RELAY OUTPUT

FOG
LAMP Z1 20BK GROUND
B13
RELAY Z1 20BK/YL GROUND

B14 - -

B15 L92 20PK FUSED FOG LAMP SWITCH FEED

CAVITY CIRCUIT FUNCTION

D2 A61 14LG/RD FUSED B(+)

FUEL D4 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)

HEATER
D5 - -
RELAY
D6 Z1 18BK GROUND

D8 A93 14RD/BK FUEL HEATER RELAY OUTPUT

CAVITY CIRCUIT FUNCTION

C10 F141 12LG/RD FUSED B(+)

RADIATOR A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT

FAN C11
A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
RELAY
C12 - -

C13 C27 20DB/PK RADIATOR FAN RELAY CONTROL

C14 C25 12LB RADIATOR FAN RELAY OUTPUT

J008W-7 XJI01010

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 11
GAS
S118

A0 A0 A11
BATTERY 6 6 FUSIBLE 6
(8W-20-2) RD RD LINK BK/WT
A11
10
ENGINE DG
GENERATOR
STARTER (8W-20-2)
MOTOR
(8W-21-2)
(8W-21-3)
(8W-21-4)
(8W-21-5)

POWER
8 9 10 11 12
DISTRIBUTION
CENTER
FUSE FUSE FUSE FUSE FUSE (8W-10-2)
2 3 4 5 6
40A 40A 50A 40A 40A
1 (8W-10-15) 2 (8W-10-15) 3 (8W-10-20) 4 (8W-10-21) 5 (8W-10-21)

A111
12
RD/LG
A1 A2 A7 F141 D5 C100
12 12 10 12
RD PK/BK RD/BK LG/RD LHD RHD

C2 C6 11 C201 7 C202
C100 TO TO
JUNCTION RADIATOR
TO TO BLOCK FAN 8 C209
IGNITION IGNITION RELAY
TO
SWITCH SWITCH (IN PDC)
BLOWER
MOTOR
RELAY

13 14 22 16 17
FUSE FUSE FUSE FUSE FUSE A
7 8 9 10 11
30A 30A 20A 20A 30A TO
(8W-10-22) (8W-10-23) (8W-10-22) (8W-10-25) (8W-10-25) FUSE 12
6 7 15 23 24
(PDC)
(8W-10-12)

A3 A16 A17 A4
14 14 16 12
RD/WT RD/LG RD/BK BK/PK

TO TO
TO AUTOMATIC A17 FUSE A41 TO
DAYTIME A3
SHUT DOWN 16 27 16 JUNCTION
RUNNING 14 RD/BK YL
RD/WT RELAY (IN PDC) BLOCK
LAMP (IN PDC)
MODULE
TO TO
D1 C100 A/C ENGINE
COMPRESSOR STARTER
TO CLUTCH MOTOR
HEADLAMP RELAY RELAY
SWITCH (IN PDC) (IN PDC)
XJI01011 J008W-7

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 8W - 10 - 12 8W-10 POWER DISTRIBUTION XJ
GAS

POWER
FROM
FUSE 11
DISTRIBUTION
(PDC) CENTER
(8W-10-11) (8W-10-2)
A

18 A23 A18
FUSE FUSE FUSE
12 16 19
40A 15A 20A
(ABS) (8W-10-27) (8W-10-28)
25 19 A24 A21 A17
(8W-10-25) (8W-10-29)
FUSE FUSE
13 17
20A 20A
26 (ABS) A22 (4.0L)
(8W-10-25) (8W-10-27)

F34
18
TN/BK
E6
C100
A18
LHD
A10 A20 M1 F99
EXCEPT BUILT-
12 12 20 18
UP-EXPORT OTHER
RD/DG RD/DB PK RD

TO TO TO TO TO TO
CONTROLLER CONTROLLER S135 OXYGEN HEADLAMP S218
ANTI-LOCK ANTI-LOCK SENSOR SWITCH
BRAKE BRAKE DOWNSTREAM
TO
RELAY DATA
(IN PDC)
CONNECTOR

A16 A11 A9 A6 A4
FUSE FUSE FUSE FUSE FUSE
20 22 23 25 26
15A 15A 15A 15A 20A
(8W-10-31) (8W-10-31) (8W-10-33) (8W-10-33) (8W-10-33)
A15 A12 A10 A5 A3

L9 A61 F32 F61

C4 C100
20 14 20 20 F75
BK/PK DG/BK PK/DB WT/OR 16
VT
F5
C100 F8 C100 LHD RHD
B11
TO TO
FUEL FOG 14 C200 21 C204
14 C107 TO F75 F75
TO PUMP LAMP
BRAKE 14 16
COMBINATION RELAY RELAY VT VT
LAMP
FLASHER (IN PDC) TO
NO. 2
SWITCH (IN PDC)
POWERTRAIN
CONTROL
MODULE TO
RHD S301
LHD
J008W-7 XJI01012

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 13
DIESEL
S118

A0 A0 A11
BATTERY 2/0 6 FUSIBLE 6
(8W-20-4) RD RD LINK BK/GY
A11
10
ENGINE DG
GENERATOR
STARTER (8W-20-4)
MOTOR
(8W-21-6)

POWER
8 9 10 11 12
DISTRIBUTION
CENTER
FUSE FUSE FUSE FUSE FUSE (8W-10-7)
2 3 4 5 6
50A 50A 30A 40A 30A
1 (8W-10-19) 2 (8W-10-19) 3 (8W-10-19) 4 (8W-10-16) 5 (8W-10-24)

A61
A54 A54 A16 A1 14
12 12 12 12 LG/RD
RD/GY RD/GY RD/LG RD

C2 C100 TO
TO TO TO FUEL
S153 S153 S151 TO HEATER
IGNITION RELAY
SWITCH (IN PDC)

13 14 22 16 17 18
FUSE FUSE FUSE FUSE FUSE FUSE B
7 8 9 10 11 12
20A 30A 50A 40A 40A 40A TO
(8W-10-24) (8W-10-24) (8W-10-26) (8W-10-16) (8W-10-26) (ABS) FUSE 13
6 7 15 23 24 25
(8W-10-26) (PDC)
(8W-10-14)

A41 A3 A7 A2 A111 A10

16 14 10 12 12 12
YL RD/WT RD/BK PK/BK RD/LG RD/DG

C6 C100 D5 C100
D1 C100 TO
LHD RHD CONTROLLER
TO ANTI-LOCK
TO
IGNITION BRAKE
HEADLAMP
SWITCH SWITCH 11 C201 7 C202
TO
ENGINE TO
STARTER JUNCTION
MOTOR BLOCK
RELAY TO 8 C209
(IN PDC) HEADLAMP
DELAY
TO
MODULE
BLOWER
MOTOR
RELAY

XJI01013 J008W-7

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 8W - 10 - 14 8W-10 POWER DISTRIBUTION XJ
DIESEL

POWER
FROM
FUSE 12
DISTRIBUTION
(PDC) CENTER
(8W-10-13) (8W-10-7)
B

19 20 21 A23 A18
FUSE FUSE FUSE FUSE FUSE
13 14 15 16 19
40A 20A 30A 15A 15A
(8W-10-26) (ABS) (8W-10-24) (8W-10-30) (8W-10-32)
26 27 28 A24 A17
(8W-10-26)

F32
F141 A4 M1 20
12 A20 12 M1 20 PK/DB
LG/RD 12 BK/PK 20 PK
RD/DB PK
F8 C100
TO TO TO
RADIATOR TO JUNCTION TO UNDERHOOD TO
FAN CONTROLLER BLOCK JUNCTION LAMP/ BRAKE
RELAY ANTI-LOCK BLOCK MERCURY LAMP
(IN PDC) BRAKE SWITCH SWITCH

A16 A11 A9 A6 A4
FUSE FUSE FUSE FUSE FUSE
20 22 23 25 26
20A 20A 15A 15A 20A
(8W-10-32) (8W-10-34) (8W-10-35) (8W-10-35) (8W-10-29)
A15 A12 A10 A5 A3

C4 C100
A17 A17 F75 L9 F61 F34
18 16 16 20 20 18
RD/BK RD/BK VT BK/PK WT/OR TN/BK
E6
LHD RHD F5 C100
TO B11 C100 TO A18
FUSE 27 FOG
(IN PDC) 14 C200 21 C204 LAMP
TO TO
F75 F75 COMBINATION RELAY S218
14 16 FLASHER (IN PDC)
VT VT

TO
A/C
COMPRESSOR
TO
CLUTCH
S301
RELAY
(IN PDC)
LHD
RHD
J008W-7 XJI01014

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 15
GAS
BATT A0 (8W-10-11)
POWER BRAKE
8 9
DISTRIBUTION WARNING
CENTER PRESSURE
FUSE FUSE (8W-10-2) SWITCH
2 3
1 (8W-40-9)
40A 40A
1 2 G9
20
GY/BK
A14
C100
E2
A1 A2
12 12 S211
RD PK/BK
G9
20
GY/BK
LHD RHD

C2 C6
C100 66 C201 13 C203

FROM
G9
S210 20
(8W-10-17) GY/BK

A1 A2 G9 G26 PARK
12 12 20 20 BRAKE
RD PK/BK GY/BK LB
SWITCH
(8W-40-9)
7 C1 3 C1 2 C1 1 C2
IGNITION
KEY-IN
SWITCH
SWITCH 1 START
1 4 1 4 1 4 1 4 1 4 2 RUN
2 3 2 3 2 3 2 3 2 3 0 OFF
0 0 0 0 0 3 LOCK
4 ACC
8 C1 9 C1 4 C1 10 C1 1 C1 2 C2
A31 A21 A22 A41 Z1 G16
12 12 12 14 20 20
BK/WT DB BK/OR YL BK BK/LB

RHD LHD
S207
(8W-15-16)
10 C201 RUN A22 TO
Z1 S200
(8W-10-18) 14 (8W-10-17)
BK
A31
12
ST-RUN A21 ST A41
BK/WT G108
(8W-10-17) (8W-10-18) (8W-15-16)
L1 C4
JUNCTION
86 BLOCK
CIGAR (8W-12-2)
FUSE FUSE CIRCUIT CIRCUIT LIGHTER
17 18 BREAKER BREAKER RELAY
15A 10A 28 30 (8W-41-2)
(8W-12-19) (8W-12-19) 25A 20A (8W-41-3)
(8W-12-20) (8W-12-20) (8W-12-25) (8W-12-27)
(8W-12-26) 85

RHD
LHD
XJI01015 J008W-7

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 8W - 10 - 16 8W-10 POWER DISTRIBUTION XJ
DIESEL
BATT A0 BRAKE
(8W-10-13)
WARNING
POWER PRESSURE
11 16
DISTRIBUTION SWITCH
CENTER 1 (8W-40-10)
FUSE FUSE (8W-10-7)
5 10 G9
40A 40A 20
4 23 GY/BK
A14
C100
E2
S211
A1 A2
12 12 G9
RD PK/BK 20
GY/BK
LHD RHD FROM
S210
C2 C6
C100 66 C201 13 C203 (8W-10-17)
G9
20
G9 GY/BK G26
20 20
A1 A2 GY/BK LB
12 12
RD PK/BK
PARK
BRAKE
SWITCH
(8W-40-10)
7 C1 3 C1 2 C1 1 C2
IGNITION
KEY-IN
SWITCH
SWITCH 1 START
1 4 1 4 1 4 1 4 1 4 2 RUN
2 3 2 3 2 3 2 3 2 3 0 OFF
0 0 0 0 0 3 LOCK
4 ACC
8 C1 9 C1 4 C1 10 C1 1 C1 2 C2
A31 A21 A22 A41 Z1 G16
12 12 12 14 20 20
BK/WT DB BK/OR YL BK BK/LB

LHD RHD
S207
10 C201 RUN A22 (8W-15-16)
(8W-10-18) Z1 TO
14 S200
BK (8W-10-17)
A31
12 ST-RUN A21 ST A41
BK/WT G108
(8W-10-17) (8W-10-18)
L1 C4 (8W-15-16)
JUNCTION
86 BLOCK
CIGAR (8W-12-2)
FUSE FUSE CIRCUIT CIRCUIT LIGHTER
17 18 BREAKER BREAKER RELAY
15A 10A 28 30 (8W-41-2)
(8W-12-19) (8W-12-19) 25A 20A (8W-41-3)
(8W-12-20) (8W-12-20) (8W-12-25) (8W-12-27)
(8W-12-26) 85

RHD
J008W-7 LHD XJI01016

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 17

INSTRUMENT PASSENGER PASSENGER

CLUSTER POWER POWER
(8W-40-11) LOCK/ LOCK/
WINDOW WINDOW
BATT A1 8 C2 8 C2 SWITCH 8 C2 SWITCH
G26 G26 (FULL G26 (FULL
(8W-10-15) 20 20 OPTIONS) 20 OPTIONS)
(8W-10-16) LB LB (8W-61-2) LB (8W-61-3)
5 C300 2 C306
G26 G26
20 20
A1
LB LB
12
RD 29 C201 3 C203
LHD RHD
S210
G26 G26
20 20
LB LB
7 C1 1 C2 5 C1
IGNITION HEADLAMP
KEY-IN
SWITCH SWITCH
SWITCH 1 START 0 OFF
1 4 1 4 2 RUN 1 PARK
0 1 2
2 3 2 3 0 OFF 2 HEAD
0 0 3 LOCK (8W-50-2)
4 ACC (8W-50-3)
(8W-10-15) 6 C1
9 C1 8 C1 2 C2 (8W-10-16)
A21 A31 G16 G16
12 12 20 20
DB BK/WT BK/LB BK/LB

S200
LHD RHD

RHD LHD 17 C200 4 C203

G16 G16
20 20
64 C201 BK/LB BK/LB
B C317 B C318
G16 G16
18 18
BK/LB BK/LB

RUN-ACC A31 2
2 DRIVER
(8W-10-15) DRIVER DOOR
A21 (8W-10-16) DOOR JAMB
12 JAMB
DB SWITCH
SWITCH (8W-39-7)
(8W-39-6)

L2 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE FUSE
8 9 10 11 27
SPARE 10A 15A 20A 10A
(8W-12-13) (8W-12-13) (8W-12-14) (8W-12-15) (8W-12-25)
(8W-12-16) (8W-12-26)

XJI01017 J008W-7

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 8W - 10 - 18 8W-10 POWER DISTRIBUTION XJ

BATT A2
(8W-10-15)
(8W-10-16)

A2
12
PK/BK

3 C1
IGNITION
SWITCH
1 START
1 4 1 4 2 RUN
2 3 2 3 0 OFF
0 0 3 LOCK
4 ACC
(8W-10-15)
4 C1 10 C1 (8W-10-16)

A22 A41
12 14
BK/OR YL

RHD LHD LHD RHD

62 63 C201

A22 A41
12 14
BK/OR YL

M2 C4 M1 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
12 22 25 19
10A 20A 15A 10A
(8W-12-17) (8W-12-22) (8W-12-22) (8W-12-19)
(8W-12-18) (8W-12-23) (8W-12-23) (8W-12-20)

86
REAR FUSE FUSE
WINDOW 24 26
DEFOGGER SPARE 10A
RELAY (8W-12-22) (8W-12-25)
(8W-48-2) (8W-12-23) (8W-12-26)
(8W-48-3)
85

J008W-7 XJI01018

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 19
DIESEL
BATT A0 (8W-10-13)
POWER
8 9 10
DISTRIBUTION
CENTER
FUSE FUSE FUSE (8W-10-7)
2 3 4
50A 50A 30A
1 2 3

A54 A54 A16

12 12 12
RD/GY RD/GY RD/LG

S153 S151
A54 A16 A16 A16
10 12 12 12
RD/GY RD/LG RD/LG RD/LG

POWER
A14
C4 C2
A8
DISTRIBUTION
AUTOMATIC CENTER
FUSE SHUT FUSE (8W-10-7)
21 DOWN 24
20A RELAY 10A
(8W-10-34) (8W-30-22)
A13 A7
C6 C8

A142
18
DG/OR

C11 A142
RADIATOR 18
DG/OR
FAN
RELAY B5
(IN PDC) A/C
(8W-42-10) COMPRESSOR
C13
CLUTCH
A142 A142
16 16 RELAY
DG/OR DG/OR B3 (IN PDC)
(8W-42-8)
S137
1
GLOW A142 A142 A142 A142 A142 F16
PLUG 16 16 16 16 16 16
DG/OR DG/OR DG/OR DG/OR DG/OR RD/LG
RELAY
(8W-30-25)
9
4 FUEL
K154 INJECTION
10 PUMP
GY (8W-30-26)

GLOW 2 C1 28 C1 12 C3 2 C1 22 C1
PLUG ENGINE POWERTRAIN
ASSEMBLY CONTROL CONTROL
(8W-30-25) MODULE MODULE
(8W-30-22) (8W-30-23)

XJI01019 J008W-7

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 8W - 10 - 20 8W-10 POWER DISTRIBUTION XJ
GAS
BATT A0 (8W-10-11)
POWER
10
DISTRIBUTION
CENTER
FUSE (8W-10-2)
4
50A
3

A7
10
RD/BK

2 C2
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE FUSE FUSE FUSE

1 2 15 20 21
25A 25A 25A 15A 15A
(8W-12-5) (8W-12-5) (8W-12-19) (8W-12-21) (8W-12-21)
(8W-12-20)

30 86 30
CIGAR HORN
CIRCUIT LIGHTER RELAY
BREAKER RELAY (8W-41-2)
29 (8W-41-2) (8W-41-3)
25A (8W-41-3)
(8W-12-27)
87 85 87

M6 C4 4 C2

F30 X2
16 20
RD DG/RD

LHD RHD

50 C201 S131
F30 F30
16 16
RD RD X2 X2
20 20
DG/RD DG/RD

1
CIGAR LOW HIGH
LIGHTER NOTE NOTE
(8W-41-2) HORN HORN
(8W-41-3) (8W-41-2) (8W-41-2)
(8W-41-3) (8W-41-3)
J008W-7 XJI01020

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 21
GAS
BATT A0 (8W-10-11)
POWER
11 12
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-2)
5 6
40A 40A
4 5

F141 A111
12 12
LG/RD RD/LG

D10
RADIATOR D5 C100
FAN
RELAY A111
(IN PDC) 12
(8W-42-9) RD/LG
D14

C25 LHD RHD

12
LB

11 C201 7 C202

8 C209

A111
12
RD/LG

1 4
RADIATOR BLOWER
FAN MOTOR
MOTOR RELAY
(8W-42-9) (8W-42-2)
(8W-42-3)
1 (8W-42-4)
(8W-42-5)

C1
12
DG

A
BLOWER
MOTOR
(8W-42-2)
(8W-42-3)
(8W-42-4)
XJI01021 (8W-42-5) J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 10 - 22 8W-10 POWER DISTRIBUTION XJ
GAS
BATT A0 (8W-10-11)
POWER
13 22 A1
DISTRIBUTION
CENTER
FUSE FUSE FUSE (8W-10-2)
7 9 27
30A 20A 10A
6 15 A2

A3 A3 A17 A17 F1
14 14 16 16 20
RD/WT RD/WT RD/BK RD/BK DB/GY

B1
A/C
COMPRESSOR
CLUTCH
RELAY
B2 (IN PDC)
(8W-42-7)
C3
16
DB/BK
4.0L
RHD OTHER E10 C100

D1 C100 4 C108

C3 F1
16 20
DB/BK DB/GY

A/C
COMPRESSOR
CLUTCH
A3 (8W-42-7)
14
RD/WT

8 C1
HEADLAMP
SWITCH
(8W-50-2)
(8W-50-3)
A3
14
RD/WT 6
SENTRY
6 2 KEY
DAYTIME HEADLAMP IMMOBILIZER
RUNNING DELAY MODULE
LAMP MODULE (8W-39-4)
(8W-39-5)
MODULE (8W-50-8)
(8W-50-18) (8W-50-9)

J008W-7 XJI01022

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 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 23
GAS
BATT A0 (8W-10-11)
POWER
14
DISTRIBUTION
A20 CENTER
FUSE FUSE (8W-10-2)
8 18
30A 15A
7 A19

A16 A142
14 18
RD/LG DG/OR
D2 1 C107
AUTOMATIC
A999 A142
SHUT 16 18
DOWN RD DG/OR
RELAY
D8 (IN PDC) S109
(8W-30-2)
A999
16 4.0L 2.5L
RD

POWER A142 A142

A14 18 18
DISTRIBUTION DG/OR DG/OR
FUSE CENTER A142 2 1
21 (8W-10-2) 18
15A DG/OR
RAIL IGNITION
A13
COIL COIL
(8W-30-5) (8W-30-5)

F142
18
DG/WT S113
4.0L 2.5L A142 A142 A142 A142 A142 A142
18 18 18 18 18 18
DG/OR DG/OR DG/OR DG/OR DG/OR DG/OR
S168
1 1
FUEL FUEL
F142 F142 INJECTOR INJECTOR
18 18 NO. 3 NO. 6
DG/WT DG/WT (8W-30-6) (4.0L)
12 C3 7 C107 1 1 (8W-30-6)
POWERTRAIN FUEL FUEL
CONTROL F142
INJECTOR INJECTOR
MODULE 20
DG/WT NO. 2 NO. 5
(8W-30-2) (8W-30-6) (4.0L)
(8W-30-6)
S110 1 1
FUEL FUEL
F142 F142
20 20
INJECTOR INJECTOR
DG/WT DG/WT NO. 1 NO. 4
(8W-30-6) (8W-30-6)
1 1

OXYGEN OXYGEN
SENSOR SENSOR
1/1 1/2
UPSTREAM DOWNSTREAM
(8W-30-8) (8W-30-8)

XJI01023 J008W-7

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 8W - 10 - 24 8W-10 POWER DISTRIBUTION XJ
DIESEL
BATT A0 (8W-10-13)
POWER
12 21 13 14
DISTRIBUTION
CENTER
FUSE FUSE FUSE FUSE (8W-10-7)
6 15 7 8
30A 30A 20A 30A
5 28 6 7

A61 A4 A41 A3
14 12 16 14
LG/RD BK/PK YL RD/WT

1 C2
JUNCTION
BLOCK
(8W-12-2) D1 C100
30
REAR D10
WINDOW ENGINE
DEFOGGER STARTER
RELAY MOTOR
(8W-48-2)
(8W-48-3) RELAY
87
D14 (IN PDC)
(8W-21-6)
T40
16
FUSE FUSE BR
13 14
SPARE 10A
(8W-12-17) (8W-12-17)
(8W-12-18) (8W-12-18)
10 C111

A3
1 C6 T40 14
14 RD/WT
C15
BR
12
BK/WT

4 C326 ENGINE
STARTER
MOTOR
C15 (8W-21-6)
D2 12
FUEL BK/WT
HEATER 8 C1
RELAY HEADLAMP
2 C312 A3
(IN PDC) 3 C310 SWITCH
(8W-30-24) 14
D8 RD/WT (8W-50-3)
C15
A93 12
14 BK/WT
RD/BK

1 2
FUEL REAR HEADLAMP
HEATER WINDOW DELAY
(8W-30-24) DEFOGGER MODULE
(8W-48-2) (8W-50-9)
(8W-48-3)
J008W-7 XJI01024

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 25
GAS
BATT A0 (8W-10-11)
POWER
16 17 18 19
DISTRIBUTION
CENTER
FUSE FUSE FUSE FUSE (8W-10-2)
10 11 12 13
20A 30A 40A 20A
23 24 25 (ABS) 26 (ABS)

A41 A4 A10 A20

16 12 12 12
YL BK/PK RD/DG RD/DB

C6 25 9
ENGINE CONTROLLER
STARTER ANTI-LOCK
MOTOR BRAKE
RELAY (8W-35-2)
C7 (IN PDC) 1 C2
(8W-21-2)
(8W-21-3)
JUNCTION
(8W-21-4) BLOCK
30
(8W-21-5) (8W-12-2)
REAR
WINDOW
DEFOGGER
T40
RELAY
16
(8W-48-2)
BR
87 (8W-48-3)

FUSE FUSE
13 14
SPARE 10A
(8W-12-17) (8W-12-17)
1 C108 (8W-12-18) (8W-12-18)

1 C6
C15
12
BK/WT

T40
4 C326
16
C15
BR
12
BK/WT
2 C312
3 C310
C15
ENGINE 12
STARTER BK/WT
MOTOR
(8W-21-2) REAR
(8W-21-3)
(8W-21-4)
WINDOW
(8W-21-5) DEFOGGER
(8W-48-2)
(8W-48-3)

XJI01025 J008W-7

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 8W - 10 - 26 8W-10 POWER DISTRIBUTION XJ
DIESEL
BATT A0 (8W-10-13)
POWER
22 17 18 20 19
DISTRIBUTION
CENTER
FUSE FUSE FUSE FUSE FUSE (8W-10-7)
9 11 12 14 13
50A 40A 40A 20A 40A
15 24 25 (ABS) 27 (ABS) 26

A7 A111 F141
10 12 12
RD/BK RD/LG LG/RD
D5 C100 C10
A10 A20 RADIATOR
LHD RHD 12 12
RD/DG RD/DB FAN
RELAY
11 C201 7 C202
(IN PDC)
C14 (8W-42-10)
8 C209 C25
4 12
25 9
BLOWER LB
CONTROLLER
MOTOR ANTI-LOCK 1
RELAY RADIATOR
BRAKE
(8W-42-2) (8W-35-3) FAN
(8W-42-3) MOTOR
(8W-42-4) (8W-42-10)
(8W-42-5)
2 C2
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT FUSE FUSE FUSE
BREAKER 2 15 21
29 25A 25A 15A
25A (8W-12-5) (8W-12-19) (8W-12-21)
(8W-12-27) (8W-12-20)
30 86 30
CIGAR HORN
LIGHTER RELAY
RELAY (8W-41-2)
(8W-41-2) (8W-41-3)
(8W-41-3)
87 85 87
FUSE FUSE
1 20
25A 15A
(8W-12-5) (8W-12-21)

M6 C4 4 C2
F30 X2
16 20
RD DG/RD
LHD RHD
S131
50 C201 X2 X2
20 20
DG/RD DG/RD
1
CIGAR LOW HIGH
LIGHTER NOTE NOTE
(8W-41-2) HORN HORN
(8W-41-3) (8W-41-2) (8W-41-2)
J008W-7 (8W-41-3) (8W-41-3) XJI01026

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 27
GAS
BATT A0 (8W-10-11)
POWER
A23 A21
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-2)
16 17
15A 20A
A24 A22 (4.0L)

M1
20 F99
PK 18
RD
S135
M1 M1 M1 C16
20 20 20 OXYGEN
PK PK PK SENSOR
12 C1 DOWNSTREAM
JUNCTION RELAY
BLOCK (IN PDC)
(8W-12-2) (8W-30-9)
1 F99
4 C7 S18 C4 3 C3 UNDERHOOD 18
LAMP/ RD
M1 M1 M1 MERCURY
20 20 20 SWITCH
PK PK PK
(8W-44-6)
5 C314 RHD LHD 25
TRANSMISSION C11
6 C201 C
CONTROL OXYGEN
TO MODULE SENSOR
S347 (4.0L) UPSTREAM
LHD RHD M1
20 S361 (8W-31-4) RELAY
PK (8W-10-28) (IN PDC)
(8W-10-29) (8W-30-9)
M1 M1
20 18 S214
PK PK
M1 M1 M1 M1
20 20 20 20
PK PK PK PK

A 7 C2
CARGO RADIO
LAMP/ A C208 A C207 (8W-47-2)
SWITCH (8W-47-3)
(8W-47-9)
(8W-44-8)
(8W-47-10)
(8W-44-9)

9 C1
INSTRUMENT
CLUSTER
(8W-40-2)
M1 M1
18 18
PK PK

1 1
LEFT RIGHT
SKIM
COURTESY COURTESY EXCEPT SKIM
LAMP LAMP
(8W-44-6) (8W-44-6)
XJI01027 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 10 - 28 8W-10 POWER DISTRIBUTION XJ
EXCEPT BUILT-UP-EXPORT
FROM BATT A0 (8W-10-11)
JUNCTION POWER
BLOCK DISTRIBUTION
(8W-10-27) A18
CENTER
C FUSE (8W-10-2)
19
20A
A17

M1
20
F34
PK
18
TN/BK
LHD RHD

E6 C100 A18 C100

F34
18
F34
TN/BK
18
TN/BK
4 C1
HEADLAMP S218
SWITCH
(8W-50-2) F34 F34 F34
18 18 18
TN/BK TN/BK TN/BK
SKIM OTHERS

16 4 C1 16
DATA HEADLAMP DATA
S361 LINK SWITCH LINK
CONNECTOR (8W-50-2) CONNECTOR
(8W-30-19) (8W-30-19)

S347

FULL
M1 M1 OTHERS OPTIONS M1 M1
20 20 20 20
PK PK PK PK
MIDLINE BASE/POLICE M1
20
PK 2
OVERHEAD
2 MODULE
M1 M1 COMPASS (8W-49-2)
20 20 (8W-49-3)
(8W-49-2)
PK PK
A (8W-49-3)
RIGHT A
VISOR/ C 2 LEFT
VANITY DOME DOME VISOR/
LAMP LAMPS LAMP VANITY
(8W-44-5) SWITCH (8W-44-5) LAMP
(8W-44-5) (8W-44-5)

J008W-7 XJI01028

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 29
BUILT-UP-EXPORT
BATT A0 (8W-10-11)
FROM (8W-10-13)
JUNCTION POWER
BLOCK DISTRIBUTION
(8W-10-27) A4 A18
CENTER
FUSE FUSE (8W-10-2)
C
26 19
20A 20A
M1 A3 A17
20
PK
DIESEL GAS
F34
18
TN/BK
LHD RHD

E6 C100 A18 C100

F34
18
TN/BK

S218

F34 F34 F34

18 18 18
TN/BK TN/BK TN/BK

B C1 4 C1 16
SKIM OTHERS POWER HEADLAMP DATA
ANTENNA SWITCH LINK
RELAY (8W-50-3) CONNECTOR
(8W-47-4) (8W-30-19)
S361 (8W-30-34)

S347
FULL
OTHERS OPTIONS
M1 M1
20 20
PK PK
M1 M1 MIDLINE BASE/POLICE M1
20 20 20
2
PK PK PK
OVERHEAD
M1 M1
20 20
2 MODULE
PK PK
COMPASS (8W-49-2)
(8W-49-2) (8W-49-3)
A (8W-49-3)
A
RIGHT LEFT
2
VISOR/ VISOR/
C DOME
VANITY VANITY
DOME LAMP
LAMP LAMP
LAMPS (8W-44-5)
(8W-44-5) (8W-44-5)
SWITCH
(8W-44-5)
XJI01029 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 10 - 30 8W-10 POWER DISTRIBUTION XJ
DIESEL
BATT A0 (8W-10-13)
POWER
A23
DISTRIBUTION
CENTER
FUSE (8W-10-7)
16
15A
A24

M1 M1
20 20
PK PK
12 C1 1
JUNCTION UNDERHOOD
BLOCK LAMP/
(8W-12-2) MERCURY
SWITCH
4 C7 S18 C4 3 C3 (8W-44-7)
M1 M1 M1
20 20 20
PK PK PK

S347
5 C314
OTHERS FULL OPTIONS
M1
LHD RHD RHD LHD M1 M1 20
20 20 PK M1 M1
PK PK
M1 M1 6 C201 A
20 20
20 18 PK PK
PK PK
RIGHT
VISOR/
VANITY 2
LAMP COMPASS
M1 (8W-44-5)
A A (8W-49-2)
20 (8W-49-3)
CARGO PK
LEFT
LAMP/ VISOR/
SWITCH VANITY
(8W-44-8) LAMP
(8W-44-9) 2 (8W-44-5)
OVERHEAD MIDLINE BASE/POLICE
MODULE
(8W-49-2)
(8W-49-3) M1 M1
20 20
S214 PK PK

M1 M1 M1 M1
20 20 20 20 C 2
PK PK PK PK DOME DOME
7 C2 LAMPS LAMP
A C208 A C207
RADIO SWITCH (8W-44-5)
(8W-47-2) M1 (8W-44-5)
M1
(8W-47-3) 18 18
(8W-47-9) PK PK
9 C1 (8W-47-10)
INSTRUMENT 1 1
CLUSTER LEFT RIGHT
(8W-40-2)
COURTESY COURTESY
LAMP LAMP
(8W-44-7) (8W-44-7)
J008W-7 XJI01030

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 31
GAS
BATT A0 (8W-10-7)
POWER
A16 A11
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-2)
20 22
15A 15A
A15 A12

A61
14
DG/BK

C1
FUEL
PUMP
RELAY
(IN PDC)
C2 (8W-30-3)
(8W-30-4)

L9 A141 A61
20 14 16
BK/PK DG/WT DG/BK

B11 D2
C100 14 C107
F5

A141
16
DG/WT

LHD RHD

13 C200 22 C204

L9 A141 A61
20 16 14
BK/PK DG/WT DG/BK

2 1 22 C1
COMBINATION FUEL POWERTRAIN
FLASHER PUMP CONTROL
(8W-52-2) MODULE MODULE
(8W-52-3) (8W-30-3) (8W-30-3)
(8W-30-4) (8W-30-4)
LHD
XJI01031 RHD J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 10 - 32 8W-10 POWER DISTRIBUTION XJ
DIESEL
BATT A0 (8W-10-13)
POWER
A18 A6 A16 A1 DISTRIBUTION
FUSE FUSE FUSE FUSE CENTER
19 25 20 27 (8W-10-7)
15A 15A 20A 10A
A17 A5 A15 A2

F61
F32 20 A17 A17
20 WT/OR 16 18 F1
PK/DB RD/BK RD/BK 20
B11
DB/GY
FOG
F8 C100 LAMP B1
A/C E10 C100
F32 RELAY
COMPRESSOR
20 (IN PDC) F1
PK/DB (8W-50-17)
CLUTCH 20
B12 RELAY
L39 DB/GY
6 20 B2 (IN PDC)
(8W-42-8) 6
BRAKE LB
C3 SENTRY
LAMP 8 C106 16 KEY
SWITCH L39 DB/BK
20 IMMOBILIZER
(8W-33-5)
LB 6 C120 MODULE
5 (8W-39-4)
S106 (8W-39-5)
L39 L39 C3
L50 20 20 14
20 LB LB DB/BK
WT/TN 2 2 1
LEFT RIGHT A/C
FOG FOG COMPRESSOR
LAMP LAMP CLUTCH
(8W-50-17) (8W-50-17) (8W-42-8)

S203
LHD RHD L50
20
24 C200 24 C204 WT/TN
B4
E1 C100
S302
L50 OTHER ABS
20
WT/TN L50 L50
5 C326 20 20 S147
L50 WT/TN WT/TN
18
WT/TN 6 C322 6 C321
1 C333
L50 L50 L50 L50 L50
18 18 18 20 18
DG/WT WT/TN WT/TN WT/TN WT/TN

2 3 3 20 C1 12
CENTER LEFT RIGHT ENGINE CONTROLLER
HIGH TAIL/ TAIL/ CONTROL ANTI-LOCK
MOUNTED STOP STOP MODULE BRAKE
STOP LAMP LAMP (8W-30-32) (8W-35-3)
LAMP (8W-51-3) (8W-51-3) RHD
(8W-51-4) LHD
J008W-7 XJI01032

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 33
GAS
BATT A0 (8W-10-11)
POWER
A9 A6 A4 DISTRIBUTION
FUSE FUSE FUSE CENTER
23 25 26 (8W-10-2)
15A 15A 20A
A10 A5 A3

F32
20
PK/DB F61 F75
20 16
F8 C100 WT/OR VT
F32 B11
20
PK/DB
FOG
LAMP
6
RELAY
BRAKE
NO. 2
LAMP
B12 (IN PDC)
SWITCH (8W-50-15)
(8W-33-4) L39
(8W-50-16)
20
5 LB
L50 L50
C4 C100
20 8 C106
20
WT/TN WT/TN S106
S203 RHD LHD L39 L39
20 20 F75
LB LB 16
LHD RHD
B4 C100 E1 C100 VT
2
24 C200 LEFT
24 C204 L50 FOG
18 LAMP
WT/TN (8W-50-15)
12 (8W-50-16) LHD RHD
L50 CONTROLLER
20
WT/TN ANTI-LOCK 14 C200
BRAKE 21 C204
(8W-35-2)
F75 F75
14 16
S302 VT VT

L50
20
WT/TN 2
L50 L50 RIGHT
5 C326 20 20
FOG
WT/TN WT/TN
L50 LAMP
18 6 C322 6 C321 (8W-50-15)
WT/TN (8W-50-16) S301
1 C333 L50 L50
18 18 F75 F75
L50 WT/TN WT/TN 16 16
18 VT VT
DG/WT 3 3
LEFT RIGHT 1 C2 2 C2
2 POWER
CENTER TAIL/ TAIL/
STOP STOP AMPLIFIER
HIGH (8W-47-2)
MOUNTED LAMP LAMP (8W-47-3)
(8W-51-3) (8W-51-3)
STOP
LAMP
(8W-51-4)
XJI01033 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 10 - 34 8W-10 POWER DISTRIBUTION XJ
DIESEL
BATT A16 (8W-10-19)
POWER
C2 DISTRIBUTION
AUTOMATIC CENTER
SHUT (8W-10-7)
DOWN
RELAY
(8W-30-22)
C8

A142
16
DG/OR

S137
(8W-10-19)
A142
16
DG/OR
BATT A0 (8W-10-13)
POWER
A14 A11 DISTRIBUTION
FUSE FUSE CENTER
21 22 (8W-10-7)
20A 20A
A13 A12

F75
F142 16
16 VT
DG/OR
C4 C100
F75
16
VT
LHD RHD
S156
F142 F142 F142 14 C200 21 C204
18 16 18
DG/OR DG/OR DG/OR F75 F75
2 14 16
GLOW VT VT
PLUG
RELAY
(8W-30-25)
3
10
FUEL S301
INJECTION
PUMP
(8W-30-26) F75 F75
16 16
VT VT

A 1 C2 2 C2
ELECTRONIC POWER
VACUUM AMPLIFIER
MODULATOR (8W-47-2)
(8W-30-24) (8W-47-3)

J008W-7 XJI01034

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 35
DIESEL
BATT A0 (8W-10-13)
POWER
A9 A6
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-7)
23 25
15A 15A
A10 A5

L9 F61
20 20
BK/PK WT/OR
B11
FOG
LAMP
RELAY
(IN PDC)
B12 (8W-50-17)

LHD RHD
L39
20
LB
F5 C100 B11 C100

L9
8 C106
20
BK/PK

L39
20
LB

S106

L39 L39
20 20
LB LB

2 2 2
COMBINATION LEFT RIGHT
FLASHER FOG FOG
(8W-52-4) LAMP LAMP
(8W-50-17) (8W-50-17)

XJI01035 J008W-7

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine
 XJ 8W - 12 JUNCTION BLOCK 8W - 12 - 1

8W-12 JUNCTION BLOCK

Component Page Component Page
A/C Compressor Clutch Relay . . . . . . . . . . . . . . . . 8W-12-14 High Note Horn . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
A/C- Heater Control . . . . . . . . . . . . . . . . . 8W-12-8, 9, 22, 23 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
Airbag Control Module . . . . . . . . . . . . . . . . . . 8W-12-25, 26 Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
Automatic Shut Down Relay . . . . . . . . . . . . . . . 8W-12-15, 16 Instrument Cluster . . . . . . . . . . . 8W-12-8, 9, 13, 17, 18, 28, 29
Back-Up Lamp Switch . . . . . . . . . . . . . . . . . . . . 8W-12-14 Junction Block . . 8W-12-2, 5, 6, 7, 8, 9, 10, 11, 13, 14, 15, 16, 17, 18,
Blend Door Actuator . . . . . . . . . . . . . . . . . . . . 8W-12-22, 23 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30,
Blower Motor Relay . . . . . . . . . . . . . . . . . . . . 8W-12-22, 23 31, 32, 33, 34, 35, 36, 37
Cargo Lamp/Switch . . . . . . . . . . . . . . . . . . 8W-12-28, 29, 30 Left City Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 12
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5 Left Courtesy Lamp . . . . . . . . . . . . . . . . . . 8W-12-28, 29, 30
Cigar Lighter Relay . . . . . . . . . . . . . . . . . . . . . 8W-12-5, 37 Left Front Park/Turn Signal Lamp No. 1 . . . . . . . . . 8W-12-10
Circuit Breaker 28 (JB) . . . . . . . . . . . . . . . . . . 8W-12-25, 26 Left Front Park/Turn Signal Lamp No. 2 . . . . . . . . . 8W-12-10
Circuit Breaker 29 (JB) . . . . . . . . . . . . . . . . . . . . 8W-12-27 Left Headlamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6, 7
Circuit Breaker 30 (JB) . . . . . . . . . . . . . . . . . . . . 8W-12-27 Left Headlamp Leveling Motor . . . . . . . . . . . . . . . . 8W-12-7
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21 Left Heated Seat Switch . . . . . . . . . . . . . . . . . 8W-12-19, 20
Clutch Interlock Switch . . . . . . . . . . . . . . . . . . 8W-12-19, 20 Left License Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Clutch Interlock Switch Jumper . . . . . . . . . . . . 8W-12-19, 20 Left Power Seat Switch . . . . . . . . . . . . . . . . . . . . 8W-12-27
Combination Flasher . . . . . . . . . . . . . . . . . . . 8W-12-17, 18 Left Rear Door Jamb Switch . . . . . . . . . . . . . . . . . 8W-12-30
Compass . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13, 30, 37 Left Rear Door Lock Motor . . . . . . . . . . . . . . . . 8W-12-31, 32
Controller Anti-Lock Brake . . . . . . . . . . . . . . . 8W-12-22, 23 Left Side Marker Lamp . . . . . . . . . . . . . . . . . . . . 8W-12-10
Controller Anti-Lock Brake Relay . . . . . . . . . . . 8W-12-22, 23 Left Tail/Stop Lamp . . . . . . . . . . . . . . . . . . . . 8W-12-10, 11
Daytime Running Lamp Module . . . . . . . . . . . . . 8W-12-7, 14 Left Visor/Vanity Lamp . . . . . . . . . . . . . . . . . . . . 8W-12-37
Diode Module . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 12 License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30 Liftgate Lock Motor . . . . . . . . . . . . . . . . . . . . 8W-12-31, 32
Dome Lamps Switch . . . . . . . . . . . . . . . . . . . . 8W-12-30, 37 Low Note Horn . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
Driver Door Jamb Switch . . . . . . . . . . . . . . . . . . . 8W-12-30 Message Center . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13
Driver Door Lock Motor . . . . . . . . . . . . . . . . . 8W-12-31, 32 Overhead Module . . . . . . . . . . . . . . . . . . . 8W-12-21, 30, 37
Driver Power Lock/Window Switch . . 8W-12-19, 20, 25, 26, 34, 36 Oxygen Sensor Downstream Relay . . . . . . . . . . . . . 8W-12-14
Driver Power Mirror . . . . . . . . . 8W-12-17, 18, 33, 34, 35, 36, 37 Oxygen Sensor Upstream Relay . . . . . . . . . . . . . . . 8W-12-14
Duty Cycle Evap/Purge Solenoid . . . . . . . . . . . . . . 8W-12-14 Passenger Door Jamb Switch . . . . . . . . . . . . . . . . 8W-12-30
Engine Control Module . . . . . . . . . . . . . . . . . . . . 8W-12-15 Passenger Door Lock Motor . . . . . . . . . . . . . . . 8W-12-31, 32
Engine Starter Motor Relay . . . . . . . . . . . . . . . 8W-12-19, 20 Passenger Power Lock/Window
Extended Idle Switch . . . . . . . . . . . . . . . . . . . . 8W-12-8, 22 Switch . . . . . . . . . . . . . . . . 8W-12-19, 20, 25, 26, 31, 32, 37
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12 Passenger Power Mirror . . . . . . . 8W-12-17, 18, 33, 34, 35, 36, 37
Fog Lamp Relay No. 1 . . . . . . . . . . . . . . . . . 8W-12-6, 10, 11 Power Distribution Center . . . . . . . . . . . . . . . . 8W-12-28, 29
Fog Lamp Relay No. 2 . . . . . . . . . . . . . . . . . . 8W-12-10, 11 Power Mirror Switch . . . . . . . . . . . . . 8W-12-19, 20, 33, 35, 37
Front Fog Lamp Switch . . . . . . . . . . . . . 8W-12-8, 9, 10, 11, 12 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27 Powertrain Control Module . . . . . . . . . . . . . . . 8W-12-15, 16
Fuel Heater Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15 PRNDL Illumination . . . . . . . . . . . . . . . . . . . . . 8W-12-8, 9
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . 8W-12-15, 16 Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . . . 8W-12-14
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5 Radio . . . . . . . . . . . . . . . . . . 8W-12-8, 9, 10, 11, 19, 20, 28, 29
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5 Rear Fog Lamp Relay . . . . . . . . . . . . . . . . . . . 8W-12-19, 20
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6 Rear Fog Lamp Switch . . . . . . . . . . . . . . . . . . . 8W-12-8, 9
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7 Rear Window Defogger . . . . . . . . . . . . . . . . . . 8W-12-17, 18
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7 Rear Window Defogger Relay . . . . . . . . . . . . . . 8W-12-17, 18
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8 Rear Window Defogger Switch . . . . . . . . . . . 8W-12-8, 9, 17, 18
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-9 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . 8W-12-22, 23
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10, 11, 12 Rear Wiper/Washer Switch . . . . . . . . . . . . . 8W-12-8, 9, 22, 23
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13 Right City Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13 Right Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-12-28, 29, 30
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14 Right Front Park/Turn Signal Lamp No. 1 . . . . . . . . 8W-12-24
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15, 16 Right Front Park/Turn Signal Lamp No. 2 . . . . . . . . 8W-12-24
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17, 18 Right Headlamp . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6, 7
Fuse 13 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17, 18 Right Headlamp Leveling Motor . . . . . . . . . . . . . . . 8W-12-7
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17, 18 Right Heated Seat Switch . . . . . . . . . . . . . . . . 8W-12-19, 20
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19, 20 Right License Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Fuse 16 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6, 28, 29 Right Power Seat Switch . . . . . . . . . . . . . . . . . . . 8W-12-27
Fuse 17 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19, 20 Right Rear Door Jamb Switch . . . . . . . . . . . . . . . . 8W-12-30
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19, 20 Right Rear Door Lock Motor . . . . . . . . . . . . . . . 8W-12-31, 32
Fuse 19 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19, 20 Right Side Marker Lamp . . . . . . . . . . . . . . . . . . . 8W-12-24
Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21 Right Tail/Stop Lamp . . . . . . . . . . . . . . . . . . . . . 8W-12-24
Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21 Right Visor/Vanity Lamp . . . . . . . . . . . . . . . . . . . 8W-12-37
Fuse 22 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22, 23 Sentry Key Immobilizer Module . . . . . . . . . . . . . . . 8W-12-13
Fuse 23 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24 Shift Lock Solenoid . . . . . . . . . . . . . . . . . . . . 8W-12-22, 23
Fuse 24 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22, 23 Trailer Tow Connector . . . . . . . . . . . . . . . . 8W-12-10, 11, 21
Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22, 23 Trailer Tow Left Turn Relay . . . . . . . . . . . . . . . . . 8W-12-21
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25, 26 Trailer Tow Right Turn Relay . . . . . . . . . . . . . . . . 8W-12-21
Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25, 26 Transfer Case Switch Illumination . . . . . . . . . . . . 8W-12-8, 9
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-35, 37 Transmission Control Module . . . . . . . . . . . . . . 8W-12-16, 28
Headlamp Beam Select Switch . . . . . . . . . . . . . . . 8W-12-6, 7 Transmission Range Sensor . . . . . . . . . . . . . . . . . 8W-12-14
Headlamp Delay Module . . . . . . . . . . . . . . . . . . . 8W-12-13 Underhood Lamp/Mercury Switch . . . . . . . . . . . 8W-12-28, 29
Headlamp Leveling Switch . . . . . . . . . . . . . . . . . . 8W-12-7 Wipe/Wash Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27
Headlamp Switch . . . . . . . . . . . . . . 8W-12-8, 9, 10, 11, 24, 30
Heated Seat Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27
Heater Control . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8, 9

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 8W - 12 - 2 8W-12 JUNCTION BLOCK XJ

C9
C3
28 29
25A 25A
30
1 25A
20A
C1
2 25A 25A 15

SPARE
3 10A 10A 16
RELAY

4 10A 15A 17
CIGAR
LIGHTER
C2 RELAY 5 10A 10A 18

6 5A 10A 19

7 10A 15A 20
C8

8 15A 21

HORN 9 10A 20A 22

RELAY
10 15A 10A 23

11 20A 24

12 10A 15A 25
C4 REAR
WINDOW
DEFOGGER 13 10A 26
RELAY
14 10A 10A 27

C5

C7 C6

FRONT OF
JUNCTION BLOCK

J008W-7 XJI01202

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 3

FUSES

FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT

1 25A F38 16RD/LB A7 10RD/BK

2 25A INTERNAL A7 10RD/BK

3 10A L33 20RD L3 16RD/OR

4 10A L43 20VT L4 16VT/WT

5 10A L44 20VT/RD L4 16VT/WT

6 5A E2 20OR E1 20TN

7 10A INTERNAL L7 18BK/YL

8 - - A21 12DB

9 10A F87 20WT/BK A21 12DB

10 15A F20 18WT A21 12DB

11 20A F12 18DB/WT A21 12DB

12 10A INTERNAL A22 12BK/OR

13 - - A4 12BK/PK

14 10A INTERNAL INTERNAL

15 25A F35 16RD A7 10RD/BK

16 10A L34 20RD/OR L3 16RD/OR

17 15A X12 16RD/WT A31 12BK/WT

18 10A F83 18YL/DG A31 12BK/WT

19 10A F45 20YL/RD A41 14YL

20 15A A6 20RD/OR A7 10RD/BK

21 15A INTERNAL A7 10RD/BK

22 20A V23 18BR/PK A22 12BK/OR

23 10A INTERNAL L7 18BK/YL

24 - - A22 12BK/OR

25 15A F15 20DB/WT A22 12BK/OR

26 10A F14 18LG/YL A22 12BK/OR

27 10A F23 18DB/YL A21 12DB

XJI01203 J008W-7

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 8W - 12 - 4 8W-12 JUNCTION BLOCK XJ

CIRCUIT BREAKERS

CB NO. AMPS FUSED CIRCUIT FEED CIRCUIT

28 25A INTERNAL A31 12BK/WT

29 25A F37 14RD/LB A7 10RD/BK

30 20A V6 16DB A31 12BK/WT

CAVITY CIRCUIT FUNCTION

30 INTERNAL FUSED B(+)
CIGAR 85 INTERNAL GROUND
LIGHTER
RELAY 86 A31 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)

87 F30 16RD CIGAR LIGHTER RELAY OUTPUT

87A - -

CAVITY CIRCUIT FUNCTION

30 INTERNAL FUSED B(+)

HORN 85 X3 20BK/RD HORN RELAY CONTROL

RELAY
86 INTERNAL FUSED B(+)

87 X2 20DG/RD HORN RELAY OUTPUT

87A - -

CAVITY CIRCUIT FUNCTION

30 A4 12BK/PK FUSED B(+)
REAR
85 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL
WINDOW
DEFOGGER 86 INTERNAL FUSED IGNITION SWITCH OUTPUT (RUN)
RELAY
87 INTERNAL REAR WINDOW DEFOGGER RELAY OUTPUT

87A - -

J008W-7 XJI01204

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 5

BATT A7 (8W-10-20)
(8W-10-26)
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE
1 2
25A 25A

30
CIGAR
LIGHTER
RELAY
(8W-41-2)
(8W-41-3)
87

M5 C4 M6 C4

F38 F30
16 16
RD/LB RD

LHD RHD LHD RHD

65 C201 50 C201

F38 F30
16 16
RD/LB RD

1 1
POWER CIGAR
OUTLET LIGHTER
(8W-41-2) (8W-41-2)
(8W-41-3) (8W-41-3)

XJI01205 J008W-7

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 8W - 12 - 6 8W-12 JUNCTION BLOCK XJ

HEADLAMP
BEAM
SELECT
SWITCH
3 (8W-50-4)
(8W-50-5)
L3 (8W-50-6)
16 (8W-50-7)
RD/OR

S213
(8W-50-4)
(8W-50-5)
L3 (8W-50-6)
16 (8W-50-7)
RD/OR

LHD RHD

16 C201

L3
16
RD/OR
S7 C4
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE
3 16
10A 10A

9 C1 11 C1
L33 L34
20 20
RD RD/OR
2 6 C106
L33 L34
18 18
RD RD/OR

L33 A A
20 LEFT RIGHT
RD HEADLAMP HEADLAMP
12 C106 (8W-50-4) (8W-50-4)
(8W-50-5) (8W-50-5)
L33
(8W-50-6) (8W-50-6)
20
(8W-50-7) (8W-50-7)
RD/WT

B10
FOG
LAMP
RELAY
NO. 1
(IN PDC)
(GAS EXCEPT DRL)
(EXCEPT BUILT-
UP-EXPORT)
(8W-50-14)
(8W-50-15)
J008W-7 XJI01206

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 7

HEADLAMP
BEAM
SELECT
SWITCH
1 (8W-50-4)
(8W-50-5)
L4 (8W-50-6)
16 (8W-50-7)
VT/WT
LHD RHD

22 C201

L4
16
VT/WT

S3 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
4 5
10A 10A

10 C1 1 C1
L43 L44
20 20
VT VT/RD

S133
13
9 C106
L43 L44
18 18
VT VT/RD
EXCEPT EXCEPT EXCEPT
BUILT- BUILT-UP BUILT-UP BUILT- BUILT- BUILT-UP
UP-EXPORT -EXPORT -EXPORT UP-EXPORT UP-EXPORT -EXPORT

L43 L44 L44

18 20 OTHER DRL
18
VT VT/RD VT/RD

S162 S163 L44 L44

20 18
F6 VT/RD VT/RD
L43 L43 L43 L44 L44 L44 C100
B12
18 18 18 18 18 18
VT VT VT VT/RD VT/RD VT/RD L44 F6 C100
20
B12 10
VT/RD
DAYTIME
3
B B RUNNING
LEFT RIGHT HEADLAMP
LAMP
HEADLAMP HEADLAMP LEVELING
MODULE
(8W-50-4) (8W-50-4) SWITCH (8W-50-18)
1 (8W-50-5) (8W-50-5) (8W-50-19)
LEFT (8W-50-6) (8W-50-6)
1
HEADLAMP (8W-50-7) (8W-50-7)
RIGHT
LEVELING
HEADLAMP
MOTOR
(8W-50-19) LEVELING RHD
MOTOR LHD
XJI01207 (8W-50-19) J008W-7

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 8W - 12 - 8 8W-12 JUNCTION BLOCK XJ
LHD
HEADLAMP
SWITCH
(8W-50-2)
(8W-50-3)

1 C1
E1
20
TN
42 C201
E1
20
TN

S1 C4
JUNCTION
BLOCK
FUSE (8W-12-2)
6
5A

S2 C4
E2
20
OR

S315

E2 E2
20 20
OR OR

1 C206
43 C201
E2 E2
20 20
OR OR
1 1
E2 PRNDL TRANSFER
20 ILLUMINATION CASE
OR
(A/T) SWITCH
(8W-44-2) ILLUMINATION
(8W-44-3) (8W-44-2)
(8W-44-3)
S215
E2 E2 E2 E2 E2 E2 E2
20 20 20 20 20 20 20
OR OR OR OR OR OR OR
A/C- POLICE
HEATER PACKAGE OTHERS
5 C2 4
RADIO 7 C1 CONTROL 4 REAR
(8W-47-2) (8W-42-4) EXTENDED FOG
(8W-47-9) IDLE LAMP
HEATER
CONTROL SWITCH SWITCH
(8W-42-2) (8W-30-17) 1 (BUILT-UP
3 C1 3 4 FRONT -EXPORT)
INSTRUMENT REAR REAR FOG (8W-51-11)
CLUSTER WIPER/ WINDOW LAMP
(8W-40-15) WASHER DEFOGGER SWITCH
SWITCH SWITCH (8W-44-2)
(8W-53-4) (8W-48-2) A/C (8W-44-3)
J008W-7 (8W-53-5) HEATER ONLY XJI01208

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 9
RHD
HEADLAMP
SWITCH
(8W-50-2)
(8W-50-3)

1 C1

E1
20
TN

S1 C4
JUNCTION
BLOCK
FUSE (8W-12-2)
6
5A

S2 C4

E2
20
OR

S215

E2 E2 E2 E2 E2 E2
20 20 20 20 20 20
OR OR OR OR OR OR

5 C2 4
12 C203 RADIO REAR
(8W-47-3) WINDOW
(8W-47-10) DEFOGGER
SWITCH
E2 (8W-48-3)
20
OR/BK 3 C1 1 4
INSTRUMENT FRONT REAR
CLUSTER FOG FOG
(8W-40-15) LAMP LAMP
SWITCH SWITCH
(8W-44-4) (BUILT-UP-EXPORT)
(8W-51-12)
1 C206

E2 E2 E2 E2
20 20 20 20
OR OR OR OR

1 1
PRNDL TRANSFER 7 C1 A/C- 3
ILLUMINATION CASE HEATER REAR
(A/T) SWITCH CONTROL WIPER/
(8W-44-4) ILLUMINATION (8W-42-5) WASHER
(8W-44-4) SWITCH
HEATER (8W-53-6)
CONTROL (8W-53-7)
A/C (8W-42-3)
HEATER ONLY
XJI01209 J008W-7

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 8W - 12 - 10 8W-12 JUNCTION BLOCK XJ
EXCEPT BUILT-UP-EXPORT
HEADLAMP
SWITCH
(8W-50-2)

9 C1
L7
18
BK/YL

S206
LHD RHD

45 C201

M3 C4 L7
JUNCTION 18
BLOCK BK/YL
FUSE (8W-12-2)
7
10A
4 C2
RADIO
(8W-47-2)
(8W-47-3)
6 C2 2 C7 (8W-47-9)
L77
20 (8W-47-10)
L77
BR/YL 18
BR/YL
B6
L77 FOG
LAMP S311
20
TRAILER
BR/YL RELAY L77 L77
TOW
7 C106 NO. 1 18 18
BR/YL CONNECTOR BR/YL
B9 (IN PDC) (8W-54-2)
L77 (8W-50-14)
L139 2 C327 5
20 20 TRAILER
BR VT TOW OTHERS
L77 L77
S104 A5 C100 18 20
7 C323
BR/YL BR/YL
L77 L77 L77 3 L77
18 18 20 FRONT 4 C311 20
BR BR BR FOG 11 C310 BR/YL L77
1 LAMP L77 18
LEFT SWITCH 18 S340 BR/YL
SIDE (8W-50-15) BR/YL L77
ON (8W-50-16) 18
MARKER INDICATOR 1 C330 BR/YL
LAMP
(8W-50-10) 4 2 L78
2 L39 18
LEFT 20 BK/YL 7 C322
FRONT LB 1 L77
PARK/ A4 C100 LICENSE 18
TURN L92 LAMP BR
20 (8W-51-4) 2
2 SIGNAL
LEFT LAMP PK LEFT
FRONT NO. 2 B15 TAIL/
PARK/ (8W-50-10) FOG STOP
TURN LAMP LAMP
RELAY (8W-51-3)
SIGNAL
LAMP NO. 2
NO. 1 B13 (IN PDC)
(8W-50-10) (8W-50-15)
(8W-50-16)
J008W-7 XJI01210

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 11
BUILT-UP-EXPORT
HEADLAMP
SWITCH
(8W-50-3)

9 C1
L7
18
BK/YL

S206
LHD RHD
L7
45 C201 18
BK/YL

M3 C4 4 C2
JUNCTION RADIO
BLOCK (8W-47-2)
(8W-12-2) (8W-47-3)
FUSE
7 (8W-47-9)
(8W-47-10)
10A

6 C2 2 C7
GAS DIESEL L77
18
L77 L77 BR/YL
20 18
BR/YL BR/YL S311
B6 L77 A
FOG 20
LAMP BR/YL TO
RELAY S169
NO. 1 (8W-12-12)
L77 TRAILER L77
B9 (IN PDC) 7 C106 18
TOW
18
L139 (8W-50-14) BR/YL BR/YL
20 L77 CONNECTOR
VT 20 (8W-54-2)
2 C327 TRAILER
BR
A5 C100 5 TOW OTHERS
3 1 L77
FRONT LEFT 18 7 C323
FOG CITY BR/YL
LAMP L77 L77 L77
LAMP
(8W-50-11) 4 C311 20 20 18
SWITCH 11 C310 BR/YL BR/YL BR/YL
ON (8W-50-15) L77
INDICATOR 18 S340
BR/YL
4 2
L39 1 C330 L77
20 18
L78 BR/YL
LB
18
S230 BK/YL
A4 C100 S333 7 C322
L92 L78 L78 L77
20 18 18 18
PK BK/YL BK/YL BR
B15 3 1 1 2
FOG DIODE LEFT RIGHT LEFT
LAMP MODULE LICENSE LICENSE TAIL/
RELAY (8W-51-9) LAMP LAMP STOP
NO. 2 (8W-51-10) (8W-51-4) (8W-51-4)
LAMP
B13 (IN PDC) (8W-51-3)
XJI01211 (8W-50-15) J008W-7

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 8W - 12 - 12 8W-12 JUNCTION BLOCK XJ
DIESEL
FROM
FUSE
7 (JB)
(8W-12-11)
A

L77
18
BR/YL

S169
L77 L77
20 20
BR/YL BR/YL
7 C106 A5 C100
L139
20
VT

1 3
FRONT
L77 FOG
20 LAMP
BR SWITCH ON
ILLUM. INDICATOR SWITCH
(8W-50-17)

4 2

1 L39
LEFT 20
CITY LB
LAMP
(8W-50-11)

S230

L39 L39
18 20
LB LB

A4 C100
L92
20
PK
3 B15
DIODE FOG
MODULE LAMP
(8W-51-9) RELAY
(8W-51-10) (IN PDC)
(8W-50-17)
B13

J008W-7 XJI01212

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 13

ST-RUN A21 (8W-10-17)

JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
9 8
10A SPARE

S13 C4

LHD RHD

F87 F87
20 20
WT/BK WT/BK
FULL
OPTIONS BASE

S225

F87 F87
20 20
WT/BK WT/BK

5 C201

F87 F87
20 20
WT/BK WT/BK

S216
F87 F87
20 20 F87 F87 F87
WT/BK WT/BK 20 20 20
WT/BK WT/BK WT/BK
LHD RHD
F87 4 8
20 SENTRY HEADLAMP
WT/BK KEY DELAY
IMMOBILIZER MODULE
6 C301
MODULE (8W-50-8)
(8W-39-4) (8W-50-9)
6 1 8 C1
COMPASS MESSAGE INSTRUMENT
(8W-49-2) CENTER CLUSTER
(DIESEL) (8W-40-2)
(8W-30-33)

XJI01213 J008W-7

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 8W - 12 - 14 8W-12 JUNCTION BLOCK XJ

ST-RUN A21 (8W-10-17) RADIATOR

FAN
JUNCTION
RELAY
BLOCK
(8W-12-2)
(IN PDC)
D11 (4.0L M/T)
FUSE
10
TRANSMISSION (4.0L A/T DRL)
15A RANGE F20 (4.0L A/T
SENSOR 18 EXCEPT FOG)
WT
(4.0L A/T) (8W-42-9)
(8W-31-6)
S12 C4 3
DAYTIME
F20
18
RUNNING
WT LAMP
MODULE F20
RHD LHD (8W-50-18) 18
5 WT

1 C201 B5
A/C
DUTY COMPRESSOR
CYCLE CLUTCH
F20 RELAY
18 EVAP/
F20 F20 (IN PDC)
WT 18 18 PURGE
(8W-42-7)
WT WT 2 SOLENOID
F20 (GAS)
E9
A9 C100 18 (8W-30-15)
RADIATOR
DIESEL OTHER WT
FAN
RELAY
S159 (IN PDC)
(4.0L M/T) D11 (8W-42-9)
(4.0L A/T DRL) (2.5L)
(4.0L A/T (4.0L A/T FOG F20
EXCEPT FOG) EXCEPT DRL) F20
18 18
WT WT
4.0L M/T 2.5L A/T 2.5L M/T DIESEL
F26
18
F20 F20 PK/OR C18
18 18
F20 F20 OXYGEN
WT WT F20 SENSOR
18 18 C18
WT WT 18 DOWNSTREAM
OXYGEN WT
11 C107 F26 SENSOR RELAY
7 C111 18 (IN PDC)
1 C113 F20 DOWNSTREAM
11 C107 PK/OR (8W-30-9)
18 RELAY
WT (IN PDC)
F20 F20 F20
18 (8W-30-9) C13
18 18
WT WT WT
OXYGEN
TO F20 SENSOR
S161 18
(8W-51-6)
UPSTREAM
WT
RELAY
C13 (IN PDC)
F20 (8W-30-9)
18 OXYGEN
WT SENSOR B5
B
A UPSTREAM A/C GAS
BACK-UP RELAY COMPRESSOR DIESEL
LAMP (IN PDC) CLUTCH LHD
SWITCH (8W-30-9) RHD
RELAY
(8W-51-6) (IN PDC)
(8W-51-7) (8W-42-7)
J008W-7 XJI01214

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 15
2.5L
ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
(8W-12-2)
FUSE
11
20A

5 C2

F12
18
DB/WT

S130

F12 F12 F12 F12 F12

18 18 18 18 18
DB/WT DB/WT DB/WT DB/WT DB/WT

47 C1
ENGINE
CONTROL
MODULE
(DIESEL)
(8W-30-22)
C5
FUEL
PUMP
RELAY
(IN PDC)
D4 C3 (GAS)
(8W-30-3)
FUEL (8W-30-4)
HEATER
RELAY
10 C107 (IN PDC)
D6 (DIESEL)
D4 (8W-30-24)
AUTOMATIC
F12
18
SHUT
DB/WT DOWN
RELAY
D6 (IN PDC)
(GAS)
2 C1 (8W-30-2)
POWERTRAIN
CONTROL
MODULE
(GAS)
(8W-30-2)

XJI01215 J008W-7

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 8W - 12 - 16 8W-12 JUNCTION BLOCK XJ
4.0L
ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
(8W-12-2)
FUSE
11
20A

5 C2

F12
18
DB/WT

S130

F12 F12 F12 F12

18 18 18 18
DB/WT DB/WT DB/WT DB/WT

RHD LHD
26
TRANSMISSION
CONTROL
F12 F12 MODULE
18 18 (RHD)
DB/WT DB/WT
(8W-31-4)
D4 C5
S136 AUTOMATIC FUEL
SHUT PUMP
DOWN RELAY
F12 F12
18 18 RELAY (IN PDC)
DB/WT DB/WT D6 (IN PDC) C3 (8W-30-3)
(8W-30-2) (8W-30-4)
26
TRANSMISSION
CONTROL
MODULE
10 C107 (8W-31-4)

F12
18
DB/WT

2 C1
POWERTRAIN
CONTROL
MODULE
(8W-30-2)

J008W-7 XJI01216

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 17
LHD
RUN A22 (8W-10-18) BATT A4 (8W-10-24)

JUNCTION
BLOCK
(8W-12-2)

FUSE
12
10A

86 30
REAR
WINDOW
DEFOGGER
RELAY
(8W-48-2)
85 87

FUSE FUSE
14 13
10A SPARE

S20 C4 S26 C4 S19 C4 3 C9 1 C6

L5 C81 C16 C16 C15
20 20 20 20 12
BK LB/WT LB/YL BK/WT BK/WT
5
3 17 2 C201
PASSENGER
C16 POWER
4 C326
L5 C81 20 MIRROR
20 20 LB/YL (8W-48-2)
BK LB/WT C15
12
BK/WT

3 C2
INSTRUMENT 2 C312
CLUSTER 3 C310
(8W-40-12)
37 C200
C16 C16
20 20
C15
LB/YL LB/YL
12
11 C305 BK/WT
3
FULL POWER
OPTIONS MIRRORS REAR
WINDOW
C16 C16 DEFOGGER
20 20 SWITCH
1
LB/YL BK/WT
COMBINATION (8W-48-2)
FLASHER
(8W-52-2) 5 REAR
(8W-52-3) DRIVER WINDOW
(8W-52-4) POWER DEFOGGER
MIRROR (8W-48-2)
(8W-48-2)
XJI01217 J008W-7

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 8W - 12 - 18 8W-12 JUNCTION BLOCK XJ
RHD
RUN A22 (8W-10-18) BATT A4 (8W-10-24)

JUNCTION
BLOCK
(8W-12-2)

FUSE
12
10A

86 30
REAR
WINDOW
DEFOGGER
RELAY
(8W-48-3)
85 87

FUSE FUSE
14 13
10A SPARE

S20 C4 S26 C4 S19 C4 5 C5 3 C9 1 C6

L5 C81 C16 C16 C16 C15

20 20 20 20 20 12
BK LB/WT BK/WT LB/YL BK/WT BK/WT

5
2 C204 DRIVER 4 C326
POWER
MIRROR
C16
(8W-48-3)
20
LB/YL
3
3 C2 REAR
C15
INSTRUMENT WINDOW 12
CLUSTER DEFOGGER BK/WT
(8W-40-13) SWITCH
(8W-48-3)
11 C305
FULL POWER
OPTIONS MIRRORS 2 C312
3 C310
C16 C16
20 20 C15
LB/YL BK/WT 12
BK/WT

1 5
COMBINATION PASSENGER REAR
FLASHER POWER WINDOW
(8W-52-2) MIRROR DEFOGGER
(8W-52-3) (8W-48-3) (8W-48-3)
(8W-52-4)

J008W-7 XJI01218

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 19
LHD
BATT A7 (8W-10-20) RUN-ACC A31 (8W-10-15) ST A41 (8W-10-18)
(8W-10-26) (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE FUSE FUSE

15 17 18 19
25A 15A 10A 10A

9 C9 S9 C4 S4 C4 3 C1
X12 F83 2.5L A/T 4.0L A/T M/T
F35 16 18
16 RD/WT YL/DG
RD F45 F45 F45
54 44 20 20 20
C201 YL/RD YL/RD YL/RD

X12 2
16 2 1
RD/WT CLUTCH CLUTCH
C2 F45
6
18
INTERLOCK INTERLOCK
RADIO YL SWITCH SWITCH
(8W-47-2) JUMPER
(8W-47-9)
1 2
F83 1
18 T141
YL/DG 20 T141
BUILT- YL 20
YL
UP-EXPORT OTHER

D11
39 C200 39 C200 C8
ENGINE
HEATED STARTER
F83 OTHER SEATS
18 MOTOR
YL/DG RELAY
F83 C10 (IN PDC)
1 18 D13 (8W-21-2)
F83
REAR YL/DG (8W-21-3)
18
(8W-21-4)
FOG YL/DG
S351 (8W-21-5)
LAMP (8W-21-6)
RELAY
(8W-51-9) 1 C316
5 C2
PASSENGER S353
(8W-63-4)
POWER 3 C305 F83 F83
LOCK/ FULL OPTIONS POWER MIRRORS 18 18
WINDOW YL/DG YL/DG
SWITCH F83 F83 4
(FULL 18 18 LEFT
OPTIONS) YL/DG YL/DG HEATED
(8W-61-2) SEAT
3 C2 2 SWITCH
DRIVER POWER 4 (8W-63-4)
DIESEL POWER MIRROR RIGHT
GAS LOCK/ SWITCH HEATED
WINDOW (8W-62-7) SEAT
SWITCH SWITCH
(8W-62-2) (8W-63-4)
XJI01219 J008W-7
(8W-62-3)

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 8W - 12 - 20 8W-12 JUNCTION BLOCK XJ
RHD
BATT A7 (8W-10-20) RUN-ACC A31 (8W-10-15) ST A41 (8W-10-18)
(8W-10-26) (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
15 17 18 19
25A 15A 10A 10A

7 C5 S9 C4 S4
F83 C4
3 C1
18
F35 X12 YL/DG F45
16 16 20
RD RD/WT OTHER BUILT-UP-EXPORT YL/RD

S232
E7 C100
F83
16 C204 18
YL/DG F45
6 C2 1 20
F35 RADIO REAR YL/RD
F83
16 (8W-47-3) 18 FOG
RD (8W-47-10) YL/DG LAMP
RELAY
3 C300 (8W-51-10)
1 C306 POWER
MIRRORS FULL OPTIONS M/T A/T

S352
F35 F83 F45 F45
F83 20 20
16 18 18
RD YL/DG YL/RD YL/RD
YL/DG
1 C324 2 2
2 CLUTCH CLUTCH
POWER INTERLOCK F45
INTERLOCK
MIRROR 18
1 C316 SWITCH YL SWITCH
SWITCH JUMPER
(8W-62-8)
1 1
S353
(8W-63-4) F83 T141 T141
F83 18 20 20
18 F83 YL/DG YL YL
YL/DG 18
4 YL/DG
LEFT
HEATED 3 C2 E8 C100
SEAT DRIVER T141
SWITCH POWER 20
5 C2 (8W-63-4) LOCK/ D11 YL
PASSENGER WINDOW C8
POWER SWITCH ENGINE
4
LOCK/ (8W-62-5) STARTER
RIGHT
WINDOW (8W-62-6) MOTOR
HEATED
SWITCH RELAY
SEAT
(FULL D13 (IN PDC)
SWITCH (8W-21-2)
OPTIONS) (8W-63-4) C10
(8W-21-3)
(8W-61-3) DIESEL (8W-21-4)
GAS (8W-21-5)
J008W-7 (8W-21-6) XJI01220

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 21

BATT A7 (8W-10-20)
(8W-10-26)
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE
20 21
15A 15A

86 30
HORN
RELAY
(8W-41-2)
(8W-41-3)

85 87

RHD LHD RHD LHD

8 C7 S22 C4 1 C5 1 C5 S22 C4 4 C2
X3 X3
20 20
BK/RD BK/RD
A6 X3 X2
20 20 20
RD/OR BK/RD
26 C201 DG/RD

7 C301
3 C323 X3
20 S131
BK/RD

A6 X3 1 C1 X2 X2
20 20 20 20
RD/OR BK/RD DG/RD DG/RD
CLOCKSPRING
(8W-41-2)
(8W-41-3)

10
OVERHEAD HORN
MODULE SWITCH
(8W-49-4) (8W-41-2)
(8W-49-5) (8W-41-3)
LOW HIGH
NOTE NOTE
S338
HORN HORN
(8W-41-2) (8W-41-2)
(8W-41-3) (8W-41-3)
A6 A6 A6
20 20 20
RD/OR RD/OR RD/OR

3 3
4 TRAILER TRAILER
TOW TOW
TRAILER
LEFT RIGHT
TOW
TURN TURN
CONNECTOR
(8W-54-3)
RELAY RELAY
(8W-54-3) (8W-54-3)
XJI01221 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 12 - 22 8W-12 JUNCTION BLOCK XJ
LHD
RUN A22 (8W-10-18)
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE FUSE

22 24 25
20A SPARE 15A

S11 C4 S8 C4 6 C1
V23 F15 F15
18 20 20
BR/PK DB/WT DB/WT
4.0L DIESEL
S219
39 C201 F15
F15 F15 20
V23 20 20 S134 DB/WT
18 DB/WT DB/WT
BR/PK F15 F15 B18
5 9 C209 18 20 CONTROLLER
5 DB/WT DB/WT ANTI-LOCK
REAR 5 BRAKE
BLOWER F15 RELAY
WIPER/ 18
WASHER D2 MOTOR DB/WT B20 (IN PDC)
SWITCH 20 RELAY (8W-35-5)
OR 23
(8W-53-4) (8W-42-2)
6
(8W-53-5) (8W-42-4) CONTROLLER
ANTI-LOCK
V23 10 BRAKE
18 BLEND (8W-35-5)
BR/PK DOOR B20
ACTUATOR CONTROLLER
29 C200 (8W-42-7) ANTI-LOCK
V23 F15 BRAKE
18 20 RELAY
BR/PK DB/WT
B18 (IN PDC)
(8W-35-4)
4 C327 40 C201
23
V23 F15 CONTROLLER
18 20
BR/PK DB/WT ANTI-LOCK
BRAKE
2 C313 (8W-35-4)
7 C310
V23 S217
18
BR/PK F15 F15 F15
20 20 20
4 DB/WT DB/WT DB/WT
REAR
WIPER 2 3 4 C2
MOTOR SHIFT EXTENDED A/C-
(8W-53-4) LOCK IDLE HEATER
(8W-53-5) SOLENOID SWITCH CONTROL
(8W-31-3) (POLICE (8W-42-7)
(8W-31-7) PACKAGE)
(8W-30-17)
J008W-7 XJI01222

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 23
RHD
RUN A22 (8W-10-18)
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE FUSE

22 24 25
20A SPARE 15A

S11 C4 S8 C4 6 C1
V23 F15 F15
18 20 20
BR/PK DB/WT DB/WT
4.0L DIESEL

6
REAR S134 F15
20
WIPER/ DB/WT
F15
WASHER F15 20
SWITCH 18 DB/WT B18
(8W-53-6) DB/WT CONTROLLER
5
(8W-53-7) B20 ANTI-LOCK
V23 CONTROLLER BRAKE
18 ANTI-LOCK RELAY
BR/PK BRAKE B20 (IN PDC)
6 C203 RELAY F15 (8W-35-5)
18
FULL B18 (IN PDC) DB/WT
OPTIONS BASE (8W-35-4)
23
V23 23 CONTROLLER
18 S324 CONTROLLER ANTI-LOCK
BR/PK ANTI-LOCK BRAKE
V23
18 BRAKE (8W-35-5)
BR/PK (8W-35-4)
4 C327 1 C303 S219
NOT
USED F15 F15 F15
V23 20 20 20
18 DB/WT DB/WT DB/WT
BR/PK
4 C2
A/C- 1 C204
2 C313 HEATER S349
7 C310 CONTROL
(8W-42-7) F15 F15
20 20
DB/WT DB/WT
V23
9
18 5 C209
BR/PK
2 D2 5
4 SHIFT 20 BLOWER
LOCK OR MOTOR
REAR
SOLENOID 10 RELAY
WIPER
(8W-31-3) BLEND (8W-42-3)
MOTOR
(8W-53-6)
(8W-31-7) DOOR (8W-42-5)
(8W-53-7) ACTUATOR
(8W-42-7)
XJI01223 J008W-7

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 8W - 12 - 24 8W-12 JUNCTION BLOCK XJ

HEADLAMP
SWITCH
HEADLAMP
(8W-50-2)
SWITCH
(8W-50-3)
OUTPUT
9 C1
L7
18
BK/YL

S206
(8W-12-10)
(8W-12-11)
LHD RHD

45 C201

L7
18
BK/YL
M3 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE
23
10A

5 C1 6 C7
GAS DIESEL

L78 L78 L78

20 18 18
DG/YL DG/YL DG/YL

7 C321
14 C106
EXCEPT BUILT-
BUILT-UP-EXPORT UP-EXPORT L78
18
L78 DG/YL
L78
20 20
DG/YL DG/YL

S101
L78 L78 L78
18 18 20
DG/YL DG/YL DG/YL
1 2 2 1 2
RIGHT RIGHT RIGHT RIGHT RIGHT
CITY FRONT FRONT SIDE TAIL/
LAMP PARK/ PARK/ MARKER STOP
(8W-50-13) TURN TURN LAMP LAMP
SIGNAL SIGNAL (8W-50-12) (8W-51-3)
LAMP LAMP
NO. 1 NO. 2
J008W-7 (8W-50-12) (8W-50-12) XJI01224

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 25
LHD

RUN A22 (8W-10-18) ST-RUN A21 (8W-10-17) RUN-ACC A31 (8W-10-15)

(8W-10-16)
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE CIRCUIT

26 27 BREAKER
10A 10A 28
25A

S21 C4 S23 C4 8 C5 1 C8

F14 F23 F81 F81

18 18 12 14
LG/YL DB/YL TN TN

13 C201

F81
12
TN

33 C200

F81
12
TN

1 C307

F81
14
TN

20 17 9 C1 4 C2
AIRBAG DRIVER PASSENGER
CONTROL POWER POWER
MODULE LOCK/ LOCK/
(8W-43-2) WINDOW WINDOW
SWITCH SWITCH
(FULL OPTIONS) (FULL OPTIONS)
(8W-60-2) (8W-61-2)

XJI01225 J008W-7

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 8W - 12 - 26 8W-12 JUNCTION BLOCK XJ
RHD

RUN A22 (8W-10-18) ST-RUN A21 (8W-10-17) RUN-ACC A31 (8W-10-15)

(8W-10-16)
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE CIRCUIT

26 27 BREAKER
10A 10A 28
25A

S21 C4 S23 C4 8 C5 1 C8

F14 F23 F81 F81

18 18 12 14
LG/YL DB/YL TN TN

15 14 C204 3 C202

F81
12
TN

F14 F23
18 18 1 C307
LG/YL DB/YL

F81
14
TN

20 17 4 C2 9 C1
AIRBAG PASSENGER DRIVER
CONTROL POWER POWER
MODULE LOCK/ LOCK/
(8W-43-3) WINDOW WINDOW
SWITCH SWITCH
(FULL OPTIONS) (FULL OPTIONS)
(8W-61-3) (8W-60-5)

J008W-7 XJI01226

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 27

BATT A7 (8W-10-20) RUN-ACC A31 (8W-10-15)

(8W-10-26) (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)

CIRCUIT CIRCUIT
BREAKER BREAKER
29 30
25A 20A

2 C6 M4 C4 8 C1

F37 V6
14 16
RD/LB DB
V6
LHD RHD 16
DB
8 C201

1
FRONT
V6 WIPER
16 MOTOR
DB (8W-53-2)
5
2 C316 WIPE/
WASH
F37 SWITCH
14 (8W-53-2)
RD/LB

S356

F37 F37 F37

14 14 14
RD/LB RD/LB RD/LB

1 C362 10 C329 1 C363

F37 F37 F37

14 14 14
RD RD/LB RD

A 8 B
LEFT HEATED RIGHT
POWER SEAT POWER
SEAT RELAY SEAT
SWITCH (8W-63-6) SWITCH
(8W-63-2) (8W-63-3)

POWER SEATS
XJI01227 J008W-7

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 8W - 12 - 28 8W-12 JUNCTION BLOCK XJ
GAS
BATT A0 (8W-10-11)
POWER
A23
DISTRIBUTION
CENTER
FUSE (8W-10-2)
16
15A
A24 (8W-10-27)

M1
20
PK

S135
M1 M1 M1
20 20 20
PK PK PK
12 C1
JUNCTION 1
BLOCK UNDERHOOD
(8W-12-2) LAMP/
MERCURY
4 C7 S18 C4 3 C3 SWITCH
(8W-44-6)
M1 M1 M1
20 20 20
PK PK PK
5 C314 RHD LHD OTHERS SKIM 25
TRANSMISSION
6 C201 CONTROL
MODULE
TO TO (4.0L)
LHD RHD M1 S347 S361
20 (8W-31-4)
(8W-10-28) (8W-10-28)
PK (8W-10-29) (8W-10-29)
M1 M1
20 18 S214
PK PK
M1 M1 M1 M1
20 20 20 20
PK PK PK PK

A 7 C2
CARGO RADIO
LAMP/ A C208 A C207 (8W-47-2)
SWITCH (8W-47-3)
(8W-47-9)
(8W-44-8)
(8W-47-10)
(8W-44-9)

9 C1
INSTRUMENT
CLUSTER
(8W-40-2)
M1 M1
18 18
PK PK

1 1
LEFT RIGHT
COURTESY COURTESY
LAMP LAMP
(8W-44-6) (8W-44-6)
J008W-7 XJI01228

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 29
DIESEL
BATT A0 (8W-10-13)
POWER
A23
DISTRIBUTION
CENTER
FUSE (8W-10-7)
16
15A
A24 (8W-10-30)

M1 M1
20 20
PK PK

12 C1 1
JUNCTION UNDERHOOD
BLOCK LAMP/
(8W-12-2) MERCURY
SWITCH
(8W-44-7)
4 C7 S18 C4 3 C3
M1 M1 M1
20 20 20
PK PK PK
5 C314 RHD LHD

6 C201
TO
LHD RHD M1 S347
20 (8W-10-30)
PK
M1 M1
20 18 S214
PK PK
M1 M1 M1 M1
20 20 20 20
PK PK PK PK

A 7 C2
CARGO RADIO
LAMP/ A C208 A C207 (8W-47-2)
SWITCH (8W-47-3)
(8W-47-9)
(8W-44-8)
(8W-47-10)
(8W-44-9)

9 C1
INSTRUMENT
CLUSTER
(8W-40-2)
M1 M1
18 18
PK PK

1 1
LEFT RIGHT
COURTESY COURTESY
LAMP LAMP
(8W-44-7) (8W-44-7)
XJI01229 J008W-7

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 8W - 12 - 30 8W-12 JUNCTION BLOCK XJ

HEADLAMP LEFT RIGHT

SWITCH COURTESY COURTESY
(8W-50-2) LAMP LAMP
(8W-50-3) (8W-44-6) (8W-44-6)
(8W-44-7) (8W-44-7)
3 C1 2 2
M2 M2 M2
20 18 18
YL BK/WT BK/WT
B C208 B C207
M2 M2
20 20
YL YL

S201
LHD RHD

46 C201

M2
20
YL
S25 C4
JUNCTION
BLOCK
(8W-12-2)
7 C7 1 C3
M2
20
YL
M2
20 OVERHEAD MODULE BASE/POLICE
YL
M2
S345 20
YL
M2
20 FULL OPTIONS MIDLINE 3
YL DOME
1
M2 M2 LAMP
OVERHEAD (8W-44-5)
20 20
MODULE YL YL
(8W-49-4) 7 B
COMPASS DOME
(8W-49-4) LAMPS
SWITCH
(8W-44-5)

S304
M2 M2 M2 M2 M2
20 20 20 20 20
YL YL YL YL YL
C317 C318
A
C318 A C320 A
C317 A C319 6 C314
M2 M2 M2 M2 M2
18 18 18 18 20
YL YL YL YL YL
1 3 1 3 B
DRIVER LEFT PASSENGER RIGHT CARGO
DOOR REAR DOOR REAR LAMP/
JAMB DOOR JAMB DOOR SWITCH
SWITCH JAMB SWITCH JAMB (8W-44-8)
(8W-39-6) SWITCH (8W-39-6) SWITCH (8W-44-9)
LHD
(8W-39-7) (8W-39-6) (8W-39-7) (8W-39-6)
J008W-7 RHD XJI01230
(8W-39-7) (8W-39-7)

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 31
LHD

PASSENGER PASSENGER
POWER DOOR
LOCK/ LOCK
WINDOW MOTOR
C1 SWITCH
(8W-61-4)
1 C1 5 2 1
(FULL OPTIONS)
(8W-61-4)
P34 P33 P33 P34
16 16 16 16
PK/BK OR/BK OR/BK PK/BK

S317

S316

P34 P33
16 16
PK/BK OR/BK

12 C9 1 C9
JUNCTION
BLOCK
(8W-12-2)

5 C7 1 C7
P34 P33
16 16
PK/BK OR/BK

S307

S306

P34 P33 P34 P33 P34 P33 P34 P33

16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK

5 4 C305 5 4 C309 5 4 C304 2 1 C326

P34 P33
16 16
PK/BK OR/BK

2 1 C311
5 4 C310
P34 P33 P34 P33 P34 P33 P34 P33
16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK

1 2 1 2 1 2 B A
DRIVER LEFT RIGHT LIFTGATE
DOOR REAR REAR LOCK
LOCK DOOR DOOR MOTOR
MOTOR LOCK LOCK (8W-61-4)
(8W-61-4) MOTOR MOTOR
(8W-61-4) (8W-61-4)

FULL OPTIONS
XJI01231 J008W-7

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 8W - 12 - 32 8W-12 JUNCTION BLOCK XJ
RHD

PASSENGER
POWER
LOCK/
WINDOW
1 C1 5 C1 SWITCH
(FULL OPTIONS)
(8W-61-5)
P34 P33
16 16
PK/BK OR/BK

S323

S322

P34 P33
P34 P33 16
16 16 16
PK/BK OR/BK
PK/BK OR/BK

1 2
PASSENGER
DOOR
5 4
C305 LOCK
MOTOR
(8W-61-5)
P34 P33
16 16
PK/BK OR/BK

S307

S306

P34 P33 P34 P33 P34 P33 P34 P33

16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK

5 C7 1 C7
5 4 C309 5 4 C304 2 1 C326 JUNCTION
P34 P33 BLOCK
16 16 (8W-12-2)
PK/BK OR/BK

2 1 C311 12 C9 1 C9
5 4 C310
P34 P33 P34 P33 P34 P33 P34 P33
16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK

1 2 1 2 B A 1 2
LEFT RIGHT LIFTGATE DRIVER
REAR REAR LOCK DOOR
DOOR DOOR MOTOR LOCK
LOCK LOCK (8W-61-5) MOTOR
MOTOR MOTOR (8W-61-5)
(8W-61-5) (8W-61-5)
FULL OPTIONS

J008W-7 XJI01232

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 33
LHD EXCEPT FULL OPTIONS

RUN-ACC F83 (8W-12-19)

POWER
4 MIRROR
1
SWITCH
(8W-62-7)
1 RIGHT
2 UP
3 LEFT
4 DOWN
5 DRIVER MIRROR
2 3 6 PASSENGER
MIRROR
6 5 6 5

1 3 4 7 8 5 6

P74 P72 P75 P71 P76 P91

20 20 20 20 20 20
DB YL/BK DB/WT YL OR/YL WT/BK

2 5 1
DRIVER
POWER
M M MIRROR
(8W-62-7)
2 C9 6 C9
3 6 4
JUNCTION
BLOCK
(8W-12-2) P91 P76
20 20
WT/BK OR/YL
9 C5 10 C5
P74 P72 10 C9 7 C9
20 20 JUNCTION
DB YL/BK BLOCK
(8W-12-2)
24 20 C201

C200 2 C5 3 C5
35 34
P76 P91
P74 P72 20 20
20 20 OR/YL WT/BK
DB YL/BK
28 67 C201
9 8 C305
36 12 C200
P74 P72
20 20 P76 P91
DB YL/BK 20 20
2 5 1 OR/YL WT/BK
PASSENGER
POWER 10 13 C305
M M MIRROR
(8W-62-7) P76 P91
20 20
OR/YL WT/BK
3 6 4

XJI01233 J008W-7

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 8W - 12 - 34 8W-12 JUNCTION BLOCK XJ
LHD FULL OPTIONS

DRIVER DRIVER
POWER POWER
LOCK/ MIRROR
WINDOW (8W-62-2)
SWITCH (8W-62-3)
4 C2 7 C2 2 C2 2 4
(8W-62-4)
P76 P76 P76
20 20 20
OR/YL OR/YL OR/YL

P74 P72
20 20 S328
DB YL/BK

P76
20
OR/YL

9 8 10
C305

P74 P72 P76

20 20 20
DB YL/BK OR/YL

35 34 36
C200

P74 P72 P76

20 20 20
DB YL/BK OR/YL

24 20 28 C201

P74 P72 P76

20 20 20
DB YL/BK OR/YL

9 C5 10 C5 2 C5
JUNCTION
BLOCK
(8W-12-2)

2 C9 6 C9 10 C9
P74 P72 P76
20 20 20
DB YL/BK OR/YL

S318

P76 P76
20 20
OR/YL OR/YL

3 1 2 4
PASSENGER
POWER
MIRROR
(8W-62-4)

J008W-7 XJI01234

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 35
RHD EXCEPT FULL OPTIONS
RUN-ACC F83 (8W-12-20)
POWER
4 MIRROR
1
SWITCH
(8W-62-8)
1 RIGHT
2 UP
3 LEFT
4 DOWN
5 DRIVER MIRRIOR
2 3
6 PASSENGER
MIRROR
6 5 6 5

1 7 8 4 3 5 6

Z1 P75 P71 P72 P74

20 20 20 20 20
BK DB/WT YL/LB YL/BK DB

1 5 2
S319 DRIVER
(8W-15-13) P76 P91
POWER 20 20
M M MIRROR OR/YL WT/BK
Z1
16 (8W-62-8)
BK
4 6 3
11 C9 2 C9 6 C9
JUNCTION P76 P91
BLOCK 20 20
(8W-12-2) OR/YL WT/BK

S5 C4 9 C5 10 C5
Z1 P74 P72
14 20 20
BK DB YL/BK
10 C9 7 C9
9 8
C204 JUNCTION
BLOCK
P74 P72 (8W-12-2)
20 20
DB YL/BK
2 C5 3 C5 3 C7
P91
9 8 C305 20
S208 WT/BK
(8W-15-14) 10 C203
(8W-15-15)
P76 P91 P91
P75 P71 20
20 20 20 20
OR/YL WT/BK WT/BK
DB/WT YL
10 C204 POWER
2 5 1 P76 BASE MIRRORS
Z1 PASSENGER 20
14 POWER OR/YL S359
BK M M MIRROR
(8W-62-8)
10 13 C305
3 6 4
P76 P91
20 20
G107 OR/YL WT/BK
(8W-15-14)
(8W-15-15)
XJI01235 J008W-7

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 8W - 12 - 36 8W-12 JUNCTION BLOCK XJ
RHD FULL OPTIONS

PASSENGER
POWER
MIRROR
(8W-62-6)
3 1 2 4

P75 P71 P76 P76

20 20 20 20
DB/RD YL OR/YL OR/YL

S328

P76
20
OR/YL

9 8 10
C305

P74 P72 P76

20 20 20
DB YL/BK OR/YL

9 8 10 C204

P74 P72 P76

20 20 20
DB YL/BK OR/YL

9 C5 10 C5 2 C5
JUNCTION
BLOCK
(8W-12-2)

2 C9 6 C9 10 C9

P75 P71 P76

20 20 20
DB/WT YL/LB OR/YL

S318

P76 P76 P76

20 20 20
OR/YL OR/YL OR/YL

6 C2 1 C2 2 C2 2 4
DRIVER DRIVER
POWER POWER
LOCK/ MIRROR
WINDOW (8W-62-5)
SWITCH
(8W-62-6)

J008W-7 XJI01236

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 XJ 8W-12 JUNCTION BLOCK 8W - 12 - 37

PASSENGER POWER DRIVER

POWER MIRROR POWER
MIRROR SWITCH MIRROR
(LHD) (8W-62-8) (8W-48-3)
6 (8W-48-2) 1 6
PASSENGER Z1 Z1
Z1 POWER 20 18
18 LOCK/ BK BK
BK
WINDOW
S319
6 C2 SWITCH (8W-15-13)
(LHD)
Z1 (8W-61-2) PASSENGER
14
BK POWER
MIRROR
S319 Z1 (8W-48-2)
16 6
(8W-15-13)
BK Z1
Z1 18
16 BK
BK

FULL OPTIONS POWER POWER

MIRRORS MIRRORS
RHD LHD
11 C9
JUNCTION
CIGAR BLOCK
LIGHTER (8W-12-2)
OVERHEAD RELAY
MODULE (8W-41-2)
(8W-49-2) (8W-41-3)
(8W-49-3) 85

3 9
2 C3 S5 C4
Z1
RIGHT 14
VISOR/ BK
VANITY LHD RHD
LAMP
B (8W-44-5)
S314
(8W-15-13)
Z1 Z1 Z1 Z1
20 20 20 20 Z1 Z1
BK BK BK BK 14 14
BK BK

S342
(OVERHEAD 14 C201
Z1 CONSOLE)
20 Z1
(8W-15-13) 14
BK
BK
OTHER COMPASS
B
LEFT
VISOR/ Z1 Z1
VANITY 20 20 S208
BK BK (8W-15-14)
LAMP
(8W-44-5) (8W-15-15)
A 1 Z1
14
DOME COMPASS BK
LAMPS (8W-49-2)
SWITCH (8W-49-3)
(8W-44-5)
G107
(8W-15-14)
XJI01237 (8W-15-15) J008W-7

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 XJ 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1

8W-15 GROUND DISTRIBUTION

Component Page Component Page
A/C Compressor Clutch . . . . . . . . . . . . . . . . . . . 8W-15-11 Left License Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
A/C High Pressure Switch . . . . . . . . . . . . . . . . . 8W-15-11 Left Power Seat Switch . . . . . . . . . . . . . . . . . . . 8W-15-22
A/C Low Pressure Switch . . . . . . . . . . . . . . . . . 8W-15-11 Left Rear Door Jamb Switch . . . . . . . . . . . . . 8W-15-17, 18
A/C- Heater Control . . . . . . . . . . . . . . . . 8W-15-14, 15, 16 Left Rear Fog Lamp . . . . . . . . . . . . . . . . . . 8W-15-17, 18
Airbag Control Module . . . . . . . . . . . . . . . . . 8W-15-17, 18 Left Repeater Lamp . . . . . . . . . . . . . . . . . . . 8W-15-10, 12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3 Left Tail/Stop Lamp . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
Blend Door Actuator . . . . . . . . . . . . . . . . . . 8W-15-14, 15 Left Turn Signal Lamp . . . . . . . . . . . . . . . . . 8W-15-17, 18
Blower Motor Relay . . . . . . . . . . . . . . . . . . . . . 8W-15-16 Left Visor/Vanity Lamp . . . . . . . . . . . . . . . . . . . 8W-15-13
Brake Lamp Switch . . . . . . . . . . . . . . . . . . . . . 8W-15-16 License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
Center High Mounted Stop Lamp . . . . . . . . . . . . 8W-15-21 Liftgate Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14, 15 Overhead Module . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
Cigar Lighter Relay . . . . . . . . . . . . . . . . . . . . . 8W-15-13 Oxygen Sensor 1/1 Upstream . . . . . . . . . . . . . . . 8W-15-2
Combination Flasher . . . . . . . . . . . . . . . . . . 8W-15-14, 15 Oxygen Sensor 1/2 Downstream . . . . . . . . . . . . . . 8W-15-2
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13, 16 Oxygen Sensor 2/1 Upstream . . . . . . . . . . . . . . . 8W-15-2
Controller Anti-Lock Brake . . . . . . . . . . . . . . . 8W-15-2, 3 Oxygen Sensor 2/2 Downstream . . . . . . . . . . . . . . 8W-15-2
Controller Anti-Lock Brake Relay . . . . . . 8W-15-5, 6, 8, 9, 11 Passenger Door Jamb Switch . . . . . . . . . . . . . 8W-15-18, 19
Data Link Connector . . . . . . . . . . . . . . . . . . . 8W-15-2, 3 Passenger Power Lock/Window Switch . . . . . . 8W-15-13, 18
Daytime Running Lamp Module . . . . . . . . . . . . . 8W-15-7 Passenger Power Mirror . . . . . . . . . . . . . . . . 8W-15-13, 18
Dome Lamps Switch . . . . . . . . . . . . . . . . . . . . 8W-15-13 Power Amplifier . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
Driver Door Jamb Switch . . . . . . . . . . . . . . . 8W-15-17, 20 Power Antenna Relay . . . . . . . . . . . . . . . . . . . . 8W-15-15
Driver Power Lock/Window Switch . . . . . . . . . 8W-15-17, 20 Power Mirror Switch . . . . . . . . . . . . . . . . . . 8W-15-13, 17
Driver Power Mirror . . . . . . . . . . . . . . . . 8W-15-13, 17, 20 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14, 15
Electronic Vacuum Modulator . . . . . . . . . . . . . . 8W-15-11 Power Steering Pressure Switch . . . . . . . . . . . . . . 8W-15-2
Engine Control Module . . . . . . . . . . . . . . . . . . . 8W-15-3 Powertrain Control Module . . . . . . . . . . . . 8W-15-2, 3, 5, 9
Engine Starter Motor Relay . . . . . . . . . . . 8W-15-2, 5, 9, 11 PRNDL Illumination . . . . . . . . . . . . . . . . . . 8W-15-13, 18
Extended Idle Switch . . . . . . . . . . . . . . . . . . . . 8W-15-14 Radiator Fan Motor . . . . . . . . . . . . . . . . . 8W-15-7, 10, 12
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
Fog Lamp Relay No. 1 . . . . . . . . . . . . 8W-15-4, 5, 6, 8, 9, 10 Rear Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . 8W-15-15
Fog Lamp Relay No. 2 . . . . . . . . . . . . . . 8W-15-4, 5, 6, 8, 9 Rear Fog Lamp Switch . . . . . . . . . . . . . . . . . . . 8W-15-15
Front Fog Lamp Switch . . . . . . . . . . . . . . . . 8W-15-14, 15 Rear Washer Pump . . . . . . . . . . . . . . 8W-15-4, 5, 6, 8, 9, 11
Front Wiper Motor . . . . . . . . . . . . . 8W-15-5, 6, 7, 8, 10, 11 Rear Window Defogger . . . . . . . . . . . . . . . . . . . 8W-15-21
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12 Rear Window Defogger Switch . . . . . . . . . . . . 8W-15-14, 15
Fuel Heater Relay . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
Fuel Pump Module . . . . . . . . . . . . . . . . . . . 8W-15-17, 18 Rear Wiper/Washer Switch . . . . . . . . . . . . . . 8W-15-14, 15
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 Right Back-Up Lamp . . . . . . . . . . . . . . . . . . 8W-15-19, 20
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 Right City Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 12
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3 Right Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-15-7, 10, 12
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3 Right Front Park/Turn Signal Lamp No. 1 . . . . . . . 8W-15-7
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3 Right Front Park/Turn Signal Lamp No. 2 . . . . . . . 8W-15-7
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, 10, 12 Right Front Turn Signal Lamp No. 1 . . . . . . . 8W-15-10, 12
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14, 15 Right Front Turn Signal Lamp No. 2 . . . . . . . 8W-15-10, 12
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16 Right Headlamp . . . . . . . . . . . . . . . . . . . 8W-15-7, 10, 12
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17 Right Headlamp Leveling Motor . . . . . . . . . . 8W-15-10, 12
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 Right Heated Seat Back . . . . . . . . . . . . . . . . . . 8W-15-22
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18 Right Heated Seat Switch . . . . . . . . . . . . . . . . . 8W-15-22
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18 Right License Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-21
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19, 20 Right Power Seat Switch . . . . . . . . . . . . . . . . . . 8W-15-22
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21 Right Rear Door Jamb Switch . . . . . . . . . . . . 8W-15-19, 20
G306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22 Right Rear Fog Lamp . . . . . . . . . . . . . . . . . 8W-15-19, 20
Headlamp Delay Module . . . . . . . . . . . . . . . . . . 8W-15-16 Right Repeater Lamp . . . . . . . . . . . . . . . . . . 8W-15-10, 12
Headlamp Leveling Switch . . . . . . . . . . . . . . . . 8W-15-15 Right Tail/Stop Lamp . . . . . . . . . . . . . . . . . . 8W-15-19, 20
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . 8W-15-16 Right Turn Signal Lamp . . . . . . . . . . . . . . . . 8W-15-19, 20
Heated Seat Relay . . . . . . . . . . . . . . . . . . . . . . 8W-15-22 Right Visor/Vanity Lamp . . . . . . . . . . . . . . . . . . 8W-15-13
Heater Control . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16 Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . 8W-15-13, 18
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16 Seat Heat Interface Module . . . . . . . . . . . . . . . . 8W-15-22
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . 8W-15-16 Sentry Key Immobilizer Module . . . . . . . . . . . . . 8W-15-16
Junction Block . . . . . . . . . . . . . . . . . . . . 8W-15-13, 14, 15 Trailer Tow Connector . . . . . . . . . . . . . . . . . 8W-15-17, 18
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . 8W-15-17, 18 Transfer Case Switch . . . . . . . . . . . . . . . . . . 8W-15-2, 11
Left City Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 12 Transfer Case Switch Illumination . . . . . . . . . 8W-15-13, 18
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-7, 10, 12 Transmission Control Module . . . . . . . . . . . . . . . 8W-15-2
Left Front Park/Turn Signal Lamp No. 1 . . . . . . . . 8W-15-7 Transmission Range Sensor . . . . . . . . . . . . . 8W-15-5, 6, 8
Left Front Park/Turn Signal Lamp No. 2 . . . . . . . . 8W-15-7 Underhood Lamp/Mercury Switch . . . . 8W-15-4, 5, 6, 8, 9, 11
Left Front Turn Signal Lamp No. 1 . . . . . . . . 8W-15-10, 12 Vehicle Speed Control Servo . . . . . . . . . . 8W-15-4, 5, 6, 8, 9
Left Front Turn Signal Lamp No. 2 . . . . . . . . 8W-15-10, 12 Washer Fluid Level Switch . . . . . . . . . . . . . . . . 8W-15-11
Left Headlamp . . . . . . . . . . . . . . . . . . . . 8W-15-7, 10, 12 Washer Fluid Level Switch . . . . . . . . . . . 8W-15-4, 5, 6, 8, 9
Left Headlamp Leveling Motor . . . . . . . . . . . 8W-15-10, 12 Windshield Washer Pump . . . . . . . . . 8W-15-4, 5, 6, 8, 9, 11
Left Heated Seat Back . . . . . . . . . . . . . . . . . . . 8W-15-22 Wipe/Wash Switch . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
Left Heated Seat Switch . . . . . . . . . . . . . . . . . . 8W-15-22

Downloaded from www.Manualslib.com manuals search engine

 8W - 15 - 2 8W-15 GROUND DISTRIBUTION XJ
GAS
TRANSFER TRANSFER OXYGEN OXYGEN
CASE CASE SENSOR SENSOR
SWITCH SWITCH 1/2 2/2
(8W-40-9) (8W-40-9) DOWNSTREAM DOWNSTREAM
A B (8W-30-8) (4.0L
(8W-30-10) CALIFORNIA/
Z1 Z1 POWERTRAIN
20 20 2 2 EUROPEAN III)
BK BK CONTROL (8W-30-11)
MODULE
4.0L A/T OTHER (2.5L M/T)
1 C112 (8W-30-14)
1 C112 6 C1
C8
ENGINE OXYGEN
STARTER SENSOR
242 4WD 231 4WD MOTOR 2/1
OXYGEN RELAY UPSTREAM
POWER SENSOR
STEERING C10 (2.5L M/T) (4.0L
1/1 (IN PDC) CALIFORNIA/
PRESSURE UPSTREAM T41 (8W-21-4) 2 EUROPEAN III)
SWITCH (8W-30-8) 20 (8W-30-11)
1 (2.5L) (8W-30-10) BK/WT
(8W-30-17) 2
2.5L 4.0L
Z1
20 5 C107
BK Z1 Z1 Z1
20 18 20 Z1 Z1 Z1 Z1 Z1
BK BK BK 20 18 20 20 20
BK BK BK BK BK

S107
POWERTRAIN
CONTROL DATA
MODULE LINK
CONTROLLER
(8W-30-2) CONNECTOR
ANTI-LOCK (8W-30-19)
31 C1 32 C1 BRAKE
TRANSMISSION 4 5
(8W-35-2)
CONTROL 8 24
Z1 Z12
MODULE 18 18
BK BK/TN
(4.0L)
24 (8W-31-4) A1 A7 C100
E7
BATTERY Z1 Z1
(8W-20-2) 12 12 Z1 Z12
BK BK 18 18
BK BK/TN

Z1 Z12 Z12 Z12 G102

16 14 14 18
BK BK/TN BK/TN BK/TN

9 C107 4.0L 2.5L

S117
Z12 Z12 Z0 Z0 Z0
14 16 8 6 4
BK/TN BK/TN BK BK BK LHD

RHD
G100

G101
J008W-7 XJI01502

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 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 3
DIESEL

CONTROLLER POWERTRAIN
ANTI-LOCK CONTROL
BRAKE MODULE
(8W-35-3) (8W-30-23)
8 24 31 C1 32 C1
DATA
LINK
CONNECTOR
(8W-30-34) ENGINE
4 5 CONTROL
MODULE
(8W-30-22)
Z1
18 LHD RHD 1 C1 27 C1
BK

Z12 Z12
18 18
BK/TN BK/TN

E7 C100 A7 C100
Z12 Z12
20 18 Z12 Z12 Z12 Z12
BK/TN BK/TN 14 14 14 16
BK/TN BK/TN BK/TN BK/TN
A1 C100

S146

BATTERY
(8W-20-4)

Z1 Z1 Z1 Z12 Z0 Z0
12 12 18 12 6 2/0
BK BK BK BK/TN BK BK

G102 G104 G105

XJI01503 J008W-7

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 8W - 15 - 4 8W-15 GROUND DISTRIBUTION XJ
LHD 2.5L GAS
REAR WINDSHIELD FOG FOG
WASHER WASHER LAMP LAMP
PUMP PUMP RELAY RELAY
(8W-53-4) (8W-53-2) NO. 2 NO. 1
2 B B13 (IN PDC) B8 (IN PDC)
(DRL) (DRL)
Z1 Z1 (8W-50-15) (8W-50-15)
18 20
BK BK

UNDERHOOD
LAMP/
MERCURY
SWITCH
2 (8W-44-6)

VEHICLE
SPEED
CONTROL
SERVO
4 (8W-33-4)

WASHER
FLUID
LEVEL
SWITCH
A (8W-40-6)

Z1 Z1
18 20 Z1 Z1 Z1
BK BK 20 18 20
BK BK BK

S132

Z1
16
BK

TO
G106
(8W-15-7)

J008W-7 XJI01504

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 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 5
LHD 4.0L EXCEPT BUILT-UP-EXPORT
REAR WINDSHIELD
WASHER WASHER
PUMP PUMP
(8W-53-4) (8W-53-2)
2 B
WASHER FRONT TRANSMISSION
Z1 FLUID WIPER RANGE
18 LEVEL MOTOR SENSOR
BK
SWITCH (8W-53-2) (A/T)
A (8W-40-6) 4 8 (8W-31-6)
(8W-40-7)
(8W-40-8)
Z1 Z1 Z1 Z1
18 20 16 18
BK BK BK BK

S141

UNDERHOOD FOG FOG Z1

LAMP/ LAMP LAMP 16
MERCURY RELAY RELAY BK
SWITCH NO. 1 NO. 2
2 (8W-44-6) B8 (IN PDC) B13 (IN PDC) C
(8W-50-14) (8W-50-14)
Z1
Z1 (8W-50-15) (8W-50-15) TO
20
20 BK G106
BK (8W-15-7)

(ABS (M/T (A/T VEHICLE

EXCEPT EXCEPT ABS EXCEPT ABS) SPEED
DRL) EXCEPT DRL) (DRL) CONTROL
Z1
20 SERVO
BK 4 (8W-33-4)

CONTROLLER ENGINE
ANTI-LOCK STARTER Z1 POWERTRAIN
BRAKE MOTOR 18
BK CONTROL
RELAY RELAY MODULE
B19 (IN PDC) C10 (IN PDC) (M/T)
(8W-35-4) (M/T) (8W-30-14)
(8W-21-5)
6 C1
T41
Z1 Z1 18
20 20 BK/WT
BK BK
5 C107
Z1 Z1 Z1 Z1
20 20 20 18
BK BK BK BK

S132

Z1
16
BK

TO
G106
(8W-15-7)
XJI01505 J008W-7

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 8W - 15 - 6 8W-15 GROUND DISTRIBUTION XJ
RHD GAS
REAR WINDSHIELD FOG FOG
WASHER WASHER LAMP LAMP
PUMP PUMP RELAY RELAY
(8W-53-6) (8W-53-2) NO. 2 NO. 1
2 B B13 (IN PDC) B8 (IN PDC)
(8W-50-14) (8W-50-14)
Z1 Z1
18 20
BK BK

UNDERHOOD
LAMP/
MERCURY
Z1
SWITCH 20
2 (8W-44-6) BK
Z1
20
BK

CONTROLLER
ANTI-LOCK
BRAKE ABS OTHER
RELAY
VEHICLE (IN PDC) Z1 Z1
B19 20 20
SPEED (8W-35-4)
BK BK
Z1 CONTROL
Z1
18 SERVO 20
BK (8W-33-4) BK
4
Z1
18
BK

S132

WASHER FRONT TRANSMISSION Z1

16
FLUID WIPER RANGE BK
LEVEL MOTOR SENSOR
SWITCH (4.0L) (4.0L A/T)
(8W-40-8) (8W-53-3) (8W-31-6) D
A 4 8
(8W-53-2)
Z1 Z1 Z1 TO
20 16 18 G106
BK BK BK (8W-15-10)
(8W-15-7)

S141

Z1
16
BK

TO
G106
(8W-15-10)
(8W-15-7)
J008W-7 XJI01506

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 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 7
EXCEPT BUILT-UP-EXPORT

LEFT LEFT LEFT LEFT

HEADLAMP FOG FRONT FRONT
(8W-50-4) LAMP PARK/ PARK/
(8W-50-5) (8W-50-14) TURN TURN
(8W-50-15) SIGNAL SIGNAL
C 1 3 3
LAMP LAMP
NO. 1 NO. 2
(8W-50-10) (8W-50-10)
Z1 Z1 Z1 (8W-52-5) Z1 (8W-52-5)
18 20 18 18
BK BK BK BK

S103
Z1
18
BK

S158

RIGHT RIGHT RIGHT RIGHT

FRONT FRONT HEADLAMP FOG
PARK/ PARK/ (8W-50-4) LAMP
TURN TURN (8W-50-5) (8W-50-14)
SIGNAL SIGNAL (8W-50-15)
3 3 C 1
LAMP LAMP
NO. 1 NO. 2
(8W-50-12) (8W-50-12)
Z1 Z1 (8W-52-7) Z1 (8W-52-7) Z1 Z1
18 18 18 18 20
BK BK BK BK BK

S102
RADIATOR FRONT
FAN WIPER
MOTOR MOTOR
(8W-42-9) (2.5L)
2 4 (8W-53-2)
Z1
18
BK FROM FROM
S132 S132
DAYTIME (8W-15-5) (8W-15-6)
RUNNING
B D
LAMP
C106 MODULE
11 4 (8W-50-18) FROM FROM FROM
8
S132 S141 S141
(8W-15-4) (8W-15-5) (8W-15-6)
A C E

Z1 Z1 Z1 Z12 Z1 Z1 Z1 Z1 Z1 Z1
20 20 12 16 16 16 16 16 16 16
BK/WT BK BK BK/TN BK BK BK BK BK BK

G106

XJI01507 J008W-7

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 8W - 15 - 8 8W-15 GROUND DISTRIBUTION XJ
BUILT-UP-EXPORT LHD 4.0L A/T
REAR WINDSHIELD VEHICLE
WASHER WASHER SPEED
PUMP PUMP CONTROL
(8W-53-4) (8W-53-2) SERVO
2 B 4 (8W-33-4)

Z1
18
BK

FOG FOG
UNDERHOOD LAMP LAMP
LAMP/ RELAY RELAY
MERCURY NO. 2 NO. 1
SWITCH B13 (IN PDC) B8 (IN PDC)
(8W-44-6) (8W-50-14) (8W-50-14)
2 Z1
20
BK

CONTROLLER
ANTI-LOCK
BRAKE ABS OTHER
RELAY
(IN PDC) Z1 Z1
B19 20 20
(8W-35-4)
BK BK
Z1 Z1 Z1 Z1
18 20 18 20
BK BK BK BK

S132

Z1
16
BK
WASHER FRONT TRANSMISSION
FLUID WIPER RANGE
LEVEL MOTOR F SENSOR
SWITCH (8W-53-2)
TO
(8W-31-6)
(8W-40-6)
A 4 G106 8
(8W-15-10)
Z1 Z1 Z1
20 16 18
BK BK BK

S141

Z1
16
BK

TO
G106
(8W-15-10)

J008W-7 XJI01508

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 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 9
BUILT-UP-EXPORT LHD 4.0L M/T

REAR WINDSHIELD
WASHER WASHER
PUMP PUMP
(8W-53-4) (8W-53-2)
2 B
Z1 FOG FOG
18 LAMP LAMP
BK RELAY RELAY
NO. 1 NO. 2
B8 (IN PDC) B13 (IN PDC)
(DRL) Z1 (DRL)
Z1 (8W-50-14) 20 (8W-50-14)
20 BK
BK

ABS EXCEPT ABS

CONTROLLER ENGINE
ANTI-LOCK STARTER
BRAKE MOTOR
RELAY RELAY
B19 (IN PDC) C10 (IN PDC)
(8W-35-4) (8W-21-5)

Z1 Z1
20 20 VEHICLE
BK BK SPEED
CONTROL
SERVO
Z1 Z1 (8W-33-4)
4
20 UNDERHOOD 20
BK LAMP/ BK
POWERTRAIN
MERCURY CONTROL
SWITCH MODULE
2 (8W-44-6) (8W-30-14)
6 C1
WASHER
FLUID T41
LEVEL 18
BK/WT
SWITCH
A (8W-40-6)
5 C107
Z1 Z1 Z1 Z1 Z1
18 20 20 18 18
BK BK BK BK BK

S132

Z1
16
BK

TO
G106
(8W-15-10)
XJI01509 J008W-7

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 8W - 15 - 10 8W-15 GROUND DISTRIBUTION XJ
BUILT-UP-EXPORT GAS
LEFT LEFT FOG
REPEATER FOG LAMP
LAMP LAMP RELAY LEFT
(8W-50-11) (8W-50-14) NO. 1 FRONT
2 1 B10 (IN PDC) TURN
L33
(8W-50-14) SIGNAL
Z1 LEFT LEFT 20 1 LAMP
18 HEADLAMP RD/WT
LEFT NO. 2
BK CITY FRONT
(8W-50-6) (8W-50-11)
LAMP (8W-50-7) TURN
(8W-50-11)
2 C114 SIGNAL
2 C 12 C106 LAMP
Z1 1
Z1 Z1 20 Z1 Z1 NO. 1
18 20 BK 18 20 (8W-50-11)
Z1
BK BK BK BK 18
BK
S103
Z1 Z1
18 18
RIGHT BK BK
FRONT RIGHT
TURN REPEATER S158
SIGNAL LAMP
LAMP (8W-50-13)
RIGHT
1
NO. 1 HEADLAMP
2 (8W-50-6)
Z1 (8W-50-13)
Z1 (8W-50-7)
18
BK
RIGHT 18
RIGHT RIGHT
BK C
FRONT CITY FOG
TURN LAMP LAMP
SIGNAL 2 C115 (8W-50-13) (8W-50-14)
1 LAMP
2 1
NO. 2
Z1 Z1 (8W-50-13) Z1 Z1 Z1 Z1
18 18 18 20 18 20
BK/WT BK BK BK BK BK

S102

RADIATOR FRONT LEFT RIGHT

FAN WIPER HEADLAMP HEADLAMP
MOTOR MOTOR LEVELING LEVELING
(8W-42-9) (2.5L) MOTOR MOTOR
2 4 (8W-53-3) 3 (8W-50-19) 3 (8W-50-19)
(8W-53-2)
Z1 Z15 Z15
18 18 18
FROM BK/GY BK/GY
BK S132
(8W-15-6)
FROM
S165
D
11 4 C106 FROM S132 FROM
S141 (8W-15-8) S141 Z15
(8W-15-6) (8W-15-9) (8W-15-8) 18
E F G BK/GY
5 C106

Z1 Z1 Z1 Z1 Z1 Z1 Z1 Z1 Z15
20 20 12 16 16 16 16 16 16
BK/WT BK BK BK BK BK BK BK BK/GY

G106
J008W-7 XJI01510

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 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 11
DIESEL
WINDSHIELD FUEL FOG
WASHER HEATER LAMP
PUMP RELAY RELAY
(8W-53-3) (IN PDC) (IN PDC)
B D6 (8W-30-24) B13 (8W-50-17)

WASHER REAR ENGINE CONTROLLER

FLUID WASHER STARTER Z1 ANTI-LOCK
LEVEL PUMP MOTOR 20 BRAKE
BK/YL
SWITCH (8W-53-5) RELAY RELAY
(8W-40-7) (8W-53-7) (IN PDC) Z1 (IN PDC)
A 2 D13 20 B19
(8W-40-8) (8W-21-6) (8W-35-5)
BK

Z1 Z1 Z1 Z1 Z1
20 18 18 18 20
BK BK BK BK BK

S141

A/C ELECTRONIC
HIGH VACUUM
PRESSURE MODULATOR
SWITCH (8W-30-24)
3 (8W-42-8) D
UNDERHOOD Z1 A/C FRONT
LAMP/ 18 COMPRESSOR WIPER
BK
MERCURY CLUTCH MOTOR
SWITCH (8W-42-8) (8W-53-3)
2 (8W-44-7) 2 4
Z1
16
BK

S170
Z1
16
Z1
BK
12
11 C120 BK
Z1 Z1 Z1 Z1
20 16 16 18
BK BK BK BK

S157
Z1 Z1
18 12
BK BK

4 C111 S132
Z1
20 Z1 Z1
BK 20 12
BK BK

1 B
A/C TRANSFER H
LOW CASE TO
PRESSURE SWITCH G106
SWITCH (231 4WD) (8W-15-12)
(8W-42-8) (8W-40-10)
XJI01511 J008W-7

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 8W - 15 - 12 8W-15 GROUND DISTRIBUTION XJ
DIESEL
LEFT LEFT LEFT
FRONT REPEATER FOG
TURN LAMP LAMP
SIGNAL (8W-50-11) (8W-50-17)
1 LAMP 2 1
NO. 1
Z1 (8W-50-11) Z1
18 18
BK
LEFT BK
FRONT
TURN 2 C114
SIGNAL
1 LAMP LEFT LEFT
Z1 NO. 2 CITY HEADLAMP
18 (8W-50-11) LAMP (8W-50-6)
BK (8W-50-11) (8W-50-7) NOT
USED
S158 2 C
12 C106
Z1 Z1 Z1 Z1 Z1 Z1
18 18 20 20 18 20
BK BK BK BK BK BK

S103
RIGHT RIGHT RIGHT
FRONT REPEATER HEADLAMP
TURN LAMP (8W-50-6)
(8W-50-13) (8W-50-7)
SIGNAL
1 LAMP 2 C
NO. 1
(8W-50-13) Z1
RIGHT 18 RIGHT RIGHT
BK CITY FOG
FRONT
TURN LAMP LAMP
(8W-50-13) (8W-50-17)
SIGNAL 2 C115
1 LAMP 2 1
NO. 2 Z1
Z1 Z1 (8W-50-13) Z1 Z1 Z1
18 18 18 20 18 20
Z1 BK BK BK BK BK BK
18
BK/WT S102
RADIATOR LEFT RIGHT
FAN HEADLAMP HEADLAMP
MOTOR LEVELING LEVELING
(8W-42-10) MOTOR MOTOR
Z1 (8W-50-19) (8W-50-19)
18 2 3 3
FROM
BK FUEL S132 Z15 Z15
(8W-15-11) 18 18
HEATER BK/GY BK/GY
(8W-30-24) H
C106 S165
11 4
2 Z15
18
BK/GY
5 C106
Z1 Z1 Z1 Z1 Z1 Z15
20 20 12 14 12 16
BK/WT BK BK BK BK BK/GY

G106
J008W-7 XJI01512

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 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 13

OVERHEAD LEFT PASSENGER POWER

MODULE VISOR/ POWER MIRROR
(8W-49-2) VANITY MIRROR SWITCH
(8W-49-3) LAMP (LHD) (8W-62-8)
(8W-44-5) (8W-48-2)
3 9 B 6 1 DRIVER
COMPASS RIGHT PASSENGER POWER
Z1 Z1
(8W-49-2) VISOR/ POWER Z1 MIRROR
(8W-49-3) Z1 20
20 20 VANITY 18 LOCK/ (8W-48-3)
BK BK BK
LAMP BK WINDOW 6
Z1
C2 SWITCH
1 B (8W-44-5) 6 18
DOME Z1 (LHD) BK
14 (8W-61-2)
LAMPS BK S319
SWITCH
(8W-44-5) S319 PASSENGER
A POWER
Z1 Z1 Z1 Z1
20 20 20 20 MIRROR
BK BK BK BK (8W-48-2)
6
COMPASS OTHERS Z1 Z1 Z1
16 16 18
S342 BK BK BK
(OVERHEAD
CONSOLE) FULL POWER POWER
OPTIONS MIRRORS MIRRORS
2 C3 11 C9 RHD LHD
JUNCTION
CIGAR BLOCK
LIGHTER (8W-12-2)
RELAY
(8W-41-2)
(8W-41-3)
85

TRANSFER PRNDL SEAT S5 C4

Z1
CASE ILLUMINATION BELT 14
SWITCH (A/T) SWITCH BK
ILLUMINATION (8W-44-2) (8W-40-6)
(8W-44-2) (8W-44-3) (8W-40-7) LHD RHD
2 2 B
Z1 (8W-44-3) Z1 Z1
20 20 20
BK BK BK
2 C206
Z1
20
BK

S314
Z1 Z1
14 14
BK BK
14 C201
Z1
14
BK

I J

TO TO
S208 S208
(8W-15-14) (8W-15-14)
(8W-15-15) (8W-15-15)
XJI01513 J008W-7

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 8W - 15 - 14 8W-15 GROUND DISTRIBUTION XJ
EXCEPT BUILT-UP-EXPORT

FROM
FROM JUNCTION EXTENDED FRONT
C201 BLOCK IDLE FOG
(8W-15-13) (8W-15-13) SWITCH LAMP
I J (8W-30-17) SWITCH
1 4 (8W-44-2)
(8W-44-4)
Z1 Z1
14 14
BK BK POLICE OTHERS
PACKAGE

LHD RHD

REAR COMBINATION REAR

WINDOW FLASHER WIPER/
DEFOGGER (8W-52-2) WASHER
SWITCH SWITCH
1 (8W-48-2) 5 1 (8W-53-4)
(8W-48-3)

Z1 Z1 Z1 Z1 Z1
14 20 20 20 20
BK BK BK BK BK

S208

A/C- BLEND
HEATER DOOR
CONTROL ACTUATOR
(8W-42-7) (8W-42-7)
CIGAR
LIGHTER
2 C2 7
(8W-41-2) D1
(8W-41-3) 20
DB/WT
3 Z1
20
BK
1 C209
RHD LHD

POWER Z1 Z1
OUTLET 20 20
(8W-41-2) BK BK
Z1 (8W-41-3) Z1
16 17 C204 7 C201 14
BK 3 BK

Z1
16
Z1
BK
20
BK

G107

J008W-7 XJI01514

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 15
BUILT-UP-EXPORT
BLEND REAR POWER
DOOR WINDOW ANTENNA
ACTUATOR FROM DEFOGGER
FROM RELAY
(8W-42-7) JUNCTION SWITCH
C201 (RHD)
7
BLOCK 1 (8W-48-2) (8W-47-4)
(8W-15-13) (8W-15-13) (8W-48-3) A C1
D1 I J
20 Z1
DB/WT 18 COMBINATION
BK FLASHER
Z1 Z1 (8W-52-3)
1 C209 14 14 (8W-52-4)
BK BK
Z1 FRONT REAR
5
20 FOG WIPER/
BK LHD RHD LAMP WASHER
SWITCH SWITCH
LHD RHD Z1 Z1 (8W-44-3) Z1
4 1 (8W-53-4)
14 20 (8W-44-4) 20 (8W-53-5)
17 C204 BK BK Z1 BK Z1 (8W-53-6)
7 C201 (8W-53-7)
20 20
BK BK

S208
Z1 POWER
20
BK ANTENNA
RELAY CIGAR REAR
(LHD) LIGHTER FOG
(8W-47-4) (8W-41-2) LAMP
A C1 (8W-41-3) SWITCH
A/C- 3 1 (8W-51-11)
HEATER (8W-51-12)
CONTROL
(8W-42-7) POWER
2 C2 OUTLET
(8W-41-2)
(8W-41-3)
Z1
3 16
Z1 BK Z1
20 14
BK BK
LHD RHD
HEADLAMP
LEVELING
SWITCH Z15 Z15
RHD LHD LHD RHD
(8W-50-19) 20 18
BK/GY BK/GY
5
S237

Z1 REAR
16
BK FOG
LAMP
RELAY
3 (8W-51-9)
Z1 Z1 (8W-51-10)
Z1 Z15 Z1
20 20 18 20
BK BK 18
BK BK/GY BK

G107

XJI01515 J008W-7

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 8W - 15 - 16 8W-15 GROUND DISTRIBUTION XJ

WIPE/ BRAKE HEADLAMP IGNITION

WASH LAMP DELAY SWITCH
SWITCH SWITCH MODULE (8W-10-15)
(8W-53-2) (8W-33-4) (8W-50-8) (8W-10-16)
(8W-53-3) (8W-33-5) (8W-50-9)
1 2 4 1 C1
Z1 Z1 Z1 HEADLAMP Z1
16 18 18 20
BK BK BK SWITCH BK
(8W-50-2)
(8W-50-3)

Z1
18
BK

S207
BLOWER
MOTOR
RELAY
SENTRY (8W-42-2)
KEY (8W-42-3)
IMMOBILIZER 2 (8W-42-4)
MODULE (8W-42-5)
Z1 COMPASS
5 3 (8W-39-4) 20
(8W-39-5) (8W-49-2)
BK
(8W-49-3)
Z2
20 10 C209
BK/LG 12
LHD RHD
INSTRUMENT Z2
20
CLUSTER BK/LG
(8W-40-2) Z8
20
BK/VT
5 C301
6 C1 9 C2 Z8
12 Z2
A/C- BK/VT 20
HEATER BK/LG
CONTROL LHD RHD
(8W-42-4)
(8W-42-5) 25 C201 58 C201
Z2
1 C1
HEATER
20
BK/LG CONTROL
POLICE/ (8W-42-2)
6 C202
OTHER POSTAL (8W-42-3)
Z2
Z8
1 C1 20
Z8 BK/LG
12
BK/VT 12 RADIO
S227 BK/VT (8W-47-2)
(8W-47-3)
(8W-47-9)
A/C OTHER (8W-47-10)

Z1 Z2 Z2 Z2 Z8 Z8 Z9
14 20 20 18 12 16 14
BK BK/LG BK/LG BK/LG BK/VT BK/VT BK

G108
J008W-7 XJI01516

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 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 17
LHD
LEFT
TAIL/ LEFT LEFT DRIVER
STOP TURN BACK-UP POWER
LAMP SIGNAL LAMP MIRROR
(8W-51-8) (8W-48-2)
1 (8W-51-3) LAMP
1 (8W-52-5) 1 6
LEFT (8W-52-6)
Z1 Z1 Z1 DRIVER
REAR 18 POWER POWER
18 18
BK FOG BK BK
LOCK/ MIRROR
LAMP WINDOW SWITCH
(BUILT-UP (8W-62-7)
1
Z1 -EXPORT) 5 C2 8 C1 SWITCH
(8W-60-4) 1
18 (8W-51-11) (8W-61-2)
BK

S341 DRIVER
POWER
BUILT- EXCEPT BUILT- MIRROR
UP-EXPORT UP-EXPORT (8W-48-2)
TRAILER 6
Z1 Z1
TOW 16 18
Z1 Z1
Z1 Z1 Z1 18 14
CONNECTOR BK BK 14 14 16
(8W-54-2) BK BK
BK BK BK
8
FUEL S329 S329
PUMP Z1 TRAILER
2 C322
14 TOW OTHER
MODULE Z1 Z1
BK
(GAS) 12 16
(8W-30-3) Z1 BK BK
6 18
BK FULL POWER
LEFT OPTIONS MIRRORS
S337 Z1
REAR 14 DRIVER
DOOR BK DOOR
JAMB Z1
14 JAMB
2 SWITCH BK SWITCH
(8W-39-6) (8W-39-6)
Z1 3
18 2 C323 Z1
BK
18
B C320 BK
C C317 3 C307

Z1 Z1 Z1 Z1 Z1
16 20 14 20 12
BK BK BK BK BK

S309
AIRBAG POWER
CONTROL AMPLIFIER
MODULE (8W-47-2)
(8W-43-2)
10 7 C2 8 C2
FULL
BASE OPTIONS Z1
12
Z6 Z6 BK
Z5 Z5
18 18 16 16
BK/YL BK/PK BK/LB BK/LB
G302

G301
XJI01517 G200 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 15 - 18 8W-15 GROUND DISTRIBUTION XJ
RHD
LEFT LEFT LEFT LEFT
TAIL/ TURN BACK-UP REAR
STOP SIGNAL LAMP FOG
LAMP LAMP (8W-51-8) LAMP
1 (8W-51-3) 1 (8W-51-5) 1 1 (BUILT-UP
-EXPORT)
Z1 Z1 Z1 Z1 (8W-51-12)
18 18 18 18
BK BK BK BK

S341
PRNDL TRAILER
TOW EXCEPT
ILLUMINATION BUILT-UP BUILT-UP
(A/T) CONNECTOR -EXPORT -EXPORT
TRANSFER (8W-44-4)
(8W-54-2)
CASE 8
2 Z1 Z1
SWITCH PASSENGER 18 16
ILLUMINATION Z1 PASSENGER
20
POWER BK BK
2 (8W-44-4) POWER MIRROR
BK
Z1 LOCK/ (8W-48-3)
20 WINDOW 6
BK
6 C2 SWITCH Z1 TRAILER
2 C322
(8W-61-3) 16 TOW OTHER
Z1 BK
14 FULL POWER
2 C206 BK OPTIONS MIRRORS
SEAT Z1 Z1 Z1
BELT 14 18 14
S329 BK BK BK
SWITCH
Z1
(8W-40-8)
Z1 16 S337
B 12 BK
BK Z1
Z1 Z1 14
20 20 LEFT PASSENGER BK
BK BK REAR DOOR 2 C323
DOOR JAMB
S313
JAMB SWITCH
FUEL 2 SWITCH (8W-39-7)
3
PUMP (8W-39-7)
Z1 Z1
MODULE 18
(GAS) 18
BK BK
(8W-30-4)
6
B C320 3 C307 C C317
Z1 Z1 Z1 Z1 Z1 Z1
16 20 20 12 20 14
BK BK BK BK BK BK

S309
AIRBAG POWER
CONTROL AMPLIFIER
MODULE (8W-47-3)
(8W-43-3)
Z1
10 7 C2 8 C2 12
FULL
BASE OPTIONS BK

Z6 Z6 Z5 Z5
18 18 16 16
BK/YL BK/PK BK/LB BK/LB

G300 G301 G302

J008W-7 XJI01518

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 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 19
LHD
RIGHT RIGHT RIGHT RIGHT
REAR TAIL/ TURN BACK-UP
FOG STOP SIGNAL LAMP
LAMP LAMP LAMP (8W-51-8)
1 (BUILT-UP- 1 (8W-51-3) 1 (8W-51-5) 1
EXPORT)
(8W-51-11)
Z1 Z1 Z1 Z1
18 18 18 18
BK BK BK BK

S348

RIGHT PASSENGER
REAR DOOR
DOOR JAMB
JAMB SWITCH
2 SWITCH 3 (8W-39-6)
(8W-39-6)

Z1 Z1 Z1
18 18 18
BK BK BK

B C319 C C318 2 C321

Z1 Z1
20 20 Z1
BK BK 18
BK

S310

Z1
16
BK

G303

XJI01519 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 15 - 20 8W-15 GROUND DISTRIBUTION XJ
RHD
RIGHT RIGHT RIGHT RIGHT
REAR TAIL/ TURN BACK-UP
FOG STOP SIGNAL LAMP
LAMP LAMP LAMP (8W-51-8)
1 (BUILT-UP 1 (8W-51-3) 1 (8W-51-5) 1
-EXPORT)
(8W-51-12)
Z1 Z1 Z1 Z1
18 18 18 18
BK BK BK BK

S348

DRIVER DRIVER DRIVER

DOOR POWER POWER
JAMB LOCK/ MIRROR
SWITCH WINDOW (FULL
3 (8W-39-7) 8 C1 5 C2 SWITCH 6 OPTIONS)
(FULL (8W-48-3)
OPTIONS)
(8W-60-5)
Z1 Z1 Z1 Z1 Z1
(8W-61-3)
18 14 16 18 18
BK BK BK BK BK

S319

RIGHT Z1
REAR 14
BK
DOOR
JAMB
2 SWITCH
(8W-39-7)

Z1
18
BK
5 C303

C C318 B C319 2 C321

Z1
Z1 Z1 14 Z1
20 20 BK 18
BK BK BK

S310
Z1
12
BK

G303

J008W-7 XJI01520

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 XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 21

LICENSE LEFT LIFTGATE REAR

LAMP LICENSE SWITCH WIPER
(8W-51-4) LAMP (8W-44-8) MOTOR
(8W-51-4) (8W-44-9) (8W-53-4)
(8W-53-5)
2 2 1 1 (8W-53-6)
RIGHT
LICENSE (8W-53-7)
LAMP
(8W-51-4)
2
Z1 Z1 Z1
18 18 18
BK BK BK

S332

Z1
18
BK

EXCEPT BUILT- BUILT-

UP-EXPORT Z1 UP-EXPORT
18
BK
2 C330
Z1 Z1 Z1
18 20 18
BK BK BK

S334

CENTER
HIGH
MOUNTED
STOP Z1
LAMP 18
(8W-51-4) BK

REAR
1 WINDOW
Z1 DEFOGGER 9 C310
18 (8W-48-2) 6 C311
BK (8W-48-3)

2 C333 Z1 Z1
12 18
Z1 BK BK
18
BK 2 C310
1 C312

Z1
12
BK

G304

XJI01521 J008W-7

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 8W - 15 - 22 8W-15 GROUND DISTRIBUTION XJ

LEFT RIGHT HEATED

HEATED HEATED SEAT
SEAT SEAT RELAY
BACK BACK (8W-63-6)
B (8W-63-5) B (8W-63-5) 6

Z1 Z1 Z1
18 18 18
BK BK BK

S354

LEFT RIGHT
Z1
18
HEATED HEATED
BK SEAT SEAT
SWITCH SWITCH
4 C332 12 C329 3 (8W-63-4) 3 (8W-63-4)

Z1 Z1 Z1 Z1
18 18 18 18
BK BK BK BK

S355

LEFT RIGHT SEAT

POWER POWER HEAT
SEAT SEAT INTERFACE
SWITCH SWITCH MODULE
B (8W-63-2) A (8W-63-3) 13 (8W-63-5)

Z1 Z1 Z1 Z2
18 14 14 18
BK BK BK BK/LG
2 C362 2 C363 13 C329
Z1 Z1 Z2
14 14 18
BK BK BK/LG

G306
(HEATED SEATS)
J008W-7 XJI01522

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 XJ 8W - 20 CHARGING SYSTEM 8W - 20 - 1

8W-20 CHARGING SYSTEM

Component Page Component Page
Automatic Shut Down Relay . . . . . . . . . . 8W-20-2, 4 Fuse 22 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-20-3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4 Fuse 24 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-20-5
Battery Temperature Sensor . . . . . . . . . . 8W-20-3, 5 Fusible Link . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4
Engine Control Module . . . . . . . . . . . . . . . . 8W-20-4 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Engine Starter Motor . . . . . . . . . . . . . . . 8W-20-2, 4 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . 8W-20-3 G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4 G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-4
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2 Generator . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-20-2 Power Distribution Center . . . . . . . . 8W-20-2, 3, 4, 5
Fuse 21 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-20-2 Powertrain Control Module . . . . . . . 8W-20-2, 3, 4, 5

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 8W - 20 - 2 8W-20 CHARGING SYSTEM XJ
GAS

POWER FUSIBLE
14 DISTRIBUTION LINK
CENTER A11
FUSE 10
8 (8W-10-2)
DG
30A
(8W-10-23)
7
A0 S118
6
A16
RD
14
A11
RD/LG
6
BK/WT
D2
AUTOMATIC
BATTERY SHUT
DOWN
GENERATOR
RELAY
D8 (IN PDC)
A0 (8W-30-2)
6
RD
A999 A999
16 16
RD RD
B(+) ENGINE
Z0 STARTER
8 MOTOR
BK (8W-21-2)
(8W-21-3) TO
(8W-21-4) 1 2
(8W-21-5) FUSE
18 (PDC)
(8W-10-23)

POWER K72 K20

16 16
A14 DISTRIBUTION DG/OR DG
FUSE CENTER
21 (8W-10-2)
15A
(8W-10-23)
A13

F142 C108
18 2 3
2.5L 4.0L DG/WT
2.5L 4.0L K72 K20
18 18
DG/OR DG
Z0 Z0
4 6 S168
BK BK (8W-10-23) S166
(8W-30-18) 2 C107

F142 K72 K20

18 18 18
DG/WT DG/OR DG

12 C3 25 C3 10 C2
G101 POWERTRAIN
FUSED GENERATOR GENERATOR
(8W-15-2)
AUTOMATIC DRIVER FIELD CONTROL
SHUT MODULE
DOWN (8W-30-2)
G100 RELAY (8W-30-18)
(8W-15-2) OUTPUT
J008W-7 XJI02002

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 XJ 8W-20 CHARGING SYSTEM 8W - 20 - 3
GAS

BATT A0 (8W-10-11)
POWER
A11 DISTRIBUTION
FUSE CENTER
22 (8W-10-2)
15A
(8W-10-31)
A12

S138
(8W-70-3)

A61 K167
14 20
DG/BK BR/YL

3 C107
C1
FUEL K167 K167
FUSED 20
B(+) PUMP 20
BR/YL BR/YL
RELAY
(IN PDC) S111
(8W-30-3) 4.0L (8W-70-3)
(8W-30-4) CALIFORNIA/
BUILT-UP-
EXPORT OTHER
2
A61 BATTERY
16 TEMPERATURE
DG/BK SENSOR K167 K167
(8W-30-13) 20 18
BR/YL BR/YL
1

S123
(8W-70-2)

K167
14 C107 18
K118 BR/YL
18
PK/YL

A61
14
DG/BK
22 C1 15 C3 4 C1
FUSED BATTERY SENSOR POWERTRAIN
B(+) TEMPERATURE GROUND CONTROL
SENSOR MODULE
SIGNAL

XJI02003 J008W-7

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 8W - 20 - 4 8W-20 CHARGING SYSTEM XJ
DIESEL

POWER FUSIBLE
10 DISTRIBUTION LINK
CENTER A11
A0 FUSE 10
4 (8W-10-7)
6 DG
RD 30A
(8W-10-19)
3
S118

A0 A16 A11
2/0 12 6
RD RD/LG BK/GY

ENGINE GENERATOR
STARTER
MOTOR
(8W-21-6)

S151
BATTERY (8W-10-19)

A16 1 2
12
RD/LG

C2
AUTOMATIC
SHUT
DOWN K72 K20
RELAY 18 18
(IN PDC) DG/OR DG
C8
(8W-30-22)

A142 7 5 C120
16
DG/OR
Z0 Z0
6 2/0
BK BK
S137 K72 K20
(8W-10-19) 18 18
DG/OR DG

G105 A142 A142

(8W-15-3) 16 16
DG/OR DG/OR

G104
(8W-15-3) 2 C1 28 C1 25 C3 10 C2
AUTOMATIC AUTOMATIC ENGINE GENERATOR GENERATOR POWERTRAIN
SHUT SHUT CONTROL SOURCE FIELD CONTROL
DOWN DOWN MODULE MODULE
RELAY RELAY (8W-30-22) (8W-30-23)
OUTPUT OUTPUT

J008W-7 XJI02004

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 XJ 8W-20 CHARGING SYSTEM 8W - 20 - 5
DIESEL

BATT A16 (8W-10-19)

POWER
A8 DISTRIBUTION
CENTER
FUSE (8W-10-7)
24
10A
(8W-10-19)
A7

S138
(8W-70-4)

K167
20
BR/YL

2
BATTERY
TEMPERATURE
SENSOR
(8W-30-31)
1

F16 K118 K167

16 18 18
RD/LG PK/YL BR/YL

22 C1 15 C3 4 C1
FUSED BATTERY SENSOR POWERTRAIN
B(+) TEMPERATURE GROUND CONTROL
SENSOR MODULE
SIGNAL (8W-30-23)
(8W-30-31)

XJI02005 J008W-7

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 XJ 8W - 21 STARTING SYSTEM 8W - 21 - 1

8W-21 STARTING SYSTEM

Component Page Component Page
Battery . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4, 5, 6 Fuse 19 (JB) . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4, 5, 6
Clutch Interlock Switch . . . . . . . . . . . . 8W-21-4, 5, 6 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-4
Clutch Interlock Switch Jumper . . . . . . . 8W-21-2, 3 G106 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-3, 5, 6
Engine Starter Motor . . . . . . . . . . 8W-21-2, 3, 4, 5, 6 Junction Block . . . . . . . . . . . . . . . 8W-21-2, 3, 4, 5, 6
Engine Starter Motor Relay . . . . . 8W-21-2, 3, 4, 5, 6 Park/Neutral Position Switch . . . . . . . . . . . 8W-21-2
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . 8W-21-6 Power Distribution Center . . . . . . 8W-21-2, 3, 4, 5, 6
Fog Lamp Relay No. 1 . . . . . . . . . . . . . . . . 8W-21-5 Powertrain Control Module . . . . . . . . . . . 8W-21-2, 3
Fuse 7 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-21-6 Transmission Range Sensor . . . . . . . . . . . . 8W-21-3
Fuse 10 (PDC) . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4, 5

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 8W - 21 - 2 8W-21 STARTING SYSTEM XJ
2.5L GAS A/T
ST A41 (8W-10-18)
JUNCTION
BLOCK POWER
FUSE
19 (8W-12-2) DISTRIBUTION
16
10A CENTER
(8W-12-19) FUSE (8W-10-2)
(8W-12-20) 10
20A
3 C1 (8W-10-25)
23
F45
20
YL/RD
LHD RHD

E7 C100
F45
20 F45
YL/RD 20
YL/RD
2 2
CLUTCH CLUTCH A41 A0
F45 F45 16 6
18
INTERLOCK 18
INTERLOCK YL RD
YL SWITCH YL SWITCH
JUMPER JUMPER
1 1
T141
T141 20
20 YL
YL
E8 C100

C8 C6
ENGINE
STARTER
BATTERY
MOTOR (8W-20-2)
RELAY
C10 C7 (IN PDC)
T41 T40
20 16
BK/WT BR
5 C107

T41
18
BK/WT 1 C108

T40 A0
16 6
BR RD
S120

T41 T41
18 18 ENGINE
BK/WT BK/WT STARTER
2 6 C1 2 1 MOTOR
PARK/ POWERTRAIN 1 PULL-IN
PARK/
P/N 2 HOLD-IN
NEUTRAL NEUTRAL CONTROL
POSITION POSITION MODULE M
SWITCH
SWITCH SENSE
(8W-30-14)
(8W-31-2)
J008W-7 XJI02102

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 XJ 8W-21 STARTING SYSTEM 8W - 21 - 3
4.0L A/T
ST A41 (8W-10-18)
JUNCTION
BLOCK POWER
FUSE DISTRIBUTION
19 (8W-12-2) 16
10A
CENTER
FUSE (8W-10-2)
(8W-12-19) 10
(8W-12-20) 20A
3 C1 (8W-10-25)
23
F45
20
YL/RD
LHD RHD

E7 C100
F45 A0
20 6
A41
YL/RD RD
16
2 YL
CLUTCH
F45 F45 INTERLOCK
20 18 SWITCH
YL/RD YL
JUMPER
1
T141
20
YL
E8 C100

C8 C6
ENGINE
STARTER
MOTOR
BATTERY
RELAY (8W-20-2)
C10 C7 (IN PDC)

T41 T41 T40

20 20 16
BK/WT BK/WT BR
7
TRANSMISSION 5 C107 1 C108
P/N RANGE T41
SENSOR 18 T40
(8W-31-6) BK/WT 16
BR
8
Z1
18
BK A0
6
S141 RD
(8W-15-5)
(8W-15-6)
(8W-15-8)
ENGINE
STARTER
Z1 6 C1 MOTOR
2 1
16 PARK/ POWERTRAIN 1 PULL-IN
BK NEUTRAL CONTROL 2 HOLD-IN
POSITION MODULE M
SWITCH (8W-30-14)
G106 SENSE
(8W-15-7)
XJI02103 (8W-15-10) J008W-7

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 8W - 21 - 4 8W-21 STARTING SYSTEM XJ
2.5L GAS M/T
ST A41 (8W-10-18)
JUNCTION POWER
BLOCK DISTRIBUTION
16
(8W-12-2) CENTER
FUSE FUSE (8W-10-2)
19 10
10A 20A
(8W-12-19) (8W-10-25)
23
(8W-12-20)
3 C1
F45
20
YL/RD

LHD RHD

E7 C100
A0
2 2 6
CLUTCH CLUTCH RD
INTERLOCK INTERLOCK
SWITCH SWITCH

1 1
BATTERY
(8W-20-2)
E8 C100

A41
T141 16
20 YL
YL
C8 C6
ENGINE
STARTER
MOTOR
RELAY
C10 C7 (IN PDC)

T41 T40
20 16
BK/WT BR

5 C107 1 C108
Z1
20 T40 A0
BK 16 6
BR RD

S107
(8W-15-2)
Z1 ENGINE
16 STARTER
BK
2 1 MOTOR
1 PULL-IN
G101 2 HOLD-IN
(8W-15-2)
M

J008W-7 XJI02104

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 XJ 8W-21 STARTING SYSTEM 8W - 21 - 5
4.0L M/T
ST A41 (8W-10-18)
JUNCTION POWER
BLOCK DISTRIBUTION
16
(8W-12-2) CENTER
FUSE FUSE (8W-10-2)
19 10
10A 20A
(8W-12-19) (8W-10-25)
23
(8W-12-20)
3 C1
F45
20
YL/RD

LHD RHD

E7 C100
A0
2 2 6
CLUTCH CLUTCH RD
INTERLOCK INTERLOCK
SWITCH SWITCH

1 1
BATTERY
(8W-20-2)
E8 C100

A41
T141 16
20 YL
YL
C8 C6
ENGINE
STARTER
MOTOR
RELAY
C10 C7 (IN PDC)
FOG
Z1 Z1 LAMP T40
20 20 RELAY 16
BK BK GROUND NO. 1 BR
B8 (IN PDC)
(EXCEPT ABS) 1 C108
S132 (EXCEPT DRL)
(8W-15-5) (8W-50-14) A0
T40
(8W-15-9) 6
16
BR RD

Z1
16 ENGINE
BK STARTER
2 1 MOTOR
1 PULL-IN
2 HOLD-IN
M
G106
(8W-15-7)
(8W-15-10)
XJI02105 J008W-7

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 8W - 21 - 6 8W-21 STARTING SYSTEM XJ
DIESEL
ST A41 (8W-10-18)
JUNCTION POWER
BLOCK DISTRIBUTION
FUSE (8W-12-2) 13
CENTER
19 FUSE (8W-10-7)
10A 7
(8W-12-19) 20A
(8W-12-20) (8W-10-24)
6
3 C1
F45
20
YL/RD

LHD RHD

E7 C100

A0
2
6
1
RD
CLUTCH
INTERLOCK
SWITCH

2 BATTERY
1 (8W-20-4)
T141
20
A41
YL
16
LHD RHD YL

E8 C100

D11 D10
ENGINE
STARTER
MOTOR
RELAY
D13 D14 (IN PDC)

Z1 T40
20 Z1 FOG 16
BK LAMP BR
20
BK/YL RELAY
S141 GROUND (IN PDC) 10 C111
(8W-15-11)
B13 (8W-50-17)
Z1
12 T40 A0
BK 14 2/0
BR RD

S132
(8W-15-11) ENGINE
Z1
STARTER
12 2 1 MOTOR
BK 1 PULL-IN
2 HOLD-IN
G106 M
(8W-15-12)

LHD
RHD
J008W-7 XJI02106

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 XJ 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1

8W-30 FUEL/IGNITION SYSTEM

Component Page Component Page
A/C Compressor Clutch Relay . . . . . . 8W-30-9, 18, 22, 27 G102 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19, 22, 23, 34
A/C High Pressure Switch . . . . . . . . . . . . . 8W-30-18, 30 G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-14
A/C Low Pressure Switch . . . . . . . . . . . . . . . . 8W-30-18 G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17
A/C- Heater Control . . . . . . . . . . . . . . . . . 8W-30-18, 30 G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-16, 32
Accelerator Pedal Position Sensor . . . . . . . . . . 8W-30-28 G123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-31
Airbag Control Module . . . . . . . . . . . . . . . 8W-30-20, 21 G154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-33
Automatic Shut Down G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3, 4
Relay . . . . . . . . . 8W-30-2, 5, 6, 8, 22, 23, 25, 26, 27, 33 Generator . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18, 23
Battery Temperature Sensor . . . . . . . . . . . 8W-30-13, 31 Glow Plug Assembly . . . . . . . . . . . . . . . . . . . 8W-30-25
Brake Lamp Switch . . . . . . . . . . . . . . . 8W-30-14, 16, 32 Glow Plug No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-30-25
Camshaft Position Sensor . . . . . . . . . . . . . . . . 8W-30-5 Glow Plug No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-30-25
Clockspring . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13, 32 Glow Plug No. 3 . . . . . . . . . . . . . . . . . . . . . . 8W-30-25
Compass . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21 Glow Plug No. 4 . . . . . . . . . . . . . . . . . . . . . . 8W-30-25
Controller Anti-Lock Brake . . . . . . . . . . . . 8W-30-19, 34 Glow Plug Relay . . . . . . . . . . . . . . . . . . . . . . 8W-30-25
Crankshaft Position Sensor . . . . . . . . . . . . . . . 8W-30-5 Headlamp Switch . . . . . . . . . . . . . . . . . 8W-30-17, 19, 34
Data Link Connector . . . . . . . . . . . . 8W-30-19, 20, 21, 34 Idle Air Control Motor . . . . . . . . . . . . . . . . . . 8W-30-16
Daytime Running Lamp Module . . . . . . . . . . . 8W-30-12 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5
Duty Cycle Evap/Purge Solenoid . . . . . . . . . . . 8W-30-15 Instrument Cluster . . . . . . . . . . . . . . . . . . 8W-30-20, 21
Engine Control Intake Air Temperature Sensor . . . . . . . . . . . . . 8W-30-7
Module . . . . . 8W-30-22, 25, 26, 27, 28, 29, 30, 32, 33, 34
Junction Block . . . . . . . . . . . . 8W-30-2, 3, 4, 9, 17, 22, 33
Engine Coolant Temperature Sensor . . . . . . . . . 8W-30-7
Left Speed Control Switch . . . . . . . . . . . . . 8W-30-13, 32
Engine Coolant Temperature Sensor No. 1 . . . . 8W-30-29
Low Coolant Level Warning Indicator . . . . . . . 8W-30-33
Engine Coolant Temperature Sensor No. 2 . . . . 8W-30-29
Low Coolant Switch . . . . . . . . . . . . . . . . . . . . 8W-30-31
Engine Oil Pressure Sensor . . . . . . . . . . . . 8W-30-12, 29
Manifold Absolute Pressure Sensor . . . . . . . . . 8W-30-12
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-30-30
Message Center . . . . . . . . . . . . . . . . . . . . . . . 8W-30-33
Engine Starter Motor Relay . . . . . . . . . . . . . . 8W-30-14
Needle Movement Sensor . . . . . . . . . . . . . . . . 8W-30-28
Evap Leak Detection Pump . . . . . . . . . . . . . . 8W-30-18
Overhead Module . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
Extended Idle Switch . . . . . . . . . . . . . . . . . . . 8W-30-17
Oxygen Sensor 1/1 Upstream . . . . . . . . . 8W-30-8, 10, 11
Fuel Injection Pump . . . . . . . . . . . . . . . . . 8W-30-26, 27
Oxygen Sensor 1/2 Downstream . . . . . . . 8W-30-8, 10, 11
Fuel Injector No. 1 . . . . . . . . . . . . . . . . . . . . . 8W-30-6
Oxygen Sensor 2/1 Upstream . . . . . . . . . . . . . 8W-30-11
Fuel Injector No. 2 . . . . . . . . . . . . . . . . . . . . . 8W-30-6
Oxygen Sensor 2/2 Downstream . . . . . . . . . . . 8W-30-11
Fuel Injector No. 3 . . . . . . . . . . . . . . . . . . . . . 8W-30-6
Oxygen Sensor Downstream Relay . . . . . . 8W-30-9, 10, 11
Fuel Injector No. 4 . . . . . . . . . . . . . . . . . . . . . 8W-30-6
Oxygen Sensor Upstream Relay . . . . . . . 8W-30-9, 10, 11
Fuel Injector No. 5 . . . . . . . . . . . . . . . . . . . . . 8W-30-6
Park/Neutral Position Switch . . . . . . . . . . . . . 8W-30-14
Fuel Injector No. 6 . . . . . . . . . . . . . . . . . . . . . 8W-30-6
Power Distribution Center . 8W-30-2, 3, 4, 5, 6, 8, 9, 14, 18,
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30-31 19, 22, 23, 25, 26, 27, 32, 33, 34,
Fuel Pump Module . . . . . . . . . . . . . . . . . . . 8W-30-3, 4 Power Steering Pressure Switch . . . . . . . . . . . 8W-30-17
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . 8W-30-2, 3, 4 Powertrain Control Module . 8W-30-2, 3, 4, 5, 6, 7, 8, 9, 10,
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-25 11, 12, 13, 14, 15, 16, 17, 18,
Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-25 19, 20, 21, 23, 29, 30, 31, 33, 34
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-22 Radiator Fan Relay . . . . . . . . . . . 8W-30-9, 18, 22, 27, 33
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17 Rail Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2 Right Speed Control Switch . . . . . . . . . . . . 8W-30-13, 32
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-33 Sentry Key Immobilizer Module . . . . . . . . . 8W-30-20, 21
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9, 15 Throttle Position Sensor . . . . . . . . . . . . . . . . . 8W-30-7
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . 8W-30-2, 3, 4, 15, 22 Torque Converter Clutch Solenoid . . . . . . . . . . 8W-30-15
Fuse 17 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9 Transmission Control Module . . . . . . . 8W-30-7, 19, 20, 21
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-30-2, 5, 6 Transmission Range Sensor . . . . . . . . . . . . . . 8W-30-14
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-30-19, 32 Turbo Boost Pressure Sensor . . . . . . . . . . . . . 8W-30-27
Fuse 21 (PDC) . . . . . . . . . . . . . . . 8W-30-2, 5, 6, 8, 25, 26 Vehicle Speed Control Servo . . . . . . . . . . . . . . 8W-30-14
Fuse 22 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-30-2, 3, 4 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . 8W-30-12, 29
Fuse 24 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-30-23 Wait To Start Warning Indicator . . . . . . . . . . . 8W-30-33
Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17 Water In Fuel Sensor . . . . . . . . . . . . . . . . . . . 8W-30-31
Fuse 26 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-30-34 Water In Fuel Warning Indicator . . . . . . . . . . . 8W-30-33
G101 . . . . . . . . . . . . . . . . . . . . 8W-30-2, 8, 10, 11, 14, 17

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 8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM XJ
GAS
ST-RUN A21 (8W-10-17) BATT A0 (8W-10-11)
JUNCTION POWER
BLOCK 14 A11 DISTRIBUTION
FUSE
(8W-12-2)
FUSE FUSE CENTER
11 8 22 (8W-10-2)
20A 30A 15A
(8W-12-15) (8W-10-23) (8W-10-31)
7 A12
(8W-12-16)

A16 A61
5 C2 14 14
F12 RD/LG DG/BK
18
DB/WT
C1
S130 FUSED FUEL
(8W-12-15) B(+) PUMP
F12 F12 (8W-12-16)
18 18 RELAY
DB/WT DB/WT (IN PDC)
(8W-30-3)
D4 D2
(8W-30-4)
AUTOMATIC
SHUT
DOWN
RELAY
D6 D8 (IN PDC)
A999
16
A61
4.0L RD
16
OTHER LHD A/T DG/BK
A14 POWER
FUSE
DISTRIBUTION
21 CENTER
15A (8W-10-2)
F12 F12
18 18 (8W-10-23)
A13
DB/WT DB/WT A999
F142 16
18 RD
S136 DG/WT
14 C107
(8W-12-16)
4.0L 2.5L

S168 TO
(8W-10-23) FUSE
10 C107 18 (PDC)
F12 K51 F142 (8W-10-23) A61
18 18 18 14
DB/WT DB/YL DG/WT DG/BK
2 C1 3 C3 12 C3 22 C1
FUSED AUTOMATIC FUSED FUSED POWERTRAIN
IGNITION SHUT AUTOMATIC B(+) CONTROL
SWITCH DOWN SHUT MODULE
OUTPUT RELAY DOWN
(ST-RUN) CONTROL RELAY
OUTPUT GROUND GROUND
32 C1 31 C1
Z12 Z12
14 14
BK/TN BK/TN

S117
(8W-15-2)
G101
(8W-15-2)
J008W-7 XJI03002

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 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3
LHD GAS
ST-RUN A21 (8W-10-17) BATT A0 (8W-10-11)
JUNCTION POWER
BLOCK A11 DISTRIBUTION
FUSE
(8W-12-2)
FUSE CENTER
11 22 (8W-10-2)
20A 15A
(8W-12-15) (8W-10-31)
A12
(8W-12-16)
5 C2 A61
F12 18DB/WT 14
S130 DG/BK
(8W-12-15)
(8W-12-16)
C5 C1
FUEL
PUMP
RELAY
(IN PDC)
C3 C2
A141 14DG/WT
D2 C100
A141
16
DG/WT
13 C200
3 1
FUEL
PUMP
M MODULE

4 6
K226 K167
20 20
DB/LG BR/YL
15 30
C200
F12 C100
S138 A61
(8W-70-3) 16
K226
20 3 C107 Z1 DG/BK
DB/LG K167 16
20 BK
F11 C100 BR/YL

4.0L S111
CALIFORNIA/ (8W-70-3)
EUROPEAN III OTHER

K167
20
K226 BR/YL K167 S309 14 C107
18 18 (8W-15-17)
K31
DB/LG
S123 BR/YL
Z1 A61
18 (8W-70-2) 12 14
K167
BR BK DG/BK
18
BR/YL
G302
19 C3 26 C3 4 C1 (8W-15-17) 22 C1
FUEL FUEL SENSOR FUSED POWERTRAIN
PUMP LEVEL GROUND B(+) CONTROL
RELAY SENSOR MODULE
CONTROL SIGNAL

XJI03003 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM XJ
RHD GAS
ST-RUN A21 (8W-10-17) BATT A0 (8W-10-11)
JUNCTION POWER
BLOCK A11 DISTRIBUTION
FUSE
(8W-12-2)
FUSE CENTER
11 22 (8W-10-2)
20A 15A
(8W-12-15) (8W-10-31)
A12
(8W-12-16)
5 C2 A61
F12 18DB/WT 14
S130 DB/BK
(8W-12-15)
(8W-12-16)
C5 C1
FUEL
PUMP
RELAY
(IN PDC)
C3 C2
A141 14DG/WT
D2 C100
A141
16
DG/WT
4 C204
3 1
FUEL
PUMP
M MODULE

4 6
K226 K167
20 20
DB/LG BR/YL
6 7 C204
B3 C100
S138 A61
(8W-70-3) 16
K226
20 3 C107 Z1 DG/BK
DB/LG K167 16
20 BK
B2 C100 BR/YL

4.0L S111
CALIFORNIA/ (8W-70-3)
EUROPEAN III OTHER

K167
20
K226 BR/YL K167 S309 14 C107
18 18 (8W-15-18)
K31
DB/LG
S123 BR/YL
Z1 A61
18 (8W-70-2) 12 14
K167
BR BK DG/BK
18
BR/YL
G302
19 C3 26 C3 4 C1 (8W-15-18) 22 C1
FUEL FUEL SENSOR FUSED POWERTRAIN
PUMP LEVEL GROUND B(+) CONTROL
RELAY SENSOR MODULE
CONTROL SIGNAL

J008W-7 XJI03004

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5
GAS
BATT A16 (8W-10-23)

D2 POWER
AUTOMATIC DISTRIBUTION
SHUT CENTER
DOWN (8W-10-2)
RELAY
(8W-30-2)
D8

A999 16RD
A999
16
RD
TO
A20 POWER FUSE
FUSE
DISTRIBUTION 21 (PDC)
18 CENTER (8W-10-23)
15A (8W-10-2)
(8W-10-23)
A19 S115
(8W-70-2)
K7 K7
20 18
A142 OR OR
18 3
DG/OR CRANKSHAFT
5V
SUPPLY POSITION
CRANKSHAFT SENSOR 3
POSITION
1 C107 SENSOR SENSOR 5V CAMSHAFT
SIGNAL GROUND SUPPLY POSITION
CAMSHAFT SENSOR
1 2 POSITION
SENSOR SENSOR
K167
GROUND SIGNAL
A142 20
18 BR/YL 2 1
DG/OR
K7 K24 S114
18 18
S109 OR GY/BK
(8W-70-3)
(8W-10-23)
K167 K167
A142 20 20
18 BR/YL BR/YL
DG/OR
4.0L S111
2 CALIFORNIA/ (8W-70-3)
1 EUROPEAN III OTHER
IGNITION
K167
COIL 20
BR/YL K167
RAIL 18
COIL S123 BR/YL
K44
2 3 1 (8W-70-2) 18
K167
1 TN/YL
18
K19 K17 K18 BR/YL
18 18 18
GY DB/TN RD/YL

7 C1 9 C2 1 C1 17 C1 8 C1 4 C1 18 C1
IGNITION IGNITION IGNITION 5V CRANKSHAFT SENSOR CAMSHAFT POWERTRAIN
COIL COIL COIL SUPPLY POSITION GROUND POSITION CONTROL
NO. 1 NO. 2 NO. 3 SENSOR SENSOR MODULE
DRIVER DRIVER DRIVER SIGNAL SIGNAL

4.0L
2.5L
XJI03005 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM XJ
GAS
BATT A16 (8W-10-23)

D2 POWER
AUTOMATIC A20 DISTRIBUTION
SHUT
FUSE CENTER
DOWN (8W-10-2)
18
RELAY
(8W-30-2) 15A
(8W-10-23)
D8 A19

A142
A999 A999 18
16 16 DG/OR
RD RD
1 C107

A142
18
DG/OR
TO
FUSE
21 (PDC) S109
(8W-10-23) (8W-10-23)
A142
18
DG/OR

S113
(8W-10-23)

A142 A142 A142 A142 A142 A142

18 18 18 18 18 18
DG/OR DG/OR DG/OR DG/OR DG/OR DG/OR

1 1
FUEL 1 FUEL
INJECTOR FUEL INJECTOR
NO. 1 INJECTOR NO. 5
NO. 3 (4.0L)
2 2
2

1 1 1
FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR
NO. 2 NO. 4 NO. 6
(4.0L)
2 2 2

K11 K12 K13 K14 K15 K16

18 18 18 18 18 18
WT/DB TN YL/WT LB/BR PK/BK LG/BK

4 C2 15 C2 5 C2 16 C2 6 C2 12 C2
FUEL FUEL FUEL FUEL FUEL FUEL POWERTRAIN
INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR CONTROL
NO. 1 NO. 2 NO. 3 NO. 4 NO. 5 NO. 6 MODULE
DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER

J008W-7 XJI03006

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7
GAS

3
THROTTLE
POSITION
SENSOR

2 1

K7 OTHER 4.0L A/T K167

20 20
OR K22 BR/YL
20
OR/DB
K22
18 S112
OR/DB
K22
20
OR/DB
6 C107
K22
20
OR/DB
17
TRANSMISSION
THROTTLE
POSITION CONTROL
SENSOR MODULE
SIGNAL (8W-31-5)

S114
S115 (8W-70-3)
(8W-70-2) K167 K167 K167
20 20 20
BR/YL BR/YL BR/YL

1 S111
(8W-70-3)
ENGINE
COOLANT
TEMPERATURE
SENSOR
2
4.0L
1 CALIFORNIA/
INTAKE EUROPEAN III OTHER
AIR K167
TEMPERATURE 20
SENSOR BR/YL K167
18
2 S123 BR/YL
(8W-70-2)
K7 K22 K21 K2 K167
18 18 18 18 18
OR OR/DB BK/RD TN/BK BR/YL

17 C1 23 C1 15 C1 16 C1 4 C1
5V THROTTLE INTAKE ENGINE SENSOR POWERTRAIN
SUPPLY POSITION AIR COOLANT GROUND CONTROL
SENSOR TEMPERATURE TEMPERATURE MODULE
SIGNAL SENSOR SENSOR
SIGNAL SIGNAL

XJI03007 J008W-7

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 8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM XJ
2.5L
BATT A16 (8W-10-23)

D2 POWER
AUTOMATIC A14 DISTRIBUTION
SHUT
FUSE CENTER
DOWN (8W-10-2)
21
RELAY
(8W-30-2) 15A
(8W-10-23)
D8 A13

F142
A999 18
16 DG/WT
RD
S168
(8W-10-23)
F142
18
DG/WT
7 C107
F142
20
DG/WT

S110
(8W-10-23)
F142 F142
20 20
DG/WT DG/WT

4 1 1 4
OXYGEN OXYGEN
SENSOR SENSOR
1/1 1/2
UPSTREAM DOWNSTREAM
3 2 2 3
K167 Z1 Z1 K167
20 18 20 20
BR/YL BK BK BR/YL

S107
S114 (8W-15-2)
(8W-70-3)
Z1
16
BK
K167
20
BR/YL G101
(8W-15-2)

S111
(8W-70-3)
K41 K167 K141
18 18 18
BK/DG BR/YL TN/WT

24 C1 4 C1 25 C1
OXYGEN SENSOR OXYGEN POWERTRAIN
SENSOR GROUND SENSOR CONTROL
1/1 1/2 MODULE
SIGNAL SIGNAL

J008W-7 XJI03008

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 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9
4.0L
ST-RUN A21 (8W-10-17) BATT A0 (8W-10-11)
JUNCTION POWER
BLOCK A21 DISTRIBUTION
FUSE
(8W-12-2)
FUSE CENTER
10 17 (8W-10-2)
15A 20A
(8W-12-14) A22 (8W-10-27)

S12 C4
F20
18
WT
LHD RHD

1 C201 A/T
C13 C11
FOG
EXCEPT OXYGEN
OTHER DRL SENSOR
E9
A9 C100
UPSTREAM
F26 F20 F99 F99 F20 RELAY
18 18 18 18 18
PK/OR WT RD RD WT C15 C12 (IN PDC)
F20
18
WT

S159
(8W-12-14) B5
A/T FOG FUSED A/C
OTHER EXCEPT DRL IGNITION COMPRESSOR
SWITCH CLUTCH
FUSED RADIATOR OUTPUT
IGNITION FAN (ST-RUN)
RELAY
F20
SWITCH RELAY (IN PDC)
F26 OUTPUT (A/T FOG)
18
(ST-RUN)
(IN PDC)
18 WT (8W-42-9) (EXCEPT DRL)
PK/OR D11 (8W-42-7)

F20 K73 A42

18 18 18
WT BR/OR DG
C18 C16
OXYGEN
SENSOR
DOWNSTREAM
RELAY
C20 C17 (IN PDC)
B
K74 A242
18 18 TO
BR/VT VT/OR C107
(8W-30-10)
(8W-30-11)
A

TO
C107
(8W-30-10)
(8W-30-11)
9 C3 8 C3
OXYGEN OXYGEN POWERTRAIN
SENSOR SENSOR CONTROL
DOWNSTREAM UPSTREAM MODULE
RELAY RELAY
LHD CONTROL CONTROL
RHD
XJI03009 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM XJ
4.0L
FROM TO
OXYGEN OXYGEN
SENSOR SENSOR
UPSTREAM DOWNSTREAM
RELAY RELAY
(8W-30-9) (8W-30-9)
B A

A42 A242
18 18
DG VT/OR
13
7 C107
CALIFORNIA/ CALIFORNIA/
EUROPEAN III OTHER OTHER EUROPEAN III

A42 4WD 2WD

20
DG A242 A242
20 20
S121 A42 A242 VT/OR DG/OR
(8W-30-11) 20 20
A42
20 DG VT/OR
DG S122
(8W-30-11)
A242
20
VT/OR

4 1 1 4
OXYGEN OXYGEN
SENSOR SENSOR
1/1 1/2
UPSTREAM DOWNSTREAM
3 2 2 3
K167 Z1 Z1 K167
20 20 20 20
BR/YL BK BK BR/YL
CALIFORNIA/
EUROPEAN III S107
OTHER
(8W-15-2)
S114 Z1
16
(8W-70-3)
BK

K167 G101
20 (8W-15-2)
BR/YL

S111
(8W-70-3)
K41 K167 K141
S123 18
18 18
(8W-70-2) TN/WT
BK/DG BR/YL
24 C1 4 C1 25 C1
OXYGEN SENSOR OXYGEN POWERTRAIN
SENSOR GROUND SENSOR CONTROL
1/1 1/2 MODULE
SIGNAL SIGNAL

CALIFORNIA/ EUROPEAN III

EXCEPT CALIFORNIA/ EUROPEAN III
J008W-7 XJI03010

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11
4.0L CALIFORNIA / EUROPEAN III
FROM FROM
OXYGEN OXYGEN
SENSOR SENSOR
UPSTREAM DOWNSTREAM
RELAY RELAY
(8W-30-9) (8W-30-9)
B A

A42 A242
18 18
DG VT/OR
13
7 C107
4WD 2WD
A42 A242 A242
20 20 20
DG VT/OR DG/OR

S121 S122
A42 A42 A242 A242
20 20 20 20
DG DG VT/OR VT/OR

1 1
OXYGEN OXYGEN
SENSOR SENSOR
1/1 1/2
UPSTREAM DOWNSTREAM
(8W-30-10) (8W-30-10)

4 1 1 4
OXYGEN OXYGEN
SENSOR SENSOR
2/1 2/2
UPSTREAM DOWNSTREAM
3 2 2 3
K167 Z1 Z1 K167
20 20 20 20
BR/YL BK BK BR/YL

S107
(8W-15-2)
Z1
16
BK

G101
(8W-15-2)
S123
(8W-70-2)
K241 K167 K341
18 18 18
LG/RD BR/YL TN

26 C1 4 C1 29 C1
OXYGEN SENSOR OXYGEN POWERTRAIN
SENSOR GROUND SENSOR CONTROL
2/1 2/2 MODULE
SIGNAL SIGNAL

XJI03011 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM XJ
GAS

3
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
2 1

K7 K167
20 20
OR BR/YL

S114
(8W-70-3)
K167
20
BR/YL

S115 4.0L S111

(8W-70-2) CALIFORNIA/ (8W-70-3)
EUROPEAN III OTHER K167 K167
18 20
K167
BR/YL BR/YL
20
BR/YL K167 2
18
S123 BR/YL SENSOR VEHICLE
(8W-70-2) GROUND VEHICLE SPEED
K167
SPEED
18 5V SENSOR
SENSOR
BR/YL SUPPLY SIGNAL
1 3
3
ENGINE ENGINE G7
SENSOR 18
OIL GROUND OIL
PRESSURE WT/OR
SENSOR
5V PRESSURE
SIGNAL SUPPLY SENSOR S108
2 1
K6 K6 G7
18 18 20
VT/OR VT/OR WT/OR

DRL OTHER

S119 4 C107
NOT
USED
G7
20
WT/OR

K7 K1 K167 G60 K6 G7 7
18 18 18 18 18 18
OR DG/RD BR/YL GY/YL VT/OR WT/OR VEHICLE DAYTIME
SPEED RUNNING
SENSOR LAMP
SIGNAL
MODULE
(8W-50-18)
17 C1 27 C1 4 C1 23 C2 31 C2 27 C2
5V MANIFOLD SENSOR ENGINE 5V VEHICLE POWERTRAIN
SUPPLY ABSOLUTE GROUND OIL SUPPLY SPEED CONTROL
PRESSURE PRESSURE SENSOR MODULE
SENSOR SENSOR SIGNAL
SIGNAL SIGNAL

J008W-7 XJI03012

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13
GAS
LEFT RIGHT
SPEED SPEED
CONTROL CONTROL
SWITCH SWITCH
1 SET 1 RESUME/ACCEL
2 ON/OFF 2 CANCEL
(8W-33-2) 3 COAST
1 2 1 2 3 (8W-33-2)

2 1 2 1
V37 K167 V37 K167
20 20 20 20
RD/LG BR/YL RD/LG BR/YL

S221
S222
B C2 A C2
CLOCKSPRING

2 C1 3 C1
K4
V37 20
20 BK/RD
RD/LG
B5 B6
F18 C100
F17
K167
20
BR/YL

S138
(8W-70-3)
3 C107
K167
20
BR/YL

K167 S111
20 (8W-70-3)
BR/YL 4.0L
CALIFORNIA/
EUROPEAN III OTHER
2
BATTERY K167
TEMPERATURE 20
BR/YL K167
SENSOR
18
S123 BR/YL
1 (8W-70-2)
K167
18
V37 K118
BR/YL
18 18
RD/LG PK/YL

32 C3 15 C3 4 C1
SPEED BATTERY SENSOR POWERTRAIN
CONTROL TEMPERATURE GROUND CONTROL
SWITCH SENSOR MODULE
SIGNAL SIGNAL

RHD
LHD
XJI03013 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM XJ
GAS
ST T141 (8W-12-19) ST F45 (8W-12-19)
(8W-12-20)
POWER
RHD LHD OTHER 4.0L A/T
DISTRIBUTION
C8 CENTER
ENGINE (8W-10-2)
V32 V32 STARTER
20 18 MOTOR
YL/RD YL/RD
RELAY
(8W-21-2)
C10 (8W-21-3)
3 (8W-21-4)
BRAKE
LAMP
SWITCH
(8W-33-4) T41
20
4 BK/WT
S132
(8W-15-5) 7
Z1 Z1 (8W-15-6) T41 TRANSMISSION
16 18 (8W-15-9) 20 P/N RANGE
BK BK BK/WT
SENSOR
(4.0L A/T)
5 C107 5 C107 8 (8W-31-6)
V30 Z1
20 18
DB/RD 4.0L M/T OTHER
BK

S141
F9 C100 G106 (8W-15-5)
F7 (8W-15-7) Z1 (8W-15-6)
(8W-15-10) 16 (8W-15-8)
V30 BK
20
DB/RD 4.0L 2.5L A/T 2.5L M/T G106
(8W-15-7)
(8W-15-10)
S120
3 (8W-21-2)
VEHICLE T41 T41 T41 Z1
18 18 18 20
SPEED BK/WT BK/WT BK/WT BK
CONTROL
SERVO
(8W-33-4)
S107
1 2 (8W-15-2)
2
PARK/
P/N NEUTRAL
POSITION
SWITCH Z1
V32 V36 V35 (8W-31-2) 18
18 18 18 BK
YL/RD TN/RD LG/RD

OTHER 2.5L M/T

11 C3 4 C3 5 C3 6 C1
SPEED SPEED SPEED A/T M/T POWERTRAIN Z1
CONTROL CONTROL CONTROL CONTROL 16
POWER VACUUM VENT PARK/NEUTRAL GROUND BK
MODULE
SUPPLY SOLENOID SOLENOID POSITION
CONTROL CONTROL SWITCH G101
SENSE (8W-15-2)

J008W-7 XJI03014

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15
GAS EXCEPT BUILT-UP-EXPORT
ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
11 10
20A 15A
(8W-12-15) (8W-12-14)
(8W-12-16)

5 C2 S12 C4
F12 F20
18 18
DB/WT WT
S130 RHD LHD
(8W-12-15)
(8W-12-16)
1 C201
OTHER 4.0L LHD A/T A9 C100 F20
18
F12 WT
18
DB/WT E9 C100
S136
(8W-12-16)
F20
18
F12 WT
18
DB/WT S159
10 11 (8W-12-14)
C107
F20 F20
18 18
WT WT

S161
(8W-51-6) 2
F20 DUTY
18
WT CYCLE
A
EVAP/
TORQUE PURGE
CONVERTER 1 SOLENOID
CLUTCH
SOLENOID
B (2.5L A/T)
(8W-31-2)
F12 K54 K52
18 18 18
DB/WT OR/BK PK/BK

2 C1 11 C2 20 C3
FUSED TORQUE DUTY POWERTRAIN
IGNITION CONVERTER CYCLE CONTROL
SWITCH CLUTCH EVAP/ MODULE
OUTPUT SOLENOID PURGE
(ST-RUN) CONTROL SOLENOID
CONTROL

XJI03015 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM XJ
GAS
POWERTRAIN
CONTROL
IDLE AIR IDLE AIR IDLE AIR IDLE AIR BRAKE MODULE
CONTROL CONTROL CONTROL CONTROL LAMP
NO. 3 NO. 2 NO. 1 NO. 4 SWITCH
DRIVER DRIVER DRIVER DRIVER SENSE
11 C1 10 C1 19 C1 20 C1 24 C3

K29
18
WT/PK

4.0L A/T OTHER

S140
(8W-31-7)
K29 K29
20 18
WT/PK WT/PK

K40 K60 K39 K59

18 18 18 18
B1
BR/WT YL/BK GY/RD VT/BK F10 C100

LHD RHD

K29 K29
20 18
WT/PK WT/PK

S204
(8W-31-3)
(8W-31-7)

2 3 4 1 K29
18
IDLE AIR IDLE AIR IDLE AIR IDLE AIR IDLE WT/PK
CONTROL CONTROL CONTROL CONTROL AIR
NO. 3 NO. 2 NO. 1 NO. 4 CONTROL 1
DRIVER DRIVER DRIVER DRIVER BRAKE
MOTOR
LAMP
SWITCH
(8W-33-4)
2
Z1
18
BK

S207
(8W-15-16)
Z1
14
BK

G108
(8W-15-16)
RHD
LHD
J008W-7 XJI03016

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 17
EXCEPT BUILT-UP-EXPORT
POWERTRAIN
PANEL HEADLAMP
LAMPS SWITCH POWER CONTROL
DIMMER (8W-50-2) STEERING MODULE
SWITCH PRESSURE
SIGNAL IDLE SWITCH
ACTUATOR SIGNAL
1 C1
12 C1 12 C1
42 C201 4.0L A/T 2.5L

E1 4.0L A/T 2.5L

20
TN RUN A22 (8W-10-18)
S1 C4 K78 K10
JUNCTION 18 18
BLOCK GY DB/BR
(8W-12-2)
FUSE FUSE
6 25
5A 15A
(8W-12-8) (8W-12-22)
POLICE
PACKAGE (LHD) OTHERS
S2 C4 S8 C4
11 C107
E2 F15 K78 NOT
20 20 18 USED
OR DB/WT GY

S315 S219 11 C107 2

(8W-12-8) (8W-12-22) K78 POWER
18 STEERING
E2 F15 GY PRESSURE
20 20 SWITCH
OR DB/WT
1
43 40
C201 F16 C100
S215 S217
(8W-12-8) (8W-12-22)
E2 F15 K78 Z1
20 20 20 20
OR DB/WT GY BK
4 3 2
FUSED FUSED IDLE EXTENDED
PANEL IGNITION ACTUATOR IDLE S107
LAMPS SWITCH SWITCH (8W-15-2)
DIMMER OUTPUT
SWITCH (RUN)
(POLICE
SIGNAL GROUND PACKAGE)
1
Z1
Z1 16
20 BK
BK

S208
(8W-15-14)
Z1
14 G101
BK (8W-15-2)

G107
(8W-15-14)
XJI03017 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 18 8W-30 FUEL/IGNITION SYSTEM XJ
GAS
GENERATOR
ST-RUN F20 (8W-12-14) GENERATOR (8W-20-2)
FIELD
POWER GENERATOR DRIVER
B5 D11 DISTRIBUTION DRIVER (+)
A/C RADIATOR CENTER 1 2
COMPRESSOR FAN (8W-10-2) K72 K20
CLUTCH RELAY 16 16
RELAY (8W-42-9) DG/OR DG
(8W-42-7) C108
2 3
B3 D13
K72
18
DG/OR

S166
K72 K20
18 18
DG/OR DG
2
EVAP
LEAK
DETECTION 2 C107
PUMP

3 4
C13 C27 K106 K105 K72 K20
18 18 18 18 18 18
DB/OR DB/PK WT/DG WT/OR DG/OR DG

1 C3 2 C3 10 C3 14 C3 25 C3 10 C2
A/C RADIATOR LEAK LEAK GENERATOR GENERATOR POWERTRAIN
COMPRESSOR FAN DETECTION DETECTION DRIVER FIELD CONTROL
CLUTCH RELAY PUMP PUMP DRIVER MODULE
RELAY CONTROL SOLENOID SWITCH (+)
CONTROL CONTROL SENSE

A/C
A/C A/C LED
SWITCH SELECT INDICATOR
SENSE INPUT SIGNAL
22 C3 23 C3 13 C3
C22 C90
18 18 C48
DB/WT LG 18
TN
S143
2.5L 4.0L 4.0L 2.5L

C90 C90 C90 C90

20 20 20 20
1 LG LG LG LG
A/C A/C 2
SWITCH LOW A6 C100
A/C A/C
SENSE PRESSURE
C90 SWITCH LOW
SWITCH 20 SENSE PRESSURE
(8W-42-6) LG SWITCH
(8W-42-6)
1 4 3 2
A/C A/C A/C A/C A/C A/C
SWITCH HIGH 6 C1 SWITCH SWITCH LED HIGH
SENSE A/C A/C- SENSE SENSE INDICATOR
PRESSURE PRESSURE
SWITCH HEATER SIGNAL
SWITCH SENSE SWITCH
(8W-42-6) CONTROL (8W-42-6)
(8W-42-4)
(8W-42-5)
J008W-7 XJI03018

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 19
GAS
BATT A0 (8W-10-11)
POWER
A18 DISTRIBUTION
FUSE CENTER
19 (8W-10-2)
20A
(8W-10-28)
A17

F34
18
TN/BK
E6
A18 C100
LHD EXCEPT BUILT-UP-EXPORT OTHER

4 C1
FUSED HEADLAMP S218
B(+) SWITCH (8W-10-28)
(8W-50-2) (8W-10-29)

F34
18
TN/BK
16
DATA
LINK
5 4 6 7 CONNECTOR
Z12 Z1 D20 D21
18 18 20 20
BK/TN BK LG/BK PK

A7 A1 B7 B8 C100
E7 F1 F2
2.5L 4.0L

D21
20
PK

S139
D21 D21
18 20
Z12 Z1
PK PK
18 18
BK/TN BK 20
D20 SCI CONTROLLER
18 D21 TRANSMIT/ ANTI-LOCK
LG/BK 18 ISO 9141K BRAKE
PK (8W-35-2)

29 C3 27 C3 14
SCI SCI POWERTRAIN SCI TRANSMISSION
RECEIVE TRANSMIT/ CONTROL TRANSMIT/ CONTROL
ISO 9141K MODULE ISO 9141K MODULE
(8W-31-7)

G102 RHD
(8W-15-2) LHD
XJI03019 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 20 8W-30 FUEL/IGNITION SYSTEM XJ
LHD
3 11 DATA SENTRY
LINK CCD CCD KEY
D1 D2
18 TWISTED 18 CONNECTOR BUS BUS IMMOBILIZER
VT/BR PAIR WT/BK (+) (-) MODULE
1 2 (8W-39-8)
D1 TWISTED D2
20 PAIR 20
VT/BR WT/BK

S238
S239

D1 TWISTED D2
TWISTED 20 PAIR 20
PAIR VT/BR WT/BK
D1 D2 D1 D2
20 20 20 20
VT/BR WT/BK VT/BR WT/BK
D1 D2 C201
20 20 51 52
VT/BR WT/BK D1 D2
2 C2 1 C2 18 18
INSTRUMENT VT/BR WT/BK
CCD CCD
BUS BUS CLUSTER 19 18
(+) (-) (8W-40-3) CCD CCD AIRBAG
BUS BUS CONTROL
(+) (-) MODULE
C201 (8W-43-2)
55 56
D1 D2 E11 E12 C100
4.0L
20 20 OTHER A/T
VT/BR WT/BK
4.0L A/T OTHER
D1
20 D2
1 2 C301 VT/BR 20
WT/BK
OTHER COMPASS COMPASS OTHER
S145 D2
D1 S144 18
18 WT/BK
S344 S346 D1 D2 D2
VT/BR TWISTED
20 20 18
D1 TWISTED D2 VT/BR PAIR WT/BK WT/BK
20 PAIR 20
7 6
VT/BR WT/BK
CCD CCD TRANSMISSION
BUS BUS CONTROL
5 11 (+) (-) MODULE
CCD CCD COMPASS D1
(8W-31-7)
D2
BUS BUS (8W-49-6) 18 18
(+) (-) VT/BR TWISTED WT/BK
PAIR

D1 D2 30 C3 28 C3
20 TWISTED 20 CCD CCD POWERTRAIN
VT/BR PAIR WT/BK BUS BUS CONTROL
(+) (-) MODULE
6 12
CCD CCD OVERHEAD
BUS BUS MODULE
(+) (-) (8W-49-6)

J008W-7 XJI03020

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 21
RHD
3 11 DATA SENTRY
LINK CCD CCD
KEY
D1 D2
18 TWISTED 18 CONNECTOR BUS BUS IMMOBILIZER
VT/BR PAIR WT/BK (+) (-) MODULE
1 2 (8W-39-9)
D1 TWISTED D2
20 PAIR 20
VT/BR WT/BK

S238
S239

D1 TWISTED D2
TWISTED 20 PAIR 20
PAIR VT/BR WT/BK
D1 D2 D1 D2
20 20 20 20
VT/BR WT/BK VT/BR WT/BK
D1 D2
20 20 19 20 C204
VT/BR WT/BK D1 D2
2 C2 1 C2 18 18
INSTRUMENT VT/BR WT/BK
CCD CCD
BUS BUS CLUSTER 19 18
(+) (-) (8W-40-3) CCD CCD AIRBAG
BUS BUS CONTROL
(+) (-) MODULE
C301 (8W-43-3)
1 2
D1 D2 A11 4.0L A12 C100
20 20 OTHER A/T 4.0L A/T OTHER
VT/BR WT/BK

D1 D2
20 20
COMPASS OTHER VT/BR WT/BK
OTHER COMPASS D2
18
S145 S144 WT/BK

S344 S346 D1 D1 D2
18 20 D2 18
D1 TWISTED D2 VT/BR VT/BR
TWISTED 20 WT/BK
20 PAIR 20 PAIR WT/BK
VT/BR WT/BK 7 6
CCD CCD TRANSMISSION
5 11 BUS BUS CONTROL
(+) (-) MODULE
CCD CCD COMPASS D1 D2
BUS BUS (8W-49-6) (8W-31-7)
18 18
(+) (-) VT/BR TWISTED WT/BK
PAIR

D1 D2 30 C3 28 C3
20 TWISTED 20 POWERTRAIN
CCD CCD
VT/BR PAIR WT/BK BUS BUS CONTROL
(+) (-) MODULE
6 12
CCD CCD OVERHEAD
BUS BUS MODULE
(+) (-) (8W-49-6)

XJI03021 J008W-7

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 8W - 30 - 22 8W-30 FUEL/IGNITION SYSTEM XJ
DIESEL
BATT A0 (8W-10-13) ST-RUN A21 (8W-10-17)
POWER JUNCTION
10 DISTRIBUTION BLOCK
FUSE CENTER FUSE
(8W-12-2)
4 (8W-10-7) 11
30A 20A
3 (8W-10-19) (8W-12-15)

A16
5 C2
12
RD/LG

S151
(8W-10-19)
A16 A16
12 12
RD/LG RD/LG

C4 C2 F12
18
AUTOMATIC DB/WT
SHUT
DOWN
RELAY
C6 C8 (IN PDC)
A142 18DG/OR
A142 S130
16 (8W-12-15)
DG/OR C11
RADIATOR
S137 FAN
(8W-10-19)
RELAY
K51 A142 A142 A142 (IN PDC) F12
20 16 16 18 C13 (8W-42-10) 18
DB/YL DG/OR DG/OR DG/OR DB/WT

B5
A/C
COMPRESSOR
CLUTCH
RELAY
B3 (IN PDC)
33 C1 2 C1 28 C1 (8W-42-8) 47 C1
AUTOMATIC AUTOMATIC AUTOMATIC FUSED ENGINE
SHUT DOWN SHUT DOWN SHUT DOWN IGNITION CONTROL
RELAY RELAY RELAY SWITCH MODULE
CONTROL OUTPUT OUTPUT OUTPUT
ECM (ST-RUN) ECM
GROUND GROUND
27 C1 1 C1
Z12 Z12
16 14
BK/TN BK/TN

S146
(8W-15-3)
Z12
12
BK/TN

G102
(8W-15-3)
J008W-7 XJI03022

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 23
DIESEL
BATT A16 (8W-10-19) BATT A16 (8W-10-19)
POWER
A8 C2 DISTRIBUTION
AUTOMATIC CENTER
FUSE SHUT
24 (8W-10-7)
DOWN
10A RELAY
A7 (8W-10-19) (8W-30-22)
C8

GENERATOR
F16 A142 GENERATOR (8W-20-4)
16 16 FIELD
RD/LG DG/OR GENERATOR DRIVER
SOURCE (+)
1 2

K72 K20
18 18
S137 DG/OR DG
(8W-10-19)

7 5 C120

A142 A142 K72 K20

16 16 18 18
DG/OR DG/OR DG/OR DG

22 C1 12 C3 2 C1 25 C3 10 C2
FUSED AUTOMATIC AUTOMATIC GENERATOR GENERATOR POWERTRAIN
B(+) SHUT DOWN SHUT DOWN SOURCE FIELD CONTROL
RELAY RELAY DRIVER MODULE
OUTPUT OUTPUT (+)

GROUND GROUND
31 C1 32 C1

Z12 Z12
14 14
BK/TN BK/TN

S146
(8W-15-3)

Z12
12
BK/TN

G102
(8W-15-3)
XJI03023 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 24 8W-30 FUEL/IGNITION SYSTEM XJ
DIESEL
ST-RUN A21 (8W-10-17) BATT A0 (8W-10-13) BATT A16 (8W-10-19)
JUNCTION C2 POWER
BLOCK 12 AUTOMATIC DISTRIBUTION
FUSE
(8W-12-2)
FUSE
SHUT CENTER
DOWN (8W-10-7)
11 6
RELAY
20A 30A (8W-30-22)
(8W-12-15) 5 (8W-10-24)
C8
5 C2
F12 A142
18 16
DB/WT DG/OR
A61
S130 14 S137
(8W-12-15) LG/RD (8W-10-19)
F12 A142
18 16
DB/WT DG/OR

POWER
D4 D2
FUEL A14 DISTRIBUTION
HEATER FUSE CENTER
RELAY 21 (8W-10-7)
20A
A13 (8W-10-34)
D6 D8

F142
16
DG/OR

Z1 A93
14 S156
18
RD/BK (8W-10-34)
BK
F142
18
DG/OR

1 A
FUEL FUSED ELECTRONIC
HEATER AUTOMATIC VACUUM
SHUT DOWN MODULATOR
RELAY OUTPUT EGR
SOLENOID
2 GROUND CONTROL
D B
Z1 Z1 K35
16 18 18
BK BK GY/YL

S141 S157
(8W-15-11) G106 (8W-15-11)
(8W-15-12)
Z1 Z1
12 12
BK BK

S132 29 C1
(8W-15-11) EGR ENGINE
Z1 SOLENOID CONTROL
12 CONTROL MODULE
BK

G106
(8W-15-12)
J008W-7 XJI03024

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 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 25
DIESEL
BATT A16 (8W-10-19) BATT A0 (8W-10-13)
POWER
C2 DISTRIBUTION
AUTOMATIC A14 8 9
CENTER
SHUT FUSE FUSE (8W-10-7)
FUSE
DOWN 2 3
21
RELAY 50A 50A
(8W-30-22) 20A
(8W-10-34) (8W-10-19) (8W-10-19)
A13 1 2
C8

A142 A142 F142 A54 A54

16 16 16 12 12
DG/OR DG/OR DG/OR RD/GY RD/GY

S137
(8W-10-19)

S156 S153
(8W-10-34) (8W-10-19)

F142 A54
18 10
DG/OR RD/GY

2 1
GLOW
PLUG
RELAY

3 4

K152 K154
18 10
WT GY

42 C1
GLOW ENGINE
PLUG CONTROL
RELAY MODULE
CONTROL

GLOW
GLOW GLOW GLOW GLOW PLUG
PLUG PLUG PLUG PLUG ASSEMBLY
NO. 1 NO. 2 NO. 3 NO. 4

XJI03025 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 26 8W-30 FUEL/IGNITION SYSTEM XJ
DIESEL
BATT A16 (8W-10-19)
POWER
C2 A14 DISTRIBUTION
AUTOMATIC CENTER
SHUT FUSE
21 (8W-10-7)
DOWN
RELAY 20A
(8W-30-22) (8W-10-34)
A13
C8

A142 A142 F142

16 16 16
DG/OR DG/OR DG/OR

S137 S156
(8W-10-19) (8W-10-34)

A142 F142
16 16
DG/OR DG/OR

9 10
FUEL
FUEL
FUEL SHUT FUEL SENSOR
INJECTION
QUANTITY DOWN TIMING GROUND PUMP
ACTUATOR SOLENOID SOLENOID

8 6 5 7 4

K140 K4
16 20
TN/WT BK/LB

S148 S149
(8W-70-4)

K140 K140 K140 K153 K126 K156 K4

18 18 18 18 18 20 20
TN/WT TN/WT TN/WT OR LG GY BK/LB

59 C2 66 C2 80 C2 77 C2 79 C2 53 C2 61 C2
FUEL QUANTITY ACTUATOR FUEL FUEL FUEL SENSOR ENGINE
CONTROL SHUT DOWN TIMING TEMP. GROUND CONTROL
SOLENOID SOLENOID SENSOR MODULE
CONTROL CONTROL SIGNAL

J008W-7 XJI03026

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 27
DIESEL
BATT A16 (8W-10-19)
AUTOMATIC
SHUT
DOWN
RELAY
C8 (8W-30-22)
A142
18
DG/OR
A142 18DG/OR
C11
RADIATOR
FAN
RELAY
(8W-42-10)
POWER
C13 B5
A/C
DISTRIBUTION
COMPRESSOR CENTER
FUEL (8W-10-7)
CLUTCH
INJECTION RELAY
CONTROL MEASURE PUMP (8W-42-8)
SLEEVE COIL
B3

2 1 3
K57 K134 K135 C13
20 20 20 20
LG/OR LB/BK WT/BK DB/OR

57 C2 56 C2 58 C2 5 C1
CONTROL CONTROL CONTROL A/C ENGINE
SLEEVE SLEEVE SLEEVE COMPRESSOR CONTROL
POSITION POSITION POSITION CLUTCH MODULE
SENSOR SENSOR SENSOR RELAY
MIDDLE SIGNAL MEASURE CONTROL
TAP COIL
SIGNAL

INTAKE
AIR BOOST
TEMPERATURE PRESSURE
SENSOR SENSOR SENSOR 5V
GROUND SIGNAL SIGNAL SUPPLY
61 C2 13 C1 40 C1 39 C1
K4 K21 K1 K9
20 20 20 20
BK/LB BK/RD DG/RD LB
2 4 3
INTAKE BOOST 5V TURBO
AIR PRESSURE SUPPLY BOOST
TEMPERATURE SENSOR PRESSURE
SENSOR SIGNAL
SENSOR
SIGNAL
SENSOR
GROUND
1
K4
20
BK/LB

S149
(8W-70-4)

XJI03027 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 28 8W-30 FUEL/IGNITION SYSTEM XJ
DIESEL

ACCELERATOR
PEDAL
POSITION
LOW ACCELERATOR ACCELERATOR SENSOR
IDLE PEDAL PEDAL
POSITION POSITION POSITION
5V SWITCH SENSOR SENSOR SENSOR
SUPPLY SIGNAL SIGNAL GROUND GROUND
10 5 7 8 3

K4
20
BK/LB NEEDLE
NEEDLE NEEDLE MOVEMENT
MOVEMENT MOVEMENT
SENSOR SENSOR SENSOR
(+) (-)
1 2

S149
(8W-70-4)

K6 K151 K22 K255 K4 K67 K68

20 20 20 20 20 18 18
VT/WT WT OR/DB WT/DG BK/LB BR/BK LG/YL

TWISTED
PAIR

11 C1 12 C1 24 C1 23 C1 61 C2 62 C2 55 C2
5V ACCELERATOR ACCELERATOR SENSOR NEEDLE NEEDLE ENGINE
LOW
SUPPLY IDLE PEDAL PEDAL GROUND MOVEMENT MOVEMENT CONTROL
POSITION POSITION POSITION SENSOR SENSOR MODULE
SWITCH SENSOR SENSOR SIGNAL GROUND
SIGNAL SIGNAL GROUND

J008W-7 XJI03028

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 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 29
DIESEL
ENGINE
ENGINE CONTROL
VEHICLE COOLANT MODULE
SPEED TEMPERATURE
SENSOR SENSOR SENSOR
SIGNAL SIGNAL GROUND
51 C1 54 C2 61 C2
G7 K2 K4
20 20 20
WT/OR TN/BK BK/LB

VEHICLE
VEHICLE SPEED S149
SPEED (8W-70-4)
5V SENSOR SENSOR SENSOR
SUPPLY GROUND SIGNAL K4
1 2 3 20
BK/LB
K7 K167 G7
18 18 18
OR BR/YL WT/OR 8 9
C120
6 8 1 C111
K2 K4
18 18
K7 K167 G7 TN/BK BK/LB
20 20 20
OR BR/YL WT/OR
1 2
S124 ENGINE
COOLANT
S138
(8W-70-4)
TEMPERATURE
K7 K167
SENSOR
20 20 NO. 1
OR BR/YL
1 3 C116 S152

K7 K167 ENGINE
18 18 COOLANT
OR BR/YL TEMPERATURE
1 3 SENSOR
ENGINE 2 1 NO. 2
OIL
PRESSURE
SENSOR K167 K222
18 18
BR/YL TN/RD
2
G60 12 C120
18 10
GY/YL S138
(8W-70-4)
2 C116
K7 G60 K167 G7 K167 K222
18 18 18 18 18 18
OR GY/YL BR/YL WT/OR BR/YL TN/RD
17 C1 23 C2 4 C1 27 C2 4 C1 16 C1
5V ENGINE SENSOR VEHICLE SENSOR ENGINE POWERTRAIN
SUPPLY OIL GROUND SPEED GROUND COOLANT CONTROL
PRESSURE SENSOR TEMPERATURE MODULE
SENSOR SIGNAL SENSOR
SIGNAL SIGNAL

XJI03029 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 30 8W-30 FUEL/IGNITION SYSTEM XJ
DIESEL

ENGINE A/C
ENGINE ENGINE A/C
SPEED RADIATOR PRESSURE
HIGH
SPEED SPEED
SENSOR SENSOR SENSOR FAN SWITCH PRESSURE
GROUND SIGNAL REQUEST SENSE SWITCH
1 3 2 4 (8W-42-8)

K3 K24 C48 C22

20 20 18 20
LG/BK GY/BK TN DB/WT

1 4 13 3 C120

A/C-
AC
HEATER
SWITCH CONTROL
SENSE (8W-42-4)
(8W-42-5)
6 C1

K3 K24 C48 C22 C90

20 20 18 20 20
LG/BK GY/BK TN DB/WT LG

69 C2 67 C2 48 C1 10 C1
ENGINE ENGINE RADIATOR A/C ENGINE
SPEED SPEED FAN PRESSURE CONTROL
SENSOR SENSOR REQUEST SWITCH MODULE
GROUND SIGNAL SENSE

SPEED FAULT A6 C100

ENGINE
A/C ENGINE CONTROL INDICATOR SPEED
REQUEST DISABLE INDICATOR REQUEST SENSOR
OUTPUT SIGNAL SIGNAL INPUT SIGNAL
8 C1 38 C1 30 C1 34 C1 6 C1

C103 G55 V66 K48 K159 C90

18 18 18 18 18 18
DG OR/BK RD/LG OR/RD VT/RD LG

1 C3 16 C3 18 C2 22 C3 8 C1 23 C3
A/C ENGINE SPEED FAULT ENGINE A/C POWERTRAIN
REQUEST DISABLE CONTROL INDICATOR SPEED SWITCH CONTROL
OUTPUT SIGNAL INDICATOR REQUEST SENSOR SENSE MODULE
SIGNAL INPUT SIGNAL

J008W-7 XJI03030

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 31
DIESEL
S138
(8W-70-4)

K167 K167 K167 K167

20 20 20 20
BR/YL BR/YL BR/YL BR/YL

B3
C100
F12
LHD RHD

30 C200 7 C204

K167 K167
20 20
BR/YL BR/YL

K167 2
20 BATTERY
2 BR/YL TEMPERATURE
LOW 4 SENSOR
COOLANT FUEL
SWITCH LEVEL 1
SENSOR
1
3
K226
20
DB/LG
2
WATER LHD RHD
IN
FUEL 15 C200 6 C204
SENSOR
1 K226 K226
20 20
DB/LG DB/LG

B2
F11 C100

G123 G18 K226 K118 K167

18 18 18 18 18
DG/WT PK/BK DB/LG PK/YL BR/YL

27 C1 12 C1 26 C3 15 C3 4 C1
WATER COOLANT FUEL BATTERY SENSOR POWERTRAIN
IN FUEL LEVEL LEVEL TEMPERATURE GROUND CONTROL
SENSOR SWITCH SENSOR SENSOR MODULE
SIGNAL SIGNAL SIGNAL SIGNAL

RHD
LHD
XJI03031 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 32 8W-30 FUEL/IGNITION SYSTEM XJ
DIESEL

BATT A0 (8W-10-13)
POWER
A18 DISTRIBUTION
FUSE CENTER
19 (8W-10-7)
15A
A17 (8W-10-32)

ENGINE
BRAKE BRAKE SPEED CONTROL
LAMP LAMP CONTROL MODULE
SWITCH SWITCH SENSOR SWITCH
OUTPUT SENSE GROUND SIGNAL
20 C1 9 C1 61 C2 60 C2
F32 L50 K29 K4 V37
20 20 20 20 20
PK/DB WT/TN WT/PK BK/LB RD/LG
OTHER ABS

S147 S149
(8W-10-32) (8W-70-4)
K4
20
L50
BK/LB
20
F18 F17
WT/TN
B6 B5 C100
E1 F10
F8 B4 B1 C100
LHD RHD K4 V37
20 20
K29 K29 BK/RD RD/LG
F32 L50 20 18
20 20 WT/PK WT/PK
PK/DB WT/TN

S203 3 C1 2 C1
(8W-10-32) S204 CLOCKSPRING
L50 K29 (8W-33-3)
20 18
WT/TN WT/PK
6 5 1
BRAKE A C2 B C2
LAMP
K167 V37
SWITCH 20 20
(8W-33-5)
BR/YL RD/LG
2
S221
Z1 S222
18
BK V37 K167 V37 K167
20 20 20 20
S207 RD/LG BR/YL RD/LG BR/YL
(8W-15-16) 2 1 2 1
Z1 SPEED SENSOR LEFT SPEED SENSOR RIGHT
14 CONTROL GROUND SPEED CONTROL GROUND SPEED
BK SWITCH CONTROL SWITCH CONTROL
SIGNAL SIGNAL
SWITCH SWITCH
G108 (8W-33-3) (8W-33-3)
(8W-15-16) RHD
J008W-7 LHD XJI03032

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 33
DIESEL
BATT A16 (8W-10-19) ST-RUN A21 (8W-10-17)
POWER JUNCTION
C2 C11 DISTRIBUTION BLOCK
AUTOMATIC RADIATOR CENTER (8W-12-2)
SHUT FAN FUSE
A142 (8W-10-7) 9
DOWN 18 RELAY
RELAY (8W-42-10) 10A
DG/OR
(IN PDC) (8W-12-13)
C8 (8W-30-22) C13
S13 C4

F87
20
WT/BK

RHD LHD

FULL
BASE OPTIONS

S225
(8W-12-13)

5 C201

F87
20
WT/BK

S216
(8W-12-13)
1
MESSAGE
C27
WAIT WATER LOW
CENTER
20
DB/PK TO IN COOLANT
START FUEL LEVEL
WARNING WARNING WARNING
INDICATOR INDICATOR INDICATOR
4 7 8
K185 G86 G154
20 20 20
OR/LB TN/OR VT/LG

E15 E16 E17 C100

K185 G86 G154

20 18 18
OR/LB TN/OR VT/LG

17 C1 32 C1 9 C3 8 C3
RADIATOR WAIT ENGINE WATER LOW POWERTRAIN
FAN TO CONTROL IN COOLANT CONTROL
RELAY START MODULE FUEL INDICATOR MODULE
CONTROL INDICATOR INDICATOR DRIVER
DRIVER DRIVER

XJI03033 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 30 - 34 8W-30 FUEL/IGNITION SYSTEM XJ
DIESEL
BATT A0 (8W-10-13)
POWER
A4 DISTRIBUTION
FUSE CENTER
26 (8W-10-7)
20A
(8W-10-29)
A3

F34
18
TN/BK
A18
C100
E6
S218
(8W-10-29)
F34 F34
18 18
TN/BK TN/BK
16
DATA
LINK
CONNECTOR
4 C1
HEADLAMP HEADLAMP
SWITCH SWITCH
5 4 6 7 OUPUT (8W-50-3)
LHD RHD Z1 D20 D21
18 20 20
Z12 Z12 BK LG/BK PK
18 18
BK/TN BK/TN

E7 A7 A1 B7 B8 C100
F1 F2
D21
Z12 Z12 20
20 18 PK
BK/TN BK/TN

S139
D21 D21 D21
18 20 18
PK PK PK

Z1 D20 45 C1
18 18 SCI ENGINE
BK LG/BK TRANSMIT/ CONTROL
ISO 9141K MODULE
S146
(8W-15-3)

29 C3 27 C3
POWERTRAIN 20
Z12 SCI SCI
RECEIVE TRANSMIT/ CONTROL SCI CONTROLLER
12
BK/TN ISO 9141K MODULE TRANSMIT/ ANTI-LOCK
ISO 9141K BRAKE
(8W-35-3)

RHD
G102 LHD
(8W-15-3)
J008W-7 XJI03034

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1

8W-31 TRANSMISSION CONTROL SYSTEM

Component Page Component Page
Brake Lamp Switch . . . . . . . . . . . . . . . . 8W-31-3, 7 Lock-Up Solenoid . . . . . . . . . . . . . . . . . . . . 8W-31-4
Data Link Connector . . . . . . . . . . . . . . . . . 8W-31-7 Output Speed Sensor . . . . . . . . . . . . . . . . . 8W-31-5
Engine Starter Motor Relay . . . . . . . . . . 8W-31-2, 6 Park/Neutral Position Switch . . . . . . . . . . . 8W-31-2
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 6 Power Distribution Center . . . . . . . . . . . 8W-31-2, 4
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 4 Powertrain Control Module . . . . . . . 8W-31-2, 3, 5, 7
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-31-4 Shift Lock Solenoid . . . . . . . . . . . . . . . . . 8W-31-3, 7
Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 7 Throttle Position Sensor . . . . . . . . . . . . . . . 8W-31-5
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4 Torque Converter Clutch Solenoid . . . . . . . 8W-31-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-6 Transmission Control Module . . . . . 8W-31-4, 5, 6, 7
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 7 Transmission Range Sensor . . . . . . . . . . . . 8W-31-6
Input Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31-5 Transmission Solenoid . . . . . . . . . . . . . . 8W-31-4, 5
Junction Block . . . . . . . . . . . . . . . 8W-31-2, 3, 4, 6, 7

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 8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM XJ
2.5L GAS A/T
ST-RUN A21 (8W-10-17) ST T141 (8W-12-19)
(8W-12-20)
JUNCTION POWER
C8
BLOCK ENGINE
DISTRIBUTION
(8W-12-2) STARTER CENTER
FUSE FUSE (8W-10-2)
MOTOR
11 10
RELAY
20A 15A (8W-21-2)
(8W-12-15) (8W-12-14)
C10

5 C2 S12 C4
F20 T41
18 20
WT BK/WT
LHD RHD

1 C201 F20
F12
18 F20 18
DB/WT 18 WT
WT
A9 C100 5 C107
E9 C100

S130 S159
(8W-12-15) (8W-12-14)
F20 T41
18 18
F12 BK/WT
WT
18
DB/WT 11 C107
S161 S120
(8W-51-6) (8W-21-2)
F20 F20 T41
18 18 18
WT WT BK/WT

1 2
PARK/
R P/N NEUTRAL
POSITION
10 C107 SWITCH
A
3
TORQUE
L10
CONVERTER 18
CLUTCH BR/LG
SOLENOID 12 C107
B
A15
C100
E3
LHD RHD
F12
18
DB/WT
16 C200 23 C204
T41
18
K54 BK/WT
18
OR/BK TO
S303
(8W-51-8)
2 C1 11 C2 6 C1
FUSED TORQUE PARK/NEUTRAL POWERTRAIN
IGNITION CONVERTER POSITION CONTROL
SWITCH CLUTCH SWITCH MODULE
OUTPUT SOLENOID SENSE (8W-30-14)
(ST-RUN) CONTROL (8W-30-15)
RHD
LHD
J008W-7 XJI03102

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 XJ 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3
2.5L GAS
RUN A22 (8W-10-18)
JUNCTION
BLOCK
FUSE (8W-12-2)
25
15A
(8W-12-22)
(8W-12-23)

S8 C4
F15
20
DB/WT

S219
(8W-12-22)
(8W-12-23)
RHD LHD

40 C201
F15 F15
20 20
DB/WT DB/WT

S217
(8W-12-22)

2
SHIFT
LOCK
SOLENOID

1
RHD LHD

K29 K29
18 20
WT/PK WT/PK

S204
K29
18
RHD LHD
WT/PK

K29 K29 1
18 20 BRAKE
WT/PK WT/PK LAMP
SWITCH
(8W-33-4)
B1
C100 2
F10
Z1
18
K29
BK
18
WT/PK S207
24 C3 (8W-15-16)
POWERTRAIN Z1
BRAKE 14
LAMP CONTROL BK
SWITCH MODULE RHD
SENSE (8W-30-16) LHD
G108
(8W-15-16)
XJI03103 J008W-7

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 8W - 31 - 4 8W-31 TRANSMISSION CONTROL SYSTEM XJ
4.0L
ST-RUN A21 (8W-10-17) BATT A0 (8W-10-11)
JUNCTION POWER
BLOCK A23 DISTRIBUTION
FUSE
(8W-12-2)
FUSE CENTER
11 16 (8W-10-2)
20A 15A
(8W-12-16) (8W-10-27)
A24

5 C2 M1
F12 20
18 PK
DB/WT

S130
(8W-12-16)

LHD RHD

F12
18
DB/WT
S135
(8W-10-27)
S136
(8W-12-16)

F12 M1
18 20
DB/WT PK
26 25
FUSED FUSED TRANSMISSION
IGNITION B(+) CONTROL
SWITCH MODULE
OUTPUT
(ST-RUN)
SOLENOID A SOLENOID B SOLENOID C
GROUND CONTROL CONTROL CONTROL
24 12 13 11
Z12 T19 T60 T22
18 20 20 20
BK/TN WT OR/WT DB/WT

3 2 4
9 C107 TRANSMISSION
1-2 SOLENOID
AND 2-3 LOCK-UP
3-4 SOLENOID SOLENOID
SOLENOID
Z12
16
BK/TN

G101
(8W-15-2)

J008W-7 XJI03104

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 XJ 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 5
4.0L
POWERTRAIN
CONTROL
5V SENSOR MODULE
SUPPLY GROUND (8W-30-5)
17 C1 4 C1
K7 4.0L
18 CALIFORNIA
OR BUILT-UP-
EXPORT OTHER

K167
18
BR/YL K167
18
S123 BR/YL
(8W-70-2)
K167
20
BR/YL

S111
(8W-70-3)

K167
20 K167
BR/YL 20
BR/YL
S115 S114
(8W-70-2) (8W-70-3)
K7 K167
3 C107
20 20
K22
OR BR/YL
20 K167
OR/DB 3 1 20
S112 THROTTLE BR/YL
(8W-30-7)
POSITION
K22 SENSOR
20 (8W-30-7) S138
OR/DB (8W-70-3)
2
6 C107

K22 K167
20 20
OR/DB BR/YL

17 16
THROTTLE SENSOR TRANSMISSION
POSITION GROUND CONTROL
INPUT SENSOR INPUT OUTPUT OUTPUT MODULE
SPEED SIGNAL SPEED SPEED SPEED
SENSOR SENSOR SENSOR SENSOR
SIGNAL GROUND SIGNAL GROUND
2 1 4 3
T52 T31 T14 T13
20 20 20 20
RD/BK VT/LG LG/WT DB/BK
1 5 7 6
TRANSMISSION
INPUT OUTPUT SOLENOID
SPEED SPEED
SENSOR SENSOR

XJI03105 J008W-7

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 8W - 31 - 6 8W-31 TRANSMISSION CONTROL SYSTEM XJ
4.0L
ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
FUSE (8W-12-2) FROM
10 ENGINE
15A
(8W-12-14)
STARTER
MOTOR
S12 C4 RELAY
(8W-21-3)
F20
18
WT
LHD RHD

1 C201 T41
F20
F20 18 20
18 WT BK/WT
WT

A9
E9 C100
F20
18
WT

S159
(8W-12-14)
F20
18
WT
3 7
TRANSMISSION
RANGE
R D D3 1-2 P/N SENSOR

6 4 2 1 8
L10 T1 T3 T42 Z1
18 18 18 18 18
BR/LG LG/BK VT VT/WT BK

S141
(8W-15-5)
(8W-15-6)
(8W-15-8)

S142
(8W-51-6)
Z1
16
L10 BK
18
BR/LG
G106
(8W-15-7)
18 22 9 21 (8W-15-10)
BACK-UP TRS TRS TRS TRANSMISSION
LAMP T1 T3 T42 CONTROL
FEED SENSE SENSE SENSE MODULE
LHD
RHD
J008W-7 XJI03106

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 XJ 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 7
4.0L
RUN A22 (8W-10-18)
7 3 11 DATA
TWISTED LINK JUNCTION
PAIR CONNECTOR BLOCK
(8W-12-2)
(8W-30-19) FUSE
(8W-30-20) 25
(8W-30-21) 15A
(8W-12-22)
(8W-12-23)
D1 D2 S8 C4
18 18 F15
VT/BR WT/BK 20
DB/WT

S219
(8W-12-22)
(8W-12-23)
S239 S238 LHD RHD
(8W-30-20) (8W-30-20) 40 C201
(8W-30-21) (8W-30-21)
F15 F15
20 20
DB/WT DB/WT
LHD RHD S217
(8W-12-22)
D21 D1 D2 K29 K29
20 20 20 20 18
F15
PK VT/BR WT/BK WT/PK WT/PK
20
DB/WT
2
SHIFT
B8 A11 A12 B1 C100 LOCK
F2 E11 E12 F10 SOLENOID

1
LHD RHD
D21 D1 D2 K29
20 20 20 20 K29 K29
PK VT/BR WT/BK WT/PK 20 18
WT/PK WT/PK

S204
S140 K29
18
S139 S145 S144 K29 WT/PK
(8W-30-19) (8W-30-20) (8W-30-20) 18
(8W-30-21) (8W-30-21) 1
WT/PK
BRAKE
LAMP
SWITCH
24 C3 (8W-33-4)
D21 D1 D2 K29 POWERTRAIN
20 BRAKE
20 20 TWISTED 20
LAMP CONTROL 2
PK VT/BR PAIR WT/BK WT/PK
SWITCH MODULE Z1
SENSE (8W-30-16) 18
BK
14 7 6 23
SCI CCD CCD BRAKE TRANSMISSION S207
TRANSMIT/ BUS BUS LAMP CONTROL (8W-15-16)
ISO9141K (+) (-) SWITCH MODULE Z1
SENSE 14
BK

RHD G108
LHD (8W-15-16)
XJI03107 J008W-7

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 XJ 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1

8W-33 VEHICLE SPEED CONTROL

Component Page Component Page
Accelerator Pedal Position Sensor . . . . . . . . 8W-33-5 G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-4
Brake Lamp Switch . . . . . . . . . . . . . . . . 8W-33-4, 5 G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-4, 5
Clockspring . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2, 3 Left Speed Control Switch . . . . . . . . . . . 8W-33-2, 3
Engine Control Module . . . . . . . . . . . . . . 8W-33-3, 5 Power Distribution Center . . . . . . . . . . . 8W-33-4, 5
Fuel Injection Pump . . . . . . . . . . . . . . . . . . 8W-33-5 Powertrain Control Module . . . . . . . . . 8W-33-2, 4, 5
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-33-5 Right Speed Control Switch . . . . . . . . . . 8W-33-2, 3
Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-33-4 Vehicle Speed Control Servo . . . . . . . . . . . . 8W-33-4

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 8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL XJ
GAS
LEFT RIGHT
SPEED SPEED
CONTROL CONTROL
SWITCH SWITCH
1 SET 1 RESUME/ACCEL
2 ON/OFF 2 CANCEL
3 COAST
1 2 1 2 3

2 1 2 1
V37 K167 V37 K167
20 20 20 20
RD/LG BR/YL RD/LG BR/YL

S221
S222
B C2 A C2
CLOCKSPRING

2 C1 3 C1
K4
V37 20
20 BK/RD
RD/LG

B5 B6 C100
F17 F18
K167
20
BR/YL

S138
(8W-70-3)
3 C107
K167
20
BR/YL
4.0L S111
CALIFORNIA (8W-70-3)
BUILT-UP-
EXPORT OTHER

K167
20
BR/YL K167
18
S123 BR/YL
(8W-70-2)
K167
18
V37
BR/YL
18
RD/LG
32 C3 4 C1
SPEED SENSOR POWERTRAIN
CONTROL GROUND CONTROL
SWITCH MODULE
SIGNAL (8W-30-13)

RHD
LHD
J008W-7 XJI03302

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 XJ 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3
DIESEL

LEFT RIGHT
SPEED SPEED
CONTROL CONTROL
SWITCH SWITCH
1 SET 1 RESUME/ACCEL
2 ON/OFF 2 CANCEL
3 COAST
1 2 1 2 3

2 1 2 1
V37 K167 V37 K167
20 20 20 20
RD/LG BR/YL RD/LG BR/YL

S221
S222
V37 K167
20 20
RD/LG BR/YL
B C2 A C2

CLOCKSPRING

2 C1 3 C1

V37
20 K4
RD/LG 20
BK/RD

B5 B6 C100
F17 F18

K4
20
BK/LB

S149
(8W-70-4)

V37 K4
20 20
RD/LG BK/LB

60 C2 61 C2
SPEED SENSOR ENGINE
CONTROL GROUND CONTROL
SWITCH MODULE
SIGNAL (8W-30-32)

RHD
LHD
XJI03303 J008W-7

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 8W - 33 - 4 8W-33 VEHICLE SPEED CONTROL XJ
GAS
BATT A0 (8W-10-7)
POWER
DISTRIBUTION
A9
LHD RHD CENTER
FUSE (8W-10-2)
23
15A
V32 V32 K29 (8W-10-33)
18 20 18 A10
YL/RD YL/RD WT/PK
F8 C100
F32
20
S204 PK/DB
(8W-31-3) 1 3 6
(8W-31-7) BRAKE
F9 C100
LAMP
SWITCH

LHD RHD 2 4 5

K29 K29 Z1 V30 L50

20 18 18 20 20
WT/PK WT/PK BK DB/RD WT/TN

S207 F7 C100
(8W-15-16)
Z1 V30
14 20 TO
B1 BK DB/RD S203
F10 C100 (8W-10-33)
G108
(8W-15-16)
OTHER 4.0L A/T 3
VEHICLE
SPEED
K29
20 CONTROL
K29 SERVO
WT/PK
18
WT/PK
S140 1 2 4
(8W-31-7)
Z1
18
BK

S132
(8W-15-4)
Z1 (8W-15-5)
V32 K29 V36 V35 16 (8W-15-6)
18 18 18 18 BK (8W-15-8)
YL/RD WT/PK TN/RD LG/RD (8W-15-9)

G106
(8W-15-7)
(8W-15-10)
11 C3 24 C3 4 C3 5 C3
SPEED BRAKE SPEED SPEED POWERTRAIN
CONTROL LAMP CONTROL CONTROL CONTROL
POWER SWITCH VACUUM VENT MODULE
SUPPLY SENSE SOLENOID SOLENOID (8W-30-14) RHD
CONTROL CONTROL (8W-30-16) LHD

J008W-7 XJI03304

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 XJ 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 5
DIESEL
BATT A0 (8W-10-13) ACCELERATOR
POWER ACCELERATOR ACCELERATOR PEDAL
A18 DISTRIBUTION PEDAL PEDAL POSITION
POSITION POSITION SENSOR
FUSE CENTER SENSOR SENSOR 5V
(8W-10-7) (8W-30-28)
19 SIGNAL GROUND SUPPLY
15A 7 8 10
A17 (8W-10-32)
K22 K255 K6
20 20 20
OR/DB WT/DG VT/WT

24 C1 23 C1 11 C1
ACCELERATOR ACCELERATOR 5V ENGINE
PEDAL PEDAL SUPPLY CONTROL
POSITION POSITION MODULE
SENSOR SENSOR (8W-30-26)
BRAKE BRAKE SIGNAL SPEED GROUND (8W-30-28)
LAMP LAMP CONTROL (8W-30-30)
SWITCH SWITCH INDICATOR FUEL QUANTITY (8W-30-32)
OUTPUT SENSE SIGNAL ACTUATOR CONTROL
20 C1 9 C1 30 C1 66 C2 59 C2 80 C2
L50 K29
20 20
F32 WT/TN WT/PK V66 K140 K140 K140
20 OTHER ABS 18 18 18 18
PK/DB RD/LG TN/WT TN/WT TN/WT
S147
(8W-10-32)

B1
B4 F10
F8 E1 C100
C100
LHD RHD

K29 K29
20 18 S148
L50 WT/PK WT/PK (8W-30-26)
20
WT/TN
F32
20 S203 S204
PK/DB (8W-10-32) (8W-30-32)
L50 K29 K140
20 18 16
WT/TN WT/PK TN/WT

6 5 1 8
BRAKE FUEL
FUEL
LAMP QUANTITY INJECTION
SWITCH ACTUATOR PUMP
CONTROL (8W-30-26)

2
Z1 18 C2
18
BK SPEED POWERTRAIN
CONTROL CONTROL
S207 INDICATOR MODULE
SIGNAL (8W-30-30)
(8W-15-16)
Z1
14
BK RHD
LHD
G108
(8W-15-16)
XJI03305 J008W-7

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 XJ 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1

8W-35 ANTI-LOCK BRAKES

Component Page Component Page
ABS Indicator . . . . . . . . . . . . . . . . . . . . . 8W-35-4, 5 Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Brake Lamp Switch . . . . . . . . . . . . . . . . 8W-35-2, 3 Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-35-4, 5
Controller Anti-Lock Brake . . . . . 8W-35-2, 3, 4, 5, 6 G Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3
Controller Anti-Lock Brake Relay . . . . . . 8W-35-4, 5 G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3
Data Link Connector . . . . . . . . . . . . . . . . 8W-35-2, 3 G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-4, 5
Engine Starter Motor Relay . . . . . . . . . . . . 8W-35-5 Instrument Cluster . . . . . . . . . . . . . . . . . 8W-35-4, 5
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . 8W-35-5 Junction Block . . . . . . . . . . . . . . . . . . . . 8W-35-4, 5
Fog Lamp Relay No. 1 . . . . . . . . . . . . . . . . 8W-35-4 Left Front Wheel Speed Sensor . . . . . . . . . 8W-35-6
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-35-4, 5 Left Rear Wheel Speed Sensor . . . . . . . . . . 8W-35-6
Fuse 12 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-35-2, 3 Power Distribution Center . . . . . . . . . . . 8W-35-2, 3
Fuse 13 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-35-2 Right Front Wheel Speed Sensor . . . . . . . . 8W-35-6
Fuse 14 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-35-3 Right Rear Wheel Speed Sensor . . . . . . . . . 8W-35-6
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-35-3

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 8W - 35 - 2 8W-35 ANTI-LOCK BRAKES XJ
GAS
BATT A0 (8W-10-11)
POWER
18 19 A9 DISTRIBUTION
FUSE FUSE FUSE CENTER
12 13 23 (8W-10-2)
40A 20A 15A
(8W-10-25) (8W-10-25) (8W-10-33)
25 26 A10

DATA
F32
LINK 20
CONNECTOR PK/DB
(8W-30-19)
7 F8 C100
D21 F32
20 20
PK PK/DB

6
B8
F2 C100 BRAKE
LAMP
4.0L 2.5L SWITCH
(8W-33-4)

D21 D21 5
20 18 L50
PK PK
G
20
WT/TN SWITCH

S139
(8W-30-19) S203
(8W-10-33)

L50
20
WT/TN 3 2 1
RHD LHD B43 B41 B42
20 20 20
PK/OR YL/VT TN/WT
B4 C100 E1 C100 C109
C A B

A10 A20 D21 L50 B43 B41 B42

12 12 18 18 18 18 18
RD/DG RD/DB PK WT/TN PK/OR YL/VT TN/WT

25 9 20 12 13 6 7
FUSED FUSED SCI BRAKE G SWITCH G SWITCH G SWITCH CONTROLLER
B(+) B(+) TRANSMIT/ LAMP TEST NO. 1 NO. 2 ANTI-LOCK
ISO 9141K SWITCH SIGNAL SENSE SENSE BRAKE
OUTPUT

GROUND GROUND
8 24

Z1 Z1
12 12
BK BK

G102
RHD (8W-15-2)
LHD
J008W-7 XJI03502

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 XJ 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3
DIESEL
BATT A0 (8W-10-13)
POWER
18 20 A18 DISTRIBUTION
FUSE FUSE FUSE CENTER
12 14 19 (8W-10-7)
40A 20A 15A
(8W-10-26) (8W-10-26) (8W-10-32)
25 27 A17

F32
20
PK/DB

F8 C100
F32
20
PK/DB

6
BRAKE
LAMP
SWITCH
(8W-33-5)
5

DATA L50 G
LINK 20
WT/TN SWITCH
CONNECTOR
(8W-30-34)
S203
7 (8W-10-32)
A10 A20
12 12 D21 L50
RD/DG RD/DB 20 20
PK WT/TN
B8 3 2 1
F2 B4 C100
E1 B43 B41 B42
D21 L50 20 20 20
20 20 PK/OR YL/VT TN/WT
PK WT/TN
C A B C109
S139 S147
(8W-30-34) (8W-10-32)

D21 L50 B43 B41 B42

18 18 18 18 18
PK WT/TN PK/OR YL/VT TN/WT

25 9 20 12 13 6 7
FUSED FUSED SCI BRAKE G SWITCH G SWITCH G SWITCH CONTROLLER
B(+) B(+) TRANSMIT/ LAMP TEST NO. 1 NO. 2 ANTI-LOCK
ISO 9141K SWITCH SIGNAL SENSE SENSE BRAKE
OUTPUT

GROUND GROUND
8 24
Z1 Z1
12 12
BK BK

RHD
G102 LHD
(8W-15-3)
XJI03503 J008W-7

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 8W - 35 - 4 8W-35 ANTI-LOCK BRAKES XJ
GAS
RUN A22 (8W-10-18) ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
FUSE FUSE (8W-12-2)
25 9
15A 10A
(8W-12-22) (8W-12-13)
(8W-12-23)

6 C1 S13 C4
F15 F87
20 20
DB/WT WT/BK
RHD LHD
FULL
BASE OPTIONS

S225
(8W-12-13)

5 C201

S216
(8W-12-13)

F87
20
WT/BK
8 C1
INSTRUMENT
S134 CLUSTER
(8W-12-22) ABS (8W-40-2)
(8W-12-23) INDICATOR (8W-40-6)
(8W-40-8)

4 C1 FOG
F15 G19 LAMP
20 20 RELAY
DB/WT LG/OR GROUND NO. 1
F13 C100 B8 (IN PDC)
B20 B16 (4.0L ABS
CONTROLLER EXCEPT
Z1
ANTI-LOCK 20 DRL)
BRAKE BK (8W-50-14)
RELAY
B18 B19 (IN PDC)
F15 G83 Z1
18 18 20
DB/WT GY/BK BK

S132
23 16 (8W-15-5)
FUSED ABS CONTROLLER (8W-15-6)
Z1 (8W-15-8)
IGNITION RELAY ANTI-LOCK 16 (8W-15-9)
SWITCH CONTROL BRAKE BK
OUTPUT
(RUN)
G106
(8W-15-7)
J008W-7 (8W-15-10) XJI03504

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 XJ 8W-35 ANTI-LOCK BRAKES 8W - 35 - 5
DIESEL
RUN A22 (8W-10-18) ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
FUSE FUSE (8W-12-2)
25 9
15A 10A
(8W-12-22) (8W-12-13)
(8W-12-23)

6 C1 S13 C4
F87
20
F15 WT/BK
20
RHD LHD
DB/WT
FULL
BASE OPTIONS

S225
(8W-12-13)

5 C201

S216
(8W-12-13)

8 C1
INSTRUMENT
CLUSTER
ABS (8W-40-7)
INDICATOR (8W-40-8)

4 C1 FOG
LAMP
G19
20 RELAY
LG/OR GROUND (IN PDC)
(8W-50-17)
F13 C100 B13

B18 B16
CONTROLLER ENGINE
Z1
ANTI-LOCK 20
STARTER
BRAKE BK/YL MOTOR
RELAY GROUND RELAY
(IN PDC) D13 (IN PDC)
B20 B19 (8W-21-6)
Z1
Z1 20
20 BK
F15 G83
BK
18 18
DB/WT GY/BK
S141
(8W-15-11)
Z1
23 16 12
CONTROLLER BK
FUSED ABS
IGNITION RELAY ANTI-LOCK S132
SWITCH CONTROL BRAKE (8W-15-11)
OUTPUT Z1
(RUN) 12
BK

G106
(8W-15-12)
XJI03505 J008W-7

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 8W - 35 - 6 8W-35 ANTI-LOCK BRAKES XJ

LEFT RIGHT
FRONT FRONT
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR

2 1 2 1

LEFT RIGHT
REAR REAR
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR

B A B A

B4 B3 B2 B1
20 20 20 20
LG LG/DB YL YL/DB

TWISTED TWISTED TWISTED TWISTED

PAIR PAIR PAIR PAIR

G F C109 E D C109

B9 B8 B4 B3 B7 B6 B2 B1
18 18 18 18 18 18 18 18
RD RD/DB LG LG/DB WT WT/DB YL YL/DB

4 11 10 2 3 18 17 1
LEFT LEFT LEFT LEFT RIGHT RIGHT RIGHT RIGHT CONTROLLER
FRONT FRONT REAR REAR FRONT FRONT REAR REAR ANTI-LOCK
WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL BRAKE
SPEED SPEED SPEED SPEED SPEED SPEED SPEED SPEED
SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
(+) (-) (+) (-) (+) (-) (+) (-)

J008W-7 XJI03506

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 XJ 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1

8W-39 VEHICLE THEFT SECURITY SYSTEM

Component Page Component Page
Cargo Lamp/Switch . . . . . . . . . . . . . . . . . 8W-39-6, 7 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-39-8, 9
Data Link Connector . . . . . . . . . . . . . . . . 8W-39-8, 9 Ignition Switch . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7
Driver Door Jamb Switch . . . . . . . . . . . . 8W-39-6, 7 Instrument Cluster . . . . . . . . . . . . . . . . . 8W-39-8, 9
Engine Control Module . . . . . . . . . . . . . . 8W-39-8, 9 Junction Block . . . . . . . . . . 8W-39-2, 3, 4, 5, 6, 7, 8, 9
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-39-2, 3 Left Rear Door Jamb Switch . . . . . . . . . . 8W-39-6, 7
Fuse 27 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5 Liftgate Switch . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5 Overhead Module . . . . . . . . . . . 8W-39-2, 3, 6, 7, 8, 9
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2, 3 Passenger Door Jamb Switch . . . . . . . . . 8W-39-6, 7
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5 Passenger Power Lock/Window Switch . . 8W-39-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7 Power Distribution Center . . . . 8W-39-2, 3, 4, 5, 8, 9
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7 Right Rear Door Jamb Switch . . . . . . . . . 8W-39-6, 7
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7 Sentry Key Immobilizer Module . . . 8W-39-4, 5, 8, 9
Headlamp Switch . . . . . . . . . . . . . . . . . . 8W-39-6, 7 Underhood Lamp/Switch . . . . . . . . . . . . . 8W-39-2, 3

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 8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM XJ
LHD
BATT A0 (8W-10-11)
(8W-10-13)
POWER
A23 DISTRIBUTION
FUSE CENTER
16 (8W-10-2)
15A (8W-10-7)
(8W-10-27)
A24
(8W-10-30) PASSENGER
DOOR POWER
DOOR UNLOCK
M1 LOCK RELAY
LOCK/
20 M1 WINDOW
CONTROL CONTROL
PK 20
PK 1 C2 2 C2 SWITCH
DIESEL GAS (8W-61-2)
1 P59 P55
S135 FUSED UNDERHOOD 20 20
(8W-10-27) B (+) LAMP/ LB/RD DB/PK

12 C1 SWITCH
(DIESEL) 4 3
JUNCTION C300
BLOCK (8W-44-7)
(8W-12-2) P59 P55
20 20
3 C3 LB/RD DB/PK
OTHERS SKIM

S361 9 8 C301
(8W-10-28)
(8W-10-29) P59 P55
20 20
S347 LB/RD DB
(8W-10-28)
M1 (8W-10-29)
20 (8W-10-30)
PK
2 11 5
FUSED DOOR DOOR OVERHEAD
B(+) LOCK UNLOCK MODULE
CONTROL RELAY (8W-49-2)
GROUND GROUND CONTROL (8W-49-4)
3 9
Z1 Z1
20 20
BK BK

S342
2 C3 (8W-15-13)
JUNCTION
BLOCK
(8W-12-2)
S5 C4

S314
(8W-15-13)
Z1
14
BK
14 C201
S208
(8W-15-14)
Z1 (8W-15-15)
14
BK

G107
(8W-15-14)
(8W-15-15)
J008W-7 XJI03902

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 XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3
RHD
BATT A0 (8W-10-11)
(8W-10-13)
POWER PASSENGER
DOOR
DISTRIBUTION DOOR UNLOCK
POWER
A23 LOCK/
CENTER LOCK RELAY
FUSE (8W-10-2) CONTROL CONTROL WINDOW
16 (8W-10-7) SWITCH
15A
1 C2 2 C2
(8W-61-3)
(8W-10-27)
A24
(8W-10-30) P59 P55
20 20
M1 M1 LB/RD DB
20 20
PK PK 3 12
C305
DIESEL GAS
1 P59 P55
S135 UNDERHOOD 20 20
FUSED
(8W-10-27) LB/RD DB/PK
B (+) LAMP/
12 C1 SWITCH
JUNCTION (DIESEL) 2 1 C203
BLOCK (8W-44-7)
(8W-12-2) P59 P55
20 20
3 C3 LB/RD DB/PK
OTHERS SKIM
9 8 C301
S361
(8W-10-28)
P59 P55
(8W-10-29)
20 20
LB/RD DB
S347
(8W-10-28)
M1 (8W-10-29)
20 (8W-10-30)
PK
2 11 5
OVERHEAD
FUSED DOOR DOOR
B(+) LOCK UNLOCK MODULE
CONTROL RELAY (8W-49-3)
CONTROL (8W-49-5)
GROUND GROUND
3 9
Z1 Z1
20 20
BK BK

S342
(8W-15-13)
2 C3
JUNCTION
BLOCK
(8W-12-2)
S5 C4
Z1
14
BK

S208
(8W-15-14)
Z1 (8W-15-15)
14
BK

G107
(8W-15-14)
(8W-15-15)
XJI03903 J008W-7

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 8W - 39 - 4 8W-39 VEHICLE THEFT SECURITY SYSTEM XJ
LHD
BATT A17 (8W-10-22) ST-RUN A21 (8W-10-17)
(8W-10-32)
POWER JUNCTION
DISTRIBUTION BLOCK
A1
CENTER (8W-12-2)
FUSE (8W-10-2) FUSE
27 (8W-10-7) 9
10A 10A
(8W-10-22) (8W-12-13)
A2
(8W-10-32)

S13 C4
F1 F87
20 20
DB/GY WT/BK

BASE FULL OPTIONS

S225
(8W-12-13)

F87
20
WT/BK

E10 C100
5 C201

F87
20
WT/BK

S216
(8W-12-13)

F1 F87
20 20
DB/GY WT/BK

6 4
FUSED FUSED SENTRY
B(+) IGNITION KEY
SWITCH IMMOBILIZER
OUTPUT MODULE
(ST-RUN)
GROUND GROUND
5 3
Z2 Z2
20 20
BK/LG BK/LG

S227
(8W-15-16)

Z2
20
BK/LG

G108
(8W-15-16)
J008W-7 XJI03904

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 XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 5
RHD
BATT A17 (8W-10-22) ST-RUN A21 (8W-10-17)
(8W-10-32)
POWER JUNCTION
DISTRIBUTION BLOCK
A1
CENTER (8W-12-2)
FUSE (8W-10-2) FUSE
27 (8W-10-7) 9
10A 10A
(8W-10-22) (8W-12-13)
A2
(8W-10-32)

S13 C4
F1 F87
20 20
DB/GY WT/BK

E10 C100

S216
(8W-12-13)

F1 F87
20 20
DB/GY WT/BK

6 4
FUSED FUSED SENTRY
B(+) IGNITION KEY
SWITCH IMMOBILIZER
OUTPUT MODULE
(ST-RUN)

GROUND GROUND
5 3

Z2 Z2
20 20
BK/LG BK/LG

S227
(8W-15-16)

Z2
20
BK/LG

G108
(8W-15-16)
XJI03905 J008W-7

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 8W - 39 - 6 8W-39 VEHICLE THEFT SECURITY SYSTEM XJ
LHD
HEADLAMP OVERHEAD B A
DOOR SWITCH MODULE CARGO
JAMB (8W-50-2) COURTESY (8W-49-4) LAMP/
SWITCH (8W-50-3) LAMPS
SENSE SWITCH
DRIVER
(8W-44-8)
6 C1 1
IGNITION M2 M2
DRIVER SWITCH 20 20
DOOR (8W-10-15) YL YL
AJAR (8W-10-16)
SWITCH S345
SENSE (8W-12-30) 6 C314
2 C2 1 C3
G16 G16 JUNCTION C
20 20 BLOCK M4
BK/LB BK/LB (8W-12-2) 20
GY/BK

S200 7 C7 7 C314
(8W-10-17)
G16 M2 M2 M4
20 20 20 20
BK/LB YL YL GY/BK
3 C326
17 C200 S304
(8W-12-30) M4
20
G16 M2 M2 M2 M2
GY/BK
20 20 20 20 20
BK/LB YL YL YL YL 5 C311
NOT
A C320 USED
A C319 10 C310
M2 M2 M4
B A C317 A B C318 20
18 18
YL YL VT/YL

3 3 3
LEFT RIGHT LIFTGATE
REAR REAR SWITCH
G16 M2 M2 G16 (8W-44-8)
18 18 DOOR 18 18 DOOR
BK/LB YL JAMB YL BK/LB JAMB
2 SWITCH 2 SWITCH 1
2 1 1 2
DRIVER PASSENGER Z1
Z1 20
DOOR 18 DOOR Z1 BK
JAMB BK JAMB 18
BK
SWITCH SWITCH S334
(8W-15-21)
3 3
Z1
Z1 Z1 18
18 18 BK
BK BK 9 C310
6 C311
C C317 B C320 C C318 B C319 Z1
Z1 Z1 Z1 Z1 18
20 20 20 20 BK
BK BK BK BK

S309 S310
(8W-15-17) (8W-15-19)
Z1 Z1
12 16
BK BK
G304
G302 G303 (8W-15-21)
(8W-15-17) (8W-15-19)
J008W-7 XJI03906

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 XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 7
RHD
B OVERHEAD DOOR HEADLAMP
CARGO MODULE JAMB SWITCH
COURTESY (8W-49-5) SWITCH (8W-50-2)
LAMP/ LAMP SENSE
DOOR IGNITION (8W-50-3)
SWITCH CONTROL
(8W-44-9) JAMB SWITCH
1 SWITCH (8W-10-15) 6 C1
M2 SENSE (8W-10-16)
M2
20 20
YL YL 2 C2
G16 G16
S345 20 20
6 C314 (8W-12-30) BK/LB BK/LB
C S200
M4 1 C3 (8W-10-17)
20 JUNCTION
GY/BK BLOCK G16
(8W-12-2) 20
7 C314 BK/LB
M4
7 C7 4 C203
20 M2 M2
GY/BK 20 20 G16
YL YL 20
3 C326 BK/LB
M4 S304
20 M2 M2 (8W-44-9)
GY/BK 20 M2 20 M2
NOT YL 20 YL 20
5 C311 USED YL YL
10 C310 B C317 A C319
A
A C320 M2
A B C318
M4
20 M2 18 M2 G16
VT/YL 18 YL 18 18
YL YL BK/LB
3 1 3 1 2
LIFTGATE LEFT DRIVER
SWITCH G16 M2 REAR DOOR
(8W-44-9) 18 18 DOOR JAMB
BK/LB YL JAMB SWITCH
2 2 SWITCH
3
2 1 3
PASSENGER RIGHT
Z1 DOOR REAR
20 JAMB DOOR
BK
SWITCH JAMB
2 SWITCH
S334 3
(8W-15-21) Z1 Z1
Z1 18 18 Z1
Z1
18 BK BK 18
18
BK BK BK
9 C310 B C319 C C318
6 C311 C C317 B C320 Z1
Z1 Z1
Z1 Z1 20 20
18 20 20 BK
BK BK
BK BK
S310
S309 (8W-15-20)
(8W-15-18) Z1
Z1 12
12 BK
BK
G304 G303
(8W-15-21) G302 (8W-15-20)
(8W-15-18)
XJI03907 J008W-7

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 8W - 39 - 8 8W-39 VEHICLE THEFT SECURITY SYSTEM XJ
LHD

DATA LINK INSTRUMENT SENTRY

CONNECTOR CCD CCD
CLUSTER CCD CCD
KEY
(8W-30-20) BUS BUS (8W-40-3) BUS BUS IMMOBILIZER
3 11 (-) (+) (-) (+) MODULE
1 C2 2 C2 2 1
D1 D2 D2 D1 D2 D1
18 18 20 20 20 20
VT/BR WT/BK WT/BK VT/BR WT/BK VT/BR
TWISTED TWISTED
TWISTED PAIR PAIR
PAIR

S238
(8W-30-20)
S239
(8W-30-20)
TWISTED
PAIR
TWISTED
BATT A7 (8W-10-20)
PAIR (8W-10-26)
D1 D2
20 20 JUNCTION
VT/BR WT/BK D2 D1 86 BLOCK
20 20 HORN (8W-12-2)
E11 E12 C100 WT/BK VT/BR RELAY
(8W-41-2)
4.0L
56 55 C201
OTHER A/T
D2 D1 85
20 20
D2 D2 WT/BK VT/BR
4.0L 18 20
OTHER A/T WT/BK WT/BK 2 1 C301
D1 1 C5
D1 D1 S144 20
(8W-30-20) VT/BR X3
18 20 20
VT/BR VT/BR D2
20 BK/RD
WT/BK OTHER COMPASS ENGINE
OTHER COMPASS CONTROL
S145 S344 ENGINE
(8W-30-20) (8W-30-20) DISABLE MODULE
S346 SIGNAL (DIESEL)
(8W-30-20) 7 C301 (8W-30-30)
TWISTED 38 C1
PAIR TWISTED
PAIR
D1 D2 D2 D1 X3 G55
18 18 20 20 20 18
VT/BR WT/BK WT/BK VT/BR BK/RD OR/BK
12 6 10
CCD CCD HORN OVERHEAD
BUS BUS RELAY MODULE
(-) (+) CONTROL (8W-49-4)
(8W-49-6)
30 C3 28 C3 16 C3
CCD CCD ENGINE POWERTRAIN
BUS BUS DISABLE CONTROL
(+) (-) SIGNAL MODULE
(8W-30-20)
(8W-30-30)

J008W-7 XJI03908

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 XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 9
RHD

DATA LINK INSTRUMENT SENTRY

CONNECTOR CCD CCD
CLUSTER CCD CCD
KEY
(8W-30-21) BUS BUS (8W-40-3) BUS BUS IMMOBILIZER
(-) (+) (-) (+) MODULE
3 11 1 C2 2 C2 2 1
D2 D1 D2 D1
D1 D2 20 20 20 20
18 18 WT/BK VT/BR WT/BK VT/BR
VT/BR WT/BK TWISTED TWISTED
TWISTED PAIR PAIR
PAIR

S238
(8W-30-21)
S239
TWISTED TWISTED (8W-30-21)
PAIR PAIR
BATT A7 (8W-10-20)
(8W-10-26)
D2 D1
D1 D2 20 20 JUNCTION
20 20 WT/BK VT/BR 86 BLOCK
VT/BR WT/BK HORN (8W-12-2)
RELAY
A11 A12 C100 (8W-41-3)

OTHER 4.0L A/T 2 1 C301

85
4.0L
D2 D2 D2 D1
OTHER A/T 18 20 20 20
WT/BK WT/BK WT/BK VT/BR
S22 C4
D1 D1 S144
18 20 OTHER COMPASS
(8W-30-21)
VT/BR VT/BR X3
S344
20
(8W-30-21)
OTHER COMPASS BK/RD

ENGINE
S346 CONTROL
S145 (8W-30-21) ENGINE
(8W-30-21) 7 C301 DISABLE MODULE
SIGNAL (DIESEL)
TWISTED (8W-30-30)
PAIR
38 C1
D2 D1 X3
20 20 20
WT/BK VT/BR G55
BK/RD
TWISTED 18
12 6 10 OR/BK
PAIR
CCD CCD HORN OVERHEAD
BUS BUS RELAY MODULE
D1 D2 (-) (+) CONTROL (8W-49-5)
18 18 (8W-49-6)
VT/BR WT/BK

30 C3 28 C3 16 C3
CCD CCD ENGINE POWERTRAIN
BUS BUS DISABLE CONTROL
(+) (-) SIGNAL MODULE
(8W-30-21)
(8W-30-30)

XJI03909 J008W-7

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 XJ 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1

8W-40 INSTRUMENT CLUSTER

Component Page Component Page
ABS Indicator . . . . . . . . . . . . . . . . . . . 8W-40-6, 7, 8 Ignition Switch . . . . . . . . . . . . . . . . . 8W-40-9, 10, 11
Airbag Control Module . . . . . . . . . . . . 8W-40-6, 7, 8 Instrument Cluster . . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10,
Airbag Warning Indicator . . . . . . . . . . 8W-40-6, 7, 8 11, 12, 13, 14, 15, 16
Brake Warning Indicator . . . . . . . . . . . . . . 8W-40-9 Junction Block . . . . . . . . . . . . 8W-40-2, 12, 13, 15, 17
Brake Warning Pressure Switch . . . . . . 8W-40-9, 10 Left Turn Signal Indicator . . . . . . . . . . . . 8W-40-14
Check Engine Warning Indicator . . . . . . 8W-40-4, 5 Liftgate Ajar Indicator . . . . . . . . . . . . . . . 8W-40-15
Check Gauges Warning Indicator . . . . . . . . 8W-40-3 Liftgate Switch . . . . . . . . . . . . . . . . . . . . . 8W-40-15
Cluster Illumination Lamps . . . . . . . . . . . 8W-40-15 Low Coolant Switch . . . . . . . . . . . . . . . . . 8W-40-17
Controller Anti-Lock Brake Relay . . . . 8W-40-6, 7, 8 Low Fuel Warning Indicator . . . . . . . . . . . . 8W-40-3
Cruise Engaged Indicator . . . . . . . . . . . . . 8W-40-16 Low Washer Fluid Indicator . . . . . . . . 8W-40-6, 7, 8
Daytime Running Lamp Module . . . . . . . . 8W-40-14 Message Center . . . . . . . . . . . . . . . . . . . . . 8W-40-17
Driver Door Jamb Switch . . . . . . . . . . . . . 8W-40-11 Odometer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-15
Engine Control Module . . . . . . . . . . . . 8W-40-16, 17 Oil Pressure Gauge . . . . . . . . . . . . . . . . . 8W-40-4, 5
Engine Coolant Temperature Gauge . . . . 8W-40-4, 5 Overhead Module . . . . . . . . . . . . . . . . . 8W-40-12, 13
Engine Coolant Temperature Sensor . . . . . 8W-40-4 Park Brake Switch . . . . . . . . . . . . . . . . 8W-40-9, 10
Engine Coolant Temperature Sensor No. 2 . 8W-40-5 Part Time 4WD Indicator . . . . . . . . . . . 8W-40-9, 10
Engine Oil Pressure Sensor . . . . . . . . . . 8W-40-4, 5 Power Distribution Center . . . . . . . . . . . . . 8W-40-2
Engine Starter Motor Relay . . . . . . . . . . 8W-40-7, 8 Powertrain Control Module . . . . 8W-40-3, 4, 5, 16, 17
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . 8W-40-7, 8 Rear Window Defogger Relay . . . . . . . . 8W-40-12, 13
Fog Lamp Relay No. 1 . . . . . . . . . . . . . . . 8W-40-14 Rear Window Defogger Switch . . . . . . . 8W-40-12, 13
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3 Red Brake Warning Indicator . . . . . . . . . . 8W-40-10
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . 8W-40-3 Right Turn Signal Indicator . . . . . . . . . . . 8W-40-14
Fuel Pump Module . . . . . . . . . . . . . . . . . . . 8W-40-3 Seat Belt Switch . . . . . . . . . . . . . . . . . 8W-40-6, 7, 8
Full Time 4wd Indicator . . . . . . . . . . . . . . . 8W-40-9 Seat Belt Warning Indicator . . . . . . . . 8W-40-6, 7, 8
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-15 Sentry Key Immobilizer Module . . . . . 8W-40-12, 13
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 17 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . 8W-40-12, 13 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-40-2 Transfer Case Switch . . . . . . . . . . . . . . 8W-40-9, 10
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-9 Transmission Control Module . . . . . . . . . . . 8W-40-3
G106 . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6, 7, 8, 10 Trip Reset Switch . . . . . . . . . . . . . . . . . . . 8W-40-15
G107 . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6, 7, 12, 13 Turn Signal/Hazard Switch . . . . . . . . . . . . 8W-40-14
G108 . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 9, 10, 14 Underhood Lamp/Switch . . . . . . . . . . . . . . 8W-40-2
G123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-17 Upshift Indicator . . . . . . . . . . . . . . . . . . . . 8W-40-3
G154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-17 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . 8W-40-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8, 11 Volt Meter . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-11 VTSS Indicator . . . . . . . . . . . . . . . . . . 8W-40-12, 13
Headlamp Beam Select Switch . . . . . . . . . 8W-40-14 Washer Fluid Level Switch . . . . . . . . . 8W-40-6, 7, 8
Headlamp Switch . . . . . . . . . . . . . . . . . 8W-40-11, 15 Water In Fuel Sensor . . . . . . . . . . . . . . . . 8W-40-17
High Beam Indicator . . . . . . . . . . . . . . . . . 8W-40-14

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 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER XJ

BATT A0 (8W-10-11) ST-RUN A21 (8W-10-17)

(8W-10-13)
POWER JUNCTION
A23
DISTRIBUTION BLOCK
CENTER (8W-12-2)
FUSE (8W-10-2) FUSE
16 (8W-10-7) 9
15A 10A
A24 (8W-10-27) (8W-12-13)
(8W-10-30)

S13 C4
GAS DIESEL M1
20 F87
PK 20
M1 M1 WT/BK
20 20 1
PK PK
FUSED UNDERHOOD LHD RHD
S135 B (+) LAMP/
(8W-10-27) SWITCH
(DIESEL)
(8W-44-7) FULL
OPTIONS BASE F87
12 C1
20
JUNCTION WT/BK
BLOCK S225
(8W-12-2) (8W-12-13)
S18 C4
M1
20 5 C201
PK

LHD RHD
F87
6 C201 20
WT/BK

S214 S216
(8W-10-27) (8W-12-13)
(8W-10-30)
9 C1 8 C1
INSTRUMENT
CLUSTER
FUSED FUSED
B(+) IGNITION
SWITCH
OUTPUT
GROUND (ST-RUN)

9 C2 6 C1
Z2 Z2
18 20
BK/LG BK/LG

POLICE/
POSTAL OTHER

S227
(8W-15-16)

G108
(8W-15-16)
J008W-7 XJI04002

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 XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3

ST-RUN F87 (8W-12-13)

INSTRUMENT
CLUSTER
LOW CHECK UPSHIFT
FUEL GAUGES INDICATOR
WARNING WARNING (M/T)
INDICATOR INDICATOR

FUSED LOW FUEL CHECK GAUGES UPSHIFT

IGN. WARNING WARNING INDICATOR
(ST-RUN) INDICATOR INDICATOR CONTROL
CONTROL CONTROL
CCD CCD FUEL
BUS BUS GAUGE TACHOMETER SPEEDOMETER VOLT METER
(+) (-) CONTROL CONTROL CONTROL CONTROL

FUEL TACHOMETER SPEEDOMETER VOLT METER

GAUGE
2 C2 1 C2
D1 D2 FUEL FUEL
20 TWISTED 20 FUEL LEVEL FUEL PUMP
PAIR LEVEL LEVEL
VT/BR WT/BK
SENSOR
SENSOR SENSOR
MODULE
SIGNAL (8W-30-31) SIGNAL (8W-30-3)
(8W-30-4)
3 3
S239 S238
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
A11 C100 DIESEL GAS VEHICLE
A12 VEHICLE SPEED
E11 E12 4.0L
K226 SPEED
OTHER A/T SENSOR
SENSOR
20
DB/LG SIGNAL (8W-30-12)
4.0L (8W-30-29)
3
OTHER A/T D2 D2
18 20 G7
LHD RHD
WT/BK WT/BK 18
D1 WT/OR
20 S144 15 C200 6 C204
D1 VT/BR (8W-30-20)
GAS DIESEL
18 (8W-30-21)
VT/BR
S145 1 C111
K226 S108
(8W-30-20) 20 G7
D1 (8W-30-21) D2 (8W-30-12) 20
DB/LG
20 20 WT/OR
G7
VT/BR WT/BK
18
TWISTED B2 WT/OR
S152
TWISTED PAIR F11 C100 (8W-30-29)
PAIR
7 6
CCD CCD TRANSMISSION
D1 D2 BUS BUS CONTROL K226 G7
18 18 (+) (-) MODULE 18 18
VT/BR WT/BK (8W-31-7) DB/LG WT/OR

30 C3 28 C3 26 C3 27 C2
CCD CCD FUEL VEHICLE POWERTRAIN
BUS BUS LEVEL SPEED CONTROL
(+) (-) SENSOR SENSOR MODULE
SIGNAL SIGNAL (8W-30-3)
(8W-30-4)
LHD (8W-30-12)
RHD (8W-30-20)
XJI04003 (8W-30-21) J008W-7

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 8W - 40 - 4 8W-40 INSTRUMENT CLUSTER XJ
GAS
ST-RUN F87 (8W-12-13)

INSTRUMENT
CLUSTER
CHECK
ENGINE
WARNING
INDICATOR

FUSED CHECK ENGINE

IGNITION ENGINE WARNING
SWITCH COOLANT INDICATOR OIL
CCD CCD OUTPUT TEMPERATURE CONTROL PRESSURE
BUS BUS (ST-RUN) GAUGE GAUGE
(+) (-) CONTROL CONTROL

ENGINE OIL
COOLANT PRESSURE
TEMPERATURE GAUGE
GAUGE
2 C2 1 C2
D1 D2
20 20
VT/BR WT/BK
ENGINE
TWISTED ENGINE
COOLANT
PAIR COOLANT
TEMPERATURE TEMPERATURE
SENSOR SENSOR
SIGNAL (8W-30-7)
S239 S238
2
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
D1 D2
20 20
VT/BR WT/BK

A11
ENGINE ENGINE
E11 A12 C100 OIL OIL
4.0L
E12 4.0L PRESSURE
OTHER A/T
SENSOR
PRESSURE
OTHER A/T SENSOR
SIGNAL
2 (8W-30-12)
D1 D1 D2 D2
18 20 18 20
VT/BR VT/OR WT/BK WT/BK

S145 S144
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
TWISTED
PAIR

D1 D2 K2 G60
18 18 18 18
VT/BR WT/BK TN/BK GY/YL
30 C3 28 C3 16 C1 23 C2
CCD CCD ENGINE ENGINE POWERTRAIN
BUS BUS COOLANT OIL CONTROL
(+) (-) TEMPERATURE PRESSURE MODULE
SENSOR SENSOR (8W-30-7)
SIGNAL SIGNAL (8W-30-12)
(8W-30-20)
LHD (8W-30-21)
RHD
J008W-7 XJI04004

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 XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5
DIESEL
ST-RUN F87 (8W-12-13)

INSTRUMENT
CLUSTER
CHECK
ENGINE
WARNING
INDICATOR

FUSED CHECK ENGINE

IGNITION ENGINE WARNING
SWITCH COOLANT INDICATOR OIL
CCD OUTPUT CCD TEMPERATURE CONTROL PRESSURE
BUS (ST-RUN) BUS GAUGE GAUGE
(+) (-) CONTROL CONTROL

ENGINE OIL
COOLANT PRESSURE
TEMPERATURE GAUGE
GAUGE
2 C2 1 C2
D1 D2
20 20
VT/BR WT/BK
TWISTED
PAIR

S239 S238 ENGINE

ENGINE ENGINE
OIL
(8W-30-20) (8W-30-20) OIL
(8W-30-21) (8W-30-21)
COOLANT PRESSURE
PRESSURE
TEMPERATURE SENSOR SENSOR
D1 D2 SENSOR SIGNAL (8W-30-29)
20 20
VT/BR WT/BK 2 1 NO. 2 2
(8W-30-29)

K167 K222 G60

A11 A12 C100 18 18 18
E11 E12 BR/YL TN/RD GY/YL

12 10 C120
2 C116
K167
18
TWISTED BR/YL
PAIR
S138
(8W-70-4)
D1 D2 K167 K222 G60
18 18 18 18 18
VT/BR WT/BK BR/YL TN/RD GY/YL

30 C3 28 C3 4 C1 16 C1 23 C2
CCD CCD SENSOR ENGINE ENGINE POWERTRAIN
BUS BUS GROUND COOLANT OIL CONTROL
(+) (-) TEMPERATURE PRESSURE MODULE
SENSOR SENSOR (8W-30-20)
SIGNAL SIGNAL (8W-30-21)
(8W-30-29)

LHD
RHD
XJI04005 J008W-7

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 8W - 40 - 6 8W-40 INSTRUMENT CLUSTER XJ
LHD GAS
ST-RUN F87 (8W-12-13)
INSTRUMENT
CLUSTER
AIRBAG SEAT LOW
ABS
WARNING BELT WASHER
INDICATOR
INDICATOR WARNING FLUID
INDICATOR INDICATOR

FUSED AIRBAG SEAT LOW

IGNITION WARNING BELT WASHER
SWITCH INDICATOR WARNING FLUID
OUTPUT CONTROL INDICATOR INDICATOR
(ST-RUN) CONTROL CONTROL

SEAT LOW
CCD CCD BELT WASHER
BUS BUS SWITCH FLUID
(+) (-) SENSE SENSE

2 C2 1 C2 10 C2 7 C1 4 C1
D1 D2 G10 G29 G19
20 20 20 20 20
VT/BR WT/BK LG/RD BK/LB LG/OR

TWISTED 69 C201 E8 F13 C100

PAIR G10 G29 G19
20 20 20
LG/RD BK/LB LG/OR

S239 S238 A B
(8W-30-20) (8W-30-20) SEAT WASHER
BELT FLUID
SWITCH LEVEL
SWITCH
B A

Z1 Z1
D1 D2 20 20
20 20 B16
BK BK
VT/BR WT/BK CONTROLLER
ANTI-LOCK
TWISTED S314
(8W-15-13)
BRAKE
PAIR RELAY
Z1
14 4.0L A/T OTHER B19 (IN PDC)
BK (8W-35-4)
51 52 C201

TWISTED 14 C201 Z1
20
PAIR Z1 S141 S132 BK
14 (8W-15-8) (8W-15-4)
BK (8W-15-9)
D1 D2 S132
Z1 Z1 (8W-15-5)
18 18
VT/BR WT/BK
S208 16 16 (8W-15-8)
(8W-15-14) BK BK
Z1
19 18 (8W-15-15)
Z1 16
CCD CCD AIRBAG 14 BK
BUS BUS CONTROL BK
(+) (-) MODULE G106
(8W-43-2) G107 (8W-15-7)
(8W-15-14) (8W-15-10)
J008W-7 (8W-15-15) XJI04006

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 XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7
LHD DIESEL
ST-RUN F87 (8W-12-13)
INSTRUMENT
CLUSTER
AIRBAG SEAT LOW
ABS
WARNING BELT WASHER
INDICATOR
INDICATOR WARNING FLUID
INDICATOR INDICATOR
FUSED AIRBAG SEAT LOW
IGNITION WARNING BELT WASHER
SWITCH INDICATOR WARNING FLUID
OUTPUT CONTROL INDICATOR INDICATOR
(ST-RUN) CONTROL CONTROL
SEAT LOW
CCD CCD BELT WASHER
BUS BUS SWITCH FLUID
(+) (-) SENSE SENSE

2 C2 1 C2 10 C2 7 C1 4 C1
D1 D2 G10 G29 G19
20 20 20 20 20
VT/BR WT/BK LG/RD BK/LB LG/OR
E8 F13 C100
TWISTED 69 C201 G29 G19
PAIR 20 20
G10
20 BK/LB LG/OR
LG/RD B16
A CONTROLLER
SEAT ANTI-LOCK
S239 S238 BELT BRAKE
(8W-30-20) (8W-30-20) SWITCH RELAY
B19 (IN PDC)
B (8W-35-5)
Z1
20 FOG
BK LAMP
RELAY
(IN PDC)
B13 (8W-50-17)
D1 D2
20 20
Z1 B ENGINE
VT/BR WT/BK WASHER STARTER
20 Z1
BK FLUID 20 MOTOR
TWISTED LEVEL BK/YL RELAY
PAIR S314 SWITCH D13 (IN PDC)
(8W-15-13) A (8W-21-6)
Z1 Z1 Z1
51 52 C201 14 20 20
BK BK BK
TWISTED
PAIR 14 C201 S141
(8W-15-11)
Z1 Z1
14 12
D1 D2
BK BK
18 18
VT/BR WT/BK S208 S132
19 18 (8W-15-15) (8W-15-11)
Z1
CCD CCD AIRBAG Z1 12
BUS BUS CONTROL 14 BK
(+) (-) MODULE BK
(8W-43-2)
G106
(8W-15-12)
G107
(8W-15-15)
XJI04007 J008W-7

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 8W - 40 - 8 8W-40 INSTRUMENT CLUSTER XJ
RHD
ST-RUN F87 (8W-12-13)
INSTRUMENT
CLUSTER
AIRBAG SEAT LOW
ABS
WARNING BELT WASHER
INDICATOR
INDICATOR WARNING FLUID
INDICATOR INDICATOR

FUSED AIRBAG SEAT LOW

IGNITION WARNING BELT WASHER
SWITCH INDICATOR WARNING FLUID
OUTPUT CONTROL INDICATOR INDICATOR
(ST-RUN) CONTROL CONTROL

SEAT LOW
CCD CCD BELT WASHER
BUS BUS SWITCH FLUID
(+) (-) SENSE SENSE

2 C2 1 C2 10 C2 7 C1 4 C1
D1 D2 G10 G29 G19
20 20 20 20 20
VT/BR WT/BK LG/RD BK/LB LG/OR
TWISTED A8
PAIR 11 C203 F13 C100
DIESEL GAS
G10 G29
20 20 B16 G19
LG/RD BK/LB CONTROLLER 20
ANTI-LOCK LG/OR
S239 S238 A BRAKE B16
(8W-30-21) (8W-30-21) SEAT RELAY CONTROLLER
BELT B19 (IN PDC) ANTI-LOCK
SWITCH (8W-35-5) BRAKE
Z1 RELAY
20 FOG
B BK LAMP B19 (IN PDC)
B (8W-35-4)
Z1 RELAY
WASHER
20 (IN PDC)
D1 D2 BK FLUID (8W-50-17)
20 20 LEVEL B13
VT/BR WT/BK S313 SWITCH
(8W-15-18)
TWISTED A ENGINE Z1
Z1
PAIR 20
Z1 Z1 STARTER 20
20 20 MOTOR BK
BK BK BK/YL
RELAY
19 20 S309 S141 D13 (IN PDC)
C204 (8W-15-18) (8W-15-6) (8W-21-6)
(8W-15-11)
Z1 S132
TWISTED 20 (8W-15-6)
PAIR Z1 GAS DIESEL BK
12 Z1
BK
S141
Z1 Z1 16
(8W-15-11)
D1 D2 16 12 Z1 BK
18 18 BK BK 12
VT/BR WT/BK G302 BK
(8W-15-18) S132
19 18 (8W-15-11) S132
CCD CCD AIRBAG (8W-15-11)
G106
BUS BUS CONTROL (8W-15-7)
(+) (-) MODULE G106 (8W-15-10)
(8W-43-3) (8W-15-7)
(8W-15-10)
(8W-15-12)
J008W-7 XJI04008

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 XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 9
GAS
ST-RUN F87 (8W-12-13)

INSTRUMENT
CLUSTER
FULL PART RED
TIME TIME BRAKE
4WD 4WD WARNING
INDICATOR INDICATOR INDICATOR

7 C2 5 C2 2 C1
G106 G107 G99
20 20 20
BK/WT BK/RD GY/WT

A2 A3 A10 C100
G106 G107 E14
20 20 G99
BK/WT BK/RD 20
GY/WT
8
12 C107
G106 G107 2
20 20 BRAKE
BK/WT BK/RD WARNING
242 4WD 231 4WD PRESSURE
SWITCH

2 3 C112
1
G106 G107 4.0L A/T OTHER G9
20 20 20
BK/WT BK/RD 3 C112 GY/BK

A14
B D A C100
E2
TRANSFER TRANSFER S211
FULL PART CASE CASE (8W-10-15)
TIME TIME SWITCH SWITCH G9 G9
20 20
GY/BK GY/BK
A B

Z1
20 2 C1 LHD RHD
Z1 BK IGNITION
20 SWITCH 66 C201
4.0L A/T OTHER 1 START
BK
2 RUN 13 C203
1 C112 1 4 0 OFF
1 C112 2 3 3 LOCK
0 4 ACC
Z1 (8W-10-15)
20 Z1 1 C1
BK 20
BK Z1 G9
20 20
BK GY/BK

S107 S207
(8W-15-2) (8W-15-16)
Z1 Z1 PARK
16 14 BRAKE
BK BK
LHD SWITCH
RHD
G101 G108
(8W-15-2) (8W-15-16)
XJI04009 J008W-7

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 8W - 40 - 10 8W-40 INSTRUMENT CLUSTER XJ
DIESEL
ST-RUN F87 (8W-12-13)

INSTRUMENT
CLUSTER
PART RED
TIME BRAKE
4WD WARNING
INDICATOR INDICATOR

5 C2 2 C1
G107 G99
20 20
BK/RD GY/WT

A3 A10 C100
E14
G107 G99
20 20
BK/RD GY/WT

3 C111 2
BRAKE
WARNING
G107
20 PRESSURE
BK/RD SWITCH

1
A
TRANSFER G9
CASE 20
GY/BK
SWITCH
(231 4WD) A14
C100
B E2
S211
(8W-10-16)
Z1 G9 G9
20 20 20
BK GY/BK GY/BK

4 C111 2 C1
IGNITION LHD RHD
SWITCH
Z1 1 START
18 66 C201
2 RUN
BK 0 OFF 13 C203
1 4
2 3 3 LOCK
S157 0 4 ACC
(8W-15-11) (8W-10-16)
1 C1
Z1
12 Z1
BK 20 G9
BK 20
GY/BK
S132 S207
(8W-15-11) (8W-15-16)

Z1 Z1
14 PARK
12
BK BK BRAKE
LHD SWITCH
G106 G108
(8W-15-16) RHD
(8W-15-12)
J008W-7 XJI04010

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 XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 11

BATT M1 (8W-10-27)
(8W-10-30)
INSTRUMENT
FUSED
CLUSTER
B(+)

CHIME
CONTROL

8 C2
G26
20
LB

S210
(8W-10-17)
1 C2 5
IGNITION HEADLAMP
KEY-IN
SWITCH SWITCH
SWITCH (8W-10-15) 0 OFF
(8W-10-16) 1 PARK
0 1 2
2 HEAD
(8W-50-2)
(8W-50-3)
2 C2 6
G16 G16
20 20
BK/LB BK/LB

S200
(8W-10-17)
LHD RHD

17 C200 4 C203
G16 G16
20 20
BK/LB BK/LB
B C317 B C318
G16 G16
18 18
BK/LB BK/LB
2 2
DRIVER DRIVER
DOOR DOOR
JAMB JAMB
SWITCH SWITCH
(8W-39-6) (8W-39-7)
3 3
Z1 Z1
18 18
BK BK
C C317 C C318
Z1 Z1
20 20
BK BK

S309 S310
(8W-15-17) (8W-15-20)
Z1 Z1
12 12
BK BK

G302 G303
(8W-15-17) (8W-15-20)

XJI04011 J008W-7

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 8W - 40 - 12 8W-40 INSTRUMENT CLUSTER XJ
LHD
RUN A22 OVERHEAD
(8W-10-18)
MODULE
CCD CCD
JUNCTION BUS BUS
(8W-49-6)
BLOCK (+) (-)
(8W-12-2)
FUSE 6 12 SENTRY
12 D1 TWISTED D2 KEY
20 20 CCD CCD
10A PAIR BUS BUS IMMOBILIZER
(8W-12-17) VT/BR WT/BK
(+) (-) MODULE
COMPASS OTHER COMPASS OTHER 1 2 (8W-39-8)
86
REAR S344 S346
WINDOW (8W-30-20) (8W-30-20) TWISTED
DEFOGGER PAIR
RELAY
1 2
(8W-48-2) C301
85 D1 D2
20 20
S26 C4 D1 D2
VT/BR WT/BK
20 20
55 56 VT/BR WT/BK
C201
C81
20 D1 TWISTED D2
LB/WT 20 PAIR 20
VT/BR WT/BK
17 C201
S239
(8W-30-20)
S238
C81 (8W-30-20)
20
D1 TWISTED D2
LB/WT PAIR
20 20
VT/BR WT/BK

3 C2 2 C2 1 C2
INSTRUMENT
REAR CCD CCD
CLUSTER
WINDOW REAR BUS BUS
DEFOGGER WINDOW (+) (-) VTSS
RELAY DEFOGGER INDICATOR
CONTROL SWITCH
SENSE

4 C2
C80
20
DB/WT
2
REAR
WINDOW
DEFOGGER
SWITCH
(8W-48-2)
1
Z1
20
BK

S208
(8W-15-14)
Z1 (8W-15-15)
14
BK

G107
(8W-15-14)
J008W-7 XJI04012
(8W-15-15)

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 XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 13
RHD
RUN A22 OVERHEAD
(8W-10-18)
MODULE
CCD CCD
JUNCTION BUS BUS
(8W-49-6)
BLOCK (+) (-)
(8W-12-2)
FUSE 6 12 SENTRY
12 D1 TWISTED D2 KEY
20 20 CCD CCD
10A PAIR BUS BUS IMMOBILIZER
(8W-12-18) VT/BR WT/BK
(+) (-) MODULE
COMPASS OTHER COMPASS OTHER 1 2 (EXCEPT
86 POLICE/
REAR S344 S346 POSTAL)
WINDOW (8W-30-21) (8W-30-21) TWISTED (8W-39-9)
DEFOGGER PAIR
RELAY
(8W-48-3) D1 D2
85 20 20
VT/BR WT/BK
S26 C4 D1 D2
1 2
C301 20 20
VT/BR WT/BK
C81
20
D1 TWISTED D2
LB/WT PAIR
20 20
VT/BR WT/BK

S239
(8W-30-21)
S238
(8W-30-21)
D1 TWISTED D2
20 PAIR 20
VT/BR WT/BK
3 C2 2 C2 1 C2
INSTRUMENT
REAR CCD CCD
CLUSTER
WINDOW REAR BUS BUS
DEFOGGER WINDOW (+) (-) VTSS
RELAY DEFOGGER INDICATOR
CONTROL SWITCH
SENSE

4 C2
C80
20
DB/WT
2
REAR
WINDOW
DEFOGGER
SWITCH
(8W-48-3)
1
Z1
20
BK

S208
(8W-15-14)
Z1 (8W-15-15)
14
BK

G107
(8W-15-14)
XJI04013 J008W-7
(8W-15-15)

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 8W - 40 - 14 8W-40 INSTRUMENT CLUSTER XJ

DAYTIME DIMMER HEADLAMP

HIGH RUNNING SWITCH BEAM
BEAM HIGH TURN
INDICATOR
LAMP BEAM
SELECT
DRIVER MODULE OUTPUT SWITCH SIGNAL/
4 (8W-50-18) 3 (8W-50-4) LEFT RIGHT HAZARD
(8W-50-5) TURN TURN SWITCH
G34 L3 (8W-50-6) SIGNAL SIGNAL
(8W-52-2)
16 16 (8W-50-7) 10 1 (8W-52-3)
RD/GY RD/OR (8W-52-4)
L61 L60
FOG 20 20
HIGH LAMP LG/WT TN
BEAM
RELAY
INDICATOR S213
DRIVER NO. 1 (8W-50-4)
B10 (IN PDC) (8W-50-5)
(8W-50-16) (8W-50-6)
(8W-50-7)
L3 S209 S212
16 (8W-52-5) (8W-52-7)
RD/OR (8W-52-6) (8W-52-8)
LHD RHD

D3 C100
L61 L60
G34 G34 L3 20 20
16 16 16 LG/WT TN
RD/GY RD/GY RD/OR

DRL OTHER
D4 C100
G34
16
RD/GY

5 C1 10 C1 6 C2
INSTRUMENT
CLUSTER
HIGH LEFT RIGHT
BEAM TURN TURN
INDICATOR SIGNAL SIGNAL
INDICATOR INDICATOR

9 C2 6 C1
POLICE/POSTAL OTHER

Z2
20
BK/LG
Z2
20 S227
Z2 (8W-15-16)
BK/LG
18
Z2
BK/LG
20
BK/LG

G108
(8W-15-16)
J008W-7 XJI04014

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 XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 15

BATT F34 (8W-10-28)

(8W-10-29)

4
HEADLAMP
SWITCH
0 OFF
1 PARK
3 4 0 1 2
2 HEAD
3 DIM
4 BRIGHT LIFTGATE
(8W-50-2) LIFTGATE SWITCH
(8W-50-3) AJAR
1 (8W-44-8)
SWITCH
(8W-44-9)
E1 SENSE
20 2
TN
LHD RHD
G78
42 C201 20
TN/BK

S1 C4
JUNCTION
BLOCK 6 C310
FUSE (8W-12-2) 3 C311
6
5A G78
(8W-12-8) 20
(8W-12-9) TN/BK
S2 C4 1 C327
E2
20 G78
OR 20
TN/BK
LHD RHD
LHD RHD
S315
(8W-12-8)
43 C201
40 C200 5 C204

S215
(8W-12-8)
(8W-12-9)
E2 G78
20 20
OR TN/BK
3 C1 1 C1
INSTRUMENT
CLUSTER CLUSTER
ILLUMINATION
LAMPS
TRIP LIFTGATE
RESET AJAR
SWITCH ODOMETER INDICATOR
SENSE CONTROL CONTROL

TRIP ODOMETER
RESET LIFTGATE
SWITCH AJAR
INDICATOR

XJI04015 J008W-7

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 8W - 40 - 16 8W-40 INSTRUMENT CLUSTER XJ

ST-RUN F87 (8W-12-13)

INSTRUMENT
CLUSTER
CRUISE
ENGAGED
INDICATOR

FUSED CRUISE
IGNITION ENGAGED
SWITCH INDICATOR
OUTPUT CONTROL
(ST-RUN)
CCD CCD
BUS BUS
(+) (-)

2 C2 1 C2
D1 D2
20 20
VT/BR WT/BK
TWISTED
PAIR

S239 S238
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
D1 D2
20 20
VT/BR WT/BK

A11 A12 C100

E11 E12

4.0L A/T OTHER OTHER 4.0L A/T

D1 D1 D2 D2
20 18 18 20
VT/BR VT/BR WT/BK WT/BK

S145 S144 ENGINE

(8W-30-20) (8W-30-20) CONTROL
(8W-30-21) (8W-30-21) SPEED MODULE
CONTROL (DIESEL)
INDICATOR (8W-30-30)
TWISTED SIGNAL
PAIR 30 C1

D1 D2 V66
18 18 18
VT/BR WT/BK RD/LG

30 C3 28 C3 18 C2
CCD CCD SPEED POWERTRAIN
BUS BUS CONTROL CONTROL
(+) (-) INDICATOR MODULE
SIGNAL (8W-30-20)
(8W-30-21)
(8W-30-30)
RHD
LHD
J008W-7 XJI04016

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 XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 17
DIESEL
ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
(8W-12-2)
FUSE
9
10A
(8W-12-13)

S13 C4
F87
20
WT/BK
RHD LHD
FULL
BASE OPTIONS

S225 WATER
WATER
(8W-12-13)
IN IN
FUEL FUEL
SENSOR
5 C201 SIGNAL
SENSOR
(8W-30-31)
1

F87
20
WT/BK LOW
COOLANT
LEVEL COOLANT
S216 SWITCH SWITCH
(8W-12-13) SENSE (8W-30-31)
1 1
MESSAGE
WAIT WATER LOW
CENTER
TO IN COOLANT (8W-30-33)
START FUEL LEVEL
WARNING WARNING WARNING
INDICATOR INDICATOR INDICATOR
4 7 8

K185 G86 G154

20 20 20
OR/LB TN/OR VT/LG

E15 E16 E17 C100

K185
20
OR/LB

G86 G154 G123 G18

18 18 18 18
TN/OR VT/LG DG/WT PK/BK
32 C1
ENGINE 9 C3 8 C3 27 C1 12 C1
WAIT
TO CONTROL WATER LOW WATER COOLANT POWERTRAIN
START MODULE IN COOLANT IN LEVEL CONTROL
INDICATOR FUEL INDICATOR FUEL SWITCH MODULE
(8W-30-33) INDICATOR DRIVER SENSOR SIGNAL
DRIVER (8W-30-31)
DRIVER SIGNAL (8W-30-33)

XJI04017 J008W-7

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 XJ 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1

8W-41 HORN/CIGAR LIGHTER/POWER OUTLET

Component Page Component Page
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3 High Note Horn . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Cigar Lighter Relay . . . . . . . . . . . . . . . . 8W-41-2, 3 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Clockspring . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3 Horn Switch . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3 Junction Block . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3 Low Note Horn . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3 Overhead Module . . . . . . . . . . . . . . . . . . 8W-41-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3 Power Outlet . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3

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 8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET XJ
LHD
RUN-ACC A31 (8W-10-15) BATT A7 (8W-10-20)
(8W-10-16) (8W-10-26)
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE FUSE

2 1 21
25A 25A 15A
(8W-12-5) (8W-12-5) (8W-12-21)

86 30 86 30
CIGAR HORN
LIGHTER RELAY
RELAY

85 87 85 87

S5 C4 M6 C4 M5 C4 S22 C4 1 C5 4 C2

Z1 F30 F38 X3 X3 X2
14 16 16 20 20 20
BK RD RD/LB BK/RD BK/RD DG/RD

S314 S131
(8W-15-13) 7 C301 (8W-10-20)
(8W-10-26)
X2 X2
Z1 20 20
14 DG/RD DG/RD
BK

14 50 65 26
C201 HIGH LOW
NOTE NOTE
Z1 F30 F38 X3 X3 HORN HORN
14 16 16 20 20
BK RD RD/LB BK/RD BK/RD

1 1 10
CIGAR POWER HORN OVERHEAD
LIGHTER OUTLET RELAY MODULE
CONTROL (8W-49-4)

3
1 C1
CLOCKSPRING
3
S208
(8W-15-14)
(8W-15-15)
Z1 Z1 Z1
14 16 16 HORN
BK BK BK SWITCH

G107
(8W-15-14)
J008W-7 (8W-15-15) XJI04102

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 XJ 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3
RHD
RUN-ACC A31 (8W-10-15) BATT A7 (8W-10-20)
(8W-10-16) (8W-10-26)
JUNCTION
BLOCK
(8W-12-2)

FUSE FUSE FUSE

2 1 21
25A 25A 15A
(8W-12-5) (8W-12-5) (8W-12-21)

86 30 86 30
CIGAR HORN
LIGHTER RELAY
RELAY

85 87 85 87

S5 C4 M6 C4 M5 C4 1 C5 S22 C4 4 C2

Z1 F30 F38 X3 X3 X2
14 16 16 20 20 20
BK RD RD/LB BK/RD BK/RD DG/RD
7 C301
S131
S208 (8W-10-20)
(8W-10-26)
(8W-15-14) X2 X2
(8W-15-15) 20 20
DG/RD DG/RD
1 1
CIGAR POWER
LIGHTER OUTLET HIGH LOW
NOTE NOTE
X3
20 HORN HORN
BK/RD
3
10
HORN OVERHEAD
3
RELAY MODULE
CONTROL (8W-49-5)

1 C1

CLOCKSPRING

Z1 Z1 Z1
14 16 16
BK BK BK

HORN
G107 SWITCH
(8W-15-14)
(8W-15-15)
XJI04103 J008W-7

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 XJ 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1

8W-42 AIR CONDITIONING-HEATER

Component Page Component Page
A/C Compressor Clutch . . . . . . . . . . . . . . 8W-42-7, 8 Fuse 11 (PDC) . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5
A/C Compressor Clutch Relay . . . . . . 8W-42-7, 8, 10 Fuse 25 (JB) . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5, 7
A/C High Pressure Switch . . . . . . . . . . . . 8W-42-6, 8 G106 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8, 9, 10
A/C Low Pressure Switch . . . . . . . . . . . . 8W-42-6, 8 G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7
A/C- Heater Control . . . . . . . . . . . . . 8W-42-4, 5, 6, 7 G108 . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5
Automatic Shut Down Relay . . . . . . . . . 8W-42-8, 10 Heater Control . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
Blend Door Actuator . . . . . . . . . . . . . . . . . . 8W-42-7 Junction Block . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5, 7
Blower Motor . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5 Power Distribution
Blower Motor Relay . . . . . . . . . . . . . 8W-42-2, 3, 4, 5 Center . . . . . . . . . . . . . 8W-42-2, 3, 4, 5, 7, 8, 9, 10
Blower Motor Resistor Block . . . . . . 8W-42-2, 3, 4, 5 Powertrain Control Module . . . . . . . . . 8W-42-6, 7, 9
Engine Control Module . . . . . . . . . . . . . 8W-42-8, 10 Radiator Fan Relay . . . . . . . . . . . . . . 8W-42-8, 9, 10
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5

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 8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER XJ
LHD HEATER ONLY
RUN A22 (8W-10-18) BATT A0 (8W-10-11)
(8W-10-13)
JUNCTION DIESEL GAS POWER
BLOCK DISTRIBUTION
FUSE
(8W-12-2) 17 12 CENTER
25 (8W-10-2)
FUSE FUSE
15A (8W-10-7)
11 6
(8W-12-22) 40A 40A
(8W-10-26) (8W-10-21)
24 5 FROM
S215
S8 C4 (8W-12-8)
F15 A111
20 12
DB/WT RD/LG E2
20
D5 C100 OR
7 C1
S219 HEATER
(8W-12-22) CONTROL
0
1 HIGH
5 9
2 MEDIUM 2
A111 3 MEDIUM 1
FAN MODE
12 1 4 4 LOW
RD/LG 6 8
2 3 7 5 DEFROST
6 HEAT/DEFROST
7 HEAT
8 VENT
2 C1 3 C1 4 C1 5 C1 1 C1 9 BI-LEVEL
C201 0 OFF
11 12 61 60 59
A111 C7 C6 C5 C4 Z8
12 12 14 14 14 12
RD/LG BK/TN LB LG TN BK/VT

8 7 4 3 2
9 C209 G108
F15 A111 C7 C6 C5 C4 (8W-15-16)
20 12 12 14 14 14
DB/WT RD/LG BK/TN LB LG TN

5 4 S228
BLOWER 4 3 2 1
MOTOR BLOWER
C7
RELAY 12
MOTOR
BK/TN RESISTOR
2 1 B BLOCK
Z1 C1 BLOWER
20 12 MOTOR
BK DG M

10 C209
A
Z8
20
BK/VT

25 C201
Z8
16
BK/VT

G108
(8W-15-16)
J008W-7 XJI04202

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 XJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3
RHD HEATER ONLY
RUN A22 (8W-10-18) BATT A0 (8W-10-11)
(8W-10-13)
JUNCTION DIESEL GAS POWER
BLOCK DISTRIBUTION
FUSE
(8W-12-2) 17 12 CENTER
25 (8W-10-2)
FUSE FUSE
15A (8W-10-7)
11 6
(8W-12-23) 40A 40A FROM
(8W-10-26) (8W-10-21) S215
24 5 (8W-12-9)
S8 C4
A111
12 E2
F15 RD/LG 20
20 OR
DB/WT D5 C100
7 C1
HEATER
S219 0 CONTROL
(8W-12-23) 1 HIGH
5 9
2 MEDIUM 2
F15 A111 3 MEDIUM 1
FAN MODE
20 12 1 4 4 LOW
DB/WT RD/LG 6 8
2 3 7 5 DEFROST
6 HEAT/DEFROST
1 C204 7 HEAT
F15 7 VENT
9 BI-LEVEL
20 2 C1 3 C1 4 C1 5 C1 1 C1 0 OFF
DB/WT C7 C6 C5 C4
12 14 14 14
BK/TN LB LG TN
S349
1 8 9 10
(8W-12-23) 7 C202
F15 A111 C7 C6 C5 C4 Z8
20 12 12 14 14 14 12
DB/WT RD/LG BK/TN LB LG TN BK/VT

8 7 4 3 2
9 C209
G108
C7 C6 C5 C4 (8W-15-16)
F15 A111 12 14 14 14
20 12 BK/TN LB LG TN
DB/WT RD/LG
5 4 S228
BLOWER 4 3 2 1
MOTOR BLOWER
C7
RELAY 12
MOTOR
BK/TN RESISTOR
2 1 B BLOCK
Z1 C1 BLOWER
20 12 MOTOR
BK DG M
10 C209
Z8 A
12
BK/VT
6 C202
Z8
16
BK/VT

G108
(8W-15-16)

XJI04203 J008W-7

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 8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER XJ
LHD
RUN A22 (8W-10-18) BATT A0 (8W-10-11)
(8W-10-13)
JUNCTION DIESEL GAS POWER
BLOCK DISTRIBUTION
FUSE
(8W-12-2) 17 12 CENTER
25 (8W-10-2)
FUSE FUSE
15A (8W-10-7)
11 6
(8W-12-22) 40A 40A
(8W-10-26) (8W-10-21)
24 5 FROM
S215
S8 C4 (8W-12-8)
F15 A111
20 12
DB/WT RD/LG E2
20
S219 OR
(8W-12-22) D5 C100
7 C1
A/C-
0 0
HEATER
5 11 5 CONTROL
11 1 HIGH
FAN 6 MODE 6
1 4 10 10 2 MEDIUM 2
7 9 7 9 3 MEDIUM 1
2 3 8 8 4 LOW
F15 A111 5 DEFROST
20 12 A/C
SELECT 6 HEAT/DEF(MIX)
DB/WT RD/LG 7 HEAT
2 C1 3 C1 4 C1 5 C1 6 C1 1 C1 8 VENT(PANEL)
9 BI-LEVEL
10 A/C
C201 11 MAX
11 12 61 60 59
0 OFF
A111 C7 C6 C5 C4 C90 Z8
12 12 14 14 14 20 12
RD/LG BK/TN LB LG TN LG BK/VT
8 7 4 3 2
9 C209
F15 A111
20 12
DB/WT RD/LG
5 4
BLOWER
MOTOR G108
A (8W-15-16)
RELAY C7 C6 C5 C4
12 14 14 14 TO
BK/TN LB LG TN C100
2 1 (8W-42-6)
Z1 C1 S228
20 12
4 3 2 1
BK DG
BLOWER
10 C209 C7
12
MOTOR
Z8 BK/TN RESISTOR
20 B BLOCK
BK/VT BLOWER
MOTOR
25 C201 M
Z8
16
A
BK/VT

G108
(8W-15-16)
J008W-7 XJI04204

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 XJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5
RHD
RUN A22 (8W-10-18) BATT A0 (8W-10-11)
(8W-10-13)
JUNCTION DIESEL GAS POWER
BLOCK DISTRIBUTION
FUSE
(8W-12-2) 17 12 CENTER
25 (8W-10-2)
FUSE FUSE
15A (8W-10-7)
11 6
(8W-12-23) 40A 40A FROM
(8W-10-26) (8W-10-21)
24 5 S215
(8W-12-9)
S8 C4
F15 A111
20 12
E2
DB/WT RD/LG
20
OR
S219
(8W-12-23) D5 C100
F15 7 C1
20 A/C-
DB/WT HEATER
0 0
5 11 5 CONTROL
11 1 HIGH
1 C204 FAN 6 MODE 6
1 4 10 10 2 MEDIUM 2
F15 7 9 7 9 3 MEDIUM 1
2 3 8 8 4 LOW
20 A111
DB/WT A/C 5 DEFROST
12 6 HEAT/DEF(MIX)
RD/LG SELECT
7 HEAT
S349 2 C1 3 C1 4 C1 5 C1 6 C1 1 C1 8 VENT(PANEL)
(8W-12-23) 9 BI-LEVEL
1 8 9 10 10 A/C
7 C202 Z8 11 MAX
F15 12 0 OFF
20 BK/VT
A111 C7 C6 C5 C4 C90
DB/WT
12 12 14 14 14 20
RD/LG BK/TN LB LG TN LG
8 7 4 3 2 G108
9 C209 (8W-15-16)
F15 A111
20 12
DB/WT RD/LG
5 4
BLOWER
MOTOR A
RELAY C7 C6 C5 C4
12 14 14 14 TO
BK/TN LB LG TN C100
2 1 (8W-42-6)
Z1 C1 S228
20 12
4 3 2 1
BK DG
BLOWER
10 C209 C7
12
MOTOR
Z8 BK/TN RESISTOR
12 B BLOCK
BK/VT BLOWER
MOTOR
6 C202 M
Z8
16
A
BK/VT

G108
(8W-15-16)
XJI04205 J008W-7

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 8W - 42 - 6 8W-42 AIR CONDITIONING-HEATER XJ

FROM
A/C-
HEATER
CONTROL
(8W-42-4)
(8W-42-5)
A

C90
20
LG
A6 C100
DIESEL GAS

C90
20
LG

S143

C90 C90
20 20
LG LG

4.0L 2.5L

4 3 2
A/C A/C
HIGH LOW
PRESSURE PRESSURE
SWITCH SWITCH
2 1 1
C21 C21
20 20
DB/PK DB/PK

2 2
A/C A/C
LOW HIGH
PRESSURE PRESSURE
C90 C90 C48
18 18 18 SWITCH SWITCH
LG LG TN 1 1

C22
18
DB/WT
23 C3 13 C3 22 C3
A/C RADIATOR A/C POWERTRAIN
SWITCH FAN SWITCH CONTROL
SENSE REQUEST SENSE MODULE
(8W-30-18)
(8W-30-30)

J008W-7 XJI04206

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 XJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 7

ST-RUN F20 (8W-12-14) BATT A17 (8W-10-22) RUN A22 (8W-10-18)

(8W-10-32)
POWER JUNCTION
B5 B1 DISTRIBUTION BLOCK
A/C CENTER FUSE (8W-12-2)
COMPRESSOR (8W-10-2) 25
CLUTCH (8W-10-7) 15A
RELAY (8W-12-22)
(8W-12-23)
B3 B2
S8 C4
F15
BLEND 20
FUSED
BLEND IGNITION
DOOR DB/WT
DOOR SWITCH ACTUATOR
FEEDBACK OUTPUT
GROUND SIGNAL (RUN)
S219
C13 C3 (8W-12-22)
18 16 7 8 10 (8W-12-23)
DB/OR DB/BK D1 D3 D2
20 20 20 F15 RHD LHD
DB/WT YL OR 20
DB/WT
1 6 5 C209 F15
Z1 C36 F15 20
20 20 20 DB/WT
BK RD/WT DB/WT
RHD LHD
40 C201
OTHER 4.0L RHD RHD LHD F15 F15
20 20
1 C204 DB/WT DB/WT
4 C201
4 C108 18 C204 S349 S217
(8W-12-23) (8W-12-22)
C36 C36
18 20
C3
RD/WT RD/WT
16
F15
DB/BK
20
DB/WT

3 C2 4 C2
BLEND FUSED A/C-
DOOR IGNITION HEATER
FEEDBACK SWITCH CONTROL
SIGNAL OUTPUT
(RUN)

GROUND
2 C2
RHD LHD
Z1
20
17 C204 7 C201 BK

LHD LHD
A/C BUILT-UP- BUILT-UP-
COMPRESSOR OTHER EXPORT EXPORT OTHER
CLUTCH
(GAS) S237
(8W-15-15)
1 C3
A/C POWERTRAIN
COMPRESSOR CONTROL Z1 Z1
CLUTCH MODULE 20 20
RELAY BK
(GAS) BK
CONTROL
(8W-30-18)
G107
(8W-15-14)
(8W-15-15)
XJI04207 J008W-7

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 8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER XJ
DIESEL
BATT A16 (8W-10-19)
AUTOMATIC
SHUT
DOWN
RELAY
C8 (IN PDC)
(8W-30-22)

A142
18
DG/OR
A142 18DG/OR BATT A17 (8W-10-32)

C11 POWER
B5 B1
RADIATOR A/C
DISTRIBUTION
FAN COMPRESSOR CENTER
CLUTCH (8W-10-7)
RELAY
RELAY
(IN PDC)
C13 (8W-42-10)
B3 B2

C13 C3
20 16
DB/OR DB/BK
5 C1 6 C120
A/C ENGINE
C3
COMPRESSOR CONTROL 14
CLUTCH MODULE DB/BK
RELAY (8W-30-27)
CONTROL (8W-30-30) 1
A/C
PRESSURE RADIATOR A/C
SWITCH FAN COMPRESSOR
SENSE REQUEST CLUTCH
10 C1 48 C1
2
Z1
16
C22 C48
BK
20 18
DB/WT TN
13 S170
3 C120 (8W-15-11)
C22 C48 Z1
20 18 16
DB/WT TN BK
4 2 11 C120
A/C Z1
HIGH 16
PRESSURE BK
SWITCH S157
1 3 (8W-15-11)
C21 Z1 Z1
20 18 12
DB/PK BK BK
2 C120 S132
2 (8W-15-11)
A/C Z1
LOW 12
BK
PRESSURE
SWITCH G106
1 (8W-15-12)
Z1 20BK
J008W-7 XJI04208

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 XJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 9
GAS

ST-RUN F20 (8W-12-14) BATT F141 (8W-10-21)

POWER
D11 D10
RADIATOR
DISTRIBUTION
FAN CENTER
RELAY (8W-10-2)

D13 D14

C27 C25
18 12
DB/PK LB

2 C3 1
RADIATOR POWERTRAIN RADIATOR
FAN CONTROL FAN
RELAY MODULE M MOTOR
CONTROL (8W-30-18)
2
Z1
12
BK

G106
(8W-15-7)
(8W-15-10)

XJI04209 J008W-7

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 8W - 42 - 10 8W-42 AIR CONDITIONING-HEATER XJ
DIESEL

BATT A16 (8W-10-19) BATT F141 (8W-10-26)

POWER
DISTRIBUTION
C2 C11 C10 CENTER
AUTOMATIC RADIATOR (8W-10-7)
SHUT FAN
DOWN RELAY
RELAY
(8W-30-22)
C8 C13 C14

A142 A142 C27 C25

18 18 20 12
DG/OR DG/OR DB/PK LB

1
RADIATOR
FAN
M MOTOR

2
Z1
12
BK

G106
17 C1 (8W-15-12)

RADIATOR ENGINE
FAN CONTROL
RELAY MODULE
CONTROL (8W-30-33)

B5
FUSED A/C
AUTOMATIC COMPRESSOR
SHUT CLUTCH
DOWN
RELAY
RELAY
OUTPUT (IN PDC)
(8W-42-8)

J008W-7 XJI04210

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 XJ 8W - 43 AIRBAG SYSTEM 8W - 43 - 1

8W-43 AIRBAG SYSTEM

Component Page Component Page
Airbag Control Module . . . . . . . . . . . . 8W-43-2, 3, 4 Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-4 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2
Data Link Connector . . . . . . . . . . . . . . . . 8W-43-2, 3 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-3
Driver Airbag . . . . . . . . . . . . . . . . . . . . . . . 8W-43-4 Junction Block . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3 Passenger Airbag . . . . . . . . . . . . . . . . . . . . 8W-43-4

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 8W - 43 - 2 8W-43 AIRBAG SYSTEM XJ
LHD
RUN A22 (8W-10-18) ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
26 27
10A 10A
(8W-12-25) (8W-12-25)

S21 C4 S23 C4
F14 F23
18 18
LG/YL DB/YL
20 17
FUSED FUSED AIRBAG
IGNITION IGNITION CONTROL
SWITCH SWITCH MODULE
OUTPUT OUTPUT
(RUN) CCD CCD (ST-RUN)
BUS BUS
(-) (+) GROUND
18 19 10
D2 D1
18 18
WT/BK VT/BR
TWISTED BASE FULL OPTIONS
PAIR

52 51 Z6 Z6
C201 18 18
BK/YL BK/PK
TWISTED
PAIR

D2 D1
20 20
WT/BK VT/BR

S238 S239
(8W-30-20) (8W-30-20)

D2 D1
18 18
WT/BK VT/BR
TWISTED
PAIR

11 3

DATA G200
LINK (8W-15-17)
CONNECTOR
(8W-30-20)

J008W-7 XJI04302

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 XJ 8W-43 AIRBAG SYSTEM 8W - 43 - 3
RHD
RUN A22 (8W-10-18) ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
26 27
10A 10A
(8W-12-26) (8W-12-26)

S21 C4 S23 C4
F14 F23
18 18
LG/YL DB/YL

15 14
C204
F14 F23
18 18
LG/YL DB/YL

20 17
FUSED FUSED AIRBAG
IGNITION IGNITION CONTROL
SWITCH SWITCH MODULE
OUTPUT OUTPUT
(RUN) CCD CCD (ST-RUN)
BUS BUS
(-) (+) GROUND
18 19 10
D2 D1
18 18
WT/BK TWISTED VT/BR
PAIR

20 19 C204
D2 D1 Z6
20 20 18
WT/BK VT/BR BK/PK
TWISTED
PAIR

S238 S239
(8W-30-21) (8W-30-21)

D2 D1
18 18
WT/BK VT/BR
TWISTED
PAIR

11 3
DATA
LINK
CONNECTOR
(8W-30-21)
G300
(8W-15-18)
XJI04303 J008W-7

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 8W - 43 - 4 8W-43 AIRBAG SYSTEM XJ

AIRBAG
CONTROL
MODULE
DRIVER DRIVER PASSENGER PASSENGER
AIRBAG AIRBAG AIRBAG AIRBAG
LINE 1 LINE 2 LINE 2 LINE 1
1 2 5 6

R45 R43 R42 R44

18 18 18 18
DG/LB BK/LB BK/YL DG/YL

TWISTED TWISTED
PAIR PAIR

4 3 1 2
C205

R45 R43 R42 R44

18 18 18 18
DG/LB BK/LB BK/YL DG/YL

TWISTED TWISTED
PAIR PAIR

1 C3 2 C3

CLOCKSPRING

3 4
DRIVER DRIVER DRIVER PASSENGER PASSENGER PASSENGER
AIRBAG AIRBAG AIRBAG AIRBAG AIRBAG AIRBAG
LINE 1 LINE 2 LINE 2 LINE 1

J008W-7 XJI04304

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 XJ 8W - 44 INTERIOR LIGHTING 8W - 44 - 1

8W-44 INTERIOR LIGHTING

Component Page Component Page
A/C- Heater Control . . . . . . . . . . . . . . 8W-44-2, 3, 4 Instrument Cluster . . . . . . . . . . . 8W-44-2, 3, 4, 8, 9
Cargo Lamp/Switch . . . . . . . . . . . . . . . . . 8W-44-8, 9 Junction Block . . . . . . . . . . . . . 8W-44-2, 3, 4, 5, 6, 7
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5 Left Courtesy Lamp . . . . . . . . . . . . . . . . 8W-44-6, 7
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5 Left Rear Door Jamb Switch . . . . . . . . . . 8W-44-8, 9
Dome Lamps Switch . . . . . . . . . . . . . . . . . . 8W-44-5 Left Visor/Vanity Lamp . . . . . . . . . . . . . . . . 8W-44-5
Driver Door Jamb Switch . . . . . . . . . . . . 8W-44-8, 9 Liftgate Switch . . . . . . . . . . . . . . . . . . . . 8W-44-8, 9
Extended Idle Switch . . . . . . . . . . . . . . . . . 8W-44-2 Passenger Door Jamb Switch . . . . . . . . . 8W-44-8, 9
Front Fog Lamp Switch . . . . . . . . . . . . 8W-44-2, 3, 4 Power Distribution Center . . . . . . . . . . . 8W-44-6, 7
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 4 PRNDL Illumination . . . . . . . . . . . . . . 8W-44-2, 3, 4
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-44-6, 7 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 4
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6, 7 Rear Fog Lamp Switch . . . . . . . . . . . . . . 8W-44-3, 4
G107 . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 4, 5 Rear Window Defogger Switch . . . . . . 8W-44-2, 3, 4
G108 . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 4, 6, 7 Rear Wiper/Washer Switch . . . . . . . . . 8W-44-2, 3, 4
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4, 8, 9 Right Courtesy Lamp . . . . . . . . . . . . . . . 8W-44-6, 7
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8, 9 Right Rear Door Jamb Switch . . . . . . . . . 8W-44-8, 9
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-8, 9 Right Visor/Vanity Lamp . . . . . . . . . . . . . . 8W-44-5
Headlamp Delay Module . . . . . . . . . . . . . 8W-44-6, 7 Transfer Case Switch Illumination . . . 8W-44-2, 3, 4
Headlamp Switch . . . . . . . . . . . . . 8W-44-2, 3, 4, 6, 7 Underhood Lamp/Switch . . . . . . . . . . . . . 8W-44-6, 7

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 8W - 44 - 2 8W-44 INTERIOR LIGHTING XJ
LHD EXCEPT BUILT-UP-EXPORT

HEADLAMP 1 C206
PANEL
LAMPS SWITCH
DIMMER (8W-50-2) 1
SWITCH PRNDL
S1 C4 SIGNAL ILLUMINATION
JUNCTION 1 (A/T) 1
BLOCK TRANSFER
FUSE (8W-12-2) E1
6 20 CASE
TN 2 SWITCH
5A
(8W-12-8)
42 C201 ILLUMINATION
E1 2
S2 C4 20
E2 E2 Z1 Z1
TN
20 20 20 20
OR OR BK BK

S315 2 C206
(8W-12-8)
Z1
43 C201 20
BK
E2 S314
20
(8W-15-13)
OR
Z1
14
S215 BK
(8W-12-8)
E2 E2 E2 E2 E2 E2 14 C201
20 20 20 20 20 20
OR OR OR OR OR OR Z1
POLICE
14
5 C2 PACKAGE OTHERS
BK
FUSED RADIO
PANEL (8W-47-2) S208
4
LAMPS (8W-47-9) 4 (8W-15-14)
DIMMER EXTENDED REAR Z1
SWITCH IDLE WINDOW 14
SIGNAL SWITCH DEFOGGER BK
(8W-30-17)
SWITCH G107
(8W-48-2)
1 (8W-15-14)
3 1
1
REAR FRONT 7 C1
WIPER/ FOG A/C-
WASHER LAMP HEATER
SWITCH SWITCH CONTROL
(8W-53-4) (8W-42-4)

1 4
Z1 Z1 Z1 Z1 1 C1
20 20 20 20
BK BK BK BK

S208
3 C1 (8W-15-14)
INSTRUMENT Z8
Z1
CLUSTER 14 12
(8W-40-15) BK BK/VT

G107 G108
(8W-15-14) (8W-15-16)

J008W-7 XJI04402

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 XJ 8W-44 INTERIOR LIGHTING 8W - 44 - 3
LHD BUILT-UP-EXPORT

HEADLAMP 1 C206
PANEL
LAMPS SWITCH 1
DIMMER (8W-50-3)
SWITCH
PRNDL
S1 C4 SIGNAL ILLUMINATION
JUNCTION (A/T) 1
BLOCK 1
TRANSFER
FUSE (8W-12-2)
6
E1 CASE
20 2 SWITCH
5A
TN
(8W-12-8) ILLUMINATION
42 C201
2
S2 C4 E1
E2 20 E2 Z1 Z1
20 TN 20 20 20
OR OR BK BK

S315 2 C206
(8W-12-8)
43 C201 Z1
20
E2 BK
20
OR S314
(8W-15-13)
S215 Z1
(8W-12-8) 14
E2 E2 E2 E2 E2 E2 E2 BK
20 20 20 20 20 20 20
OR OR OR OR OR OR OR 14 C201
Z1
5 C2 4 14
FUSED RADIO REAR BK
PANEL (8W-47-2) WINDOW
LAMPS (8W-47-9) S208
DEFOGGER (8W-15-15)
DIMMER
SWITCH
SWITCH
(8W-48-2) Z1
SIGNAL 14
1 BK
3 1 7 C1 G107
REAR FRONT A/C- (8W-15-15)
WIPER/ FOG HEATER
WASHER LAMP CONTROL
SWITCH SWITCH (8W-42-4)
(8W-53-4)
(8W-53-5) 4
1 4 1 C1 REAR
Z8
12
FOG
Z1 Z1 LAMP
Z1 BK/VT
20 20 SWITCH
BK BK 20
BK
G108 (8W-51-11)
(8W-15-16)
1
S208
3 C1 (8W-15-15)
INSTRUMENT Z15
Z1 20
CLUSTER 14
(8W-40-15) BK/GY
BK

G107
(8W-15-15)

XJI04403 J008W-7

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 8W - 44 - 4 8W-44 INTERIOR LIGHTING XJ
RHD
HEADLAMP
PANEL
LAMPS SWITCH
1 C206
DIMMER (8W-50-5)
SWITCH (8W-50-7)
SIGNAL E2 E2
20 20
OR OR

E1 1 1
20 PRNDL TRANSFER
TN ILLUMINATION CASE
(A/T) SWITCH
S1 C4 E2
20 ILLUMINATION
JUNCTION OR/BK
BLOCK 2 2
FUSE (8W-12-2) Z1
Z1
6 20
20
5A BK
BK
(8W-12-9) 12 C203
2 C206
S2 C4
S313
E2 E2 (8W-15-18)
20 20 Z1
OR OR 20
BK

S215 S309
(8W-12-9) (8W-15-18)
E2 E2 E2 E2 E2 E2 Z1
20 20 20 20 20 20 12
OR OR OR OR OR OR BK

G302
7 C1 5 C2 4 (8W-15-18)
A/C- FUSED RADIO REAR
HEATER PANEL (8W-47-3) WINDOW
CONTROL LAMPS (8W-47-10) DEFOGGER
DIMMER
(8W-42-5)
E2 SWITCH
SWITCH
20 SIGNAL (8W-48-3)
OR
1 C1 1
3 1 4
Z8 REAR FRONT REAR
12
BK/VT WIPER/ FOG FOG
WASHER LAMP LAMP
SWITCH SWITCH SWITCH
(8W-53-6) (BUILT-UP
(8W-53-7) EXPORT)
G108 1 4 1
(8W-51-12)
(8W-15-16)
Z1 Z1 Z1 Z15
20 20 20 18
BK BK BK BK/GY

3 C1 S208
(8W-15-14)
INSTRUMENT
(8W-15-15)
CLUSTER Z1
(8W-40-15) 14
BK

G107
(8W-15-14)
(8W-15-15)
J008W-7 XJI04404

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 XJ 8W-44 INTERIOR LIGHTING 8W - 44 - 5

BATT M1 (8W-10-27)
(8W-10-30)
JUNCTION
BLOCK
(8W-12-2)
3 C3
M1 20PK
SKIM OTHERS

S361
(8W-10-28)
(8W-10-29)

S347
(8W-10-28)
(8W-10-29)
(8W-10-30)
FULL OPTIONS OTHERS
M1 M1 M1
20 20 20
2 MIDLINE BASE/POLICE
PK PK PK
COMPASS
(8W-49-2) C
(8W-49-3) DOME
(8W-49-4) LAMPS
(8W-49-5) SWITCH
2
DOME
LAMP
A
LEFT
VISOR/ 1 7
VANITY Z1 M2 B A 3
LAMP 20 20 M2 Z1 M2
BK YL 20 20 20
YL BK YL
S342 S345
(8W-15-13) (8W-12-30)
S342
Z1 2 C3 (8W-15-13)
20 JUNCTION
BK BLOCK 2 C3
A
(8W-12-2) JUNCTION
S5 C4 BLOCK
B TO
(8W-12-2)
A Z1 Z1 JUNCTION S5 C4
RIGHT 20 14 BLOCK Z1
BK BK (8W-44-6)
VISOR/ 14
(8W-44-7) BK
VANITY
LAMP
LHD RHD
S208
S314 (8W-15-14)
(8W-15-13) (8W-15-15)
14 C201
Z1
Z1 14
14 BK
BK
B
G107
(8W-15-14)
(8W-15-15)
XJI04405 J008W-7

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 8W - 44 - 6 8W-44 INTERIOR LIGHTING XJ
GAS
BATT A0 (8W-10-11)
POWER
A23
DISTRIBUTION FROM
CENTER DOME
FUSE (8W-10-2) LAMPS
FROM
16
15A COMPASS SWITCH
A24 (8W-10-27) FULL (8W-44-5) MIDLINE
OPTIONS
A
M1
20
M2
PK
20
S135 YL
(8W-10-27)
12 C1 1 C3
M1 JUNCTION
20 BLOCK
PK (8W-12-2)
4 C7 S18 C4 7 C7 S25 C4
M1 LHD RHD M2
20 20 M2
PK 6 C201 YL 20
YL
5 C314 LHD RHD
S214
LHD RHD (8W-10-27)
M1 M1
M1 M1 20 20
20 18 D E
PK PK
PK PK
A C208 A C207 TO TO
B C S304 S304
M1 M1
18 18 (8W-44-8) (8W-44-9)
TO TO
PK PK
CARGO CARGO
1 1
LAMP/ LAMP/ RIGHT LHD RHD
LEFT
SWITCH SWITCH COURTESY
COURTESY
(8W-44-8) (8W-44-9) LAMP 46 C201
2 LAMP 2
1 M2 18BK/WT M2 18BK/WT
B C208 B C207
UNDERHOOD M2 M2 M2
LAMP/ 20 20 20
SWITCH YL YL YL

S201
(8W-12-30)
3 C1
HEADLAMP HEADLAMP
DOME
2 DELAY LAMP SWITCH
MODULE SWITCH (8W-50-2)
Z1 (8W-50-3)
20 GROUND (8W-50-8)
(8W-50-9)
BK 4
Z1 Z1
S132 18 18
(8W-15-4) BK BK
Z1 (8W-15-5)
16 (8W-15-6) S207
BK (8W-15-8) (8W-15-16)
(8W-15-9) Z1
G106 14
(8W-15-7) BK
(8W-15-10)
G108
J008W-7 (8W-15-16) XJI04406

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 XJ 8W-44 INTERIOR LIGHTING 8W - 44 - 7
DIESEL
BATT A0 (8W-10-13) FROM
POWER DOME
DISTRIBUTION FROM LAMPS
A23 SWITCH
CENTER COMPASS
FUSE (8W-10-7) FULL MIDLINE
16 (8W-44-5)
OPTIONS
15A A
A24 (8W-10-30)

M2
20
M1 M1
YL
20 20
PK PK
12 C1 1 C3
JUNCTION
BLOCK
(8W-12-2)
4 C7 S18 C4 7 C7 S25 C4
M1 RHD LHD M2
20 20 M2
PK 6 C201 YL 20
YL
5 C314 LHD RHD

LHD RHD S214

(8W-10-30)
M1 M1
20 18
M1 M1
PK PK
20 20
PK PK
B C D E
A C208 A C207
TO TO M1 M1 TO TO
CARGO CARGO 18 18 S304 S304
LAMP/ LAMP/ PK PK (8W-44-8) (8W-44-9)
SWITCH SWITCH 1 1
(8W-44-8) (8W-44-9) LEFT RIGHT LHD RHD
1
COURTESY COURTESY
UNDERHOOD LAMP 46 C201
2 LAMP 2
LAMP/
M2 18BK/WT M2 18BK/WT
SWITCH B C208 B C207
M2 M2 M2
20 20 20
YL YL YL

2 S201
3 C1 (8W-12-30)
Z1
20 HEADLAMP HEADLAMP
DOME
BK DELAY LAMP SWITCH
MODULE SWITCH (8W-50-3)
S157 GROUND (8W-50-9)
(8W-15-11)
4
Z1
12 Z1 Z1
BK 18 18
BK BK
S132 S207
(8W-15-11) (8W-15-16)
G106 Z1
14
(8W-15-12)
BK

G108
XJI04407 (8W-15-16) J008W-7

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 8W - 44 - 8 8W-44 INTERIOR LIGHTING XJ
LHD
FROM
JUNCTION FROM
BLOCK C314
(8W-44-6) (8W-44-6)
(8W-44-7) (8W-44-7)

D B

S304

M2 M2 M2 M2 M2
20 20 20 20 20
YL YL YL YL YL
6 C314
A C317 A C320 A C318 A C319 B A
CARGO
M2 M2 M2 M2 LAMP/
18 18 18 18 SWITCH
YL YL YL YL

3 3
C
LEFT RIGHT
M4
REAR REAR 20
DOOR DOOR GY/BK
JAMB JAMB
SWITCH SWITCH 7 C314
2 2
3 C326
M4
20
GY/BK
1 1 5 C311
DRIVER PASSENGER 10 C310
Z1 Z1 M4
DOOR 18
DOOR 18 20
JAMB BK JAMB BK VT/YL
SWITCH SWITCH 3 1
(8W-39-6) (8W-39-6) LIFTGATE
3 3 SWITCH

2
G78 Z1
Z1 Z1 20
18 18 20
TN/BK BK
BK BK
6 C310 S334
C C317 B C320 C C318 B C319 3 C311 (8W-15-21)
G78 Z1
Z1 Z1 Z1 Z1 18
20 20 20 20 20
TN/BK BK
BK BK BK BK
1 C327 9 C310
6 C311
S309 S310 G78
(8W-15-17) (8W-15-19) 20 Z1
TN/BK 18
BK
Z1 Z1 40 C200
12 16
1 C1 G304
BK BK (8W-15-21)
LIFTGATE INSTRUMENT
AJAR CLUSTER
G302 G303 SWITCH (8W-40-15)
(8W-15-17) (8W-15-19) SENSE

J008W-7 XJI04408

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 XJ 8W-44 INTERIOR LIGHTING 8W - 44 - 9
RHD
FROM
JUNCTION FROM
BLOCK C314
(8W-44-6) (8W-44-6)
(8W-44-7) (8W-44-7)

E C

S304

M2 M2 M2 M2 M2
20 20 20 20 20
YL YL YL YL YL
6 C314

A C317 A C320 A C318 A C319 B A

CARGO
M2 M2 M2 M2 LAMP/
18 18 18 18 SWITCH
YL YL YL YL

3 3
C
LEFT RIGHT
M4
REAR REAR 20
DOOR DOOR GY/BK
JAMB JAMB
SWITCH SWITCH 7 C314
2 2
3 C326
Z1 Z1 M4
18 18 20
BK BK GY/BK
1 1
PASSENGER DRIVER 5 C311
DOOR DOOR
M4 C310
10
JAMB JAMB 20
SWITCH SWITCH VT/YL
(8W-39-7) (8W-39-7) 3 1
3 3 LIFTGATE
SWITCH
Z1 Z1
18 18
BK BK
2
C C317 B C320 C C318 B C319 Z1
G78
20 20
Z1 Z1 Z1 Z1
TN/BK BK
20 20 20 20
BK BK BK BK S334
6 C310 (8W-15-21)
S309 S310 3 C311 Z1
(8W-15-18) (8W-15-20) 18
1 C327 BK
9 C310
Z1
6 C311
12 5 C204
Z1
Z1 BK
18
12 1 C1 BK
BK LIFTGATE INSTRUMENT
AJAR CLUSTER
G302 SWITCH (8W-40-15) G304
(8W-15-18) G303 SENSE
(8W-15-20) (8W-15-21)
XJI04409 J008W-7

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 XJ 8W - 47 AUDIO SYSTEM 8W - 47 - 1

8W-47 AUDIO SYSTEM

Component Page Component Page
Antenna . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 9, 10 Left Front Door Speaker . . . . . . . . 8W-47-5, 6, 9, 10
Combination Flasher . . . . . . . . . . . . . . . . . 8W-47-4 Left Front Door Tweeter . . . . . . . . . . . . . 8W-47-5, 6
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 9, 10 Left Soundbar Speaker . . . . . . . . . . . 8W-47-5, 6, 11
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3 Power Amplifier . . . . . . . . . . 8W-47-2, 3, 4, 5, 6, 7, 8
Fuse 17 (JB) . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 9, 10 Power Antenna . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-47-4 Power Antenna Relay . . . . . . . . . . . . . . . . . 8W-47-4
Fuse 22 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3 Power Distribution Center . . . . . . . . . . 8W-47-2, 3, 4
Fuse 26 (PDC) . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 4 Radio . . . . . . . . . . . . 8W-47-2, 3, 4, 5, 6, 7, 8, 9, 10, 11
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4 Right Front Door Speaker . . . . . . . 8W-47-7, 8, 9, 10
G108 . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 9, 10 Right Front Door Tweeter . . . . . . . . . . . . 8W-47-7, 8
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3 Right Soundbar Speaker . . . . . . . . . . 8W-47-7, 8, 11
Headlamp Switch . . . . . . . . . . . . . . 8W-47-2, 3, 9, 10 Underhood Lamp/Switch . . . . . . . . . . . . . 8W-47-2, 3
Junction Block . . . . . . . . . . . . . . . . 8W-47-2, 3, 9, 10

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 8W - 47 - 2 8W-47 AUDIO SYSTEM XJ
LHD 6 SPEAKER SYSTEM
BATT F34 (8W-10-28) BATT A0 (8W-10-11)
(8W-10-29) (8W-10-13)
HEADLAMP POWER
SWITCH DIESEL GAS DISTRIBUTION
0 OFF A23
A11 A4
CENTER
1 PARK FUSE (8W-10-2)
0 2 3 4 2 HEAD 16 FUSE FUSE (8W-10-7)
1
3 DIM 15A 22 26
4 BRIGHT (8W-10-27) 20A 20A
(8W-50-2) A24
(8W-10-30) (8W-10-34) (8W-10-33)
(8W-50-3) A12 A3
9 1

E1
20 M1 M1 F75
TN 20 20 16
PK PK VT
42 C201 1
GAS DIESEL FUSED UNDERHOOD
L7 E1 B(+) LAMP/
18 20 S135 SWITCH
BK/YL TN (8W-10-27) (DIESEL)
(8W-44-7)
M1
20
PK
RUN-ACC A31 (8W-10-15)
S1 C4 12 C1 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
6 17 C4 C100
5A 15A
(8W-12-8) (8W-12-19)
F75
16
S2 C4 S18 C4 S9 C4 VT
E2 M1 X12
20 20 16
OR PK RD/WT
14 C200

S315 F75
43 (8W-12-8) 6 54 14
C201 VT
S206 M1
(8W-12-10) 20 S301
S215 PK
(8W-12-11)
(8W-12-8)
S214 F75 F75
16 16
ANTENNA (8W-10-27)
VT VT
L7 E2 M1 (8W-10-30) X12
18 20
(EXCEPT 20 16
BK/YL OR BUILT-UP PK RD/WT
1 C2 2 C2
EXPORT) FUSED FUSED POWER
4 C2 5 C2 7 C2 6 C2 B(+) B(+) AMPLIFIER
HEADLAMP FUSED FUSED FUSED RADIO
SWITCH PANEL B(+) IGNITION
OUTPUT LAMPS SWITCH
DIMMER OUTPUT GROUND GROUND
SWITCH (RUN-ACC) 7 C2 8 C2
SIGNAL
GROUND
Z5 Z5
16 16
Z9 BK/LB BK/LB
14
BK G301
(8W-15-17)
G108
J008W-7 (8W-15-16) XJI04702

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 XJ 8W-47 AUDIO SYSTEM 8W - 47 - 3
RHD 6 SPEAKER SYSTEM
BATT F34 (8W-10-28) BATT A0 (8W-10-11)
(8W-10-29) (8W-10-13)
HEADLAMP POWER
SWITCH DIESEL GAS DISTRIBUTION
0 OFF A23
A11 A4
CENTER
1 PARK FUSE (8W-10-2)
0 2 3 4 2 HEAD 16 FUSE FUSE (8W-10-7)
1
3 DIM 15A 22 26
4 BRIGHT (8W-10-27) 20A 20A
(8W-50-2) A24
(8W-10-30) (8W-10-34) (8W-10-33)
(8W-50-3) A12 A3
9 1
L7 E1
18 20
BK/YL TN

M1 M1 F75
20 20 16
PK PK VT

1
GAS DIESEL FUSED UNDERHOOD
B(+) LAMP/
S135 SWITCH
(8W-10-27) (DIESEL)
(8W-44-7)
M1
20
PK RUN-ACC A31 (8W-10-15)
S1 C4 12 C1 (8W-10-16)
JUNCTION
BLOCK C4 C100
(8W-12-2)
FUSE FUSE
6 17
5A 15A F75
(8W-12-9) (8W-12-20) 16
VT

S2 C4 S18 C4 S9 C4 21 C204

E2 M1 X12 F75
20 20 16 16
OR PK RD/WT VT

S215 S301
S206 (8W-12-9) S214
(8W-12-10) (8W-10-27) F75 F75
(8W-12-11) (8W-10-30) 16 16
ANTENNA VT VT
L7 E2 M1
18 20
(EXCEPT 20
BK/YL OR BUILT-UP PK
1 C2 2 C2
EXPORT) FUSED FUSED POWER
4 C2 5 C2 7 C2 6 C2 B(+) B(+) AMPLIFIER
HEADLAMP FUSED FUSED FUSED RADIO
SWITCH PANEL B(+) IGNITION
OUTPUT LAMPS SWITCH
DIMMER OUTPUT GROUND GROUND
SWITCH (RUN-ACC) 7 C2 8 C2
SIGNAL
GROUND
Z5 Z5
16 16
Z9 BK/LB BK/LB
14
BK G301
(8W-15-18)
G108
XJI04703 (8W-15-16) J008W-7

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 8W - 47 - 4 8W-47 AUDIO SYSTEM XJ
BUILT-UP-EXPORT
BATT A0 (8W-10-11)
(8W-10-13)
POWER
DIESEL GAS DISTRIBUTION
RADIO A4 A18
CENTER
(8W-10-2)
FUSE FUSE (8W-10-7)
26 19
RADIO
20A 20A
12V
(8W-10-29) (8W-10-29)
OUTPUT A3 A17
1 C1

X60
16
DG/RD
F34
18
TN/BK
S229
A18
E6 C100
X60 X60 F34
16 18 18
DG/RD DG/RD TN/BK

LHD RHD
S218
11 C200 14 C203 (8W-10-29)
X60 X60
18 18 F34
DG/RD DG/RD 18
TN/BK

4 C1 C C1 B C1
POWER POWER
RADIO
12V AMPLIFIER ANTENNA
OUTPUT RELAY
1 UP
1 2 1 2 2 DOWN

A C1 B C2 C C2 A C2

Z1 X17 X14 X13

COMBINATION 18 18 18 18
FLASHER BK GY DG WT
(8W-52-3)
GROUND (8W-52-4) B C A
5 RHD LHD POWER
ANTENNA
M
Z1
20
BK ANTENNA
COAX

S208
(8W-15-15)
Z1
14 ANTENNA RADIO
BK COAX
RHD
G107 LHD
(8W-15-15)
J008W-7 XJI04704

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 XJ 8W-47 AUDIO SYSTEM 8W - 47 - 5
LHD 6 SPEAKER SYSTEM
RADIO
LEFT LEFT LEFT LEFT
REAR REAR FRONT FRONT RADIO
SPEAKER SPEAKER SPEAKER SPEAKER 12V
(+) (-) (+) (-) OUTPUT
2 C1 6 C1 4 C1 2 C2 1 C1
EXCEPT
BUILT-UP-EXPORT BUILT-UP-EXPORT
X51 X57 X53 X55
16 16 16 16
BR/YL BR/LB DG BR/RD S229
(8W-47-4)

X60
16
DG/RD

6 7 1 2 11 C200
X51 X57 X53 X55 X60
18 18 18 18 18
BR/YL BR/LB DG BR/RD DG/RD
7 C1 8 C1 5 C1 1 C1 4 C1
LEFT LEFT LEFT LEFT RADIO POWER
REAR REAR FRONT FRONT 12V AMPLIFIER
SPEAKER SPEAKER SPEAKER SPEAKER OUTPUT
(+) (-) (+) (-)
AMPLIFIED AMPLIFIED
AMPLIFIED AMPLIFIED LEFT LEFT
LEFT LEFT FRONT FRONT
REAR REAR DOOR DOOR
SPEAKER SPEAKER SPEAKER SPEAKER
(-) (+) (+) (-)
6 C2 14 C2 4 C2 12 C2
X93 X91 X87 X85
18 18 18 18
WT/RD WT/BK LG/VT BR/RD

4 3 C314 2 1 C305

X93 X91 X87 X85

16 16 18 18
BR/YL BR/DB DG BR/RD

S326

X85 X85
18 18
BK/RD LG/RD

A 1 1
LEFT LEFT LEFT
SOUNDBAR FRONT FRONT
SPEAKER DOOR DOOR
SPEAKER TWEETER
B 2 2

X87 X87
18 18
DG LG/BK

S327
XJI04705 J008W-7

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 8W - 47 - 6 8W-47 AUDIO SYSTEM XJ
RHD 6 SPEAKER SYSTEM
RADIO
LEFT LEFT LEFT LEFT
REAR REAR FRONT FRONT RADIO
SPEAKER SPEAKER SPEAKER SPEAKER 12V
(+) (-) (+) (-) OUTPUT
2 C1 6 C1 4 C1 2 C2 1 C1
EXCEPT
BUILT-UP-EXPORT BUILT-UP-EXPORT

X51 X57 X53 X55

16 16 16 16
BR/YL BR/LB DG BR/RD
S229
(8W-47-4)

X60
16
DG/RD
16 20 18 14
22 C203
X51 X57 X53 X55 X60
18 18 18 18 18
BR/YL BR/LB DG BR/RD DG/RD
7 C1 8 C1 5 C1 1 C1 4 C1
LEFT LEFT LEFT LEFT RADIO POWER
REAR REAR FRONT FRONT 12V AMPLIFIER
SPEAKER SPEAKER SPEAKER SPEAKER OUTPUT
(+) (-) (+) (-)

AMPLIFIED AMPLIFIED
AMPLIFIED AMPLIFIED LEFT LEFT
LEFT LEFT FRONT FRONT
REAR REAR DOOR DOOR
SPEAKER SPEAKER SPEAKER SPEAKER
(-) (+) (+) (-)
6 C2 14 C2 4 C2 12 C2
X93 X91 X87 X85
18 18 18 18
WT/RD WT/BK LG/VT BR/RD
4 3 C314 2 1 C305

X93 X91 X87 X85

16 16 18 18
BR/YL BR/DB DG BR/RD

S326

X85 X85
18 18
LG/RD LG/RD

A 1 1
LEFT LEFT LEFT
SOUNDBAR FRONT FRONT
SPEAKER DOOR DOOR
SPEAKER TWEETER
B 2 2

X87 X87
18 18
LG/BK LG/BK

S327
J008W-7 XJI04706

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 XJ 8W-47 AUDIO SYSTEM 8W - 47 - 7
LHD 6 SPEAKER SYSTEM
RADIO
RIGHT RIGHT RIGHT RIGHT
REAR REAR FRONT FRONT
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
3 C1 7 C1 5 C1 3 C2
X52 X58 X54 X56
16 16 16 16
DB/WT DB/OR VT DB/RD

9 10 4 5 C200

X52 X58 X54 X56

18 18 18 18
DB/WT DB/OR VT DB/RD

9 C1 3 C1 6 C1 2 C1
RIGHT RIGHT RIGHT RIGHT POWER
REAR REAR FRONT FRONT AMPLIFIER
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)

AMPLIFIED AMPLIFIED
AMPLIFIED AMPLIFIED RIGHT RIGHT
RIGHT RIGHT FRONT FRONT
REAR REAR DOOR DOOR
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
5 C2 13 C2 11 C2 10 C2

X94 X92 X82 X80

18 18 18 18
TN/RD TN/BK LB/RD LB/BK

2 1 C314 5 4
C303

X94 X92 X82 X80

16 16 18 18
TN/RD TN/BK LB/RD LB/BK

S320

X80 X80
18 18
LB/BK LB/BK

A 1 1
RIGHT RIGHT RIGHT
SOUNDBAR FRONT FRONT
SPEAKER DOOR DOOR
SPEAKER TWEETER
B 2 2
X82 X82
18 18
LB/RD LB/RD

S321

XJI04707 J008W-7

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 8W - 47 - 8 8W-47 AUDIO SYSTEM XJ
RHD 6 SPEAKER SYSTEM
RADIO
RIGHT RIGHT RIGHT RIGHT
REAR REAR FRONT FRONT
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
3 C1 7 C1 5 C1 3 C2
X52 X58 X54 X56
16 16 16 16
DB/WT DB/OR VT DB/RD

15 19 17
21 C203

X52 X58 X54 X56

18 18 18 18
DB/WT DB/OR VT DB/RD

9 C1 3 C1 6 C1 2 C1
RIGHT RIGHT RIGHT RIGHT POWER
REAR REAR FRONT FRONT AMPLIFIER
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)

AMPLIFIED AMPLIFIED
AMPLIFIED AMPLIFIED RIGHT RIGHT
RIGHT RIGHT FRONT FRONT
REAR REAR DOOR DOOR
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
5 C2 13 C2 11 C2 10 C2

X94 X92 X82 X80

18 18 18 18
TN/RD TN/BK LB/RD LB/BK

2 1 C314 3 2
C324

X94 X92 X82 X80

16 16 18 18
TN/RD TN/BK LB/RD LB/BK

S320

X80 X80
18 18
LB/BK LB/BK

A 1 1
RIGHT RIGHT RIGHT
SOUNDBAR FRONT FRONT
SPEAKER DOOR DOOR
SPEAKER TWEETER
B 2 2
X82 X82
18 18
LB/RD LB/RD

S321

J008W-7 XJI04708

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 XJ 8W-47 AUDIO SYSTEM 8W - 47 - 9
LHD 4 SPEAKER SYSTEM
BATT F34 (8W-10-28)
(8W-10-29) E1
HEADLAMP 20
SWITCH TN
0 OFF
1 PARK 42 C201
0 2 3 4 2 HEAD
1 E1
3 DIM
20
4 BRIGHT
TN
(8W-50-2)
(8W-50-3)
9 1

BATT M1 (8W-10-27) RUN-ACC A31 (8W-10-15)

(8W-10-30) (8W-10-16) S1 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
L7 17 6
18 15A 5A
BK/YL (8W-12-19) (8W-12-8)

S18 C4 S9 C4 S2 C4
M1 X12 E2
S206 20 16 20
(8W-12-10) PK RD/WT OR
(8W-12-11)
S315
(8W-12-8)

6 54 43
C201
L7 M1 E2
18 20 20
BK/YL PK OR

S214 ANTENNA S215

(8W-10-27) (8W-12-8)
M1 (8W-10-30) X12 (EXCEPT E2
20 16 BUILT-UP 20
PK RD/WT EXPORT) OR
4 C2 7 C2 6 C2 5 C2
HEADLAMP FUSED FUSED FUSED RADIO
SWITCH B(+) IGNITION PANEL
OUTPUT SWITCH LAMPS
LEFT LEFT OUTPUT RIGHT RIGHT DIMMER
FRONT FRONT (RUN-ACC) FRONT FRONT SWITCH
SPEAKER SPEAKER SPEAKER SPEAKER SIGNAL
(+) (-) (+) (-) GROUND
4 C1 2 C2 5 C1 3 C2
X53 X55 X54 X56
16 16 16 16
Z9
DG BR/RD VT DB/RD
14
1 2 4 5 C200 BK
X53 X55 X54 X56
18 18 18 18
DG BR/RD VT DB/RD
G108
(8W-15-16)
2 1 C305 5 4 C303
X53 X55 X82 X80
18 18 18 18
LG/BK LG/RD LB/RD LB/BK
1 1
LEFT RIGHT
FRONT FRONT
DOOR DOOR
SPEAKER SPEAKER
2 2
XJI04709 J008W-7

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 8W - 47 - 10 8W-47 AUDIO SYSTEM XJ
RHD 4 SPEAKER SYSTEM
BATT F34 (8W-10-28)
(8W-10-29)
HEADLAMP
SWITCH
0 OFF
1 PARK
0 1 2 3 4 2 HEAD
3 DIM
4 BRIGHT
(8W-50-2)
(8W-50-3)
9 1
L7
18
BK/YL

S206 E1
(8W-12-10) 20
(8W-12-11) TN
BATT M1 (8W-10-27) RUN-ACC A31 (8W-10-15)
(8W-10-30) (8W-10-16) S1 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
17 6
15A 5A
(8W-12-20) (8W-12-9)

S18 C4 S9 C4 S2 C4
L7 M1 X12 E2
18 20 16 20
BK/YL PK RD/WT OR

S214 S215
(8W-10-27) (8W-12-9) ANTENNA
M1 (8W-10-30) E2 (EXCEPT
20 20 BUILT-UP
PK OR
EXPORT)
4 C2 7 C2 6 C2 5 C2
HEADLAMP FUSED FUSED FUSED PANEL RADIO
SWITCH B(+) IGNITION LAMPS DIMMER
OUTPUT SWITCH SWITCH SIGNAL
OUTPUT
RIGHT RIGHT (RUN-ACC) LEFT LEFT
FRONT FRONT FRONT FRONT
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-) GROUND
5 C1 3 C2 4 C1 2 C2
X54 X56 X53 X55
16 16 16 16
Z9
VT DB/RD DG BR/RD
14
17 20 18
19 C203 BK
X54 X56 X53 X55
18 18 18 18
VT DB/RD DG BR/RD G108
(8W-15-16)
5 4 C303 2 1 C305
X80 X55
18 18
X82 LB/BK X53 LG/RD
18 1 18 1
LB/RD RIGHT LG/BK LEFT
FRONT FRONT
DOOR DOOR
SPEAKER SPEAKER
2 2
J008W-7 XJI04710

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 XJ 8W-47 AUDIO SYSTEM 8W - 47 - 11
4 SPEAKER SYSTEM

RADIO

LEFT LEFT RIGHT RIGHT

REAR REAR REAR REAR
SPEAKER(+) SPEAKER(-) SPEAKER(+) SPEAKER(-)
2 C1 6 C1 3 C1 7 C1

X51 X57 X52 X58

16 16 16 16
BR/YL BR/LB DB/WT DB/OR

LHD RHD LHD RHD LHD RHD LHD RHD

6 C200 22 C203 7 C200 16 C203 9 C200 21 C203 10 C200 15 C203

X51 X57 X52 X58

18 18 18 18
BR/YL BR/LB DB/WT DB/OR

3 4 1 2 C314

X51 X57 X52 X58

18 18 18 18
BR/YL BR/LB DB/WT DB/OR

A A
LEFT RIGHT
SOUNDBAR SOUNDBAR
SPEAKER SPEAKER

B B

XJI04711 J008W-7

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 XJ 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1

8W-48 REAR WINDOW DEFOGGER

Component Page Component Page
Driver Power Mirror . . . . . . . . . . . . . . . . 8W-48-2, 3 Instrument Cluster . . . . . . . . . . . . . . . . . 8W-48-2, 3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3 Junction Block . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3 Passenger Power Mirror . . . . . . . . . . . . . 8W-48-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3 Rear Window Defogger . . . . . . . . . . . . . . 8W-48-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3 Rear Window Defogger Relay . . . . . . . . . 8W-48-2, 3
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3 Rear Window Defogger Switch . . . . . . . . 8W-48-2, 3
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3

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 8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER XJ
LHD
RUN A22 (8W-10-18) BATT A4 (8W-10-24)
(8W-10-25)
JUNCTION
BLOCK
(8W-12-2)
FUSE
12
10A
(8W-12-17)

86 30
REAR
WINDOW FUSE
DEFOGGER 14
RELAY 10A
(8W-12-17)
85 87

S26 C4 S19 C4 3 C9 1 C6
C81 C16
20 2 C201 C15
20 12
LB/WT C16 BK/WT BK/WT
17 C201 20
5
LB/YL 4 C326
3 C2 PASSENGER
REAR WINDOW INSTRUMENT POWER 2 C312
DEFOGGER CLUSTER MIRROR 3 C310
RELAY CONTROL (8W-40-12) 37 C200 C15
REAR WINDOW 11 C305 6 12
DEFOGGER FULL POWER POWER FULL BK/WT
SWITCH SENSE OPTIONS MIRRORS MIRRORS OPTIONS
4 C2 C16 C16 Z1 REAR
20 20 18
FROM LB/YL BK/WT Z1 WINDOW
BK
S215 18 DEFOGGER
(8W-12-8) 5 BK S319
DRIVER (8W-15-13)
Z1
E2 C80 C16 POWER 16
20 20 20 MIRROR
OR DB/WT LB/YL BK

4 2 3 6 11 C9
REAR FULL POWER
JUNCTION
WINDOW OPTIONS MIRRORS
BLOCK
DEFOGGER (8W-12-2) Z1
Z1 Z1 12
SWITCH 16 18 S5 C4
DEFOGGER BK
SWITCH BK BK Z1
ON
ILLUM. INDICATOR
14 2 C310
S329 S329 BK 1 C312
(8W-15-17) (8W-15-17)
S314 Z1
Z1 Z1 (8W-15-13)
1 12 16 12
Z1 BK BK
14 C201 BK
20
BK
S208
(8W-15-14)
Z1 (8W-15-15) G304
S208 3 C307 (8W-15-21)
14
(8W-15-14)
Z1 S309 BK
(8W-15-15)
14
(8W-15-17)
BK G107
G302 (8W-15-14)
G107 (8W-15-17) (8W-15-15)
(8W-15-14)
J008W-7 XJI04802
(8W-15-15)

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 XJ 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 3
RHD
RUN A22 (8W-10-18) BATT A4 (8W-10-24)
(8W-10-25)
JUNCTION
BLOCK
(8W-12-2)
FUSE
12
10A
(8W-12-18)

FUSE
86 30
14
REAR
10A
WINDOW
(8W-12-18)
DEFOGGER
RELAY

85 87

S26 C4 5 C5 S19 C4 3 C9 1 C6
C16 20BK/WT
2 C204
C81 C16 C15
20 C16 20 12
LB/WT 20 BK/WT BK/WT
LB/YL
11 C305 5 4 C326
3 C2 FULL POWER DRIVER 2 C312
REAR WINDOW INSTRUMENT OPTIONS MIRRORS POWER 3 C310
DEFOGGER CLUSTER MIRROR
TIMER (8W-40-13) C16 C16
20 20 REAR
REAR WINDOW LB/YL BK/WT
6
WINDOW
C16
DEFOGGER
20 DEFOGGER
SWITCH SENSE 5 Z1
LB/YL
4 C2 PASSENGER 18
POWER BK
POWER FULL
C80 MIRROR MIRRORS OPTIONS
20
DB/WT 6
Z1 S319 S319 Z1
16 (8W-15-13) (8W-15-20) 12
FROM FULL BK POWER Z1 Z1 BK
OPTIONS MIRRORS 16 14
S215 BK BK
(8W-12-9)
S329 Z1
(8W-15-18) 11 C9 2 C310
16
E2 Z1
BK
JUNCTION 1 C312
20 12 BLOCK 5 C303
OR BK (8W-12-2) Z1
2 4 3 14
REAR S5 C4 BK Z1
WINDOW 12
Z1
DEFOGGER S310 BK
SWITCH DEFOGGER 14
ON BK (8W-15-20)
ILLUM. INDICATOR SWITCH 3 C307 Z1
Z1 12
12 BK
BK G304
1
Z1 20BK
S208 G303 (8W-15-21)
S208 S309 (8W-15-14) (8W-15-20)
(8W-15-14) (8W-15-18) Z1 (8W-15-15)
Z1 Z1
(8W-15-15) 14
14 12
BK BK
BK
G107 G107
G302 (8W-15-14)
(8W-15-14) (8W-15-18)
XJI04803 (8W-15-15) (8W-15-15) J008W-7

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 XJ 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1

8W-49 OVERHEAD CONSOLE

Component Page Component Page
Ambient Temperature Sensor . . . . . . . . . 8W-49-4, 5 G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3
Compass . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3, 4, 5, 6 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . 8W-49-4, 5
Data Link Connector . . . . . . . . . . . . . . . . . 8W-49-6 Junction Block . . . . . . . . . . . . . . . . . 8W-49-2, 3, 4, 5
Driver Door Jamb Switch . . . . . . . . . . . . 8W-49-4, 5 Overhead Module . . . . . . . . . . . . . 8W-49-2, 3, 4, 5, 6
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3 Passenger Power Lock/Window Switch . . 8W-49-4, 5
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3 Power Distribution Center . . . . . . . . . . . 8W-49-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3 Underhood Lamp/Switch . . . . . . . . . . . . . 8W-49-2, 3

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 8W - 49 - 2 8W-49 OVERHEAD CONSOLE XJ
LHD
BATT A0 (8W-10-11) ST-RUN A21 (8W-10-17)
(8W-10-13)
POWER JUNCTION
A23 DISTRIBUTION FUSE
BLOCK
FUSE CENTER 9 (8W-12-2)
16 (8W-10-2) 10A
15A (8W-10-7) (8W-12-13)
(8W-10-27)
A24
(8W-10-30) S13 C4
DIESEL GAS
F87
M1 M1 20
20 S135 20 WT/BK
PK (8W-10-27) PK
S225
1 (8W-12-13)
12 C1 FUSED UNDERHOOD
JUNCTION (B+) LAMP/ F87
BLOCK SWITCH 20
(8W-12-2) WT/BK
(DIESEL)
(8W-44-7)
3 C3
6 C301
OTHERS SKIM
F87
20
S361 WT/BK
(8W-10-28) M1
(8W-10-29) 20
PK

S347 2 6
(8W-10-28)
M1 FUSED FUSED COMPASS
(8W-10-29)
20 (8W-10-30) B(+) IGNITION (FULL
PK SWITCH OPTIONS)
OUTPUT
2 (ST-RUN)
FUSED OVERHEAD GROUND GROUND
B(+) MODULE
1 12
Z1 Z2
20 20
GROUND GROUND BK BK/LG

9 3 S342
Z1 Z1 (8W-15-13) 5 C301
20 20
BK BK
2 C3
JUNCTION Z2
BLOCK 20
(8W-12-2) BK/LG
S5 C4
Z1 58 C201
14
BK

S314 Z2
20
(8W-15-13)
BK/LG
14 C201
S208
(8W-15-14) G108
(8W-15-15) (8W-15-16)
G107
(8W-15-14)
(8W-15-15)
J008W-7 XJI04902

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 XJ 8W-49 OVERHEAD CONSOLE 8W - 49 - 3
RHD
BATT A0 (8W-10-11) ST-RUN A21 (8W-10-17)
(8W-10-13)
POWER JUNCTION
A23 DISTRIBUTION BLOCK
FUSE CENTER (8W-12-2)
(8W-10-2) FUSE
16 9
15A (8W-10-7)
10A
(8W-10-27) (8W-12-13)
A24
(8W-10-30)
S13 C4
DIESEL GAS
F87
20
M1 M1
S135 WT/BK
20 20
PK (8W-10-27) PK
S216
(8W-12-13)

12 C1 1
JUNCTION UNDERHOOD F87
FUSED 20
BLOCK B(+) LAMP/
(8W-12-2) WT/BK
SWITCH
3 C3 (DIESEL)
OTHERS SKIM (8W-44-7)

S361
(8W-10-28) 6 C301
(8W-10-29)
M1 F87
20 20
PK WT/BK
S347
(8W-10-28) 2 6
M1 (8W-10-29) FUSED FUSED COMPASS
20 (8W-10-30) B (+) IGNITION
PK SWITCH
OUTPUT
2 (ST-RUN)
FUSED OVERHEAD GROUND GROUND
B (+) MODULE
1 12
Z1
20
GROUND GROUND BK
Z2
9 3 S342 20
Z1 Z1 (8W-15-13) BK/LG
20 20
BK BK
2 C3
JUNCTION
BLOCK 5 C301
(8W-12-2)
S5 C4
Z1
14
BK

S208 Z2
(8W-15-14) 20
Z1 (8W-15-15) BK/LG
14
BK

G107
(8W-15-14) G108
(8W-15-15) (8W-15-16)
XJI04903 J008W-7

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 8W - 49 - 4 8W-49 OVERHEAD CONSOLE XJ
LHD
BATT A7 (8W-10-20)
(8W-10-26)
JUNCTION AMBIENT
AMBIENT
BLOCK TEMPERATURE TEMPERATURE
86
HORN
(8W-12-2) SENSOR SENSOR SENSOR
RELAY SIGNAL GROUND
(8W-41-2) 1 2
G31 G32
85 20 20
VT/LG BK/LB
F14 F15
1 C5 C100
PASSENGER
DOOR G31 G32
X3 DOOR UNLOCK
POWER 20 20
20 LOCK RELAY LOCK/ VT/LG BK/LB
BK/RD CONTROL CONTROL WINDOW
1 C2 2 C2 SWITCH
(8W-61-2)
P59 P55 C201
20 20 32 35
LB/RD DB/PK
4 3 C300
P59 P55 G31 G32
20 20 20 20
LB/RD DB/PK VT/LG BK/LB
C301
7 9 8 C301 4 3
X3 P59 P55 G31 G32
20 20 20 20 20
BK/RD LB/RD DB VT/LG BK/LB
10 11 5 4 10
HORN DOOR DOOR OVERHEAD AMBIENT SENSOR COMPASS
RELAY LOCK UNLOCK MODULE TEMPERATURE GROUND
CONTROL CONTROL RELAY SENSOR
COURTESY CONTROL SIGNAL COURTESY
LAMPS LAMPS
DRIVER DRIVER
1 7
M2 M2
20 20
YL YL

S345
(8W-12-30)
1 C3
JUNCTION
BLOCK
(8W-12-2)

7 C7
M2
20
YL

S304
M2 20YL (8W-12-30)
A C317
M2
18
YL
1
COURTESY DRIVER
LAMPS DOOR
DRIVER JAMB
SWITCH
J008W-7 (8W-39-6) XJI04904

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 XJ 8W-49 OVERHEAD CONSOLE 8W - 49 - 5
RHD
BATT A7 (8W-10-20)
(8W-10-26)
JUNCTION AMBIENT
AMBIENT
86 BLOCK TEMPERATURE TEMPERATURE
HORN (8W-12-2) SENSOR SENSOR SENSOR
RELAY SIGNAL GROUND
(8W-41-3)
1 2
G31 G32
85 20 20
VT/LG BK/LB
S22 C4
X3 PASSENGER F14 F15
20 DOOR C100
BK/RD DOOR UNLOCK
POWER
LOCK RELAY LOCK/
CONTROL CONTROL WINDOW G31 G32
1 C2 2 C2 SWITCH 20 20
(8W-61-3) VT/LG BK/LB
P59 P55
20 20
LB/RD DB
3 12
C305
P59 P55 4 3 C301
20 20
LB/RD DB/PK

2 1 C203
P59 P55 G31 G32
20 20 20 20
LB/RD DB/PK VT/LG BK/LB

7 9 8 C301
X3 P59 P55
20 20 20
BK/RD LB/RD DB
10 11 5 4 10
HORN DOOR DOOR OVERHEAD AMBIENT SENSOR COMPASS
RELAY LOCK UNLOCK MODULE TEMPERATURE GROUND
CONTROL CONTROL RELAY SENSOR
COURTESY CONTROL SIGNAL COURTESY
LAMPS LAMPS
DRIVER DRIVER
1 7
M2 M2
20 20
YL YL

S345
(8W-12-30)
M2
20
YL
1 C3 A C318
JUNCTION
M2
BLOCK 18
(8W-12-2) YL
7 C7 1
M2 M2 COURTESY DRIVER
20 20 LAMPS DOOR
YL YL DRIVER JAMB
S304 SWITCH
(8W-39-7)
(8W-12-30)
XJI04905 J008W-7

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 8W - 49 - 6 8W-49 OVERHEAD CONSOLE XJ

DATA LINK
CONNECTOR
(8W-30-20)
(8W-30-21)

3 11
D1 D2
18 18
VT/BR TWISTED WT/BK
PAIR

S239 S238
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
D1 D2
20 20
VT/BR WT/BK
LHD RHD LHD RHD

55 C201 56 C201

D1 TWISTED D2
20 PAIR 20
VT/BR WT/BK

1 2 C301
D1 D2
20 20
VT/BR WT/BK

OTHER COMPASS COMPASS OTHER

S344 S346
(8W-30-20) (8W-30-20)
D1 (8W-30-21) D2 (8W-30-21)
20 20
VT/BR WT/BK
5 11
CCD CCD COMPASS
BUS BUS
(+) (-)

D1 D2
20 TWISTED 20
VT/BR PAIR WT/BK

6 12
CCD CCD OVERHEAD
BUS BUS MODULE
(+) (-)

J008W-7 XJI04906

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 XJ 8W - 50 FRONT LIGHTING 8W - 50 - 1

8W-50 FRONT LIGHTING

Component Page Component Page
Controller Anti-Lock Brake Relay . . . . 8W-50-14, 17 Instrument Cluster . . . . . . . . 8W-50-4, 5, 6, 7, 16, 18
Daytime Running Lamp Junction Block . . . . . . . . 8W-50-4, 5, 6, 7, 8, 9, 10, 11,
Module . . . . . . . . . . . . . . . . . 8W-50-2, 4, 8, 16, 18 12, 13, 14, 16, 17, 18, 19
Diode Module . . . . . . . . . . . . . . . . . . 8W-50-3, 15, 17 Left City Lamp . . . . . . . . . . . . . . . . 8W-50-11, 14, 17
Engine Starter Motor Relay . . . . . . . . . 8W-50-14, 17 Left Fog Lamp . . . . . . . . . . . . . . . . 8W-50-15, 16, 17
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . 8W-50-17 Left Front Park/Turn Signal Lamp No. 1 . 8W-50-10
Fog Lamp Relay No. 1 . . . . . 8W-50-10, 11, 14, 16, 18 Left Front Park/Turn Signal Lamp No. 2 . 8W-50-10
Fog Lamp Relay No. 2 . . . . . . . . . . . . . 8W-50-15, 16 Left Front Turn Signal Lamp No. 1 . . . . . 8W-50-11
Front Fog Lamp Switch . . . . . . . . . 8W-50-15, 16, 17 Left Front Turn Signal Lamp No. 2 . . . . . 8W-50-11
Fuse 3 (JB) . . . . . . . . . . . . . . . . . 8W-50-4, 5, 6, 7, 18 Left Headlamp . . . . . . . . . . . . . . 8W-50-4, 5, 6, 7, 19
Fuse 4 (JB) . . . . . . . . . . . . . . . . . 8W-50-4, 5, 6, 7, 19 Left Headlamp Leveling Motor . . . . . . . . . 8W-50-19
Fuse 5 (JB) . . . . . . . . . . . . . . . . . 8W-50-4, 5, 6, 7, 19 Left Repeater Lamp . . . . . . . . . . . . . . . . . 8W-50-11
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 3 Left Side Marker Lamp . . . . . . . . . . . . . . . 8W-50-10
Fuse 7 (JB) . . . . . . . . . . . . . 8W-50-10, 11, 14, 16, 17 Power Distribution
Fuse 7 (PDC) . . . . . . . . . . . . . . . 8W-50-2, 3, 8, 9, 18 Center . . . . . . . . 8W-50-2, 3, 8, 9, 14, 15, 16, 17, 18
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 9 Right City Lamp . . . . . . . . . . . . . . . . . . . . 8W-50-13
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-50-8, 9 Right Fog Lamp . . . . . . . . . . . . . . . 8W-50-15, 16, 17
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-50-18 Right Front Park/Turn Signal
Fuse 16 (JB) . . . . . . . . . . . . . . . . 8W-50-4, 5, 6, 7, 18 Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-50-12
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 3 Right Front Park/Turn Signal
Fuse 23 (JB) . . . . . . . . . . . . . . . . . . . . 8W-50-12, 13 Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-50-12
Fuse 26 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-50-3 Right Front Turn Signal Lamp No. 1 . . . . 8W-50-13
G106 . . . . . . . . . . . . . . . . 8W-50-4, 5, 6, 7, 10, 11, 12, Right Front Turn Signal Lamp No. 2 . . . . 8W-50-13
13, 14, 15, 16, 17, 18, 19 Right Headlamp . . . . . . . . . . 8W-50-4, 5, 6, 7, 18, 19
G107 . . . . . . . . . . . . . . . . . . . . . 8W-50-15, 16, 17, 19 Right Headlamp Leveling Motor . . . . . . . . 8W-50-19
G108 . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 3, 8, 9 Right Repeater Lamp . . . . . . . . . . . . . . . . 8W-50-13
Headlamp Beam Select Right Side Marker Lamp . . . . . . . . . . . . . 8W-50-12
Switch . . . . . . . . . . . . . . . 8W-50-4, 5, 6, 7, 8, 9, 19 Turn Signal/Hazard Switch . . . . 8W-50-10, 11, 12, 13
Headlamp Delay Module . . . . . . . . . 8W-50-2, 3, 8, 9 Vehicle Speed Sensor . . . . . . . . . . . . . . . . 8W-50-18
Headlamp Leveling Switch . . . . . . . . 8W-50-6, 7, 19
Headlamp Switch . . . . . . . . . . . . 8W-50-2, 3, 8, 9, 10,
11, 12, 13, 14, 16, 17

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 8W - 50 - 2 8W-50 FRONT LIGHTING XJ
EXCEPT BUILT-UP-EXPORT
BATT A0 (8W-10-11)
POWER
A18 13 DISTRIBUTION A3
FUSE FUSE CENTER 14
19 7 (8W-10-2) RD/WT
20A 30A 6
HEADLAMP A17 (8W-10-28) 6 (8W-10-22) FUSED DAYTIME
DELAY B(+) RUNNING
MODULE LAMP
F34 A3
GROUND (8W-50-8) 18 14 MODULE
4 TN/BK RD/WT (8W-50-18)

RHD LHD
Z1
18
E6 D1
BK A18 C100
FROM S218 A3 FROM
S201 14 S210
(8W-10-28)
(8W-12-30) RD/WT (8W-10-17)
2
FUSED HEADLAMP
F34 A3 B(+) DELAY
M2 18 14 MODULE G26
20 TN/BK RD/WT (8W-50-8) 20
YL LB

3 4 8 5
HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
3 DOME
0 3 4 5 0 1 2 0 1 2 0 1 2 4 DIM
5 BRIGHT

1 9 2 7 6

E1 L7 L2 G16
20 18 L2 14 L20 20
TN BK/YL 14 LG 14 BK/LB
LG LG/WT
6
LHD RHD
HEAD HEADLAMP
LAMP DELAY TO
Z1 42 C201 SWITCH MODULE
18 S200
OUTPUT (8W-50-8)
BK (8W-10-17)

A B
S207
(8W-15-16) TO TO
HEADLAMP HEADLAMP
TO TO
Z1 BEAM BEAM
FUSE S206
14 SELECT SELECT
BK 6 (JB) (8W-12-10)
(8W-12-8)
SWITCH SWITCH
(8W-12-9) (8W-50-4) (8W-50-4)
G108 (8W-50-5) (8W-50-5)
(8W-15-16)

J008W-7 XJI05002

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 XJ 8W-50 FRONT LIGHTING 8W - 50 - 3
BUILT-UP-EXPORT
BATT A0 (8W-10-11)
(8W-10-13)
POWER
DIESEL GAS DIESEL GAS DISTRIBUTION
A4 A18 14 13
CENTER
(8W-10-2)
FUSE FUSE FUSE FUSE (8W-10-7)
26 19 8 7
HEADLAMP 20A 20A 30A 30A
DELAY A3 (8W-10-29) A17 (8W-10-29) 7 (8W-10-24) 6 (8W-10-22)
MODULE
GROUND (8W-50-9)
4

F34 A3
18 14
TN/BK RD/WT
Z1
18
A18 D1
BK FROM E6 C100 A3
S201 14
(8W-12-30) S218 RD/WT FROM
(8W-10-29) 2 S210
HEADLAMP (8W-10-17)
FUSED
F34 A3 B(+) DELAY
M2 18 14 MODULE G26
20 TN/BK RD/WT (8W-50-9) 20
YL LB
3 4 8 5
HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
3 DOME
4 DIM
0 3 4 5 0 1 2 0 1 2 0 1 2
5 BRIGHT

1 9 2 7 6

Z1 E1 L7
18 20 18 L2 G16
BK TN BK/YL 14 20
LG BK/LB

TO S226
S207 S206 L2 L2 L2 L20
(8W-15-16) (8W-12-11) 16 14 14 14
LG LG LG LG/WT

TO 6 TO
FUSE HEADLAMP HEADLAMP S200
6 (JB) SWITCH DELAY (8W-10-17)
OUTPUT MODULE
(8W-12-8)
(8W-12-9) (8W-50-9)
Z1 C D
14 1
BK DIODE TO TO
MODULE HEADLAMP HEADLAMP
(8W-51-9) BEAM BEAM
G108 (8W-51-10) SELECT SELECT
(8W-15-16) SWITCH SWITCH
(8W-50-6) (8W-50-6) RHD
(8W-50-7) (8W-50-7) LHD
XJI05003 J008W-7

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 8W - 50 - 4 8W-50 FRONT LIGHTING XJ
LHD EXCEPT BUILT-UP-EXPORT
FROM INSTRUMENT DAYTIME
DIMMER
HEADLAMP FROM HIGH CLUSTER SWITCH RUNNING
DELAY HEADLAMP BEAM (8W-40-14) HIGH LAMP
MODULE SWITCH INDICATOR BEAM MODULE
DRIVER OUTPUT
(8W-50-2) (8W-50-2) (8W-50-18)
A B
5 C1 1
G34
16
2 4
RD/GY L3
HEADLAMP D4 C100 16
BEAM RD
SELECT G34
SWITCH 16
1 2 3 1 2 3 RD/GY
1 FLASH
2 LOW
3 HIGH OTHER DRL
1 3
D3 C100
L4 L3 L3
16 16 16
VT/WT RD/OR RD/OR

S213
22 16 C201
L4 L3
16 16
VT/WT RD/OR
S3 C4 S7 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
4 3 5 16
10A 10A 10A 10A
(8W-12-7) (8W-12-6) (8W-12-7) (8W-12-6)

10 C1 9 C1 1 C1 11 C1
L43 L33 L44 L34
20 20 20 20
VT RD VT/RD RD/OR
9 2
C106 S133
L43 L33 (8W-12-7)
L44
18 18 20
VT RD VT/RD
13 6
C106
L33 20RD L44 L44 L34
B A 12 C106 18 18 18
VT/RD VT/RD RD/OR
LEFT L33 B A
HEADLAMP 20
C RD/WT 10 RIGHT
FUSED DAYTIME HEADLAMP
RIGHT RUNNING C
E
S103 LOW LAMP S102
(8W-15-7) TO BEAM (8W-15-7)
Z1 OUTPUT
MODULE Z1
FOG (8W-50-18)
18 18
BK LAMP BK
RELAY
11 C106 4 C106
NO. 1
Z1 (IN PDC) Z1
20 20
BK/WT (EXCEPT DRL) BK
(8W-50-14)
G106
(8W-15-7)
J008W-7 XJI05004

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-50 FRONT LIGHTING 8W - 50 - 5
RHD EXCEPT BUILT-UP-EXPORT
FROM
HEADLAMP FROM
DELAY HEADLAMP
MODULE SWITCH
(8W-50-2) (8W-50-2)
A B

2 4
HEADLAMP
BEAM INSTRUMENT
DIMMER
SELECT SWITCH CLUSTER
HIGH (8W-40-14)
1 3 1 3
SWITCH
2 2 1 FLASH BEAM
2 LOW OUTPUT

1 3 3 HIGH 5 C1
L4 L3 L3
16 16 16
VT/WT RD/OR RD/OR

S213
L3
16
RD/OR
S3 C4 S7 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
4 3 5 16
10A 10A 10A 10A
(8W-12-7) (8W-12-6) (8W-12-7) (8W-12-6)

10 C1 9 C1 1 C1 11 C1
L43 L33 L44 L34
20 20 20 20
VT RD VT/RD RD/OR
9 2
C106 S133
L43 L33 13 (8W-12-7) 6
C106
18 18
L44 L44 L34
VT RD
20 18 18
VT/RD VT/RD RD/OR
L33 20RD B12 C100 B A
NOT
B A 12 C106 USED
RIGHT
LEFT HEADLAMP
HEADLAMP C
L33
C 20 Z1
RD/WT 18
BK

S103 E S102
(8W-15-7) (8W-15-7)
Z1 TO Z1
18 18
BK
FOG BK
LAMP
11 C106 4 C106
RELAY
Z1
NO. 1 Z1
20 (IN PDC) 20
BK/WT (EXCEPT DRL) BK
(8W-50-14)
G106
(8W-15-7)
XJI05005 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 50 - 6 8W-50 FRONT LIGHTING XJ
LHD BUILT-UP-EXPORT
FROM INSTRUMENT
FROM HEADLAMP HIGH CLUSTER
S226 SWITCH BEAM (8W-40-14)
(8W-50-3) (8W-50-3) INDICATOR
DRIVER
C D 5 C1
G34
2 4 16
HEADLAMP RD/GY
BEAM D4 C100
SELECT
G34
1 3 1 3
SWITCH 16
2 2 1 FLASH RD/GY
2 LOW
3 HIGH D3 C100
1 3
L4 L3 L3
16 16 16
VT/WT RD/OR RD/OR

S213
22 16 C201
L4 L3
16 16
VT/WT RD/OR
S3 C4 S7 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
4 3 5 16
10A 10A 10A 10A
(8W-12-7) (8W-12-6) (8W-12-7) (8W-12-6)

10 C1 9 C1 1 C1 11 C1
L43 L33 S133 L34
20 20 20
(8W-12-7)
VT RD L44 RD/OR
20
9 2 VT/RD
C106
13 6
L43 C106
18 L44
VT 18
VT/RD
L33 L44 L34
S162 18 20 S163 18
(8W-12-7) RD VT/RD (8W-12-7) RD/OR
B A B A
F6 C100
LEFT RIGHT
HEADLAMP L44 HEADLAMP
C 20 C
VT/RD
Z1 Z1
18 18
3
BK BK
FUSED HEADLAMP
S103 RIGHT LEVELING S102
(8W-15-10) LOW SWITCH (8W-15-10)
Z1 (8W-15-12) BEAM (8W-50-19) Z1 (8W-15-12)
18 OUTPUT 18
BK/WT BK
11 4 C106
Z1 Z1
20 20
BK/WT BK

G106
(8W-15-10)
(8W-15-12)
J008W-7 XJI05006

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-50 FRONT LIGHTING 8W - 50 - 7
RHD BUILT-UP-EXPORT
FROM
FROM HEADLAMP
S226 SWITCH
(8W-50-3) (8W-50-3)
C D DIMMER INSTRUMENT
SWITCH CLUSTER
2 4 HIGH (8W-40-14)
HEADLAMP BEAM
BEAM OUTPUT
SELECT 5 C1
1 3 1 3
SWITCH
2 2 1 FLASH L3
2 LOW 16
3 HIGH RD/OR
1 3
L4 L3
16 16
VT/WT RD/OR

S213
L3
16
RD/OR
S3 C4 S7 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
4 3 5 16
10A 10A 10A 10A
(8W-12-7) (8W-12-6) (8W-12-7) (8W-12-6)

10 C1 9 C1 1 C1 11 C1
L43 L33 S133 L34
20 20 20
(8W-12-7)
VT RD L44 RD/OR
9 2 20
C106 VT/RD
13 6
L43 C106
18 L44 L44 L34
VT 20 18 18
VT/RD VT/RD RD/OR
L33
S162 18 B12 C100 S163
(8W-12-7) RD (8W-12-7)
B A L44 B A
20
LEFT VT/RD RIGHT
HEADLAMP HEADLAMP
C 3 C
Z1 FUSED HEADLAMP Z1
18 RIGHT LEVELING 18
BK LOW SWITCH BK
BEAM (8W-50-19)
S103 OUTPUT S102
(8W-15-10) (8W-15-10)
Z1 (8W-15-12) Z1 (8W-15-12)
18 18
BK/WT BK
11 4 C106
Z1 Z1
20 20
BK/WT BK

G106
(8W-15-10)
(8W-15-12)
XJI05007 J008W-7

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 8W - 50 - 8 8W-50 FRONT LIGHTING XJ
EXCEPT BUILT-UP-EXPORT
BATT A0 (8W-10-11) ST-RUN A21 (8W-10-17)
POWER JUNCTION
13 DISTRIBUTION BLOCK
FUSE CENTER FUSE (8W-12-2)
7 (8W-10-2) 9
30A 10A
(8W-10-22) (8W-12-13)
6

S13 C4
F87
A3 A3 20
14 14 WT/BK
RD/WT RD/WT
LHD RHD
D1 C100 6
FUSED DAYTIME BASE FULL OPTIONS
B(+) RUNNING
A3 LAMP
F87
14 MODULE 20 S225
RD/WT (8W-50-18) WT/BK (8W-12-13)

5 C201

F87
8 20
HEADLAMP WT/BK
FUSED
B(+) SWITCH
(8W-50-2) A3 S216
14 (8W-12-13)
HEADLAMP RD/WT
SWITCH
OUTPUT 2 8
2 HEADLAMP
DELAY
L2 MODULE
14 FUSED FUSED
LG B(+) IGNITION
SWITCH
OUTPUT
(ST-RUN)
HEADLAMP
TIMER GROUND

HEADLAMP
6 4
SWITCH
(8W-50-2)
L2 Z1
14 18 GROUND
LG BK

2 Z1
18
HEAD- HEADLAMP BK
LAMP BEAM
SWITCH SELECT
OUTPUT
S207
SWITCH (8W-15-16)
(8W-50-4) Z1
(8W-50-5) 14
BK

G108
(8W-15-16)
J008W-7 XJI05008

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-50 FRONT LIGHTING 8W - 50 - 9
BUILT-UP-EXPORT
BATT A0 (8W-10-11) ST-RUN A21 (8W-10-17)
(8W-10-13)
POWER JUNCTION
DISTRIBUTION BLOCK
GAS DIESEL
CENTER FUSE (8W-12-2)
(8W-10-2) 9
13 14 (8W-10-7) 10A
FUSE FUSE (8W-12-13)
7 8
30A 30A S13 C4
6 (8W-10-22) (8W-10-24)
7 F87
20
WT/BK

LHD RHD

A3 BASE FULL OPTIONS

14
RD/WT
S225
D1 C100 F87 (8W-12-13)
20 F87
WT/BK 20
A3 WT/BK F87
14 20
RD/WT WT/BK

5 C201
8
FUSED HEADLAMP S216
B(+) SWITCH (8W-12-13)
(8W-50-3) A3 F87
14 20
HEADLAMP RD/WT WT/BK
SWITCH
OUTPUT 2 8
2 HEADLAMP
DELAY
L2 MODULE
14 FUSED FUSED
LG B(+) IGNITION
SWITCH
OUTPUT
(ST-RUN)
HEADLAMP
TIMER GROUND

HEADLAMP
6 4
SWITCH
L2 (8W-50-3)
Z1
14 18 GROUND
LG BK

S226 Z1
18
(8W-50-3)
L2 BK
14
LG S207
(8W-15-16)
2 Z1
HEAD- HEADLAMP 14
LAMP BEAM BK
SWITCH SELECT
OUTPUT G108
SWITCH
(8W-50-6) (8W-15-16)
XJI05009 J008W-7
(8W-50-7)

Downloaded from www.Manualslib.com manuals search engine

 8W - 50 - 10 8W-50 FRONT LIGHTING XJ
EXCEPT BUILT-UP-EXPORT
BATT F34 (8W-10-28) TURN
LEFT SIGNAL/
HEADLAMP
TURN HAZARD
SWITCH SIGNAL SWITCH
1 PARK
10 (PART OF
2 HEAD
0 2 MULTI-
1 0 OFF L61
(8W-50-2) FUNCTION
20 SWITCH)
LG/WT
9 (8W-52-2)
S209
L7 (8W-52-5)
18
L61
BK/YL
20
LG/WT
S206
(8W-12-10) B10 C100
F4
L7 L61
18 20
BK/YL LG/WT
LHD RHD
3 C106
45 C201 L61
20
LG

L7 S105
18
L61
BK/YL
20
M3 C4 LG
JUNCTION 2
BLOCK LEFT
(8W-12-2) SIDE
FUSE MARKER
7 1 LAMP
10A L77 L61
(8W-12-10) 20 18
BR LG

6 C2 S104
(8W-12-10)
L77 L61 L77
L77 18 18
20 BR LG
LEFT 18
BR FRONT BR LEFT
2 1
PARK/ 2 1 FRONT
7 C106 TURN PARK/
L77 SIGNAL TURN
L77 20 3 SIGNAL
20
LAMP 3
BR/YL Z1 Z1 LAMP
BR/YL NO. 1
18 18 NO. 2
BK BK

B6 S158
(8W-15-7)
FOG
LAMP S103
RELAY (8W-15-7)
Z1
NO. 1 18
B9 (IN PDC) BK
(8W-50-14)
(8W-50-16)
11 C106
Z1
20
BK/WT

RHD G106
LHD (8W-15-7)
J008W-7 XJI05010

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-50 FRONT LIGHTING 8W - 50 - 11
BUILT-UP-EXPORT
BATT F34 (8W-10-29)
TURN
LEFT SIGNAL/
HEADLAMP
TURN HAZARD
SWITCH SIGNAL SWITCH
1 PARK
10 (8W-52-3)
2 2 HEAD
0 1 (8W-52-4)
0 OFF L61
(8W-50-3) 20
9 LG/WT
L7
18
BK/YL S209
(8W-52-6)
S206 L61
(8W-12-11) 20
L7 LG/WT
18
B10
BK/YL C100
F4
LHD RHD L61
20
45 C201 LG/WT
3 C106
L7 L61
18 20
BK/YL LG
M3 C4
JUNCTION S105
BLOCK
(8W-12-2) L61
FUSE 18
7 LG
10A 1 C114
(8W-12-11)
L61 L61 L61
18 18 18
6 C2 LG LG GY

2 LEFT 2 LEFT 1
DIESEL GAS
FRONT FRONT LEFT
TURN TURN REPEATER
L77 L77 SIGNAL SIGNAL LAMP
18 20 1 1 2
BR/YL BR/YL
LAMP LAMP
Z1 Z1 Z1
NO. 1 NO. 2
18 18 18
S169 BK BK BK
(8W-50-17)
S158 2 C114
(8W-15-10)
B6 Z1 (8W-15-12) Z1
FOG 18 18
LAMP BK BK
L77
20 RELAY S103
BR/YL NO. 1 (8W-15-10)
(IN PDC) (8W-15-12)
B9 Z1
7 C106 (8W-50-14)
Z1 18
L77 20 BK/WT
20 BK
BR/YL 11 C106
Z1
1 20
LEFT BK/WT
CITY
LAMP G106
2 LHD
(8W-15-10)
RHD (8W-15-12)
XJI05011 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 50 - 12 8W-50 FRONT LIGHTING XJ
EXCEPT BUILT-UP-EXPORT
BATT F34 (8W-10-28) TURN
HEADLAMP RIGHT SIGNAL/
SWITCH TURN HAZARD
1 PARK SIGNAL SWITCH
2 HEAD 1 (8W-52-2)
0 1 2
0 OFF
(8W-50-2) L60
9 20
TN
L7
18 S212
BK/YL (8W-52-7)
S206 L60
(8W-12-10) 20
L7 TN
18 B9
BK/YL
C100
F3
LHD RHD L60
20
45 C201 TN
10 C106
L7
18 L60
BK/YL 20
TN
M3 C4
JUNCTION S100
BLOCK
(8W-12-2)
FUSE L60
23 20
10A TN
(8W-12-24) 2 RIGHT
SIDE
MARKER
5 C1
L78
1 LAMP
20 L78
DG/YL 20
DG/YL
14 C106
L78
20
DG/YL

S101
L78 L60 L78 L60
18 18 18 18
DG/YL TN DG/YL TN
2 1 RIGHT 2 1 RIGHT
FRONT FRONT
PARK/ PARK/
TURN TURN
3 3
SIGNAL SIGNAL
Z1 Z1
LAMP LAMP
18 18
BK NO. 1 BK NO. 2
S102
Z1 18BK (8W-15-7)
4 C106
Z1
20
BK
LHD
G106
RHD
J008W-7 (8W-15-7) XJI05012

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-50 FRONT LIGHTING 8W - 50 - 13
BUILT-UP-EXPORT
BATT F34 (8W-10-29)
TURN
SIGNAL/
HEADLAMP RIGHT
TURN HAZARD
SWITCH
SIGNAL SWITCH
1 PARK
1 (8W-52-3)
2 2 HEAD
0 1 (8W-52-4)
0 OFF L60
(8W-50-3) 20
9 TN
L7
18
BK/YL

S206 S212
(8W-12-11) (8W-52-8)
L7 L60
18 20
BK/YL TN
B9
LHD RHD F3 C100

45 C201 L60
20
TN
L7 10 C106
18
BK/YL L60
20
M3 C4 TN
JUNCTION
BLOCK S116
(8W-12-2)
FUSE L60
23 18
10A TN
(8W-12-24) 1 C115

L60 L60 L60

18 18
5 C1 18
TN GY
TN
2 RIGHT 2 RIGHT 1
GAS DIESEL
FRONT FRONT RIGHT
TURN TURN REPEATER
SIGNAL SIGNAL LAMP
L78 L78 2
1 1
20 18 LAMP LAMP
DG/YL DG/YL Z1 NO. 1 Z1 NO. 2 Z1
18 18 18
BK BK BK
2 C115
Z1
14 C106 18
BK
L78 S102
20
(8W-15-10)
DG/YL Z1
(8W-15-12)
18
1 BK
RIGHT Z1
CITY 20 4 C106
BK
LAMP Z1
2 20
BK

LHD G106
RHD (8W-15-10)
(8W-15-12)

XJI05013 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 50 - 14 8W-50 FRONT LIGHTING XJ
GAS EXCEPT DRL
BATT F34 (8W-10-28) S206
(8W-10-29) (8W-12-10)
HEADLAMP L7 (8W-12-11)
SWITCH 18
1 PARK BK/YL
2 HEAD LHD RHD
0 2 0 OFF
1 45 C201
(8W-50-2)
(8W-50-3) FROM
9
C106 L7
L7 18
18 (8W-50-4)
(8W-50-5) BK/YL
BK/YL
M3 C4
E JUNCTION
BLOCK
(8W-12-2)
FUSE
FROM 7
FOG L33 10A
20 (8W-12-10)
LAMP (8W-12-11)
12 C106 RD/WT
RELAY
NO. 2 6 C2
(IN PDC) BUILT-UP- EXCEPT
Z1 EXPORT L33 BUILT-UP- L77
20 (8W-50-15) 20 20
EXPORT
BK F RD/WT BR/YL

POWER
S103 B10 B6
DISTRIBUTION
(8W-15-10) FOG
LAMP CENTER
Z1 Z1 RELAY (8W-10-2)
18 20 NO. 1
BK/WT BK L77
20
B8 B9 BR/YL
11 C106
Z1 L139
20 20
(2.5L) BK VT
(4.0L (4.0L A/T (4.0L LHD M/T
ABS) EXCEPT ABS) EXCEPT ABS)
A5 C100
L139
20
Z1 CONTROLLER Z1 ENGINE VT
7 C106
20 ANTI-LOCK 20 STARTER
BK BRAKE BK MOTOR
GROUND RELAY GROUND RELAY
B19 (IN PDC) C10 (IN PDC)
(8W-35-4) (8W-21-5) G
Z1 Z1 Z1 Z1 L77
20 20 20 20 TO 20
BK/WT BK BK BK FRONT BR/YL
FOG
LAMP
Z1 SWITCH
20 (8W-50-15)
BK EXCEPT
BUILT-UP-EXPORT BUILT-UP-EXPORT
S132
(8W-15-4)
Z1 (8W-15-5) 1
16 (8W-15-6) FUSED LEFT
BK (8W-15-8) HEAD CITY TO
G106 (8W-15-9) LAMP S104
LAMP
(8W-15-10) G106 SWITCH (8W-50-11) (8W-12-10)
(8W-15-7) OUTPUT
J008W-7 (8W-15-10) XJI05014

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-50 FRONT LIGHTING 8W - 50 - 15
GAS EXCEPT DRL
BATT F61 (8W-10-33)
FROM POWER
FOG LAMP DISTRIBUTION
RELAY NO. 1 CENTER
(IN PDC) B15 B11 (8W-10-2)
(8W-50-14) FOG
LAMP
G RELAY
NO. 2

B13 B12

L139 L92 Z1 L39

20 20 20 20
VT PK BK LB

1 3
FRONT
FOG A4 C100 8 C106
F
SWITCH ON LAMP
ILLUM. INDICATOR SWITCH TO L39
FOG LAMP 20
RELAY NO. 1 LB
(IN PDC)
4 2 (8W-50-14)

S106
EXCEPT L39 L39
BUILT-UP- BUILT-UP- 20 20
EXPORT EXPORT LB LB
2 2
LEFT RIGHT
FOG FOG
Z1 L39 L39 LAMP LAMP
20 20 20 1 1
BK LB LB Z1 Z1
20 20
BK BK

S103 S102
S208 S230 (8W-15-7) (8W-15-7)
(8W-15-14) (8W-12-11) (8W-15-10) (8W-15-10)
EXCEPT
BUILT-UP- BUILT-UP-
EXPORT EXPORT
Z1 L39 L39 Z1
14 18 20 Z1 Z1 18
BK LB LB 18 18 BK
BK BK/WT

11 4 C106
3
FOG DIODE
LAMP MODULE
SWITCH (8W-51-9) Z1 Z1
OUTPUT (8W-51-10) 20 20
BK/WT BK

G107 G106
(8W-15-14) (8W-15-7)
(8W-15-10)
XJI05015 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 50 - 16 8W-50 FRONT LIGHTING XJ
DRL
INSTRUMENT BATT F34
HIGH M3 C4 (8W-10-28)
CLUSTER
BEAM (8W-40-14) JUNCTION HEADLAMP
INDICATOR BLOCK
DRIVER SWITCH
(8W-12-2) 1 PARK
5 C1 FUSE L7 2 HEAD
DAYTIME 7 18
0 2 0 OFF
HIGH BK/YL 1
G34 RUNNING 10A (8W-50-2)
BEAM (8W-12-10)
16
INDICATOR
LAMP 45 C201
RD/GY MODULE 9
DRIVER L7 L7
4 (8W-50-18) 18 18
6 C2 BK/YL BK/YL
D4 C100
7 C106 L77
G34 G34 L77 L77 20 S206
16 16 20 20 BR (8W-12-10)
RD/GY RD/GY BR/YL BR/YL
TO
S104 BATT F61 (8W-10-33)
(8W-12-10)
POWER
DISTRIBUTION
B10 B6 CENTER
FOG B15 B11 (8W-10-2)
LAMP FOG
RELAY LAMP
NO. 1 RELAY
NO. 2
B8 B9
B13 B12

Z1 L139 L39
20 20 20
BK VT LB
Z1 20BK
A5 C100 L92 8 C106
20
L139 L39
PK
20 20
VT A4 C100 LB
1 3
FRONT S106
FOG
L39 L39
SWITCH ON LAMP 20 20
ILLUM. INDICATOR SWITCH LB LB
2 2
LEFT RIGHT
FOG FOG
4 2 LAMP LAMP
1 1
Z1 L39 Z1 Z1
20 20 20 20
BK LB BK BK

S103 S102
S132 S208 (8W-15-7) (8W-15-7)
(8W-15-4) (8W-15-14) Z1 Z1
Z1 (8W-15-5) Z1 18 18
16 14 BK BK
BK BK
11 4 C106
Z1 Z1
20 20
G106 G107 BK/WT BK
(8W-15-7) (8W-15-14)
G106
(8W-15-7)
J008W-7 XJI05016

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-50 FRONT LIGHTING 8W - 50 - 17
DIESEL
M3 C4 BATT F34 (8W-10-29)
L7
JUNCTION 18 HEADLAMP
BLOCK BK/YL SWITCH
(8W-12-2) 1 PARK
FUSE LHD RHD 2 HEAD
7 0 2 0 OFF
10A 45 C201 1
(8W-50-3)
(8W-12-11)
9
L7 L7
18 18
BK/YL BK/YL
6 C2
S206
L77 (8W-12-11)
18
BR/YL
BATT F61 (8W-10-35)
S169 POWER
(8W-12-12) DISTRIBUTION
B15 B11
FOG CENTER
L77 L77
LAMP (8W-10-7)
20 20
BR/YL BR/YL RELAY

7 C106 A5 C100 B13 B12

L77 L139 L92 Z1 L39

20 20 20 20 20
BR VT PK BK/YL LB

CONTROLLER 8 C106
TO ANTI-LOCK L39
BRAKE 20
LEFT LB
CITY GROUND RELAY
LAMP B19 (IN PDC)
(8W-50-11) (8W-35-5) S106
1 3
FRONT L39 L39
FOG 20 20
ENGINE LB LB
LAMP Z1 STARTER
SWITCH ON SWITCH 20 2 2
MOTOR
ILLUM. INDICATOR BK/YL LEFT RIGHT
GROUND RELAY
FOG FOG
D13 (IN PDC)
(8W-21-6) 1 LAMP 1 LAMP
Z1 Z1 Z1
4 2 20 20 20
BK BK BK
L39 A4 C100
20
Z1 LB
S141 S103 S102
20 (8W-15-11) (8W-15-12) (8W-15-12)
Z1 Z1 Z1
BK S230 12 18 18
L39 L39 (8W-12-12) BK BK/WT BK
S208 18 20
S132
(8W-15-15) LB LB 11 4 C106
3 (8W-15-11)
Z1 Z1 Z1
14 DIODE Z1
FOG 12 20 20
BK LAMP MODULE BK/WT BK
BK
SWITCH (8W-51-9)
G107 OUTPUT (8W-51-10) G106 G106
(8W-15-15) (8W-15-12) (8W-15-12)

XJI05017 J008W-7

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 8W - 50 - 18 8W-50 FRONT LIGHTING XJ
DRL
BATT A0 (8W-10-11) ST-RUN A21 (8W-10-17)

POWER JUNCTION
DISTRIBUTION BLOCK
13 CENTER (8W-12-2)
FUSE (8W-10-2) FUSE
7 10 RIGHT
15A FUSED VEHICLE
RIGHT HEADLAMP
30A
(8W-10-22) (8W-12-14) VEHICLE SPEED
6 LOW (8W-50-4) SPEED
BEAM SENSOR
SENSOR
S12 C4 OUTPUT SIGNAL (8W-30-12)
B 3
F20
18 L44 G7
WT 18 18
VT/RD WT/OR
1 C201
13 C106 S108
F20 (8W-30-12)
18
WT
L44 G7
20 20
E9 C100 VT/RD WT/OR

F20 S133 4 C107

18 (8W-12-7)
WT
A3 L44 G7
14 S159 18 20
RD/WT (8W-12-14) VT/RD WT/OR
6 5 10 7
FUSED FUSED FUSED VEHICLE DAYTIME
B(+)
DIMMER
IGNITION RIGHT SPEED RUNNING
SWITCH LOW SENSOR LAMP
SWITCH HIGH
OUTPUT BEAM SIGNAL
HIGH
(ST-RUN) OUTPUT
BEAM MODULE
BEAM INDICATOR
OUTPUT GROUND DRIVER
1 8 4
L3 G34
16 16
RD RD/GY
Z12
D3 C100 16
BK/TN
L3 B10
16 FOG
RD/OR LAMP
G34
S213 16 RELAY
(8W-50-4) G106 RD/GY NO. 1
L3 (8W-15-7)
16 B13 (IN PDC)
RD/OR (8W-50-16)

16 C201 D4 C100
L3 G34
16 16
RD/OR RD/GY
S7 C4
JUNCTION 5 C1
BLOCK HIGH INSTRUMENT
(8W-12-2) BEAM CLUSTER
FUSE FUSE INDICATOR (8W-40-14)
3 16 DRIVER
10A 10A
(8W-12-6) (8W-12-6)

J008W-7 XJI05018

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 XJ 8W-50 FRONT LIGHTING 8W - 50 - 19
BUILT-UP-EXPORT
DIMMER HEADLAMP
LHD RHD SWITCH BEAM
LOW SELECT
22 C201 BEAM SWITCH
OUTPUT
(8W-50-6)
1 (8W-50-7)
S3 C4
JUNCTION L4
BLOCK 16
(8W-12-2) VT/WT
FUSE FUSE
4 5
10A 10A
(8W-12-7) (8W-12-7)

10 C1 1 C1
L43 L44
20 20
VT VT/RD

S133
9 C106 (8W-12-7)

2
HEADLAMP
L44
LEVELING 20
L43 L13
18 SWITCH VT/RD
20
VT BR/YL
E18 C100
L13
13 C106
3 5
20
L44 L44 Z15
BR/YL
20 20 20 L44
VT/RD VT/RD BK/GY 1 C106 18
B12 VT/RD
C100 G107 L13
F6 (8W-15-15) 18
BR/YL

S162 S164 S163

(8W-12-7) (8W-12-7)
L43 L13 L13 L44
18 18 18 18
VT BR/YL BK VT/RD
1 2 2 1
LEFT RIGHT
LOGIC HEADLAMP LOGIC HEADLAMP
LEVELING LEVELING
M MOTOR M MOTOR
3 3
L43 Z15 Z15 L44
18 18 18 18
VT BK/GY BK/GY VT/RD

S165
(8W-15-10)
Z15
(8W-15-12)
B 18 B
LEFT BK/GY RIGHT
HEADLAMP 5 C106 HEADLAMP
(8W-50-6) Z15 (8W-50-6)
(8W-50-7) 16 (8W-50-7)
BK/GY

LHD G106
RHD (8W-15-10)
XJI05019 (8W-15-12) J008W-7

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 XJ 8W - 51 REAR LIGHTING 8W - 51 - 1

8W-51 REAR LIGHTING

Component Page Component Page
Back-Up Lamp Switch . . . . . . . . . . . . . . 8W-51-6, 7 Left Rear Fog Lamp . . . . . . . . . . . . . . . 8W-51-11, 12
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-51-2 Left Tail/Stop Lamp . . . . . . . . . . . . . . . . . . 8W-51-3
Center High Mounted Stop Lamp . . . . . . . . 8W-51-4 Left Turn Signal Lamp . . . . . . . . . . . . . . . . 8W-51-5
Diode Module . . . . . . . . . . . . . . . . . . . . 8W-51-9, 10 License Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4
Driver Power Lock/Window Switch . . . . 8W-51-9, 10 Park/Neutral Position Switch . . . . . . . . . . . 8W-51-6
Fog Lamp Relay . . . . . . . . . . . . . . . . . . 8W-51-9, 10 Power Distribution Center . . . . . . . . . . . . . 8W-51-2
Fog Lamp Relay No. 2 . . . . . . . . . . . . . . 8W-51-9, 10 Powertrain Control Module . . . . . . . . . . . . 8W-51-6
Front Fog Lamp Switch . . . . . . . . . . . . . 8W-51-9, 10 Rear Fog Lamp Indicator . . . . . . . . . . . 8W-51-11, 12
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2 Rear Fog Lamp Relay . . . . . . . . . . . . . . 8W-51-9, 10
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-51-6, 7 Rear Fog Lamp Switch . . . . . . . . . . . . 8W-51-11, 12
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . 8W-51-9, 10 Right Back-Up Lamp . . . . . . . . . . . . . . . . . 8W-51-8
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-51-2 Right License Lamp . . . . . . . . . . . . . . . . . . 8W-51-4
Fuse 23 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2 Right Rear Fog Lamp . . . . . . . . . . . . . 8W-51-11, 12
Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-51-2 Right Tail/Stop Lamp . . . . . . . . . . . . . . . . . 8W-51-3
G107 . . . . . . . . . . . . . . . . . . . . . . 8W-51-9, 10, 11, 12 Right Turn Signal Lamp . . . . . . . . . . . . . . . 8W-51-5
G302 . . . . . . . . . . . . . . . . . . . . . 8W-51-3, 5, 8, 11, 12 Switch Illumination . . . . . . . . . . . . . . . 8W-51-11, 12
G303 . . . . . . . . . . . . . . . . . . . . . 8W-51-3, 5, 8, 11, 12 Torque Converter Clutch Solenoid . . . . . . . 8W-51-6
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4 Trailer Tow Connector . . . . . . . . . . . . . 8W-51-3, 5, 8
Headlamp Switch . . . . . . . . . . . . . . . . 8W-51-2, 9, 10 Transmission Control Module . . . . . . . . . . . 8W-51-6
Junction Block . . . . . . . . . . . . . . 8W-51-2, 6, 7, 9, 10 Transmission Range Sensor . . . . . . . . . . . . 8W-51-6
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . 8W-51-8 Turn Signal/Hazard Switch . . . . . . . . . . . . . 8W-51-5
Left License Lamp . . . . . . . . . . . . . . . . . . . 8W-51-4

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 8W - 51 - 2 8W-51 REAR LIGHTING XJ

(8W-10-28) BATT A0 (8W-10-11)

BATT F34 (8W-10-13)
(8W-10-29)
POWER
4 DIESEL GAS
DISTRIBUTION
HEADLAMP A18 A9 CENTER
SWITCH FUSE FUSE
(8W-10-2)
1 PARK (8W-10-7)
19 23
2 2 HEAD 15A 15A
0 1 0 OFF (8W-10-32) (8W-10-33)
(8W-50-2) A17 A10
(8W-50-3)
9

L7 F32
18 20
BK/YL PK/DB

S206 F8 C100
(8W-12-10)
(8W-12-11) F32
20
L7 PK/DB
18 6
BK/YL BRAKE
LHD RHD LAMP
SWITCH
(8W-33-4)
45 C201 (8W-33-5)
5

L50
20
L7
WT/TN
18
BK/YL
S203
M3 C4 (8W-10-32)
(8W-10-33)
JUNCTION L50
BLOCK 20
(8W-12-2) WT/TN
FUSE FUSE
7 23
10A 10A LHD RHD
(8W-12-10) (8W-12-24)
(8W-12-11)
24 C200 24 C204
2 C7 6 C7
L77 L78
18 18
L50
BR/YL DG/YL
20
WT/TN
7 C321

L78
18
DG/YL

A B C

TO TO TO
S311 RIGHT S302
(8W-51-3) TAIL/ (8W-51-3)
(8W-51-4) (8W-51-4)
STOP
LAMP
(8W-51-3)

J008W-7 XJI05102

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 XJ 8W-51 REAR LIGHTING 8W - 51 - 3

FROM FROM
FUSE S203
(8W-51-2)
7 (JB)
(8W-51-2) C
A
L50
20
L77 WT/TN
18
BR/YL S302
(8W-10-32)
S311
(8W-12-10) FROM L50 (8W-10-33)
L77 (8W-12-11) FUSE 20
TRAILER TOW OTHER WT/TN
18
BR/YL
23 (JB)
6 C323 (8W-51-2)
TRAILER TOW OTHERS 6 C321
S336 B
(8W-54-3)
7 C323
L78 L50
L77 L77 18 18
20 18 L50 DG/YL WT/TN
BR/YL BR/YL 20
WT/TN
S340 6 C322
(8W-12-10)
(8W-12-11) L50
L77 L77 L77 18
20 18 18 WT/TN
BR/YL BR/YL BR
2 3 LEFT 2 3 RIGHT
TAIL/ TAIL/
7 C322 STOP STOP
1 LAMP 1 LAMP
5 Z1 Z1
18 18
TRAILER BK BK
TOW
S341 S348
CONNECTOR (8W-15-17) (8W-15-19)
(8W-54-2)
(8W-15-18) Z1 (8W-15-20)
8 BUILT- EXCEPT BUILT- 18
UP-EXPORT UP-EXPORT BK
Z1 Z1
16 18 2 C321
BK BK
Z1
18
2 C322 BK
TRAILER TOW OTHER
S310
Z1 Z1 (8W-15-19)
14 18 (8W-15-20)
BK BK Z1
14
S337 BK RHD LHD
(8W-15-17)
Z1 (8W-15-18) Z1 Z1
14 12 16
BK S309 BK BK
(8W-15-17)
2 C323 Z1 Z1
(8W-15-18)
14 12
BK BK

G302 G303
(8W-15-17) (8W-15-19)
(8W-15-18) (8W-15-20)
XJI05103 J008W-7

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 8W - 51 - 4 8W-51 REAR LIGHTING XJ

FROM
FUSE FROM
7 (JB) S203
(8W-51-2) (8W-51-2)
A C

L77 L50
18 20
BR/YL WT/TN

S311 S302
(8W-12-10) (8W-10-32)
(8W-12-11) (8W-10-33)
L77 L50
18 20
BR/YL WT/TN
2 C327 5 C326
L77 L50
18 18
BR/YL WT/TN
4 C311
11 C310
L77
1 C333
18
BR/YL L50
18
1 C330 DG/WT
EXCEPT
BUILT-UP-EXPORT BUILT-UP-EXPORT

L78 L78
18 18
BK/YL BK/YL

S333 2
(8W-12-11) CENTER
1 1 1 HIGH
LEFT RIGHT LICENSE MOUNTED
LICENSE LICENSE LAMP STOP
2 LAMP 2 LAMP 2 LAMP
S332 1
(8W-15-21)
Z1 Z1
18 18
BK BK

2 C330 Z1
18
Z1 BK
18
BK

S334
(8W-15-21) 2 C333
Z1
18
BK
9 C310
6 C311
Z1 Z1
18 18
BK BK

G304
J008W-7 (8W-15-21) XJI05104

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 XJ 8W-51 REAR LIGHTING 8W - 51 - 5

TURN
SIGNAL/
LEFT RIGHT
TURN TURN
HAZARD
SIGNAL SIGNAL SWITCH
9 3 (8W-52-2)
L63 L62 (8W-52-3)
20 20
DG/RD BR/RD
LHD RHD LHD RHD

26 C200 12 C204 25 C200 11 C204

TRAILER TOW OTHERS
S312
1 C323 (8W-70-2)
S335 L62
20
(8W-54-3)
BR/RD

L63
1 C321
20
DG/RD L62
18
1 C322 BR/RD
L63
18 2
DG/RD
RIGHT
2 TURN
LEFT
SIGNAL
TURN 1 LAMP
SIGNAL
1 LAMP Z1
Z1 18
18 BK
BK

S341 S348
EXCEPT BUILT- (8W-15-17) (8W-15-19)
(8W-15-18) (8W-15-20)
UP-EXPORT BUILT-UP-EXPORT
TRAILER Z1 Z1 Z1
TOW 18 16 18
CONNECTOR BK BK BK
(8W-54-2)
8
2 C322 2 C321
TRAILER TOW OTHERS

Z1 Z1 Z1
14 18 18
BK BK Z1
BK
14
S337 BK
Z1
(8W-15-17) S310
(8W-15-18) (8W-15-19)
14
BK (8W-15-20)
2 C323 LHD RHD

Z1
14 Z1 Z1
BK 16 12
BK BK
S309
(8W-15-17)
Z1
(8W-15-18)
12
BK
G303
G302 (8W-15-19)
(8W-15-17) (8W-15-20)
XJI05105 (8W-15-18) J008W-7

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 8W - 51 - 6 8W-51 REAR LIGHTING XJ
GAS
ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
FUSE (8W-12-2)
10
15A
(8W-12-14)

S12 C4
F20
18
WT
LHD RHD

1 C201
F20
18
WT

A9
C100
E9
S159
(8W-12-14)
F20
18
WT
4.0L A/T 4.0L M/T 2.5L M/T 2.5L A/T

1 C113 11 C107 11 C107

3
TRANSMISSION F20
18
RANGE F20
WT
R SENSOR 18
(8W-31-6) WT S161
A 1
6
BACK-UP PARK/ F20
L10 LAMP NEUTRAL 18
18 R R WT
SWITCH POSITION
BR/LG
SWITCH
(8W-31-2)
B 3
S142 L10
18 L10 A
L10 L10 BR/LG 18 TORQUE
18 18 BR/LG CONVERTER
BR/LG BR/LG
12 C107 CLUTCH
2 C113 12 C107 SOLENOID
(8W-31-2)
B
4.0L A/T 4.0L M/T 2.5L M/T 2.5L A/T
K54
E3
18 C100 18
A15 OR/BK
BACK-UP TRANSMISSION
LAMP CONTROL LHD RHD
FEED 11 C2
MODULE 16 C200 23 C204 TORQUE POWERTRAIN
(4.0L)
L10 L10 CONVERTER CONTROL
(8W-31-6)
18 18 CLUTCH MODULE
BR/LG BR/LG SOLENOID (8W-30-15)
CONTROL
D E

TO TO
S303 S303 RHD
(8W-51-8) (8W-51-8) LHD
J008W-7 XJI05106

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 XJ 8W-51 REAR LIGHTING 8W - 51 - 7
DIESEL
ST-RUN A21 (8W-10-17)
JUNCTION
BLOCK
(8W-12-2)
FUSE
10
15A
(8W-12-14)

S12 C4
F20
18
WT

LHD RHD

1 C201

A9
C100
E9

F20
18
WT

7 C111
F20
18
WT

B
BACK-UP
LAMP
R SWITCH

A
L10
18
BR/LG

5 C111
L10
18
BR/LG
A15
C100
E3
L10
18
BR/LG

LHD RHD

16 C200 23 C204

L10 L10
18 18
BR/LG BR/LG
D E

TO TO
S303 S303 RHD
(8W-51-8) (8W-51-8) LHD
XJI05107 J008W-7

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 8W - 51 - 8 8W-51 REAR LIGHTING XJ
FROM FROM
C200 C204
(8W-51-6) (8W-51-6)
(8W-51-7) (8W-51-7)
D E

LHD RHD

S303
L10 L10
18 18
BR/LG BR/LG
TRAILER
TOW OTHERS 5 C321
5 C323
S339
(8W-54-2)
L10
18
5 C322 BR/LG
L10
18
BR/LG
2 2
LEFT RIGHT
BACK-UP BACK-UP
1 LAMP LAMP
1
Z1 Z1
18 18
BK BK
S341
(8W-15-17) S348
EXCEPT BUILT- (8W-15-18) (8W-15-19)
UP EXPORT BUILT-UP-EXPORT (8W-15-20)

Z1 Z1
18 16 Z1
TRAILER BK BK 18
TOW BK
CONNECTOR
(8W-54-2) TRAILER 2 C322
8 TOW OTHER
2 C321
Z1 Z1 Z1
14 18 18
BK BK BK

S337 Z1
(8W-15-17) 14 S310
Z1 (8W-15-19)
(8W-15-18) BK
14 (8W-15-20)
BK
2 C323 LHD RHD

Z1 14BK Z1 Z1
16 12
S309 BK BK
(8W-15-17)
Z1 (8W-15-18)
12
BK
G303
G302 (8W-15-19)
(8W-15-17) (8W-15-20)
J008W-7 (8W-15-18) XJI05108

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 XJ 8W-51 REAR LIGHTING 8W - 51 - 9
LHD BUILT-UP-EXPORT
RUN-ACC A31 (8W-10-15)
FRONT HEADLAMP (8W-10-16)
FOG FOG HEAD SWITCH JUNCTION
LAMP LAMP LAMP (8W-50-3) BLOCK
SWITCH SWITCH (8W-12-2)
OUTPUT
SWITCH OUTPUT FUSE
(8W-50-15) 18
2 2
(8W-50-17) 10A
(8W-12-19)
L39 L2
20 14
LB LG S4 C4
F83
18
S230 S226 YL/DG
(8W-12-12) (8W-50-3)
(8W-50-15) 44 C201
L39 L39 L2
20 18 16 F83
LB LB LG 18
YL/DG
3 1
A4 C100 DIODE
MODULE 39 C200
F83
18
YL/DG
2
GAS DIESEL 3 C305

L92 F83
20 18
PK YL/DG
3 C2
B15 L25 DRIVER F83
FUSED
FOG FOG 18 IGNITION POWER 18
LAMP LAMP BR SWITCH YL/DG
SWITCH LOCK/
L92 RELAY OUTPUT
20 OUTPUT (RUN-ACC)
WINDOW
(IN PDC) SWITCH
PK
(8W-50-17) (8W-62-3)
5 1
B15 REAR
FOG FOG
FOG 86 30
LAMP LAMP LAMP
SWITCH RELAY RELAY
OUTPUT NO. 2 LOGIC
(IN PDC)
(8W-50-15)
85 87

2 3 4

L36 Z1
18 18 L38 L38
LG/BK BK 18 18
BR/WT BR/WT
F
G107 G H
TO (8W-15-15)
REAR TO TO
FOG REAR C200
LAMP FOG (8W-51-11)
SWITCH LAMP
(8W-51-11) SWITCH
(8W-51-11)
XJI05109 J008W-7

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 8W - 51 - 10 8W-51 REAR LIGHTING XJ
RHD BUILT-UP-EXPORT
RUN-ACC A31 (8W-10-15)
FRONT HEADLAMP (8W-10-16)
FOG FOG HEAD SWITCH JUNCTION
LAMP LAMP LAMP (8W-50-3) BLOCK
RELAY SWITCH (8W-12-2)
OUTPUT
SWITCH OUTPUT FUSE
(8W-50-15) 18
2 (8W-50-17)
2 C1 10A
(8W-12-20)
L39 L2
20 14
LB LG S4 C4

S230 S226
(8W-12-12) (8W-50-3) F83
18
L39 L39 L2 YL/DG
20 18 16
LB LB LG
A4 C100 3 1
S232
DIODE (8W-12-20)
MODULE
L92
20 F83
PK 18
2 YL/DG
F83
GAS DIESEL 18
YL/DG
L92
20
PK

B15 L25
FOG FOG 18
LAMP LAMP BR
L92 RELAY RELAY
OUTPUT
3 C300
20 (IN PDC)
PK
(8W-50-17)

5 1
B15 REAR
FOG FOG FOG
LAMP LAMP 86 30
LAMP
RELAY RELAY RELAY F83
OUTPUT
NO. 2 LOGIC
18
(IN PDC) YL/DG
(8W-50-14)
85 87
S352
(8W-12-20)
2 3 4
F83
L36 Z1 L38 18
18 18 18 YL/DG
LG/BK BK BR/WT

3 C2
I J
G107 FUSED DRIVER
(8W-15-15) IGNITION POWER
TO TO SWITCH LOCK/
REAR S220 OUTPUT
(8W-51-12) WINDOW
FOG (RUN-ACC)
SWITCH
LAMP (8W-62-5)
SWITCH
(8W-51-12)
J008W-7 XJI05110

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 XJ 8W-51 REAR LIGHTING 8W - 51 - 11
LHD BUILT-UP-EXPORT

FROM
FROM S215 FROM FROM
REAR (8W-12-8) REAR REAR
FOG FOG FOG
LAMP LAMP LAMP
RELAY RELAY RELAY
(8W-51-9) (8W-51-9) (8W-51-9)
F G H
E2
20
L36 OR L38 L38
18 18 18
LG/BK BR/WT BR/WT
23 C200
2 4 3
REAR L38
FOG 18
REAR BR/WT
LAMP
SWITCH FOG
ILLUMINATION LAMP SWITCH
INDICATOR
S308

L38 L38
18 18
BR/WT BR/WT
1
4 C322 4 C321

L38 L38
18 18
OR/WT OR/WT
2 LEFT 2 RIGHT
REAR REAR
FOG FOG
1 LAMP 1 LAMP
Z1 Z1
18 18
BK BK

S341 S348
(8W-15-17) (8W-15-19)
Z15
20 Z1 Z1
BK/GY 16 18
BK BK

2 C322 2 C321
Z1 Z1
14 18
BK BK

S309 S310
(8W-15-17) (8W-15-19)

Z1 Z1
12 16
BK BK

G107 G302 G303

(8W-15-15) (8W-15-17) (8W-15-19)

XJI05111 J008W-7

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 8W - 51 - 12 8W-51 REAR LIGHTING XJ
RHD BUILT-UP-EXPORT

FROM FROM
S215 REAR
FROM
(8W-12-9) FOG
REAR
LAMP
FOG RELAY
LAMP
(8W-51-10)
RELAY
(8W-51-10) J
I
E2 S220
20
OR L38
L36 L38
18 18 18
LG/BK BR/WT BR/WT

2 4 3 8 C203
REAR L38
FOG 18
REAR LAMP BR/WT
SWITCH FOG
ILLUMINATION LAMP SWITCH
INDICATOR
S308

L38 L38
18 18
BR/WT BR/WT
1
4 C322 4 C321

L38 L38
18 18
OR/WT OR/WT
2 LEFT 2 RIGHT
REAR REAR
FOG FOG
1 LAMP 1 LAMP
Z1 Z1
18 18
BK BK

S341 S348
(8W-15-18) (8W-15-20)
Z15
18 Z1 Z1
BK/GY 16 18
BK BK

2 C322 2 C321
Z1 Z1
14 18
BK BK

S309 S310
(8W-15-18) (8W-15-20)

Z1 Z1
12 12
BK BK

G107 G302 G303

(8W-15-15) (8W-15-18) (8W-15-20)

J008W-7 XJI05112

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 XJ 8W - 52 TURN SIGNALS 8W - 52 - 1

8W-52 TURN SIGNALS

Component Page Component Page
Combination Flasher . . . . . . . . . . . . . . 8W-52-2, 3, 4 Left Repeater Lamp . . . . . . . . . . . . . . . . . . 8W-52-6
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3, 4 Left Side Marker Lamp . . . . . . . . . . . . . . . 8W-52-5
Fuse 20 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3 Left Turn Signal Lamp . . . . . . . . . . . . . . 8W-52-5, 6
Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-52-4 Power Antenna Relay . . . . . . . . . . . . . . . 8W-52-3, 4
G106 . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 6, 7, 8 Power Distribution Center . . . . . . . . . . 8W-52-2, 3, 4
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3, 4 Right Front Park/Turn Signal Lamp No. 1 . 8W-52-7
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 6 Right Front Park/Turn Signal Lamp No. 2 . 8W-52-7
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7, 8 Right Front Turn Signal Lamp No. 1 . . . . . 8W-52-8
Instrument Cluster . . . . . . . . . . . . . 8W-52-5, 6, 7, 8 Right Front Turn Signal Lamp No. 2 . . . . . 8W-52-8
Junction Block . . . . . . . . . . . . . . . . . . . 8W-52-2, 3, 4 Right Repeater Lamp . . . . . . . . . . . . . . . . . 8W-52-8
Left Front Park/Turn Signal Lamp No. 1 . . 8W-52-5 Right Side Marker Lamp . . . . . . . . . . . . . . 8W-52-7
Left Front Park/Turn Signal Lamp No. 2 . . 8W-52-5 Right Turn Signal Lamp . . . . . . . . . . . . . 8W-52-7, 8
Left Front Turn Signal Lamp No. 1 . . . . . . 8W-52-6 Turn Signal/Hazard Switch . . . . . . . . . 8W-52-2, 3, 4
Left Front Turn Signal Lamp No. 2 . . . . . . 8W-52-6

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 8W - 52 - 2 8W-52 TURN SIGNALS XJ
EXCEPT BUILT-UP-EXPORT
RUN A22 (8W-10-18) BATT A0 (8W-10-11)
JUNCTION POWER
BLOCK A16 DISTRIBUTION
FUSE (8W-12-2)
FUSE CENTER
12 20 (8W-10-2)
10A 15A
(8W-12-17) (8W-10-31)
(8W-12-18) A15

S20 C4
L5 L9
20 20
BK BK/PK

LHD RHD
B11
3 C201 C100
F5
L9
20
L5
BK/PK
20
BK
1 2
FUSED FUSED COMBINATION
IGNITION B(+) FLASHER
SWITCH HAZARD
OUTPUT FLASHER
FLASHER (RUN) SELECT
OUTPUT SIGNAL GROUND
4 3 5

L6 Z1
20 L55 L12
20 20 20
RD/WT BK
RD/WT VT/TN

5 4 11 6
TURN S208
(8W-15-14)
SIGNAL/
HAZARD
SWITCH
(PART OF
MULTI-
FUNCTION
SWITCH)
L R L R L R L R

3 10 1 9
L62 L61 L60 L63
20 20 20 20
BR/RD LG/WT TN DG/RD

A B C D

TO TO TO TO Z1
14
C200 S209 S212 C200 BK
C204 (8W-52-5) (8W-52-7) C204
(8W-52-7) (8W-52-5)
G107
(8W-15-14)
LHD
RHD
J008W-7 XJI05202

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 XJ 8W-52 TURN SIGNALS 8W - 52 - 3
BUILT-UP-EXPORT GAS
BATT A0 (8W-10-11) RUN A22 (8W-10-18)
POWER JUNCTION
A16 DISTRIBUTION BLOCK
FUSE CENTER FUSE (8W-12-2)
20 (8W-10-2) 12
15A 10A
(8W-10-31) (8W-12-17)
A15 (8W-12-18)

S20 C4
L9 L5
20 20
BK/PK BK
LHD RHD
B11
C100 3 C201
POWER F5
ANTENNA L9
RELAY 20
L5
GROUND (RHD) BK/PK
20
(8W-47-4) BK
A C1
Z1 2 1
18 FUSED FUSED COMBINATION
BK B(+) IGNITION FLASHER
SWITCH HAZARD
OUTPUT FLASHER
FLASHER (RUN) SELECT
GROUND OUTPUT SIGNAL
5 4 3

Z1 L6 L55 L12
20 20 20 20
BK RD/WT RD/WT VT/TN

5 4 11 6
TURN
SIGNAL/
HAZARD
SWITCH
(PART OF
MULTI-
FUNCTION
SWITCH)
L R L R L R L R

3 10 1 9
S208 L62 L61 L60 L63
(8W-15-15) 20 20 20 20
BR/RD LG/WT TN DG/RD

E F G H
Z1 TO TO TO TO
14
BK
C200 S209 S212 C200
C204 (8W-52-6) (8W-52-8) C204
(8W-52-8) (8W-52-6)
G107
(8W-15-15)
LHD
RHD
XJI05203 J008W-7

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 8W - 52 - 4 8W-52 TURN SIGNALS XJ
DIESEL
BATT A0 (8W-10-13) RUN A22 (8W-10-18)
POWER JUNCTION
A9 DISTRIBUTION BLOCK
FUSE CENTER FUSE (8W-12-2)
23 (8W-10-7) 12
15A 10A
(8W-10-35) (8W-12-17)
A10 (8W-12-18)

S20 C4
L9 L5
20 20
BK/PK BK
LHD RHD
B11
C100 3 C201
POWER F5
ANTENNA L9
RELAY 20
L5
GROUND (RHD) BK/PK
20
(8W-47-4) BK
A C1
Z1 2 1
18 FUSED FUSED COMBINATION
BK B(+) IGNITION FLASHER
SWITCH HAZARD
OUTPUT FLASHER
FLASHER (RUN) SELECT
GROUND OUTPUT SIGNAL
5 4 3

Z1 L6 L55 L12
20 20 20 20
BK RD/WT RD/WT VT/TN

5 4 11 6
TURN
SIGNAL/
HAZARD
SWITCH
(PART OF
MULTI-
FUNCTION
SWITCH)
L R L R L R L R

3 10 1 9
S208 L62 L61 L60 L63
(8W-15-15) 20 20 20 20
BR/RD LG/WT TN DG/RD

E F G H
Z1 TO TO TO TO
14
BK
C200 S209 S212 C200
C204 (8W-52-6) (8W-52-8) C204
(8W-52-8) (8W-52-6)
G107
(8W-15-15)
LHD
RHD
J008W-7 XJI05204

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 XJ 8W-52 TURN SIGNALS 8W - 52 - 5
EXCEPT BUILT-UP-EXPORT
FROM FROM
TURN TURN
SIGNAL/ SIGNAL/
HAZARD HAZARD TRAILER
LHD RHD
SWITCH SWITCH TOW OTHER
(8W-52-2) (8W-52-2)
B D 1 C323
L63 L63
20 20
L61 L63
DG/RD DG/RD
S335
20 20 (8W-54-3)
LG/WT DG/RD

S209 26 C200 12 C204

L63
20
L61 L63 L63
DG/RD
20 20 20
L61 DG/RD DG/RD 1 C322
LG/WT
20
B10 LG/WT
F4 C100 L63
18
10 C1 DG/RD
L61 LEFT INSTRUMENT
20 TURN CLUSTER 2 LEFT
LG/WT SIGNAL (8W-40-14) TURN
SIGNAL
3 C106 1 LAMP

L61 Z1
20 18
LG BK

S341
S105 (8W-15-17)
(8W-50-10) (8W-15-18)
S104
(8W-12-10) Z1
L61 18
20 BK
LG
2 LEFT 2 C322
L77 L61 L77 L61
SIDE 18 18 18 18 TRAILER TOW OTHERS
MARKER BR LG BR LG
1 LAMP 2 1 LEFT 2 1 LEFT Z1
FRONT FRONT 18
L77 BK
20
PARK/ PARK/
BR TURN TURN S337
3 3
SIGNAL SIGNAL (8W-15-17) Z1
Z1 LAMP Z1 LAMP Z1 (8W-15-18) 14
18 NO. 1 18 NO. 2 14 BK
BK BK BK
S158 2 C323
(8W-15-7)
Z1
S103 14
(8W-15-7) BK
Z1
18
BK
S309
11 C106 (8W-15-17)
Z1 (8W-15-18)
Z1 12
20 BK
BK/WT
G302
G106 LHD
(8W-15-17)
(8W-15-7) RHD (8W-15-18)
XJI05205 J008W-7

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 8W - 52 - 6 8W-52 TURN SIGNALS XJ
BUILT-UP-EXPORT
FROM FROM
TURN TURN
SIGNAL/ SIGNAL/
HAZARD HAZARD
SWITCH SWITCH
(8W-52-3) (8W-52-3)
(8W-52-4) (8W-52-4)
TRAILER
F H LHD RHD
TOW OTHER

L61 1 C323
20
L63 L63
LG/WT S335
20 20
DG/RD DG/RD (8W-54-3)
S209 L63
20
L61
DG/RD 26 C200 12 C204
20
L61 L63
LG/WT
20 20
B10 L63 L63
C100 LG/WT DG/RD
20 20
F4
DG/RD DG/RD 1 C322
L61 10 C1
20 LEFT INSTRUMENT
LG/WT L63
TURN CLUSTER 18
SIGNAL (8W-40-14)
3 C106 DG/RD
L61 2 LEFT
20 TURN
LG
SIGNAL
S105 1 LAMP
(8W-50-11) Z1
L61 18
18 BK
LG
1 C114 S341
(8W-15-17)
L61 (8W-15-18)
L61 L61 Z1
18 18 18 16
LG LG GY BK
2 LEFT 2 LEFT 1
FRONT FRONT LEFT 2 C322
TURN TURN REPEATER TRAILER TOW OTHERS
SIGNAL SIGNAL LAMP
1 1 2
LAMP LAMP Z1 Z1
Z1 Z1 Z1 18 14
18
NO. 1 18
NO. 2 18 BK BK
BK BK BK
S337
2 C114 (8W-15-17)
S158 Z1 (8W-15-18)
(8W-15-10) Z1
18 14
(8W-15-12) BK
BK

S103 2 C323
(8W-15-10)
(8W-15-12) Z1
Z1
18 14
BK/WT BK

11 C106 S309
(8W-15-17)
Z1 Z1 (8W-15-18)
20 12
BK/WT BK
LHD
G106 RHD G302
(8W-15-10) (8W-15-17)
J008W-7 XJI05206
(8W-15-12) (8W-15-18)

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 XJ 8W-52 TURN SIGNALS 8W - 52 - 7
EXCEPT BUILT-UP-EXPORT
FROM FROM
TURN TURN
SIGNAL/ SIGNAL/
HAZARD HAZARD
SWITCH SWITCH
(8W-52-2) (8W-52-2)
A C

L62 L60
20 20
BR/RD TN
LHD RHD S212

25 C200 11 C204 L60

20
L60
TN
20
B9 TN
C100
F3
L62
20 L60 6 C2
BR/RD 20 RIGHT INSTRUMENT
TN TURN CLUSTER
S312 10 C106 SIGNAL (8W-40-14)
(8W-70-2)
L60
L62 20
20 TN
BR/RD
S100
1 C321 (8W-50-12)
L62 L60
18 20
BR/RD TN

2 2 RIGHT
RIGHT
TURN SIDE
SIGNAL MARKER
1 LAMP 1 LAMP
Z1 L78
18 20
BK DG/YL

S348 S101
(8W-15-19) (8W-12-24)
Z1 (8W-15-20)
18 L78 L60 L78 L60
BK 18 18 18 18
DG/YL TN DG/YL TN
2 C321 2 1 RIGHT 2 1 RIGHT
Z1 FRONT FRONT
18 PARK/ PARK/
BK TURN TURN
3 3
SIGNAL SIGNAL
S310 Z1 LAMP Z1 LAMP
(8W-15-19) 18 18
(8W-15-20) NO. 1 NO. 2
BK BK
LHD RHD
S102
Z1 18BK (8W-15-7)
Z1 Z1
16 12 4 C106
BK BK
Z1
20
BK
LHD
G303
(8W-15-19)
RHD G106
(8W-15-20) (8W-15-7)
XJI05207 J008W-7

Downloaded from www.Manualslib.com manuals search engine

 8W - 52 - 8 8W-52 TURN SIGNALS XJ
BUILT-UP-EXPORT
FROM FROM
TURN TURN
SIGNAL/ SIGNAL/
HAZARD HAZARD
SWITCH SWITCH
(8W-52-3) (8W-52-3)
(8W-52-4) (8W-52-4)
E G

L62 L60
20 20
BR/RD TN
LHD RHD S212

25 C200 11 C204 L60

20 L60
TN 20
B9 TN
C100
F3 6 C2
L62 L60
20 20 RIGHT INSTRUMENT
BR/RD TN TURN CLUSTER
SIGNAL (8W-40-14)
S312 10 C106
(8W-70-2)
L60
L62 20
20 TN
BR/RD
S116
1 C321 (8W-50-13)
L62 L60
18 18
BR/RD TN

2 RIGHT 1 C115
TURN L60 L60 L60
SIGNAL 18 18 18
TN TN GY
1 LAMP RIGHT RIGHT
2 2 1
S348 FRONT FRONT RIGHT
(8W-15-19) TURN TURN REPEATER
(8W-15-20) LAMP
Z1 SIGNAL SIGNAL
1 1 2
18 LAMP LAMP
BK Z1
Z1 NO. 1 18
NO. 2 Z1
2 C321 18
BK
18
BK BK
Z1
18 2 C115
BK
Z1
S310 18
(8W-15-19) BK
(8W-15-20)
S102
(8W-15-10)
LHD RHD
Z1 (8W-15-12)
18
Z1 Z1 BK
16 12 4 C106
BK BK
Z1
20
BK

G303 LHD G106

RHD (8W-15-10)
(8W-15-19)
(8W-15-20) (8W-15-12)
J008W-7 XJI05208

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 XJ 8W - 53 WIPERS 8W - 53 - 1

8W-53 WIPERS
Component Page Component Page
A/C- Heater Control . . . . . . . . . . . . . . . . 8W-53-6, 7 Headlamp Switch . . . . . . . . . . . . . . . 8W-53-4, 5, 6, 7
Circuit Breaker 30 (JB) . . . . . . . . . . . . . . 8W-53-2, 3 Junction Block . . . . . . . . . . . . . 8W-53-2, 3, 4, 5, 6, 7
Front Wiper Motor . . . . . . . . . . . . . . . . . 8W-53-2, 3 Rear Washer Pump . . . . . . . . . . . 8W-53-2, 4, 5, 6, 7
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . 8W-53-4, 5, 6, 7 Rear Wiper Motor . . . . . . . . . . . . . . 8W-53-4, 5, 6, 7
Fuse 22 (JB) . . . . . . . . . . . . . . . . . . 8W-53-4, 5, 6, 7 Rear Wiper/Washer Switch . . . . . . . 8W-53-4, 5, 6, 7
G106 . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3, 4, 5, 6, 7 Windshield Washer Pump . . . . . . . . 8W-53-2, 3, 4, 6
G107 . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4, 5, 6, 7 Wipe/Wash Switch . . . . . . . . . . . . . . . . . . 8W-53-2, 3
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3 Wiper Motor Relay . . . . . . . . . . . . . . . . . 8W-53-2, 3
G304 . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4, 5, 6, 7

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 8W - 53 - 2 8W-53 WIPERS XJ
GAS
RUN-ACC A31 (8W-10-15)
JUNCTION
BLOCK
CIRCUIT (8W-12-2)
BREAKER
30
20A
(8W-12-27)

M4 C4 8 C1
V6 V6
16 16
DB DB
LHD RHD

8 C201

5
WIPE/
WASH
SWITCH
3 3 3 0 OFF
0 0 0 1 DELAY
2 1 2 1 2 1 2 LOW
4 3 HIGH
INTERMITTENT WIPER 4 WASH
LOGIC 5 INTERMITTENT

WIPER
MOTOR
RELAY
5
MIN MAX

3 1 2 6 4
V10 V5 V4 V3
18 Z1 16 16 16
BR 16 DG/YL BR/VT BR/WT
E4 BK C5 C100
C3 C1
A16 C100 V5 V4 V3
A S207
16 16 16
(8W-15-16)
WINDSHIELD Z1 DG/YL BR/VT BR/WT
WASHER 14 2 6 5 1
M PUMP BK FRONT
REAR WIPER
G108 M
B WASHER (8W-15-16) PARK MOTOR
RUN
Z1 PUMP
18 GROUND (8W-53-4)
BK (8W-53-5) 4
2
LHD 4.0L
OTHER Z1 18BK EXCEPT BUILT-UP-EXPORT OTHER 2.5L

S132 S141
(8W-15-4) (8W-15-5)
Z1 (8W-15-8) Z1
(8W-15-6)
Z1 (8W-15-8) 16 16
16 (8W-15-9) BK BK
RHD
BK
LHD
G106
(8W-15-7)
J008W-7 (8W-15-10) XJI05302

Downloaded from www.Manualslib.com manuals search engine

 XJ 8W-53 WIPERS 8W - 53 - 3
DIESEL
RUN-ACC A31 (8W-10-16)

JUNCTION
BLOCK
(8W-12-2)
CIRCUIT
BREAKER
30
20A
(8W-12-27)

M4 C4 8 C1
V6 V6
16 16
DB DB
LHD RHD

8 C201

5
WIPE/
WASH
SWITCH
3 3 3 0 OFF
0 0 0 1 DELAY
2 1 2 1 2 1 2 LOW
4 3 HIGH
INTERMITTENT WIPER LOGIC 4 WASH
5 INTERMITTENT
WIPER
MOTOR
RELAY
5
MIN MAX

3 1 2 6 4
V10 Z1 V5 V4 V3
18 16 16 16 16
BR BK DG/YL BR/VT BR/WT
E4 S207 C5 C3 C1 C100
A16 C100 V5 V4 V3
(8W-15-16)
16 16 16
A Z1 DG/YL BR/VT BR/WT
WINDSHIELD 14 2 6 5 1
WASHER BK FRONT
M PUMP
G108 WIPER
M
(8W-15-16) PARK MOTOR
RUN
B
Z1
18 4
BK Z1
16
BK
S141
(8W-15-11) S157
Z1 (8W-15-11)
12 Z1
BK 12
BK

S132
Z1 (8W-15-11)
12 LHD
BK
RHD
G106
(8W-15-12)
XJI05303 J008W-7

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 8W - 53 - 4 8W-53 WIPERS XJ
LHD GAS
RUN A22 (8W-10-18) HEADLAMP S1 C4
PANEL SWITCH JUNCTION
JUNCTION LAMPS (8W-50-2) BLOCK
BLOCK DIMMER (8W-50-3) FUSE (8W-12-2)
(8W-12-2) SWITCH 6
FUSE SIGNAL 5A
22 1 (8W-12-8)
20A E1
(8W-12-22) E1 20
20 TN
S2 C4
TN
S11 C4 E2 20OR
V23
18 S315
BR/PK (8W-12-8)
43
39 C201 42 C201
V23 S215
18
(8W-12-8)
BR/PK
5 3
REAR
WIPER/
WASHER
SWITCH
1 2 0 1 0 0 OFF
2
1 WASH
2 WIPE
6 4 2 1
V23 V13 V20 Z1
18 18 18 20
BR/PK BR/LG BK/WT BK
29 27 C200 S205
V23 V13 28 C200 S208
18 18 V20 (8W-15-14)
BR/PK BR 18 Z1 (8W-15-15)
BK/WT 14
4 3 5 C327 BK
E5 C100
V23 V13 V20 G107
18 18 18 (8W-15-14)
BR/PK BR/LG BK/WT V20 (8W-15-15)
18
2 1 3 C313 BK/WT WINDSHIELD
7 C310 WASHER
8 1 1
4 3 2 PUMP
REAR (8W-53-2)
REAR WASHER GROUND
REAR WIPER MODULE WIPER M PUMP B
MOTOR Z1
1 PARK 18
2 RUN 2 BK
M OTHER 4.0L EXCEPT BUILT-UP-EXPORT
1 2
Z1 Z1
1 18 18
BK BK
S334
(8W-15-21) S132 S141
(8W-15-4)
9 C310 (8W-15-5)
(8W-15-8)
6 C311 Z1 (8W-15-9) Z1
Z1 16
18 16
BK BK
BK
G106
(8W-15-7) G106
G304 (8W-15-7)
(8W-15-10)
J008W-7 (8W-15-21) XJI05304

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 XJ 8W-53 WIPERS 8W - 53 - 5
LHD DIESEL
S1 C4
RUN A22 (8W-10-18) JUNCTION
JUNCTION BLOCK
FUSE (8W-12-2)
BLOCK HEADLAMP 6
(8W-12-2) PANEL SWITCH 5A
FUSE LAMPS (8W-50-3) (8W-12-8)
22 DIMMER
E1
20A SWITCH
20
(8W-12-22) SIGNAL
TN
S2 C4
(8W-12-23) 1
E2 20OR
S11 C4
V23 E1 S315
18 20 (8W-12-8)
BR/PK TN 43
39 C201 42 C201
V23 S215
18
(8W-12-8)
BR/PK
5 3
REAR
WIPER/
WASHER
SWITCH
1 0 1 0 0 OFF
2 2
1 WASH
2 WIPE
6 4 2 1
V23 V13 V20 Z1
18 18 18 20
BR/PK BR/LG BK/WT BK
29 27 C200 S205
V23 V13 V20 S208
18 18
BR/PK BR
28 C200 18 (8W-15-15)
BK/WT Z1
14
BK
4 3 5 C327 E5 C100
V23 V13 V20 G107
18 18 18 V20 (8W-15-15)
BR/PK BR/LG BK/WT 18
BK/WT
2 1 3
C313
7 1
8 1 C310
V23 V13 V20 REAR
18 18 18 WASHER
BR/PK BR/LG BK/WT M PUMP
4 3 2
REAR
2
REAR WIPER MODULE WIPER
Z1
MOTOR 18
1 PARK BK
2 RUN
M S141
1 2 (8W-15-11)
Z1
1 12
S334 BK
(8W-15-21)
9 C310 S132
6 C311 (8W-15-11)
Z1 Z1
18 12
BK BK

G304 G106
(8W-15-21) (8W-15-12)
XJI05305 J008W-7

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 8W - 53 - 6 8W-53 WIPERS XJ
RHD GAS
RUN A22 (8W-10-18) HEADLAMP S1 C4
PANEL SWITCH JUNCTION
JUNCTION LAMPS (8W-50-2) BLOCK
BLOCK DIMMER (8W-50-3) FUSE (8W-12-2)
(8W-12-2) SWITCH 6
FUSE SIGNAL 5A
22 1 (8W-12-9)
20A E1
(8W-12-23) E1 20
20 TN
S2 C4
TN
S11 C4 S215
(8W-12-9)
7 C1
V23
18 FUSED A/C- E2
BR/PK PANEL HEATER 20
LAMPS CONTROL OR
DIMMER (8W-42-5)
SWITCH
SIGNAL
6 3
REAR
WIPER/
WASHER
SWITCH
1 2 0 1 2 0 0 OFF
1 WASH
5 4 2 1 2 WIPE
V23 V13 V20 Z1
18 18 18 20
BR/PK BR/LG BK/WT BK

S208
6 7 5 C203 S205 (8W-15-14)
Z1 (8W-15-15)
V23 V13 V20 14
18 18 18 BK
V20
BR/PK BR BK/WT
18
FULL G107
4 C327 BK/WT
BASE OPTIONS 3 5 (8W-15-14)
V23 V13 V20 (8W-15-15)
S324 E5 C100
18 18 18
(8W-12-23)
BR/PK BR/LG BK/WT WINDSHIELD
2 1 3 C313 V20 WASHER
7 C310 18
8 1 PUMP
BK/WT (8W-53-2)
4 3 2 GROUND
REAR B
1
WIPER Z1
REAR WIPER MODULE REAR 18
MOTOR
1 PARK WASHER BK
2 RUN M PUMP

M 2
1 2

Z1
1 18
S334 BK
(8W-15-21)
S132
9 C310 (8W-15-6)
6 C311
Z1 Z1
18 16
BK BK

G304 G106
(8W-15-21) (8W-15-7)
J008W-7 XJI05306
(8W-15-10)

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 XJ 8W-53 WIPERS 8W - 53 - 7
RHD DIESEL
S1 C4
RUN A22 (8W-10-18) JUNCTION
BLOCK
JUNCTION FUSE (8W-12-2)
BLOCK 6
(8W-12-2) HEADLAMP 5A
FUSE PANEL SWITCH (8W-12-9)
22 LAMPS (8W-50-3)
20A DIMMER
SWITCH S2 C4
(8W-12-23)
SIGNAL S215
1 E1 (8W-12-9)
S11 C4
20
V23 E1
TN
7 C1
18 20 FUSED A/C- E2
BR/PK TN PANEL HEATER 20
LAMPS CONTROL OR
DIMMER (8W-42-5)
SWITCH
SIGNAL
6 3
REAR
WIPER/
WASHER
SWITCH
1 0 1 0 0 OFF
2 2
1 WASH
2 WIPE
5 4 2 1
V23 V13 V20 Z1
18 18 18 20
BR/PK BR/LG BK/WT BK

S205
6 7 5
C203 V20
V23 V13 V20 18 S208
18 18 18 BK/WT (8W-15-15)
BR/PK BR BK/WT E5 C100 Z1
FULL 14
BASE OPTIONS 4 3 5 C327 V20 BK
18
S324 V23 V13 V20 BK/WT G107
18 18 18
(8W-12-23) 1 (8W-15-15)
BR/PK BR/LG BK/WT
2 C313 REAR
1 3
7 C310 WASHER
8 1 M PUMP
4 3 2
REAR
2
WIPER
REAR WIPER MODULE Z1
MOTOR
1 PARK 18
2 RUN BK

S141
M (8W-15-11)
1 2
Z1
12
1 BK
S334
(8W-15-21) S132
9 C310 (8W-15-11)
6 C311 Z1
Z1
18 12
BK BK

G304 G106
(8W-15-21) (8W-15-12)
XJI05307 J008W-7

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 XJ 8W - 54 TRAILER TOW 8W - 54 - 1

8W-54 TRAILER TOW

Component Page Component Page
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-54-3 Left Tail/Stop Lamp . . . . . . . . . . . . . . . . . . 8W-54-3
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2 Left Turn Signal Lamp . . . . . . . . . . . . . . . . 8W-54-3
Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3 Trailer Tow Connector . . . . . . . . . . . . . . . 8W-54-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2 Trailer Tow Electric Brake Provision . . . . . 8W-54-2
Headlamp Switch . . . . . . . . . . . . . . . . . . . . 8W-54-2 Trailer Tow Left Turn Relay . . . . . . . . . . . . 8W-54-3
Junction Block . . . . . . . . . . . . . . . . . . . . 8W-54-2, 3 Trailer Tow Right Turn Relay . . . . . . . . . . . 8W-54-3
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . 8W-54-2 Turn Signal/Hazard Switch . . . . . . . . . . . . . 8W-54-3

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 8W - 54 - 2 8W-54 TRAILER TOW XJ

BATT F34 (8W-10-28)

(8W-10-29)

4
S206 HEADLAMP
LHD RHD
(8W-12-10) SWITCH
L7 (8W-12-11) 1 PARK
18 2 HEAD
45 C201 BK/YL
0 1 2
0 OFF
(8W-50-2)
(8W-50-3)
9
L7
18
BK/YL
M3 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE
7
10A FROM
(8W-12-10) S303
(8W-12-11) (8W-51-8)

2 C7
L77
18 L10
BR/YL 18
BR/LG
S311 5 C323
(8W-12-10)
L77 (8W-12-11) L10
18 18
BR/YL BR/LG
7 C323
S339
L77
20
BR/YL L10 L10
18 18
S340 BR/LG BR/LG
(8W-12-10)
(8W-12-11)
5 3 5 C322
7 8 TRAILER
B40 Z1 TOW L10
14 14 CONNECTOR 18
LB BK BR/LG

S337 2
TRAILER (8W-15-17) BACK-UP LEFT
(8W-15-18) LAMP BACK-UP
TOW
FEED LAMP
ELECTRIC 2 C323
(8W-51-8)
BRAKE Z1
PROVISION 14
BK

S309
(8W-15-17)
Z1
(8W-15-18)
12
BK

G302
(8W-15-17)
(8W-15-18)
J008W-7 XJI05402

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 XJ 8W-54 TRAILER TOW 8W - 54 - 3

BATT A7 (8W-10-20)
(8W-10-26)
JUNCTION
BLOCK
(8W-12-2)
FUSE
20
15A
(8W-12-21)

8 C7
A6
20
RD/OR
3 C323
S338
TURN BRAKE TURN (8W-12-21)
SIGNAL/ BRAKE LAMP SIGNAL/
LEFT LAMP RIGHT
TURN HAZARD SWITCH
SWITCH TURN HAZARD
SIGNAL SWITCH OUTPUT (8W-33-4) SIGNAL SWITCH
(8W-52-2) (8W-33-5) (8W-52-2)
9 5 3
(8W-52-3) (8W-52-3)
L63 (8W-52-4) L50 L62 (8W-52-4)
20 20 20
DG/RD WT/TN BR/RD
LHD RHD
S203
LHD RHD (8W-10-32) 25 C200 11 C204
(8W-10-33)
26 C200 12 C204 LHD RHD
S312
24 C200 24 C204 (8W-70-2)
1 C323 L62
20
S335 BR/RD
S302 8 C323
L63 L63 A6 (8W-10-32)
20 20 20 (8W-10-33) L62 A6
DG/RD DG/RD RD/OR 20 20
L50
1 3 BK/RD RD/OR
20
TRAILER WT/TN 1 3
TOW TRAILER
LEFT 6 C323 TOW
TURN RIGHT
2 5 RELAY L50
TURN
L50 20 2 5 RELAY
20 WT/TN L50
WT/TN 20
WT/TN
1 C322 S336

L63
6 C322
L74 A6
18 20 20
L73 L50
DG/RD LG RD/OR
20 18
2 YL WT/TN
LEFT LEFT 3
TURN TURN BRAKE LEFT
SIGNAL SIGNAL LAMP TAIL/
LAMP SWITCH STOP
SIGNAL
(8W-51-5) LAMP
(8W-52-5) 10 (8W-51-3) 2 4
(8W-52-6)
XJI05403 TRAILER TOW CONNECTOR J008W-7

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 XJ 8W - 60 POWER WINDOWS 8W - 60 - 1

8W-60 POWER WINDOWS

Component Page Component Page
Circuit Breaker 28 (JB) . . . . . . . . . .. . . . 8W-60-2, 3 Left Rear Window Motor . . . . . . . . . . . . . 8W-60-4, 5
Driver Power Lock/Window Switch . 8W-60-2, 3, 4, 5 Left Rear Window Switch . . . . . . . . 8W-60-2, 3, 4, 5
Driver Power Window Motor . . . . . .. . . . 8W-60-2, 3 Passenger Power Lock/Window Switch . . 8W-60-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . .. . . . 8W-60-2, 4 Passenger Power Window Motor . . . . . . . 8W-60-2, 3
G303 . . . . . . . . . . . . . . . . . . . . . . . .. . . . 8W-60-3, 5 Right Rear Window Motor . . . . . . . . . . . . 8W-60-4, 5
Junction Block . . . . . . . . . . . . . . . .. . . . 8W-60-2, 3 Right Rear Window Switch . . . . . . . 8W-60-2, 3, 4, 5

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 8W - 60 - 2 8W-60 POWER WINDOWS XJ
LHD
RUN-ACC A31 (8W-10-15)
(8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT
BREAKER
28
25A
(8W-12-25)

8 C5
F81 12TN
13 C201
33 C200
F81
12
TN
1 C307
F81 14TN
9 C1
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 UP
1 2 1 2 1 2 1 2 2 DOWN
3 LOCK
4 4 UNLOCK
3

5 C1 12 C1 3 C1 6 C1 8 C2 8 C1
Q16 Q26 Q1 Z1
14 14 14 14
BR/WT VT/WT YL BK
4
3 C306
S329
1 2 3 C303 (8W-15-17)
Q1 Z1
4 C1 3 C1 10 C1 14 12
PASSENGER YL BK
POWER 3
2 C307
LOCK/
Q11 Q21 WINDOW Q1 Z1
14 14 SWITCH 14 12
LB WT 1 UP YL BK
2 DOWN
3 LOCK S305 S309
4 UNLOCK (8W-15-17)
Q1 Q1 Z1
1 2 14 14 12
YL YL BK
3 C309 3 C304
9 C1 2 C1
Q12 Q22 Q1 Q1
14 14 14 14 G302
1 2 BR VT YL YL (8W-15-17)
DRIVER 1 2 6 6
POWER PASSENGER POWER LEFT POWER RIGHT
WINDOW POWER WINDOW REAR WINDOW REAR
MOTOR WINDOW SWITCH WINDOW SWITCH WINDOW
M FEED FEED
MOTOR SWITCH SWITCH
M (8W-60-4) (8W-60-4)
J008W-7 XJI06002

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 XJ 8W-60 POWER WINDOWS 8W - 60 - 3
RHD
RUN-ACC A31 (8W-10-15)
(8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT
BREAKER
28
25A
(8W-12-26)

1 C8
F81
14
TN
9 C1
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 UP
1 2 1 2 1 2 1 2 2 DOWN
3 LOCK
4 4 UNLOCK
3

3 C1 6 C1 5 C1 12 C1 8 C2 8 C1
Q1 Z1
Q11 Q21 Q16 Q26 14
14 14 14 14 14
YL BK
BR VT BR/WT VT/WT

7 8
C303 S319
(8W-15-20)
Q16 Q26
2 C307 4 5
C303
14 14
BR/WT VT/WT Q1 Q1 Q1
14 14 14
C306 YL YL YL
3 4
4 C1 3 C1 10 C1 S305
PASSENGER Z1
POWER 14
BK
LOCK/ Q1
Q1
WINDOW 14 14
S310
SWITCH YL YL
(8W-15-20)
1 UP Z1
2 DOWN 3 C309 3 C304 12
3 LOCK BK
4 UNLOCK Q1
1 2
14 G303
YL (8W-15-20)
6
9 C1 2 C1 POWER RIGHT
Q12 Q22 Q1 WINDOW REAR
14 14 14 SWITCH WINDOW
BR VT YL FEED
1 2 SWITCH
DRIVER 1 2 6 (8W-60-5)
POWER PASSENGER POWER LEFT
WINDOW POWER WINDOW REAR
MOTOR WINDOW SWITCH WINDOW
M FEED
MOTOR SWITCH
M (8W-60-5)
XJI06003 J008W-7

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 8W - 60 - 4 8W-60 POWER WINDOWS XJ
LHD
RUN-ACC F81 (8W-12-25)
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 UP
1 2 1 2 1 2 1 2 2 DOWN
3 LOCK
4 4 UNLOCK
3

4 C1 10 C1 2 C1 1 C1 8 C2 8 C1
Q1 Z1
14 14
YL BK

Q17 Q27 Q18 Q28 S329

14 14 14 14 (8W-15-17)
Z1
DB/WT RD/BK GY/BK DG/WT
12
BK
2 3
6 1 2 C307
5 C306

S309
Q17 Q27 Q18 Q28 Q1 (8W-15-17)
14 14 14 14 14 Z1
DB/WT RD/BK GY/BK DG/WT YL 12
BK

S305 G302
(8W-60-2) (8W-15-17)
Q1 Q1
14 14
YL YL
2 3 2 3
1 C309 1 C304

4 2 6 4 2 6
LEFT RIGHT
REAR REAR
WINDOW WINDOW
SWITCH SWITCH
1 UP 1 UP
2 DOWN 2 DOWN

1 2 1 2

1 5 1 5
Q13 Q23 Q14 Q24
14 14 14 14
DB RD/WT GY DG
1 2 1 2
LEFT RIGHT
REAR REAR
WINDOW WINDOW
MOTOR MOTOR
M M
J008W-7 XJI06004

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 XJ 8W-60 POWER WINDOWS 8W - 60 - 5
RHD
RUN-ACC F81 (8W-12-26)
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 UP
1 2 1 2 1 2 1 2 2 DOWN
3 LOCK
4 4 UNLOCK
3

4 C1 10 C1 2 C1 1 C1 8 C2 8 C1
Q1 Z1
14 14
YL BK

S319
(8W-15-20)
Q17 Q27 Q18 Q28
14 14 14 14 Z1
DB/WT RD/BK GY/BK DG/WT 14
BK

6 1 2 4 5
3 C303
Q17 Q27 Q18 Q28 Q1
14 14 14 14 14
DB/WT RD/BK GY/BK DG/WT YL

S305
(8W-60-3)
Q1 Q1 Z1
14 14 14
YL YL BK
2 3 2 3
1 C309 1 C304
4 2 6 4 2 6
LEFT RIGHT
REAR REAR
WINDOW WINDOW
SWITCH SWITCH
1 UP 1 UP S310
2 DOWN 2 DOWN (8W-15-20)

1 2 1 2

1 5 1 5
Q13 Q23 Q14 Q24 Z1
14 14 14 14 12
DB RD/WT GY DG BK
1 2 1 2
LEFT RIGHT
REAR REAR
WINDOW WINDOW
MOTOR MOTOR G303
M M (8W-15-20)

XJI06005 J008W-7

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 XJ 8W - 61 POWER DOOR LOCKS 8W - 61 - 1

8W-61 POWER DOOR LOCKS

Component Page Component Page
Circuit Breaker 28 (JB) . . . . . . . . . . . . . . 8W-61-2, 3 Junction Block . . . . . . . . . . . . . . . . . 8W-61-2, 3, 4, 5
Driver Door Lock Motor . . . . . . . . . . . . . 8W-61-4, 5 Left Rear Door Lock Motor . . . . . . . . . . . 8W-61-4, 5
Driver Power Lock/Window Switch . . . . . 8W-61-2, 3 Liftgate Lock Motor . . . . . . . . . . . . . . . . 8W-61-4, 5
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3 Overhead Module . . . . . . . . . . . . . . . . . . 8W-61-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2 Passenger Door Lock Motor . . . . . . . . . . 8W-61-4, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3 Passenger Power Lock/Window
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3 Switch . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3, 4, 5
Ignition Switch . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3 Right Rear Door Lock Motor . . . . . . . . . . 8W-61-4, 5

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 8W - 61 - 2 8W-61 POWER DOOR LOCKS XJ
LHD
BATT A7 (8W-10-20) RUN-ACC A31 (8W-10-15) OVERHEAD
(8W-10-26) (8W-10-16) DOOR MODULE
JUNCTION UNLOCK DOOR (8W-49-4)
BLOCK RELAY LOCK
(8W-12-2) CONTROL CONTROL
FUSE CIRCUIT
15 BREAKER 5 11
25A 28
P55 P59
(8W-12-19) 25A
20 20
(8W-12-25)
DB LB/RD
9
8 C301
P55 P59
9 C9 1 C8 20 20
DB/PK LB/RD
F35 F81
16 14 3 4 C300
RD TN
P55 P59
20 20
DB/PK LB/RD
5 C2 4 C2 2 C2 1 C2
FUSED FUSED DOOR DOOR
PASSENGER
B(+) IGNITION UNLOCK LOCK POWER
DOOR DOOR SWITCH RELAY CONTROL LOCK/
LOCK LOCK OUTPUT KEY-IN CONTROL
(RUN-ACC)
WINDOW
SWITCH SWITCH IGNITION SWITCH
OUTPUT OUTPUT SWITCH
(LOCK) (UNLOCK) SENSE GROUND
3 C2 7 C2 8 C2 6 C2
P35 P36 G26 Z1
20 20 20 14
OR/VT PK/VT LB BK
2
1 C300 S319
9 5 C300 (8W-15-13)
23 C201 Z1
32
31 C200 G26 16
20 BK
P35 P36
LB 11 C9
20 20
OR/VT PK/VT JUNCTION
7 BLOCK
6 C305 29 C201 (8W-12-2)
P35 P36
18 18 G26
OR/VT PK/VT 20 S5 C4
7 C1 11 C1 LB
DRIVER Z1
POWER S210 14
LOCK/ (8W-10-17) BK
WINDOW G26
20
SWITCH LB
S314
(8W-15-13)
5 C2
Z1 14 C201
14
BK
1 C2
IGNITION Z1
KEY-IN 14
S329 IGNITION SWITCH BK
(8W-15-17) SWITCH (8W-10-15)
Z1
SENSE (8W-10-16)
12 S208
BK (8W-15-14)
3 C307 Z1 (8W-15-15)
14
S309 BK
(8W-15-17)
G302 G107
(8W-15-17) (8W-15-14)
J008W-7 XJI06102
(8W-15-15)

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 XJ 8W-61 POWER DOOR LOCKS 8W - 61 - 3
RHD
BATT A7 (8W-10-20) RUN-ACC A31 (8W-10-15)
(8W-10-26) (8W-10-16)
JUNCTION OVERHEAD
BLOCK DOOR MODULE
(8W-12-2) UNLOCK DOOR (8W-49-5)
FUSE CIRCUIT
RELAY LOCK
15 BREAKER
CONTROL CONTROL
25A 28
(8W-12-20) 25A 5 11
(8W-12-26) P55 P59
20 20
DB LB/RD
9
7 C5 8 C5 8 C301
F35 F81 P55 P59
16 12 20 20
RD TN DB/PK LB/RD
16 C204 3 C202 1 2
C203
F35 F81 P55 P59
16 12 20 20
RD TN DB/PK LB/RD

1 C306 1 C307 12 3 C305

F35 F81 P55 P59
16 14 20 20
RD TN DB LB/RD
5 C2 4 C2 2 C2 1 C2
FUSED FUSED DOOR DOOR
PASSENGER
B(+) IGNITION UNLOCK LOCK POWER
SWITCH RELAY CONTROL LOCK/
OUTPUT CONTROL
DOOR DOOR
(RUN-ACC)
WINDOW
LOCK LOCK KEY-IN SWITCH
SWITCH SWITCH IGNITION
OUTPUT OUTPUT SWITCH
(LOCK) (UNLOCK) SENSE GROUND
7 C2 3 C2 8 C2 6 C2
P35 P36 G26
18 18 20
OR/VT PK/VT LB
6 7 C305 2 C306
P35 P36 3 C203 Z1
20 20
OR/VT PK/VT
S210 14
(8W-10-17) BK
3 4 C204 G26
P35 P36 20
20 20 LB S329
OR/VT PK/VT 1 C2 (8W-15-18)
1 C300 KEY-IN
IGNITION Z1
2
P35 P36 IGNITION SWITCH 12
18 18 SWITCH (8W-10-15) BK
OR/VT PK/VT SENSE (8W-10-16)
7 C1 11 C1 3 C307
DRIVER
POWER 5 C303 Z1
LOCK/ 12
Z1
WINDOW BK
14
SWITCH BK
5 C2 S309
Z1 S310 (8W-15-18)
16 (8W-15-20) Z1
BK Z1 Z1 12
14 12 BK
S319 BK BK
(8W-15-20)
G303 G302
(8W-15-20) (8W-15-18)
XJI06103 J008W-7

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 8W - 61 - 4 8W-61 POWER DOOR LOCKS XJ
LHD
PASSENGER
POWER
DOOR DOOR
LOCK UNLOCK LOCK/
DRIVER DRIVER WINDOW
5 C1 1 C1 SWITCH
P33 P34
16 16
OR/BK PK/BK

S317 S316
(8W-12-31) (8W-12-31)
P33 P33 P34 P34
16 16 16 16
OR/BK OR/BK PK/BK PK/BK

2 1
PASSENGER
DOOR
LOCK
MOTOR
M

1 C9 12 C9
JUNCTION
BLOCK
(8W-12-2)

1 C7 5 C7
P33 P34
16 16
OR/BK PK/BK

S307
(8W-12-31)
S306
(8W-12-31)
P34 P33 P34 P33 P34 P33 P34 P33
16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK

2 1 C326
5 4 C305 5 4 C309 5 4 C304
2 1 C311
5 4 C310
P34 P33 P34 P33 P34 P33 P34 P33
16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK

1 2 1 2 1 2 B A
DRIVER LEFT RIGHT LIFTGATE
DOOR REAR REAR LOCK
LOCK DOOR DOOR MOTOR
MOTOR LOCK LOCK
M M M M
MOTOR MOTOR

J008W-7 XJI06104

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 XJ 8W-61 POWER DOOR LOCKS 8W - 61 - 5
RHD
PASSENGER
POWER
DOOR DOOR
LOCK UNLOCK LOCK/
DRIVER DRIVER WINDOW
5 C1 1 C1 SWITCH
P33 P34
16 16
OR/BK PK/BK

S323 S322
(8W-12-32) (8W-12-32)
P33 P33 P34 P34
16 16 16 16
OR/BK OR/BK PK/BK PK/BK
2 1
PASSENGER
DOOR
LOCK
MOTOR
M

5
4 C305
P33 P34
16 16
OR/BK PK/BK

S306
(8W-12-32)

S307
(8W-12-32)
P34 P33
16 16
PK/BK OR/BK
5 C7 1 C7
JUNCTION
P34 P33 BLOCK
16 16 (8W-12-2)
PK/BK OR/BK

2 1 C326 12 C9 1 C9

P34 P33 P34 P33 P34 P33

16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK

C309 5 4 C304 2 1 C311

5 4 C310
5 4

P34 P33 P34 P33 P34 P33 P34 P33

16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK
1 2 1 2 B A 1 2
LEFT RIGHT LIFTGATE DRIVER
REAR REAR LOCK DOOR
DOOR DOOR MOTOR LOCK
LOCK LOCK MOTOR
M M M M
MOTOR MOTOR

XJI06105 J008W-7

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 XJ 8W - 62 POWER MIRRORS 8W - 62 - 1

8W-62 POWER MIRRORS

Component Page Component Page
Driver Power Lock/Window G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-5, 6
Switch . . . . . . . . . . . . . . . . . . . 8W-62-2, 3, 4, 5, 6 Junction Block . . . . . . . . . . . 8W-62-2, 3, 4, 5, 6, 7, 8
Driver Power Mirror . . . . . . . 8W-62-2, 3, 4, 5, 6, 7, 8 Passenger Power Mirror . . . . . . . . . 8W-62-4, 6, 7, 8
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3, 5 Power Mirror Switch . . . . . . . . . . . . . . . . 8W-62-7, 8
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-8 Rear Fog Lamp Relay . . . . . . . . . . . . . . . . . 8W-62-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3, 4, 7

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 8W - 62 - 2 8W-62 POWER MIRRORS XJ
LHD EXCEPT BUILT-UP-EXPORT FULL OPTIONS
RUN-ACC A31 (8W-10-15)
JUNCTION
BLOCK
(8W-12-2)
FUSE
18
10A
(8W-12-19)

S4 C4
F83
18
YL/DG

44 C201
F83
18
YL/DG
39 C200

F83
18
YL/DG

3 C305
F83
18
YL/DG
3 C2
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 4 1 4 1 4 0 REST
2 0 3 2 0 3 2 0 3 1 LEFT
2 RIGHT
3 UP
4 DOWN
5 6 5 6 5 DRIVER MIRROR
6 PASSENGER MIRROR
5 C2 2 C2 6 C2 1 C2
Z1
14 P76 P75 P71
BK 20 20 20
OR/YL DB/WT YL
S329
(8W-15-17)
Z1
12
3 5 1
BK
DRIVER
3 C307 POWER
Z1 M M
12 MIRROR
BK

S309 2 6 4
(8W-15-17)
Z1 P76 P76
12 20 20
BK OR/YL OR/YL

G302 S328
J008W-7 (8W-15-17) (8W-12-34) XJI06202

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 XJ 8W-62 POWER MIRRORS 8W - 62 - 3
LHD BUILT-UP-EXPORT FULL OPTIONS
RUN-ACC A31 (8W-10-15)
(8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
FUSE
18
10A
(8W-12-19)

S4 C4
F83
18
YL/DG
44 C201
F83
18
YL/DG

39 C200

F83 F83
18 18
YL/DG YL/DG
1
3 C305 REAR
FUSED
F83 IGNITION FOG
18 SWITCH LAMP
YL/DG OUTPUT
(RUN-ACC)
RELAY
3 C2 (8W-51-9)
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 4 1 4 1 4 0 REST
2 0 3 2 0 3 2 0 3 1 LEFT
2 RIGHT
3 UP
4 DOWN
5 6 5 6 5 DRIVER MIRROR
6 PASSENGER MIRROR
5 C2 2 C2 6 C2 1 C2
Z1
14 P76 P75 P71
BK 20 20 20
OR/YL DB/WT YL
S329
(8W-15-17)
Z1
12
3 5 1
BK
DRIVER
3 C307 POWER
Z1 M M
12 MIRROR
BK

S309 2 6 4
(8W-15-17)
Z1 P76 P76
12 20 20
BK OR/YL OR/YL

G302 S328
XJI06203 (8W-15-17) (8W-12-34) J008W-7

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 8W - 62 - 4 8W-62 POWER MIRRORS XJ
LHD FULL OPTIONS
RUN-ACC F83 (8W-12-19)
DRIVER
POWER
LOCK/
WINDOW
SWITCH
0 REST
1 4 1 4 1 4 1 LEFT
2 0 3 2 0 3 2 3 2 RIGHT
0 3 UP
4 DOWN
5 DRIVER MIRROR
5 6 5 6 6 PASSENGER MIRROR

5 C2 2 C2 4 C2 7 C2
Z1 P76 P74 P72
14 20 20 20
BK OR/YL DB YL/BK

S329 S328
(8W-15-17) (8W-12-34)

10 9 8
C305

Z1 P76 P74 P72

12 20 20 20
BK OR/YL DB YL/BK

3 C307 36 35 34
C200
Z1 P76 P74 P72
12 20 20 20
BK OR/YL DB YL/BK

S309 28 24 20 C201
(8W-15-17)
P76 P74 P72
Z1 20 20 20
12 OR/YL DB YL/BK
BK
2 C5 9 C5 10 C5
G302 JUNCTION
(8W-15-17) BLOCK
(8W-12-2)

10 C9 2 C9 6 C9
P76 P76 P74 P72
20 20 20 20
OR/YL OR/YL DB YL/BK

2 4 3 5 1
MIRROR MIRROR DRIVER PASSENGER
COMMON COMMON POWER POWER
DRIVER DRIVER M M
MIRROR MIRROR
(8W-62-2)
(8W-62-3)
2 6 4
P76 P76 P76
20 20 20
OR/YL OR/YL OR/YL

S318
(8W-12-34)
J008W-7 XJI06204

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 XJ 8W-62 POWER MIRRORS 8W - 62 - 5
RHD FULL OPTIONS
RUN-ACC A31 (8W-10-15)
JUNCTION
BLOCK
(8W-12-2)
FUSE
18
10A
(8W-12-20)

S4 C4
F83
18
YL/DG
BUILT-
UP-EXPORT EXCEPT BUILT-UP-EXPORT

S232
(8W-12-20)

F83
18
YL/DG

3 C300
S352
(8W-12-20)
3 C2
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 4 1 4 1 4 0 REST
2 0 3 2 0 3 2 0 3 1 LEFT
2 RIGHT
3 UP
4 DOWN
5 6 5 6 5 DRIVER MIRROR
6 PASSENGER MIRROR
5 C2 2 C2 4 C2 7 C2
Z1
16 P76 P74 P72
BK 20 20 20
OR/YL DB YL/BK
S319
(8W-15-20)
Z1
14
BK
5 C303 3 5 1
DRIVER
Z1
14
POWER
M M MIRROR
BK

S310
2 6 4
(8W-15-20)
Z1 P76 P76
12 20 20
BK OR/YL OR/YL

G303 S318
(8W-15-20) (8W-12-36)
XJI06205 J008W-7

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 8W - 62 - 6 8W-62 POWER MIRRORS XJ
RHD FULL OPTIONS
RUN-ACC F83 (8W-12-20)
DRIVER
POWER
LOCK/
WINDOW
SWITCH
0 REST
1 4 1 4 1 4 1 LEFT
2 0 3 2 0 3 2 3 2 RIGHT
0 3 UP
4 DOWN
5 DRIVER MIRROR
5 6 5 6 6 PASSENGER MIRROR

5 C2 2 C2 6 C2 1 C2
Z1 P76 P75 P71
16 20 20 20
BK OR/YL DB/WT YL/LB

S319
(8W-15-20) S318
(8W-12-36)
P76
20
Z1 OR/YL
14
BK
10 C9 2 C9 6 C9
JUNCTION
BLOCK
5 C303 (8W-12-2)

Z1
14 2 C5 9 C5 10 C5
BK
P76 P74 P72
20 20 20
S310 OR/YL DB YL/BK
(8W-15-20)
9 8
Z1 10 C204
12
BK P76 P74 P72
20 20 20
G303 OR/YL DB YL/BK
(8W-15-20)
10 9 8 C305

P76 P75 P71

20 20 20
OR/YL DB/RD YL

P76 P76 3 5 1
20 20 PASSENGER
OR/YL OR/YL POWER
2 4 M M MIRROR
MIRROR MIRROR DRIVER
COMMON COMMON POWER 2 6 4
DRIVER DRIVER MIRROR
(8W-62-5) P76 P76
20 20
OR/YL OR/YL

S328
(8W-12-36)
J008W-7 XJI06206

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 XJ 8W-62 POWER MIRRORS 8W - 62 - 7
LHD EXCEPT FULL OPTIONS

RUN-ACC F83 (8W-12-19)

POWER
4 MIRROR
1
SWITCH
1 RIGHT
2 UP
3 LEFT
4 DOWN

2 3

1 3 4 7 8 5 6

Z1 P74 P72 P75 P71 P76 P91

14 20 20 20 20 20 20
BK DB YL/BK DB/WT YL OR/YL WT/BK

S329 2 5 1
(8W-15-17) DRIVER
POWER
M M MIRROR
Z1
16 2 C9 6 C9
BK 3 6 4
JUNCTION
BLOCK
(8W-12-2) P91 P76
20 20
WT/BK OR/YL
9 C5 10 C5
P74 P72 10 C9 7 C9
3 C307 JUNCTION
20 20
DB YL/BK BLOCK
Z1 (8W-12-2)
12 24 20 C201
BK
C200 2 C5 3 C5
35 34
P76 P91
P74 P72 20 20
20 20 OR/YL WT/BK
DB YL/BK
S309
(8W-15-17) 28 67 C201
9 8 C305
Z1 36 12 C200
P74 P72
12 20 20 P76 P91
BK DB YL/BK 20 20
2 5 1 OR/YL WT/BK
PASSENGER
POWER 10 13 C305
M M MIRROR
P76 P91
20 20
OR/YL WT/BK
3 6 4
G302
(8W-15-17)
XJI06207 J008W-7

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 8W - 62 - 8 8W-62 POWER MIRRORS XJ
RHD EXCEPT FULL OPTIONS
RUN-ACC F83 (8W-12-20)
POWER
4 MIRROR
1
SWITCH
1 RIGHT
2 UP
3 LEFT
4 DOWN

2 3

1 7 8 4 3 5 6

Z1 P75 P71 P72 P74

20 20 20 20 20
BK DB/WT YL/LB YL/BK DB

1 5 2
S319 DRIVER
(8W-15-13) P76 P91
POWER 20 20
M M MIRROR OR/YL WT/BK
Z1
16
BK
4 6 3
11 C9 2 C9 6 C9
JUNCTION P76 P91
20 20
BLOCK OR/YL WT/BK
(8W-12-2)

S5 C4 9 C5 10 C5
Z1 P74 P72
14 20 20
BK DB YL/BK
10 C9 7 C9
9 8
C204 JUNCTION
BLOCK
P74 P72 (8W-12-2)
20 20 2 C5
DB YL/BK
3 C5 3 C7
P76 P91
20 20
OR/YL WT/BK
9 8 C305
S208 10 C204
(8W-15-14)
P76
10 C203
(8W-15-15)
20 P91 P91
P75 P71 OR/YL 20 20
20 20 WT/BK WT/BK
DB/WT YL
POWER
2 5 1 BASE MIRRORS
Z1 PASSENGER
14 POWER S359
BK M M (8W-12-35)
MIRROR
10 13 C305
3 6 4 P76 P91
20 20
G107 OR/YL WT/BK
(8W-15-14)
(8W-15-15)
J008W-7 XJI06208

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 XJ 8W - 63 POWER SEAT 8W - 63 - 1

8W-63 POWER SEAT

Component Page Component Page
Circuit Breaker 29 (JB) . . . . . . . . . . . . 8W-63-2, 3, 6 Left Power Seat Motors . . . . . . . . . . . . . . . 8W-63-2
Forward/Rearward Motor . . . . . . . . . . . . 8W-63-2, 3 Left Power Seat Switch . . . . . . . . . . . . 8W-63-2, 3, 6
Front Motor . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3 Rear Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-63-4, 6 Right Heated Seat Back . . . . . . . . . . . . . . . 8W-63-5
G306 . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3, 4, 5, 6 Right Heated Seat Cushion . . . . . . . . . . . . 8W-63-5
Heated Seat Relay . . . . . . . . . . . . . . . . . 8W-63-4, 6 Right Heated Seat Switch . . . . . . . . . . . . . . 8W-63-4
Junction Block . . . . . . . . . . . . . . . . . 8W-63-2, 3, 4, 6 Right Power Seat Motors . . . . . . . . . . . . . . 8W-63-3
Left Heated Seat Back . . . . . . . . . . . . . . . . 8W-63-5 Right Power Seat Switch . . . . . . . . . . . . . 8W-63-3, 6
Left Heated Seat Cushion . . . . . . . . . . . . . . 8W-63-5 Seat Heat Interface Module . . . . . . . . . 8W-63-4, 5, 6
Left Heated Seat Switch . . . . . . . . . . . . . . . 8W-63-4

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 8W - 63 - 2 8W-63 POWER SEAT XJ

BATT A7 (8W-10-20)
(8W-10-26)
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT
BREAKER
29
25A
(8W-12-27)

2 C6
F37
14
RD/LB
2 C316
S356
(8W-12-27)

F37
14
RD/LB

1 C362
F37
14
RD
A
LEFT
POWER
SEAT
SWITCH
1 FRONT DOWN
2 FRONT UP
3 REAR DOWN
4 REAR UP
5 FORWARD
6 REARWARD

1 2 3 4 5 6

N M E J L K B
Z1
14
BK
P21 P19 P13 P11 P15 P17
14 14 14 14 14 14 2 C362
RD/LG YL/LG RD/WT YL/WT YL/LB RD/LB
Z1
14
BK

G306
(8W-15-22)
LEFT
FRONT REAR FORWARD/ POWER
M MOTOR M MOTOR M REARWARD SEAT
MOTOR MOTORS

J008W-7 XJI06302

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 XJ 8W-63 POWER SEAT 8W - 63 - 3

BATT A7 (8W-10-20)
(8W-10-26)
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT
BREAKER
29
25A
(8W-12-27)

2 C6

F37
14
RD/LB

2 C316

S356
(8W-12-27)
F37
F37 14
14 RD/LB
RD/LB
1 C362
F37
1 C363 14
RD
A
F37 FUSED LEFT
14 B(+) POWER
RD
SEAT
SWITCH
(8W-63-2)
B
RIGHT
POWER
SEAT
SWITCH
1 2 3 4 5 6 1 FRONT UP
2 FRONT DOWN
3 REAR UP
4 REAR DOWN
N M J E K L A 5 FORWARD
6 REARWARD
Z1
14
P20 P18 P12 P10 P14 P16 BK
14 14 14 14 14 14
RD/LG YL/LG RD/WT YL/WT YL/LB RD/LB
2 C363

Z1
14
BK

G306
(8W-15-22)

RIGHT
FRONT REAR FORWARD/ POWER
M MOTOR M MOTOR M REARWARD SEAT
MOTOR MOTORS

XJI06303 J008W-7

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 8W - 63 - 4 8W-63 POWER SEAT XJ
HEATED SEATS
RUN-ACC A31 (8W-10-15)
(8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
FUSE
18
10A
(8W-12-19)
(8W-12-20)

S4 C4
RHD LHD

F83 F83
18 18
YL/DG YL/DG

3 C300 44 C201 FUSED HEATED

IGNITION SEAT
F83 F83 SWITCH RELAY
18 18 OUTPUT (8W-63-6)
YL/DG YL/DG (RUN-ACC)
4
S352 39 C200
(8W-12-20) F83
18
1 C324 S351 YL/DG
(8W-12-19)

1 C316 11 C329
F83 F83
18 18
YL/DG YL/DG

S353

4 4
LEFT RIGHT
HEATED HEATED
2 1 SEAT 1 2 SEAT
SWITCH SWITCH
1 HIGH 1 HIGH
2 LOW 2 LOW

3 1 5 6 6 5 1 3
Z1 P137 P139 P133 P134 P140 P138 Z1
18 18 18 18 18 18 18 18
BK VT VT/WT TN/DG TN/RD VT/BK VT/LG BK
3 5 1 2 6 4
S355 C329 S355
(8W-15-22) P137 P139 P133 P134 P140 P138 (8W-15-22)
Z1 18 18 18 18 18 18
18 VT VT/WT TN/DG TN/RD VT/BK VT/LG
BK
G306
12 14 1 9 11 10 (8W-15-22)
LEFT LEFT LEFT RIGHT RIGHT RIGHT SEAT
G306 SEAT SEAT SEAT SEAT SEAT SEAT HEAT
(8W-15-22) LOW HIGH HEATER HEATER HIGH LOW INTERFACE
HEAT HEAT SWITCH SWITCH HEAT HEAT
LED LED MUX MUX LED LED
MODULE
DRIVER DRIVER DRIVER DRIVER
J008W-7 XJI06304

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 XJ 8W-63 POWER SEAT 8W - 63 - 5
HEATED SEATS
SEAT
HEAT
LEFT LEFT RIGHT RIGHT INTERFACE
HEATED HEAT HEAT HEATED MODULE
SEAT SENSE SENSOR SENSE SEAT
DRIVER INPUT FEED INPUT DRIVER GROUND
5 8 2 7 3 13

P87 P143 P144 P86 Z2

18 18 18 18 18
BK/OR BK/DG BK/YL PK/BK BK/LG

7 9 C329 13 C329
P87 P143 P141
18 18 18 Z2
BK/OR BK/DG TN/LB 18
BK/LG
3 2
C332
P87 P143
18 18 G306
BK/OR BK/DG (8W-15-22)

A D D A
LEFT RIGHT
HEATED HEATED
SEAT SEAT
CUSHION CUSHION
B C C B

P88 P141 P141 P89

18 18 18 18
BR/BK TN/LB TN/LB BR

1 C332
A P141 A
18
LEFT TN/LB
RIGHT
HEATED HEATED
SEAT SEAT
8 C329
BACK BACK
B P141 B
18
Z1 TN/LB Z1
18 18
BK BK
S357
4 C332 S354
(8W-15-22)
12 C329
Z1 Z1
18 18
BK BK

S355
(8W-15-22)
Z1
18
BK

G306
(8W-15-22)
XJI06305 J008W-7

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 8W - 63 - 6 8W-63 POWER SEAT XJ
HEATED SEATS
RUN-ACC A31 (8W-10-15) BATT A7 (8W-10-20)
(8W-10-16) (8W-10-26)
JUNCTION
BLOCK
(8W-12-2)
FUSE CIRCUIT
18 BREAKER
10A 29
(8W-12-19) 25A
(8W-12-20) (8W-12-27)

S4 C4 2 C6
RHD LHD

F83 F83 F37

18 18 14
YL/DG YL/DG RD/LB
3 C300 44 C201
S352 F83
18
(8W-12-20)
F83 YL/DG
18
YL/DG
39 C200
F83
1 C324 18
F83 YL/DG
18
YL/DG S351
(8W-12-19)
F83
18
YL/DG

1 2 C316
F83 F37
18 14
YL/DG RD/LB

S353 S356
(8W-63-4) (8W-12-27)
F83 F37 F37 F37
18 14 14 14
YL/DG RD/LB RD/LB RD/LB
10
11 C329 1 C363
F83 F37
1 C362
F37
18 14 F37 14
YL/DG RD/LB 14 RD
4 8 RD
HEATED B
SEAT A FUSED RIGHT
S354 FUSED LEFT B(+) POWER
RELAY
(8W-15-22) B(+) POWER SEAT
Z1 SEAT GROUND SWITCH
18 6 2 GROUND SWITCH (8W-63-3)
BK A
Z1 F235 F235 B (8W-63-2)
18 16 16
BK RD RD
2 C362 2 C363
12 C329 4 6 Z1 Z1
S355 HEATED HEATED SEAT 14 14
(8W-15-22) SEAT SEAT HEAT BK BK
RELAY RELAY INTERFACE
G306 OUTPUT OUTPUT G306
(8W-15-22) MODULE (8W-15-22)

J008W-7 XJI06306

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 XJ 8W - 70 SPLICE INFORMATION 8W - 70 - 1

8W-70 SPLICE INFORMATION

Component Page Component Page
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-12 S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-28, 29
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-24 S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8, 9
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, -10, 12 S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, -10, 12 S217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10 S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28, 29
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-10, 11 S219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22, 23
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32, -33, 35 S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-12
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13, 32
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12 S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13, 32
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23 S225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23 S226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3 S227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-7 S228 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, -3, -4, 5
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23 S229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3 S230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 12
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2 S232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-13 S237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 S238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-11, 13 S239 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12 S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-33, 34
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2 S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32, 33
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11 S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-8
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11 S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2 S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-29 S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31, 32
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15, 16 S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31, 32
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 26 S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-11, 12
S132 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, -5, -6, -8, -9, 11 S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7 S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19, 20
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22, 23 S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10, 11
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27 S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-16 S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19 S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3, 4 S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19, 34 S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-7 S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, -6, -8, 11 S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-34, 36
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6 S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13, 20
S143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18 S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7, 8
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21 S321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-7, 8
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21 S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-32
S146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3 S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-32
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32 S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23
S148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-26 S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
S149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4 S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-5, 6
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19 S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-34, 36
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-29 S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19 S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
S156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-34 S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
S157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
S158 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, -10, 12 S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
S159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14 S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
S161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6 S337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7 S338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
S163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7 S339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
S164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-19 S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10, 11
S165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 12 S341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17, 18
S166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18 S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
S168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-23 S344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
S169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12 S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30
S170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17 S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28, -29, 30
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-30 S348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19, 20
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32, 33 S349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-32 S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4, -5, -6, 7 S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10, 11 S353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16 S354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14, 15 S355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5, 6 S356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17 S357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 16 S359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-35
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-7, 8 S361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28, 29
S213 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, -5, -6, 7
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-27, 30

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 8W - 70 - 2 8W-70 SPLICE INFORMATION XJ

POWERTRAIN CAMSHAFT CRANKSHAFT THROTTLE

CONTROL POSITION POSITION POSITION
MODULE SENSOR SENSOR SENSOR
(8W-30-5) (8W-30-5) (8W-30-5) (8W-30-7)
17 C1 3 3 3
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
3 (8W-30-12)

K7 K7 K7 K7 K7
18 18 20 20 20
OR OR OR OR OR

S115
(GAS)
OXYGEN OXYGEN POWERTRAIN
SENSOR SENSOR CONTROL
1/1 2/1 MODULE
TURN UPSTREAM UPSTREAM (8W-30-10)
SIGNAL/ (8W-30-10) (8W-30-11) (8W-30-11)
3 3
4 C1
HAZARD
SWITCH OXYGEN OXYGEN
3 (8W-52-2) SENSOR SENSOR
(8W-52-3)
(8W-52-4)
1/2 2/2
L62
20 DOWNSTREAM DOWNSTREAM
BR/RD (8W-30-10) (8W-30-11)
3 3

LHD RHD
K167 K167 K167 K167 K167
25 C200 11 C204 20 20 20 20 18
BR/YL BR/YL BR/YL BR/YL BR/YL
L62 L62
20 20
BR/RD BR/RD S123
(4.0L
CALIFORNIA/
S312 EUROPEAN III)
L62 L62
20 20
BR/RD BR/RD K167
20
1 C321 8 C323 BR/YL

L62 L62
18 20
A
BR/RD BK/RD
TO
2 1 S111
RIGHT TRAILER (8W-70-3)
TURN TOW
SIGNAL RIGHT
LAMP TURN
(8W-52-7) RELAY
(8W-52-8) (8W-54-3)
J008W-7 XJI07002

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 XJ 8W-70 SPLICE INFORMATION 8W - 70 - 3
GAS
FUEL CLOCKSPRING
PUMP (8W-30-13)
MODULE
(8W-30-3)
(8W-30-4)
4
K167
3 C1 BATTERY
20 TEMPERATURE
BR/YL K4 SENSOR
LHD RHD 20 (4.0L)
BK/RD (8W-30-13)
2
30 C200 7 C204
TRANSMISSION
CONTROL K167
MODULE B6
20
K167 (4.0L) F18 C100 BR/YL
20 (8W-31-5)
BR/YL 16
K167
B3 K167 20
C100 BR/YL
F12 20
BR/YL

S138
INTAKE MANIFOLD ENGINE
AIR ABSOLUTE COOLANT
TEMPERATURE PRESSURE TEMPERATURE
SENSOR SENSOR SENSOR
1 (8W-30-7) 1 (8W-30-12) 1 (8W-30-7)

CRANKSHAFT THROTTLE OXYGEN

POSITION POSITION SENSOR
SENSOR SENSOR 1/1
(8W-30-5) (8W-30-7) UPSTREAM
2 1 (EXCEPT 4.0L
3
CALIFORNIA/
K167 K167 K167 K167 K167 K167 EUROPEAN III)
20 20 20 20 20 20 (8W-30-8)
BR/YL BR/YL BR/YL BR/YL BR/YL BR/YL (8W-30-10)

S114
POWERTRAIN OXYGEN
CONTROL SENSOR
MODULE 1/2 ENGINE
(EXCEPT 4.0L DOWNSTREAM OIL
PRESSURE
4 C1 CALIFORNIA/ (EXCEPT 4.0L K167
EUROPEAN III CALIFORNIA/ SENSOR 20
3 (8W-30-12) BR/YL
(8W-30-3) EUROPEAN III 3
(8W-30-4) (8W-30-8)
(8W-30-10) K167
18 FROM
BR/YL S123 3 C107
CAMSHAFT VEHICLE (8W-70-2) K167
POSITION SPEED 20
A K167
SENSOR SENSOR BR/YL
20
(8W-30-5) (8W-30-12) BR/YL
K167 RHD
2 2 20 LHD
K167
18 K167 K167 K167 BR/YL
BR/YL 20 20 20
BR/YL BR/YL BR/YL

S111
XJI07003 J008W-7

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 8W - 70 - 4 8W-70 SPLICE INFORMATION XJ
DIESEL
LEFT RIGHT
SPEED SPEED
CONTROL CONTROL
SWITCH SWITCH
1 (8W-33-3) 1 (8W-33-3)

S222
K167 FUEL ENGINE
20 INJECTION COOLANT
BR/YL PUMP TEMPERATURE
A C2
(8W-30-26) SENSOR
4 2 NO. 1
CLOCKSPRING (8W-30-29)
(8W-33-3)

ACCELERATOR ENGINE
PEDAL CONTROL
K4
POSITION 18 MODULE
3 C1 SENSOR BK/LB (8W-30-26)
(8W-30-28) TURBO
3
BOOST
61 C2
K4 PRESSURE
20 SENSOR
BK/RD
1 (8W-30-27)

B6
C100 9 C120
F18 K4
20
K4 K4 K4 BK/LB K4 K4
20 20 20 20 20
BK/LB BK/LB BK/LB BK/LB BK/LB

S149
FUEL ENGINE
LEVEL COOLANT
SENSOR TEMPERATURE
BATTERY
(8W-30-31) SENSOR
TEMPERATURE
4 2 NO. 2
(8W-30-29)
SENSOR
(8W-30-31)
K167 12 C120
20 2
BR/YL ENGINE
OIL
LHD RHD PRESSURE VEHICLE
SENSOR SPEED
(8W-30-29) SENSOR
30 C200 7 C204 3 (8W-30-29)
LOW
K167 2
COOLANT
18
BR/YL SWITCH K167
K167 K167 (8W-30-31) 20
20 WATER 18 BR/YL
POWERTRAIN
BR/YL IN BR/YL 2 CONTROL
FUEL 8 C111 MODULE
B3 SENSOR (8W-30-29)
C100 K167
F12 (8W-30-31) 3 C116 20
2
BR/YL
4 C1

K167 K167 K167 K167 K167 K167

20 20 20 20 20 18
BR/YL BR/YL BR/YL BR/YL BR/YL BR/YL RHD
LHD
S138
J008W-7 XJI07004

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 XJ 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1

8W-80 CONNECTOR PIN-OUTS

Component Page Component Page
A/C Compressor Clutch . . . . . . . . . . . . . . . . 8W-80-4 C320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28
A/C Heater Control . . . . . . . . . . . . . . . . . . . 8W-80-4 C321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28
A/C High Pressure Switch . . . . . . . . . . . . . 8W-80-4 C322 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28, 29
A/C Low Pressure Switch . . . . . . . . . . . . . . 8W-80-5 C323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
Accelerator Pedal Position Sensor . . . . . . . . 8W-80-5 C324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
Airbag Control Module . . . . . . . . . . . . . . . . 8W-80-5 C326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Ambient Temperature Sensor . . . . . . . . . . . 8W-80-6 C327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Back-Up Lamp Switch . . . . . . . . . . . . . . . . 8W-80-6 C329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-31
Battery Temperature Sensor . . . . . . . . . . . . 8W-80-6 C330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-31
Blend Door Actuator . . . . . . . . . . . . . . . . . . 8W-80-6 C332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-31
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7 C333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
Blower Motor Relay . . . . . . . . . . . . . . . . . . 8W-80-7 C362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
Blower Motor Resistor Block . . . . . . . . . . . 8W-80-7 C363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
Brake Lamp Switch . . . . . . . . . . . . . . . . . . 8W-80-7 Camshaft Position Sensor . . . . . . . . . . . . . 8W-80-32
Brake Warning Pressure Switch . . . . . . . . . 8W-80-7 Cargo Lamp/Switch . . . . . . . . . . . . . . . . . . 8W-80-32
C100 . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8, 9, 10, 11 Center High Mounted Stop Lamp . . . . . . . 8W-80-33
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12 Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
C107 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-13, 14 Clockspring-C1 . . . . . . . . . . . . . . . . . . . . . 8W-80-33
C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15 Clockspring-C2 . . . . . . . . . . . . . . . . . . . . . 8W-80-33
C109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15 Clockspring-C3 . . . . . . . . . . . . . . . . . . . . . 8W-80-33
C111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15 Clutch Interlock Switch . . . . . . . . . . . . . . 8W-80-34
C113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15 Clutch Interlock Switch Jumper . . . . . . . . 8W-80-34
C114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 Combination Flasher . . . . . . . . . . . . . . . . . 8W-80-34
C115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 Compass . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
C116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 Controller Anti-Lock Brake . . . . . . . . . . . . 8W-80-35
C120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16 Crankshaft Position Sensor . . . . . . . . . . . . 8W-80-36
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 Data Link Connector . . . . . . . . . . . . . . . . . 8W-80-36
C201 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18, 19 Daytime Running Lamp Module . . . . . . . . 8W-80-37
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20 Diode Module . . . . . . . . . . . . . . . . . . . . . . 8W-80-37
C203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20 Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-80-37
C204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21 Dome Lamps Switch . . . . . . . . . . . . . . . . . 8W-80-37
C205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21 Driver Door Jamb Switch . . . . . . . . . . . . . 8W-80-38
C206 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21, 22 Driver Door Lock Motor . . . . . . . . . . . . . . 8W-80-38
C207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22 Driver Power Lock/Window Switch . . . 8W-80-38, 39
C208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22 Driver Power Mirror . . . . . . . . . . . . . . . . . 8W-80-39
C300 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22, 23 Driver Power Window Motor . . . . . . . . . . . 8W-80-40
C301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23 Duty Cycle Evap/Purge Solenoid . . . . . . . . 8W-80-40
C303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23 Electronic Vacuum Modulator . . . . . . . . . . 8W-80-40
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24 Engine Control Module . . . . . . . . . . . . 8W-80-41, 42
C305 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24, 25 Engine Coolant Temperature Sensor . . . . . 8W-80-43
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25 Engine Oil Pressure Sensor . . . . . . . . . . . 8W-80-43
C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26 Engine Speed Sensor . . . . . . . . . . . . . . . . 8W-80-43
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26 Evap Leak Detection Pump . . . . . . . . . . . . 8W-80-44
C310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26 Extended Idle Switch . . . . . . . . . . . . . . . . 8W-80-44
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26 Front Fog Lamp Switch . . . . . . . . . . . . . . 8W-80-44
C312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26 Front Wiper Motor . . . . . . . . . . . . . . . . . . 8W-80-44
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26 Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-45
C314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27 Fuel Injector No. 1 . . . . . . . . . . . . . . . . 8W-80-45, 46
C316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27 Fuel Injector No. 2 . . . . . . . . . . . . . . . . 8W-80-45, 46
C317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27 Fuel Injector No. 3 . . . . . . . . . . . . . . . . 8W-80-45, 46
C318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28 Fuel Injector No. 4 . . . . . . . . . . . . . . . . 8W-80-45, 46
C319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28 Fuel Injector No. 5 . . . . . . . . . . . . . . . . . . 8W-80-46

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 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS XJ

Component Page Component Page

Fuel Injector No. 6 . . . . . . . . . . . . . . . . . . 8W-80-46 Liftgate Switch . . . . . . . . . . . . . . . . . . . . . 8W-80-64
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . 8W-80-47 Low Coolant Switch . . . . . . . . . . . . . . . . . 8W-80-64
Fuel Pump Module . . . . . . . . . . . . . . . . . . 8W-80-47 Manifold Absolute Pressure Sensor . . . . . . 8W-80-65
G Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-47 Needle Movement Sensor . . . . . . . . . . . . . 8W-80-65
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-47 Overhead Module . . . . . . . . . . . . . . . . . . . 8W-80-65
Glow Plug Relay . . . . . . . . . . . . . . . . . . . . 8W-80-48 Oxygen Sensor 1/1 Upstream . . . . . . . . . . 8W-80-65
Headlamp Beam Select Switch . . . . . . . . . 8W-80-48 Oxygen Sensor 1/2 Downstream . . . . . . . . 8W-80-66
Headlamp Delay Module . . . . . . . . . . . . . . 8W-80-48 Oxygen Sensor 2/1 Upstream . . . . . . . . . . 8W-80-66
Headlamp Leveling Switch . . . . . . . . . . . . 8W-80-49 Oxygen Sensor 2/2 Downstream . . . . . . . . 8W-80-66
Headlamp Switch . . . . . . . . . . . . . . . . . . . 8W-80-49 Park/Neutral Position Switch . . . . . . . . . . 8W-80-66
Heated Seat Relay . . . . . . . . . . . . . . . . . . 8W-80-50 Passenger Airbag . . . . . . . . . . . . . . . . . . . 8W-80-66
Heater Control . . . . . . . . . . . . . . . . . . . . . . 8W-80-4 Passenger Door Jamb Switch . . . . . . . . . . 8W-80-66
Idle Air Control Motor . . . . . . . . . . . . . . . . 8W-80-50 Passenger Door Lock Motor . . . . . . . . . . . 8W-80-67
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . 8W-80-51 Passenger Power Lock/Window Switch . . . 8W-80-67
Ignition Switch . . . . . . . . . . . . . . . . . . . . . 8W-80-51 Passenger Power Mirror . . . . . . . . . . . . . . 8W-80-68
Instrument Cluster . . . . . . . . . . . . . . . . . . 8W-80-52 Passenger Power Window Motor . . . . . . . . 8W-80-68
Intake Air Temperature Sensor . . . . . . . . . 8W-80-53 Power Amplifier . . . . . . . . . . . . . . . . . . . . 8W-80-69
Junction Block . . . . . . . . . . . . . 8W-80-53, 54, 55, 56 Power Antenna . . . . . . . . . . . . . . . . . . . . . 8W-80-69
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . 8W-80-56 Power Antenna Relay . . . . . . . . . . . . . 8W-80-69, 70
Left City Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-57 Power Mirror Switch . . . . . . . . . . . . . . . . . 8W-80-70
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-80-57 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . 8W-80-70
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-57 Power Steering Pressure Switch . . . . . . . . 8W-80-70
Left Front Door Speaker . . . . . . . . . . . . . . 8W-80-57 Powertrain Control
Left Front Door Tweeter . . . . . . . . . . . . . . 8W-80-57 Module . . . . . . . . . . . . 8W-80-71, 72, 73, 74, 75, 76
Left Front Park/Turn Signal Lamp No. 1 . 8W-80-58 PRNDL Illumination . . . . . . . . . . . . . . . . . 8W-80-77
Left Front Park/Turn Signal Lamp No. 2 . 8W-80-58 Radiator Fan Motor . . . . . . . . . . . . . . . . . 8W-80-77
Left Front Turn Signal Lamp No. 1 . . . . . 8W-80-58 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-77
Left Front Turn Signal Lamp No. 2 . . . . . 8W-80-58 Rail Coil . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-77
Left Front Wheel Speed Sensor . . . . . . . . . 8W-80-59 Rear Fog Lamp Relay . . . . . . . . . . . . . . . . 8W-80-78
Left Headlamp . . . . . . . . . . . . . . . . . . . . . 8W-80-59 Rear Fog Lamp Switch . . . . . . . . . . . . . . . 8W-80-78
Left Headlamp Leveling Motor . . . . . . . . . 8W-80-59 Rear Washer Pump . . . . . . . . . . . . . . . . . . 8W-80-78
Left Heated Seat Back . . . . . . . . . . . . . . . 8W-80-59 Rear Window Defogger Switch . . . . . . . . . 8W-80-78
Left Heated Seat Cushion . . . . . . . . . . . . . 8W-80-59 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . 8W-80-78
Left Heated Seat Switch . . . . . . . . . . . . . . 8W-80-60 Rear Wiper/Washer Switch . . . . . . . . . . . . 8W-80-79
Left License Lamp . . . . . . . . . . . . . . . . . . 8W-80-60 Right Back-Up Lamp . . . . . . . . . . . . . . . . 8W-80-79
Left Power Seat Front Vertical Motor . . . . 8W-80-60 Right City Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-79
Left Power Seat Horizontal Motor . . . . . . 8W-80-60 Right Courtesy Lamp . . . . . . . . . . . . . . . . 8W-80-79
Left Power Seat Rear Vertical Motor . . . . 8W-80-60 Right Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-79
Left Power Seat Switch . . . . . . . . . . . . . . . 8W-80-61 Right Front Door Speaker . . . . . . . . . . . . . 8W-80-80
Left Rear Door Jamb Switch . . . . . . . . . . . 8W-80-61 Right Front Door Tweeter . . . . . . . . . . . . . 8W-80-80
Left Rear Door Lock Motor . . . . . . . . . . . . 8W-80-61 Right Front Park/Turn Signal
Left Rear Fog Lamp . . . . . . . . . . . . . . . . . 8W-80-61 Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-80-80
Left Rear Wheel Speed Sensor . . . . . . . . . 8W-80-62 Right Front Park/Turn Signal
Left Rear Window Motor . . . . . . . . . . . . . . 8W-80-62 Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-80-80
Left Rear Window Switch . . . . . . . . . . . . . 8W-80-62 Right Front Turn Signal Lamp No. 1 . . . . 8W-80-80
Left Repeater Lamp . . . . . . . . . . . . . . . . . 8W-80-62 Right Front Turn Signal Lamp No. 2 . . . . 8W-80-81
Left Side Marker Lamp . . . . . . . . . . . . . . . 8W-80-63 Right Front Wheel Speed Sensor . . . . . . . 8W-80-81
Left Soundbar Speaker . . . . . . . . . . . . . . . 8W-80-63 Right Headlamp . . . . . . . . . . . . . . . . . . . . 8W-80-81
Left Speed Control Switch . . . . . . . . . . . . 8W-80-63 Right Headlamp Leveling Motor . . . . . . . . 8W-80-81
Left Tail/Stop Lamp . . . . . . . . . . . . . . . . . 8W-80-63 Right Heated Seat Back . . . . . . . . . . . . . . 8W-80-81
Left Turn Signal Lamp . . . . . . . . . . . . . . . 8W-80-64 Right Heated Seat Cushion . . . . . . . . . . . . 8W-80-81
Left Visor/Vanity Lamp . . . . . . . . . . . . . . . 8W-80-64 Right Heated Seat Switch . . . . . . . . . . . . . 8W-80-82
License Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-80-64 Right License Lamp . . . . . . . . . . . . . . . . . 8W-80-82
Liftgate Lock Motor . . . . . . . . . . . . . . . . . 8W-80-64 Right Power Seat Front Vertical Motor . . . 8W-80-82

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 XJ 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3

Component Page Component Page

Right Power Seat Rear Vertical Motor . . . 8W-80-82 Throttle Position Sensor . . . . . . . . . . . . . . 8W-80-87
Right Power Seat Switch . . . . . . . . . . . . . 8W-80-83 Torque Converter Clutch Solenoid . . . . . . . 8W-80-87
Right Rear Door Jamb Switch . . . . . . . . . . 8W-80-83 Trailer Tow Connector . . . . . . . . . . . . . . . . 8W-80-87
Right Rear Door Lock Motor . . . . . . . . . . . 8W-80-83 Trailer Tow Left Turn Relay . . . . . . . . . . . 8W-80-87
Right Rear Fog Lamp . . . . . . . . . . . . . . . . 8W-80-83 Trailer Tow Right Turn Relay . . . . . . . . . . 8W-80-87
Right Rear Wheel Speed Sensor . . . . . . . . 8W-80-84 Transfer Case Switch . . . . . . . . . . . . . . . . 8W-80-88
Right Rear Window Motor . . . . . . . . . . . . 8W-80-84 Transfer Case Switch Illumination . . . . . . 8W-80-88
Right Rear Window Switch . . . . . . . . . . . . 8W-80-84 Transmission Solenoid . . . . . . . . . . . . . . . 8W-80-88
Right Repeater Lamp . . . . . . . . . . . . . . . . 8W-80-84 Transmission Control Module . . . . . . . . . . 8W-80-89
Right Side Marker Lamp . . . . . . . . . . . . . 8W-80-84 Transmission Range Sensor . . . . . . . . . . . 8W-80-89
Right Soundbar Speaker . . . . . . . . . . . . . . 8W-80-84 Turbo Boost Pressure Sensor . . . . . . . . . . 8W-80-89
Right Speed Control Switch . . . . . . . . . . . 8W-80-85 Turn Signal/Hazard Switch . . . . . . . . . . . . 8W-80-90
Right Tail/Stop Lamp . . . . . . . . . . . . . . . . 8W-80-85 Underhood Lamp/Switch . . . . . . . . . . . . . . 8W-80-90
Right Turn Signal Lamp . . . . . . . . . . . . . . 8W-80-85 Vehicle Speed Control Servo . . . . . . . . . . . 8W-80-90
Right Visor/Vanity Lamp . . . . . . . . . . . . . . 8W-80-85 Vehicle Speed Sensor . . . . . . . . . . . . . . 8W-80-90, 91
Seat Belt Switch . . . . . . . . . . . . . . . . . . . . 8W-80-85 Washer Fluid Level Switch . . . . . . . . . . . . 8W-80-91
Seat Heat Interface Module . . . . . . . . . . . 8W-80-86 Water In Fuel Sensor . . . . . . . . . . . . . . . . 8W-80-91
Sentry Key Immobilizer Module . . . . . . . . 8W-80-86 Windshield Washer Pump . . . . . . . . . . . . . 8W-80-91
Shift Lock Solenoid . . . . . . . . . . . . . . . . . . 8W-80-86 Wipe/Wash Switch . . . . . . . . . . . . . . . . . . . 8W-80-91

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 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

1 2
CAV CIRCUIT FUNCTION
1 C3 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
2 Z1 16BK GROUND
A/C COMPRESSOR
CLUTCH
(DIESEL)

CAV CIRCUIT FUNCTION

BLACK 1 Z8 12BK/VT GROUND
2 C7 12BK/TN BLOWER MOTOR HIGH DRIVER
3 C6 14LB BLOWER MOTOR M2 DRIVER
7 1 4 C5 14LG BLOWER MOTOR M1 DRIVER
5 C4 14TN BLOWER MOTOR LOW DRIVER
A/C-HEATER 6 C90 20LG A/C SWITCH SENSE
CONTROL-C1 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
OR 7
E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
HEATER
CONTROL-C1

NATURAL CAV CIRCUIT FUNCTION

1 - -
2 Z1 20BK GROUND
1 3 C36 20RD/WT BLEND DOOR FEEDBACK SIGNAL
5
3 C36 18RD/WT BLEND DOOR FEEDBACK SIGNAL
A/C-HEATER 4 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
CONTROL-C2 5 - -

1 2
CAV CIRCUIT FUNCTION
1 C22 18DB/WT A/C SWITCH SENSE
A/C HIGH
2 C21 20DB/PK A/C SWITCH SENSE
PRESSURE
SWITCH
(2.5L GAS)

CAV CIRCUIT FUNCTION

1 C21 20DB/PK A/C SWITCH SENSE
2 1
2 C48 18TN RADIATOR FAN REQUEST
4 3
3 C90 20LG A/C SWITCH SENSE
3 Z1 18BK GROUND
A/C HIGH 4 C90 20LG A/C SWITCH SENSE
PRESSURE 4 C22 20DB/WT A/C PRESSURE SWITCH SENSE
SWITCH
(4.0L GAS, A/C ONLY GAS
DIESEL) RHD DIESEL
LHD
J008W-7 XJI08004

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5

1 2 CAV CIRCUIT FUNCTION

1 Z1 20BK GROUND
2 C21 20DB/PK A/C SWITCH SENSE
A/C LOW
PRESSURE
SWITCH
(DIESEL)

CAV CIRCUIT FUNCTION

1 2 1 C21 20DB/PK A/C SWITCH SENSE
1 C22 18DB/WT PRESSURE SWITCH OUTPUT
2 C90 20LG A/C SWITCH SENSE
A/C LOW 2 C21 20DB/PK A/C SWITCH SENSE
PRESSURE
SWITCH
(GAS)
BLACK
CAV CIRCUIT FUNCTION
1 - -
2 - -
5 1 3 K4 20BK/LB SENSOR GROUND
10 6 4 - -
5 K151 20WT LOW IDLE POSITION SWITCH SIGNAL
6 - -
ACCELERATOR K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
7
PEDAL POSITION 8 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR GROUND
SENSOR 9 - -
(DIESEL) 10 K6 20VT/WT 5V SUPPLY

CAV CIRCUIT FUNCTION

1 R45 18DG/LB DRIVER AIRBAG LINE 1
2 R43 18BK/LB DRIVER AIRBAG LINE 2
3 - -
4 - -
YELLOW 5 R42 18BK/YL PASSENGER AIRBAG LINE 2
6 R44 18DG/YL PASSENGER AIRBAG LINE 1
7 - -
1 12
8 - -
9 - -
10 Z6 18BK/PK GROUND
10 Z6 18BK/YL GROUND
11 22 11 - -
12 - -
AIRBAG 13 - -
CONTROL 14 - -
MODULE 15 - -
16 - -
17 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (ST-RUN)
18 D2 18WT/BK CCD BUS(-)
19 D1 18VT/BR CCD BUS(+)
20 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN)

2.5L FULL OPTIONS

4.0L BASE
XJI08005 J008W-7

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 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

CAV CIRCUIT FUNCTION

2 1
1 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G32 20BK/LB SENSOR GROUND
AMBIENT
TEMPERATURE
SENSOR
BLACK

CAV CIRCUIT FUNCTION

A L10 18BR/LG BACK UP LAMP FEED
A B
A F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
B L10 18BR/LG BACK UP LAMP FEED
BACK-UP LAMP B F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
SWITCH

BLACK

CAV CIRCUIT FUNCTION

1 2 1 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
BATTERY 2 K167 20BR/YL SENSOR GROUND
TEMPERATURE
SENSOR
(GAS)
BLACK

1 2 CAV CIRCUIT FUNCTION

1 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
BATTERY 2 K167 20BR/YL SENSOR GROUND
TEMPERATURE
SENSOR
(DIESEL)

BLACK
CAV CIRCUIT FUNCTION
5 - -
10 5 6 - -
7 D1 20DB/WT GROUND
BLEND
8 D3 20YL BLEND DOOR FEEDBACK SIGNAL
DOOR
9 - -
ACTUATOR
10 D2 20OR FUSED IGNITION SWITCH OUTPUT (RUN)

GAS
DIESEL

J008W-7 XJI08006

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7

CAV CIRCUIT FUNCTION

A B
A C1 12DG BLOWER MOTOR RELAY OUTPUT
B C7 12BK/TN BLOWER MOTOR HIGH DRIVER
BLOWER
MOTOR

BLACK
CAV CIRCUIT FUNCTION
4
3 1 C1 12DG BLOWER MOTOR RELAY OUTPUT
2 5 2 Z1 20BK GROUND
3 - -
1
4 A111 12RD/LG FUSED B(+)
BLOWER
5 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
MOTOR
RELAY

BLACK

CAV CIRCUIT FUNCTION

4 1
1 C4 14TN BLOWER MOTOR LOW DRIVER
BLOWER 2 C5 14LG BLOWER MOTOR M1 DRIVER
MOTOR 3 C6 14LB BLOWER MOTOR M2 DRIVER
RESISTOR 4 C7 12BK/TN BLOWER MOTOR HIGH DRIVER
BLOCK

CAV CIRCUIT FUNCTION

GRAY
1 K29 18WT/PK BRAKE LAMP SWITCH SENSE
2 Z1 18BK GROUND
1 2 3 4 5 6 3 V32 20YL/RD SPEED CONTROL POWER SUPPLY
3 V32 18YL/RD SPEED CONTROL POWER SUPPLY
4 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
BRAKE LAMP 5 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
SWITCH 6 F32 20PK/DB FUSED B(+)

BLACK
1 2

CAV CIRCUIT FUNCTION

1 G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER
2 G99 20GY/WT RED BRAKE WARNING INDICATOR DRIVER
BRAKE WARNING
PRESSURE SWITCH

LHD
RHD
XJI08007 J008W-7

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 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT CAV CIRCUIT

A1 Z1 18BK A1 Z1 18BK
A2 G106 20BK/WT A2 G106 20BK/WT
A3 G107 20BK/RD A3 G107 20BK/RD
A4 L92 20PK A4 L39 20LB
A5 L139 20VT
A5 L139 20VT
A5 L77 20BR/YL
A6 C90 20LG
A6 C90 20LG
A6 C90 18LG
A7 - A7 -
A8 - A8 -
A9 - A9 -
A10 - A10 -
BLACK BLACK
A11 - A11 -
A12 - A12 -
E1 F6
F6 E1 A13 - A13 -
F12 E7 E7 F12
A14 - E13 A14 -
F18 E13 F18
A15 - C1 D2 A15 -
D2 C1 A16 A16
- C3 D4 -
D4 C3
A17 - C5 D6 A17 -
D6 C5
A18 - A18 -
A1 B6
B6 A1 B1 - B1 -
A7 B12
B12 A7 B2 - B18 B2 -
A13
B18 A13 B3 B3
- -
B4 - B4 -
B5 - B5 -
C100 B6 -
C100 B6 -
(LHD) B7 -
(LHD) B7 -
B8 - B8 -
B9 - B9 -
B10 - B10 -
B11 - B11 -
B12 - B12 -
B13 - B13 -
B14 - B14 -
B15 - B15 -
B16 - B16 -
B17 - B17 -
B18 - B18 -
C1 V3 16BR/WT C1 V3 16BR/WT
C2 A1 12RD C2 A1 12RD
C3 V4 16BR/VT C3 V4 16BR/VT
C4 F75 16VT C4 F75 16VT
C5 V5 16DG/YL C5 V5 16DG/YL
C6 A2 12PK/BK C6 A2 12PK/BK
D1 A3 14RD/WT D1 A3 14RD/WT
D2 A141 14DG/WT D2 A141 16DG/WT
D3 G34 16RD/GY D3 L3 16RD/OR
D4 G34 16RD/GY D4 G34 16RD/GY
D5 A111 12RD/LG (CONTINUED ON NEXT PAGE) D5 A111 12RD/LG
D6 - D6 -
4.0L A/T
GAS
POWER AMPLIFIER
FOG LAMPS
DRL
DIESEL
GAS
EXCEPT DRL
J008W-7 XJI08008

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9

(CONTINUED)

CAV CIRCUIT CAV CIRCUIT

E1 L50 18WT/TN
E1 L50 20WT/TN
E1 L50 20WT/TN
E2 G9 20GY/BK E2 G9 20GY/BK
E3 L10 18BR/LG E3 L10 18BR/LG
E4 V10 18BR E4 V10 18BR
E5 V20 18BK/WT E5 V20 18BK/WT
E6 F34 18TN/BK E6 F34 18TN/BK
E7 Z12 20BK/TN
E7 Z12 18BK/TN
E7 Z12 18BK/TN
E8 G29 20BK/LB E8 G29 20BK/LB
E9 F20 18WT E9 F20 18WT
E10 F1 20DB/GY E10 F1 20DB/GY
E11 D1 20VT/BR
E11 D1 20VT/BR
E11 D1 18VT/BR
E12 D2 20WT/BK
E12 D2 20WT/BK
E12 D2 18WT/BK
E13 F26 18PK/OR E13 -
E14 G99 20GY/WT E14 G99 20GY/WT
E15 K185 20OR/LB E15 K185 20OR/LB
E16 G86 18TN/OR E16 G86 20TN/OR
E17 G154 18VT/LG E17 G154 20VT/LG
E18 L13 20BR/YL E18 L13 20BR/YL
F1 D20 18LG/BK F1 D20 20LG/BK
F2 D21 20PK
F2 D21 20PK
F2 D21 18PK
F3 L60 20TN F3 L60 20TN
F4 L61 20LG/WT F4 L61 20LG/WT
F5 L9 20BK/PK F5 L9 20BK/PK
F6 L44 20VT/RD F6 L44 20VT/RD
F7 V30 20DB/RD F7 V30 20DB/RD
F8 F32 20PK/DB F8 F32 20PK/DB
F9 V32 18YL/RD F9 V32 18YL/RD
F10 K29 18WT/PK
F10 K29 20WT/PK
F10 K29 20WT/PK
F11 K226 18DB/LG F11 K226 20DB/LG
F12 K167 20BR/YL F12 K167 20BR/YL
F13 G19 20LG/OR F13 G19 20LG/OR
F14 G31 20VT/LG F14 G31 20VT/LG
F15 G32 20BK/LB F15 G32 20BK/LB
F16 K78 18GY F16 K78 20GY
F17 V37 20RD/LG
F17 V37 20RD/LG
F17 V37 18RD/LG
F18 K4 20BK/LB
F18 K4 20BK/RD
F18 K167 20BR/YL

2.5L GAS ABS

HEADLAMP LEVELING 4.0L A/T
SENTRY KEY IMMOBILIZER MODULE DIESEL
4.0L A/T / DIESEL EXCEPT 4.0L A/T / EXCEPT DIESEL
EXCEPT 4.0L A/T SPEED CONTROL (GAS)
EXCEPT 2.5L GAS GAS
XJI08009 J008W-7

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 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS XJ
CAV CIRCUIT CAV CIRCUIT
A1 Z1 18BK A1 Z1 18BK
A2 G106 20BK/WT A2 G106 20BK/WT
A3 G107 20BK/RD A3 G107 20BK/RD
A4 L92 20PK A4 L39 20LB
A5 L77 20BR/YL
A5 L139 20VT
A5 L139 20VT
A6 C90 20LG
A6 C90 18LG A6 C90 20LG
A7 Z12 18BK/TN A7 Z12 18BK/TN
A8 G29 20BK/LB A8 G29 20BK/LB
A9 F20 18WT A9 F20 18WT
A10 G99 20GY/WT A10 G99 20GY/WT
A11 D1 18VT/BR
A11 D1 20VT/BR
WHITE A11 D1 20VT/BR WHITE
A12 D2 18WT/BK
A12 D2 20WT/BK
F6 E1 A12 D2 20WT/BK F6
E1
F12 E7 A13 - F12 A13 -
E7
F18 E13 F18
A14 G9 20GY/BK E13 A14 G9 20GY/BK
C1 D2
D2 A15 L10 18BR/LG C1 A15 L10 18BR/LG
C3 D4
D4 A16 V10 18BR C3 A16 V10 18BR
C5 D6
D6 A17 V20 18BK/WT C5 A17 V20 18BK/WT
A18 F34 18TN/BK A1 B6 A18 F34 18TN/BK
B6 A1 A7 B12
B12 A7 B1 K29 18WT/PK
A13 B18 B1 K29 18WT/PK
B18 A13 B1 K29 20WT/PK
B2 K226 18DB/LG B2 K226 20DB/LG
B3 K167 20BR/YL B3 K167 20BR/YL
C100 B4 L50 18WT/TN C100
(RHD) B4 L50 20WT/TN (RHD) B4 L50 20WT/TN
B5 V37 18RD/LG
B5 V37 20RD/LG B5 V37 20RD/LG
B6 K167 20BR/YL
B6 K4 20BK/LB B6 K4 20BK/RD
B7 D20 18LG/BK B7 D20 20LG/BK
B8 D21 18PK
B8 D21 20PK
B8 D21 20PK
B9 L60 20TN B9 L60 20TN
B10 L61 20LG/WT B10 L61 20LG/WT
B11 L9 20BK/PK B11 L9 20BK/PK
B12 L44 20VT/RD B12 L44 20VT/RD
B13 - B13 -
B14 - B14 -
B15 - B15 -
B16 - B16 -
B17 - B17 -
B18 - B18 -
C1 V3 16BR/WT C1 V3 16BR/WT
C2 A1 12RD C2 A1 12RD
C3 V4 16BR/VT C3 V4 16BR/VT
C4 F75 16VT C4 F75 16VT
C5 V5 16DG/YL C5 V5 16DG/YL
C6 A2 12PK/BK (CONTINUED ON NEXT PAGE) C6 A2 12PK/BK
D1 A3 14RD/WT D1 A3 14RD/WT
D2 A141 14DG/WT D2 A141 16DG/WT
D3 - D3 -
D4 - GAS DRL D4 -
D5 A111 12RD/LG DIESEL 4.0L A/T D5 A111 12RD/LG
- ABS FOG LAMPS
D6 D6 -
2.5L HEADLAMP LEVELING
POWER AMP EXCEPT 4.0L A/T
J008W-7 XJI08010

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11

(CONTINUED)

CAV CIRCUIT CAV CIRCUIT

E1 - E1 -
E2 - E2 -
E3 - E3 -
E4 - E4 -
E5 - E5 -
E6 - E6 -
E7 F45 20YL/RD E7 F45 20YL/RD
E8 T141 20YL E8 T141 20YL
E9 - E9 -
E10 F1 20DB/GY E10 F1 20DB/GY
E11 - E11 -
E12 - E12 -
E13 - E13 -
E14 - E14 -
E15 K185 20OR/LB E15 K185 20OR/LB
E16 G86 18TN/OR E16 G86 20TN/OR
E17 G154 18VT/LG E17 G154 20VT/LG
E18 L13 20BR/YL E18 L13 20BR/YL
F1 D20 18LG/BK F1 -
F2 - F2 -
F3 - F3 -
F4 - F4 -
F5 - F5 -
F6 - F6 -
F7 V30 20DB/RD F7 V30 20DB/RD
F8 F32 20PK/DB F8 F32 20PK/DB
F9 V32 18YL/RD F9 V32 20YL/RD
F10 - F10 -
F11 - F11 -
F12 - F12 -
F13 G19 20LG/OR F13 G19 20LG/OR
F14 G31 20VT/LG F14 G31 20VT/LG
F15 G32 20BK/LB F15 G32 20BK/LB
F16 - F16 -
F17 - F17 -
F18 - F18 -

ABS
SENTRY KEY IMMOBILIZER MODULE
MESSAGE CENTER
HEADLAMP LEVELING

XJI08011 J008W-7

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 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT CAV CIRCUIT

1 L13 20BR/YL 1 L13 18BR/YL
BLACK 2 L33 20RD BLACK 2 L33 18RD
3 L61 20LG/WT 3 L61 20LG
4 Z1 20BK 4 Z1 18BK
5 Z15 16BK/GY 5 Z15 18BK/GY
1 7
7 1 6 L34 20RD/OR 6 L34 18RD/OR
14 8 8 14
7 L77 20BR/YL 7 L77 20BR
8 L39 20LB 8 L39 20LB
9 L43 20VT 9 L43 18VT
C106 C106
10 L60 20TN 10 L60 20TN
(DIESEL) 11 Z1 20BK/WT (DIESEL) 11 Z1 18BK/WT
12 - 12 Z1 20BK
13 L44 20VT/RD 13 L44 18VT/RD
14 L78 18DG/YL 14 L78 20DG/YL

CAV CIRCUIT CAV CIRCUIT

1 L13 20BR/YL 1 L13 18BR/YL
2 L33 20RD 2 L33 18RD
BLACK 3 L61 20LG/WT BLACK 3 L61 20LG
4 Z1 20BK 4 Z1 18BK
5 Z15 16BK/GY 5 Z15 18BK/GY
6 L34 20RD/OR 1 7 6 L34 18RD/OR
7 1 7 L77 20BR/YL 7 L77 20BR
14 8 8 14
8 L39 20LB 8 L39 20LB
9 L43 20VT 9 L43 18VT
C106 10 L60 20TN C106 10 L60 20TN
(GAS) (GAS) 11 Z1 18BK
11 Z1 20BK/WT
11 Z1 18BK/WT
12 L33 20RD
12 L33 20RD/WT
12 Z1 20BK
13 L44 20VT/RD 13 L44 18VT/RD
14 L78 20DG/YL 14 L78 20DG/YL

FOG LAMPS
FOG LAMPS EXCEPT BUILT-UP-EXPORT
FOG LAMPS BUILT-UP-EXPORT
EXCEPT BUILT-UP-EXPORT
BUILT-UP-EXPORT
RHD
EXCEPT ABS
HEADLAMP LEVELING

J008W-7 XJI08012

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13

CAV CIRCUIT CAV CIRCUIT

1 A142 18DG/OR 1 A142 18DG/OR
2 K20 18DG 2 K20 18DG
BLACK 3 K167 20BR/YL BLACK 3 K167 20BR/YL
4 G7 20WT/OR 4 G7 20WT/OR
5 Z1 20 BK
5 T41 20BK/WT
1 7 5 T41 18BK/WT
7 1 6 - 6 -
14 8 8 14
7 F142 18DG/WT 7 F142 20DG/WT
8 G107 20BK/RD 8 G107 20BK/RD
C107 9 - C107 9 -
(LHD 2.5L GAS) 10 F12 18DB/WT (LHD 2.5L GAS) 10 F12 18DB/WT
11 F20 18WT 11 F20 18WT
12 - 12 L10 18BR/LG
13 - 13 -
14 A61 16DG/BK 14 A61 14DG/BK

CAV CIRCUIT CAV CIRCUIT

1 A142 18DG/OR 1 A142 18DG/OR
2 K20 18DG 2 K20 18DG
BLACK BLACK
3 K167 20BR/YL 3 K167 20BR/YL
4 G7 20WT/OR 4 G7 20WT/OR
5 T41 20BK/WT
1 7 5 T41 18BK/WT
5 Z1 18BK
7 1
14 8 6 K22 20OR/DB 8 14 6 K22 20OR/DB
7 A42 18DG 7 A42 20DG
8 G107 20BK/RD 8 G107 20BK/RD
C107 9 Z12 18BK/TN C107 9 Z12 16BK/TN
(LHD 4.0L GAS) 10 F12 18DB/WT (LHD 4.0L GAS) 10 F12 18DB/WT
11 K78 18GY 11 K78 18GY
12 G106 20BK/WT 12 G106 20BK/WT
13 A242 20VT/OR
13 A242 18VT/OR
13 A242 20DG/OR
14 A61 16DG/BK 14 A61 14DG/BK

4.0L A/T
4WD
A/T
M/T
4WD A/T
EXCEPT 4.0L M/T 2WD
DRL
2WD CALIFORNIA, BUILT-UP-EXPORT
4WD CALIFORNIA, BUILT-UP-EXPORT
EXTENDED IDLE

XJI08013 J008W-7

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 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT CAV CIRCUIT

1 A142 18DG/OR 1 A142 18DG/OR
2 K20 18DG 2 K20 18DG
BLACK BLACK
3 K167 20BR/YL 3 K167 20BR/YL
4 - 4 G7 20WT/OR
5 Z1 20 BK
5 T41 20BK/WT
1 7 5 T41 18BK/WT
7 1
14 8 6 - 6 -
8 14
7 F142 18DG/WT 7 F142 20DG/WT
8 G107 20BK/RD 8 G107 20BK/RD
C107 9 - C107 9 -
(RHD 2.5L GAS) 10 F12 18DB/WT (RHD 2.5L GAS) 10 F12 18DB/WT
11 F20 18WT 11 F20 18WT
12 L10 18BR/LG 12 L10 18BR/LG
13 - 13 -
14 A61 16DG/BK 14 A61 14DG/BK

CAV CIRCUIT CAV CIRCUIT

1 A142 18DG/OR 1 A142 18DG/OR
2 K20 18DG 2 K20 18DG
3 K167 20BR/YL 3 K167 20BR/YL
4 G7 20WT/OR 4 G7 20WT/OR
BLACK 5 T41 20BK/WT BLACK
5 T41 18BK/WT
5 Z1 18BK
6 K22 20OR/DB 6 K22 20OR/DB
7 A42 18DG 1 7 7 A42 20DG
7 1
14 8 8 G107 20BK/RD 8 G107 20BK/RD
8 14
9 Z12 18BK/TN 9 Z12 16BK/TN
10 F12 18DB/WT 10 F12 18DB/WT
C107 11 - C107 11 -
(RHD 4.0L GAS) 12 G106 20BK/WT (RHD 4.0L GAS) 12 G106 20BK/WT
13 A242 20VT/OR
13 A242 18VT/OR
13 A242 20DG/OR
14 A61 16DG/BK 4.0L A/T 14 A61 14DG/BK
4WD
A/T
M/T
4WD A/T
4.0L GAS (EXCEPT M/T 2WD)
DRL
2WD CALIFORNIA/BUILT-UP-EXPORT
4WD CALIFORNIA/BUILT-UP-EXPORT
J008W-7 XJI08014

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15

BLACK BLACK
4 1
4 1 CAV CIRCUIT CAV CIRCUIT
1 T40 16BR 1 T40 16BR
2 K72 18DG/OR 2 K72 16DG/OR
3 K20 18DG 3 K20 16DG
4 C3 16DB/BK C108 4 C3 16DB/BK
C108
(GAS) (GAS)

BLACK CAV CIRCUIT CAV CIRCUIT

A B41 18YL/VT BLACK A B41 20YL/VT
B B42 18TN/WT B B42 20TN/WT
D A C B43 18PK/OR A D C B43 20PK/OR
E H D B1 18YL/DB H E D B1 20YL/DB
E B2 18YL E B2 20YL
C109 F B3 18LG/DB C109 F B3 20LG/DB
G B4 18LG G B4 20LG

CAV CIRCUIT CAV CIRCUIT

LT GRAY 1 G7 20WT/OR 1 G7 18WT/OR
LT GRAY
2 - 2 -
3 G107 20BK/RD 3 G107 20BK/RD
5 4 Z1 18BK 4 Z1 20BK
1 1 5
5 L10 18BR/LG 5 L10 18BR/LG
10 6
6 K7 20OR 6 10 6 K7 18OR
7 F20 18WT 7 F20 18WT
C111 8 K167 20BR/YL C111 8 K167 18BR/YL
(DIESEL) 9 - (DIESEL) 9 -
10 T40 16BR 10 T40 14BR

GRAY GRAY

CAV CIRCUIT CAV CIRCUIT

1 Z1 20BK 1 Z1 20BK
3 1 1 3
2 G106 20BK/WT 2 G106 20BK/WT
3 G107 20BK/RD 3 G107 20BK/RD
C112
(4.0L A/T 4WD) C112
(4.0L A/T 4WD)
1 2

CAV CIRCUIT CAV CIRCUIT

1 F20 18WT 1 F20 18WT
2 1
2 L10 18BR/LG 2 L10 18BR/LG
C113 C113
(GAS M/T) (GAS M/T)

XJI08015 J008W-7

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 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

BLACK

CAV CIRCUIT CAV CIRCUIT

1 2 2 1
1 L61 18LG 1 L61 18GY
2 Z1 18BK 2 Z1 18BK
C114 C114
(BUILT-UP-EXPORT) (BUILT-UP-EXPORT)

BLACK

BLACK

CAV CIRCUIT CAV CIRCUIT

1 2 1 L60 18TN 2 1 1 L60 18GY
2 Z1 18BK 2 Z1 18BK
C115 C115
(BUILT-UP-EXPORT) (BUILT-UP-EXPORT)

BLACK BLACK

CAV CIRCUIT CAV CIRCUIT

1 K7 20OR 1 K7 18OR
3 1 1 3
2 G60 18GY/YL 2 G60 18GY/YL
3 K167 20BR/YL 3 K167 18BR/YL
C116
(DIESEL) C116
(DIESEL)

CAV CIRCUIT CAV CIRCUIT

1 K3 20LG/BK BLACK 1 K3 20LG/BK
BLACK 2 C21 20DB/PK 2 C21 20DB/PK
3 C22 20DB/WT 3 C22 20DB/WT
4 K24 20GY/BK 4 K24 20GY/BK
7 1 1 7
5 K20 18DG 5 K20 18DG
14 8 6 C3 16DB/BK 8 14 6 C3 14DB/BK
7 K72 18DG/OR 7 K72 18DG/OR
C120 8 K2 20TN/BK C120 8 K2 18TN/BK
(DIESEL) 9 K4 20BK/LB (DIESEL) 9 K4 18BK/LB
10 K222 18TN/RD 10 K222 18TN/RD
11 Z1 16BK 11 Z1 16BK
12 K167 18BR/YL 12 K167 18BR/YL
13 C48 18TN 13 C48 18TN
14 - 14 -

J008W-7 XJI08016

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17

CAV CIRCUIT CAV CIRCUIT

1 X53 18DG 1 X53 16DG
2 X55 18BR/RD 2 X55 16BR/RD
3 - 3 -
4 X54 18VT 4 X54 16VT
5 X56 18DB/RD 5 X56 16DB/RD
6 X51 18BR/YL 6 X51 16BR/YL
7 X57 18BR/LB GRAY 7 X57 16BR/LB
GRAY
8 - 8 -
5 1 9 X52 18DB/WT 9 X52 16DB/WT
1 5
10 X58 18DB/OR 10 X58 16DB/OR
11 X60 18DG/RD 11 X60 16DG/RD
12 P91 20WT/BK 12 P91 20WT/BK
13 A141 16DG/WT 13 A141 16DG/WT
14 F75 14VT 14 F75 16VT
15 K226 20DB/LG 15 K226 20DB/LG
40 36 16 L10 18BR/LG 36 40 16 L10 18BR/LG
17 G16 20BK/LB 17 G16 20BK/LB
C200 18 -
C200
18 -
(LHD) (LHD)
19 - 19 -
20 - 20 -
21 - 21 -
22 - 22 -
23 L38 18BR/WT 23 L38 18BR/WT
24 L50 20WT/TN 24 L50 20WT/TN
25 L62 20BR/RD 25 L62 20BR/RD
26 L63 20DG/RD 26 L63 20DG/RD
27 V13 18BR 27 V13 18BR/LG
28 V20 18BK/WT 28 V20 18BK/WT
29 V23 18BR/PK 29 V23 18BR/PK
30 K167 20BR/YL 30 K167 20BR/YL
31 P35 20OR/VT 31 P35 20OR/VT
32 P36 20PK/VT 32 P36 20PK/VT
33 F81 12TN 33 F81 12TN
34 P72 20YL/BK 34 P72 20YL/BK
35 P74 20DB 35 P74 20DB
36 P76 20OR/YL 36 P76 20OR/YL
C16 20LB/YL
37 C16 20LB/YL 37
C16 20LB/YL
38 - 38 -
F83 18YL/DG
39 F83 18YL/DG 39
F83 18YL/DG
40 G78 20TN/BK 40 G78 20TN/BK

FULL OPTIONS (WITH POWER AMPLIFIER)

FULL OPTIONS
BUILT-UP-EXPORT

XJI08017 J008W-7

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 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT CAV CIRCUIT

1 F20 18WT 1 F20 18WT
2 C16 20LB/YL 2 C16 20LB/YL
3 L5 20BK 3 L5 20BK
4 C36 20RD/WT 4 C36 20RD/WT
5 F87 20WT/BK 5 F87 20WT/BK
6 M1 20PK 6 M1 20PK
7 Z1 20BK 7 Z1 20BK
8 V6 16DB 8 V6 16DB
9 P36 20PK/VT 9 P36 20PK/VT
10 A31 12BK/WT 10 A31 12BK/WT
11 A111 12RD/LG 11 A111 12RD/LG
NATURAL 12 C7 12BK/TN 12 C7 12BK/TN
68 37 F81 12TN F81 12TN
13 NATURAL 13
31 37 68
14 Z1 14BK 14 Z1 14BK
29
72 15 - 74 15 -
65 20 16 L3 16RD/OR 29 72 16 L3 16RD/OR
63 17 C81 20LB/WT 17 C81 20LB/WT
17 20
64 65
18 - 18 -
62 17 64
16 19 - 19 -
61 16 61
14 20 P72 20YL/BK 15 20 P72 20YL/BK
59 60
21 - 14 21 -
58 13 59
50 11 22 L4 16VT/WT 11 58 22 L4 16VT/WT
55 12 23 P35 20OR/VT 10 23 P35 20OR/VT
47 10 55
24 P74 20DB 24 P74 20DB
46 3 25 Z8 20BK/VT 46 25 Z8 16BK/VT
1
26 X3 20BK/RD 26 X3 20BK/RD
38 27 - 1 7 38 44 27 -
28 P76 20OR/YL 28 P76 20OR/YL
C201 29 G26 20LB C201 29 G26 20LB
(LHD) 30 -
(LHD) 30 -
31 - 31 -
32 G31 20VT/LG 32 G31 20VT/LG
33 - 33 -
34 - 34 -
35 G32 20BK/LB 35 G32 20BK/LB
36 - 36 -
37 - 37 -
38 - 38 -
39 V23 18BR/PK 39 V23 18BR/PK
40 F15 20DB/WT 40 F15 20DB/WT
41 - 41 -
42 E1 20TN 42 E1 20TN
43 E2 20OR 43 E2 20OR

(CONTINUED)

J008W-7 XJI08018

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19

CAV CIRCUIT (CONTINUED) CAV CIRCUIT

44 F83 18YL/DG 44 F83 18YL/DG
45 L7 18BK/YL 45 L7 18BK/YL
46 M2 20YL 46 M2 20YL
47 - 47 -
48 - 48 -
49 - 49 -
50 F30 16RD 50 F30 16RD
51 D1 18VT/BR 51 D1 20VT/BR
52 D2 18WT/BK 52 D2 20WT/BK
53 - 53 -
54 X12 16RD/WT 54 X12 16RD/WT
55 D1 20VT/BR 55 D1 20VT/BR
56 D2 20WT/BK 56 D2 20WT/BK
57 - 57 -
58 Z2 20BK/LG 58 Z2 20BK/LG
59 C4 14TN 59 C4 14TN
60 C5 14LG 60 C5 14LG
61 C6 14LB 61 C6 14LB
62 A22 12BK/OR 62 A22 12BK/OR
63 A41 14YL 63 A41 14YL
64 A21 12DB 64 A21 12DB
65 F38 16RD/LB 65 F38 16RD/LB
66 G9 20GY/BK 66 G9 20GY/BK
67 P91 20WT/BK 67 P91 20WT/BK
68 - 68 -
69 G10 20LG/RD 69 G10 20LG/RD
70 - 70 -
71 - 71 -
72 - 72 -
73 - 73 -
74 - 74 -

XJI08019 J008W-7

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 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT CAV CIRCUIT

1 C7 12BK/TN 1 C7 12BK/TN
2 - 2 -
GRAY 3 F81 12TN GRAY 3 F81 12TN
4 - 4 -
5 - 5 -
5 1 6 Z8 16BK/VT 1 5 6 Z8 12BK/VT
7 A111 12RD/LG 7 A111 12RD/LG
10 6 8 C6 14LB 6 10 8 C6 14LB
9 C5 14LG 9 C5 14LG
C202 10 C4 14TN C202 10 C4 14TN
(RHD) (RHD)

CAV CIRCUIT CAV CIRCUIT

1 P55 20DB/PK 1 P55 20DB/PK
2 P59 20LB/RD 2 P59 20LB/RD
3 G26 20LB 3 G26 20LB
4 G16 20BK/LB 4 G16 20BK/LB
5 V20 18BK/WT 5 V20 18BK/WT
6 V23 18BR/PK 6 V23 18BR/PK
BLUE BLUE
7 V13 18BR/LG 7 V13 18BR
8 L38 18BR/WT 8 L38 18BR/WT
15 22 9 - 22 15 9 -
9 14 10 P91 20WT/BK 14 9
5 8 8 5 10 P91 20WT/BK
11 G10 20LG/RD 11 G10 20LG/RD
1 4 4 1
12 E2 20OR 12 E2 20OR/BK
13 G9 20GY/BK 13 G9 20GY/BK
C203 14 X60 16DG/RD C203 14 X60 18DG/RD
(RHD) 15 (RHD)
X58 16DB/OR 15 X58 18DB/OR
16 X57 16BR/LB 16 X57 18BR/LB
17 X56 16DB/RD 17 X56 18DB/RD
18 X55 16BR/RD 18 X55 18BR/RD
19 X54 16VT 19 X54 18VT
20 X53 16DG 20 X53 18DG
21 X52 16DB/WT 21 X52 18DB/WT
22 X51 16BR/YL 22 X51 18BR/YL

FULL OPTIONS W/ POWER AMPLIFIER

BUILT UP EXPORT
BASE AND FULL OPTIONS W/O POWER AMPLIFIER
FULL OPTIONS

J008W-7 XJI08020

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21

CAV CIRCUIT CAV CIRCUIT

1 F15 20DB/WT 1 F15 20DB/WT
WHITE 2 C16 20BK/WT 2 C16 20LB/YL
WHITE
3 P35 20OR/VT 3 P35 20OR/VT
24 19 4 P36 20PK/VT 19 24 4 P36 20PK/VT
18 11 5 G78 20TN/BK 11 18 5 G78 20TN/BK
10 5 5 10
6 K226 20DB/LG 6 K226 20DB/LG
4 1 1 4
7 K167 20BR/YL 7 K167 20BR/YL
8 P72 20YL/BK C204 8 P72 20YL/BK
C204
9 P74 20DB (RHD) 9 P74 20DB
(RHD)
10 P76 20OR/YL 10 P76 20OR/YL
11 L62 20BR/RD 11 L62 20BR/RD
12 L63 20DG/RD 12 L63 20DG/RD
13 - 13 -
14 F23 18DB/YL 14 F23 18DB/YL
15 F14 18LG/YL 15 F14 18LG/YL
16 F35 16RD 16 F35 16RD
17 Z1 20BK 17 Z1 20BK
18 C36 18RD/WT 18 C36 20RD/WT
19 D1 20VT/BR 19 D1 18VT/BR
20 D2 20WT/BK 20 D2 18WT/BK
21 F75 16VT 21 F75 16VT
22 A141 16DG/WT 22 A141 16DG/WT
23 L10 18BR/LG 23 L10 18BR/LG
24 L50 20WT/TN 24 L50 20WT/TN

YELLOW
YELLOW CAV CIRCUIT CAV CIRCUIT
1 R42 18BK/YL 1 R42 18BK/YL
2 R44 18DG/YL 2 R44 18DG/YL
1 4
3 R43 18BK/LB 3 R43 18BK/LB
4 1 4 R45 18DG/LB 4 R45 18DG/LB
C205 C205

BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
1 E2 20OR E2 20OR
1 2 1 1
2 1 E2 20OR/BK E2 20OR
Z1 20BK
2 Z1 20BK 2
C206 Z1 20BK
C206
(A/T)
(A/T)

FULL OPTIONS
RHD
LHD
XJI08021 FULL OPTIONS W/POWER AMP J008W-7

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 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS XJ

BLACK BLACK

1 2 1
2 CAV CIRCUIT CAV CIRCUIT
1 E2 20OR 1 E2 20OR
1 E2 20OR/BK 2 Z1 20BK
C206 2 Z1 20BK C206
(M/T) (M/T)

BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
A M1 20PK B A A M1 18PK
A B
B M2 20YL B M2 18BK/WT
C207 C207

BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
A M1 20PK B A A M1 18PK
A B
B M2 20YL B M2 18BK/WT
C208 C208

CAV CIRCUIT CAV CIRCUIT

1 Z1 20BK 1 D1 20DB/WT
BLACK
2 C4 14TN LT. GREEN 2 C4 14TN
3 C5 14LG 3 C5 14LG
4 C6 14LB 4 C6 14LB
5 1 5 F15 20DB/WT 5 5 D2 20OR
1
10 6 6 C36 20RD/WT 10 6 D3 20YL
6
7 C7 12BK/TN 7 C7 12BK/TN
8 A111 12RD/LG 8 A111 12RD/LG
C209 C209
9 F15 20DB/WT 9 F15 20DB/WT
10 Z8 12BK/VT
10 Z1 20BK
10 Z8 20BK/VT

NATURAL
NATURAL
CAV CIRCUIT CAV CIRCUIT
1 P35 20OR/VT 1 P35 20OR/VT
1 3 2 P36 20PK/VT 3 1 2 P36 20PK/VT
3 P55 20DB/PK 3 P55 20DB/PK
4 6 6 4
4 P59 20LB/RD 4 P59 20LB/RD
5 G26 20LB 5 G26 20LB
C300 6 - C300 6 -
(LHD) (LHD)

RHD
LHD
J008W-7 XJI08022

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23

WHITE
WHITE
CAV CIRCUIT CAV CIRCUIT
1 P35 18OR/VT 1 P35 20OR/VT
1 3 2 P36 18PK/VT 3 1 2 P36 20PK/VT
3 F83 18YL/DG 3 F83 18YL/DG
4 6 - 6 4
4 4 -
5 - 5 -
C300 6 - C300 6 -
(RHD) (RHD)

CAV CIRCUIT CAV CIRCUIT

1 D1 20VT/BR WHITE 1 D1 20VT/BR
WHITE 2 D2 20WT/BK 2 D2 20WT/BK
3 G32 20BK/LB 3 G32 20BK/LB
4 G31 20VT/LG 4 1 4 G31 20VT/LG
1 4
5 Z2 20BK/LG 10 5 5 Z2 20BK/LG
5 10
6 F87 20WT/BK 6 F87 20WT/BK
C301 7 X3 20BK/RD C301 7 X3 20BK/RD
8 P55 20DB 8 P55 20DB/PK
9 P59 20LB/RD 9 P59 20LB/RD
10 - 10 -

NATURAL CAV CIRCUIT BLACK CAV CIRCUIT

3 1 1 Q16 14BR/WT
1 Q16 14BR/WT
1 V23 18BR/PK
1 3
2 Q26 14VT/WT 2 Q26 14VT/WT
4 6 3 Q1 14YL
3 Q1 14YL
6 4
4 X80 18LB/BK
4 X80 18LB/BK
C303 C303 4 X56 18DB/RD
(EXCEPT RHD (EXCEPT RHD 5 X82 18LB/RD
5 X82 18LB/RD
FULL OPTIONS) FULL OPTIONS) 5 X54 18VT
6 - 6 -

CAV CIRCUIT CAV CIRCUIT

WHITE 1 Q18 14GY/BK
WHITE 1 Q18 14GY/BK
1 V23 18BR/PK
2 Q28 14DG/WT 2 Q28 14DG/WT
3 Q17 14DB/WT 1 4 3
1 2 3 4 Q17 14DB/WT
4 1
5 6 7 8 8 4 Q1 14YL
4 Q1 14YL 5
8 5 4 X56 18DB/RD
5 Z1 14BK
C303 5 Z1 14BK C303 5 X54 18VT
(RHD FULL 6 Q27 14RD/BK (RHD FULL 6 Q27 14RD/BK
OPTIONS) 7 Q16 14BR/WT OPTIONS) 7 Q16 14BR/WT
8 Q26 14VT/WT 8 Q26 14VT/WT

FULL OPTIONS
OVERHEAD CONSOLE
FULL OPTIONS AND POWER MIRRORS 4 SPEAKER SYSTEM
XJI08023 BASE 6 SPEAKER SYSTEM J008W-7

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 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS XJ

BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
3 1 1 Q18 14GY/BK 1 Q18 14GY/BK
2 Q28 14DG/WT 1 3 2 Q28 14DG/WT
3 Q1 14YL 3 Q1 14YL
4 6
6 4 4 P33 16OR/BK 4 P33 16OR/BK
5 P34 16PK/BK 5 P34 16PK/BK
C304 6 - C304 6 -
(LHD) (LHD)

BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
3 1 1 Q18 14GY/BK 1 Q18 14GY/BK
2 Q28 14DG/WT 1 3 2 Q28 14DG/WT
3 Q1 14YL 3 Q1 14YL
4 6
6 4 4 P33 16OR/BK 4 P33 16OR/BK
5 P34 16PK/BK 5 P34 16PK/BK
C304 6 - C304 6 -
(RHD) (RHD)

CAV CIRCUIT CAV CIRCUIT

1 X85 18BR/RD 1 X85 18BR/RD
1 X55 18LG/RD 1 X55 18BR/RD
2 X87 18DG WHITE 2 X87 18LG/VT
WHITE 2 X53 18LG/BK 2 X53 18DG
3 F83 18YL/DG 3 F83 18YL/DG
1 3 4 P33 16OR/BK 3 1
4 P33 16OR/BK
4 8 5 P34 16PK/BK 8 4
5 P34 16PK/BK
9 13 6 P35 20OR/VT 13 9 6 P35 18OR/VT
7 P36 20PK/VT 7 P36 18PK/VT
C305 8 P72 20YL/BK C305 8 P72 20YL/BK
(LHD) 9 P74 20DB (LHD) 9 P74 20DB
10 P76 20OR/YL 10 P76 20OR/YL
11 C16 20LB/YL
11 C16 20LB/YL
11 C16 20BK/WT
12 - 12 -
13 P91 20WT/BK 13 P91 20WT/BK

FULL OPTIONS AND POWER MIRRORS

POWER LOCK/WINDOWS
POWER MIRRORS 4 SPEAKERS
FULL OPTIONS 6 SPEAKERS
J008W-7 XJI08024

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25

CAV CIRCUIT CAV CIRCUIT

1 X85 18BR/RD 1 X85 18BR/RD
1 X55 18LG/RD 1 X55 18BR/RD
2 X87 18DG 2 X87 18LG/VT
2 X53 18LG/BK 2 X53 18DG
3 P59 20LB/RD 3 P59 20LB/RD
4 P33 16OR/BK WHITE 4 P33 16OR/BK
WHITE 5 P34 16PK/BK 5 P34 16PK/BK
6 P35 20OR/VT 6 P35 18OR/VT
1 3 3 1
7 P36 20PK/VT 7 P36 18PK/VT
4 8 8 P71 20YL 8 4 8 P72 20YL/BK
9 13 9 P75 20DB/RD 13 9
9 P74 20DB
9 P75 20DB/WT
C305 C305
10 P76 20OR/YL 10 P76 20OR/YL
(RHD) (RHD)
11 C16 20LB/YL
11 C16 20LB/YL
11 C16 20BK/WT
12 P55 20DB 12 P55 20DB/PK
13 P91 20WT/BK 13 P91 20WT/BK

WHITE
CAV CIRCUIT WHITE CAV CIRCUIT
1 1 Q18 14GY/BK 1 Q18 14GY/BK
2
2 Q28 14DG/WT 2 Q28 14DG/WT
3 Q16 14BR/WT 2 1 3 Q16 14BR/WT
3 6 4 Q26 14VT/WT 6 3 4 Q26 14VT/WT
5 Q17 14DB/WT 5 Q17 14DB/WT
C306 6 Q27 14RD/BK C306 6 Q27 14RD/BK
(LHD) (LHD)
(POWER WINDOWS) (FULL OPTIONS)

WHITE
CAV CIRCUIT WHITE CAV CIRCUIT
1 2 1 F35 16RD 1 F35 16RD
2 G26 20LB 2 G26 20LB
3 Q16 14BR/WT 2 1 3 Q16 14BR/WT
3 6 4 Q26 14VT/WT 6 3 4 Q26 14VT/WT
5 - 5 -
C306 6 - C306 6 -
(RHD) (RHD)
(POWER WINDOWS) (FULL OPTIONS)

POWER MIRRORS
FULL OPTIONS
POWER MIRRORS W/O FULL OPTIONS
POWER LOCK/WINDOW SWITCHES
4 SPEAKERS
6 SPEAKERS
XJI08025 J008W-7

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 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS XJ

WHITE WHITE
CAV CIRCUIT CAV CIRCUIT
1 F81 14TN 1 F81 12TN
2 Q1 14YL 1 3 2 Q1 14YL
3 1
3 Z1 12BK
3 Z1 12BK
3 Z1 16BK
C307 C307

BLACK BLACK
3 1 CAV CIRCUIT CAV CIRCUIT
1 Q17 14DB/WT 1 3 1 Q17 14DB/WT
2 Q27 14RD/BK 2 Q27 14RD/BK
4 6
6 4 3 Q1 14YL 3 Q1 14YL
4 P33 16OR/BK 4 P33 16OR/BK
C309 5 P34 16PK/BK
C309 5 P34 16PK/BK
(FULL OPTIONS) -
(FULL OPTIONS) -
6 6

CAV CIRCUIT
BLACK
1 P33 16OR/BK
2 P34 16PK/BK
3 4 3 G78 20TN/BK
4 L77 18BR/YL BLACK
1 6 5 M4 20GY/BK
6 Z1 18BK
C311

GREEN CAV CIRCUIT

1 V20 18BK/WT
2 11 6 2 Z1 12BK
CAV CIRCUIT 10 5
3 C15 12BK/WT
1 Z1 12BK 9 4
4 P33 16OR/BK
2 C15 12BK/WT 3
1 5 P34 16PK/BK
2 6 G78 20TN/BK
C312 8 7 V23 18BR/PK
8 V13 18BR/LG
7 1
9 Z1 18BK
10 M4 20VT/YL
11 L77 18BR/YL
GRAY
1
CAV CIRCUIT
1 V13 18BR/LG
2 V23 18BR/PK C310
3 2 3 V20 18BK/WT

C313

POWER MIRRORS
FULL OPTIONS
J008W-7 XJI08026

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27

WHITE
WHITE
CAV CIRCUIT CAV CIRCUIT
1 2 1 X92 16TN/BK 2 1 1 X92 18TN/BK
3 6 1 X52 18DB/WT 6 3 1 X52 18DB/WT
7 8 8 7
2 X94 16TN/RD 2 X94 18TN/RD
2 X58 18DB/OR 2 X58 18DB/OR
C314 3 X91 16BR/DB C314 3 X91 18WT/BK
3 X51 18BR/YL 3 X51 18BR/YL
4 X93 16BR/YL 4 X93 18WT/RD
4 X57 18BR/LB 4 X57 18BR/LB
5 M1 18PK
5 M1 20PK
5 M1 20PK
6 M2 20YL 6 M2 20YL
7 M4 20GY/BK 7 M4 20GY/BK
8 - 8 -

BLACK
BLACK

2 1
1 2
CAV CIRCUIT CAV CIRCUIT
1 F83 18YL/DG 1 F83 18YL/DG
2 F37 14RD/LB 2 F37 14RD/LB

C316 C316

BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
A M2 18YL A M2 20YL
A C B G16 18BK/LB C A B G16 20BK/LB
C Z1 18BK C Z1 20BK
C317 C317
HEATED SEATS
6 SPEAKER
4 SPEAKER
LHD
XJI08027 RHD J008W-7

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 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS XJ

BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
A M2 18YL A M2 20YL
B G16 18BK/LB C A B G16 20BK/LB
A C
C Z1 18BK C Z1 20BK
C318 C318

BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
A M2 18YL A M2 20YL
B A A B
B Z1 18BK B Z1 20BK

C319 C319

BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
A M2 18YL A M2 20YL
B A A B
B Z1 18BK B Z1 20BK

C320 C320

CAV CIRCUIT BLACK CAV CIRCUIT

BLACK
1 L62 18BR/RD 1 L62 20BR/RD
1 3
2 Z1 18BK 2 Z1 18BK
3 1
3 - 3 -
8 4
4 8 4 L38 18OR/WT 4 L38 18BR/WT
5 L10 18BR/LG 5 L10 18BR/LG
C321 C321
6 L50 18WT/TN 6 L50 20WT/TN
7 L78 18DG/YL 7 L78 18DG/YL
8 - 8 -

CAV CIRCUIT BLACK CAV CIRCUIT

BLACK
1 L63 18DG/RD 1 L63 20DG/RD
1 3 2 Z1 16BK
3 1 2 Z1 14BK
2 Z1 18BK
3 - 8 4 3 A6 20RD/OR
4 8
4 L38 18OR/WT 4 L38 18BR/WT
C322 5 L10 18BR/LG C322 5 L10 18BR/LG
(W/O TRAILER TOW) 6 L50 18WT/TN (W/O TRAILER TOW) 6 L50 20WT/TN
7 L77 18BR 7 L77 18BR/YL
8 - 8 L62 20BR/RD

BUILT-UP-EXPORT
EXCEPT BUILT-UP-EXPORT
RHD
J008W-7 XJI08028

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29

CAV CIRCUIT BLACK CAV CIRCUIT

BLACK
1 L63 18DG/RD 1 L63 20DG/RD
1 3 2 Z1 16BK
2 Z1 18BK
2 Z1 18BK 3 1
3 - 8 4 3 -
4 8 4 L38 18OR/WT 4 L38 18BR/WT
5 L10 18BR/LG 5 L10 18BR/LG
C322 C322
6 L50 18WT/TN 6 L50 20WT/TN
(TRAILER TOW) (TRAILER TOW)
7 L77 18BR 7 L77 18BR/YL
8 - 8 -

CAV CIRCUIT BLACK CAV CIRCUIT

BLACK
1 L63 20DG/RD 1 L63 20DG/RD
1 3 2 Z1 14BK 2 Z1 14BK
3 A6 20RD/OR 3 1 3 A6 20RD/OR
4 L38 20OR/WT 8 4 4 L38 18BR/WT
4 8 5 L10 18BR/LG 5 L10 18BR/LG
6 L50 20WT/TN 6 L50 20WT/TN
C323 C323
7 L77 20BR/YL 7 L77 18BR/YL
(TRAILER TOW) (TRAILER TOW)
8 L62 20BK/RD 8 L62 20BR/RD

WHITE

WHITE

3 CAV CIRCUIT CAV CIRCUIT

1
1 F83 18YL/DG 3 2 1 1 F83 18YL/DG
2 X80 18LB/BK 2 X80 18LB/BK
C324 3 X82 18LB/RD C324 3 X82 18LB/RD
(RHD) (RHD)
(FULL OPTIONS) (FULL OPTIONS)

W/ POWER AMPLIFIER
BUILT-UP-EXPORT
EXCEPT BUILT-UP-EXPORT

XJI08029 J008W-7

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 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS XJ

BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
1 P33 16OR/BK 1 P33 16OR/BK
1 2 2 P34 16PK/BK 2 1 2 P34 16PK/BK
3 5 3 M4 20GY/BK 5 3 3 M4 20GY/BK
4 C15 12BK/WT 4 C15 12BK/WT
5 L50 18WT/TN 5 L50 20WT/TN
C326 C326

BLACK CAV CIRCUIT BLACK

CAV CIRCUIT
1 G78 20TN/BK 1 G78 20TN/BK
2 L77 18BR/YL 2 L77 18BR/YL
1 2 2 1
3 V13 18BR/LG 3 V13 18BR
3 6 6 3
4 V23 18BR/PK 4 V23 18BR/PK
5 V20 18BK/WT 5 V20 18BK/WT
C327 6 - C327 6 -

FULL OPTIONS
J008W-7 XJI08030

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31

CAV CIRCUIT CAV CIRCUIT

1 P133 18TN/DG 1 P133 18TN/DG
2 P134 18TN/RD 2 P134 18TN/RD
NATURAL NATURAL 3 P137 18VT
3 P137 18VT
4 P138 18VT/LG 4 P138 18VT/LG
5 P139 18VT/WT 5 P139 18VT/WT
P140 18VT/BK 1 7 6 P140 18VT/BK
7 1 6
14 8 7 P87 18BK/OR 7 P87 18BK/OR
8 14
8 P141 18TN/LB 8 P141 18TN/LB
9 P143 18BK/DG 9 P143 18BK/DG
C329 10 F37 14RD/LB C329 10 F37 14RD/LB
11 F83 18YL/DG 11 F83 18YL/DG
12 Z1 18BK 12 Z1 18BK
13 Z2 18BK/LG 13 Z2 18BK/LG
14 - 14 -

BLACK
BLACK

CAV CIRCUIT CAV CIRCUIT

1 L77 18BR/YL 1 L78 18BK/YL
2 1 1 2
2 Z1 18BK 2 Z1 18BK

C330 C330

NATURAL NATURAL
CAV CIRCUIT CAV CIRCUIT
1 P141 18TN/LB 1 P141 18TN/LB
2 P143 18BK/DG 1 4 2 P143 18BK/DG
4 1 3 P87 18BK/OR 3 P87 18BK/OR
4 Z1 18BK 4 Z1 18BK

C332 C332

XJI08031 J008W-7

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 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS XJ

BLACK BLACK
CAV CIRCUIT 2 1 CAV CIRCUIT
1 2 1 L50 18WT/TN 1 L50 18DG/WT
2 Z1 18BK 2 Z1 18BK

C333 C333

BLACK BLACK

CAV CIRCUIT CAV CIRCUIT

1 F37 14RD/LB 1 F37 14RD
2 1 1 2
2 Z1 14BK 2 Z1 14BK

C362 C362

BLACK BLACK

CAV CIRCUIT CAV CIRCUIT

1 F37 14RD/LB 1 F37 14RD
2 1 1 2
2 Z1 14BK 2 Z1 14BK

C363 C363

GRAY

CAV CIRCUIT FUNCTION

1 3 1 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
2 K167 20BR/YL SENSOR GROUND
3 K7 18OR 5V SUPPLY
CAMSHAFT
POSITION
SENSOR
(GAS)

BLACK
CAV CIRCUIT FUNCTION
A M1 18PK FUSED B(+)
A C A M1 20PK FUSED B(+)
B M2 20YL COURTESY LAMPS DRIVER
CARGO C M4 20GY/BK LIFTGATE COURTESY LAMP DRIVER
LAMP/SWITCH

RHD
LHD

J008W-7 XJI08032

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33

BLACK
1

CAV CIRCUIT FUNCTION

1 Z1 18BK GROUND
2
2 L50 18DG/WT BRAKE LAMP SWITCH OUTPUT
CENTER HIGH
MOUNTED STOP
LAMP

RED

1 CAV CIRCUIT FUNCTION

2
1 F30 16RD CIGAR LIGHTER RELAY OUTPUT
2 - -
3 3 Z1 16BK GROUND
CIGAR
LIGHTER

CAV CIRCUIT FUNCTION

NATURAL
1 X3 20BK/RD HORN RELAY CONTROL
2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
1 4 3 K4 20BK/RD SENSOR GROUND
4 - -
CLOCKSPRING - C1

CAV CIRCUIT FUNCTION

A B A K167 20BR/YL SENSOR GROUND
B V37 20RD/LG SPEED CONTROL SWITCH SIGNAL

CLOCKSPRING - C2

YELLOW
CAV CIRCUIT FUNCTION
2 1 1 R45 18DG/LB DRIVER AIRBAG LINE 1
2 R43 18BK/LB DRIVER AIRBAG LINE 2

CLOCKSPRING - C3

XJI08033 J008W-7

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 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS XJ

GREEN
2 1

CAV CIRCUIT FUNCTION

1 F45 20YL/RD FUSED B(+) ENGINE STARTER MOTOR RELAY
1 T141 20YL IGNITION SWITCH OUTPUT (START)
CLUTCH INTERLOCK 2 T141 20YL IGNITION SWITCH OUTPUT (START)
SWITCH 2 F45 20YL/RD FUSED B(+) ENGINE STARTER MOTOR RELAY

BLACK

1 2 CAV CIRCUIT FUNCTION

1 F45 18YL FUSED B(+) ENGINE STARTER MOTOR RELAY
2 F45 18YL FUSED B(+) ENGINE STARTER MOTOR RELAY
CLUTCH INTERLOCK
SWITCH JUMPER

BLACK

5 1 2 CAV CIRCUIT FUNCTION

3 1 L5 20BK FUSED IGNITION SWITCH OUTPUT (RUN)
2 L9 20BK/PK FUSED B (+)
4 3 L12 20VT/TN HAZARD FLASHER SELECT SIGNAL
4 L6 20RD/WT FLASHER OUTPUT
Z1 18BK GROUND
5
COMBINATION Z1 20BK GROUND
FLASHER
RHD BUILT-UP-EXPORT
LHD DIESEL
EXCEPT LHD DIESEL

J008W-7 XJI08034

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35

CAV CIRCUIT FUNCTION

1 Z1 20BK GROUND
BLACK 2 M1 20PK FUSED B(+)
3 - -
6 1
4 G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
5 D1 20VT/BR CCD BUS (+)
6 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)
7 M2 20YL COURTESY LAMPS DRIVER
12 7 - -
8
COMPASS 9 - -
10 G32 20BK/LB SENSOR GROUND
11 D2 20WT/BK CCD BUS (-)
12 Z2 20BK/LG GROUND

CAV CIRCUIT FUNCTION

1 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
3 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+)
4 B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+)
BLACK
5 - -
6 B41 18YL/VT G SWITCH NO. 1 SENSE
7 B42 18TN/WT G SWITCH NO. 2 SENSE
8 Z1 12BK GROUND
1 10 17 9 A20 12RD/DB FUSED B(+)
10 B4 18LG LEFT REAR WHEEL SPEED SENSOR (+)
11 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
12 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
13 B43 18PK/OR G SWITCH TEST SIGNAL
14 - -
16 15 - -
16 G83 18GY/BK ABS RELAY CONTROL
9 25 17 B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+)
18 B6 18WT/DB RIGHT REAR WHEEL SPEED SENSOR (-)
19 - -
CONTROLLER 20 D21 18PK SCI TRANSMIT/ ISO 9141K
ANTI-LOCK 21 - -
BRAKE 22 - -
23 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
24 Z1 12BK GROUND
25 A10 12RD/DG FUSED B(+)

XJI08035 J008W-7

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 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

1 3 CAV CIRCUIT FUNCTION

1 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
2 K167 20BR/YL SENSOR GROUND
CRANKSHAFT 3 K7 20OR 5V SUPPLY
POSITION
SENSOR
(GAS)

CAV CIRCUIT FUNCTION

1 - -
2 - -
3 D1 18VT/BR CCD BUS (+)
BLACK 4 Z1 18BK GROUND
16 9 5 Z12 18BK/TN GROUND
6 D20 20LG/BK SCI RECEIVE
7 D21 20PK SCI TRANSMIT/ ISO 9141K
8 - -
8 1 9 - -
10 - -
DATA LINK 11 D2 18WT/BK CCD BUS (-)
CONNECTOR 12 - -
13 - -
14 - -
15 - -
16 F34 18TN/BK FUSED B(+)

J008W-7 XJI08036

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37

CAV CIRCUIT FUNCTION

1 L3 16RD DIMMER SWITCH HIGH BEAM OUTPUT
BLACK 2 - -
3 - -
4 G34 16RD/GY HIGH BEAM INDICATOR DRIVER
5 1
5 F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
10 6 6 A3 14RD/WT FUSED B(+)
7 G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL
DAYTIME RUNNING 8 Z12 16BK/TN GROUND
LAMP MODULE
9 - -
(EXCEPT BUILT-
10 L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
UP-EXPORT)

BLACK

CAV CIRCUIT FUNCTION

1 L2 16LG HEADLAMP RELAY OUTPUT
2 L25 18BR REAR FOG LAMP FEED
3 3 L39 18LB FOG LAMP SWITCH OUTPUT

DIODE MODULE
(BUILT-UP-EXPORT)

CAV CIRCUIT FUNCTION

3 1 1 - -
2 M1 20PK FUSED B(+)
DOME LAMP 3 M2 20YL COURTESY LAMPS DRIVER
(BASE/POLICE)

BLACK

C A CAV CIRCUIT FUNCTION

A Z1 20BK GROUND
B M2 20YL COURTESY LAMPS DRIVER
DOME LAMPS C M1 20PK FUSED B(+)
SWITCH
(MIDLINE)

XJI08037 J008W-7

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 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS XJ

1 BLACK
CAV CIRCUIT FUNCTION
1 M2 18YL COURTESY LAMPS DRIVER
2 3 2 G16 18BK/LB DRIVER DOOR AJAR SWITCH SENSE
3 Z1 18BK GROUND

DRIVER DOOR
JAMB SWITCH

2 1

CAV CIRCUIT FUNCTION

1 P34 16PK/BK DOOR UNLOCK DRIVER
2 P33 16OR/BK DOOR LOCK DRIVER
DRIVER DOOR
LOCK MOTOR

CAV CIRCUIT FUNCTION

1 Q28 14DG/WT MASTER WINDOW SWITCH RIGHT REAR DOWN
BLUE 2 Q18 14GY/BK RIGHT REAR WINDOW DRIVER UP
3 Q16 14BR/WT MASTER WINDOW SWITCH PASSENGER UP
5 1 4 Q17 14DB/WT LEFT REAR WINDOW DRIVER UP
12 6 5 Q11 14LB DRIVER WINDOW DRIVER UP
6 Q26 14VT/WT MASTER WINDOW SWITCH PASSENGER DOWN
DRIVER POWER 7 P35 18OR/VT DOOR LOCK SWITCH OUTPUT (LOCK)
LOCK/WINDOW 8 Z1 14BK GROUND
SWITCH-C1 9 F81 14TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
(LHD) 10 Q27 14RD/BK LEFT REAR WINDOW DRIVER DOWN
(FULL OPTIONS) 11 P36 18PK/VT DOOR LOCK SWITCH OUPUT (UNLOOK)
12 Q21 14WT DRIVER WINDOW DRIVER DOWN

CAV CIRCUIT FUNCTION

BLUE 1 Q28 14DG/WT MASTER WINDOW SWITCH RIGHT REAR DOWN
2 Q18 14GY/BK RIGHT REAR WINDOW DRIVER UP
5 1 3 Q11 14BR DRIVER WINDOW DRIVER UP
12 6 4 Q17 14DB/WT LEFT REAR WINDOW DRIVER UP
5 Q16 14BR/WT MASTER WINDOW SWITCH PASSENGER UP
6 Q21 14VT DRIVER WINDOW DRIVER DOWN
DRIVER POWER
7 P35 18OR/VT DOOR LOCK SWITCH OUTPUT (LOCK)
LOCK/WINDOW
8 Z1 14BK GROUND
SWITCH-C1
(RHD) 9 F81 14TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
(FULL OPTIONS) 10 Q27 14RD/BK LEFT REAR WINDOW DRIVER DOWN
11 P36 18PK/VT DOOR LOCK SWITCH OUTPUT (UNLOCK)
12 Q26 14VT/WT MASTER WINDOW SWITCH PASSENGER DOWN

J008W-7 XJI08038

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39

WHITE CAV CIRCUIT FUNCTION

1 P71 20YL LEFT POWER MIRROR VERTICAL DRIVER
4 1 1 P71 20YL/LB LEFT POWER MIRROR VERTICAL DRIVER
2 P76 20OR/YL MIRROR COMMON DRIVER
3 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
8 5 4 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER
5 Z1 14BK GROUND
DRIVER POWER
5 Z1 16BK GROUND
LOCK/WINDOW
6 P75 20DB/WT LEFT POWER MIRROR HORIZONTAL DRIVER
SWITCH-C2
(FULL OPTIONS) 7 P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER
8 Q1 14YL POWER WINDOW SWITCH FEED

CAV CIRCUIT FUNCTION

RED 1 P71 20YL LEFT POWER MIRROR VERTICAL DRIVER
6 4 2 P75 20DB/WT LEFT POWER MIRROR HORIZONTAL DRIVER
2 P76 20OR/YL MIRROR COMMON DRIVER
3 P91 20WT/BK MIRROR COMMON DRIVER
3 3 P75 20DB/WT LEFT POWER MIRROR HORIZONTAL DRIVER
1
4 P76 20OR/YL MIRROR COMMON DRIVER
DRIVER POWER
MIRROR 5 C16 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
(LHD) 5 C16 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
6 Z1 18BK GROUND
6 Z1 16BK GROUND

RED CAV CIRCUIT FUNCTION

6 4 1 P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER
2 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER
2 P76 20OR/YL MIRROR COMMON DRIVER
3 3 P91 20WT/BK MIRROR COMMON DRIVER
1
3 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER
DRIVER POWER 4 P76 20OR/YL MIRROR COMMON DRIVER
MIRROR 5 C16 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
(RHD) 6 Z1 18BK GROUND

POWER MIRRORS
FULL OPTIONS
LHD
RHD
XJI08039 J008W-7

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 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

CAV CIRCUIT FUNCTION

1 2
1 Q11 14LB LEFT FRONT WINDOW DRIVER UP
2 Q21 14WT LEFT FRONT WINDOW DRIVER DOWN
DRIVER POWER
WINDOW MOTOR
(LHD)

BLACK

1 2
CAV CIRCUIT FUNCTION
1 Q11 14BR LEFT WINDOW DRIVER UP
2 Q21 14VT LEFT FRONT WINDOW DRIVER DOWN
DRIVER POWER
WINDOW MOTOR
(RHD)

BLACK

2 1

CAV CIRCUIT FUNCTION

1 K52 18PK/BK DUTY CYCLE EVAP PURGE/SOLENOID CONTROL
2 F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
DUTY CYCLE
EVAP/PURGE
SOLENOID
(GAS)

A D CAV CIRCUIT FUNCTION

A F142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
B K35 18GY/YL EGR SOLENOID CONTROL
ELECTRONIC C - -
VACUUM D Z1 18BK GROUND
MODULATOR
(DIESEL)

J008W-7 XJI08040

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41

CAV CIRCUIT FUNCTION

1 Z12 14BK/TN GROUND
2 A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
3 - -
4 - -
5 C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
6 K159 18VT/RD ENGINE SPEED SENSOR SIGNAL
7
8 C103 18DG A/C REQUEST INPUT
9 K29 20WT/PK BRAKE LAMP SWITCH SENSE
10 C22 20DB/WT A/C PRESSURE SWITCH SENSE
11 K6 20VT/WT 5V SUPPLY
12 K151 20WT LOW IDLE POSITION SWITCH SIGNAL
13 K21 20BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
14 - -
15 - -
16 - -
17 C27 20DB/PK RADIATOR FAN RELAY CONTROL
BLACK
18 G8 18LB/BK FUEL MONITOR OUTPUT SIGNAL
19 - -
20 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
21 - -
41 1
22 - -
23 K255 20WT/DG ACCELERATOR PEDAL POSITION SENSOR GROUND
24 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
25 - -
26 - -
27 Z12 16BK/TN GROUND
28 A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
29 K35 18GY/YL EGR SOLENOID CONTROL
51 14 30 V66 18RD/LG SPEED CONTROL INDICATOR SIGNAL
31 - -
32 K185 20OR/LB WAIT TO START INDICATOR DRIVER
33 K51 20DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
ENGINE CONTROL
MODULE - C1 34 K48 18OR/RD FAULT INDICATOR REQUEST INPUT
(DIESEL) 35 - -
36 - -
37 - -
38 G55 18OR/BK ENGINE DISABLE SIGNAL
39 K9 20LB 5V SUPPLY
40 K1 20DG/RD BOOST PRESSURE SENSOR SIGNAL
41 - -
42 K152 18WT GLOW PLUG RELAY CONTROL
43 - -
44 - -
45 D21 20PK SCI TRANSMIT/ ISO 9141K
46 - -
47 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
48 C48 18TN RADIATOR FAN REQUEST -
49 - -
50 - -
51 G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL

XJI08041 J008W-7

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 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

52 - -
53 K156 20GY FUEL TEMPERATURE SENSOR SIGNAL
54 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
55 K68 18LG/YL NEEDLE MOVEMENT SENSOR GROUND
56 K134 20LB/BK CONTROL SLEEVE POSITION SENSOR SIGNAL
57 K57 20LG/OR CONTROL SLEEVE POSITION SENSOR MIDDLE TAP
BLACK 58 K135 20WT/BK CONTROL SLEEVE POSITION SENSOR MEASURE COIL
59 K140 18TN/WT FUEL QUANTITY ACTUATOR CONTROL
60 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
61 K4 20BK/LB SENSOR GROUND
59 80 62 K67 18BR/BK NEEDLE MOVEMENT SENSOR SIGNAL
63 -
64 -
65 -
66 K140 18TN/WT FUEL QUANTITY ACTUATOR CONTROL
53 72 67 K24 20GY/BK ENGINE SPEED SENSOR SIGNAL
68 -
69 K3 20LG/BK ENGINE SPEED SENSOR GROUND
ENGINE CONTROL 70 -
MODULE - C2 71 -
(DIESEL) 72 -
73 -
74 -
75 -
76 -
77 K153 18OR FUEL SHUTDOWN SOLENOID CONTROL
78 -
79 K126 18LG FUEL TIMING SOLENOID CONTROL
80 K140 18TN/WT FUEL QUANTITY ACTUATOR CONTROL

J008W-7 XJI08042

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43

BLACK

1 2
CAV CIRCUIT FUNCTION
1 K167 20BR/YL SENSOR GROUND
ENGINE COOLANT 2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
TEMPERATURE
SENSOR
(GAS)

BLACK

2 1
CAV CIRCUIT FUNCTION
1 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE 2 K4 18BK/LB SENSOR GROUND
COOLANT
TEMPERATURE
SENSOR NO. 1
(DIESEL)

BLACK

2 1
CAV CIRCUIT FUNCTION
1 K222 18TN/RD ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
2 K167 18BR/YL SENSOR GROUND
ENGINE
COOLANT
TEMPERATURE
SENSOR NO. 2
(DIESEL)

BLACK

3 1
CAV CIRCUIT FUNCTION
1 K6 18VT/OR 5V SUPPLY
ENGINE OIL 1 K7 18OR 5V SUPPLY
PRESSURE SENSOR 2 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
3 K167 18BR/YL SENSOR GROUND

BLACK

CAV CIRCUIT FUNCTION

1 3 1 K3 20LG/BK ENGINE SPEED-SENSOR GROUND
2 - -
3 K24 20GY/BK ENGINE SPEED SENSOR SIGNAL
ENGINE
SPEED SENSOR
(DIESEL) GAS
DIESEL
XJI08043 J008W-7

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 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

4 1 CAV CIRCUIT FUNCTION

1 - -
2 K72 18DG/OR GENERATOR DRIVER
EVAP LEAK 3 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
DETECTION 4 K105 18WT/OR LEAK DETECTION PUMP SWITCH SENSE
PUMP

WHITE

CAV CIRCUIT FUNCTION

1 Z1 20BK GROUND
1 4 2 K78 20GY IDLE ACTUATOR
EXTENDED IDLE 3 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
SWITCH 4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
(POLICE PACKAGE)

BLACK

CAV CIRCUIT FUNCTION

1 4 1 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
2 L39 20LB FOG LAMP SWITCH OUTPUT
3 L139 20VT FUSED HEADLAMP SWITCH OUTPUT
FRONT FOG 4 Z1 20BK GROUND
LAMP
SWITCH

BLACK CAV CIRCUIT FUNCTION

1 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 V5 16DG/YL WIPER PARK SWITCH SENSE
3 1 3 - -
6 4 4 Z1 16BK GROUND
5 V3 16BR/WT WIPER LOW SPEED OUTPUT
FRONT WIPER 6 V4 16BR/VT WIPER HIGH SPEED OUTPUT
MOTOR

J008W-7 XJI08044

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45

2 1

CAV CIRCUIT FUNCTION

1 A93 14RD/BK FUEL HEATER RELAY OUTPUT
FUEL HEATER 2 Z1 14BK GROUND
(DIESEL)

BLACK CAV CIRCUIT FUNCTION

1 K134 20LB/BK CONTROL SLEEVE POSITION SENSOR SIGNAL
2 K57 20LG/OR CONTROL SLEEVE POSITION SENSOR MIDDLE TAP SIGNAL
5 1 3 K135 20WT/BK CONTROL SLEEVE POSITION SENSOR MEASURE COIL
10 6 4 K4 20BK/LB SENSOR GROUND
5 K126 18LG FUEL TIMING SOLENOID CONTROL
6 K153 18OR FUEL SHUT DOWN SOLENOID CONTROL
FUEL INJECTION 7 K156 20GY FUEL TEMPERATURE SENSOR SIGNAL
PUMP 8 K140 16TN/WT FUEL QUANITY ACTUATOR CONTROL
(DIESEL) 9 A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
10 F142 16DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
BLACK

1 2
CAV CIRCUIT FUNCTION
1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR 2 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
NO. 1
(2.5L GAS)

BLACK

CAV CIRCUIT FUNCTION

1 2 1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K12 18TN FUEL INJECTOR NO. 2 DRIVER

FUEL INJECTOR
NO. 2
(2.5L GAS)

BLACK

CAV CIRCUIT FUNCTION

1 2
1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
FUEL INJECTOR
NO. 3
(2.5L GAS)
BLACK

1 2 CAV CIRCUIT FUNCTION

1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER
FUEL INJECTOR
NO. 4
(2.5L GAS)
XJI08045 J008W-7

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 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
2 1

CAV CIRCUIT FUNCTION

1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER

FUEL INJECTOR NO. 1

(4.0L GAS)

BLACK
2 1

CAV CIRCUIT FUNCTION

1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K12 18TN FUEL INJECTOR NO. 2 DRIVER

FUEL INJECTOR NO. 2

(4.0L GAS)
BLACK
2 1

CAV CIRCUIT FUNCTION

1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER

FUEL INJECTOR NO. 3

(4.0L GAS)
BLACK
2 1
CAV CIRCUIT FUNCTION
1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER

FUEL INJECTOR NO. 4

(4.0L GAS)

BLACK
2 1

CAV CIRCUIT FUNCTION

1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K15 18PK/BK FUEL INJECTOR NO. 5 DRIVER

FUEL INJECTOR NO. 5

(4.0L GAS)

BLACK
2 1

CAV CIRCUIT FUNCTION

1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K16 18LG/BK FUEL INJECTOR NO. 6 DRIVER
FUEL INJECTOR NO. 6
(4.0L GAS)
J008W-7 XJI08046

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47

BLACK
6 5 4 CAV CIRCUIT FUNCTION
1 A141 16DG/WT NOT USED
2 - -
3 K226 20DB/LG FUEL LEVEL SENSOR SIGNAL
4 K167 20BR/YL SENSOR GROUND
3 2 1 5 - -
6 Z1 16BK NOT USED
FUEL LEVEL
SENSOR
(DIESEL)

BLACK
6 5 4
CAV CIRCUIT FUNCTION
1 A141 16DG/WT FUEL PUMP RELAY OUTPUT
2 - -
3 K226 20DB/LG FUEL LEVEL SENSOR SIGNAL
4 K167 20BR/YL SENSOR GROUND
3 2 1 5 - -
FUEL PUMP 6 Z1 16BK GROUND
MODULE
(GAS)

BLACK

CAV CIRCUIT FUNCTION

1 B42 20TN/WT G SWITCH NO. 2 SENSE
3 1 2 B41 20YL/VT G SWITCH NO.1 SENSE
3 B43 20PK/OR G SWITCH TEST SIGNAL

G SWITCH

BLACK
CAV CIRCUIT FUNCTION
1 K72 18DG/OR GENERATOR SOURCE
1 K72 16DG/OR GENERATOR SOURCE
1 2 2 K20 18DG GENERATOR FIELD
2 K20 16DG GENERATOR FIELD
GENERATOR
GAS
XJI08047 DIESEL J008W-7

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 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS XJ

1
CAV CIRCUIT FUNCTION
3 2 1 A54 10RD/GY FUSED B (+)
4 2 F142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K152 18WT GLOW PLUG RELAY CONTROL
GLOW PLUG 4 K154 10GY GLOW PLUG RELAY OUTPUT
RELAY
(DIESEL)

BLACK
CAV CIRCUIT FUNCTION
1 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
4 1
2 L2 14LG HEADLAMP SWITCH OUTPUT
3 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
HEADLAMP BEAM 4 L20 14LG/WT FUSED B (+)
SELECT SWITCH

CAV CIRCUIT FUNCTION

BLACK 1 - -
8 6 4 2
2 A3 14RD/WT FUSED B(+)
3 - -
4 Z1 18BK GROUND
5 - -
7 5 3 1 L2 14LG HEADLAMP SWITCH OUTPUT
6
L2 14LG HEADLAMP SWITCH OUTPUT
HEADLAMP 7 - -
DELAY MODULE 8 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)

EXCEPT BUILT-UP-EXPORT

J008W-7 XJI08048

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49

CAV CIRCUIT FUNCTION

BLACK 1 - -
2 L13 20BR/YL HEADLAMP ADJUST SIGNAL
1 6 3 L44 20VT/RD FUSED RIGHT LOW BEAM OUTPUT
4 - -
5 Z15 20BK/GY GROUND
HEADLAMP 6 - -
LEVELING SWITCH
(BUILT-UP-EXPORT)

BLACK CAV CIRCUIT FUNCTION

1 E1 20TN PANEL LAMPS DIMMER SWITCH SIGNAL
1
3 2 L2 14LG HEADLAMP SWITCH OUTPUT
3 M2 20YL COURTESY LAMPS DRIVER
2
F34 18TN/BK FUSED B(+)
4
9 4 F34 18TN/BK FUSED B(+)
7 5 G26 20LB KEY-IN IGNITION SWITCH SENSE
8 5 6 G16 20BK/LB DRIVER DOOR AJAR SWITCH SENSE
7 L20 14LG/WT FUSED B (+)
6
A3 14RD/WT FUSED B (+)
8
HEADLAMP A3 14RD/WT FUSED B (+)
SWITCH 9 L7 18BK/YL HEADLAMP SWITCH OUTPUT

LHD EXCEPT BUILT-UP-EXPORT

XJI08049 J008W-7

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 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

3 2 1 1 - -
F235 16RD B(+) TO HEATED SEAT MODULE
2
6 5 4 F235 16RD B(+) TO HEATED SEAT MODULE
3 - -
9 8 7 4 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
5 - -
6 Z1 18BK GROUND
HEATED SEAT 7 - -
RELAY 8 F37 14RD/LB FUSED B(+)

BLACK

1 4
CAV CIRCUIT FUNCTION
1 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
2 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
IDLE AIR 3 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
CONTROL 4 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
MOTOR

J008W-7 XJI08050

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51

BLACK

CAV CIRCUIT FUNCTION

2 1 1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 K19 18GY IGNITION COIL NO. 1 DRIVER

IGNITION COIL
(2.5L GAS)

CAV CIRCUIT FUNCTION

1 Z1 20BK GROUND
BLACK 2 G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER
3 A2 12PK/BK FUSED B(+)
5 1 4 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
5 - -
6 - -
10 6 7 A1 12RD FUSED B(+)
8 A31 12BK/WT IGNITION SWITCH OUTPUT (RUN-ACC)
IGNITION
SWITCH - C1 9 A21 12DB IGNITION SWITCH OUTPUT (ST-RUN)
10 A41 14YL IGNITION SWITCH OUTPUT (START)

GREEN

CAV CIRCUIT FUNCTION

2 1 1 G26 20LB KEY-IN IGNITION SWITCH SENSE
2 G16 20BK/LB DRIVER DOOR AJAR SWITCH SENSE

IGNITION
SWITCH - C2

XJI08051 J008W-7

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 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

BLACK 1 G78 20TN/BK LIFTGATE AJAR SWITCH SENSE
2 G99 20GY/WT RED BRAKE WARNING INDICATOR DRIVER
3 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
4 G19 20LG/OR ABS WARNING INDICATOR DRIVER
5 1
5 G34 16RD/GY HIGH BEAM INDICATOR DRIVER
6 Z2 20BK/LG GROUND
10 6 7 G29 20BK/LB LOW WASHER FLUID SENSE
8 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (START-RUN)
INSTRUMENT
CLUSTER - C1 9 M1 20PK FUSED B(+)
(LHD) 10 L61 20LG/WT LEFT TURN SIGNAL

CAV CIRCUIT FUNCTION

1 G78 20TN/BK LIFTGATE AJAR SWITCH SENSE
BLACK
2 G99 20GY/WT RED BRAKE WARNING INDICATOR DRIVER
3 E2 20OR FUSED PANEL LAMPS SWITCH SIGNAL
4 G19 20LG/OR ABS WARNING INDICATOR DRIVER
5 1
5 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
6 Z2 20BK/LG GROUND
10 6 7 G29 20BK/LB LOW WASHER FLUID SENSE
8 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (START-RUN)
INSTRUMENT 9 M1 20PK FUSED B(+)
CLUSTER - C1 10 L61 20LG/WT LEFT TURN SIGNAL
(RHD)

CAV CIRCUIT FUNCTION

1 D2 20WT/BK CCD BUS (-)
BLACK
2 D1 20VT/BR CCD BUS (+)
3 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL
4 C80 20DB/WT REAR WINDOW DEFOGGER SWITCH SENSE
5 1 5 G107 20BK/RD 4WD SWITCH SENSE (PART-TIME)
6 L60 20TN RIGHT TURN SIGNAL
7 G106 20BK/WT 4WD SWITCH SENSE (FULL-TIME)
10 6
8 G26 20LB KEY-IN IGNITION SWITCH SENSE
INSTRUMENT
9 Z2 18BK/LG GROUND
CLUSTER - C2
10 G10 20LG/RD SEAT BELT SWITCH SENSE

J008W-7 XJI08052

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53

GRAY

1 2 CAV CIRCUIT FUNCTION

1 K167 20BR/YL SENSOR GROUND
2 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
INTAKE AIR
TEMPERATURE
SENSOR

CAV CIRCUIT FUNCTION

1 L44 20VT/RD FUSED RIGHT LOW BEAM OUTPUT
NATURAL 2 - -
3 F45 20YL/RD FUSED B(+) ENGINE STARTER MOTOR RELAY
4 - -
1 2
5 L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT
3 7 5 L78 20DG/YL FUSED HEADLAMP SWITCH OUTPUT
8 12 6 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
7 - -
JUNCTION 8 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
BLOCK - C1 9 L33 20RD FUSED LEFT HIGH BEAM OUTPUT
10 L43 20VT FUSED LEFT LOW BEAM OUTPUT
11 L34 20RD/OR FUSED RIGHT HIGH BEAM OUTPUT
12 M1 20PK FUSED B(+)

WHITE CAV CIRCUIT FUNCTION

1 A4 12BK/PK FUSED B(+)
2 A7 10RD/BK FUSED B(+)
1 2
3 - -
3 6 4 X2 20DG/RD HORN RELAY OUTPUT
5 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
6 L77 20BR/YL FUSED HEADLAMP SWITCH OUTPUT
JUNCTION
6 L77 18BR/YL FUSED HEADLAMP SWITCH OUTPUT
BLOCK - C2

GAS
DIESEL
4.0L AND DIESEL

XJI08053 J008W-7

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 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS XJ

NATURAL
CAV CIRCUIT FUNCTION
1 3
1 M2 20YL COURTESY LAMPS DRIVER
2 Z1 20BK GROUND
3 M1 20PK FUSED B(+)

JUNCTION
BLOCK - C3

CAV CIRCUIT FUNCTION

L1 A31 12BK/WT IGNITION SWITCH OUTPUT (RUN-ACC)
L2 A21 12DB IGNITION SWITCH OUTPUT (ST-RUN)
M1 A41 14YL IGNITION SWITCH OUTPUT (ST)
M2 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
M3 L7 18BK/YL HEADLAMP SWITCH OUTPUT
M4 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
M5 F38 16RD/LB FUSED B(+)
M6 F30 16RD CIGAR LIGHTER RELAY OUTPUT
S1 E1 20TN PANEL LAMPS DIMMER SWITCH SIGNAL
S2 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
S3 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
WHITE S4 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
S7 L1 S14
S5 Z1 14BK GROUND
S1 S6 - -
M4
S2 S7 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
M5
S3 M6 S8 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
S9 X12 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
M1
S24 S10 - -
M2
S25 S11 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
M3
S26
S12 F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
S13 L2 S20 S13 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)
S14 - -
JUNCTION S15 - -
BLOCK - C4 S16 - -
S17 - -
S18 M1 20PK FUSED B(+)
S19 C16 20LB/YL FUSED REAR WINDOW DEFFOGGER RELAY OUTPUT
S19 C16 20BK/WT FUSED REAR WINDOW DEFFOGGER RELAY OUTPUT
S20 L5 20BK FUSED IGNITION SWITCH OUTPUT (RUN)
S21 F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN)
S22 X3 20BK/RD HORN RELAY CONTROL
S23 F23 18DB/YL FUSED IGNITION SWITCH OUTPUT (ST-RUN)
S24 -
S25 M2 20YL COURTESY LAMPS DRIVER
S26 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL

OVERHEAD CONSOLE
LHD
RHD

J008W-7 XJI08054

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55

CAV CIRCUIT FUNCTION

WHITE 1 X3 20BK/RD HORN RELAY CONTROL
2 P76 20OR/YL MIRROR COMMON DRIVER
1 4 3 P91 20WT/BK MIRROR COMMON DRIVER
4 - -
5 C16 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
6 - -
5 7 8 10 7 F35 16RD FUSED B(+)
8 F81 12TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
JUNCTION 9 P74 20DB LEFT POWER MIRROR HORIZONTAL DRIVER
BLOCK - C5 9 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER
10 P72 20YL/BK LEFT POWER MIRROR VERTICAL DRIVER
10 P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER

2 1 NATURAL

CAV CIRCUIT FUNCTION

1 C15 12BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT
2 F37 14RD/LB FUSED B(+)

JUNCTION
BLOCK - C6

CAV CIRCUIT FUNCTION

1 P33 16OR/BK DOOR LOCK DRIVER
NATURAL 2 L77 18BR/YL FUSED HEADLAMP SWITCH OUTPUT
3 P91 20WT/BK MIRROR COMMON DRIVER
1 3
4 M1 20PK FUSED B(+)
4 8 5 P34 16PK/BK DOOR UNLOCK DRIVER
6 L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT
7 M2 20YL COURTESY LAMPS DRIVER
JUNCTION
8 A6 20RD/OR FUSED B(+)
BLOCK - C7

FULL OPTIONS
RHD EXCEPT FULL OPTIONS
BASE
RHD
POWER SEATS
XJI08055 LHD J008W-7

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 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS XJ

NATURAL

2 1 CAV CIRCUIT FUNCTION

1 F81 14TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
2 - -

JUNCTION
BLOCK - C8

CAV CIRCUIT FUNCTION

1 P33 16OR/BK DOOR LOCK DRIVER
2 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER
3 C16 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
NATURAL
4 - -
5 - -
12 6
6 P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER
5 1 7 P91 20WT/BK COMMON MIRROR DRIVER
8 - -
9 F35 16RD FUSED B(+)
JUNCTION 10 P76 20OR/YL MIRROR COMMON DRIVER
BLOCK - C9 11 Z1 18BK GROUND
(LHD) 11 Z1 16BK GROUND
12 P34 16PK/BK DOOR UNLOCK DRIVER

CAV CIRCUIT FUNCTION

1 P33 16OR/BK DOOR LOCK DRIVER
2 P75 20DB/WT LEFT POWER MIRROR HORIZONTAL DRIVER
NATURAL
3 C16 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
4 - -
12 6
5 - -
5 1 6 P71 20YL/LB LEFT POWER MIRROR VERTICAL DRIVER
7 P91 20WT/BK MIRROR COMMON DRIVER
8 - -
JUNCTION 9 - -
BLOCK - C9 10 P76 20OR/YL MIRROR COMMON DRIVER
(RHD) 11 Z1 16BK GROUND
12 P34 16PK/BK DOOR UNLOCK DRIVER

GRAY

1 2
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L10 18BR/LG BACK-UP LAMP FEED
LEFT BACK-UP
LAMP

POWER MIRROR
J008W-7 FULL OPTIONS XJI08056

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57

2
CAV CIRCUIT FUNCTION
1 1 L77 20BR FUSED HEADLAMP SWITCH OUTPUT
2 Z1 20BK GROUND
LEFT CITY
LAMP
(BUILT-UP-EXPORT)

BLACK

CAV CIRCUIT FUNCTION

1 M1 18PK FUSED B(+)
2 M2 18BK/WT COURTESY LAMPS DRIVER
LEFT
COURTESY LAMP

GRAY

CAV CIRCUIT FUNCTION

1 2 1 Z1 20BK GROUND
2 L39 20LB FOG LAMP RELAY OUTPUT

LEFT FOG
LAMP

BLACK
CAV CIRCUIT FUNCTION
1 2 1 X85 18BK/RD AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
1 X55 18LG/RD LEFT FRONT SPEAKER (-)
1 X85 18LG/RD AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
LEFT FRONT
2 X87 18DG AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
DOOR SPEAKER
2 X53 18LG/BK LEFT FRONT SPEAKER (+)
2 X87 18LG/BK AMPLIFIED LEFT FRONT DOOR SPEAKER (+)

BLACK

1
CAV CIRCUIT FUNCTION
2
1 X85 18LG/RD AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
2 X87 18LG/BK AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
LEFT FRONT
DOOR TWEETER

6 SPEAKER LHD
6 SPEAKER RHD
4 SPEAKER

XJI08057 J008W-7

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 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS XJ

GRAY

CAV CIRCUIT FUNCTION

1 L61 18LG LEFT TURN SIGNAL
3 1 2 L77 18BR FUSED HEADLAMP SWITCH OUTPUT
3 Z1 18BK GROUND
LEFT FRONT
PARK/TURN
SIGNAL LAMP NO. 1
(EXCEPT BUILT-UP-
EXPORT)

GRAY

CAV CIRCUIT FUNCTION

1 L61 18LG LEFT TURN SIGNAL
3 1 2 L77 18BR FUSED HEADLAMP SWITCH OUTPUT
3 Z1 18BK GROUND
LEFT FRONT
PARK/TURN
SIGNAL LAMP NO. 2
(EXCEPT BUILT-UP-
EXPORT)

GRAY

CAV CIRCUIT FUNCTION

2 1 1 Z1 18BK GROUND
2 L61 18LG LEFT TURN SIGNAL
LEFT FRONT
TURN SIGNAL
LAMP NO. 1
(BUILT-UP-EXPORT)

GRAY

CAV CIRCUIT FUNCTION

1 Z1 18BK GROUND
2 1 2 L61 18LG LEFT TURN SIGNAL

LEFT FRONT
TURN SIGNAL
LAMP NO. 2
(BUILT-UP-EXPORT)

J008W-7 XJI08058

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59

GRAY

CAV CIRCUIT FUNCTION

2 1
1 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
2 B9 18RD LEFT FRONT WHEEL SPEED SENSOR (+)
LEFT FRONT
WHEEL SPEED
SENSOR

B CAV CIRCUIT FUNCTION

L33 18RD FUSED LEFT HIGH BEAM OUTPUT
A
A C L33 20RD FUSED LEFT HIGH BEAM OUTPUT
B L43 18VT FUSED LEFT LOW BEAM OUTPUT
C Z1 18BK GROUND
LEFT HEADLAMP

BLACK

CAV CIRCUIT FUNCTION

3 2 1
1 L43 18VT FUSED LEFT LOW BEAM OUTPUT
2 L13 18BR/YL HEADLAMP ADJUST SIGNAL
LEFT HEADLAMP 3 Z15 18BK/GY GROUND
LEVELING MOTOR
(BUILT-UP-EXPORT)

A B CAV CIRCUIT FUNCTION

A P88 18BR/BK LEFT HEATED SEAT BACK DRIVER
B Z1 18BK GROUND
LEFT HEATED
SEAT BACK

B CAV CIRCUIT FUNCTION

A
A P87 18BK/OR LEFT HEATED SEAT DRIVER
C D B P88 18BR/BK LEFT HEATED SEAT BACK DRIVER
C P141 18TN/LB SENSOR FEED
LEFT HEATED D P143 18BK/DG LEFT HEAT SENSE INPUT
SEAT CUSHION

FOG LAMPS

XJI08059 J008W-7

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 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS XJ

RED

CAV CIRCUIT FUNCTION

4 6 1 P137 18VT LEFT SEAT LOW HEAT LED DRIVER
3 1 2 - -
3 Z1 18BK GROUND
4 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
LEFT HEATED
5 P139 18VT/WT LEFT SEAT HIGH HEAT LED DRIVER
SEAT SWITCH
6 P133 18TN/DG LEFT SEAT HEATER SWITCH MUX

1 2 CAV CIRCUIT FUNCTION

1 L78 18BK/YL FUSED HEADLAMP SWITCH OUTPUT
2 Z1 18BK GROUND
LEFT LICENCE
LAMP
(BUILT-UP-EXPORT)
YELLOW

CAV CIRCUIT FUNCTION

1 P19 14YL/LG LEFT POWER SEAT FRONT UP
2 P21 14RD/LG LEFT POWER SEAT FRONT DOWN

LEFT POWER
SEAT FRONT
VERTICAL MOTOR

YELLOW

CAV CIRCUIT FUNCTION

1 P17 14RD/LB LEFT POWER SEAT HORIZONTAL REARWARD
2 P15 14YL/LB LEFT POWER SEAT HORIZONTAL FORWARD

LEFT POWER
SEAT HORIZONTAL
MOTOR
YELLOW

CAV CIRCUIT FUNCTION

1 P13 14RD/WT LEFT POWER SEAT REAR DOWN
2 P11 14YL/WT LEFT POWER SEAT REAR UP

LEFT POWER
SEAT REAR
VERTICAL MOTOR

J008W-7 XJI08060

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61

BLACK
CAV CIRCUIT FUNCTION
A F37 14RD FUSED B(+)
M N Z1 14BK GROUND
B B
L C - -
K E P13 14RD/WT LEFT POWER SEAT REAR DOWN
F - -
A J
G - -
E F H - -
J P11 14YL/WT LEFT POWER SEAT REAR UP
C H G K P17 14RD/LB LEFT POWER SEAT HORIZONTAL REARWARD
L P15 14YL/LB LEFT POWER SEAT HORIZONTAL FORWARD
LEFT POWER M P19 14YL/LG LEFT POWER SEAT FRONT UP
SEAT SWITCH N P21 14RD/LG LEFT POWER SEAT FRONT DOWN

BLACK
1

CAV CIRCUIT FUNCTION

2 3
1 - -
2 Z1 18BK GROUND
3 M2 18YL COURTESY LAMPS DRIVER
LEFT REAR
DOOR JAMB
SWITCH

BLACK

2 1
CAV CIRCUIT FUNCTION
1 P34 16PK/BK DOOR UNLOCK DRIVER
LEFT REAR 2 P33 16OR/BK DOOR LOCK DRIVER
DOOR LOCK
MOTOR

BLACK

1 2 CAV CIRCUIT FUNCTION

1 Z1 18BK GROUND
2 L38 18OR/WT REAR FOG LAMP FEED

LEFT REAR
FOG LAMP
(BUILT-UP-EXPORT)

XJI08061 J008W-7

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 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

CAV CIRCUIT FUNCTION

B A
A B3 20LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
B B4 20LG LEFT REAR WHEEL SPEED SENSOR (+)
LEFT REAR
WHEEL SPEED
SENSOR

BLACK

CAV CIRCUIT FUNCTION

1 Q13 14DB POWER WINDOW LEFT REAR B(+) UP
1 2
2 Q23 14RD/WT LEFT REAR WINDOW DRIVER DOWN

LEFT REAR
WINDOW MOTOR

BLUE CAV CIRCUIT

1 Q13 14DB POWER WINDOW LEFT REAR B(+) UP
2 Q27 14RD/BK LEFT REAR WINDOW DRIVER DOWN
3 -
3 1
4 Q17 14DB/WT LEFT REAR WINDOW DRIVER UP
6 4 5 Q23 14RD/WT LEFT REAR WINDOW DRIVER DOWN
6 Q1 14YL POWER WINDOW SWITCH FEED
LEFT REAR
WINDOW SWITCH

2
1
CAV CIRCUIT FUNCTION
1 L61 18GY LEFT TURN SIGNAL
LEFT 2 Z1 18BK GROUND
REPEATER
LAMP
(BUILT-UP-EXPORT)

J008W-7 XJI08062

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63

NATURAL

1 2 CAV CIRCUIT FUNCTION

1 L77 20BR FUSED LEFT HEADLAMP SWITCH OUTPUT
2 L61 20LG LEFT TURN SIGNAL

LEFT SIDE
MARKER LAMP
(EXCEPT BUILT
-UP-EXPORT)

CAV CIRCUIT FUNCTION

A X57 18BR/LB LEFT REAR SPEAKER (-)
LEFT A X91 16BR/DB AMPLIFIED LEFT REAR SPEAKER (+)
SOUNDBAR B X51 18BR/YL LEFT REAR SPEAKER (+)
SPEAKER B X93 16BR/YL AMPLIFIED LEFT REAR SPEAKER (-)

1 2
CAV CIRCUIT FUNCTION
1 K167 20BR/YL SENSOR GROUND
LEFT SPEED 2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
CONTROL
SWITCH

BLACK
1 2 3

CAV CIRCUIT FUNCTION

1 Z1 18BK GROUND
2 L77 18BR FUSED LEFT HEADLAMP SWITCH OUTPUT
3 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
LEFT TAIL/
STOP LAMP

4 SPEAKER SYSTEM
6 SPEAKER SYSTEM
XJI08063 J008W-7

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 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

2 1 1 Z1 18BK GROUND
LEFT TURN 2 L63 18DG/RD LEFT TURN SIGNAL
SIGNAL LAMP
BLACK

A B
CAV CIRCUIT FUNCTION
A M1 20PK FUSED B(+)
LEFT VISOR/ B Z1 20BK GROUND
VANITY
LAMP

1 2 CAV CIRCUIT FUNCTION

1 L78 18BK/YL FUSED HEADLAMP SWITCH OUTPUT
2 Z1 18BK GROUND

LICENSE LAMP

BLACK
CAV CIRCUIT FUNCTION
A P33 16OR/BK DOOR LOCK DRIVER
B P34 16PK/BK DOOR UNLOCK DRIVER
A B

LIFTGATE
LOCK MOTOR

BLACK
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
3 1 2 G78 20TN/BK LIFTGATE AJAR SWITCH SENSE
3 M4 20VT/YL LIFTGATE COURTESY LAMP DRIVER

LIFTGATE
SWITCH

2 1
CAV CIRCUIT FUNCTION
1 G18 18PK/BK COOLANT LEVEL SWITCH SIGNAL
2 K167 20BR/YL SENSOR GROUND
LOW COOLANT
SWITCH
(DIESEL)

J008W-7 XJI08064

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65

BLACK

CAV CIRCUIT FUNCTION

1 K167 20BR/YL SENSOR GROUND
1 3 2 K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
3 K7 20OR 5V SUPPLY

MANIFOLD
ABSOLUTE
PRESSURE
SENSOR

CAV CIRCUIT FUNCTION

BLACK 1 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)
2 - -
3 - -
4 1
4 K185 20OR/LB WAIT TO START INDICATOR DRIVER
8 5
5 - -
6 - -
7 G86 20TN/OR WATER IN FUEL INDICATOR DRIVER
MESSAGE
8 G154 20VT/LG LOW COOLANT INDICATOR DRIVER
CENTER
(DIESEL)

1 2 CAV CIRCUIT FUNCTION

1 K67 18BR/BK NEEDLE MOVEMENT SENSOR (+)
NEEDLE 2 K68 18LG/YL NEEDLE MOVEMENT SENSOR (-)
MOVEMENT
SENSOR
(DIESEL)
CAV CIRCUIT FUNCTION
1 M2 20YL COURTESY LAMPS DRIVER
2 M1 20PK FUSED B(+)
3 Z1 20BK GROUND
BLACK 4 - -
6 1 5 P55 20DB DOOR UNLOCK RELAY CONTROL
6 D1 20VT/BR CCD BUS(+)
7 - -
8 - -
12 7 9 Z1 20BK GROUND
10 X3 20BK/RD HORN RELAY CONTROL
OVERHEAD
11 P59 20LB/RD DOOR LOCK CONTROL
MODULE
12 D2 20WT/BK CCD BUS(-)

CAV CIRCUIT FUNCTION

GRAY
1 A42 20DG FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT
1 2
1 F142 20DG/WT FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT
2 Z1 20BK GROUND
3 4 2 Z1 18BK GROUND
3 K167 20BR/YL SENSOR GROUND
4 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
OXYGEN
SENSOR 1/1
UPSTREAM
2.5L
4.0L
XJI08065 J008W-7

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 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS XJ
1 2 BLACK
CAV CIRCUIT FUNCTION
1 F142 20DG/WT FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT

3 4 1 A242 20VT/OR OXYGEN SENSOR RELAY OUTPUT

2 Z1 20BK GROUND
OXYGEN 3 K167 20BR/YL SENSOR GROUND
SENSOR 1/2 4 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
DOWNSTREAM
1 2 GRAY

CAV CIRCUIT FUNCTION

1 A42 20DG OXYGEN SENSOR RELAY OUTPUT
3 4
2 Z1 20BK GROUND
3 K167 20BR/YL SENSOR GROUND
OXYGEN
SENSOR 2/1 4 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
UPSTREAM
(4.0L CALIFORNIA/
EUROPEAN III)

1 2 BLACK

CAV CIRCUIT FUNCTION

1 A242 20VT/OR OXYGEN SENSOR RELAY OUTPUT
3 4
2 Z1 20BK GROUND
3 K167 20BR/YL SENSOR GROUND
OXYGEN
SENSOR 2/2 4 K341 18TN OXYGEN SENSOR 2/2 SIGNAL
DOWNSTREAM
(4.0L CALIFORNIA/
EUROPEAN III)

BLACK

CAV CIRCUIT FUNCTION

1 F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
1 3 2 T41 18BK/WT PARK/NETURAL POSITION SWITCH SENSE
3 L10 18BR/LG BACK-UP LAMP FEED

PARK/NEUTRAL
POSITION SWITCH
(2.5L GAS A/T)

YELLOW CAV CIRCUIT FUNCTION

1 - -
2 - -
4 1 3 R42 18BK/YL PASSENGER AIRBAG LINE 2
4 R44 18DG/YL PASSENGER AIRBAG LINE 1
PASSENGER
AIRBAG
BLACK
1

CAV CIRCUIT FUNCTION

2 3
1 M2 18YL COURTESY LAMPS DRIVER
2 G16 18BK/LB DRIVER DOOR AJAR SWITCH SENSE
3 Z1 18BK GROUND
PASSENGER
DOOR JAMB 2.5L
J008W-7
SWITCH 4.0L XJI08066

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67

2 1

CAV CIRCUIT FUNCTION

1 P34 16PK/BK DOOR UNLOCK DRIVER
2 P33 16OR/BK DOOR LOCK DRIVER
PASSENGER DOOR
LOCK MOTOR

CAV CIRCUIT FUNCTION

1 P34 16PK/BK DOOR UNLOCK DRIVER
2 Q22 14VT PASSENGER FRONT WINDOW DRIVER DOWN
3 Q26 14VT/WT MASTER WINDOW SWITCH PASSENGER FRONT DOWN
BLUE
4 Q16 14BR/WT MASTER WINDOW SWITCH PASSENGER FRONT UP
5 P33 16OR/BK DOOR LOCK DRIVER
5 1
6 - -
12 6
7 - -
8 - -
PASSENGER 9 Q12 14BR PASSENGER FRONT WINDOW DRIVER UP
POWER 10 Q1 14YL POWER WINDOW SWITCH FEED
LOCK/WINDOW
11 - -
SWITCH - C1
12 - -
(FULL OPTIONS)

BLUE
CAV CIRCUIT FUNCTION
1 P59 20LB/RD DOOR LOCK CONTROL
4 1 2 P55 20DB/PK DOOR UNLOCK RELAY CONTROL
2 P55 20DB DOOR UNLOCK RELAY CONTROL
3 P35 20OR/VT DOOR LOCK SWITCH OUTPUT (LOCK)
3 P36 18PK/VT DOOR LOCK SWITCH OUTPUT (UNLOCK)
8 5
4 F81 14TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
PASSENGER 5 F35 16RD FUSED B(+)
POWER LOCK/WINDOW 6 Z1 14BK GROUND
SWITCH - C2 7 P36 20PK/VT DOOR LOCK SWITCH OUTPUT (UNLOCK)
(FULL OPTIONS) 7 P35 18OR/VT DOOR LOCK SWITCH OUTPUT (LOCK)
8 G26 20LB KEY-IN IGNITION SWITCH SENSE

LHD
RHD
XJI08067 J008W-7

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 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

RED
6 5 4 1 P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER
2 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER
2 P76 20OR/YL MIRROR COMMON DRIVER
3 P91 20WT/BK MIRROR COMMON DRIVER
1 2 3
3 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER
4 P76 20OR/YL MIRROR COMMON DRIVER
PASSENGER
5 C16 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
POWER MIRROR
(LHD) 6 Z1 18BK GROUND

CAV CIRCUIT FUNCTION

1 P71 20YL LEFT POWER MIRROR VERTICAL DRIVER
RED
6 5 4 2 P75 20DB/WT LEFT POWER MIRROR HORIZONTAL DRIVER
2 P76 20OR/YL MIRROR COMMON DRIVER
3 P91 20WT/BK MIRROR COMMON DRIVER
3 P75 20DB/RD LEFT POWER MIRROR HORIZONTAL DRIVER
1 2 3
4 P76 20OR/YL MIRROR COMMON DRIVER
5 C16 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
PASSENGER
5 C16 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
POWER MIRROR
(RHD) 6 Z1 16BK GROUND

BLACK

1 2 CAV CIRCUIT FUNCTION

1 Q12 14BR RIGHT FRONT WINDOW DRIVER (UP)
2 Q22 14VT RIGHT FRONT WINDOW DRIVER (DOWN)
PASSENGER POWER
WINDOW MOTOR

POWER MIRRORS
FULL OPTIONS

J008W-7 XJI08068

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69

CAV CIRCUIT FUNCTION

NATURAL 1 X55 18BR/RD LEFT FRONT SPEAKER (-)
2 X56 18DB/RD RIGHT FRONT SPEAKER (-)
3 X58 18DB/OR RIGHT REAR SPEAKER (-)
1 4
4 X60 18DG/RD RADIO 12V OUTPUT
5 10 5 X53 18DG LEFT FRONT SPEAKER (+)
6 X54 18VT RIGHT FRONT SPEAKER (+)
7 X51 18BR/YL LEFT REAR SPEAKER (+)
POWER 8 X57 18BR/LB LEFT REAR SPEAKER (-)
AMPLIFIER - C1 9 X52 18DB/WT RIGHT REAR SPEAKER (+)
10 - -

CAV CIRCUIT FUNCTION

1 F75 16VT FUSED B(+)
NATURAL 2 F75 16VT FUSED B(+)
3 - -
1 6 4 X87 18LG/VT AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
5 X94 18TN/RD AMPLIFIED RIGHT REAR SPEAKER (+)
7 14 6 X93 18WT/RD AMPLIFIED LEFT REAR SPEAKER (-)
7 Z5 16BK/LB GROUND
8 Z5 16BK/LB GROUND
POWER 9 - -
AMPLIFIER - C2 10 X80 18LB/BK AMPLIFIED RIGHT FRONT DOOR SPEAKER (-)
11 X82 18LB/RD AMPLIFIED RIGHT FRONT DOOR SPEAKER (+)
12 X85 18BR/RD AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
13 X92 18TN/BK AMPLIFIED RIGHT REAR SPEAKER (-)
14 X91 18WT/BK AMPLIFIED LEFT REAR SPEAKER (+)

BLACK

CAV CIRCUIT FUNCTION

A C
A X13 18WT RADIO CHOKE OUTPUT
B X17 18GY POWER ANTENNA UP (-)
POWER ANTENNA C X14 18DG POWER ANTENNA B(+) DOWN
(BUILT-UP-EXPORT)

BLACK

C
A B CAV CIRCUIT FUNCTION
A Z1 18BK GROUND
POWER ANTENNA B F34 18TN/BK FUSED B(+)
RELAY - C1 C X60 18DG/RD RADIO 12V OUTPUT
(BUILT-UP-EXPORT)

XJI08069 J008W-7

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 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

C
A B CAV CIRCUIT FUNCTION
A X13 18WT RADIO CHOKE OUTPUT
POWER ANTENNA B X17 18GY POWER ANTENNA UP (-)
C X14 18DG POWER ANTENNA B(+) DOWN
RELAY - C2
(BUILT-UP-EXPORT)

CAV CIRCUIT FUNCTION

1 Z1 20BK GROUND
5 1
1 Z1 14BK GROUND
2 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
8 4
3 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER
4 P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER
P76 20OR/YL MIRROR COMMON DRIVER
5
P76 20OR/YL MIRROR COMMON DRIVER
POWER
MIRROR P91 20WT/BK MIRROR COMMON DRIVER
6
SWITCH P91 20WT/BK MIRROR COMMON DRIVER
7 P75 20 DB/WT LEFT POWER MIRROR HORIZONTAL DRIVER
8 P71 20YL/LB LEFT POWER MIRROR VERTICAL DRIVER
8 P71 20YL LEFT POWER MIRROR VERTICAL DRIVER

RED

2 1 CAV CIRCUIT FUNCTION

1 F38 16RD/LB FUSED B(+)
2 - -
3
3 Z1 16BK GROUND
POWER OUTLET

WHITE

CAV CIRCUIT FUNCTION

1 2
1 Z1 20BK GROUND
2 K10 18DB/BR POWER STEERING PRESSURE SWITCH SENSE

POWER STEERING
PRESSURE SWITCH
(2.5L GAS)
RHD
LHD

J008W-7 XJI08070

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71

CAV CIRCUIT FUNCTION

1 - -
2 A142 16DG/DR AUTOMATIC SHUT DOWN RELAY OUTPUT
3 - -
4 K167 18BR/YL SENSOR GROUND
5 - -
6 - -
6 - -
6 - -
7 - -
8 K159 18VT/RD ENGINE SPEED SENSOR SIGNAL
9 - -
10 - -
11 - -
12 G18 18PK/BK COOLANT LEVEL SWITCH SIGNAL
22 32 13 - -
14 - -
15 - -
12 21
16 K222 18TN/RD ENGINE COOLANT TEMP SENSOR SIGNAL
17 K7 18OR 5V SUPPLY
1 11 18 G8 18LB/BK FUEL MONITOR OUTPUT SIGNAL
19 - -
20 - -
POWERTRAIN
21 - -
CONTROL MODULE - C1
22 F16 16RD/LG FUSED B(+)
(DIESEL)
23 - -
24 - -
25 - -
26 - -
27 G123 18DG/WT WATER IN FUEL SENSOR SIGNAL
28 - -
29 - -
30 - -
31 Z12 14BK/TN GROUND
32 Z12 14BK/TN GROUND

XJI08071 J008W-7

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 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

1 K18 18RD/YL IGNITION COIL NO. 3 DRIVER
2 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
3 - -
4 K167 18BR/YL SENSOR GROUND
5 - -
6 T41 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE
6 Z1 18BK GROUND
7 K19 18GY IGNITION COIL NO. 1 DRIVER
8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
9 - -
10 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
BLACK 11 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
12 K10 18DB/BR POWER STEERING PRESSURE SWITCH SENSE
22 32 12 K78 18GY IDLE ACTUATOR
13 - -
14 - -
12 21
15 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
1 11 17 K7 18OR 5V SUPPLY
18 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
19 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
POWERTRAIN
20 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
CONTROL MODULE - C1
21 - -
(GAS)
22 A61 14DG/BK FUSED B(+)
23 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
24 K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL
25 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
26 K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
27 K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
28 - -
29 K341 18TN OXYGEN SENSOR 2/2 SIGNAL
30 - -
31 Z12 14BK/TN GROUND
32 Z12 14BK/TN GROUND

4.0L CALIFORNIA/ BUILT-UP-EXPORT

2.5L M/T
EXCEPT 2.5L M/T
4.0L
2.5L
2.5L A/T
4.0L A/T

J008W-7 XJI08072

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73

CAV CIRCUIT FUNCTION

1 - -
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 K20 18DG GENERATOR FIELD
11 - -
12 - -
22 32
13 - -
14 - -
12 21 15 - -
16 - -
1 11 17 - -
18 V66 18RD/LG SPEED CONTROL INDICATOR SIGNAL
19 - -
POWERTRAIN
20 - -
CONTROL MODULE - C2
21 - -
(DIESEL)
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
24 - -
25 - -
26 - -
27 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
28 - -
29 - -
30 - -
31 - -
32 - -

XJI08073 J008W-7

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 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

1 - -
2 - -
3 - -
4 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
5 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
6 K15 18PK/BK FUEL INJECTOR NO. 5 DRIVER
7 - -
8 - -
9 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
WHITE 10 K20 18DG GENERATOR FIELD
11 K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
12 K16 18LG/BK FUEL INJECTOR NO. 6 DRIVER
22 32
13 - -
14 - -
12 21 15 K12 18TN FUEL INJECTOR NO. 2 DRIVER
16 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER
1 11 17 - -
18 - -
19 - -
POWERTRAIN
20 - -
CONTROL MODULE - C2
21 - -
(GAS)
22 - -
23 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
24 - -
25 - -
26 - -
27 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
28 - -
29 - -
30 - -
31 K6 18VT/OR 5V SUPPLY
32 - -

4.0L
2.5L A/T

J008W-7 XJI08074

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75

CAV CIRCUIT FUNCTION

1 C103 18DG A/C REQUEST OUTPUT
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
GRAY 8 G154 18VT/LG LOW COOLANT INDICATOR DRIVER
9 G86 18TN/OR WATER IN FUEL INDICATOR DRIVER
22 32 10 - -
11 - -
12 21 12 A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
13 - -
14 - -
1 11
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 G55 18OR/BK ENGINE DISABLE SIGNAL
POWERTRAIN 17 - -
CONTROL MODULE - C3 18 - -
(DIESEL) 19 - -
20 - -
21 - -
22 K48 18OR/RD FAULT INDICATOR REQUEST INPUT
23 C90 18LG A/C SWITCH SENSE
24 - -
25 K72 18DG/OR GENERATOR SOURCE
26 K226 18DB/LG FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT/ ISO 9141K
28 D2 18WT/BK CCD BUS(-)
29 D20 18LG/BK SCI RECEIVE
30 D1 18VT/BR CCD BUS(+)
31 - -
32 - -

XJI08075 J008W-7

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 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
2 C27 18DB/PK RADIATOR FAN RELAY CONTROL
3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
6 - -
7 - -
GRAY 8 K73 18BR/OR OXYGEN SENSOR UPSTREAM RELAY CONTROL
9 K74 18BR/VT OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
22 32 10 K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL
11 V32 18YL/RD SPEED CONTROL POWER SUPPLY
12 21 12 F142 18DG/WT FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
13 C48 18TN RADIATOR FAN REQUEST
14 K105 18WT/OR LEAK DETECTION PUMP SWITCH SENSE
1 11
15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
16 - -
POWERTRAIN 17 - -
CONTROL 18 - -
MODULE - C3 19 K31 18BR FUEL PUMP RELAY CONTROL
(GAS) 20 K52 18PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
21 - -
22 C22 18DB/WT A/C SWITCH SENSE
23 C90 18LG A/C SELECT INPUT
24 K29 18WT/PK BRAKE LAMP SWITCH SENSE
25 K72 18DG/OR GENERATOR DRIVER
26 K226 18DB/LG FUEL LEVEL SENSOR SIGNAL
27 D21 18PK SCI TRANSMIT/ ISO 9141K
28 D2 18WT/BK CCD BUS (-)
29 D20 18LG/BK SCI RECEIVE
30 D1 18VT/BR CCD BUS (+)
31 - -
32 V37 18RD/LG SPEED CONTROL SWITCH SIGNAL

LEAK DETECT
4.0L
J008W-7 XJI08076

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77

CAV CIRCUIT FUNCTION

1 2
1 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
2 Z1 20BK GROUND

PRNDL
ILLUMINATION
(A/T)

LT.GRAY
1 2

CAV CIRCUIT FUNCTION

1 C25 12LB RADIATOR FAN RELAY OUTPUT
2 Z1 12BK GROUND
RADIATOR
FAN MOTOR

CAV CIRCUIT FUNCTION

BLACK
1 X60 16DG/RD RADIO 12V OUTPUT
2 X51 16BR/YL LEFT REAR SPEAKER (+)
7 1 3 X52 16DB/WT RIGHT REAR SPEAKER (+)
4 X53 16DG LEFT FRONT SPEAKER (+)
RADIO - C1 5 X54 16VT RIGHT FRONT SPEAKER (+)
6 X57 16BR/LB LEFT REAR SPEAKER (-)
7 X58 16DB/OR RIGHT REAR SPEAKER (-)

GRAY CAV CIRCUIT FUNCTION

1 - -
2 X55 16BR/RD LEFT FRONT SPEAKER (-)
7 1
3 X56 16DB/RD RIGHT FRONT SPEAKER (-)
4 L7 18BK/YL HEADLAMP SWITCH OUTPUT
RADIO - C2 5 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
6 X12 16RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
7 M1 20PK FUSED B(+)

BLACK

CAV CIRCUIT FUNCTION

1 K19 18GY IGNITION COIL NO. 1 DRIVER
4 1
2 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
3 K17 18DB/TN IGNITION COIL NO. 2 DRIVER
RAIL COIL 4 K18 18RD/YL IGNITION COIL NO. 3 DRIVER
(4.0L GAS)

XJI08077 J008W-7

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 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

5 1 2
1 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
3 2 L36 18LG/BK REAR FOG LAMP
4 3 Z1 18BK GROUND
L38 18BR/WT REAR FOG LAMP FEED
4
L38 18BR/WT REAR FOG LAMP FEED
REAR FOG 5 L25 18BR REAR FOG LAMP FEED
LAMP RELAY
(BUILT-UP-EXPORT)

WHITE

CAV CIRCUIT FUNCTION

1 4 1 Z15 18BK/GY GROUND
1 Z15 20BK/GY GROUND
2 L36 18LG/BK REAR FOG LAMP
REAR FOG 3 L38 18BR/WT REAR FOG LAMP FEED
LAMP 4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
SWITCH
(BUILT-UP-
EXPORT)
BLACK

1 CAV CIRCUIT FUNCTION

2 1 V20 18BK/WT REAR WASHER MOTOR CONTROL
Z1 18BK GROUND
2
REAR Z1 18BK GROUND
WASHER
PUMP

GRAY

CAV CIRCUIT FUNCTION

1 4 1 Z1 20BK GROUND
2 C80 20DB/WT REAR WINDOW DEFOGGER SWITCH SENSE
3 C16 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
REAR
4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
WINDOW
DEFOGGER
SWITCH

CAV CIRCUIT FUNCTION

1 Z1 18BK GROUND
2 V20 18BK/WT REAR WASHER MOTOR CONTROL
1 4 3 V13 18BR/LG REAR REAR WIPER MOTOR CONTROL
REAR WIPER 4 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
MOTOR
GAS
LHD
RHD
J008W-7 XJI08078

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79

BLACK
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
1 2 2 V20 18BK/WT REAR WASHER MOTOR CONTROLLER
3 6 3 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
4 V13 18BR/LG REAR WIPER MOTOR CONTROL
5 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
REAR WIPER/
6 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
WASHER SWITCH

GRAY
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
1 2
2 L10 18BR/LG BACK-UP LAMP FEED

RIGHT BACK-UP
LAMP

1 CAV CIRCUIT FUNCTION

1 L78 20DG/YL FUSED HEADLAMP SWITCH OUTPUT
RIGHT CITY 2 Z1 20BK GROUND
LAMP
(BUILT-UP-EXPORT)

BLACK

CAV CIRCUIT FUNCTION

1 M1 18PK FUSED B(+)
2 M2 18BK/WT COURTESY LAMPS DRIVER

RIGHT COURTESY
LAMP

GRAY

CAV CIRCUIT FUNCTION

1 2 1 Z1 20BK GROUND
2 L39 20LB FOG LAMP RELAY OUTPUT

RIGHT
FOG LAMP
XJI08079 J008W-7

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 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

1 2 CAV CIRCUIT FUNCTION

1 X80 18LB/BK AMPLIFIED RIGHT FRONT DOOR SPEAKER (-)
RIGHT FRONT 2 X82 18LB/RD AMPLIFIED RIGHT FRONT DOOR SPEAKER (+)
DOOR SPEAKER

BLACK

1 CAV CIRCUIT FUNCTION

2 1 X80 18LB/BK AMPLIFIED RIGHT FRONT DOOR SPEAKER (-)
2 X82 18LB/RD AMPLIFIED RIGHT FRONT DOOR SPEAKER (+)
RIGHT FRONT
DOOR TWEETER

BLACK

CAV CIRCUIT FUNCTION

1 L60 18TN RIGHT TURN SIGNAL
2 L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT
3 1 3 Z1 18BK GROUND

RIGHT FRONT
PARK/TURN
SIGNAL LAMP NO. 1
(EXCEPT BUILT-UP-EXPORT)

BLACK
CAV CIRCUIT FUNCTION
1 L60 18TN RIGHT TURN SIGNAL
2 L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT
3 Z1 18BK GROUND
3 1

RIGHT FRONT
PARK/TURN
SIGNAL LAMP NO. 2
(EXCEPT BUILT-UP-EXPORT)

GRAY

CAV CIRCUIT FUNCTION

2 1 1 Z1 18BK GROUND
2 L60 18TN RIGHT TURN SIGNAL
RIGHT FRONT
TURN SIGNAL
LAMP NO. 1
(BUILT-UP-EXPORT)

J008W-7 XJI08080

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81

GRAY

CAV CIRCUIT FUNCTION

2 1 1 Z1 18BK GROUND
2 L60 18TN RIGHT TURN SIGNAL
RIGHT FRONT
TURN SIGNAL
LAMP NO.2
(BUILT-UP-EXPORT)

CAV CIRCUIT FUNCTION

1 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
2 1 2 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+)
RIGHT FRONT
WHEEL SPEED
SENSOR
B

CAV CIRCUIT FUNCTION

A C A L34 18RD/OR FUSED RIGHT HIGH BEAM OUTPUT
B L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
C Z1 18BK GROUND
RIGHT
HEADLAMP
BLACK

CAV CIRCUIT FUNCTION

3 2 1
1 L44 18VT/RD FUSED RIGHT LOW BEAM OUTPUT
2 L13 18BK HEADLAMP ADJUST SIGNAL
RIGHT HEADLAMP 3 Z15 18BK/GY GROUND
LEVELING MOTOR
(BUILT-UP-EXPORT)

CAV CIRCUIT FUNCTION

A B A P89 18BR RIGHT HEATED SEAT BACK DRIVER
B Z1 18BK GROUND
RIGHT HEATED
SEAT BACK

A B CAV CIRCUIT FUNCTION

A P86 18PK/BK RIGHT HEAT SEAT DRIVER
C D
B P89 18BR RIGHT HEATED SEAT BACK DRIVER
C P141 18TN/LB SENSOR FEED
RIGHT HEATED D P144 18BK/YL RIGHT HEAT SENSE INPUT
SEAT CUSHION

XJI08081 J008W-7

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 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS XJ

BLUE

CAV CIRCUIT FUNCTION

4 6
1 P138 18VT/LG RIGHT SEAT LOW HEAT LED DRIVER
3 1
2 - -
3 Z1 18BK GROUND
4 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
RIGHT HEATED
5 P140 18VT/BK RIGHT SEAT HIGH HEAT LED DRIVER
SEAT SWITCH
6 P134 18TN/RD RIGHT SEAT HEATER SWITCH MUX

1 2 CAV CIRCUIT FUNCTION

1 L78 18BK/YL FUSED HEADLAMP SWITCH OUTPUT
2 Z1 18BK GROUND

RIGHT
LICENCE LAMP
(BUILT-UP-EXPORT)

YELLOW

CAV CIRCUIT FUNCTION

1 P18 14YL/LG RIGHT POWER SEAT FRONT UP
2 P20 14RD/LG RIGHT POWER SEAT FRONT DOWN

RIGHT POWER
SEAT FRONT
VERTICAL MOTOR

YELLOW

CAV CIRCUIT FUNCTION

1 P16 14RD/LB RIGHT POWER SEAT HORIZONTAL REARWARD
2 P14 14YL/LB RIGHT POWER SEAT HORIZONTAL FORWARD

RIGHT POWER
SEAT HORIZONTAL
MOTOR
YELLOW

CAV CIRCUIT FUNCTION

1 P10 14YL/WT RIGHT POWER SEAT REAR UP
2 P12 14RD/WT RIGHT POWER SEAT REAR DOWN

RIGHT POWER
SEAT REAR
VERTICAL MOTOR

J008W-7 XJI08082

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83

BLACK CAV CIRCUIT FUNCTION

A Z1 14BK GROUND
N
B M B F37 14RD FUSED B(+)
L C - -
K E P10 14YL/WT RIGHT POWER SEAT REAR UP
F - -
A J
G - -
E F H - -
J P12 14RD/WT RIGHT POWER SEAT REAR DOWN
C H G K P14 14YL/LB RIGHT POWER SEAT HORIZONTAL FORWARD
L P16 14RD/LB RIGHT POWER SEAT HORIZONTAL REARWARD
RIGHT POWER M P18 14YL/LG RIGHT POWER SEAT FRONT UP
SEAT SWITCH N P20 14RD/LG RIGHT POWER SEAT FRONT DOWN

BLACK
1

CAV CIRCUIT FUNCTION

2 3 1 - -
2 Z1 18BK GROUND
3 M2 18YL COURTESY LAMPS DRIVER
RIGHT REAR
DOOR JAMB
SWITCH

BLACK

2 1 CAV CIRCUIT FUNCTION

1 P34 16PK/BK DOOR UNLOCK DRIVER
2 P33 16OR/BK DOOR LOCK DRIVER
RIGHT REAR
DOOR LOCK
MOTOR

BLACK

1 2 CAV CIRCUIT FUNCTION

1 Z1 18BK GROUND
2 L38 18OR/WT REAR FOG LAMP FEED

RIGHT REAR
FOG LAMP
(BUILT-UP-EXPORT)

XJI08083 J008W-7

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 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS XJ

RED

CAV CIRCUIT FUNCTION

B A
A B1 20YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
B B2 20YL RIGHT REAR WHEEL SPEED SENSOR (+)
RIGHT REAR
WHEEL SPEED
SENSOR
BLACK

1 2 CAV CIRCUIT FUNCTION

1 Q14 14GY POWER WINDOW RIGHT REAR B(+) UP
2 Q24 14DG RIGHT REAR WINDOW DRIVER DOWN

RIGHT REAR
WINDOW MOTOR

BLUE

CAV CIRCUIT FUNCTION

1 Q14 14GY POWER WINDOW RIGHT REAR B(+) UP
3 1 2 Q28 14DG/WT MASTER WINDOW SWITCH RIGHT REAR DOWN
6 4 3 - -
4 Q18 14GY/BK RIGHT REAR WINDOW DRIVER (UP)
5 Q24 14DG RIGHT REAR WINDOW DRIVER (DOWN)
RIGHT REAR
6 Q1 14YL POWER WINDOW SWITCH FEED
WINDOW SWITCH

2
1 CAV CIRCUIT FUNCTION
1 L60 18GY RIGHT TURN SIGNAL
2 Z1 18BK GROUND
RIGHT
REPEATER
LAMP
(BUILT-UP-EXPORT)

NATURAL
CAV CIRCUIT FUNCTION
1 1 L78 20DG/YL FUSED HEADLAMP SWITCH OUTPUT
2
2 L60 20TN RIGHT TURN SIGNAL

RIGHT SIDE
MARKER LAMP
(EXCEPT BUILT
-UP-EXPORT)
CAV CIRCUIT FUNCTION
A X58 18DB/OR RIGHT REAR SPEAKER (-)
RIGHT A X92 16TN/BK AMPLIFIED RIGHT REAR SPEAKER (-)
SOUNDBAR B X52 18DB/WT RIGHT REAR SPEAKER (+)
SPEAKER B X94 16TN/RD AMPLIFIED RIGHT REAR SPEAKER (+)

4 SPEAKER SYSTEM
J008W-7 6 SPEAKER SYSTEM XJI08084

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85

1 2
CAV CIRCUIT FUNCTION
1 K167 20BR/YL SENSOR GROUND
RIGHT SPEED 2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
CONTROL SWITCH

1 3
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT
3 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
RIGHT TAIL/
STOP LAMP

CAV CIRCUIT FUNCTION

2 1 1 Z1 18BK GROUND
RIGHT TURN 2 L62 18BR/RD RIGHT TURN SIGNAL
SIGNAL LAMP

BLACK

A B CAV CIRCUIT FUNCTION

A M1 20PK FUSED B(+)
RIGHT VISOR/ B Z1 20BK GROUND
VANITY
LAMP

BLACK

CAV CIRCUIT FUNCTION

A B
A G10 20LG/RD SEAT BELT SWITCH SENSE
B Z1 20BK GROUND
SEAT BELT
SWITCH

XJI08085 J008W-7

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 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

1 P133 18TN/DG LEFT SEAT HEATER SWITCH MUX
2 P141 18TN/LB SENSOR FEED
BLACK
3 P86 18PK/BK RIGHT HEAT ELEMENT OUTPUT
4 F235 16RD HEATED SEAT RELAY OUTPUT
1 6 5 P87 18BK/OR LEFT HEAT ELEMENT OUTPUT
6 F235 16RD HEATED SEAT RELAY OUTPUT
7 14
7 P144 18BK/YL RIGHT HEAT SENSE INPUT
8 P143 18BK/DG LEFT HEAT SENSE INPUT
SEAT 9 P134 18TN/RD RIGHT SEAT HEATER SWITCH MUX
HEAT 10 P138 18VT/LG RIGHT SEAT LOW HEAT LED DRIVER
INTERFACE 11 P140 18VT/BK RIGHT SEAT HIGH HEAT LED DRIVER
MODULE 12 P137 18VT LEFT SEAT LOW HEAT LED DRIVER
13 Z2 18BK/LG GROUND
14 P139 18VT/WT LEFT SEAT HIGH HEAT LED DRIVER

BLACK
CAV CIRCUIT FUNCTION
1 D1 20VT/BR CCD BUS (+)
6 1
2 D2 20WT/BK CCD BUS (-)
3 Z2 20BK/LG GROUND
SENTRY KEY
IMMOBILIZER 4 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)
MODULE 5 Z2 20BK/LG GROUND
6 F1 20DB/GY FUSED B(+)

WHITE

CAV CIRCUIT FUNCTION

1 K29 20WT/PK BRAKE SWITCH SENSE
1 K29 18WT/PK BRAKE SWITCH SENSE
SHIFT LOCK
2 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
SOLENOID

LHD
RHD
J008W-7 XJI08086

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87

WHITE

CAV CIRCUIT FUNCTION

1 3 1 K167 20BR/YL SENSOR GROUND
2 K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL
2 K22 20OR/DB THROTTLE POSITION SENSOR SIGNAL
THROTTLE 3 K7 20OR 5V SUPPLY
POSITION
SENSOR

A B
CAV CIRCUIT FUNCTION
A F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
TORQUE CONVERTER B K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
CLUTCH SOLENOID
(2.5L GAS A/T)

LT GRAY CAV CIRCUIT FUNCTION

1 - -
2 L74 20LG BRAKE LAMP SWITCH OUTPUT
3 L10 18BR/LG BACK-UP LAMP FEED
5 1
4 A6 20RD/OR FUSED B(+)
10 6
5 L77 20BR/YL FUSED HEADLAMP SWITCH OUTPUT
6 - -
7 B40 14LB TRAILER TOW BRAKE B(+)
TRAILER TOW 8 Z1 14BK GROUND
CONNECTOR 9 - -
10 L73 20YL BRAKE LAMP SWITCH OUTPUT

BLACK
3 5 2 CAV CIRCUIT FUNCTION
1 L63 20DG/RD LEFT TURN SIGNAL
2 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
4 3 A6 20RD/OR FUSED B(+)
4 - -
1
5 L73 20YL BRAKE LAMP SWITCH OUTPUT
TRAILER TOW
LEFT TURN RELAY

BLACK
3 5 2 CAV CIRCUIT FUNCTION
1 L62 20BK/RD RIGHT TURN SIGNAL
2 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
4
3 A6 20RD/OR FUSED B(+)
4 - -
1
TRAILER TOW 5 L74 20LG BRAKE LAMP SWITCH OUTPUT
RIGHT TURN RELAY
4.0L A/T
EXCEPT 4.0L A/T
XJI08087 J008W-7

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 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS XJ

BLACK

CAV CIRCUIT FUNCTION

A B A G107 20BK/RD 4WD SWITCH SENSE (PART-TIME)
B Z1 20BK GROUND

TRANSFER
CASE SWITCH
(231 4WD)

BLACK

CAV CIRCUIT FUNCTION

A A Z1 20BK GROUND
D C
B G106 20BK/WT 4WD SWITCH SENSE (FULL-TIME)
B
C - -
D G107 20BK/RD 4WD SWITCH SENSE (PART-TIME)
TRANSFER
CASE SWITCH
(242 4WD)

BLACK

CAV CIRCUIT FUNCTION

1 2 1 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
2 Z1 20BK GROUND
TRANSFER CASE
SWITCH
ILLUMINATION

BLACK
1 4
CAV CIRCUIT FUNCTION
1 T52 20RD/BK INPUT SPEED SENSOR SIGNAL
2 T60 20OR/WT SOLENOID B CONTROL
3 T19 20WT SOLENOID A CONTROL
4 T22 20DB/WT SOLENOID C CONTROL
4 8 5 T31 20VT/LG INPUT SPEED SENSOR GROUND
6 T13 20DB/BK OUTPUT SPEED SENSOR GROUND
TRANSMISSION 7 T14 20LG/WT OUTPUT SPEED SENSOR SIGNAL
SOLENOID 8 - -
(4.0L)
DIESEL
GAS

J008W-7 XJI08088

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89

CAV CIRCUIT FUNCTION

1 T31 20VT/LG INPUT SPEED SENSOR GROUND
2 T52 20RD/BK INPUT SPEED SENSOR SIGNAL
3 T13 20DB/BK OUTPUT SPEED SENSOR GROUND
4 T14 20LG/WT OUTPUT SPEED SENSOR SIGNAL
5 - -
6 D2 20WT/BK CCD BUS (-)
BLACK CCD BUS (+)
7 D1 20VT/BR
8 - -
9 T3 18VT TRS T3 SENSE
10 - -
1 13
11 T22 20DB/WT SOLENOID C CONTROL
14 26 12 T19 20WT SOLENOID A CONTROL
13 T60 20OR/WT SOLENOID B CONTROL
14 D21 20PK SCI TRANSMIT/ISO 9141K
TRANSMISSION
15 - -
CONTROL
16 K167 20BR/YL SENSOR GROUND
MODULE
(4.0L) 17 K22 20OR/DB THROTTLE POSITION SENSOR SIGNAL
18 L10 18BR/LG BACK-UP LAMP FEED
19 - -
20 - -
21 T42 18VT/WT TRS T42 SENSE
22 T1 18LG/BK TRS T1 SENSE
23 K29 20WT/PK BRAKE LAMP SWITCH SENSE
24 Z12 18BK/TN GROUND
25 M1 20PK FUSED B(+)
26 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)

GRAY
CAV CIRCUIT FUNCTION
1 T42 18VT/WT TRS T42 SENSE
1 2 T3 18VT TRS T3 SENSE
2
3 3 F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
5 4
4 T1 18LG/BK TRS T1 SENSE
6
8 5 - -
7
6 L10 18BR/LG BACK-UP LAMP FEED
7 T41 20BK/WT PARK/ NEUTRAL POSITION SWITCH SENSE
TRANSMISSION 8 Z1 18BK GROUND
RANGE
SENSOR
(4.0L A/T)

CAV CIRCUIT FUNCTION

BLACK
1 K4 20BK/LB SENSOR GROUND
2 K21 20BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
1 4 3 K9 20LB 5V SUPPLY
4 K1 20DG/RD BOOST PRESSURE SENSOR SIGNAL
TURBO BOOST
PRESSURE
SENSOR
(DIESEL)
XJI08089 J008W-7

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 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS XJ

CAV CIRCUIT FUNCTION

BLACK 1 L60 20TN RIGHT TURN SIGNAL
2 - -
3 L62 20BR/RD RIGHT TURN SIGNAL
6 1
4 L55 20RD/WT COMBINATION FLASHER INPUT
5 L6 20RD/WT FLASHER OUTPUT
6 L12 20VT/TN HAZARD FLASHER SELECT SIGNAL
7 - -
8 - -
11 7
9 L63 20DG/RD LEFT TURN SIGNAL
TURN SIGNAL/ 10 L61 20LG/WT LEFT TURN SIGNAL
HAZARD SWITCH 11 L55 20RD/WT COMBINATION FLASHER INPUT

BLACK

CAV CIRCUIT FUNCTION

1 M1 20PK FUSED B(+)
1
2 2 Z1 20BK GROUND

UNDERHOOD
LAMP/
SWITCH

BLACK

CAV CIRCUIT FUNCTION

1 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
4 1 2 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT
4 Z1 18BK GROUND
VEHICLE SPEED
CONTROL SERVO

CAV CIRCUIT FUNCTION

3 1 1 K7 18OR 5V SUPPLY
2 K167 20BR/YL SENSOR GROUND
3 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
VEHICLE SPEED
SENSOR
(DIESEL)

J008W-7 XJI08090

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 XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91

BLACK

CAV CIRCUIT FUNCTION

3 1 1 K6 18VT/OR 5V SUPPLY
2 K167 20BR/YL SENSOR GROUND
VEHICLE SPEED 3 G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL
SENSOR
(GAS)

BLACK

CAV CIRCUIT FUNCTION

B A A Z1 20BK GROUND
B G29 20BK/LB LOW WASHER FLUID SENSE
WASHER
FLUID LEVEL
SWITCH

BLACK

CAV CIRCUIT FUNCTION

2 1 1 G123 18DG/WT WATER IN FUEL SENSOR SIGNAL
2 K167 20BR/YL SENSOR GROUND
WATER IN FUEL
SENSOR
(DIESEL)

BLACK

CAV CIRCUIT FUNCTION

A B A V10 18BR WASHER PUMP CONTROL
B Z1 18BK GROUND
WINDSHIELD
WASHER PUMP

NATURAL
CAV CIRCUIT FUNCTION
1 Z1 16BK GROUND
2 V5 16DG/YL WIPER PARK SWITCH SENSE
6 1 3 V10 18BR WASHER PUMP CONTROL
4 V3 16BR/WT WIPER LOW SPEED OUTPUT
WIPE/WASH 5 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
SWITCH 6 V4 16BR/VT WIPER HIGH SPEED OUTPUT

XJI08091 J008W-7

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 1

8W-90 CONNECTOR LOCATIONS

DESCRIPTION AND OPERATION each section for connector number identification.
Refer to the index for the proper figure number.
INTRODUCTION
This section provides illustrations identifying com- CONNECTOR/GROUND LOCATIONS
ponent and connector locations in the vehicle. A con- For items that are not shown in this section N/S is
nector index is provided. Use the wiring diagrams in placed in the Fig. column.

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
A/C BK Left Rear of 41, 42 A/C Low Left Rear of 37
Compressor Engine Pressure Switch Engine
Clutch (Diesel) Compartment (Diesel)(RHD) Compartment
A/C-Heater BK Center of 22, 23 A/C Low Right Rear of 4, 12
Control or Instrument Pressure Switch Engine
Heater Control - Panel (Gas)(LHD) Compartment
C1 A/C Low Left Rear of 3, 11
A/C-Heater NAT Center of 22, 23 Pressure Switch Engine
Control - C2 Instrument (Gas)(RHD) Compartment
Panel Accelerator BK Near T/O for N/S
A/C High Near T/O for 8 Pedal Position Engine Control
Pressure Switch C107 Sensor (Diesel) Module - C1,
(2.5L)(LHD) (LHD) C2
A/C High Right Side of 7 Accelerator BK Right Kick 40
Pressure Switch Engine Pedal Position Panel Area
(2.5L)(RHD) Compartment Sensor
Near Power (Diesel)(RHD)
Distribution Airbag Control YL Under Center 27, 32
Center Module Console
A/C High Right Side of 12, 14 Ambient BK Center Grill 4, 5,
Pressure Switch Engine Temperature Opening 12, 13,
(4.0L)(LHD) Compartment Sensor 39, 40
Near Power
Back-Up Lamp BK Right Side of 19
Distribution
Switch (2.5L) Transmission
Center
Near Shifter
A/C High Left Side of 15
Back-Up Lamp BK Left Side of 20
Pressure Switch Engine
Switch (4.0L) Transmission
(4.0L)(RHD) Compartment
Near T/O for Back-Up Lamp BK Left Side of 43
A/C Switch (Diesel) Transmission
Compressor Battery BK At Battery 6, 7,
Clutch Temperature 12, 13,
A/C High Left Side of 41, 42 Sensor 14, 15,
Pressure Switch Engine 38
(Diesel) Blend Door BK T/O at T/O for N/S
A/C Low Right Rear of 39 Actuator C209 on HVAC
Pressure Switch Engine Harness
(Diesel)(LHD) Compartment Blower Motor On HVAC N/S
Harness

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 8W - 90 - 2 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
Blower Motor BK Near T/O for N/S C200 (LHD) GY Left Lower 21, 26
Relay C209 Instrument
Blower Motor BK On HVAC N/S Panel
Resistor Block Harness C201 (LHD) NAT Lower Center 21
Brake Lamp GY Near Brake 21, 24, of Instrument
Switch Pedal 25 Panel
Brake Warning BK Left Side of 2, 10, C202 (RHD) GY Lower Center 24, 27
Pressure Switch Engine 36 of Instrument
(LHD) Compartment Panel
Brake Warning BK Right Side of 5, 7, C203 (RHD) BL Lower Center 24, 27
Pressure Switch Engine 13, 15, of Instrument
(RHD) Compartment 40 Panel
C100 (LHD) BK Left Lower 6, 14, C204 (RHD) WT Lower Center 24, 27
Instrument 21, 25 of Instrument
Panel Panel
C100 (RHD) WT Right Lower 24, 40 C205 (LHD) YL Left Lower 21, 22
Instrument Instrument
Panel Panel
C106 BK Left Front 1, 6, 7, C205 (RHD) YL Right Lower 23, 24
Engine 14, 15, Instrument
Compartment 38 Panel
C107 (2.5L) BK Rear of Engine 2, 3, 4, C206 BK At Center 26, 27,
Compartment 5, 16 Console 32
C107 (4.0L) BK Rear of Engine 12, 13, C207 BK Right Lower 21, 24
Compartment 17 Instrument
Panel
C108 (Gas) BK Right Side of 4, 5, 6,
Engine 7, 12, C208 BK Left Lower 21, 24
Compartment 13, 14, Instrument
15 Panel
C109 BK Left Lower 14, 15, C209 (LHD) BK/LT Right Lower 32
Instrument 26, 27, GN Instrument
Panel 38 Panel
C111 (Diesel) LT GY Left Rear of 36, 37, C209 (RHD) BK/LT Left Lower 27
Engine 42 GN Instrument
Compartment Panel
C112 (4.0L A/T GY Left Side of 20 C300 (LHD) NAT At Right Kick 32
4WD) Transfer Case Panel
C113 (Gas M/T) Rear Center of 12, 17 C300 (RHD) WT At Right Kick 24
Engine Panel
Compartment C301 WT At Right Kick 24, 32
C114 (Built-Up- BK T/O at Left 1 Panel
Export) Headlamp T/O C303 NAT/ T/O at Junction N/S
C115 (Built-Up- BK T/O at Right N/S BK Block - C7 T/O
Export) Headlamp T/O (LHD)
WT
C116 (Diesel) BK Right Side of 39, 40,
(RHD)
Engine 41
C304 BK Right Lower B 29
C120 (Diesel) BK Rear of Engine 36, 37,
Pillar
41

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 3
DESCRIPTION AND OPERATION (Continued)

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
C305 WT At Left Kick 26, 27 C332 NAT Under Left 26, 27
Panel Front Seat
C306 WT At Left Kick 26, 27 C333 BK At Center High N/S
Panel Mounted Stop
C307 WT At Left Kick 26, 27 Lamp Jumper
Panel C362 BK Under Left 26, 27
C309 BK Left Lower B 26, 27 Front Seat
Pillar C363 BK Under Right 26, 27
C310 BK Top Center of 31 Front Seat
Liftgate Camshaft GY Right Side of 16, 17
C311 BK Top Center of 31 Position Sensor Engine
Liftgate (GAS)
C312 GN Top Center of 31 Cargo BK At Lamp N/S
Liftgate Lamp/Switch
C313 GY Top Center of 31 Center High BK At Liftgate N/S
Liftgate Mounted Stop
Lamp
C314 WT At Soundbar N/S
Cigar Lighter RD Lower Center 22, 23
C316 BK Under Right 26, 27,
of Instrument
Front Seat 29
Panel
C317 BK Left Lower A 26, 27
Clockspring - NAT At Clockspring 35
Pillar
C1
C318 BK Right Lower A 29
Clockspring - At Clockspring N/S
Pillar
C2
C319 BK Right Lower B 29
Clockspring - YL At Clockspring 35
Pillar
C3
C320 BK Left Lower B 26, 27
Clutch Interlock GN At Clutch Pedal 14, 24,
Pillar
Switch 25
C321 BK At Right Tail N/S
Clutch Interlock BK Lower Steering N/S
Lamp Harness
Switch Jumper Column
C322 (Trailer BK At Left Tail 33 (LHD)
Tow) Lamp Harness
Clutch Interlock BK Lower Steering 24
C322 (Without BK At Left Tail 28 Switch Jumper Column
Trailer Tow) Lamp Harness (RHD)
C323 (Trailer BK At Trailer Tow 28, 33 Combination BK Lower Left of 21
Tow) Harness Flasher Instrument
C324 (RHD) WT In T/O for N/S Panel
Junction Block - Compass BK In Headliner 34
C7
Controller BK Left Side of 10, 11,
C326 BK At Left Rear 28 Anti-Lock Brake Engine 36, 37
Quarter Panel Compartment
C327 BK At Left Rear 28 Crankshaft BK Left Side of 20
Quarter Panel Position Sensor Transmission
C329 NAT Under Right 26, 27 (Gas)
Front Seat Data Link BK Lower Left of 21
C330 BK Center of 31 Connector Instrument
Liftgate (LHD) Panel

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 8W - 90 - 4 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
Data Link BK Lower Right of N/S Engine Coolant BK Front of Engine 16, 17
Connector Instrument Temperature
(RHD) Panel Sensor (GAS)
Daytime BK Right Rear of 6, 8, Engine Coolant BK Left Rear of 41
Running Lamp Engine 14 Temperature Engine
Module (Except Compartment Sensor NO.1
Built-Up-Export) (Diesel)
Diode Module BK T/O at Rear N/S Engine Coolant BK Left Side of 41, 42
(Built-Up- Fog Lamp Temperature Engine
Export) Relay T/O Sensor NO.2
Dome Lamp At Lamp N/S (Diesel)
(Base/Police) Engine Oil BK Right Side of 16, 17,
Dome Lamps BK At Switch N/S Pressure Engine 41
Switch (Midline) Sensor
Driver Door BK Left Lower A N/S Engine Speed BK Left Side of 41
Jamb Switch Pillar Sensor (Diesel) Engine
Driver Door At Motor 30 EVAP Leak BK In T/O for N/S
Lock Motor Detection Pump Power
(Except Distribution
Driver Power BL At Switch 30
Built-Up-Export) Center
Lock/Window
Switch-C1 Extended Idle WT Instrument N/S
Switch (Police Panel Harness
Driver Power WT At Switch 30
Package) Near T/O to
Door Lock/
Power Outlet
Window
Switch-C2 Front Fog Lamp BK Lower Center 22, 23
Switch of Instrument
Driver Power RD At Mirror 30
Panel
Mirror
Front Wiper BK At Wiper Motor 8, 9
Driver Power BK At Motor 30
Motor
Window Motor
Fuel Heater Left Rear of 36, 37
Duty Cycle BK Right Rear of 2, 4,
(Diesel) Engine
EVAP/Purge Engine 10, 12
Compartment
Solenoid (Gas) Compartment
(LHD) Fuel Injection BK Left Side of 36, 37,
Pump (Diesel) Engine 42
Duty Cycle BK Left Rear of 3, 11
EVAP/Purge Engine Fuel Injector BK At Injector 16, 17
Solenoid (Gas) Compartment No. 1
(RHD) Fuel Injector BK At Injector 16, 17
Electronic Right Front of 39, 40 No. 2
Vacuum Engine Fuel Injector BK At Injector 16, 17
Modulator Compartment No. 3
(Diesel) Fuel Injector BK At Injector 16, 17
Engine Control BK Center of Cowl 38 No. 4
Module - C1 Under Fuel Injector BK At Injector 17
(Diesel) Instrument No. 5 (4.0L)
Panel
Fuel Injector BK At Injector 17
Engine Control BK Center of Cowl 38 No. 6 (4.0L)
Module - C2 Under
Fuel Level BK At Sensor 28
(Diesel) Instrument
Sensor (Diesel)
Panel

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 5
DESCRIPTION AND OPERATION (Continued)

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
Fuel Pump BK At Fuel Pump 28 G300 In T/O for N/S
Module (GAS) Module Airbag Control
G100 (4.0L) Right Front of 12, 13 Module
Engine G301 Near T/O for 28
Compartment Power Amplifier
G100 (2.5L) Right Front of N/S G302 At Left Rear 28
Engine Quarter Panel
Compartment G303 Under Right 26, 27,
at Battery Front Seat 29
Negative
G304 T/O at T/O’s for N/S
Terminal
C326 and C327
G101 Right Side of 16, 17
G306 Under Right 26, 27
Engine
Front Seat
G102 (Diesel) Right Side of 39, 40
G Switch BK Under Rear 28, 29
Engine
Seat
G102 (Gas) Rear of Engine 2, 3, 4,
Generator BK At Generator N/S
Compartment 5, 12,
(2.5L)
13
Generator BK At Generator 18
G104 (Gas) T/O at Engine N/S
(4.0L)
Starter Motor
T/O on Battery Generator BK At Generator 41, 42
Harness (Diesel)
G104 (Diesel) T/O at Battery N/S Glow Plug Left Rear of 36, 37
Negative Relay (Diesel) Engine
Terminal on Compartment
Battery Headlamp BK On Steering 35
Harness Beam Select Column
G105 (Diesel) On Negative N/S Switch
Battery HeadLamp BK Lower Left of 21
Harness Delay Module Instrument
G106 Left Side of 2, 3, (LHD) Panel
Engine 10, 11 Headlamp BK Lower Right of N/S
Compartment Delay Module Instrument
G107 (LHD) Right Side of 21 (RHD) Panel
Instrument Headlamp BK Lower Center 22, 23
Panel Leveling Switch of Instrument
G107 (RHD) Left Side of 24 (Built-Up- Panel
Instrument Export)
Panel Headlamp BK Left Side of 22
G108 (LHD) Left Side of 21 Switch (LHD) Instrument
Instrument Panel
Panel Headlamp BK Right Side of 23
G108 (RHD) Right Side of 24 Switch (RHD) Instrument
Instrument Panel
Panel Heated Seat Under Right N/S
G200 Under Left 27, 32 Relay Front Seat
Front Seat Idle Air Control BK Left Side of 16, 17
Motor Engine

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 8W - 90 - 6 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
Ignition Coil BK Right Side of 16 Left Front GY At Lamp 1
(2.5L) Engine Park/Turn
Ignition Switch - BK At Steering 21, 24, Signal Lamp
C1 Column 35 NO.1 (Except
Built-Up-Export)
Ignition Switch - GN At Steering 21, 24,
C2 Column 35 Left Front GY At Lamp 1
Park/Turn
Instrument BK At Instrument 21, 22,
Signal Lamp
Cluster - C1 Cluster 23, 24
NO.2 (Except
Instrument BK At Instrument 21, 22, Built-Up-Export)
Cluster - C2 Cluster 23, 24
Left Front Turn GY At Lamp 1
Intake Air GY Left Side of 16, 17 Signal Lamp
Temperature Engine NO.1 (Built-Up-
Sensor Export)
Junction Block - NAT At Right Kick 25, 29 Left Front Turn GY At Lamp 1
C1 Panel Area Signal Lamp
Junction Block - WT At Right Kick 25, 29 NO.2 (Built-Up-
C2 Panel Area Export)
Junction Block - NAT At Right Kick 29 Left Front GY Left Side of 10, 11,
C3 Panel Area Wheel Speed Engine 38
Sensor Compartment
Junction Block - WT At Right Kick 24, 29
C4 Panel Area Left Headlamp At Headlamp 1
Junction Block - WT At Right Kick 24, 29 Left Headlamp BK At Headlamp 1
C5 Panel Area Leveling Motor
(Built-Up-
Junction Block - NAT At Right Kick 29
Export)
C6 Panel Area
Left Heated At Left Seat N/S
Junction Block - NAT At Right Kick 29
Seat Back
C7 Panel Area
Left Heated At Left Seat N/S
Junction Block - NAT At Right Kick 29
Seat Cushion
C8 Panel Area
Left Heated RD At Center 26, 27
Junction Block - NAT At Right Kick 29
Seat Switch Console
C9 Panel Area
Left License At Lamp N/S
Left Back-Up GY At Lamp N/S
Lamp
Lamp
(Built-Up-
Left City Lamp At Lamp 1 Export)
(Built-Up-
Left Power Seat YL Under Left Seat N/S
Export)
Front Vertical
Left Courtesy BK Lower Left of 21, 24 Motor
Lamp Instrument
Left Power Seat YL Under Left Seat N/S
Panel
Horizontal Motor
Left Fog Lamp GY At Lamp 1
Left Power Seat YL Under Left Seat N/S
Left Front Door BK At Speaker 30 Rear Vertical
Speaker Motor
Left Front Door BK Left Front Door 30 Left Power Seat BK At Switch N/S
Tweeter Switch
Left Rear Door BK At Left B Pillar N/S
Jamb Switch

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 7
DESCRIPTION AND OPERATION (Continued)

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
Left Rear Door BK In Left Rear 30 Overhead BK Front Center of 34
Lock Motor Door Module Headliner
Left Rear Fog BK At Lamp N/S Oxygen Sensor GY Left Side of 16
Lamp 1/1 Upstream Engine
(Built-Up- (2.5L)
Export) Oxygen Sensor GY Right Side of 20
Left Rear Wheel BK Under Rear 28 1/1 Upstream Transmission
Speed Sensor Seat (4.0L)
Left Rear BK In Left Rear 30 Oxygen Sensor GY Left Side of 17
Window Motor Door 1/1 Upstream Engine
Left Rear BL In Left Rear 30 (California/
Window Switch Door European III)
Left Repeater At Lamp 1 Oxygen Sensor BK Right Side of 19
Lamp 1/2 Downstream Transmission
(Built-Up- (2.5L)
Export) Oxygen Sensor BK Right Side of 20
Left Side NAT At Lamp 1 1/2 Downstream Transmission
Marker Lamp (4.0L)
(Except Oxygen Sensor BK Left Side of 17
Built-Up-Export) 1/2 Downstream Engine
Left Soundbar At Soundbar N/S (California/
Speaker European III)
Left Speed On Steering N/S Oxygen Sensor GY Left Side of 17
Control Switch Wheel 2/1 Upstream Engine
(California/
Left Tail/Stop BK At Lamp N/S
European III)
Lamp
Oxygen Sensor BK Left Side of 20
Left Turn Signal At Rear Lamp N/S
2/2 Downstream Engine
Lamp
(California/
Left Visor/Vanity BK Left Side of 34 European III)
Lamp Headliner
Park/Neutral BK Left Side of 19
License Lamp At Lamp N/S Position Switch Transmission
Liftgate Lock BK In Liftgate 31 (2.5L Gas A/T)
Motor Passenger YL At Airbag 21, 22,
Liftgate Switch BK In Liftgate 31 Airbag 23, 24
Low Coolant Right Side of 39, 40 Passenger Door BK Kick Panel Area N/S
Switch (Diesel) Engine Jamb Switch at Door
Compartment Opening
Manifold BK Left Side of 16, 17 Passenger Door At Motor 30
Absolute Engine Lock Motor
Pressure Passenger BL At Switch 30
Sensor Power
Message Center BK Upper Center 21, 22, Lock/Window
(Diesel) of Instrument 23, 24 Switch - C1
Panel Passenger BL At Switch 30
Needle Rear of Engine 36, 37 Power
Movement Compartment Lock/Window
sensor (Diesel) Switch - C2

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 8W - 90 - 8 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
Passenger RD At Mirror 30 Radiator Fan LT GY Front of Engine 2, 3, 6,
Power Mirror Motor Compartment 7, 10,
Passenger BK At Motor 30 11, 14,
Power Window 15, 36,
Motor 37, 38
Power Amplifier NAT Under Left 28 Radio - C1 BK Center of 22, 23
- C1 Rear Seat Instrument
Panel
Power Amplifier NAT Under Left 28
- C2 Rear Seat Radio - C2 GY Center of 22, 23
Instrument
Power Antenna BK Right Side of 21, 24
Panel
(Built-Up- Instrument
Export) Panel Rail Coil (4.0L) BK Right Side of 17
Engine
Power Antenna BK Right Side of 21, 24
Relay - C1 Instrument Rear Fog Lamp Right Side of 21
(Built-Up- Panel Relay Instrument
Export) (Built-Up- Panel
Export) (LHD)
Power Antenna BK Right Side of 21, 24
Relay - C2 Instrument Rear Fog Lamp Left Side of 24
(Built-Up- Panel Relay Instrument
Export) (Built-Up- Panel
Export) (RHD)
Power Mirror At Switch N/S
Switch Rear Fog Lamp WT Center of 22, 23
Switch Instrument
Power Outlet RD Lower Center 22, 23
(Built-Up- Panel
of Instrument
Export)
Panel
Rear Washer BK Left Front of 2, 3, 8,
Power Steering WT Front of Engine 16
Pump Engine 9, 10,
Pressure Switch
Compartment 11, 36,
(2.5L)
37
Powertrain Right Side of 39, 40
Rear Window GY Center of 22, 23
Control Module Engine
Defogger Switch Instrument
- C1 (Diesel) Compartment
Panel
Powertrain BK Left Side of 8, 9,
Rear Wiper In Liftgate 31
Control Module Engine 16, 17
Motor
- C1 (Gas) Compartment
Rear Wiper/ BK Center of 22, 23
Powertrain Right Side of 39, 40
Washer Switch Instrument
Control Module Engine
Panel
- C2 (Diesel) Compartment
Right Back-Up GY At Lamp N/S
Powertrain WT Left Side of 8, 9,
Lamp
Control Module Engine 16, 17
- C2 (Gas) Compartment Right City Lamp At Lamp 1
(Built-Up-
Powertrain GY Right Side of 39, 40
Export)
Control Module Engine
- C3 (Diesel) Compartment Right Courtesy BK Lower Right of 21, 24
Lamp Instrument
Powertrain GY Left Side of 8, 9, 2,
Panel
Control Module Engine 3, 10,
- C3 (Gas) Compartment 11 Right Fog Lamp GY At Lamp 1
PRNDL At Center 26, 27 Right Front BK At Speaker 30
Illumination Console Door Speaker
(A/T)

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 9
DESCRIPTION AND OPERATION (Continued)

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
Right Front BK At Right Front 30 Right Rear Door BK At Right B Pillar 29
Door Tweeter Door Jamb Switch
Right Front BK At Lamp 1 Right Rear Door BK In Right Rear 30
Park/Turn Lock Motor Door
Signal Lamp Right Rear Fog BK At Lamp N/S
NO.1 (Except Lamp
Built-Up-Export) (Built-Up-
Right Front BK At Lamp 1 Export)
Park/Turn Right Rear RD Under Rear 28
Signal lamp Wheel Speed Seat
NO.2 (Except Sensor
Built-Up-Export)
Right Rear BK In Right Rear 30
Right Front Turn GY At Lamp 1 Window Motor Door
Signal Lamp
Right Rear BL In Right Rear 30
NO.1 (Built-Up-
Window Switch Door
Export)
Right Repeater At Lamp N/S
Right Front Turn GY At Lamp 1
Lamp
Signal Lamp
(Built-Up-
NO.2 (Built-Up-
Export)
Export)
Right Side NAT At Lamp 1
Right Front Right Side of 11, 12,
Marker Lamp
Wheel Speed Engine 39, 40
(Except
Sensor Compartment
Built-Up-Export)
Right Headlamp At Headlamp 1
Right Sound At Soundbar N/S
Right Headlamp BK At Headlamp 1 Bar Speaker
Leveling Motor
Right Speed On Steering N/S
(Built-Up-
Control Switch Wheel
Export)
Right Tail/Stop At Lamp N/S
Right Heated At Right Seat N/S
Lamp
Seat Back
Right Turn At Rear Lamp N/S
Right Heated At Right Seat N/S
Signal Lamp
Seat Cushion
Right Visor/ BK Right Side of 34
Right Heated BL At Center 26, 27
Vanity Lamp Headliner
Seat Switch Console
Seat Belt Switch BK T/O at T/O for 32
Right License At Lamp N/S
(LHD) Airbag Control
Lamp
Module
(Built-Up-
Export) Seat Belt Switch BK T/O at T/O for N/S
(RHD) C206
Right Power YL Under Right N/S
Seat Front Seat Seat Heat BK Under Right N/S
Vertical Motor Interface Front Seat
Module
Right Power YL Under Right N/S
Seat Horizontal Seat Sentry Key BK At Steering 21, 24
Motor Immobilizer Column
Module
Right Power YL Under Right N/S
Seat Rear Seat Shift Lock WT At Steering 21, 35
Vertical Motor Solenoid (LHD) Column
Right Power BK At Switch N/S Shift Lock WT At Steering 35
Seat Switch Solenoid (RHD) Column

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 8W - 90 - 10 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)

Connector Color Location Fig. Connector Color Location Fig.

Name/Number Name/Number
Throttle Position WT Left Side of 16, 17 Turbo Boost BK Rear of Engine 36, 37
Sensor Engine Pressure Compartment
Torque Left Side of 19 Sensor (Diesel)
Converter Transmission Turn Signal/ BK At Steering 21, 24,
Clutch Solenoid Hazard Switch Column 35
(2.5L Gas A/T) Underhood BK At Lamp 2, 5,
Trailer Tow LT GY At Rear 33 Lamp/Switch 10, 11,
Connector Bumper 36, 37
Trailer Tow Left BK At Left Rear 33 Vehicle Speed BK Right Front of 4, 12,
Turn Relay Quarter Panel Control Servo Engine 14
Trailer Tow BK At Left Rear 33 (LHD) Compartment
Right Turn Quarter Panel Vehicle Speed BK Right Rear of 5, 9,
Relay Control Servo Engine 13, 15
Transfer Case BK Left Side of 19, 20, (RHD) Compartment
Switch (231 Transmission 43 Vehicle Speed Left Side of 43
4WD) Sensor (Diesel) Transmission
Transfer Case BK Left Side of 20 Vehicle Speed BK Left Side of 19, 20
Switch (242 Transmission Sensor (Gas) Transmission
4WD) Washer Fluid BK Left Front of 2, 3, 8,
Transfer Case BK At Center 26, 27 Level Switch Engine 9, 10,
Switch Console Compartment 11, 36,
Illumination 37
Transmission BK Rear of Engine 12, 13 Water In Fuel BK Rear of Engine 36, 37
Control Compartment Sensor (Diesel) Compartment
Assembly or Windshield BK Left Front of 2, 3, 8,
Transmission Washer Pump Engine 9, 10,
Solenoid (4.0L) Compartment 11, 36,
Transmission BK Under 14, 15, 37
Control Module Instrument 25 Wipe/Wash NAT At Steering 21, 24,
(4.0L) Panel near Switch Column 35
Transmission
Tunnel
Transmission BK/ Rear of Engine 12, 13
Range Sensor GY Compartment
(4.0L A/T)

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 11
DESCRIPTION AND OPERATION (Continued)

Fig. 1 Front End Lighting

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 8W - 90 - 12 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)

Fig. 2 Left Engine Compartment 2.5L Engine LHD

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 13
DESCRIPTION AND OPERATION (Continued)

Fig. 3 Left Engine Compartment 2.5L Engine RHD

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 8W - 90 - 14 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)

Fig. 4 Right Engine Compartment 2.5L Engine LHD

Fig. 5 Right Engine Compartment 2.5L Engine RHD

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 15
DESCRIPTION AND OPERATION (Continued)

Fig. 6 Engine Compartment Auxiliary Views 2.5L Engine LHD

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 8W - 90 - 16 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)

Fig. 7 Engine Compartment Auxiliary Views 2.5L Engine RHD

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 17
DESCRIPTION AND OPERATION (Continued)

Fig. 8 Engine Compartment Components LHD

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 8W - 90 - 18 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)

Fig. 9 Engine Compartment Components RHD

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 XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 19
DESCRIPTION AND OPERATION (Continued)

Fig. 10 Left Engine Compartment 4.0L Engine LHD

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 8W - 90 - 20 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)