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Jeep XJ. Manual - part 99

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.)

8D - 24

IGNITION SYSTEM

SPECIFICATIONS (Continued)

INSTRUMENT PANEL SYSTEMS

TABLE OF CONTENTS

page

DESCRIPTION AND OPERATION

INSTRUMENT PANEL SYSTEM . . . . . . . . . . . . . . 1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . 1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 2
INSTRUMENT PANEL CIGAR LIGHTER . . . . . . . . 3
CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . . . . 4
INSTRUMENT PANEL POWER OUTLET . . . . . . . . 4

DIAGNOSIS AND TESTING

INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . 5
INSTRUMENT PANEL CIGAR LIGHTER . . . . . . . 11
CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . . . 12
INSTRUMENT PANEL POWER OUTLET . . . . . . . 12

REMOVAL AND INSTALLATION

STEERING COLUMN OPENING COVER . . . . . . . 13
KNEE BLOCKER . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTRUMENT PANEL CENTER BEZEL . . . . . . . . 14

INSTRUMENT PANEL ACCESSORY SWITCH

BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

INSTRUMENT PANEL ASSEMBLY . . . . . . . . . . . 26

DESCRIPTION AND OPERATION

INSTRUMENT PANEL SYSTEM

DESCRIPTION

The instrument panel serves as the command cen-

ter of the vehicle, which necessarily makes it a very
complex unit. The instrument panel is designed to
house the controls and monitors for standard and
optional powertrains, climate control systems, audio
systems, lighting systems, safety systems and many
other comfort or convenience items. The instrument
panel is also designed so that all of the various con-
trols can be safely reached and the monitors can be
easily viewed by the vehicle operator when driving,
while still allowing relative ease of access to each of
these items for service. See the owner’s manual in
the vehicle glove box for more information on the fea-
tures, use and operation of all of the instrument
panel components and systems.

This group is responsible for covering service infor-

mation for the vehicle instrument panel systems.
However, complete service information coverage for
all of the systems and components housed in the
instrument panel in a single section of the service
manual would not be practical. Therefore, the service
information for any component will be found in the
group designated to cover the vehicle system that the
component belongs to, even though the component is

mounted on or in the instrument panel. If you cannot
locate a listing for the component or system you are
servicing in the table of contents for this group, or if
you are uncertain as to which vehicle system a com-
ponent belongs to, it is suggested that you refer to
the alphabetical Component and System Index
found at the back of this service manual.

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

applied to either version. Exceptions to this rule
have been clearly identified as LHD or RHD, if a
special illustration or procedure is required.

INSTRUMENT PANEL

DESCRIPTION

This instrument panel uses a full-width structural

plastic foundation as its primary support. When the
two primary molded plastic components of this struc-
ture are vibration welded together they provide supe-
rior instrument panel stiffness and integrity to help

INSTRUMENT PANEL SYSTEMS

8E - 1

reduce buzzes, squeaks, and rattles even on the
bumpiest roads.

This type of construction also provides improved

energy absorption which, in conjunction with the
dual airbag modules and seat belts, helps to improve
occupant protection. This foundation structure also
serves as the air duct for the heating and air condi-
tioning system panel outlets, which greatly reduces
the number of components used over conventional
instrument panel construction.

Modular instrument panel construction allows all

of the gauges and controls to be serviced from the
front of the panel. In addition, most of the instru-
ment panel electrical components can be accessed
without complete instrument panel removal. If neces-
sary, the instrument panel can be removed from the
vehicle as an assembly.

Removal of the steering column opening cover and

knee blocker provides access to the steering column
mounts, the steering column wiring, the headlamp
switch, the electronic combination flasher, and much
of the instrument panel wiring. Removal of the glove
box provides access to the heating and air condition-
ing electrical and vacuum harnesses, the blower
motor relay, the radio antenna coaxial cable, the
lower passenger side airbag mounts, and additional
instrument panel wiring.

Removal of the instrument panel center bezel

allows access to the radio, the heating and air condi-
tioning controls, the accessory switches, the cigar
lighter, and the accessory power outlet. Removal of
the instrument cluster bezel allows access to the
instrument cluster. Removal of the cluster assembly
allows access to the cluster illumination and indica-
tor lamp bulbs, and more of the instrument panel
wiring.

Removal of the instrument panel top cover allows

access to the upper passenger side airbag mounts.
Instrument panel removal is required for service of
most internal components of the heating and air con-
ditioning system housing.

INSTRUMENT CLUSTER

DESCRIPTION

Two basic instrument clusters are offered on this

model: low-line, or high-line. Both clusters are elec-
tromechanical units that utilize integrated circuitry
and information carried on the Chrysler Collision
Detection (CCD) data bus network for control of all
gauges and many of the indicator lamps. These clus-
ters also incorporate a digital Vacuum Fluorescent
Display (VFD) for the odometer/trip odometer display
functions. Some variations of each cluster exist due
to optional equipment and regulatory requirements.

The low-line cluster includes the following analog

gauges:

• Fuel gauge

• Speedometer.
This cluster also includes provisions for the follow-

ing indicator lamps:

• Airbag indicator lamp

• Anti-lock brake system lamp

• Brake warning lamp

• Coolant temperature warning lamp

• Cruise-on indicator lamp

• Four-wheel drive (Part Time and/or Full Time)

indicator lamps

• Headlamp high beam indicator lamp

• Low oil pressure warning lamp

• Low washer fluid warning lamp

• Malfunction Indicator Lamp (MIL)

• Seat belt reminder lamp

• Sentry Key Immobilizer System (SKIS) indicator

lamp

• Turn signal indicator lamps

• Upshift indicator lamp (manual transmission)

• Voltage warning lamp.
The high-line cluster replaces some of the indicator

lamps found in the low-line cluster with analog
gauges. The high-line cluster includes the following
analog gauges:

• Coolant temperature gauge

• Fuel gauge

• Oil pressure gauge

• Speedometer

• Tachometer

• Voltmeter.
The high-line cluster also adds a check gauges

lamp and a low fuel warning lamp to the remaining
indicator lamps found in the low-line cluster.

Both instrument clusters feature circuitry that has

a self-diagnostic actuator test capability, which will
test each of the CCD bus message-controlled func-
tions of the cluster by lighting the appropriate indi-
cator lamps and positioning the gauge needles at
several predetermined locations on the gauge faces in
a prescribed sequence. For more information on this
function, refer to Instrument Cluster in the Diag-
nosis and Testing section of this group.

The instrument cluster circuitry also integrates a

chime tone generator and a timer circuit. These
items replace the chime or buzzer module, and the
separate timer circuit for the rear window defogger
system. Refer to Chime Warning System in the
Description and Operation section of Group 8U -
Chime/Buzzer Warning Systems for more information
on the chime functions of the instrument cluster.
Refer to Rear Window Defogger System in the
Description and Operation section of Group 8N -

8E - 2

INSTRUMENT PANEL SYSTEMS

DESCRIPTION AND OPERATION (Continued)

Electrically Heated Systems for more information on
the timer function of the instrument cluster.

The instrument clusters for this model are serviced

only as complete units. If a cluster gauge or the clus-
ter circuit board are faulty, the entire cluster must be
replaced. The cluster lens, the cluster hood and
mask, the rear cluster housing cover, the odometer
reset knob boot and the incandescent lamp bulbs and
holders are available for service replacement.

OPERATION

GAUGE

With the ignition switch in the On or Start posi-

tions, voltage is supplied to all gauges through the
instrument cluster electronic circuit board. With the
ignition switch in the Off position, voltage is not sup-
plied to the gauges. The gauges do not accurately
indicate any vehicle condition unless the ignition
switch is in the On or Start positions.

All of the instrument cluster gauges, except the

odometer, are air core magnetic units. Two fixed elec-
tromagnetic coils are located within the gauge. These
coils are wrapped at right angles to each other
around a movable permanent magnet. The movable
magnet is suspended within the coils on one end of a
shaft. The gauge needle is attached to the other end
of the shaft.

One of the coils has a fixed current flowing

through it to maintain a constant magnetic field
strength. Current flow through the second coil
changes, which causes changes in its magnetic field
strength. The current flowing through the second coil
is changed by the instrument cluster electronic cir-
cuitry in response to messages received on the
Chrysler Collision Detection (CCD) data bus network.

The gauge needle moves as the movable permanent

magnet aligns itself to the changing magnetic fields
created around it by the electromagnets. The instru-
ment cluster circuitry is programmed to move all of
the gauge needles back to the low end of their respec-
tive scales after the ignition switch is turned to the
Off position.

INDICATOR LAMP

Indicator lamps are located in the instrument clus-

ter and are served by the cluster circuit board and
connectors. Many of the indicator lamps in the
instrument cluster are controlled by the instrument
cluster circuitry in response to messages received
over the Chrysler Collision Detection (CCD) data bus
network.

The anti-lock brake system lamp, brake warning

lamp, four-wheel drive indicator lamps, headlamp
high beam indicator lamp, low washer fluid warning
lamp and turn signal indicator lamps are hard wired.

The seat belt reminder lamp is controlled by the
instrument cluster programming. The Malfunction
Indicator Lamp (MIL) is normally controlled by CCD
data bus messages from the Powertrain Control Mod-
ule (PCM); however, if the instrument cluster detects
a loss of CCD data bus communication, the cluster
will automatically turn the MIL on and display the
message “NO BUS” in the odometer VFD until CCD
data bus communication is restored. The instrument
cluster circuitry uses CCD data bus messages from
the Powertrain Control Module (PCM), Airbag Con-
trol Module (ACM), and the Sentry Key Immobilizer
Module (SKIM) to control all of the remaining indi-
cator lamps.

Each of the indicator lamps in the instrument clus-

ter uses incandescent bulbs and holders, which are
available for service replacement.

CLUSTER ILLUMINATION LAMP

The cluster illumination lamps are hard wired in

the instrument cluster. When the park or head lamps
are turned on, the cluster illumination lamps light.
Illumination brightness is adjusted by rotating the
headlamp switch knob (clockwise to dim, counter-
clockwise to brighten). The instrument cluster illumi-
nation lamps receive battery feed from the panel
dimmer rheostat in the headlamp switch through a
fuse in the fuseblock module.

The instrument cluster electronic circuitry also

monitors the cluster illumination lamp dimming level
whenever the park or head lamps are turned on. The
instrument cluster electronic circuitry responds by
adjusting the dimming level of the odometer Vacuum
Fluorescent Display (VFD), and sending dimming
level messages over the Chrysler Collision Detection
(CCD) data bus network. When the park lamps or
headlamps are turned off, the VFD is illuminated at
full brightness for improved daylight visibility.

Each of the cluster illumination lamps is located on

the instrument cluster circuit board. Each cluster
illumination lamp has a replaceable bulb and bulb
holder.

INSTRUMENT PANEL CIGAR LIGHTER

DESCRIPTION

A cigar lighter is standard equipment on this

model. The cigar lighter is installed in the instru-
ment panel accessory switch bezel, which is located
near the bottom of the instrument panel center bezel
area, below the heater and air conditioner controls.
The cigar lighter base is secured by a snap fit within
the accessory switch bezel.

The cigar lighter receptacle is serviced only as a

part of the accessory switch bezel unit. If the cigar
lighter base is faulty or damaged, the accessory

INSTRUMENT PANEL SYSTEMS

8E - 3

DESCRIPTION AND OPERATION (Continued)

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