Jeep XJ. Manual — part 340
INSTALLATION
(1) Place accelerator pedal assembly over studs
protruding from floor pan. Tighten mounting nuts to
5 N·m (36 in. lbs.) torque.
(2) Slide throttle cable into opening in top of pedal
arm. Push plastic cable retainer (clip) into accelera-
tor pedal arm opening until it snaps into place.
(3) Before
starting
engine,
operate
accelerator
pedal to check for any binding.
THROTTLE CABLE
REMOVAL
(1) From inside vehicle, hold up accelerator pedal.
Remove plastic cable retainer (clip) and throttle cable
core wire from upper end of accelerator pedal arm
(Fig. 38). Plastic cable retainer (clip) snaps into pedal
arm.
(2) Remove cable core wire at pedal arm.
(3) From inside vehicle, pinch both sides of cable
housing retainer tabs (Fig. 38) at dash panel.
Remove cable housing from dash panel and pull into
engine compartment.
(4) Remove cable from cable guide on engine cylin-
der head (valve) cover.
(5) Remove throttle cable ball end socket at throt-
tle body by pushing ball socket towards rear of vehi-
cle (ball snaps off throttle body pin) (Fig. 39).
(6) Remove
throttle
cable
from
throttle
body
mounting bracket by compressing release tabs (Fig.
39) and pushing cable through hole in bracket.
(7) Remove throttle cable from vehicle.
INSTALLATION
(1) Slide throttle cable through hole in throttle
body bracket until retainer tabs lock into bracket.
(2) Connect cable ball end to throttle body linkage
ball (snaps on).
(3) Snap cable into cable guide on engine cylinder
head (valve) cover.
(4) Push other end of cable through opening in
dash panel until retaining tabs lock into panel.
(5) From inside drivers compartment, slide throttle
cable core wire into opening in top of accelerator
pedal arm. Push cable retainer (clip) into pedal arm
opening until it snaps in place.
(6) Before
starting
engine,
operate
accelerator
pedal to check for any binding.
Fig. 38 Accelerator Pedal Mounting—Typical
1 – RETAINER TABS
2 – CLIP
3 – MOUNTING NUTS
4 – CABLE
Fig. 39 Throttle Cable at Throttle Body
1 – ACCELERATOR CABLE
2 – OFF
3 – OFF
4 – THROTTLE BODY BELLCRANK
5 – SPEED CONTROL CABLE
6 – RELEASE TABS
7 – BRACKET
14 - 22
FUEL SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
FUEL TANK CAPACITY
FUEL SYSTEM PRESSURE
339 kPa
6 34 kPa (49.2 psi 6 2 psi).
FUEL REQUIREMENTS
Your engine is designed to meet all emissions reg-
ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality reg-
ular gasoline, and in some circumstances may result
in poorer performance.
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
Over 40 auto manufacturers world-wide have
issued and endorsed consistent gasoline specifications
(the Worldwide Fuel Charter, WWFC) to define fuel
properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We rec-
ommend the use of gasolines that meet the WWFC
specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as “reformulat-
ed” gasoline. Reformulated gasoline contain oxygen-
ates, and are specifically blended to reduce vehicle
emissions and improve air quality.
We strongly supports the use of reformulated gas-
oline. Properly blended reformulated gasoline will
provide excellent performance and durability for the
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasolines free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gaso-
line retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline with-
out MMT in Canada because MMT can be used at
levels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with Cleaner-Burning Cali-
fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
emission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission
control
system
performance
may
be
adversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle’s catalytic con-
verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a dif-
ferent brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Models
Liters
U. S. Gallons
All
76
20
Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
XJ
FUEL SYSTEM
14 - 23
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle’s performance:
• The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could result in loss of warranty coverage.
• An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
• When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
• The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
or additives is not the responsibility of Daimler-
Chrysler Corporation and may not be covered under
the new vehicle warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
TORQUE CHART
DESCRIPTION
TORQUE
Accelerator Pedal Bracket Mounting Nuts . . 5 N·m
(36 in. lbs.)
Fuel Hose Clamps . . . . . . . . . . . 3 N·m (25 in. lbs.)
Fuel Rail Mounting Bolts . . . . 11 N·m (100 in. lbs.)
Fuel Tank Mounting Strap Nuts . . . . . . . . . 10 N·m
(90 in. lbs.)
Fuel Pump Module Locknut . . . 74 N·m (55 ft. lbs.)
14 - 24
FUEL SYSTEM
XJ
SPECIFICATIONS (Continued)
FUEL INJECTION SYSTEM
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
POWERTRAIN CONTROL MODULE (PCM) . . . . . 25
MODES OF OPERATION . . . . . . . . . . . . . . . . . . . 26
AUTOMATIC SHUTDOWN (ASD) RELAY
SENSE—PCM INPUT . . . . . . . . . . . . . . . . . . . . 29
AND SECONDARY . . . . . . . . . . . . . . . . . . . . . . 29
FUEL LEVEL SENSOR—PCM INPUT . . . . . . . . . . 30
ENGINE COOLANT TEMPERATURE
SENSOR—PCM INPUT . . . . . . . . . . . . . . . . . . . 30
EXTENDED IDLE SWITCH—PCM INPUT . . . . . . . 30
OXYGEN SENSOR—PCM INPUT. . . . . . . . . . . . . 30
IGNITION CIRCUIT SENSE—PCM INPUT . . . . . . 31
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR—PCM INPUT . . . . . . . . . . . . . . . . . . . 32
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR—PCM INPUT . . . . . . . . . . . . . . . . . . . 32
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SENSOR RETURN—PCM INPUT . . . . . . . . . . . . . 34
THROTTLE POSITION SENSOR (TPS)—PCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
VEHICLE SPEED AND DISTANCE SENSOR—
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS . . . . . . 35
DATA LINK CONNECTOR—PCM INPUT AND
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DIAGNOSIS AND TESTING
VISUAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . 37
ASD AND FUEL PUMP RELAYS . . . . . . . . . . . . . . 41
THROTTLE BODY MINIMUM AIR FLOW
CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . . 42
REMOVAL AND INSTALLATION
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . . 43
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . . 44
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 44
THROTTLE POSITION SENSOR (TPS) . . . . . . . . 45
IDLE AIR CONTROL (IAC) MOTOR . . . . . . . . . . . 45
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
POWERTRAIN CONTROL MODULE (PCM) . . . . . 46
POWER STEERING PRESSURE SWITCH—
2.5L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OXYGEN SENSOR. . . . . . . . . . . . . . . . . . . . . . . . 47
AIR CLEANER ELEMENT (FILTER) . . . . . . . . . . . 49
ENGINE COOLANT TEMPERATURE SENSOR . . . 49
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . 51
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 51
SPECIAL TOOLS
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
DESCRIPTION AND OPERATION
POWERTRAIN CONTROL MODULE (PCM)
DESCRIPTION
The Powertrain Control Module (PCM) is located
in the engine compartment (Fig. 1). The PCM is
referred to as JTEC.
OPERATION
The PCM operates the fuel system. The PCM is a
pre-programmed, triple microprocessor digital com-
puter. It regulates ignition timing, air-fuel ratio,
emission control devices, charging system, certain
transmission features, speed control, air conditioning
compressor clutch engagement and idle speed. The
PCM can adapt its programming to meet changing
operating conditions.
The PCM receives input signals from various
switches and sensors. Based on these inputs, the
PCM regulates various engine and vehicle operations
through different system components. These compo-
nents are referred to as Powertrain Control Module
(PCM) Outputs. The sensors and switches that pro-
vide inputs to the PCM are considered Powertrain
Control Module (PCM) Inputs.
The PCM adjusts ignition timing based upon
inputs it receives from sensors that react to: engine
rpm, manifold absolute pressure, engine coolant tem-
XJ
FUEL SYSTEM
14 - 25
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