Jeep XJ. Manual — part 347
(2) Disconnect coolant temperature sensor wire
connector.
(3) Remove sensor from thermostat housing.
INSTALLATION
(1) Apply sealant to sensor threads (new replace-
ment sensors will have sealant already applied).
(2) Install coolant temperature sensor into thermo-
stat housing. Tighten to 11 N·m (8 ft. lbs.) torque.
(3) Connect wire connector.
(4) Fill cooling system. Refer to Group 7, Cooling
System.
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR
The intake manifold air temperature (IAT) sensor
is installed into intake manifold plenum near throttle
body (Fig. 41) or (Fig. 42).
REMOVAL
(1) Disconnect electrical connector from IAT sen-
sor.
(2) Remove sensor from intake manifold.
INSTALLATION
(1) Install
IAT
sensor
into
intake
manifold.
Tighten sensor to 28 N·m (20 ft. lbs.) torque.
(2) Connect electrical connector to sensor.
Fig. 40 Engine Coolant Temperature Sensor—
Typical
1 – THERMOSTAT
2 – ENGINE COOLANT TEMPERATURE SENSOR
3 – ELECTRICAL CONNECTOR
Fig. 41 IAT Sensor Location—4.0L Engine
1 – MOUNTING BOLTS (4)
2 – THROTTLE BODY
3 – IAC MOTOR
4 – ELEC. CONN.
5 – TPS
6 – MAP SENSOR
7 – ELEC. CONN.
8 – IAT SENSOR
9 – ELEC. CONN.
Fig. 42 IAT Sensor Location—2.5L Engine
1 – ELECTRICAL CONNECTOR
2 – INTAKE MANIFOLD TEMPERATURE SENSOR
3 – FUEL INJECTOR
14 - 50
FUEL SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
VEHICLE SPEED SENSOR
The Vehicle Speed Sensor (VSS) is located on the
speedometer pinion gear adapter. If equipped with
4WD, this adapter is located on the transfer case
extension (left side) (Fig. 43). If equipped with 2WD,
this adapter is located on the extension housing of
the transmission (left side).
REMOVAL
(1) Raise and support vehicle.
(2) Disconnect electrical connector from sensor by
pushing slide tab (Fig. 43). After slide tab has been
positioned, push in on secondary release lock (Fig. 43)
on side of connector and pull connector from sensor.
(3) Remove sensor mounting bolt (Fig. 44).
(4) Remove sensor (pull straight out) from speed-
ometer pinion gear adapter (Fig. 44). Do not remove
gear adapter from transmission.
INSTALLATION
(1) Clean
inside
of
speedometer
pinion
gear
adapter before installing speed sensor.
(2) Install sensor into speedometer gear adapter
and install mounting bolt. Before tightening bolt,
verify speed sensor is fully seated (mounted
flush) to speedometer pinion gear adapter.
(3) Tighten sensor mounting bolt to 2.2 N·m (20 in.
lbs.) torque.
(4) Connect electrical connector to sensor.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION
TORQUE
Air Cleaner Housing Mount. Bolts . . . . . . . . 8 N·m
(71 in. lbs.)
Engine Coolant Temperature Sensor . . . . . . 11 N·m
(96 in. lbs.)
IAC Motor-To-Throttle Body Bolts . . . . . . . . 7 N·m
(60 in. lbs.)
Intake Manifold Air Temp. Sensor . . . . . . . 28 N·m
(20 ft. lbs.)
MAP Sensor Mounting Screws . . 3 N·m (25 in. lbs.)
Oxygen Sensor . . . . . . . . . . . . . 30 N·m (22 ft. lbs.)
PCM Mounting Screws . . . . . . . . 4 N·m (35 in. lbs.)
Power Steering Pressure Switch . . . . . . 14–22 N·m
(124–195 in. lbs.)
Throttle Body Mounting Bolts . . . . . . . . . . . 11 N·m
(100 in. lbs.)
Throttle Position Sensor Mounting Screws . . 7 N·m
(60 in. lbs.)
Vehicle Speed Sensor Mounting Bolt . . . . . 2.2 N·m
(20 in. lbs.)
Fig. 43 VSS Location—4WD Shown
1 – SENSOR ELECTRICAL CONNECTOR
2 – SLIDE TAB
3 – 4WD TRANSFER CASE EXTENSION
4 – VEHICLE SPEED SENSOR
5 – RELEASE LOCK
Fig. 44 VSS Removal/Installation
1 – ELECTRICAL CONNECTOR
2 – SENSOR MOUNTING BOLT
3 – O-RING
4 – SPEEDOMETER PINION GEAR
5 – SPEEDOMETER PINION GEAR ADAPTER
6 – O-RING
7 – VEHICLE SPEED SENSOR
XJ
FUEL SYSTEM
14 - 51
REMOVAL AND INSTALLATION (Continued)
SPECIAL TOOLS
FUEL SYSTEM
Spanner Wrench—6856
Adapters, Fuel Pressure Test—6539 and/or 6631
Fitting, Air Metering—6714
O2S (Oxygen Sensor) Remover/Installer—C-4907
Test Kit, Fuel Pressure—5069
Test Kit, Fuel Pressure—C-4799-B
Fuel Line Removal Tool—6782
14 - 52
FUEL SYSTEM
XJ
FUEL SYSTEM—2.5L DIESEL ENGINE
TABLE OF CONTENTS
page
page
FUEL DELIVERY SYSTEM—2.5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FUEL INJECTION SYSTEM—2.5L DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FUEL DELIVERY SYSTEM—2.5L DIESEL ENGINE
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FUEL SYSTEM PRESSURE WARNING . . . . . . . . . 2
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL TANK MODULE . . . . . . . . . . . . . . . . . . . . . . 2
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . . 2
FUEL FILTER/WATER SEPARATOR . . . . . . . . . . . . 2
FUEL SHUTDOWN SOLENOID . . . . . . . . . . . . . . . 3
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . 3
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL TUBES/LINES/HOSES AND CLAMPS—
LOW-PRESSURE TYPE . . . . . . . . . . . . . . . . . . . 4
PRESSURE TYPE. . . . . . . . . . . . . . . . . . . . . . . . 5
HIGH-PRESSURE FUEL LINES . . . . . . . . . . . . . . . 5
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 6
VISUAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . 6
AIR IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 9
FUEL HEATER RELAY TEST . . . . . . . . . . . . . . . . . 9
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . 10
FUEL INJECTOR / NEEDLE MOVEMENT
SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL INJECTION PUMP TEST. . . . . . . . . . . . . . . 10
FUEL SUPPLY RESTRICTIONS . . . . . . . . . . . . . . 11
FUEL SHUTDOWN SOLENOID TEST . . . . . . . . . . 11
HIGH-PRESSURE FUEL LINE LEAK TEST . . . . . . 11
SERVICE PROCEDURES
AIR BLEED PROCEDURES . . . . . . . . . . . . . . . . . 12
FUEL INJECTION PUMP TIMING . . . . . . . . . . . . . 13
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . 13
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . . 14
FUEL FILTER/WATER SEPARATOR . . . . . . . . . . . 14
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . . 15
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . 15
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . 15
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUEL RESERVOIR MODULE . . . . . . . . . . . . . . . . 21
HIGH-PRESSURE LINES . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
DESCRIPTION AND OPERATION
INTRODUCTION
DESCRIPTION
This Fuel Delivery section will cover components
not controlled by the PCM. For components con-
trolled by the PCM, refer to the Fuel Injection Sys-
tem—2.5L Diesel Engine section of this group.
The fuel heater relay, fuel heater and fuel gauge
are not operated by the PCM. These components are
controlled by the ignition (key) switch. All other fuel
system electrical components necessary to operate
the engine are controlled or regulated by the PCM.
XJ
FUEL SYSTEM—2.5L DIESEL ENGINE
14 - 1
2000 JEEP CHEROKEE
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