Jeep XJ. Manual — part 103
CIGAR LIGHTER RELAY
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 fuse access panel by unsnapping it
from the right cowl side trim panel.
(3) Remove the stamped nut that secures the right
cowl side trim to the junction block stud (Fig. 9).
(4) Remove the screw located above the fuse access
opening that secures the right cowl side trim to the
right cowl side inner panel.
(5) Remove the screw that secures the right door
sill trim and the right cowl side trim to the right
door opening sill.
(6) Remove the right cowl side trim panel from the
vehicle.
(7) Refer to Junction Block in the Contents of
Group 8W - Wiring Diagrams for cigar lighter relay
identification and location.
(8) Remove the cigar lighter relay from the recep-
tacle in the junction block.
INSTALLATION
(1) Refer to Junction Block in the Contents of
Group 8W - Wiring Diagrams for the proper cigar
lighter relay location.
(2) Position the cigar lighter relay to the receptacle
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
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.
Fig. 9 Right Cowl Side 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
8E - 16
INSTRUMENT PANEL SYSTEMS
XJ
REMOVAL AND INSTALLATION (Continued)
(2) Remove the knee blocker from the instrument
panel. Refer to Knee Blocker in the Removal and
Installation section of this group for the procedures.
(3) 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.
(4) Remove the four screws exposed by the center
bezel removal that secure the cluster bezel to the
instrument panel.
(5) Remove the headlamp switch knob and shaft
from the headlamp switch. Refer to Headlamp
Switch in the Removal and Installation section of
this group for the procedures.
(6) Disengage the two ends of the steering column
sight shield from each other at the connector located
below the lower steering column shroud (Fig. 10).
(7) If the vehicle is so equipped, set the tilt steer-
ing column in its lowest position.
(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
their receptacles in the instrument panel.
(9) Remove the cluster bezel from the instrument
panel.
INSTALLATION
(1) Position the cluster bezel to the instrument
panel.
(2) Align the snap clips on the cluster bezel with
the receptacles in the instrument panel.
(3) Press firmly on the cluster bezel over each of
the snap clip locations until each of the snap clips is
fully engaged in its receptacle.
(4) Engage the two ends of the steering column
sight shield with each other at the connector located
below the lower steering column shroud.
(5) Install the headlamp switch knob and shaft
onto the headlamp switch. Refer to Headlamp
Switch in the Removal and Installation section of
this group for the procedures.
(6) Install and tighten the four screws that secure
the cluster bezel to the instrument panel beneath the
instrument panel center bezel. Tighten the screws to
2.2 N·m (20 in. lbs.).
(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-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: IF THE HEADLAMP SWITCH WAS ON,
WAIT FIVE MINUTES TO ALLOW THE CERAMIC
DIMMER RESISTOR TO COOL. IF THE CERAMIC
DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT
CAN BURN YOUR FINGERS.
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 this group for the procedures.
(3) Pull the headlamp switch control knob out to
the On position stop.
Fig. 10 Cluster Bezel Remove/Install
1 – INSTRUMENT PANEL
2 – CLUSTER BEZEL
3 – SCREW
4 – STEERING COLUMN SIGHT SHIELD CONNECTOR
5 – HEADLAMP SWITCH KNOB AND SHAFT
XJ
INSTRUMENT PANEL SYSTEMS
8E - 17
REMOVAL AND INSTALLATION (Continued)
(4) Reach up under the instrument panel through
the outboard side of the steering column opening to
access and depress the headlamp switch control knob
and shaft release button on the inboard side of the
switch body.
(5) While holding the release button depressed,
pull the headlamp switch control knob and shaft out
of the headlamp switch.
(6) Remove the spanner nut that secures the head-
lamp switch to the instrument panel (Fig. 11).
(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.
(2) Reconnect the two instrument panel wire har-
ness connectors to the headlamp switch.
(3) Position
the
headlamp
switch
behind
its
mounting hole on the instrument panel.
(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.).
(5) Insert the shaft of the headlamp switch control
knob and shaft unit through the opening in the span-
ner nut and into the headlamp switch.
(6) Push the headlamp switch control knob and
shaft unit all the way into the headlamp switch body.
(7) Install the knee blocker onto the instrument
panel. Refer to Knee Blocker in the Removal and
Installation section of this group for the procedures.
(8) Reconnect the battery negative cable.
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-
ment cluster to the instrument panel (Fig. 12).
(4) Pull
the
instrument
cluster
rearward
far
enough to disengage the two self-docking instrument
panel wire harness connectors from the connector
Fig. 11 Headlamp Switch Remove/Install
1 – WIRE HARNESS CONNECTORS
2 – HEADLAMP SWITCH
3 – NUT
4 – INSTRUMENT PANEL
Fig. 12 Instrument Cluster Remove/Install
1 – INSTRUMENT PANEL
2 – SELF-DOCKING WIRE HARNESS CONNECTORS
3 – INSTRUMENT CLUSTER
4 – SCREW
8E - 18
INSTRUMENT PANEL SYSTEMS
XJ
REMOVAL AND INSTALLATION (Continued)
receptacles on the back of the cluster housing. Do
not pull on the instrument cluster by the lens
or mask sections, or the cluster components
may become separated.
(5) Remove the instrument cluster from the instru-
ment panel.
INSTALLATION
(1) Position the instrument cluster to the instru-
ment panel.
(2) Align the instrument cluster with the cluster
opening in the instrument panel and push the cluster
firmly and evenly into place. The instrument panel
has two self-docking wire harness connectors that
will be automatically aligned with, and connected to
the cluster connector receptacles when the cluster is
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
lamp bulbs (including the integral bulb holders), the
odometer reset knob boot, the cluster lens, the clus-
ter hood and mask unit, and the instrument cluster
housing rear cover. Following are the service proce-
dures for the instrument cluster components.
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
CLUSTER BULB
This procedure applies to each of the incandescent
cluster illumination lamp or indicator lamp bulb and
bulb holder units. However, the illumination lamps
and the indicator lamps use different bulb and bulb
holder unit sizes. They must never be interchanged.
Be certain that any bulb and bulb holder unit
removed from the cluster electronic circuit board is
reinstalled in the correct position. Always use the
correct bulb size and type for replacement. An incor-
rect bulb size or type may overheat and cause dam-
age to the instrument cluster, the electronic circuit
board and/or the gauges.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument cluster from the instru-
ment panel. Refer to Instrument Cluster in the
Removal and Installation section of this group for the
procedures.
(3) Turn the bulb holder counterclockwise about
sixty degrees on the cluster electronic circuit board.
(4) Pull the bulb and bulb holder unit straight
back to remove it from the bulb mounting hole in the
cluster electronic circuit board (Fig. 13).
CLUSTER LENS
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument cluster from the instru-
ment panel. Refer to Instrument Cluster in the
Removal and Installation section of this group for the
procedures.
(3) Work around the perimeter of the cluster hous-
ing to disengage each of the latches that secure the
cluster lens to the cluster housing (Fig. 14).
(4) Gently pull the cluster lens away from the clus-
ter housing.
ODOMETER RESET KNOB BOOT
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument cluster from the instru-
ment panel. Refer to Instrument Cluster in the
Removal and Installation section of this group for the
procedures.
(3) Remove the cluster lens from the cluster hous-
ing. Refer to Instrument Cluster Components -
Cluster Lens in the Removal and Installation sec-
tion of this group for the procedures.
Fig. 13 Cluster Bulb Locations
1 – CLUSTER ILLUMINATION BULBS
XJ
INSTRUMENT PANEL SYSTEMS
8E - 19
REMOVAL AND INSTALLATION (Continued)
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