Jeep XJ. Manual — part 633
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Install a substitute relay in place of the Fuel Heater Relay.
Disconnect the Fuel Heater harness connector.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Fuel Heater Relay Output
circuit.
Is the test light on?
All
Yes
→
Replace the initial Fuel Heater Relay.
Perform ROAD TEST VERIFICATION - VER-2.
No
→
5
Turn the ignition off.
Remove the Fuel Heater Relay.
Using a 12-volt test light connected to ground, check the Fused B+ circuit.
Is the test light on?
All
Yes
→
No
→
Repair the Fused B+ circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
6
Turn the ignition off.
Remove the Fuel Heater Relay.
Turn the ignition on.
Using a 12-volt test light connected to ground, check the Ignition Switch Output
circuit.
Is the test light on?
All
Yes
→
No
→
Repair the Ignition Switch Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
7
Turn the ignition off.
Remove the Fuel Heater Relay.
Turn the ignition on.
Using a 12-volt test light connected to 12-volts, check the Ground circuit at the Fuel
Heater Relay connector.
Is the test light on?
All
Yes
→
Repair the Fuel Heater Relay Output circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
No
→
Repair the Ground circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
184
DRIVEABILITY - DIESEL
*CHECKING THE FUEL HEATER OPERATION —
Continued
Symptom:
*CHECKING THE FUEL INJECTION PUMP
POSSIBLE CAUSES
CHECKING THE FUEL INJECTION PUMP
TEST
ACTION
APPLICABILITY
1
NOTE: This test should be performed before replacing the ECM during fault
code diagnostics.
NOTE: This test checks for shorted circuits internal to the Fuel Injection
Pump assembly.
Turn the ignition off.
Disconnect the Fuel Injection Pump 10-way harness connector.
NOTE: The following resistance measurements are performed on the Fuel
Injection Pump 10-way harness connector (pump side). Resistance on these
measurements should be greater than 100.0 ohms each.
Measure the resistance between cavity 1 and cavities 4, 5, 6, 7, 8, 9, 10 and case
ground.
Measure the resistance between cavity 4 and cavities 5, 6, 8, 9, 10 and case ground.
Measure the resistance between cavity 5 and cavities 6, 7, 8 and case ground.
Measure the resistance between cavity 6 and cavities 7, 8, 9 and 10.
Measure the resistance between cavity 7 and cavities 8, 9, 10 and case ground.
Is the resistance below 100.0 ohms for any of the measurements?
All
Yes
→
Replace the Fuel Injection Pump Assembly in accordance with the
Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No
→
Test Complete.
185
DRIVEABILITY - DIESEL
Symptom:
*CHECKING THE FUEL LEVEL GAUGE OPERATION
POSSIBLE CAUSES
FUEL LEVEL SENSOR
FUEL LEVEL SENSOR SIGNAL CIRCUIT OPEN
FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND
INSTRUMENT CLUSTER
TEST
ACTION
APPLICABILITY
1
Turn the ignition on.
With the DRB, perform the Instrument Cluster Self Test.
NOTE: The 5 calibration points are: #1 Empty Stop, #2 Empty, #3 1/2 Full, #4
Full, #5 Full Stop.
Observe the gauge during the Self Test and compare the readings with the readings
described in the NOTE.
NOTE: With the DRB ensure there are no PCM Fuel Level Sensor DTCs. If
there are DTCs, they must be repaired before continuing.
Did the gauge reach the proper calibration points?
All
Yes
→
No
→
Replace the Instrument Cluster.
Perform ROAD TEST VERIFICATION - VER-2.
2
Turn the ignition off.
Disconnect the Fuel Level Sensor harness connector.
Disconnect the PCM harness connectors.
Measure the resistance of the Fuel Level Sensor Signal circuit.
Is the resistance below 10.0 ohms?
All
Yes
→
No
→
Repair the Fuel Level Sensor Signal circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
3
Turn the ignition off.
Disconnect the Fuel Level Sensor harness connector.
Disconnect the PCM harness connectors.
Measure the resistance between ground and the Fuel Level Sensor Signal circuit.
Is the resistance below 1000.0 ohms?
All
Yes
→
Repair the Fuel Level Sensor Signal circuit for a short to ground.
Perform ROAD TEST VERIFICATION - VER-2.
No
→
186
DRIVEABILITY - DIESEL
TEST
ACTION
APPLICABILITY
4
Turn the ignition off.
Disconnect the Fuel Level Sensor harness connector.
Disconnect the PCM harness connectors.
Measure the resistance between Sensor Ground and the Fuel Level Sensor Signal
circuit.
Is the resistance below 1000.0 ohms?
All
Yes
→
Repair the Fuel Level Sensor Signal circuit for a short to Sensor
Ground.
Perform ROAD TEST VERIFICATION - VER-2.
No
→
5
Turn the ignition off.
Completely drain the fuel tank. Refer to Service Information for proper procedure.
NOTE: It is necessary to know the fuel tank capacity for this test.
Fill the fuel tank to 1/4 of its capacity then turn the ignition on and note the
instrument cluster fuel gauge reading.
Turn the ignition off.
Fill the fuel tank to 3/4 of its capacity then turn the ignition on and note the
instrument cluster fuel gauge reading.
Does the Fuel Gauge read the fuel tank levels accurately?
All
Yes
→
Test Complete.
No
→
Replace the Fuel Level Sensor.
Perform ROAD TEST VERIFICATION - VER-2.
187
DRIVEABILITY - DIESEL
*CHECKING THE FUEL LEVEL GAUGE OPERATION —
Continued
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