Jeep XJ. Manual — part 346
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR
The MAP sensor is mounted to the side of the
throttle body (Fig. 24) or (Fig. 25). An L-shaped rub-
ber fitting is used to connect the MAP sensor to
throttle body (Fig. 29).
REMOVAL
(1) Remove air cleaner intake tube at throttle
body.
(2) Remove
two
MAP
sensor
mounting
bolts
(screws) (Fig. 29).
(3) While removing MAP sensor, slide the rubber
L-shaped fitting (Fig. 29) from throttle body.
(4) Remove rubber L-shaped fitting from MAP sen-
sor.
INSTALLATION
(1) Install rubber L-shaped fitting to MAP sensor.
(2) Position sensor to throttle body while guiding
rubber fitting over throttle body vacuum nipple.
(3) Install MAP sensor mounting bolts (screws).
Tighten screws to 3 N·m (25 in. lbs.) torque.
(4) Install air cleaner intake tube.
POWERTRAIN CONTROL MODULE (PCM)
The PCM is located in the engine compartment
next to the air cleaner assembly (Fig. 30).
REMOVAL
To avoid possible voltage spike damage to the
PCM, ignition key must be off, and negative battery
cable must be disconnected before unplugging PCM
connectors.
(1) Disconnect negative battery cable at battery.
(2) Remove cover over electrical connectors. Cover
snaps onto PCM.
(3) Carefully unplug the three 32–way connectors
(Fig. 31) from PCM.
(4) Remove three PCM mounting bolts and remove
PCM from vehicle.
INSTALLATION
(1) Install PCM and mounting bolts to vehicle.
(2) Tighten bolts to 4 N·m (35 in. lbs.).
(3) Check pin connectors in the PCM and the three
32–way connectors for corrosion or damage. Also, the
pin heights in connectors should all be same. Repair
as necessary before installing connectors.
Fig. 28 Mounting Bolts (Screws)—IAC Motor
1 – IDLE AIR CONTROL MOTOR
2 – MOUNTING SCREWS
Fig. 29 MAP Sensor Mounting
1 – THROTTLE BODY
2 – MAP SENSOR
3 – RUBBER FITTING
4 – MOUNTING SCREWS (2)
Fig. 30 PCM Location
1 – (3) 32–WAY CONNECTORS
2 – PCM
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FUEL SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
(4) Install three 32–way connectors.
(5) Install cover over electrical connectors. Cover
snaps onto PCM.
(6) Install battery cable.
(7) Use the DRB scan tool to reprogram new PCM
with vehicles original Identification Number (VIN)
and original vehicle mileage.
POWER STEERING PRESSURE SWITCH—2.5L
ENGINE
This switch is not used with 4.0L six-cylinder
engines.
The power steering pressure switch is installed in
the power steering high-pressure hose (Fig. 32).
REMOVAL
(1) Disconnect electrical connector from power
steering pressure switch.
(2) Place a small container or shop towel beneath
switch to collect any excess fluid.
(3) Remove switch. Use back-up wrench on power
steering line to prevent line bending.
INSTALLATION
(1) Install power steering switch into power steer-
ing line.
(2) Tighten to 14–22 N·m (124–195 in. lbs.) torque.
(3) Connect electrical connector to switch.
(4) Check power steering fluid and add as neces-
sary.
(5) Start engine and again check power steering
fluid. Add fluid if necessary.
OXYGEN SENSOR
REMOVAL
Never apply any type of grease to the oxygen
sensor electrical connector, or attempt any sol-
dering of the sensor wiring harness. For sensor
operation, it must have a comparison source of
oxygen from outside the exhaust system. This
fresh air is supplied to the sensor through its
pigtail wiring harness.
Refer to (Fig. 33), (Fig. 34), (Fig. 35) or (Fig. 36) for
O2S (oxygen sensor) location.
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES
AND
CATALYTIC
CONVERTER
BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(1) Raise and support vehicle.
(2) Disconnect wire connector from O2S sensor.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove O2S sensor with an oxygen sensor
removal and installation tool.
(4) Clean threads in exhaust pipe using appropri-
ate tap.
Fig. 31 PCM Mounting
1 – PCM
2 – L. F. FENDER
3 – PCM MOUNTING BOLTS (3)
Fig. 32 Power Steering Pressure Switch
1 – POWER STEERING PRESSURE SWITCH
2 – ELECTRICAL CONNECTOR
3 – POWER STEERING PUMP
XJ
FUEL SYSTEM
14 - 47
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
Threads of new oxygen sensors are factory coated
with anti-seize compound to aid in removal. DO
NOT add any additional anti-seize compound to
threads of a new oxygen sensor.
Fig. 33 Front Oxygen Sensor—4.0L—Federal
Emissions
1 – 1/1 O2S
Fig. 34 Oxygen Sensors—4.0L—California
Emissions
1 – 1/1 O2S
2 – 2/1 O2S
3 – 2/2 O2S
4 – 1/2 O2S
Fig. 35 Front Oxygen Sensor—2.5L—Federal
Emissions
1 – 1/1 O2S
Fig. 36 Rear Oxygen Sensor—2.5L/4.0L—Federal
Emissions
1 – 1/2 O2S
14 - 48
FUEL SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
(1) Install O2S sensor. Tighten to 30 N·m (22 ft.
lbs.) torque.
(2) Connect O2S sensor wire connector.
(3) Lower vehicle.
AIR CLEANER ELEMENT (FILTER)
REMOVAL
(1) Unlock air tube clamp (Fig. 37) at air cleaner
cover. To unlock clamp, attach adjustable pliers to
clamp and rotate pliers as shown in (Fig. 38).
(2) Remove air tube at cover.
(3) Pry back three clips retaining air cleaner cover
to air cleaner housing.
(4) Remove housing cover and remove air cleaner
element.
(5) Clean inside of housing before replacing ele-
ment.
INSTALLATION
(1) Install air cleaner element into housing.
(2) Install air cleaner cover to housing (three
clips). Be sure cover is properly seated to air cleaner
housing.
(3) Install air tube and clamp to cover. Compress
clamp snugly with adjustable pliers as shown in (Fig.
39).
ENGINE COOLANT TEMPERATURE SENSOR
WARNING: HOT,
PRESSURIZED
COOLANT
CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING
THE
COOLANT
TEMPERATURE
SENSOR.
REFER TO GROUP 7, COOLING.
The coolant temperature sensor is installed in the
thermostat housing (Fig. 40).
REMOVAL
(1) Partially drain cooling system until coolant
level is below cylinder head. Observe the WARN-
INGS in Group 7, Cooling.
Fig. 37 Air Cleaner Housing and Element (Filter)
1 – COVER
2 – AIR TUBE
3 – CLAMPS (2)
4 – HOUSING
5 – CLIPS (3)
6 – ELEMENT (FILTER)
Fig. 38 Clamp Removal
1 – CLAMP
2 – ADJUSTABLE PLIERS
3 – REMOVAL
Fig. 39 Clamp Installation
1 – CLAMP
2 – ADJUSTABLE PLIERS
XJ
FUEL SYSTEM
14 - 49
REMOVAL AND INSTALLATION (Continued)
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