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*VOTE NOW Help Metalcloak Giveaway an XJ Suspension*Stainless Steel Door Hinge PinsPoly Door Hinge Bushings

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Unread 09-04-2005, 09:03 PM   #61
Meerkat
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1996 ZJ 
 
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Fuel Pump - Diagnosis

NO: 14-06-97
GROUP: Fuel
DATE: Jul. 3, 1997
SUBJECT:
Fuel Pump Diagnosis
MODELS:
1997 (TJ) Wrangler
1996 (ZJ) Grand Cherokee
1996 (ZG) Grand Cherokee - International Markets
1994 - 1996 (XJ) Cherokee
SYMPTOM/CONDITION:
Symptoms may include no start, rough idle, long crank times, driveway die outs or erratic fuel pressure. A new fuel pump has been released which delivers improved performance. This pump should be used whenever fuel pump failures are encountered.
DIAGNOSIS:
Basic fuel system diagnostics should be used as outlined in the appropriate service manual. A brief recap of the basic diagnostics follows:
Fuel pressure specification - 49 psi - plus or minus 5 psi.
High fuel pressure indicates problems with the fuel pressure regulator. Refer to the service manual for regulator diagnosis. Do not replace the fuel pump for high pressure.
Low fuel pressure - Low pressure could indicate a pump problem or it could indicate a plugged fuel filter or restricted fuel line or no fuel in the tank. Be sure to check these items before replacing the fuel pump.
Fuel System Leak down - When checking fuel pressure be sure to check the integrity of the system after shut down. With the fuel pressure gauge connected, shut the engine off and observe the pressure gauge. The system should maintain at least 24 psi for five minutes after shut down. If the pressure bleeds off quicker, it could indicate that an injector is leaking down or that the pressure regulator is leaking. This can lead to driveablity problems and require further diagnosis.
NOTE: IN RARE CASES WHERE MULTIPLE FUEL PUMP FAILURES HAVE OCCURRED ON THE SAME VEHICLE, A BUILD UP OF RESIDUE MAY HAVE ACCUMULATED ON THE INSIDE OF THE FUEL TANK. THE PRESENCE OF THIS RESIDUE IS NOT EASILY IDENTIFIABLE. THE RESIDUE CAN PASS THROUGH THE IN TANK FILTER AND CONTAMINATED THE PUMP ROTOR. IF MULTIPLE FAILURES HAVE OCCURRED WITH NO OBVIOUS INDICATION OF THE CAUSE, CONSIDERATION SHOULD BE MADE TO REPLACING THE FUEL TANK TO AVOID FUTURE PROBLEMS.
PARTS REQUIRED:
1 04762964 Pump Module - 1994-1995 XJ
1 04798941 Pump Module - 1996 XJ
1 04883261 Pump Module - 1996 ZJ
1 04897754AB Pump Module - 1997 TJ - 15 gallon tank
1 04897755AB Pump Module - 1997 TJ - 19 gallon tank
POLICY: Information Only

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Unread 09-04-2005, 09:04 PM   #62
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Heater A/C Housing - Service

NO: 24-02-98
GROUP: Air Conditioning
DATE: Mar 13, 1998
SUBJECT:
Heater A/C Housing, Service
MODELS:
1993 - 1998 (ZJ) Grand Cherokee, Grand Wagoneer
1994 - 1998 (ZG) Grand Cherokee (International Markets)
DISCUSSION:


The service manual procedures to service the heater A/C housing, evaporator or heater core have been revised, based on feedback from our training and field personnel as well as dealership technicians. The new procedure is simpler and more efficient than the current service manual procedure. The revised service manual procedure is included and should - be used starting immediately. Listed are the labor operation numbers and times that will be affected by this revision.
NOTE : THE REVISED LABOR OPERATION TIMES WILL BE EFFECTIVE ON MARCH 16, 1998.
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Unread 09-04-2005, 09:06 PM   #63
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Heater A/C Housing - Service
Removal and Installation
Heater A/C housing
Removal


1. Disconnect battery. This must be done to prevent accidental airbag deployment.
2. Using on A/C recovery unit, remove all R-134a refrigerant from the A/C system. Refer to Service Manual Procedures for A/C system evacuation and charge.
3. Remove the shift knob by pulling sharply upward.
4. Place the transfer case in low range. Pry the shift indicator bezel out of the console using a trim stick.
5. Apply the parking brake and place the transfer case in neutral. Remove the parking brake trim insert. Remove the console attaching screws. Lift the console up and disconnect the 4WD indicator lamp hamess. Remove the console.
6. Remove the passenger side knee blocker. Remove the single end screw. Remove the screws below the glove box. Remove the screw at the courtesy lamp. Remove the ash receiver and the screws behind it. Remove the instrument panel armature screw behind the ash receiver. Open the glove box and remove the screws behind it. Lower the panel and disconnect the lamp harnesses.
7. Remove the pod switch bezels on both sides of the steering column with a trim stick.
8. Remove the drive side knee blocker. Remove the end screw and screws located at the bottom of the knee blocker.
9. Remove the cowl top trim panel by prying it up with a trim stick. Remove the solar sensor if equipped.

10. Remove the "A" post trim panels.
11. Remove the remove the bolts that attach the lower instrument panel reinforcement to the instrument panel armature and remove the reinforcement.
12. Disconnect the park lamp switch.
13. Pull back the carpet at the transmission tunnel from the base of the instrument panel center bezel. Remove the nuts from the upper studs and bolts through the floor that secure the instrument panel center bracket.
14. Remove the bolts that secure the instrument panel center bracket to the drivers side of the transmission tunnel.
15. Remove the screws securing the Vehicle Information Center and remove it. Remove the screw fastening the mounting bracket.
16. Unplug the vacuum harness connector or vent tube on ATC equipped vehicles and the wire harness located under the passenger side of the instrument panel.
17. Remove the screws holding the passenger side kick panel, along with the screw from the kick panel shroud.
18. Unplug the antenna cable near the right cowl side panel.
19. Unplug the instrument panel wire harness connectors from the junction block at the right cowl side panel.
20. Remove the bolts that secure the instrument panel armature to the windshield fence.
21. Remove the nuts that secure the top if the instrument panel armature to the windshield fence.
22. Remove the bolts that secure the ends of the instrument panel to the cowl side panel.
23. Remove the nuts that secure the steering column to the brake pedal support and lower the steering column.
24. Remove the bolts that secure the instrument panel armature to the brake pedal support.
25. Place a protective cover on the seats. Lift the instrument panel off the windshield fence studs and maneuver the instrument panel out and lower it onto the seats.
26. Disconnect the refrigerant lines from the evaporator tubes. Make sure to install plugs or tape the ends of the lines and fittings to ensure that excessive amounts of moisture do not contaminate the A/C system.

27. Remove the vacuum line at the tee from the main vacuum supply harness. This line runs through the body with the upper refrigerant line.
28. Disconnect the heater hoses from the heater core and clamp the ends closed to prevent coolant loss.
29. Remove the coolant overflow bottle.
30. Remove the Powertrain Control Module with connectors intact and set aside.
31. Remove the heater A/C housing mounting nuts from the studs on the engine compartment side of the dash.
32. Remove the heater A/C housing from the vehicle.
33. To install the components, reverse the procedure stated above.
Torque Specifications:
Instrument panel center bracket to floor transmission tunnel fastener 28 Nm (250 in. Lbs.)
Instrument panel to windshield fence bolts and nuts 12 Nm (105 in. Lbs.)
Instrument panel to cowl side inner panel bolts 12 Nm (105 in. Lbs.)
Instrument panel to steering column support bolts 12 Nm (105 in. Lbs.)
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Unread 09-04-2005, 09:07 PM   #64
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Engine - High Driveability Index Fuels
NO: 14-08-97
GROUP: Fuel
DATE: Nov. 21, 1997
SUBJECT:
Poor Driveability With High DI (Driveability Index) Fuel
MODELS:
1996 - 1998 (AB) Ram Van/Wagon
1996 - 1998 (AN) Dakota
1996 - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
1996 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (PL) Neon
1997 (PR) Prowler
1996 - 1998 (SR) Viper Roadster/Coupe
1997 - 1998 (TJ) Wrangler
1996 - 1998 (XJ) Cherokee
1995 - 1998 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80 degrees F).
DISCUSSION:
Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI gasolines also cause higher emissions for the same reasons they cause driveability problems.
For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly required. Using premium fuel with a higher than recommended octane rating is not recommended. Owners who experience fuel related cold start and warm up driveability problems should try a gasoline with the recommended octane rating or different brands of gasoline until they find one that provides good performance.
The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher than recommended octane gasoline under normal operating conditions does NOT improve startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In fact, most higher octane gasolines available in the U.S. have higher DI values than regular gasoline. Customers are most likely to experience poor driveability with premium gasoline than with regular.
Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC Neon have been specifically designed to take advantage of higher octane. These vehicles may have higher compression ratios, and/or more aggressive spark calibrations which provide optimum performance with the specified higher octane. However, other vehicles which are not specifically designed and calibrated to take advantage of higher octane will not benefit from higher octane.
Some vehicles may experience light spark knock in situations such as trailer towing or climbing steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing heavy spark knock on gasoline with its designed octane rating, this may be an indication of excessive combustion chamber deposits, or some other problem. Combustion chamber deposits can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic procedures may help in identifying other potential causes of excessive knock.
Some gasoline marketers may advertise that their premium gasoline contains extra detergent additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are suspected of contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is a much less expensive way to maintain engine cleanliness than regular use of premium gasoline.






The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer satisfaction.
If fuel quality is suspected in causing a customers driveability concern, your zone technical office may be able to provide direction on procedures for fuel sample analysis.
POLICY: Information Only
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Unread 09-04-2005, 09:07 PM   #65
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Liftgate Ajar Switch - Terminal Corrosion

NO: 08-28-97
GROUP: Electrical
EFFECTIVE DATE: Sept. 8, 1997
SUBJECT:
Liftgate Ajar Switch Terminal Corrosion
MODELS:
1996 - 1997 (ZJ) Grand Cherokee
1996 - 1997 (ZG) Grand Cherokee (International Markets)
NOTE: THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO JUNE 18, 1997 (MDH 06- 08-XX)
SYMPTOM/CONDITION:
Water can enter the liftgate ajar switch causing corrosion to the terminals. This condition can lead to any of the symptoms listed below:
- Vehicle Information Center displays liftgate ajar
- Rear Wiper inoperative
- Security alarm will not set
- Courtesy lamps stay on
- Ignition off draw causing dead battery
DIAGNOSIS:
If customer complaints are received indicating any of the complaints listed above, perform the Repair Procedure.
PARTS REQUIRED:
1 56005640 Switch - Liftgate Ajar
1 05011102AA Connector Repair Package
1 04778570 Heat Shrink Tubing
REPAIR PROCEDURE:
This bulletin involves replacing the liftgate ajar switch and repairing the harness connector.
1. Disconnect and isolate the battery negative cable.
2. Remove the liftgate lower trim panel.
3. Remove the liftgate latch and remove the ajar switch from the latch.
4. Install the new switch, P/N 56005640.
5. Stagger cut the liftgate ajar switch connector from the harness.
6. Strip approximately 1 inch of insulation from the wires at the harness and repair package.
7. Slide two pieces of heat shrink tubing over the wires on the connector package. Using rosin core solder, twist the wires together and solder the two wires making sure of a hot solder joint by heating the wire hot enough to melt the solder.
8. Position the heat shrink tubing over the bare wire and apply heat to the tubing with a heat gun to fully shrink the tubing and seal the wires at both ends.
9. Connect the harness to the switch.
10. Install the liftgate trim panel.
11. Connect the battery negative cable.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-80-88-94 0.5 Hrs.

FAILURE CODE: P8 - New Part
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Unread 09-04-2005, 09:08 PM   #66
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Garage Door Opener - Rolling Code Information

NO: 08-20-97
GROUP: Electrical
DATE: May, 16, 1997
SUBJECT:
Garage Door Opener
MODELS:
1996 - 1997 (FJ) Avenger/Sebring/Talon
1996 - 1997 (JA) Cirrus
1996 - 1997 (JX) Sebring Convertible
1996 - 1997 (LH) LHS
1996 - 1997 (ZJ) Grand Cherokee
DISCUSSION:
Rolling code technology (random digital code signals from the remote transmitter) is a security feature incorporated into some recently manufactured garage door openers. Garage door opener transmitters on Chrysler vehicles built before approximately March 1, 1997 will not function with a random digital code receiver. Owners who own or purchase vehicles built before March 1, 1997 and have or purchase a random digital code garage door opener have three options that will make this combination work.
Option # 1 For garage door opener's with a rolling code activation switch (or button): disengage (turn off) the rolling code feature on the garage door opener via the on/off switch (or button).
Option # 2 Replace the non-rolling code visor/garage door opener assembly with the new rolling code compatible visor/garage door opener assembly. The new assembly can be identified by the shape of the LED (LED in the shape of a house is rolling code compatible).
Option # 3 Purchase a Universal Receiver (via HomeLink(R): 1-800-355-3515) which allows the existing non-rolling code garage door opener transmitter to activate the rolling code garage door receiver, however, bypassing the rolling code security feature.
POLICY: Information Only
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Unread 09-04-2005, 09:20 PM   #67
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Speedometer - Needle Jumps/Vibrates

NO: 08-36-97
GROUP: Electrical
DATE: Oct. 3, 1997
SUBJECT:
**Speedometer Needle Jumps**
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 08-29-96, DATED SEPTEMBER 6, 1996, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE BOUND 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-97010.) THE BULLETIN REVISES THE SUBJECT/SYMPTOM TO HIGHLIGHT THE MOST COMMON SYMPTOM OF THOSE LISTED BELOW. THE REVISION IS HIGHLIGHTED WITH ASTERISKS.
MODELS:
1996 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
An short circuit in the shift interlock cable solenoid may cause a variety of symptoms including the following:
** The speedometer needle jumps or vibrates when the brakes are applied.** Blown fuse at location 5 in the fuse panel.
Brake warning light is illuminated.
DIAGNOSIS:
If fuse 5 is blown or any of the symptoms described above are present, perform the Repair Procedure.
PARTS REQUIRED:
1 52078961 Shift interlock cable
REPAIR PROCEDURE:
This bulletin involves replacing the shift interlock cable.
1. Lower the steering column. (Refer to the 1996 Grand Cherokee Service Manual, Publication No. 81-370-6147, page 19-22 for this procedure if you are not familiar with it.)


2. Remove the two screws retaining the interlock mechanism to the steering column and unsnap the mechanism from the column. (See Illustration)
3. Remove the center console and related trim.
(Refer to the 1996 Grand Cherokee Service Manual, Publication No.81-370-6147, page 23-35 for this procedure if you are not familiar with it.)
4. Disconnect the cable eyelet from the bell crank.
5. Remove the wire from the solenoid on the cable.
6. Remove the accelerator pedal. Release the cable from the accelerator pedal clip and remove the cable.
7. Install the new cable P/N 52078961 and snap the interlock mechanism into the steering column. Secure the mechanism with the two screws removed earlier.
CAUTION : THE INTERLOCK CABLE MUST BE CLIPPED TO THE RIGHT HAND STUD UNDER THE ACCELERATOR PEDAL. THIS WILL PREVENT ANY INTERFERENCE WITH THE ACCELERATOR PEDAL.
8. Install the accelerator pedal, routing the cable between the accelerator pedal mounting studs and securing it with the clip to the right hand stud.
9. Place the ignition switch in the "ACCESSORY" position.
10. Remove the shipping pin from the interlock mechanism.
11. Connect the cable eyelet to the bell crank.
12. Place the gear shift selector in park.
13. Push the spring loaded cable adjuster forward and insert the cable into the bracket.
14. Push the cable adjuster lock down to lock the adjustment.
15. Connect the solenoid wire.
16. Install the center console and related trim.
17. Verify correct operation of the interlock system.
18. Install the steering column onto the bracket.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 19-20-69-90 0.7 Hrs.

FAILURE CODE: P8 - New Part
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Unread 09-04-2005, 09:24 PM   #68
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Tire & Wheel - Runout

NO: 22-01-97
GROUP: Wheels & Tires
DATE: Jun. 13, 1997
SUBJECT:
Tire & Wheel Runout
MODELS:
1994 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1994 - 1997 (AB) Ram Van/Wagon
1994 - 1995 (AJ) LeBaron Convertible
1994 - 1997 (AN) Dakota
1994 (AP) Shadow/Sundance
1994 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 1997 (BR) Ram Pickup
1994 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1997 (FJ) Sebring/Avenger/Talon
1996 - 1997 (GS) Chrysler Voyager (International Market)
1995 - 1997 (JA) Cirrus/Stratus/Breeze
1996 - 1997 (JX) Sebring Convertible
1994 - 1997 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1997 (NS) Town & Country/Caravan/Voyager
1995 - 1997 (PL) Neon
1994 - 1997 (SR) Viper/Viper GTS
1997 (TJ) Wrangler
1994 - 1997 (XJ) Cherokee
1994 - 1995 (YJ) Wrangler
1994 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Radial runout is the vertical distance between the high and low points on the tire or wheel edge measured at the center line of the tread.
Lateral runout is the horizontal movement of the tire or wheel measured near the shoulder of the tire.
Runout of more than the preferred specification may cause the vehicle to shake. Refer to the following specifications and appropriate Service Manual procedures.


PREFERRED TIRE & WHEEL RUNOUT
Usually runout can be reduced by relocating the wheel and tire on the wheels studs and/or rotating the tire on the wheel (match mounting).
POLICY: Information Only
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Unread 09-04-2005, 09:25 PM   #69
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Windshield Area - Wind Noise

NO: 23-17-97
GROUP: Body
DATE: Apr. 4, 1997
SUBJECT:
Wind Noise - Windshield Area
MODELS:
1996 - 1997 (ZJ) Grand Cherokee
1996 - 1997 (ZG) Grand Cherokee (Overseas Markets)
SYMPTOM/CONDITION:
Wind noise at the sides of the windshield. This noise may be a result of sealer skips/leaks in the "A" pillar area. A sealer patch is applied in the assembly process to cover an access hole in the "A" pillar. This patch may not be fully sealed to the body and may leak. This can lead to wind noise or whistles which can easily be mistaken for a windshield sealer leak.
DIAGNOSIS/REPAIR PROCEDURE:
This bulletin involves testing the "A" pillar area for sealer leaks and applying sealer to the area if leaks are found.
If wind noise is present at the "A" pillar to the sides of the windshield, perform the Repair Procedure.
1. Remove the "A" pillar interior trim.


2. Apply a solution of soapy water to the area around the sealer patch (see Figure 1).
3. From outside of the vehicle, close the door and using an approved air nozzle direct the air flow at the "A" Pillar area and watch for air bubbles.
4. If leaks are found, clean the area with a solvent such as MOPAR Super Cleen, p/n 04318015 or equivalent, and apply body seam sealer such as MOPAR 04318025 or equivalent to the affected areas.
5. Install the "A" pillar trim.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-94 (right side) 0.2 Hrs.

23-50-02-95 (left Side) 0.2 Hrs.

FAILURE CODE: XX - Service Adjustment
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