exj_19a99 jeep xj service manual

7/29/2019 EXJ_19A99 jeep xj service manual

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STEERING

CONTENTS

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POWER STEERING PUM P 2. 5L VM DIESEL . . . 2POWER STEERING 2. 5L VM DIESEL . . . . . . . . 1

STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . 8

POWER STEERING2.5L VM DIESEL

INDEX

page

GENERAL INFORMATION

POWER STEERING PUMP . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION

POWER STEERING PUMPT h e p o w e r s t e e r i n g p u m p u s e d w i t h t h e 2 .5 L VM

D i e s e l e n g i n e o p e r a t e s t h e s a m e w a y a s t h e p o w e r

s t eer i ng p um p u s ed w i t h t h e 2. 5/4. 0L g a s ol in e

engines. Refer to the Description and Operation sec-

tion for the 2.5/4.0L gasoline engine power steering

pump for more information.

XJ STEER IN G 1 9 - 1


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POWER STEERING PUMP2.5L VM DIESEL

INDEX

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SERVICE PROCEDURESPOWER STEERING PUMP INITIAL

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

REMOVAL AND INSTALLATIONPOWER STEERING PUMP LHD . . . . . . . . . . . 2

POWER STEERING PUMP RHD . . . . . . . . . . . 5

SERVICE PROCEDURES

POWER STEERING PUMP INITIAL

OPERATION

WARNING: THE FLUID LEVEL SHOULD BECHECKED WITH ENGINE OFF TO PREVENT INJURY

FROM MOVING COMPONENTS.

CAUTION: Use MOPAR Power Steering Fluid or

equivalent. Do not use automatic transmission fluidand do not overfill.

Wi pe f i ll er ca p cl ea n , t h e n ch e ck t h e f lu i d l ev el .

The dipstick should indicate COLD w h e n t h e f l u id i sa t n o r m a l a m bi e n t t e m p e r a t u r e .

(1) Fill the pump fluid reservoir to the proper level

a n d l e t t h e f l u i d s e t t l e f o r a t l e a s t t w o m i n u t e s .

(2 ) St a r t t h e e n g i n e a n d l e t r u n f o r a f e w s e c o n d s

then turn engine off.(3) Add fluid i f necessary. Repeat the above proce-

d u r e u n t i l t h e f l u i d l e ve l r e m a i n s c on s t a n t a f t e r r u n -

ning the engine.

(4) Raise the front wheels off the ground.

(5) S l ow l y t u r n t h e s t e e r in g w h e el r i g h t a n d l ef t ,

l ightly contacting the wheel stops at least 20 t imes.

(6) Check the fluid level add i f necessary.

(7) L o w er t h e v eh i cl e, s t a r t t h e e ng in e a n d t u r n

the steering wheel slowly from lock to lock.

(8 ) St o p t h e e n g i n e a n d c h e c k t h e f l u i d l e v e l a n d

refi l l as required.

(9) I f t h e f lu i d i s e xt r e m el y f oa m y or m i lk y l ook -

i n g, a l l ow t h e v e hi cl e t o s t a n d a f ew m i nu t es a n drepeat the procedure.

CAUTION: Do not run a vehicle with foamy fluid foran extended period. This may cause pump damage.

REMOVAL AND INSTALLATION

POWER STEERING PUM P LHD

Removal

(1) Disconnect the negative battery cable.

(2) Remove th e A/C line support bra cket from t he

rear of the rocker cover.(3) Disconnect the A/C compressor electr ical con-

nector.

(4) Remove t he (2) engine mount upper si l l plat e

nuts (Fig. 1).

(5) Ma ke su re t he s teer in g w h eel is in t he

unlocked position.

Fig. 1 Engine Mount Sill Plate Nuts

1 9 - 2 STEER IN G XJ


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(6) Raise the vehicle on a hoist .

(7) Remove the steering shaft pinch bolt and sl ide

t h e s t eer in g s ha f t s t ra i gh t of f t h e g ea r b ox i npu t

s h a f t , p os i t ion t h e s h a f t a s i d e.

CAUTION: Avoid turning the steering shaft whiledisconnected from the steering gearbox. Damage tosteering column clockspring could occur.

(8) R e m ov e t h e p ow e r s t e er i n g f l ui d s u pp ly h os e

f r o m t h e p u m p a n d l e t t h e f l u i d d r a i n .

(9) Loosen the (4) H-Block retaining bolts. Do not

r e m o v e t h e bo l t s a t t h i s t i m e .

(10) R em ov e t h e a c ce ss or y d r iv e b el t f r om t h e

power steering pump pulley. Refer to Group 7, Cool-

ing System for procedure.

(11) Remove the power steering pump pulley. Use

a h e x s ock et t o s e cu r e t h e p u m p s h a f t w h i l e r e m ov -

i n g t h e p u l l e y n u t w i t h a bo x w r e n c h (Fi g . 2 ) .

NOTE: Mark the position of the H-Block in relationto the A/C Compressor so it may be reinstalled in

the same position.

(12) Remove the (2) bolts retaining the H-Block to

the power steering pump shaft coupler.

(13) L o os en t h e cou p le r p in ch bol t a n d s l id e t h e

coupler towards the pump.

(14) R em ov e t h e p ow e r s t e er i n g p u mp p r es s u r e

line from the steering gear. This is more accessible,

b u t w i l l r e q u ir e y ou t o i n st a l l t h e p re ss u re l in e on

t h e n e w p u mp p r i or t o i n s t a l l a t i o n .

(15) R em ov e t h e r em a i ni ng 2 b ol t s f rom t h e

H-Block and remove the H-Block from the compres-

sor.

(16) S upport th e A/C compressor w ith mechanics

wire before proceding to the next step.

(17) R em ov e t h e (4) A/C com p r es s or r e t a i n i n g

bolts.(18) Remove the left engine mount throughbolt nut

on l y. Do n o t r e m ov e t h e bol t a t t h i s t i m e.

(19) Position a jack stand and raise weight off left

engine mount.

(20) Remove the track bar support bracket retain-

ing bolts and remove bracket (Fig. 3).

(21) Remove the lower engine mount bolt from the

sill plate (Fig. 3).

(22) R e m ov e t h e (4) e n gi n e m ou n t br a c ke t bol t s

from the engine block.

(23) Remove the engine mount throughbolt .

(24) Remove the engine mount and engine mount

bracket from the vehicle.

(25) Remove the (2) power steering pump retaining

nuts (Fig. 4).(26) R e mov e t h e p ow e r s t e er i n g p u m p f r o m t h e

vehicle.

Installation

WARNING: Power steering system fluid may becontaminated with metal shavings, overheated orimproper fluid. All fluid should be drained from thesystem. After component replacement, system

should be flushed and filled with Mopar PowerSteering Fluid, or equivalent.

Fig. 2 Removing the Power Steering Pump Pulley

Fig. 3 Engine Mount Retaining Bolts


REMOVAL AND INSTALLATION (Continued)


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(1) Tr a n s f e r t h e p r es s u r e l i n e t o t h e n e w p u m p ,

making sure l ine is in original position.

(2) Tran sfer th e coupler to t he n ew pump leaving

pinch bolt lose at this t ime (Fig. 5).

(3) Instal l the power steering pump (Fig. 5).

(4) Instal l the engine mount and the engine mount

bracket in the vehicle.

(5) Instal l the engine mount throughbolt and leave

l oos e a t t h i s t i m e.

(6) I n s t a l l, b u t d o n ot t or q u e t h e e ng in e m ou n t

and track bar support bracket bolts (Fig. 6).

(7) Instal l the (4) engine mount bracket to engine

block reta ining bolts. Torque bolts to 47 Nm (35 ft .

lbs.).

(8) Torque th e engine m ount si l l plate bolts to 41

Nm (30 ft. lbs.).

(9) Tor q u e t h e l a r g er t r a c kb a r s u pp or t b r a ck et

bolts to 125 Nm (92ft. lbs.).(10) Remove the jack stand.

(11) I nsta ll th e H -B lock on t he A/C compressor in

i t s o r i g i n a l p o s i t i o n a n d l e a v e t h e bo l t s l o o s e a t t h i s

time.

(12) P osition a nd insta ll t he A/C compressor.

(13) Slide the drive coupler in i ts original position

and instal l the remaining (2) H-Block bolts.

(14) I n s t a l l t h e p ow e r s t e er i n g p u m p p u l le y (Fi g .

7). Torque nut to 166 Nm (120 ft . lbs.).

(15) Instal l the accessory drive belt . See Group 7,

Cooling System for procedure.

(16) Torque all th e H -B lock bolts.

(17) I nsta l l th e steering sha ft . Torque the steeringshaft pinch bolt to 49 Nm (36 ft . lbs.).

(18) I n st a l l t h e p re ss u re l in e on s t ee ri n g g ea r .

Torque n ut to 28 Nm (21 ft. lbs.).

(19) Insta l l th e power steering fluid supply hose on

the pump.

(20) Lower the vehicle from the hoist .

(21) Instal l and torque the engine mount upper si l l

plate nuts to 41 Nm (30 ft . lbs.) (Fig. 8).

(22) Conn ect t he A/C compressor electrical conn ec-

tor.

Fig. 4 Power Steering Pump


Fig. 6 Engine Mount Retaining Bolts




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(23) Inst a ll the A/C line support bra cket bolt a t t he

rear of the valve cover.

(24) F i l l t h e p ow e r s t e er i n g f l ui d . Se e Gr o u p 19,

St e e r in g f or P o w e r St e e r in g P u m p-I n i t i a l op er a t i on

procedure.

(25) Connect the negative battery cable.

POWER STEERING PUMP RHD

Removal

(1) Disconnect the negative battery cable.

(2) R e m ov e t h e r e fr i g er e n t l in e s u pp or t br a c ke t

bol t f r om t h e t o p of t h e r a d i a t or.

(3) Remove the A/C filter-drier a ssembly supportbracket nuts from left fender well .

(4) Disconnect the A/C compressor electr ical con-

nector.

(5) Raise the vehicle on a hoist .

(6) R e mov e t h e p ow e r s t e er i n g f l ui d s u pp ly h os e

f r o m p u m p a n d d r a i n f l u i d .

(7) R e m ov e p ow e r s t e er i n g l in e s u pp or t br a c ke t

bolt from below radiator.

(8) Remove the engine mount upper si l l plate nuts.

(9) Loosen the (4) H-Block retaining bolts. Do not

r e m o v e a t t h i s t i m e .

(10) R em ov e t h e a c ce ss or y d r iv e b el t f r om t h e

p ow e r s t e er i n g p u mp p u ll ey. Se e Gr o u p 7, C o ol in gSystem for procedure.

(11) Remove the power steering pump pulley. Use

a h e x s ock et t o s e cu r e t h e p u mp s h a f t w h i l e r e m ov -

i n g t h e p u l l e y n u t w i t h a bo x w r e n c h (Fi g . 9 ) .

NOTE: Mark position of the H-Block in relation tothe A/C Compressor so it can be installed in thesame position.

(12) Remove the (2) bolts retaining the H-Block to

the power steering pump shaft coupler.

(13) Loosen the coupler pinch bolt an d sl ide cou-

pler towards pump.

Fig. 7 Installing Pump Pulley

Fig. 8 Engine Mount Sill Plate Nuts

Fig. 9 Removing Pump Pulley




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(14) Remove the left engine mount throughbolt nut

on l y. Do n o t r e m ov e t h e bol t a t t h i s t i m e.

(15) R em ov e t h e r em a in in g 2 b ol t s f rom t h e

H-Block and remove the H-Block from the compres-

sor.

(16) P o s it i on a ja c k s t a n d a n d r a i s e w e ig h t of f l e ft

engine mount.(17) Remove t he (2) engine mount si l l plat e bolts.

(18) R e m ov e t h e (4) e n g in e m ou n t br a c ke t bol t s

from the engine block.

(19) Remove the engine mount throughbolt .

(20) Remove the engine mount a nd engine mount

bracket from vehicle.

(21) Remove the (2) power steering pump retaining

nuts (Fig. 10).

(22) Slide pump off mounting studs an d position so

pressure l ine can be removed. This wil l require you

t o i n st a l l p re ss u re l in e on t h e n ew p um p p ri or t o

instal l ing i t in the engine block.

(23) R em ov e t h e p ow e r s t e er i n g p u mp f r om t h e

vehicle.

Installation

WARNING: Power steering system fluid may becontaminated with metal shavings, overheated orimproper fluid. All fluid should be drained from the

system. After component replacement, systemshould be flushed and filled with Mopar PowerSteering Fluid, or equivalent.

(1) I n s t a l l t h e p r es s u r e l i n e o n p u mp i n or i g in a l

position.

(2) Tra nsfer t he drive coupler to new pump leaving

pinch bolt lose at this t ime (Fig. 11).

(3 ) I n s t a l l t h e p o w e r s t e e r i n g p u m p i n t h e e n g i n e

block. Torque reta ining nuts to 24 Nm (18 ft . lbs.)

(Fig. 11).

(4) I n s t a ll t h e e ng in e m ou n t a n d e ng in e m ou n t

bracket in vehicle.(5) Instal l the engine mount throughbolt and leave

loose at this t ime.

(6) I n s t a l l, d o n o t t o r q u e e n g in e m o u n t s i ll p la t e

n u t s a n d bo l t s .

(7) I n st a l l (4) e ng in e m ou n t b r a ck et t o e ng in e

bl ock r e t a i n i n g bol t s a n d Tor q u e t o 61 N m (45 f t .

lbs.).

(8) Tor q u e t h e e n gi n e m o u n t s i ll p la t e n u t s t o 41

Nm (30 ft. lbs.).

(9) Torque th e engine m ount si l l plate bolts to 41

Nm (30 ft. lbs.).

(10) Remove jack sta nd.

(11) I nsta ll th e H -B lock on t he A/C compressor int h e or i gi n a l p os it i on a n d l ea v e b ol t s l oos e a t t h i s

time.

(12) P osition a nd insta ll A/C compressor.

(13) Slide the drive coupler into i t s original posi-

tion and start remaining (2) H-Block bolts.

(14) I n s t a l l t h e p ow e r s t e er i n g p u m p p u l le y (Fi g .

12). Torque nut to 166 N m (120 ft . lbs.).






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(15) Instal l the accessory drive belt . See Group 7,

Cooling for procedure.

(16) Torque all th e H -B lock bolts.

(17) Torque th e engine mount throughbolt nut to

65 Nm (48 ft. lbs.).

(18) Insta l l th e power steering fluid supply hose on

pump.(19) I n st a l l t h e p ow e r s t eer in g l in e s up por t

bracket bolt .

(20) Lower the vehicle from hoist.

(21) I n s t a l l t h e r e fr i g er e n t l in e s u pp or t br a c ke t

a n d bo l t o n t h e t o p o f t h e r a d i a t o r .

(22) Inst al l the A/C fi l ter-drier assembly support

br a c ke t n u t s on t h e l ef t f en d e r w e ll .

(23) Reconnect the A/C compressor electrica l con-

nector.

(24) R e-f il l t h e p ow e r s t ee ri n g f lu id . R ef er t o

G r ou p 19, St e e r in g f or P o w e r St e e r in g P u m p -I n i t i a l

Operation for procedure.

(25) Connect the negative battery cable.

Fig. 12 Installing Pump Pulley




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STEERING COLUMN

INDEX

page page

GENERAL INFORMATIONSTEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 8

DIAGNOSIS AND TESTING

IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 9

REMOVAL AND INSTALLATIONSTEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 9

SPECIFICATIONS

TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 11

GENERAL INFORMATION

STEERING COLUMNTh e t i lt a n d s t a n d a r d col um n (F i g. 1) h a s b ee n

d e s i g n e d t o be s e r v i c e d a s a n a s s e m bl y ; l e s s w i r i n g ,

switches, shrouds, steering wheel, etc. Most steering

column components can be serviced with out remov-ing the steering column from the vehicle.

SERVICE PRECAUTIONS

S a f e t y g o gg le s s h ou ld b e w o r n a t a l l t i m es w h e n

working on steering columns.

To service t he steering wheel, sw itches or a irbag,

r e fe r t o G r ou p 8 M a n d f ol low a l l WAR NI NGS a n d

CAUTIONS.

WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,

COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE

ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALLTHE AIRBAG SYSTEM COMPONENTS YOU MUSTFIRST DISARM THE AIRBAG FIRING MECHANISM.

FAILURE TO DO SO COULD RESULT IN ACCIDEN-TAL DEPLOYMENT OF THE AIRBAG AND POSSI-BLE PERSONAL INJURY.

WARNING: THE FASTENERS, SCREWS, AND

BOLTS, ORIGINALLY USED FOR THE AIRBAG COM-PONENTS, HAVE SPECIAL COATINGS AND ARESPECIFICALLY DESIGNED FOR THE AIRBAG SYS-TEM. THEY MUST NEVER BE REPLACED WITH ANY

SUBSTITUTES. ANYTIME A NEW FASTENER ISNEEDED, REPLACE WITH THE CORRECT FASTEN-ERS PROVIDED IN THE SERVICE PACKAGE ORFASTENERS LISTED IN THE PARTS BOOKS.

Fig. 1 Steering Column



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(12) Remove upper fixed column shroud.

(13) Remove multi-function switch ta mper proof

m ou n t i n g s cr e w s a n d con n e ct o r s cr e w. C o n n ect o r

screw wil l stay in the connector.

(14) U n pl ug w i ri ng h a r n es s f rom t h e col um nswitches (Fig. 7).

(15) Remove the wiring harness from steering col-

umn.

(16) Remove ignition switch.

(17) Remove interlock cable from the steering col-

u m n , r ef er t o G r o up 21 Au t om a t i c Tr a n s m is si on

Sh ifter/Ignit ion Int erlock.

(18) Remove the column.

INSTALLATION

(1) Align a nd insta l l th e column t o the coupler. Donot apply force at the top of the steering col-umn shaft.

(2) Ensure the ground clip is position (Fig. 8).

(3) I n s t a l l i n t er l ock ca bl e f r om t h e s t e er i n g col -

u m n , r ef er t o G r o up 21 Au t om a t i c Tr a n s m is si on

Sh ifter/Ignit ion Int erlock.

(4) I n s t a l l w i r i n g h a r n e s s con n e ct i on s t o s t e er i n g

column.Ensure the wiring is not pinched and allconnections are correctly locked in place.

(5) I n s t a ll w i r in g h a r n es s con n ect or on t o m u lt i

function swit ch. Tighten function switch w iring ha r-

ness connector retaining bolt to 2 Nm (17 in. lbs.).

(6) Plug in wiring harness connector to remaining

switches.(7) Instal l ignition switch.

(8) Install upper fixed column shroud cover.

(9) Insta l l sha ft coupler pinch bolt loose, load col-

u m n u p t o p a n e l br a c k e t .

Fig. 5 Steering Column

Fig. 6 Steering Column Braces

1 9 - 1 0 STEER IN G XJ



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(10) B e s u r e bot h s pa c er s a r e f u ll y s e a t e d i n t h e

column support bracket. Tighten the column panel

bracket support nuts to 12 Nm (105 in. lbs.).

(11) Tight en th e coupler pinch bolt to 47 Nm (35

ft. lbs.).(12) Instal l lower fixed shroud.

(13) I n s t a l l u p p er a n d l ow e r s h r ou d s . I n s t a l l t h e

tilt lever (if equipped).

(14) Instal l relay box.

(15) Inst a ll lower instr ument pan el/knee blocker.

(16) Instal l clockspring, steering wheel and airbag.

Refer to G roup 8M Restra int Systems for service pro-

cedures.

(17) R e m ov e t h e col u m n s h a f t s h i pp in g l ock p in

(installed in service column).

(18) Connect the battery ground (negative) cable.

SPECIFICATIONS

TORQUE CHART

DESCRIPTION TORQUE

Tilt Steering Column

St eering Wheel Nut . . . . . . . . 54 Nm (40 ft . lbs.)

Mounting Nuts . . . . . . . . . . . . 23 Nm (17 ft . lbs.)

Coupler Bolt . . . . . . . . . . . . . . 49 Nm (36 ft . lbs.)

Non-Tilt Steering Column

St eering Wheel Nut . . . . . . . . 54 Nm (40 ft . lbs.)

Mounting Nuts . . . . . . . . . . . . 23 Nm (17 ft . lbs.)

Coupler Bolt . . . . . . . . . . . . . . 49 Nm (36 ft . lbs.)Upper B ra cket Nut . . . . . . . . 17 Nm (150 in. lbs.)

Fig. 7 Steering Column Wiring Harness

Fig. 8 Ground Clip & Spacer

XJ STEER IN G 1 9 - 1 1



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exj_19a99 jeep xj service manual

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