Jeep Cherokee (XJ): Ignition coil-4.0L engine. Crankshaft position (CKP) sensor. Camshaft position sensor-2.5L engine

Jeep Cherokee (XJ) 1984 - 2001 Service Manual > Ignition system > Removal and installation > Ignition coil-4.0L engine. Crankshaft position (CKP) sensor. Camshaft position sensor-2.5L engine

Ignition coil-4.0L engine

REMOVAL

A one-piece coil rail assembly containing three individual coils is used on the 4.0L engine (Fig. 21).

The coil rail must be replaced as one assembly. The bottom of the coil is equipped with 6 individual rubber boots (Fig. 21) to seal the 6 spark plugs to the coil. Inside each rubber boot is a spring. The spring is used for an electrical contact between the coil and the top of the spark plug. These rubber boots and springs are a permanent part of the coil and are not serviced separately.

(1) Disconnect negative battery cable at battery.

(2) The coil is bolted directly to the cylinder head.

Remove 4 coil mounting bolts (Fig. 22).

(3) Carefully pry up coil assembly from spark plugs. Do this by prying alternately at each end of coil until rubber boots have disengaged from all spark plugs. If boots will not release from spark plugs, use a commercially available spark plug boot removal tool. Twist and loosen a few boots from a few spark plugs to help remove coil.

(4) After coil has cleared spark plugs, position coil for access to primary electrical connector. Disconnect connector from coil by pushing slide tab outwards to right side of vehicle (Fig. 23). After slide tab has been positioned outwards, push in on secondary release lock (Fig. 23) on side of connector and pull connector from coil.

(5) Remove coil from vehicle.

Fig. 21 Ignition Coil Assembly-4.0L 6-Cylinder Engine
Fig. 21 Ignition Coil Assembly-4.0L 6-Cylinder Engine

1 - CYL. #6
2 - CYL. #5
3 - CYL. #4
4 - CYL. #3
5 - CYL. #2
6 - CYL. #1
7 - COILS (3)
8 - MOUNTING BOLTS (4)
9 - BOLT BASES (4)
10 - RUBBER BOOTS (6)

Fig. 22 Ignition Coil Rail Location-4.0L 6-Cylinder Engine
Fig. 22 Ignition Coil Rail Location-4.0L 6-Cylinder Engine

1 - COIL RAIL
2 - COIL MOUNTING BOLTS (4)
3 - COIL
4 - COIL ELECTRICAL CONNECTION

Fig. 23 Ignition Coil Electrical Connector-4.0L 6-Cylinder Engine
Fig. 23 Ignition Coil Electrical Connector-4.0L 6-Cylinder Engine

1 - REAR OF VALVE COVER
2 - COIL RAIL
3 - SLIDE TAB
4 - RELEASE LOCK
5 - COIL CONNECTOR

INSTALLATION

(1) Position ignition coil rubber boots to all spark plugs. Push down on coil assembly until bolt bases have contacted cylinder head (2) Install 4 coil mounting bolts. Loosely tighten 4 bolts just enough to allow bolt bases to contact cylinder head. Do a final tightening of each bolt in steps down to 29 N·m (250 in. lbs.) torque. Do not apply full torque to any bolt first.

(3) Connect engine harness connector to coil by snapping into position. Move slide tab towards engine (Fig. 23) for a positive lock.

(4) Connect negative battery cable to battery.

Crankshaft position (CKP) sensor

REMOVAL

The crankshaft position (CKP) sensor is mounted to the transmission bellhousing at the left/rear side of the engine block.

The sensor may be mounted to the transmission with one of the following three different configurations:

  •  with one bolt (Fig. 24). If sensor is equipped with one mounting bolt, it is adjustable..
  •  with two nuts (Fig. 25).
  •  with two bolts (Fig. 26).

Fig. 24 Crankshaft Position Sensor-One-Bolt Mounting
Fig. 24 Crankshaft Position Sensor-One-Bolt Mounting

1 - SENSOR PIGTAIL
2 - CRANKSHAFT POSITION SENSOR
3 - MOUNTING BOLT
4 - TRANSMISSION HOUSING
5 - PAPER SPACER
6 - SLOTTED HOLE

Fig. 25 Crankshaft Position Sensor-Two-Nut Mounting
Fig. 25 Crankshaft Position Sensor-Two-Nut Mounting

1 - TRANSMISSION BELLHOUSING
2 - MOUNTING NUTS (2)
3 - CRANKSHAFT POSITION SENSOR
4 - MOUNTING STUDS (2)
5 - RUBBER GROMMET
6 - SENSOR PIGTAIL

(1) Near left-rear side of engine, disconnect sensor pigtail harness (electrical connector) from main electrical harness connector. These connectors are attached to a bracket which is attached to the leftfront side of the transmission.

(2) Depending upon application, remove either sensor mounting bolt(s) or nuts.

(3) Remove sensor from engine.

INSTALLATION

Sensor With 2-Bolt Mounting:

(1) Install sensor flush against opening in transmission housing.

(2) Install and tighten two sensor mounting bolts to 19 N·m (14 ft. lbs.) torque. The two sensor mounting bolts are specially machined to correctly space unit to flywheel. Do not attempt to install any other bolts.

Sensor With 2-Nut Mounting: (3) Install and tighten two sensor mounting nuts to 19 N·m (14 ft. lbs.) torque.

Sensor With One-Bolt Mounting:

New replacement sensors will be equipped with a paper spacer glued to bottom of sensor. If installing (returning) a used sensor to vehicle, a new paper spacer must be installed to bottom of sensor. This spacer will be ground off the first time engine is started. If spacer is not used, sensor will be broken the first time engine is started.

Fig. 26 Crankshaft Position Sensor-Two-Bolt Mounting
Fig. 26 Crankshaft Position Sensor-Two-Bolt Mounting

1 - TRANSMISSION BELLHOUSING
2 - MOUNTING BOLTS (2)
3 - CRANKSHAFT POSITION SENSOR
4 - RUBBER GROMMET
5 - SENSOR PIGTAIL

(4) New Sensors: Be sure paper spacer is installed to bottom of sensor. If not, obtain spacer PN05252229.

(5) Used Sensors: Clean bottom of sensor and install spacer PN05252229.

(6) Install sensor into transmission bellhousing hole.

(7) Push sensor against flywheel/drive plate. With sensor pushed against flywheel/drive plate, tighten mounting bolt to 7 N·m (60 in. lbs.) torque.

(8) Connect sensor pigtail harness electrical connector to main wiring harness connector.

Camshaft position sensor-2.5L engine

On 2.5L engines, the camshaft position sensor is located in the distributor (Fig. 27).

REMOVAL

Distributor removal is not necessary to remove camshaft position sensor.

(1) Disconnect negative battery cable at battery.

(2) Remove distributor cap from distributor (two screws).

(3) Disconnect camshaft position sensor wiring harness from main engine wiring harness

Fig. 27 Camshaft Position Sensor-2.5L Engine
Fig. 27 Camshaft Position Sensor-2.5L Engine

1 - SYNC SIGNAL GENERATOR
2 - CAMSHAFT POSITION SENSOR
3 - PULSE RING
4 - DISTRIBUTOR ASSEMBLY

(4) Remove distributor rotor from distributor shaft.

(5) Lift camshaft position sensor assembly from distributor housing (Fig. 27).

INSTALLATION

(1) Install camshaft position sensor to distributor.

Align sensor into notch on distributor housing.

(2) Connect wiring harness.

(3) Install rotor.

(4) Install distributor cap. Tighten mounting screws.

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