Jeep cherokee 1989 Owner's Manual

Table of Contents

Quick Links

The Motor Manual Guy

Introductory pages

About This Manual

Vehicle Identification Numbers

Buying parts

Maintenance Techniques, Tools And Working Facilities

Booster Battery (Jump) Starting

Jacking And Towing

Automotive Chemicals And Lubricants

Safety First!

Conversion Factors

Troubleshooting

Chapter 1

Tune-Up And Routine Maintenance

Chapter 2 Part A

Four-Cylinder Engine

Chapter 2 Part

Chapter 2 Part C

Chapter 2 Part D

General Engine Overhaul Procedures

Chapter 3

Cooling, heating and air conditioning systems

Chapter 4

Fuel And Exhaust Systems

Chapter 7 Part A

Manual transmlsslon

Transfer Case

Chapter 8

Clutch and drlvetraln

Chapter 9

Brakes

Chapter 10

Chapter 11

Body

Chapter 12

Wiring diagrams

Index

0-5

0-7

0-10

0-17

0-19

Q-20

0-22

1-1

28-0

2C-0

2D-0

4-0

IMD-1

Table of Contents

Troubleshooting

Summary of Contents for Jeep cherokee 1989

Page 1 The Motor Manual Guy Contents Introductory pages About this manual Vehicle identification numbers Buying parts 0-10 Maintenance techniques, tools and working facilities 0-10 Booster battery (jump) starting 0-17 Jacking and towing 0-17 Automotive chemicals and lubricants 0-19 Safety first! Q-20 Conversion factors Troubleshooting 0-22...
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Page 4 The Motor Manual Guy Vehicle identification numbers of production, the Gross Vehicle Weight Rating (GVWR) and the certi- Modifications are a continuing and unpublicized process in vehicle fication statement. manufacturing. Since spare parts manuals and lists are compiled on a numerical basis, the individual vehicle numbers are essential to cor- rectly identify the component required.
Page 5 The Motor Manual Guy The build date and serial number are stamped on the BA 1015 manual transmission ID number location bottom of the AX 415 manual transmission case TRANSMISSION NUMBER DATE NUMBER The four-speed automatic transmission ID plate is on the The three-speed automatic transmission numbers are right rear side of the case stamped on the edge of the left side of the case...
Page 6 The Motor Manual Guy Vehicle identification numbers Transmission identification number BUILD DATE The ID number on T 415 manual transmissions is located on a tag MANUFACTURER attached to the rear of the case. On AX 415 manual transmissions, there are two identification codes: a modellcode shipping date stamped on the shift tower and an eight digit code stamped on the bottom sur- face of the case (see illustration).
Page 7 The Motor Manual Guy Maintenance techniques, tools and working facilities 0-1 1 Fastener sizes standard wrench should not be used on a metric bolt and a metric For a number of reasons, automobile manufacturers are making wider wrench should not be used o n a standard bolt. Also, most standard and wider use of metric fasteners.
Page 8 The Motor Manual Guy Maintenance techniques, tools and working facilities Tightening sequences and procedures while smaller studs carry a geometric code to denote grade. It should be noted that many fasteners, especially Grades 0 through Most threaded fasteners should be tightened to a specific torque 2, have no distinguishing marks on them.
Page 9 The Motor Manual Guy 0-13 Maintenance techniques, tools and working facilities for Grade 2 and Grade 3 fasteners. Higher grades can tolerate higher can easily mar the gasket sealing surfaces of the parts, which must torque values. remain smooth. If prying is absolutely necessary, use an old broom Fasteners laid out In a pattern, such as cylinder head bolts, oil pan handle, but keep in mind that extra clean u p will be necessary if the bolts, differential cover bolts, etc., must be loosened or tightened in...
Page 10 The Motor Manual Guy Maintenance techniques, tools and working facilities 0-1 4 Timing light Hand-operated vacuum pump Compression gauge with spark plug General purpose puller hole adapter Valve spring compressor Valve spring compressor Hydraulic lifter removal tool Ring removallinstallation tool Ridge reamer Piston ring groove cleaning tool...
Page 12 The Motor Manual Guy 0-16 Maintenance techniques, tools and working facilities Pliers vise grip on the other hand, extensive work is planned, it would be a good idea Pliers lineman's to purchase a modest tool set from one of the large retail chain stores. Pliers needle nose A set can usually be bought at a substantial savings over the individual...
Page 13 The Motor Manual Guy Booster battery (jump) starting Certain precautions must be observed when using a booster battery to start a vehicle. switch is in the Off position. one in the vehicle. (automatic). vent caps and lay a cloth over the vent holes. Connect the red jumper cable to the positive ( + I terminals of each battery.
Page 14 The Motor Manual Guy Jacking and towing 0-18 not the bumper or brackets. Tow hooks are attached t o the frame at is lowered to tighten them completely. Note that some spare tires are both ends of the vehicle. However, they are for emergency use only designed for temporary use only don't exceed the recommended and should not be used for highway towing.
Page 15 The Motor Manual Guy Automotive chemicals and lubricants is used for mounting HE1 ignition modules where it is essential that A number of automotive chemicals and lubricants are available for heat be transferred away from the module. use during vehicle maintenance and repair. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl.
Page 16: Safety First
The Motor Manual Guy Safety first! Fire Regardless of h o w enthusiastic you may be about getting on with the job at hand, take the time t o ensure that your safety is not jeopard- Remember at all times that gasoline is highly flammable. Never smoke ized.
Page 17 The Motor Manual Guy Conversion factors Length (distance) Inches (in) 25.4 Inches (in) Feet (ft) X 0.3G5 Feet Metres (m) Miles Miles Kilometres (km) Volume (capacity) Cubic inches (cu in; in Cubic inches (cu in; in X 16.387 Cubic centimetres (cc; cm3) lrnperial pints (Imp pt) lmperial pints (Imp pt) X 0.568...
Page 18: Table Of Contents
The Motor Manual Guy Troubleshooting Contents Section Section Symptom Symptom Driveshaft Engine and performance Knock or clunk when transmission is under initial Alternator light fails to come on when key is turned on ... load (just after transmission is put into gear) Alternator light stays on .
Page 19 On 1986 Cherokee Wagoneer and Comanche models with four- potential failure or incorrect functioning of a more important component cylinder TBI-equipped engines, a Jeep service bulletin no. INJ TBIIG-9-8 or system. has been issued concerning this problem. Take the vehicle to a dealer and inform him of the problem.
Page 20: Alternator Light Fails To Come On When Key Is Turned On 1
The Motor Manual Guy Troubleshooting 0-24 lgnition system not operating properly (Chapter 5). Wet or damaged distributor components (Chapter 1 Dirty or clogged carburetor or fuel injector (Chapter 4). Short circuits in ignition, coil or spark plug wires. Low fuel pressure. Check for proper operation of the fuel pump Sticking or faulty emissions systems (see Chapter 6).
Page 21: Excessive Fuel Consumption 2
The Motor Manual Guy Troubleshooting 0-25 worn crankshaft. To pinpoint the trouble spot, remove the spark plug 21 Engine diesels (continues t o run) after being turned off wire from one plug at a time and crank the engine over. If the noise stops, the cylinder with the removed plug wire indicates the problem area.
Page 22: Troubleshooting
The Motor Manual Guy Troubleshooting 0-26 Chapters 1 and 2). 35 Clutch slips (engine speed increases with no increase Leak from coolant temperature switch (Chapter 3). i n vehicle speed) Leak from damaged gaskets or small cracks (Chapter 2). Damaged head gasket. This can be verifed by checking the con- dition of the engine oil as noted in Section 30.
Page 23 The Motor Manual Guy Troubleshooting 8-27 air flow t o the transmission. To pinpoint a leak, first remove all built-up dirt and grime from the 4 1 Noisy i n all gears transmission. Degreasing agents and/or steam cleaning will achieve this.
Page 24 The Motor Manual Guy 0-28 Troubleshooting Loose driveshaft bolts. lnspect all bolts and nuts and tighten them securely. 60 Noise when turning Worn or damaged universal joint bearings. Replace driveshaft (Chapter 8). Defective differential. Worn sleeve yoke and mainshaft spline. Vibration 5 4 Metallic grating sound consistent with vehicle speed See probable causes under Driveshaft.
Page 25: Suspension And Steering
The Motor Manual Guy Troubleshooting 0-29 Caliper not sliding properly due to improper installation or obstruc- piston or damage. tions. Remove and inspect. Brake pad to rotor adjustment needed. lnspect automatic adjusting Rotor not within specifications. Remove the rotor and check for mechanism for proper operation.
Page 26 The Motor Manual Guy Troubleshooting Steering column out of alignment. Steering gear improperly adjusted. Loose, worn or damaged steering components. Worn or damaged balljoint. Worn or damaged steering linkage. 1 0 Damaged idler arm. Improperly lubricated idler arm. 11 Worn balljoint. Insufficient oil in steering gear.
Page 27: Tune-Up And Routine Maintenance
Brake fluid DOT-3 brake fluid ..................Clutch fluid DOT-3 brake fluid ................. Power steering fluid Jeep power steering fluid or equivalent ............Manual steering box lubricant SAE 75W-90 GL-5 gear lubricant Wheel bearing grease (2WD) NLGl No. 2 moly-base wheel...
Page 28 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance Capacities (continued) Manual transmission (approximate) 7.5 pints 4-speed 7.2 pints 5-speed Transfer case (approximate) ................... 3.0 pints Selec-trac 2.2 pints Command-trac Ignition system Firing order Four-cylinder engine ................... V6 engine CYLINDER NUMBERS ORDER Spark plug type and gap...
Page 29 The Motor Manual Guy Jeep CherokeeIComanche Maintenance schedule The following maintenance intervals are based on the assumption Check the carburetor choke operation (Section 22) that the vehicle owner will be doing the maintenance or service Check the carburetorlthrottle body mounting nut...
Page 30 The Motor Manual Guy Engine compartment component checking points (inline six-cylinder engine shown) 1 Crankcase Ventilation (CCVI 7 Drivebelt system hose and fitting 8 CCV fresh air hose 9 Engine oil filler cap 2 Clutch fluid reservoir 10 Engine oil dipstick 3 Brake fluid reservoir 4 Windshield washer reservoir 12 Battery...
Page 31 The Motor Manual Guy Typical engine compartment under side components (4WD vehicle shown) Front driveshaft slip joint 6 Steering linkage grease fitting 7 Steering damper 2 Transmission 8 Front driveaxle 3 Engine oil drain plug 9 Front disc brake caliper 4 Exhaust pipe Front driveshaft 5 Brake hose...
Page 32 The Motor Manual Guy...
Page 33 Check the ignition system (Chapter 5) This Chapter is designed to help the home mechanic maintain the Check the charging system (Chapter 5) Jeep Cherokee or Comanche with the soak of maximum ~erformance, Check the fuel system (Section 21 economy, safety and reliability in mind.
Page 34: Index
The Motor Manual Guy Chapter 1 Tune-up and routine maintenance COOLANT RESERVE BOTTLE On four-cylinder and V6 engines, the coolant reserve bottle The twist-off oil filler cap is located on the rocker cover (except on V6 models, which have it mounted on top of a filler allows for contraction and expansion of the coolant can be checked visually with the engine hot or cold...
Page 35 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 4.18 The clutch master cylinder is located next t o the 4.14 The windshield washer fluid reservoir is located on the driver's side of the engine compartment keep the brake booster maintain the fluid level between the MAX and MIN marks level at or near the FULL line;...
Page 36 The Motor Manual Guy Chapter 1 1-10 Tune-up and routine maintenance reservoir cap or cover with a clean rag to prevent contamination of the brake andlor clutch system before removing the cover. 2 0 When adding fluid, pour it carefully into the reservoir to avoid spill- ing it onto surrounding painted surfaces.
Page 37 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-11 If a tire loses air on a steady basis, check the valve If the valve core is tight, raise the corner of the core first to make sure it's snug (special inexpensive vehicle with the low tire and sway a soapy water solution wrenches are commonly available at auto parts stores) onto the tread as the tire is'turned...
Page 38 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-12 battery cells is actually dilute sulfuric acid, which will cause injury if a funnel. It takes about one pint to raise the level from the ADD mark splashed on your skin or in your eyes. It will also ruin clothes and painted to the FULL mark with a warm transmission, so add the fluid a little surfaces.
Page 39 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance reinstall them (see illustrations). Corrosion can be kept to a minimum has been installed, the following procedure can be used. by installing specially treated washers available at auto parts stores Check the electrolyte level in each of the battery cells.
Page 40 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-14 areas adjoining the leak. If wire-type clamps are used at the ends of 9 Cooling system check the hoses, it may be a good idea to replace them with more secure screw-type clamps.
Page 41 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-15 the line has not been bent or crimped and that cracks have not started in the line. 1 2 If a section of metal fuel line must be replaced, only seamless steel tubing should be used, since copper and aluminum tubing don't have Refer to illustrations 12.3, 12.9, 12.
Page 42 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance the pan as the oil flow slows to a trickle. If this is your first oil change, get under the vehicle and familiarize 1 1 After all the oil has drained, wipe off the drain plug with a clean yourself with the locations of the oil drain plug and the oil filter.
Page 43 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-17 19 Attach the new filter to the engine, following the tightening direc- tions printed on the filter canister or packing box. Most filter manufac- turers recommend against using a filter wrench due t o the possibility of overtightening and damage to the seal.
Page 44 The Motor Manual Guy Chapter 1 1-18 Tune-up and routine maintenance into the fitting until can be seen coming out of the slip joint seal (see illustration) 11 Lubricate conventional universal joints until grease can be seen coming out of the contact points (see illustration). 12 While you are under the vehicle, clean and lubricate the parking brake cable along with the cable guides and levers.
Page 45 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance syringe or squeeze bottle. Exhaust system check Install and tighten the plug and check for leaks after the first few miles of driving. With the engine cold (at least three hours after the vehicle has been driven), checkthe complete exhaust system from the manifold to the end of the tailpipe.
Page 46 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-20 20.6 You will find an inspection hole like this i n each caliper placing a steel ruler across the window should enable you t o determine the thickness of remaining pad 19.2 The recommended tire rotation patterns for these vehicles material for both inner and outer pads...
Page 47: Fuel Odor
The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-21 and the tank is especially critical. Sometimes a rubber filler neck will leak due to loose clamps or deteriorated rubber; these are problems a home mechanic can usually rectify. Warning: Do not, under any circumstances, try to repair a fuel tank yourself (except rubber com- ponents).
Page 48 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-22 Thermostatic air cleaner check Drivebelt check, adjustment and replacement Refer to illustrations 26.3, 26.4a, 26.4b, 26.5a, 26.56, 26.12a and Refer to itlustrations 25.3a and 25.3b Some engines are equipped with a thermostatically controlled air cleaner which draws air to the carburetor from different locations, de- The drivebelts, or V-belts as they are often called, are located at pending on engine temperature.
Page 49 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance leys spaced 12-to-1 6 inches apart, the belt should deflect 112-inch. The tension on serpentine belts can only be checked using a belt ten- BURROUGHS sion gauge, available at auto parts stores (see illustration). If adjustment is needed, either to make the belt tighter or looser, it's done by moving the belt-driven accessory on the bracket.
Page 50 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-24 SOLE-VAC VACUUM ACTUATOR Check the seatbelts, buckles, latch plates and guide loops for any obvious damage or signs of wear. Make sure the seatbelt reminder light comes on when the key is turned on.
Page 51 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-25 this fitting is drawn away from the carburetor body, be careful not to lose the thin washer-type gasket on the nut or the spring, located behind Fuel filter replacement the fuel filter.
Page 52 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-26 Remove the old filter. Install the new PCV filter and the new air filter. 3 2 Air filter and PCV filter replacement Install the cover and any hoses which were disconnected Refer to illustrations 32.2a, 32.
Page 53 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-27 33.4 The ignition timing marks are located at the front of the engine (four-cylinder shown) pick-up lead. Instead, use an adapter between the spark plug and plug wire. If the insulation on the plug wire is damaged, the secondary volt- age will jump to ground at the damaged point and the engine will mis- fire.
Page 54 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-28 . . . SCREWS FILTER 34.10 The automatic transmission fluid filter is held i n place by three screws (three-speed transmission shown) 10 Remove the filter from the transmission valve body (see illus- tration).
Page 55 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 36.8 Carefully scrape the old gasket or sealant material off to ensure a clean surface for the new gasket t o seal against Remove the fill plug from the differential. If equipped with a drain plug, remove the plug and allow the dif- ferential lubricant to drain completely.
Page 56 The Motor Manual Guy Chapter 1 1-30 Tune-up and routine maintenance Remove the cotter pin and discard use a new 38.6 Dislodge the dust cap by working around the outer 38.7 one when the hub is reinstalled edge with a screwdriver or hammer and chisel and chisel (see illustration).
Page 57 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-31 38.1 1 Use a screwdriver to pry the grease seal from the 38.1 5 Work the grease into each bearing from the large- rear of the hub diameter side until grease oozes out the small-diameter side 25 Using your hand (not a wrench of any kind), tighten the nut until it's snug.
Page 58 The Motor Manual Guy Chapter Tune-up and routine maintenance 1-32 With the engine idling at normal operating temperature, pull the valve (with hose attached) or CCV hose from the rubber grommet in the cover. Place your finger over the valve or hose opening. If there's no vacuum, check for a plugged hose, manifold port, or valve.
Page 59 The Motor Manual Guy Chapter 1 Tune-up and routine maintenance 1-33 40.1 1 A paper clip can be used t o 41.2 The charcoal canister (arrow) is 42.2 Move the EGR valve diaphragm in clean the CCV system orifice located on the firewall i n the engine and out to make sure isn't stuck compartment...
Page 60 The Motor Manual Guy Chapter 1 1-34 Tune-up and routine maintenance any built-up dirt and grease. Once the wire is clean, check for holes, plug. Pull only on the boot at the end of the wire do not pull on the burned areas, cracks and other damage.
Page 61 The Motor Manual Guy NORMAL : Dry sooty deposits Symptoms: Brown to grayish- ich mixture or weak tan color and slight electrode uses misfiring, hard wear. Correct heat range for engine and operating condi- Recommendation: Check for tions. a clogged air cleaner, high float Recommendation: When new level, sticky choke and worn ig- spark plugs are installed, re-...
Page 62 The Motor Manual Guy 1-36 Chapter 1 Tune-up and routine maintenance wires, one at a time, to the new cap. Be very careful not t o mix up damage. Closely examine the terminals on the inside of the cap for the wires! excessive corrosion and damage (see illustration).
Page 63 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine Contents ..Camshaft and bearings removal, inspection Oil pump removal and installation ....
Page 64 The Motor Manual Guy 2A-2 Chapter Part Four-cylinder engine Torque specifications Ft-lbs (unless otherwise indicated) Camshaft sprocket bolt Crankshaft pulley-to-vibration damper bolts Cylinder head bolts 1984 through 1987 Step 1 Step 2 Step 3 ......... . . Bolt 8 only All other bolts Step 1...
Page 65 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine 2A-3 Make a mark on the aluminum distributor body Turn the crankshaft clockwise until the notch aligns directly below the number one spark plug wire terminal on with the the distributor cap (arrow) of the distributor cap and ground it on the block with a jumper Rocker arm cover removal and installation...
Page 66 On models which use RTV, apply a continuous 118-inch (3mm) their original locations). bead of sealant (Jeep Gasket-In-a-Tube or equivalent) to the cover Remove the pushrods and store them separately to make sure they flange. Be sure the sealant is applied to the inside of the bolt holes don't get mixed up during installation (see illustration).
Page 67 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine 2A-5 ROCKER ARM 5.4 If more than one pushrod is being removed. store them i n a perforated cardboard box t o prevent mixups during installation note the label indicating the front 5.3 Rocker arm mounts of the engine exploded view...
Page 68 The Motor Manual Guy 2A-6 Chapter Part A Four-cylinder engine 6.9 Once the spring is depressed, the kee ers-can be 6.17 Apply a small dab of grease to the keepers before installation i t will hold them i n place on the valve stem removed with a small magnet or needle-nose pliers (a as the spring is released magnet is preferred t o prevent dropping the keepers)
Page 69 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine 2A-7 INTAKE MANIFOLD Remove the old intake manifold gasket with a scraper 7.12 Intake and exhaust manifold bolt tightening sequence don't leave any material on the mating surfaces 9 Cylinder head removal and installation Refer to illustrations 9.9 and 9.15 8 Exhaust manifold...
Page 70 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine 2A-8 9.1 5 Cylinder head boltlnut tightening sequence Inspect the cylinder head for cracks and check it for warpage. Refer to Chapter 2, Part D, for cylinder head servicing procedures. through four-cylinder engines use different head gaskets than...
Page 71 The Motor Manual Guy Part A Chapter Four-cylinder engine 2A-9 The foot of each lifter should be slightly convex here), scratched or galled, replace the entire set with new lifters side of another lifter can be used as a straightedge to check if it appears flat, it's worn and must not be reused lifter for wear 12 lnstall the lifter(s) in the lifter bore(s).
Page 72 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine 12.2 The front crankshaft seal can be removed with a seal 12.6 Once the timing chain cover is removed, place on a flat surface and gently pry the old seal out with a large screwdriver removal tool or a large screwdriver (V6 engine shown cylinder similar) Slide the vibration damper onto the crankshaft.
Page 73 Chapter 2 Part Four-cylinder engine with RTV sealant (Jeep Gasket-In-A-Tube or equivalent) and position bore with the lip (open end) of the seal facing in. A small amount of the seal onto the timing chain cover. Then apply a film of oil to the oil applied to the outer edge of the new seal will make installation easier seal-to-oil pan contact surface.
Page 74 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine 2A-12 1 4 Timing chain and sprockets removal, inspection and installation Refer to illustrations 14.3, 14.5, 14.7a, 14.76 and 14. 10 Set the number one piston at Top Dead Center (see Section 3). Remove the timing chain cover (see Section 13).
Page 75 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine the marks on the sprockets are still properly aligned (see illustration 16 Remove the rocker arms and pushrods (see Section 5). 17 Remove the hydraulic lifters (see Section 10). 14.3). 1 8 Remove the timing chain and sprockets (see Section 14).
Page 76 The Motor Manual Guy Chapter 2 Part Four-cylinder engine 2A-14 GASKETS 15.27 Be sure to apply moly-base grease or engine assembly lube t o the cam lobes and bearing journals 16.8 Oil pan components exploded view before installing the camshaft the engine (see illustration).
Page 77 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine Detach the oil pump and strainer assembly from the block. the clutch components and pilot bearing. Use paint or a center punch to make alignment marks on the fly- If the pump is defective, replace it with a new one. If the engine is being completely overhauled, install a new oil pump don't reuse reinstallation (see illustration).
Page 78 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine 1 9 Rear main oil seal replacement threads. 10 Wedge a screwdriver into the ring gear teeth to keep the flywheel/ Refer to illustrations 1 9.5, 19. 8a, 19.8b and 1 9 . 8 ~ driveplate from turning as you tighten the bolts to the specified torque.
Page 79 The Motor Manual Guy Chapter 2 Part A Four-cylinder engine Install the flywheel or driveplate. 1 0 If equipped with a manual transmission, reinstall the clutch disc and pressure plate. Engine mounts check and replacement Refer to illustration 20.8 Engine mounts seldom require attention, but broken or deteriorated mounts should be replaced immediately or the added strain placed on the driveline components may cause damage or wear.
Page 80 The Motor Manual Guy Part B V6 engine Chapter Contents Air filter replacement. See Chapter Oil pan removal and installation ....Camshaft and bearings removal, inspection Oil pump removal and installation...
Page 81 The Motor Manual Guy Part B V6 engine Chapter Intake manifold-to-cylinder head bolts Oil pan mounting bolts ..........6 x 1.0 m m .
Page 82 The Motor Manual Guy Chapter Part B V6 engine 4.1 1 Make sure the sealant is applied t o the inside of the bolt holes or oil will leak out around the bolt threads 4.12 On models that use gaskets, apply RTV sealant t o Disconnect the rubber hose from the air injection manifold (the air the joints between the head and intake manifold (arrows) injection manifold is the group of metal tubes which are screwed into...
Page 83 The Motor Manual Guy Part B V 6 engine Chapter Moly-base grease applied to the pivot balls will 5.10 The ends of the pushrods and the valve stems ensure adequate lubrication until oil pressure builds up should be lubricated with moly-base grease prior to when the engine is started installation of the rocker arms Valve spring, retainer and seals...
Page 84 The Motor Manual Guy B V6 Chapter Part engine 2B-4 Use a 3116-inch diameter cutter to form a groove in 8.17 the manifold 8.13 If a machined groove (arrow) is not present on the underside of the rear of the manifold, scribe marks to outline the area to be ground out 12 Thoroughly clean all sealing surfaces, removing all traces of oil and old gasket material.
Page 85 The Motor Manual Guy Chapter Part B V6 engine Right-side exhaust manifold exploded view (left side similar) 10.13 Tightening sequence for V6 engine cylinder head Right side bolts loosen the bolts in a sequence opposite t o this Remove the cable from the negative battery terminal. Raise the front of the vehicle and support it securely on jackstands.
Page 86 The Motor Manual Guy Chapter Part B V6 engine 30 Loosen the rocker arm nuts sufficiently to allow removal of the pushrods, then remove the pushrods (see Section 5). 31 Loosen the head bolts in a sequence opposite t o the one used for tightening them (see illustration 10.13).
Page 87 The Motor Manual Guy Chapter 2 Part B V6 engine Driving the seal out of the front cover 12.9 Installing the new oil seal with a wood block and a hammer After the water pump (1) is removed, t w o bolts and t w o studs secure the timing chain cover to the engine block exert even pressure around the entire circumference of the seal as it Disconnect the lower radiator hose at the front cover.
Page 88 The Motor Manual Guy Chapter 2 Part B V 6 engine 28-8 14.8 The camshaft and crankshaft timing marks (arrows) should be in exact alignment before removing the timing sprockets and chain anaerobic sealant a worn timing chain and sprockets may result in erratic engine perform- ance, loss of power and lowered gas mileage.
Page 89 The Motor Manual Guy Chapter 2 Part B V6 engine 2B-9 lifters, the lifter boss will be marked with a dab of white paint and will have 0.25 (mm) OS stamped on i t 14.12 Lubricating the thrust surface of the camshaft sprocket 1 2 Lubricate the thrust (rear) surface of the camshaft sprocket with moly-base grease or engine assembly lube (see illustration).
Page 90 The Motor Manual Guy Part B V6 engine Chapter 16.1 1 A length of wire with a hook on 16.10 Long bolts can be threaded into the camshaft bolt holes can be used t o to provide a handle for removal and installation of the support the camshaft as you guide it out of the block camshaft support the cam near the block as it's withdrawn...
Page 91 The Motor Manual Guy Chapter 2 Part B V6 engine corners (arrows) 1 9 8 5 and 1986 models 1 1 Inspect the oil pan cradle corners for deformation using a straight- edge across the cradle opening (see illustration). 17.13 The raised stand-offs (arrows) must be filed or 12 Replace the oil pan with part no.
Page 92 The Motor Manual Guy Chapter 2 Part B V6 engine 20.7 Using guide tools t o install short pieces of seal cut 20.3 Using a packing tool to pack the old rear main oil seal into the groove rope-type seal engines from the old main seal in the upper seal groove type seal engines T ENGINE...
Page 93 The Motor Manual Guy Chapter Part B engine 2B-13 ALIGNMENT HOLE DUST LIP ATTACHING SCREWS 20.31 Using a screwdriver, pry the rear main seal from 20.32 Using the rear main oil seal installation 1985 and later models the bore be careful not t o scratch the crankshaft seal tool surface or the edge of the seal bore the rear main oil seal end and oil pan rear seal groove.
Page 94 The Motor Manual Guy Chapter 2 Part C Contents Intake manifold removal and installation See Chapter 1 Air filter and PCV filter replacement Camshaft. bearings and lifters removal. inspection Oil pan removal and installation and installation Oil pump removal and installation Compression check See Chapter 2 D Rear crankshaft oil seal...
Page 95 The Motor Manual Guy Chapter 2 Part C lnline six-cylinder engine Oil pump mounting bolt Short Long Rear main bearing cap bolts Rocker arm bolts Rocker arm cover-to-cylinder head bolts With RTV 28 in-lbs With permanent gasket in-lbs Tensioner bracket-to-block bolts Timing chain cover-to-block Bolts Studs...
Page 96 The Motor Manual Guy 2C-2 Chapter Part C Pull off the wire loom clips Rocker arm cover removal and installation View from above shows locations of crankcase breather Refer to illustrations 4.1, 4.3 and 4.4 tube and hose (arrows) Pull the crankcase breather tube and hose off the rocker arm cover (see illustration).
Page 97 The Motor Manual Guy Part C Chapter Lubricate the lower end of each pushrod with clean engine oil or moly-base grease and install it in its original location. Make sure each Bring the number one piston to top dead center on the compression stroke (Section 3).
Page 98 The Motor Manual Guy Chapter 2 Part C 2C-4 7.1 1 Remove the bolts (arrows) and lift the heat shield off 7.12 Four of the intake manifold mounting bolts (arrows) can be accessed from the top you must reach below the manifold to remove the remaining four, which are visible in illustration 7.20 11 Remove the intake manifold heat shield (see illustration).
Page 99 The Motor Manual Guy Chapter 2 Part C 2C-5 Position a new gasket on the locating dowels and slide the manifold 1 0 Loosen the alternator drivebelt and remove the alternator bracket- over the studs. to-cylinder head mounting bolt. Install the attaching nuts on the studs finger tight. 1 1 Unplug the wiring and unbolt the air conditioning compressor (see Reinstall the intake manifold (see Section 7) and tighten all fasten- Chapter 3) without disconnecting the refrigerant hoses.
Page 100 The Motor Manual Guy Chapter 2 Part C 2C-6 592 sealant (or equivalent) and install the head bolts hand tight. Note: replacement Clean each bolt and mark it with a dab of paint. Replace any bolts which were painted and reused during an earlier servicing operation. 22 Tighten the cylinder head bolts in sequence (see illustration 9.211, Refer to illustrations 1 1.2 and 1 1.3 according to the following procedure:...
Page 101 The Motor Manual Guy Chapter 2 Part C 2C-7 1 1 . 3 Gently drive the new seal into place with a hammer 1 2 . 4 Once the alternator has been removed, remove the and large socket bracket retaining nuts (arrows), then unbolt the timing chain cover engine block gasket and position the gasket on the engine.
Page 102 The Motor Manual Guy Chapter 2 Part C 2C-8 13.3 Slip the oil slinger off the 13.7 With the number one piston at 13.8 Remove the thrust pin and spring crankshaft, noting that the cupped side (arrow), then remove the bolt in the Top Dead Center, the timing chain faces away from the engine sprocket index dots (arrows) are...
Page 103 The Motor Manual Guy Chapter 2 Part C CAMSHAFT SPROCKET C RAN K S HAFT SPROCKET . . . for the camshaft locating dowel (arrow) 13.13 To verify correct installation. turn the crankshaft sure they are aligned properly during installation clockwise until the timing marks are positioned as shown and count the pins between the marks o'clock position.
Page 104 16 Position new gaskets (see illustration) on the pan with Jeep Spray- removal remove the two attaching bolts and detach .
Page 105 The Motor Manual Guy Chapter 2 Part C 2C-1 I the corners where the gaskets join. Coat the inside curved surface of the replacement rear gasket section (where it contacts the bearing cap) with soap. 17 Slide the oil pan up under the engine and reinstall the oil pump and pickup tube, tighening the oil pump mounting bolts to the specified torque.
Page 106 The Motor Manual Guy Chapter 2 Part General engine overhaul procedures Contents ......Crankshaft inspection. Engine rebuilding alternatives .
Page 107: Chapter 2 Part D General Engine Overhaul Procedures
The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures Crankshaft and connecting rods Connecting rod journal ........Diameter.
Page 108 The Motor Manual Guy Chapter 2 Part D 2D-2 General engine overhaul procedures General Cylinder compression pressure 1 2 0 t o 1 5 0 psi 3 0 psi Maximum variation between cylinders Oil pressure A t idle ( 6 0 0 rpm) 1 3 psi Above 1 6 0 0 r p m 3 7 t o 7 5 psi...
Page 109 The Motor Manual Guy Part D General engine overhaul procedures Chapter 2D-3 . . . Remove the oil pressure sending unit (arrow) and connect a gauge to check oil pressure the sending unit is located near the oil filter on all models sands of miles of reliable service.
Page 110 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-4 Crank the engine over at least seven compression strokes and Engine removal and installation watch the gauge. The compression should build up quickly in a healthy engine. Low compression on the first stroke, followed by gradually in- creasing pressure on successive strokes, indicates worn piston rings.
Page 111 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-5 Remove the attaching screw and unplug the firewall 5.56 the ground strap (arrow) electrical connector 16 Unbolt the exhaust system from the engine (see Chapter 4). 17 If you're working on a vehicle with an automatic transmission, refer to Chapter 7 and remove the torque converter-to-driveplate fasteners.
Page 112 The Motor Manual Guy 2D-6 Chapter 2 Part D General engine overhaul procedures Pull the engine forward as far as possible t o clear then lift the engine high enough to clear the body . . . the transmission, Slowly raise the engine out of the engine compartment (see illustra- tions).
Page 113 The Motor Manual Guy Chapter Part D General engine overhaul procedures 2D-7 7 . 5 Internal engine components exploded view Main bearings Vibration damper pulley 2 Oil filter b y-pass plug 3 Build date code location Washer 4 Ring set Vibration damper 5 Piston Seal...
Page 114 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-8 specialized tools are necessary for the disassembly and inspection pro- Before beginning the disassembly and overhaul procedures, make sure the following items are available. Also, refer to Engine overhaul cedures, and replacement parts may n o t b e readily available, i t may reassembly sequence for a list of tools and materials needed for engine be more practical and economical for the home mechanic t o purchase...
Page 115 The Motor Manual Guy Chapter 2 Part General engine overhaul procedures A dial indicator can be used t o determine the valve 9.14 9.12 Check the cylinder head gasket surface for warpage by trying t o slip a feeler gauge under the straightedge stem-to-guide clearance (move the valve stem as indicated by the arrows) (see the Specifications for the maximum warpage allowed...
Page 116 The Motor Manual Guy Chapter Part D General engine overhaul procedures 2D-10 VALVE MARGIN WIDTH NO MARGIN 9.16 The margin width on each valve must be as 9.17 Measure the free length of each valve spring with a specified (if no margin exists, the valve cannnot be reused) dial or vernier caliper 16 Measure the margin width on each valve (see illustration).
Page 117 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-I 1 Make sure the new valve stem seals are seated 11.3 against the tops of the valve guides Valve seated in tool 3 Seal 4 Valve seal installation tool End of valve stem be sure (if you don't have this tool, a...
Page 118 The Motor Manual Guy Part D 2D-12 Chapter General engine overhaul procedures shown here before installation it will hold them i n place on the valve stem as the spring is released A special adapter and vacuum pump are required t o 11.8 check the O-ring valve stem seals for leaks then slowly release the compressor and make sure the keepers seat...
Page 119 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-13 12.6 To prevent damage t o the crankshaft journals and 12.3 Check the connecting rod side clearance with a cylinder walls, slip sections of hose over the rod bolts feeler gauge as shown before removing the pistons exceeds the service limit, new connecting rods will be required.
Page 120 The Motor Manual Guy Chapter Part D General engine overhaul procedures Use a center punch or number stamping dies t o Mark the caps in order from the front of the engine mark the main bearing caps t o ensure that they're t o the rear (one mark for the front cap, t w o for the second reinstalled in their original locations on the block one and so on)
Page 121 The Motor Manual Guy 'Chapter 2 Part D General engine overhaul procedures On V6 engines. remove the rear 14.8 All bolt holes in the block camshaft cover plate (arrow) particularly the main bearing cap and head bolt holes should be cleaned and restored with a tap (be sure t o 14.10 A large socket on an extension...
Page 122 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-16 To check the clearance, select a feeler gauge and slip it into the Next, measure each cylinder's diameter at the same three locations cylinder along with the matching piston. The piston must be positioned across the crankshaft axis.
Page 123 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-17 in place) with moderate pressure. falls through or slides through easily, the clearance is excessive and a new piston will be required. If the piston binds at the lower end of the cylinder and is loose toward the top, the cylinder is tapered.
Page 124 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-18 . . . or a section of a broken ring The piston ring grooves can be cleaned with a special tool, as shown here, of the ring grooves (see illustrations). knock (detonation).
Page 125 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-19 2.8 LITER V-6 SERVICE PISTONS CODE 89.540-89.553 mm 90.001-90.014 rnm 3.5435-3.5438 90.014-90.027 mm 3.5438-3.5443 90.027-90.040 mm 3.5443-3.5448 0.040 In 90.040-90.053 mm Hi-limit pistons for V6 engines are available to 18.6 Measure the diameter of each crankshaft journal at compensate for slight cylinder bore wear...
Page 126 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-20 related causes. Excessive heat (which thins the oil), overloading (which Bearing failure occurs because of lack of lubrication, the presence squeezes the oil from the bearing face) and oil leakage or throw off of dirt or other foreign particles, overloading the engine and corrosion.
Page 127 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-21 Bearing selection (four and inline six-cylinder engines) 11 Four and inline six-cylinder engines are assembled at the factory Refer to illustrations l9.8a, l9.8b, 1 9 . 8 ~ and l 9 . 8 d with various sizes of color-coded bearing inserts as listed in illustra- If you have a four or inline six-cylinder engine and the oil clearances tions 19.8a through 19.8d.
Page 128 The Motor Manual Guy Crankshaft No. Main Bearing Cylinder Block No. Bore Color Code and Journal Color Code and Diameter Size Yellow Yellow Black 0.025 mm Black Yellow Standard (Standard) Undersize (0.001 in.) 12.6915-2.6920 in.) Yellow Standard Black 0.025 mm Yellow Orange Undersize (0.001 In.)
Page 129 The Motor Manual Guy Chapter 2 Part General engine overhaul procet?res during the end gap measuremen,? and engine assembly. 20 Engine overhaul reassembly sequence Insert the top (number one) ring.into the first Winder and square up with the cylinder walls by (see illustration).
Page 130 The Motor Manual Guy Chapter Part D General engine overhaul procedures 2D-24 DO NOT use a piston ring installation tool when lnstalling the spacerlexpander in the oil control installing the oil ring side rails ring groove Repeat the procedure for each ring that will be installed in the first cylinder and for each ring in the remaining cylinders.
Page 131 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures 2D-25 22.6 Be sure the thrust bearings (arrows) are installed i n the proper location number three (counting from the front of the engine) on all six-cylinder engines and number 22.1 1 Lay the Plastigage strips (arrow) on the main t w o on four-cylinder engines (V6 shown) bearing journals, parallel t o the crankshaft centerline...
Page 132 The Motor Manual Guy Chapter Part D General engine overhaul procedures lips. Also,lubricate the seal lips with moly-base grease or engine 2 7 Retighten all main bearing cap bolts t o the specified torque, start- assembly lube. ing with the center main and working out toward the ends. 2 8 On manual transmission equipped models, install a n e w pilot bear- 1984 V6 engine ing in the end of the crankshaft (see Chapter 8).
Page 133 The Motor Manual Guy Chapter 2 Part D General engine overhaul procedures CRANKSHAFT OIL PAN GASKET SURFACE FRONT Position the piston ring gaps as shown here before 24.5 installing the pistonlconnecting rod assemblies in the engine A Oil ring rail gaps D Oil ring spacer gap (tang in hole or slot with arc) ring gap...
Page 134 The Motor Manual Guy Part D 2D-28 Chapter General engine overhaul procedures 24.1 7 24.13 Lay the Plastigage strips on each rod bearing Measuring the width of the crushed Plastigage t o journal, parallel t o the crankshaft centerline determine the rod bearing oil clearance (be sure t o use the correct scale standard and metric scales are included) permanently bolted in place.
Page 135 The Motor Manual Guy Chapter 3 Cooling. heating and air conditioning systems Contents Cooling system servicing (draining. flushing Air conditioner and heater control assembly removal and installation and refilling) See Chapter 1 Air conditioning system compressor removal Drivebelt check. adjustment and and installation replacement .See Chapter 1...
Page 136 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems and scale in the system. Use distilled water with the antifreeze. 1 General information Before adding antifreeze, check all hose connections, because anti- freeze tends to search out and leak through very minute openings. Engines don't normally consume coolant, so if the level goes down, Engine cooling system find the cause and correct it.
Page 137 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems 3.14 Before installing the gasket, apply a thin, uniform 3.10 After the hose(s) are removed, remove the bolts layer of RTV sealant to both sides of it (arrows) and detach the housing from the engine six-cylinder engine shown;...
Page 138 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems On inline six-cylinder models, use a Torx-bit t o remove the On some models, you must remove the bolt (arrow) hood safety catch, then unbolt the panel above the radiator t o disconnect the air conditioning line bracket attached t o the top of the radiator On all inline six-cylinder models, remove the mounting bolts for the...
Page 139: Fluid Leakage
The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems 5.13 Disconnect the fan electrical connector and run The fan clutch is mounted with four nuts; two are jumper wires directly to the positive and negative terminals visible in this photo (arrows) of the battery be sure the clips don't touch each other and create a short circuit...
Page 140 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems for the indicator system. Warning: If the vehicle is equipped with an Coolant reservoir removal and installation electric cooling fan, stay clear of the fan blades. The fan can come on at any time.
Page 141 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems With the engine running at normal operating temperature, squeeze the upper radiator hose. If the water pump is working properly, a pressure surge should be felt as the hose is released. Warning: Keep your hands away from the fan blades! Water pumps are equipped with weep or vent holes.
Page 142 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems couple of bolts through the pump mounting holes to hold the gasket 10 Heater and air conditioner blower in place. motor removal and installation 1 4 Carefully attach the pump and gasket to the engine and thread the bolts into the holes finger tight.
Page 143 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems Cut the retaining strap that holds the blower/evaporator housing down and toward the rear of the vehicle to disengage the housing studs to the heater core housing (see illustration). from the dash panel.
Page 144 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems 3-10 don't miss this alignment tab 1 1.17a Use the alignment tabs to position the housing and a "fin c o m b or compressed air to clean the condenser. 17 Reinstall the remaining parts in the reverse order of removal.
Page 145 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems 3-1 1 1 3 Air conditioning system receiver-drier removal and installation Refer to illustration 13.3 Warning: The air conditioning system is under high pressure. DO NOT disassemble any part of the system (hose, compressor, line fittings, etc.) until after the system has been depressurized b y a dealer service department or service station.
Page 146 The Motor Manual Guy Chapter Cooling, heating and air conditioning systems 3-12 On four-cylinder and V6 models, remove the screws connections are located next to the battery (arrows) and pull off the cover to reach the mounting bolts Remove the mounting bolts from the condenser brackets (see il- lustration).
Page 147 The Motor Manual Guy Chapter 3 Cooling, heating and air conditioning systems 3-13 16.8 Detach the ring on the end of the control cable 16.7 Release the control cable locking tab with a screwdriver Detach the instrument panel bezel (see Chapter 11 illustration).
Page 148: Vibration
The Motor Manual Guy Chapter 4 Fuel and exhaust systems Contents Air cleaner removal and installation. Fuel pumplfuel pressure check Air and PCV filter replacement See Chapter 1 Fuel pump removal and installation Carburetor adjustments Fuel system check. See Chapter 1 Carburetor choke check See Chapter 1 Fuel tank cleaning and repair...
Page 149 The Motor Manual Guy Chapter 4 Fuel and exhaust systems . . . then depress the valve in the test port with a small To relieve the fuel pressure on an MPI-equipped screwdriver or pin punch wear safety goggles during pressure vehicle, remove the cap from the pressure test port, place relief t o protect your eyes from spraying fuel some shop towels underneath to absorb sprayed fuel...
Page 150 If the pump volume is less than one pint, repeat the test with 29 Install a pressure test fitting (available at a Jeep parts department) an auxiliary fuel supply and, for four-cylinder engines, a replace- in place of the test port plug.
Page 151 The Motor Manual Guy Chapter 4 Fuel and exhaust systems 3.36 Detach the vacuum tube from the fuel pressure regulator, start the vehicle and note the gauge reading with the vacuum line detached, fuel pressure should be about 3.35 To test the MPI fuel system pressure, you will need to attach a 0-to-60 psi pressure gauge to the test port pressure fitting on the fuel rail vacuum line attached to the regulator than with the vacuum line discon-...
Page 152 The Motor Manual Guy Chapter 4 Fuel and exhaust systems on four-cylinder models the pressure is not within specifications, one of the following problems exists: Installation details of the mechanical fuel pump used a) There is a kink or other restriction in a fuel supply or return line on V6 models hose.
Page 153 The Motor Manual Guy Chapter 4 Fuel and exhaust systems HOSE BRACKET NUT PUMP FUEL PUMP The TBI fuel pumplsending unit assembly loose. A spark could cause an explosion! not work in a garage if a natural gas-type appliance with a pilot !igh? 16 Extract the fuel pumpisending unit assembly from the fuel tank.
Page 154 The Motor Manual Guy (Cherokee) Retaining strap nuts 2 Fuel feed line 3 Fuel return line 4 Fuel filler hose 5 Filler vent hose 6 Fuel gauge sending unit electrical connector 7 Protective shield 8 Fuel tank 9 Vapor vent hose 10 Fuel pump (TBl and MPI models) components...
Page 155 The Motor Manual Guy Fuel a 1 nd exhaust systems Chapter dangerous work. Even after cleaning and flushing of the fuel system, Siphon the fuel from the tank at the fuel feed line, not the return line. Support the fuel tank with a floor jack or jackstands. Position a explosive fumes can remain and ignite during repair of the tank.
Page 156 The Motor Manual Guy Chapter 4 Fuel and exhaust systems some adjustments are listed on the Vehicle Emissions Control lnfor- whichever comes first see your dealer for details). We don't recommend carburetor adjustments while it's still under warranty. If you are having problems related t o fuel delivery Carburetor problems usually show up as flooding, hard starting, stalling, severe backfiring and poor acceleration.
Page 157 The Motor Manual Guy Chapter 4 Fuel and exhaust systems inexperienced mechanics can result in an engine which runs poorly or regulations, it isn't feasible to include a step-by-step overhaul of each not at all. To avoid this, use care and patience when disassembling type.
Page 158 The Motor Manual Guy carburetor used on 49-State V6 engines Air horn components Air horn long screw Air horn large screw Air horn short screw Air horn medium screw Vent stack assembly Hot idle compensator screw Hot idle compensator Hot idle compensator screw Air horn assembly Air horn gasket Pump retainer...
Page 159 The Motor Manual Guy California V6 engines Air horn components 2 Solenoid attaching screw assembly 3 M/C solenoid-to-air horn gasket 4 M/C solenoid spacer 5 M/C solenoid-to-float bowl seal 6 M/C solenoid seal retainer 7 Air horn assembly 8 Air horn-to-float bowl gasket 9 Air horn-to-float bowl short screw 10 Air horn-to-float bowl...
Page 160 The Motor Manual Guy Chapter 4 Fuel and exhaust systems 4-12 11 Fuel injection system general information QUICK-CONNECT FITTINGS Fuel-injected vehicles are equipped with either a Throttle Body In- jection (TBI) system (four-cylinder engine) or a Multi-Point lnjection tronic Control Unit (ECU) to control pulse width. The pulse width is the period of time during which the injector is energized (squirts fuel).
Page 161 The Motor Manual Guy Chapter 4 Fuel and exhaust systems 4-13 REPLACEMENT KI FITTING SPACER QUICK-CONNECT DISPOSABLE PLUG FITTING O-RINGS RETAINER 12.13 The new O-rings, spacer and retainer are already installed on a disposable plug t o install them in the 12.10 Cutaway of quick-connect fitting showing quick-connect fitting, insert the plug into the fitting until...
Page 162 The Motor Manual Guy Chapter 4 Fuel and exhaust systems NUTS (4) 13.8 ldentify and tag the vacuum tubes at the back of the throttle body, then detach them accelerator cable and return spring 1 4 Throttle body injection (TBI) Disconnect the ISA motor harness connector (see illustration system component replacement...
Page 163 The Motor Manual Guy Chapter 4 Fuel and exhaust systems 4-1 5 lock tabs and lifting up. RETAINER Remove the screws and lift off the retainer (see illustration). 1 0 Using a small pair of pliers, gently grasp the center collar of the injector and carefully remove the injector by rocking it back and forth while lifting up (see illustration).
Page 164 The Motor Manual Guy Chapter 4 Fuel and exhaust systems 4-16 15.4 ldle speed stepper motor connector (left) connector (right) 14.33 Disconnect the ISA motor harness connector; t o 3 8 After you have replaced the ISA motor, have adjusted by a dealer remove the motor, unscrew the three mounting nuts service department.
Page 165 The Motor Manual Guy Chapter 4 Fuel and exhaust systems 4-1 7 TRANSMISSION 15.15 To remove the TPS, remove the retaining screws (arrows), then pull the TPS from the throttle plate assembly 15.7 If the vehicle is equipped with an automatic transmission, the screws are secured by lock tabs (as shown here), bend the detach the line pressure cable at the throttle arm tabs back...
Page 166 The Motor Manual Guy Chapter 4 Fuel and exhaust systems 4-18 Remove the nut from the fuel return line bracket . . . and slide the bracket off its mounting stud, . . . then detach the fuel return line from the fuel 15.24 Remove the fuel rail mounting bolts (arrows) pressure regulator...
Page 167 The Motor Manual Guy Chapter 4 Fuel and exhaust systems 4-19 15.33 Be sure to remove the old O-ring and seal from the injector (a replacement kit, available at a dealer, includes six screws (arrows) O-rings and seven seals enough O-rings and seals for all six injectors and an extra seal for the fuel pressure regulator) regulator (see illustrations).
Page 168 The Motor Manual Guy Chapter 4 Fuel and exhaust systems 4-20 Exploded views of t w o typical exhaust systems (four-cylinder models above. V 6 models below) 1 Upstream air injection tube (if equipped) 2 Downstream air injection tube (if equipped) 3 Upper heat shield 4 Tail pipe 5 Muffler...
Page 169 The Motor Manual Guy Chapter 5 Engine electrical systems Contents ..........lgnition pick-up coil engines only) check Alternator brushes replacement ..........and replacement Alternator removal and installation ........Ignition system check Battery cables check and replacement ..........Ignition system general information Battery check and maintenance See Chapter ..........
Page 170 The Motor Manual Guy Chapter 5 Engine electrical systems Lift out the battery. Be careful it's heavy. from a TDC sensor mounted on the flywheelidriveplate housing. The While the battery is out, inspect the carrier (tray) for corrosion (see flywheel has t w o teeth machined off every 180" to define a precise point 90°...
Page 171: Electrical Systems
The Motor Manual Guy Chapter 5 electrical systems Engine The ignition coil on four and inline six-cylinder models is located on the right side of the engine compartment when terminals to check the coil, select the high resistance scale on removing the coil, unscrew the mounting bracket bolts (arrows) the ohmmeter, touch the positive lead to the coil positive terminal and the negative lead to ground (the coil frame)
Page 172 The Motor Manual Guy Chapter 5 Engine electrical systems If the distributor is not installed in the engine, support the shaft while installing the trigger wheel pin. 1 4 lnstall the rotor and the distributor cap. 15 Attach the cable to the negative battery terminal. Vacuum advance mechanism check and replacement (1984 and 1 9 8 5 four-cylinder models only)
Page 173 The Motor Manual Guy Chapter 5 Engine electrical systems 12.3 Before removing the pick-up coil, unplug the lead from the ignition module 12.4 Ohmmeter connections for checking the pick-up coil on a typical V6 Replacement Detach the cable from the negative battery terminal. Ignition pick-up coil (V6 engines only) check and Remove the distributor cap and rotor (see Chapter 1).
Page 174 The Motor Manual Guy Chapter 5 Engine electrical systems 12.1 1 b Remove the driven gear and spacer washers from the end a drift punch and hammer, knock out the roll pin of the shaft, making sure to note the order in which you remove any spacers remove the retaining clip 10 Mark the distributor gear and shaft so they can be reassembled in...
Page 175 The Motor Manual Guy Chapter 5 Engine electrical systems FRONT FACE OF ENGINE BLOCK OIL PUMP GEAR SLOT screwdriver to rotate the oil pump gear so the slot is slightly past . . . the three o'clock position, 13.6 Before loosening the distributor hold-down bolt, make a mark on the edge of the distributor base directly below, and in line with, the rotor tip (I), then mark the distributor base and the FRONT FACE OF...
Page 176 The Motor Manual Guy Chapter 5 Engine electrical systems FRONT ENGINE O' C LOCK P U M P GEAR SHAFT a screwdriver to turn the oil pump gear shaft until the slot is slightly past the 11 o'clock position, FRONT B O L T H O L E CLAMP visually line up the hold-down ear of the distributor...
Page 177: Noise
The Motor Manual Guy Chapter 5 Engine electrical systems STATOR-HARNESS GROMMET STATOR RETAINING SCREW 14.6 After marking the position of the stator assembly with paint or a scribe, remove the retaining screw, push the grommet 16.5 To test the alternator, locate the test hole in the back, through the distributor housing and remove the stator ground the tab that's located inside the hole by inserting a screwdriver blade into the hole and touching the tab and the case...
Page 178 The Motor Manual Guy Chapter 5 Engine electrical systems . . . 17.2 To remove the alternator, detach the electrical connectors loosen the alternator adjustment bolt (arrow). (arrows) from below, and remove the alternator pivot bolt (arrow) from below 18.2 Mark the drive end frame and rectifier end frame assemblies with a scribe or paint before separating the two halves tab grounded any longer than necessary to obtain a voltmeter reading.
Page 179 The Motor Manual Guy Engine Chapter 5 electrical systems drive end frame and the rectifier end frame Brush holder Resistor (not all models) Paper clip retaining Diode trio brushes (for reassembly) Rectifier bridge Regulator 18.4 After removing the nuts holding the stator assembly to the end frame, remove the stator 18.5 Remove the nuts attaching the diode trio to the rectifier bridge and remove the trio...
Page 180 The Motor Manual Guy Chapter 5 Engine electrical systems 5-12 21.3 Before unbolting the starter motor assembly, detach the 18.10 To hold the brushes in place during reassembly, insert wires (arrows) from the solenoid (or from the starter motor itself a paper clip through the hole in the end frame nearest to the on some models) be sure the battery is disconnected!
Page 181 The Motor Manual Guy 5-13 Chapter 5 Engine electrical systems shown) view is from the front, looking to the rear shown) view is from the rear, looking forward 22.4 To detach the solenoid from the starter motor, remove the 22.3 Before removing the solenoid from the starter motor, detach solenoid attaching screws (arrows) from the front of the starter's the starter motor terminal strap (arrow) Mitsubishi starter shown...
Page 182 The Motor Manual Guy Chapter 5 Engine electrical systems 5-14 Motorcraft solenoid Refer to illustration 22.7 Locate the solenoid it's mounted in the engine compartment near the battery (see illustration). Detach the electrical wires from the starter solenoid terminals. Label them to assure proper reassembly. Remove the solenoid mounting bracket bolts and detach the solenoid.
Page 183 The Motor Manual Guy Chapter 6 Emissions and engine control systems Contents Air filter and PCV filter replacement See Chapter I Oxygen sensor and emissions maintenance ..........................timer replacement See Chapter 1 Air injection systems ................. Positive Crankcase Ventilation (PCV) valve or Crankcase Ventilation Catalytic converter ...
Page 184 The Motor Manual Guy Chapter 6 Emissions and engine control systems with common tune-up and hand tools. Note: Because of a Federally mandated extended warranty which covers the emission control system components land any components which have a primary purpose other than emissions control but have significant effects on emissions), check with your dealer about warranty coverage before working on any emissions-related systems.
Page 185 The Motor Manual Guy VAC R S V R V A C U U M SWITCH ASSEMRLV four-cylinder m&!els with manual transmission (1 DISTRIBUTOR...
Page 186 The Motor Manual Guy TAC SENSOR TO FUEL TANK EGR CANISTER 031 RESTRICTOR O M RESTRICTOR for TBI-equipped four-cylinder PCV'CANISTER PURGE models (1 986) PURGE SIGNAL AIR CLEANER for TBI-equipped four-cylinder models...
Page 187 The Motor Manual Guy PURGE...
Page 188 The Motor Manual Guy CANISTER SPARK CHECK VACUUM HOSES VACUUM HOSES M A P SENSOR 6 M M - BI-METAL BI-METAL TEMP TEMP SENSOR FRONT VEHICLE EGR SOLENOID EGR SOLENOID...
Page 189 The Motor Manual Guy Chapter 6 Emissions and engine control systems is operating, fresh air enters the engine and mixes with the crankcase Positive Crankcase Ventilation (PCV) system vapors. Manifold vacuum draws the vaporlair mixture through the metered orifice and into the intake manifold. The vapors are consum- ed during combustion.
Page 190 The Motor Manual Guy Chapter 6 Emissions and engine control systems airstream flowing through the venturi. These vapors pass through the Checking intake manifold into the combustion chambers, where they are con- sumed during combustion. Periodically, inspect the evaporative system vacuum hoses t o be The fuel filler cap incorporates a t w o -w a y relief valve that is closed sure they are attached and in good condition.
Page 191 The Motor Manual Guy...
Page 192 The Motor Manual Guy 6-10 Chapter 6 Emissions and engine control systems 1 0 Have an assistant rapidly depress and release the accelerator 112 Thermostatic Air Cleaner (TAC) (carburetor to 314 of its travel. The heat duct valve should briefly remain stationary, and TBI-equipped vehicles move toward the heat off position, then back to the heat on position.
Page 193 The Motor Manual Guy Chapter 6 Emissions and engine control systems 6-1 1 the air injection check valve. The valve is opened and closed by the air switch solenoid. vacuum to the air control valve on and off during varying opera- ting conditions.
Page 194 The Motor Manual Guy 6-12 Chapter 6 Emissions and engine control systems and, with the engine operating at about 1500 rpm, squeeze the Drivebelt (air pump system only) hose. You should be able to feel the air pulsing through the hose. 1 0 Drivebelt replacement procedures are in Chapter 1.
Page 195 The Motor Manual Guy Chapter 6 Emissions and engine control systems 6-13 27 Installation is the reverse of removal. Be sure to coat the threads 3 0 Remove the attaching bolts and nut (see illustration) and remove of the air injection manifold fittings with Fel-Pro C 100 anti-seize com- the pump.
Page 196 The Motor Manual Guy 6-14 Chapter 6 Emissions and engine control systems carefully check all hoses connected to the valve for cracks, leaks and Exhaust Gas Recirculation (EGR) system kinks. Replace or repair the valve and hoses as necessary. With the engine idling at normal operating temperature, detach the vacuum hose from the EGR valve and connect a vacuum pump.
Page 197 The Motor Manual Guy Chapter 6 Emissions and engine control systems 6-15 6.1 1 b Refer t o this schematic when testing the EGR system on an inline six-cylinder model I Solenoid vacuum source 6.1 l a Refer t o this schematic when testing the EGR 2 Vacuum connector system on a four-cylinder model 3 Solenoid output port...
Page 198 The Motor Manual Guy 6-16 Chapter 6 Emissions and engine control systems and then sends a command to the carburetor Mixture Control (M/C) 25 Remove the EGR tube. solenoid, telling it to change the fuel/air mixture. To be effective, all 26 Install the EGR tube, but don't tighten the line nuts at this time.
Page 199 The Motor Manual Guy Chapter 6 Emissions and engine control systems 6-1 7 Furthermore, when diagnosing an engine performance, fuel econ- Command Control System. Also included are simplified troubleshoot- omy or exhaust emissions problem (which is not accompanied by a ing procedures.
Page 200 The Motor Manual Guy 6-18 Chapter 6 Emissions and engine control systems 9.6 Typical MAP sensor installation details 9.3 Wrap the threads of the coolant temperature sensor with Teflon tape to prevent leaks Vacuum line MAP sensor Electrical connector Mounting screw Information sensors (V6 models) corresponding terminals in the electrical connector.
Page 201 The Motor Manual Guy Chapter 6 Emissions and engine control systems 6-19 Replacement 16 Refer to Chapter 1 for the oxygen sensor replacement procedure. Throttle Position Sensor (TPS) T.P.S. ASSEMBLY General description 17 The Throttle Position Sensor (TPS) is located on the carburetor float bowl.
Page 202 The Motor Manual Guy 6-20 Chapter 6 Emissions and engine control systems Trouble code chart 1991 and later models Code Circuit or system Probable cause Oxygen sensor or circuit Check oxygen sensor and circuit. Replace sensor.* Coolant temperature sensor or circuit Check coolant temperature sensor circuit.
Page 203 The Motor Manual Guy Chapter 6 Emissions and engine control systems 6-21 11.13 The Coolant Temperature Sensor (CTS) is normally mounted in the thermostat housing valve cover (see illustration 9.8). It is connected electrically to the 11.4 The knock sensor (arrow) is located on the engine block (on six-cylinder models shown) or on the intake manifold computer and by a vacuum hose to the throttle body.
Page 204 The Motor Manual Guy 6-22 Chapter 6 Emissions and engine control systems SEAL RETAINER 11.42 The Crankshaft Position Sensor (CPS) is mounted in the transmission bellhousing ADAPTER Distance (speed) sensor installation details ied input voltage to the computer. The computer uses this information to alter the fuel/air mixture.
Page 205 The Motor Manual Guy 7 Part A Manual transmission Chapter Contents ....... General information Manual transmission overhaul general information...
Page 206 The Motor Manual Guy Chapter 7 Part A 7A-2 Manual transmission 2.1 1 Before loosening the retaining bolt, mark the Use a small screwdriver t o remove the O-ring from . . . relationship between the speedometer adapter housing and the groove, the transmission or transfer case with white paint adapter is offset and must be installed in the same...
Page 207 The Motor Manual Guy 7A-3 Chapter 7 Part A Manual transmission 5 Manual transmission removal and installation Note: On 4 WD models, the transmission and transfer case are removed as a unit. Removal Disconnect the negative cable from the battery. DUST Working inside the vehicle, remove the shift lever (see Section 3).
Page 208 The Motor Manual Guy Chapter 7 Part A Manual transmission 7A-4 repair shop. Rebuilt transmissions may be available check with your 6 Manual transmission overhaul general information dealer parts department and auto parts stores. A t any rate, the time and money involved in an overhaul is almost sure to exceed the cost of a rebuilt unit.
Page 209 The Motor Manual Guy 7A-5 Chapter 7 Part A Manual transmission Before taking the transmission apart for repair, it will help if you have During disassembly of the transmission, make careful notes of how some idea what area of the transmission is malfunctioning. Certain each piece comes off, where it fits in relation to other pieces and what problems can be closely tied to specific areas in the transmission, which holds it in place.
Page 210 The Motor Manual Guy mission exploded view 2 Shift lever retainer 3 Restrict pins 4 Front bearing retainer 5 Clutch housing Snap-ring 7 Back-up light switch 8 Intermediate plate 9 Adapter housing 10 Adapter sere w plug 12 Reverse idler gear 13 lnput shaft 14 Counter gear 15 Straight sere w plug...
Page 211 The Motor Manual Guy AX 415 manual transmission output shaft exploded view 1 Rear bearing 8 2nd gear 9 2nd gear needle roller bearing 2 Inner race 3 1st gear needle roller bearing 10 Output shaft I 1 3rd gear 5 1st gear synchronizer ring 12 3rd gear synchronizer ring 13 Hub sleeve no.
Page 212 The Motor Manual Guy BA 10115 manual trans- mission exploded view 2 5th gear roller bearing 3 5th gear 4 5th gear snap-ring 5 Reverse gear nut 6 Washer (not used in 2 7 Pilot bearing shims all models) 28 Pilot bearing 4 8 Thrust washer 67 Roll pin 7 Reverse gear...
Page 213 The Motor Manual Guy Chapter 7 Part B Automatic transmission Contents Automatic transmission removal and installation Neutral start switch check, adjustment Bands adjustment (three-speed transmission) and replacement Diagnosis general. Oil seal replacement See Chapter 7A Fluid and filter change See Chapter 1 Shift linkage check and adjustment.
Page 214 The Motor Manual Guy Chapter 7 Part B Automatic transmission 7B-2 tools and expertise. Such problems must be referred to a transmission maintenance, adjustment and removal and installation procedures. repair shop or a dealer service department. If the transmission requires major repair work, it should be left to a dealer service department or an automotive or transmission repair Gasket leaks shop.
Page 215 The Motor Manual Guy CLAMP TRANSM SHIFT 3.3 Three-speed transmission shift linkage LEVER I Jam nut 3 Shift rod 4 Bellcrank 2 Trunnion 3.4 Four-speed transmission shift linkage but the starter operates in positions other than Park or Neutral, check the neutral start switch (see Section 6).
Page 216 The Motor Manual Guy Chapter 7 Part B Automatic transmission 7B-4 VALVE STOP CLAMP RETAINER BOLT BOLT SPRING V6 engine TV rod adjustment link details 4.12 Secure the TV lever in the forward position using a spare return spring (V6 models) V6 engine to the rear so the bolt bottoms in the rear of the rod slot.
Page 217 The Motor Manual Guy Chapter 7 Part B Automatic transmission 78-5 ADJUSTING ADAPTER EXTENSION SCREW IN-LB TORQUE ,WRENCH The rear band adjusting screw is accessible after removing the transmission pan unit. The switch has three terminals with the neutral switch being the center one.
Page 218 The Motor Manual Guy Chapter 7 Part B Automatic transmission 7B-6 SWITCH TERMINAL IDENTIFICATION The terminals for the four-speed transmission neutral start switch connector are shown above the chart shows when 6.10 Four-speed neutral start switch mounting details continuity should exist between the terminals: when i n Park or Neutral, continuity should exist between B and when in Reverse, between A and E;...
Page 219 The Motor Manual Guy Chapter 7 Part B Automatic transmission 7B-7 2 0 Lower the transmission slightly and disconnect and plug the trans- the specified torque. mission fluid cooler lines. 28 lnstall the torque converter-to-driveplate bolts. Tighten the bolts 21 Remove the transmission dipstick tube. to the specified torque.
Page 220 The Motor Manual Guy ter 7 Part C Transfer case Contents Transfer case overhaul general information General information See Chapter 7 A Transfer case removal and installation Oil seal replacement ......Shift linkage adjustment Transmission mount check...
Page 221 The Motor Manual Guy Chapter 7 Part C Transfer case Support the transmission with a jack or jackstand. The transmission 1 General information should remain supported at all times while the transfer case is out of the vehicle. Support the transfer case with a jack preferably a special jack The transfer case is a device which passes the power from the engine made for this purpose.
Page 222 The Motor Manual Guy Chapter 7 Part C Transfer case Transfer case overhaul general information Numerous clearances must be precisely measured and, if necessary, changed with select fit spacers and snap-rings. As a result, if transfer Refer to illustrations 4.4a, 4.4b, 4.4c, 4.4d and 4.4e case problems arise, it can be removed and installed by a competent do-it-yourselfer, but overhaul should be left to a transmission repair Overhauling a transfer case is a difficult job for the do-it-yourselfer.
Page 223 The Motor Manual Guy Typical Command-Trac transfer case (New Process 231 exploded view Front yoke nut, seal washer, yoke and oil seal Output shaft rear bearing Shift detent plug, spring Mainshaft and pin Oil seal Front retainer and seal Oil pump assembly Front case Rear bearing Vacuum switch and seal...
Page 224 The Motor Manual Guy exploded view 2 Side gear 3 Differential 35 Front output shaft bearing 67 Thrust washer 4 Pilot bearing rollers assembly race (thin) 5 O-ring seal 36 Retaining ring 68 Retaining ring 37 Chain 69 Thrust bearing 6 Rear output shaft 38 Driven sprocket 70 High range sliding...
Page 225 The Motor Manual Guy exploded view Spacer Side gear Bearing Annulus bushing Viscous coupling Bearing race (thhin) Thrust washer 7 Retaining ring Pilot bearing rollers Retaining ring Drive chain Thrust bearing O-ring Rear output shaft Driven sprocket Range sleeve 7 Oil pump Front output shaft Mode sleeve Front output shaft...
Page 226 The Motor Manual Guy Typical Selec-Trac transfer case (New Process 242) exploded view Mainshaft bearing rollers Front bearing retainer Drive sprocket Rear bearing retainer and seal Drive chain Front case Extension housing Snap-ring Bushing and oil seal Shift sector Oil pump seal Low range fork and inserts Vacuum switch Oil pump...
Page 227 The Motor Manual Guy Chapter 7 Part C Transfer case each piece comes off, where it fits in relation to other pieces and what parts department and auto parts stores. At any rate, the time and money involved in an overhaul is almost sure to exceed the cost of a rebuilt holds it in place.
Page 228 The Motor Manual Guy Clutch and drivetrain Contents . . . Clutch components removal. inspection and installation removal and installation Clutch description and check Flywheel removal and installation See Chapter 2 Clutch fluid level check See Chapter 1 Front axle assembly removal and installation Clutch hydraulic system bleeding...
Page 229 The Motor Manual Guy Chapter 8 Clutch and drivetrain 8- 1 General information Clutch description and check Refer to illustrations 2. l a and 2.16 The information in this Chapter deals w i t h the components from the rear of the engine t o the drive wheels, except for the transmission and transfer case, which are dealt with in the previous Chapter.
Page 230 The Motor Manual Guy Chapter 8 Clutch and drivetrain marks. The marks are usually an X, an 0 or a white letter. If they cannot release cylinder) and the clutch release (or throwout) bearing. Later models use a hydraulic release bearing, which is a combination release be found, scribe marks yourself so the pressure plate and the flywheel bearinglslave cylinder assembly mounted inside the clutch housing.
Page 231 The Motor Manual Guy Chapter 8 Clutch and drivetrain lnspect the pilot bearing (see Section 18 Install the clutch release bearing as described in Section 4. 1 0 lnspect the lining on the clutch disc. There should be at least 111 6- 19 Install the transmission, release cylinder (externally mounted type only) and all components removed previously.
Page 232 The Motor Manual Guy Chapter 8 Clutch and drivetrain Removal Following the appropriate procedure outlined in Chapter 7, remove the transmission. Externally m o u n t e d release cylinder Unbolt the release cylinder from the clutch housing and pull it out of its recess.
Page 233 The Motor Manual Guy Chapter 8 Clutch and drivetrain BEARING SEAL MUST FACE The pilot bearing incorporates an O-ring seal which cannot be replaced separately. If there is any indication that the seal is leaking, or if the bearing is dry, replace The bearing must be installed with the seal towards the transmission.
Page 234 The Motor Manual Guy Chapter 8 Clutch and drivetrain VALVE STEM 6.11 Pull the plunger assembly from the bore Pry the retainer tab out with a small screwdriver t o release the valve stem 11 Pull the plunger assembly from the bore (see illustration). If it's hard to pull out, remove the cylinder from the vise, turn it so the flanged 19 lnstall the new valve stem tip seal and spring washer onto the valve end is down and tap it sharply against a block of wood.
Page 235 The Motor Manual Guy Chapter Clutch and drivetrain Installation 26 Position the cylinder against the firewall and install the lower mounting nut, but don't tighten it fully yet. 27 Connect the hydraulic line t o the cylinder, tightening the fitting by hand only.
Page 236 The Motor Manual Guy Chapter 8 Clutch and drivetrain equipped with grease fittings and require periodic lubrication (see Chap- ter 1). 9 Clutch pedal removal and installation The rear driveshaft on Command-Trac vehicles is a one piece shaft with welded yokes at each end. Vehicles with the Selec-Trac system Removal employ a shaft with a welded yoke at the rear and a slip yoke at the Disconnect the cable from the negative battery terminal.
Page 237 The Motor Manual Guy Chapter 8 Clutch and drivetrain same position to preserve the balance. On vehicles with Selec-Trac 1 1 Driveline inspection (welded yokes at both ends of the driveshaft), also mark the rela- tionship of the front driveshaft yoke to the transfer case yoke. Remove the rear universal joint bolts and straps (see illustration Raise the rear of the vehicle and support it securely on jackstands.
Page 238 Double offset constant velocity joint (upper joint on some front driveshafts) 13 As of the time of writing, no information was available on this type of joint. Consult your local Jeep dealer service department. pinion shaft yoke...
Page 239 The Motor Manual Guy Chapter Clutch and drivetrain 8-1 1 shaft spines and, using a soft-faced hammer, tap the pinion shaft yoke onto the shaft, making sure the match-marks line up. 11 Coat the threads of a new pinion shaft nut with multi-purpose grease and, using the holder to hold the flange, tighten the nut just enough t o eliminate all end-play in the pinion shaft.
Page 240 The Motor Manual Guy Chapter 8 Clutch and drivetrain 8-12 Service Due t o the special tools and expertise required to separate and reassemble the hub and bearings, this job should be left t o a dealer service department or repair shop. lnstalla tion Using sandpaper or emery cloth, clean the opening in the steering knuckle to remove any rust or dirt that may be present.
Page 241 The Motor Manual Guy Chapter 8 Clutch and drivetrain 16.1 l a Exploded view of the double offset (CV) joint 1 Clamps 4 Retaining ring 5 Boot 2 Joint assembly 6 Axleshaft 3 Spacer ring Note: The constant velocity outer front axle joint is n o t repairable becomes worn, noisy or breaks, the entire joint must be replaced.
Page 242 The Motor Manual Guy Chapter 8 Clutch and drivetrain 8-14 16.14 Align the inner race lands with the cage windows and rotate the inner grooves for pitting and score marks pitting and score marks (shiny spots are race out of the cage normal and don't affect operation) 14 Align the inner race lands with the cage windows and rotate the inner 21 Install the replacement retaining ring and spacer ring on the shaft.
Page 243 The Motor Manual Guy Chapter 8 Clutch and drivetrain 8-1 5 Apply vacuum to the motor and rotate the right front wheel t o en- sure that the axle is fully disengaged. The shift motor should hold vacuum for at least 3 0 seconds. If it leaks, replace it. If the motor holds vacuum, connect the vacuum pump t o the rear port on the shift motor.
Page 244 The Motor Manual Guy Chapter 8 8-1 6 Clutch and drivetrain the axle into position, make sure the coil springs seat properly. Be sure t o use new U-joint straps. For fasteners with specified torque values, be sure they are tightened to the specified torque. 1 9 Rear axleshaft and bearing assembly removal and installation...
Page 245 The Motor Manual Guy Chapter 8 Clutch and drivetrain ter 9). Disconnect the height sensing proportioning valve control rod 20 Rear axle assembly removal and installation from the axle housing (Comanche models only). Disconnect the flexible brake hose from the junction block on the rear axle housing.
Page 246 The Motor Manual Guy Chapter Brakes Contents Disc brake pads replacement Anti-lock brake system (ABS) general information inspection, removal and installation Drum brake shoes replacement Brake disc Brake fluid level check See Chapter 1 Front wheel bearing service See Chapter General information Brake hoses and lines inspection and replacement...
Page 247 The Motor Manual Guy 9 Brakes Chapter 9- 1 Power brake booster (non-ABS models) General information The power brake booster, utilizing engine manifold vacuum and at- mospheric pressure to provide assistance to the hydraulically operated Refer to illustration 7.2 brakes, is mounted on the firewall in the engine compartment. The vehicles covered by this manual are equipped with hydraulically Parking brake operated front and rear brake systems.
Page 248 The Motor Manual Guy Chapter 9 Brakes booster unit, an electric booster pump and motor assembly (which con- from the internal mercury switch to control the hydraulic line pressure, tains an accumulator), a pressure modulator and an accumulator and avoiding wheel lock-up. The controller also constantly monitors the pressure switch assembly (see illustration).
Page 249 The Motor Manual Guy Chapter Brakes Front wheel sensor details Rear wheel sensor details Remove the front wheels. Workon one brake assembly at a time, 3 Disc brake pads replacement using the assembled brake for reference if necessary. Inspect the brake disc carefully as outlined in Section 5. If machin- Refer to illustrations 3.5 and 3.6a through 3.6k ing is necessary, follow the information in that Section to remove the disc, at which time the pads can be removed from the calipers as well.
Page 250 The Motor Manual Guy Chapter Brakes Once the caliper is removed from Pry downward on the lower anti-rattle clip and remove the caliper out of the anchor plate, then the anchor plate, hang i t from the coil outer brake pad remove the caliper completely.
Page 251 The Motor Manual Guy Chapter Brakes securely on jackstands. Remove the front wheels. 4 Disc brake caliper removal, overhaul and installation 3.5). Bottom the piston in the caliper bore (see illustration Note: Do not remove the brake hose from the caliper if you are only removing the caliper.
Page 252 The Motor Manual Guy Chapter 9 Brakes Grab the ends of the mounting pin bushings with The piston seal should be removed with a plastic or 4.10 needle-nose pliers and, using a twisting motion. push wooden tool to avoid damage to the bore and seal groove. A pencil will do the job them through the caliper ears 17 Install the bleeder screw.
Page 253 The Motor Manual Guy Chapter 9 Brakes Use a dial indicator to check disc runout if the reading exceeds the specified allowable runout limit, the disc surface with sandpaper or emery cloth disc will have to be machined or replaced To check disc runout, place a dial indicator at a point about 112-inch Brake disc inspection, removal and installation...
Page 254 The Motor Manual Guy Chapter 9 Brakes the parking brake is completely released, then apply some penetrating oil at the hub-to-drum joint. Allow the oil to soak in and try to pull the models, install the disc and hub assembly and adjust the drum off.
Page 255 The Motor Manual Guy Chapter 9 Brakes Pull back on the self-adjuster Remove the self-adjuster cable cable and push the adjusting lever secondary shoe retracting springs and anchor pin plate from the anchor pin toward the rear, unhooking i t from spring removal tool shown here can be the secondary brake shoe purchased at most auto parts stores...
Page 256 The Motor Manual Guy 9 Brakes Chapter 9-10 Install the secondary shoe and Attach the new shoe t o the Lubricate the brake shoe contact hold down spring t o the backing plate, areas (arrows) with high parking brake lever, install the spring then position the end of the parking washer and retaining clip on the pivot temperature grease...
Page 257 The Motor Manual Guy Chapter 9 Brakes 9-1 1 into the hole at the bottom of the and cable into the adjuster lever and pull the shoes are centered on the primary shoe the cable down and t o the rear, inserting backing plate the hook on the lever into the hole in the secondary shoe...
Page 258 The Motor Manual Guy Chapter 9 Brakes 9-12 Completely loosen the brake line fitting (11, then remove the t w o wheel cylinder mounting bolts (2) Exploded view of the wheel cylinder (one is barely visible in this photo) 1 Piston and boot 4 Expander assembly Wheel cylinder body 5 Bleeder screw...
Page 259 The Motor Manual Guy Chapter Brakes 9-13 8.7 Use a Phillips head screwdriver to push the primary Remove the primary piston assembly from the cylinder piston into the cylinder, then remove the snap-ring with a pair of snap-ring pliers Overhaul Refer to illustrations 8.7, 8.8, 8.9, and 8.
Page 260 The Motor Manual Guy Brakes Chapter piston assembly, remove one of the plugs completely. Before releasing light when a jumper is connected t o ground, the warning light switch portion of the combination valve is defective and the combination valve the piston, however, instead of replacing the plug, simply put your finger tightly over the hole to keep air from being drawn back into the must be replaced with a new one since the components of the com-...
Page 261 The Motor Manual Guy 9 Brakes Chapter 9-15 LINES T O WHEEL BRAKE 11.8 When bleeding the brakes, a hose is connected to the bleeder valve at the caliper or wheel cylinder and then submerged in brake fluid. Air will be seen as bubbles in the tube and container.
Page 262 The Motor Manual Guy Chapter 9 9-1 6 Brakes First 12.3 With the engine turned off, 12.2 Push down on the brake pedal, then start the engine the brake pedal should the pedal should gradually rise go down slightly, indicating normal with each pump if the booster 12.9 Disconnect the wire connector from is functioning properly...
Page 263 The Motor Manual Guy 9 Brakes Chapter 14.4 Compress the retainer tangs (arrows) t o free the 14.3 To disconnect the cable end from the parking brake cable and housing from the backing plate lever, pull back on the return spring and maneuver the cable out of the slot i n the lever PARKING B R A K E LEVER AND...
Page 264 The Motor Manual Guy Chapter 9 Brakes 9-18 6 Position the pedal in the bracket and slide the pivot pin to the DASH SUPPORT PANEL right, making sure it passes through the pedal bushings, Install the nut and tighten it to the specified torque. Connect the booster pushrod to the brake pedal, inserting a new bolt from the right side on models with a manual transmission and from the left side on automatic transmission models (see illustration...
Page 265 The Motor Manual Guy Chapter 10 Suspension and steering systems Contents Balljoints replacement Rear leaf spring removal and installation Rear leaf spring bushing check and replacement Front axle suspension arms removal and installation Rear shock absorber removal and installation Front coil spring(s) removal and installation Front end alignment general information...
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Page 268 The Motor Manual Guy Chapter 10 Suspension and steering systems it. Whenever any of the suspension or steering fasteners are loosened or removed they must be inspected and, if necessary, be replaced with 1 General information new ones of the same part number or of original equipment quality and design.
Page 269 The Motor Manual Guy Chapter Suspension and steering systems 10-5 When removing the shock absorber stem nut (arrow), The lower end of the shock absorber is connected to it may be necessary to hold the stem with an open end the front axle housing by two bolts and nuts wrench or locking pliers to prevent it from turning brake master cylinder has been removed for clarity...
Page 270 The Motor Manual Guy Chapter 10 Suspension and steering systems 10-6 Remove the arm-to-frame bracket bolt and remove the arm from Installation the vehicle. Position the coil spring on the axle housing, place the spring re- Check the arm for distortion and cracks, replacing i t if either of tainer over the bottom coil of the spring and tighten the spring retainer these conditions are noted.
Page 271 The Motor Manual Guy Chapter 10 Suspension and steering systems 10-7 7.9 The split ring seat must be screwed in t o a depth of 7.6 Strike the steering knuckle at the top to separate 0.206 i n (5.23 mm), measured from the spindle boss t o from the balljoint studs note that the castellated nuts are loosened, but not removed...
Page 272 The Motor Manual Guy Chapter 10 Suspension and steering systems 10-8 10.2 Remove the nut and bolt (arrow) that retain the 10.3 The stabilizer bar is connected to the frame rails stabilizer bar link to the spring tie plate with two brackets like this 1 0 Rear stabilizer bar removal and installation Refer to illustrations 10.2 and 10.3...
Page 273 The Motor Manual Guy Chapter 10 Suspension and steering systems 10-9 Installation Installation is the reverse of the removal procedure. Be sure to tighten the spring mounting bolts and the spring tie plate U-bolt nuts FLA T to the specified torque. Note: The vehicle must be standing at normal WASHER ride height before tightening the front and rear mounting bolts.
Page 274 The Motor Manual Guy Chapter 10 Suspension and steering systems 10-10 13.3 Before removing the steering wheel, check to see if 13.4 Remove the wheel from the shaft with a puller DO NOT HAMMER ON THE SHAFT! any relationship marks exist (arrows) if not, use a sharp scribe or white paint to make your own marks Remove the steering wheel retaining nut, then mark the relationship...
Page 275 The Motor Manual Guy Chapter 10 Suspension and steering systems 10-1 1 15.4 Before removing the Pitman arm, mark its 1 5 . 5 Use a two-jaw puller to separate the Pitman arm from the steering gear shaft relationship to the steering gear shaft the Pitman arm t o the shaft so it can be installed in the same position (see illustration).
Page 276 The Motor Manual Guy Chapter 10 Suspension and steering systems 16.8 Use a two-jaw puller t o detach the tie-rod end from 16.9 If the tie-rod ends must be replaced, measure the distance from the end of the tie rod tube t o the center of the ballstud so the steering knuckle notice the nut has been loosened but not removed;...
Page 277 The Motor Manual Guy Chapter 10 Suspensia In and steering systems 17.4 This special tool, designed for removing power steering pump pulleys, is available at most auto parts stores 1 7 . 3 Power steering pump front attaching bolts to the return hose (if so, see Chapter 4). Cap the ends of the lines to prevent excessive fluid leakage and the entry of contaminants.
Page 278 The Motor Manual Guy Chapter 10 Suspension and steering systems 10-1 4 20.1 Toe-in is the only normally adjusted alignment setting or type o f tires may affect the ride and handling o f the vehicle. Don't mix different types of tires, such as radials and bias belted, on the same vehicle as handling may be seriously affected.
Page 279 The Motor Manual Guy Chapter 11 Body Contents Body maintenance General information Body repair major damage Hinges and locks maintenance Body repair minor damage Hood removal, installation and adjustment Bumpers removal and installation removal, installation ....Center console removal and installation and adjustment...
Page 280 The Motor Manual Guy Chapter 11 Body 11 -2 At the same time, clean the engine and the engine compartment Repair of dents with a steam cleaner or water soluble degreaser. When repairing dents, the first job is to pull the dent out until the The wheel wells should be given close attention, since undercoating affected area is as close as possible to its original shape.
Page 281 The Motor Manual Guy Chapter 11 Body 11-3 wooden block, otherwise the surface of the filler will not be completely flat. During the sanding of the filler surface, the wet-or-dry paper should be periodically rinsed in water. This will ensure that a very smooth finish is produced in the final stage.
Page 282 The Motor Manual Guy These photos illustrate a method of repairing simple dents. They are intended to supplement Body repair minor damage in this Chapter and should not be used as the sole instructions for body repair on these vehicles. .
Page 283 The Motor Manual Guy Let the filler harden until you can just dent it with your 8 Use coarse-grit sandpaper and a sanding board or block to fingernail. Use a body file or Surform tool (shown here) to rough- work the filler down until it's smooth and even. Work down to shape the filler finer grits sandpaper...
Page 284 The Motor Manual Guy Chapter 11 Body Have an assistant support the weight of the hood. Remove the hinge-to-hood bolts and adjusting shims (see illustration). Lift off the hood. Installation is the reverse of removal. Be sure to reinstall the ad- justing shims and tighten the hinge-to-hood bolts t o the specified torque.
Page 285 The Motor Manual Guy Chapter 11 Body 11-7 1 1 The rear of the hood can also be adjusted up-and-down so it is an assistant support the bumper as the bolts are removed. Remove the bolts that secure the bumper mounting brackets t o flush with the fenders.
Page 286 The Motor Manual Guy Chapter 11 Body 11-8 HINGE PLATES M ENT JU S T SHIMS 12.4 A flat, forked tool such as this one makes door panel removal much easier because the long ribbed plastic retainers are difficult t o pry out Insert a flat, forked tool or a putty knife between the trim panel and the door and disengage the ribbed plastic retainers (see illustration).
Page 287 The Motor Manual Guy Chapter 11 Body 11-9 14.8 14.5 A #30 Torx head tool will be required to remove the end of the support from the retaining dowel (see illustration). hinge bolts Pull the right side of the tailgate rearward t o disengage the right hinge, then pull the tailgate t o the right to disengage the left hinge.
Page 288 The Motor Manual Guy Chapter 11 Body 61-10 BEZEL ATTACHING SCREWS SNAP FIT LOCATION SNAP FIT LOCATIONS 1 6 . 4 The instrument cluster bezel is held in place by four 1 6 . 1 0 The left side of the defroster cowl is retained by a clip screws and is a snap fit Defroster cowl panel Instrument cluster bezel...
Page 289 The Motor Manual Guy Chapter 11 Body 11-11 If you have a 4WD vehicle, also console retaining screws (arrows) transmission shift boot t o detach detach the transfer case shift plate (manual transmission shown, automatic transmission similar) corner with a small screwdriver (see illustration). On 4WD vehicles, On vehicles with automatic transmission, remove the shift handle also remove the transfer case shift plate (see illustration).
Page 290 The Motor Manual Guy Chapter 11 Body 11-12 18 Door window glass removal and installation Refer to illustrations 18.4, 18.5, 18.6, 18.8 and 18.9 Remove the door trim panel and watershield (see Section 12). Lower the window glass. Remove the door window hardware, weatherseal and moldings as necessary for access.
Page 291 The Motor Manual Guy Chapter 11 Body 11-13 solenoid (see illustration). On power door locks, it will be necessary 10 Remove the window glass by 'tilting it to detach the stud, then to drill out the rivets retaining the solenoid to the door. sliding the glass up and out of the door.
Page 292 The Motor Manual Guy Chapter 11 Body 11-14 Three bolts (arrows) retain the mirror to the door 20.3 20.2 Remove the retaining screw, pull out the trim cover loosen the adjustment knob set screw (2) and detach the panel from the door 21 Seats removal and installation 20 Outside mirror...
Page 293 The Motor Manual Guy Body Chapter 11 11-15 . . . tilt the cushion forward, then unlock the frame release lever (arrow) . . . To install the cushion, place the cushion assembly in position, insert the left pivot shaft into the receptacle, snap the release lever in place and swing the seat down.
Page 294 The Motor Manual Guy Chapter 12 Chassis electrical system Contents Battery check and maintenance See Chapter 1 Ignition switch removal and installation Instrument cluster removal and installation Battery removal and installation See Chapter 5 Instrument panel removal and installation Bulb replacement Brake light switch replacement and adjustment Neutral start switch removal, installation...
Page 295 The Motor Manual Guy Chapter 12 Chassis electrical system 12-1 Finding an open circuit 2 Electrical troubleshooting general information When diagnosing for possible open circuits, is often difficult t o locate them by sight because oxidation or terminal misalignment are A typical electrical circuit consists of an electrical component, any hidden by the connectors.
Page 296 The Motor Manual Guy Chapter 12 Chassis electrical system 12-2 If a faulty relay is suspected, it can be removed and tested by a dealer needs a specific amount of protection. The amperage value of each service department or a repair shop. Defective relays must be replaced fuse is molded into the fuse body.
Page 297 The Motor Manual Guy Chapter Chassis electrical system 12-3 Remove the turn signal lever attaching screw and withdraw the extreme left. On tilt columns, the Accessory position is on the extreme turn signal lever from the side of the column. right.
Page 298 The Motor Manual Guy Chapter 12 Chassis electrical system 12-4 F E R R U L E NUT CONTROL SHAFT 10.4 Headlight switch component layout Unplug the electrical connector, unscrew the ferrule nut and remove the switch from the instrument panel (see illustration). To install the switch, plug in the electrical connector, place the switch in position and install the ferrule nut.
Page 299 The Motor Manual Guy Chapter 12 Chassis electrical system 12-5 13. I b Side marker light housing removal details 13.1 e Comanche license plate bulb removal details removal details replacement details GASKET LICENSE PLATE BULB HOUSING 13.1 g Cherokee license plate bulb replacement details (with swing-out spare tire) the right of the headlight vertical line.
Page 300 The Motor Manual Guy Chapter 12 Chassis electrical system 12-6 Pry up on the locking lever with a small screwdriver, 13.3 To remove a bulb housing, rotate the housing 14.2 counterclockwise about and pull it out then pull the wiper arm off the pivot On some lights the lenses are held in place by clips.
Page 301 The Motor Manual Guy Chapter 12 Chassis electrical system 12-7 PIVOT PIN INSTRUMENT CLUSTER ATTACHING SCREWS CIGAR LIGHTER HOUSING SWITCH SCREWS HOUSINGS 14.8 Rear wiper motor installation details 15.3 lnstrument cluster, switch housing and cigar lighter screw locations 1 5 lnstrument cluster removal and installation Refer to illustration 15.3 and 15.4 16 lnstrument panel...
Page 302 The Motor Manual Guy Chapter 12 Chassis electrical system 12-8 or hoses get pinched between components when the instrument panel is rotated-back into position. STANDARD STANDARD TRACER COLOR COLOR TRACER 17 Cruise control system description and check CODE COLOR CODE BK O R The cruise control system maintains vehicle speed with a vacuum BLACK...
Page 303 The Motor Manual Guy LEGEND OF SYMBOLS USED ON WIRING DIAGRAMS CONNECTOR POSITIVE MALE CONNECTOR NEGATIVE FEMALE CONNECTOR GROUND FUSE DENOTES WlRE CONTINUES ELSEWHERE DENOTES WlRE GOES TO ONE OF TWO GANG FUSES WITH BUSS BAR CIRCUITS CIRCUIT BREAKER SPLICE SPLICE IDENTIFICATION THERMAL ELEMENT RESISTOR...
Page 304 The Motor Manual Guy TO TURNIHAZZARD SWITCH 79 18BR ASSEMBLY (SEE SH 47,49) 77 16LG TO HEADLAMP DIMMER SWITCH TO TURNIHAZZARD SWITCH 78 18GY ASSEMBLY (SEE SH 47,49) (BEHIND TO HEADLAMP LH HEAD 72 18BL LAMP) TO CHIME MODULE (SEE SH 67) LEFT 76 16WT 76 16WT...
Page 305 The Motor Manual Guy (BEHIND LH HEAD- LAMP) TO FOG LAMP TO HEATER A/C 16BK BLOWER MOTOR 99 1 2 8 K - 5 SPLICE RIGHT 99 16BK RIGHT -99 12BK 117 14LG (OPTIONAL) Front lighting (two-headlight models) wiring diagram (continued)
Page 306 The Motor Manual Guy TO TURNIHAZZARD SWITCH 79 18BR ASSEMBLY 77 16LG TO HEADLAMP DIMMER SWITCH 78 18GY ASSEMBLY (BEHIND T O HEADLAMP SWITCH 72 18BL SIGNAL LAMP LEFT SIDE MARKER LAMP 16BK 99 18BK (OPITIONAL) FOG LAMP RELAY (LH FRONT ENGINE COMPART- MENT)
Page 307 The Motor Manual Guy RIGHT RIGHT 99 12BK LAMP (OPTIONAL) Front lighting (four-headlight models) wiring diagram (continued)
Page 308 The Motor Manual Guy SPLICE WARNING SWITCH 98 20BKlWT SPLICE TO LH FRONT 98 ~OBKIWT-~, DOOR JAMB SWITCH SPLICE TO INST LPS FUSE TO CLOCK TO HEAD- LAMP DELAYS- MODULE TO CHIME MODULE ILLUMINATION RE L.W (LH OF STEERING- 76 I6WH TO HEADLAMPS 76 16WT 16LG...
Page 309 The Motor Manual Guy * , - a 98 2 0 8 ~ 4 DOOR ONLY RH REAR DOOR JAMB SWITCH RH FRONT DOOR JAMB SWITCH SPLICE FOG LAMP SWITCH TO INSTRUMENT PANEL TO INSTRUMENT CLUSTER TO RADIO CLOCK ILLUMINATION SPLICE CIGAR INSTRUMENT...
Page 310 The Motor Manual Guy SPLICE TO IGNITION KEY WARNING SWITCH SPLICE TO LH FRONT 98 ZOBKIWTJ SWITCH SWITCH SPLICE TO HEAD- LAMP DELAYS- MODULE (BEHIND LH KICK PANEL) TO CHIME MODULE DIMMER TO LH TAIL SWITCH LAMP (LH OF STEERING- COLUMN) TO HEADLAMPS CLUSTER...
Page 311 The Motor Manual Guy 77 16LG SWITCH F5 I6BLlWT A l l SPLICE FOG LAMP SWITCH (ON DASH) TO GLOVE INDICATOR TO INSTRUMENT PANEL TO INSTRUMENT CLUSTER TO RADIO CLOCK ILLUMINATION SPLICE LIGHTER TO INSTRUMENT CLUSTER RADIO ILLUMINATION TO FOG LAMP RELAY 99 20BK MODULE...
Page 312 The Motor Manual Guy HEATER PANEL LAMP 52 180RIBK TO HEADLAMP SWITCH RHEOSTAT 99 18BK 99 18BK...
Page 313 The Motor Manual Guy INSTRUMENT 52 2 TO RADIO 52 2 0 0 ~ 1 ~ ~ TO ILLUMINATION 52 2OORIBK RELAY 52 200RIBK GROUNDS ON IIP PANEL TRAY LAMP (UNDER TRANSFER CASE CENTER CONSOLE) LAMP 20BK ------ SPLICE Instrument panel illumination wiring diagram (continued)
Page 314 The Motor Manual Guy SPLICE RADIO WASHER FLUID LEVEL SWITCH Instrument cluster illumination wiring diagram...
Page 315 The Motor Manual Guy (RH SHOCK 4L MANUAL TOWER) OPERATED) LAMP DELAY TRANSMISSION TRANS- MISSION (ABOVE (RH SIDE OF TRANSFER TRANSMISSION) CASE) Instrument cluster illumination wiring diagram (continued)
Page 316 The Motor Manual Guy (NOT USED) TO FRONT LIGHTING INSTRUMENT CLUSTER (BEHIND RH SIDE) 18GY COLUMN COLUMN TO FRONT LIGHTING (BLACK) TO REAR LIGHTING...
Page 317 The Motor Manual Guy BRAKE SWITCH TURN (ABOVE 15 AMP BRAKE 20 AMP PEDAL) REFER CRUISE CONTROL TO REAR DEFOGGER HAZARD LAMP FLASHER PANEL) COLUMN HAZARD SWITCH STOP LAMP...
Page 318 The Motor Manual Guy TO FRONT LIGHTING INSTRUMENT CLUSTER (BEHIND RH SIDE) TO FRONT LIGHTING TO REAR LIGHTING...
Page 319 The Motor Manual Guy BRAKE SWITCH REFER CRUISE TO REAR DEFOGGER HAZARD TURN SIGNAL LAMP FLASHER FLASHER COLUMN COLUMN HAZARD SWITCH STRG NORMAL COLUMN SWITCH ASSEMBLY (BEHIND STEERING WHEEL) COLUMN COLUMN Stoplturn and hazard system wiring diagram (Comanche models) (continued)
Page 320 The Motor Manual Guy SPLICE WINDSHIELD WASHER SWITCH CIRCUIT BREAKER (ON TURN 4.8 AMPS SIGNAL STALK) WASH SWITCH FRONT WASHER PUMP FRONT MOTOR FRONT WIPERS WIPERS COWL) DOWN TO REAR 99 18BK UNDER FRONT WASHER BOTTLE Windshield washerlwiper wiring diagram (intermittent)
Page 321 The Motor Manual Guy SPLICE USED WINDSHIELD CIRCUIT BREAKER 4.8 AMPS WASHER WIPER SWITCH SWITCH TO LO (ON TURN STALK) (NOT USED) A l l SPLICE FRONT WASHER PUMP (UNDER WASHER BOTTLE) FRONT WIPER MOTOR (UNDER FRONT DOWN COWL) 99 16BK TO REAR 99 I8BK$1 99 I B B R ~ W ;...
Page 322 The Motor Manual Guy SPLICE R3 1 8 B R W R4 18VTlOH WIPER 25 AMP ------------- ON IIP TO ,RIGHT OF STEERING COLUMN REAR WIPER/ WASHER SWITCH KICK BEHIND PANEL) r-------- I - - - - - - - - ____- - - - (SEE SH 82) Rear washerlwiper wiring diagram...
Page 323 The Motor Manual Guy TO TRANS. COMFORT SWITCH ILLUMINATION MODEL 70) TO CRUISE TRANS. SWITCH TO WIPER SWITCH FOG LAMP SWITCH TO FOG LAMP ILLUMINATION TO REAR DEFOGGER TO REAR WASH1 -99 20BK TO REAR DEFOGGER SWITCH TO REAR DEFOGGER TO VANITY MIRROR BEHIND KICK TO READING LAMP...
Page 324 The Motor Manual Guy TO KEYLESS ENTRY DOME TO RADIO GROUND (SEE SH 63) LAMP SPLICE 99 2081 WITHOUT READING LAMPS LIGHTER CIGAR TO POWER DOME DOOR LOCKS LAMP GROUND VANITY LAMPS TO RADIOILCD HE LAY RH REAR (ABOVE DOOR JAMB TRANSFER SWITCH CASE)
Page 325 The Motor Manual Guy RH FRONT DOOR JAMB SWITCH Interior lighting wiring diagram (Cherokee models) (continued)
Page 326 The Motor Manual Guy RADIO CIGAR LIGHTER TO GLOVE BOX LAMP SWITCH Interior lighting wiring diagram (Comanche models)
Page 327 The Motor Manual Guy TO VANITY LAMP CARGO FRONT DOOR JAMB SWITCH Interior lighting wiring diagram (Comanche models) (continued)
Page 328 The Motor Manual Guy TO GEAR 75 18BR 75 I8BRMIT SWITCH 71 18LBlBK 71 18LBIBK (BLACK) TO HEAD- LAMP SWITCH 5 - TO TURN/ TRAILER TOWER LH TAIL1 LAMP (LH SIDE OF LIFT- GATE) 20BL 72 20BL 72 20BK LAMP 99 20BK (BEHIND LICENSE)
Page 329 The Motor Manual Guy 72 2 0 ~ ~ - - 1 99 18BK 99 20BK Rear lighting wiring diagram (Cherokee models) (continued)
Page 330 The Motor Manual Guy (BEHIND RH REAR PANEL) -75 :al3RIWT 71 18LBIBK 72 1 (BEHIND LICENSE) 72 20BL 99 20BK Rear lighting wiring diagram (Commanche models)
Page 331 The Motor Manual Guy RH STOP1 TURN LAMP RH STOP1 TURN LAMP BACKUP LAMP LICENSE LAMP (BEHIND LICENSE) Rear lighting wiring diagram (Commanche models) (continued)
Page 332: About This Manual
The Motor Manual Guy Index check, 1-20 combination valve, check and replacement, 9-14 disc, inspection, removal and installation, 9-7 About this manual, fluid level check, 1-9 Air cleaner general information, 9-1 removal and installation, 4-7 height sensing proportioning valve, general information, 9-1 8 thermostatic, check, 1-22 hoses and lines, inspection and replacement, 9-14 Air conditioning system...
Page 333 The Motor Manual Guy Index Coolant cleaning, 2D-14 level check, 1-8 inspection, 2D-15 general information, 3-2 camshaft and bearings, removal, inspection and installation reservoir, removal and installation, 3-6 Four-cylinder engine, 2A-13 temperature sending unit, check and replacement, 3-5 Cooling system V6 engine, 2B-9 check, 1-14 compression check, 2D-3...
Page 334 V6 engine, 2B-3 (2WD models), 1-29 lntroduction to routine maintenance, 1-7 Fuel and exhaust systems, 4-0 through 4-20 lntroduction t o the Jeep Cherokee and Comanche, 0-5 evaporative control system, 6-7 filter replacement, 1-25 injection system, general information, 4-12 injector, replacement, 4-1 9...
Page 335 The Motor Manual Guy Index Safety, 0-20 change, 1-15 filter change, 1-1 5 Seats, removal and installation, 11 -14 level check, 1-7 Self-diagnosis codes (1991 and later models) description and pan, removal and installation code retrieving, 6-19 Four-cylinder engine, 2A-14 Shock absorber removal and installation lnline six-cylinder engine, 2C-10...
Page 336: Vehicle Identification Numbers
The Motor Manual Guy Index fluid and filter change, 1-27 fluid level check, 1-1 1 V6 engine, 28-0 through 28-13 general information, 78-1 Vacuum advance mechanism, check and replacement, 5-4 Neutral start switch check, adjustment and replacement, 7B-5 Valve cover removal and installation removal and installation, 78-6 Four-cylinder engine, 2A-3...

This manual is also suitable for:

Comanche 1989

Jeep cherokee 1989 Owner's Manual

Troubleshooting

Manual Transmission

Suspension and Steering

Automatic Transmission

Quick Links

Contents

Troubleshooting

Summary of Contents for Jeep cherokee 1989

Page 16: Safety First

Page 18: Table Of Contents

Page 20: Alternator Light Fails To Come On When Key Is Turned On 1

Page 21: Excessive Fuel Consumption 2

Page 22: Troubleshooting

Page 25: Suspension And Steering

Page 27: Tune-Up And Routine Maintenance

Page 34: Index

Page 47: Fuel Odor

Page 107: Chapter 2 Part D General Engine Overhaul Procedures

Page 139: Fluid Leakage

Page 148: Vibration

Page 171: Electrical Systems

Page 177: Noise

Page 332: About This Manual

Page 336: Vehicle Identification Numbers

This manual is also suitable for:

Jeep cherokee 1989 Owner's Manual

Troubleshooting

Manual Transmission

Suspension and Steering

Automatic Transmission

Quick Links

Contents

Troubleshooting

Related Manuals for Jeep cherokee 1989

Summary of Contents for Jeep cherokee 1989

This manual is also suitable for:

Table of Contents