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J-20 Series 1982
Jeep J-20 Series 1982 Manuals
Manuals and User Guides for Jeep J-20 Series 1982. We have
1
Jeep J-20 Series 1982 manual available for free PDF download: Technical & Service Manual
Jeep J-20 Series 1982 Technical & Service Manual (1312 pages)
Brand:
Jeep
| Category:
Automobile
| Size: 306.98 MB
Table of Contents
Contents
3
General Information
4
Organization
4
Warnings and Cautions
4
Diagnosis and Repair Simplification Charts
4
How to Use this Manual
4
Service Diagnosis Charts
5
Torque Information
5
Standard Torque Specifications and Capscrew Markings Chart
5
Torx-Head Fasteners
6
Service Manual Improvements
6
Cj/Scrambler Models
6
Wagoneer Model
8
Truck Models
8
Truck Model Identification
8
Vehicle Identification Number (VIN)
9
Special Sales Request and Order (SSR &0] Number
9
Paint Option Number
9
Trim Option Number
9
VIN Decoding Chart
10
Cherokee, Wagoneer and Truck
10
CJ and Scrambler
10
Safety Certification Sticker
11
Towing
11
Keys and Locks
11
Paint Option Numbers
11
Key Codes
11
Rear Towing—Rear End Raised
12
Part Time Transfer Case
12
Cherokee-Wagoneer-Truck Models
12
Part Tims Transfer Case—Automatic Transmission
12
Convesion of English and Metric Measures
14
CJ and Scrambler General Dimensions
14
Rear Towing
14
Metric System
17
Decimal Equivalents
18
Reader's Comments
20
First Class
21
Maintenance
22
Maintenance Schedule
22
Fuel Requirements
22
Heavy-Duty Operation
22
After First 200 Miles
23
Not Applicable
23
1982 Jeep Engine Maintenance
24
Chassis Illustration
25
Lubrication Points
25
Description of Services - Engine Components
26
1982 Jeep Chassis Maintenance Schedule
26
Oil Check
26
Oil Change
26
Oil Filter
27
Automatic Transmission
27
Battery
27
Engine Oil Viscosity
27
Brake Master Cylinder
28
Coolant
28
Power Steering Pump
28
Power Steering Pump Dipstick Location
28
Drive Belts
29
Fuel Filter
29
Exhaust Heat Valve
29
Air Cleaner
29
Bearings - Front Wheel
30
Manual Locking Hubs
30
Brake and Chassis Inspection
30
Axle Fill Plug Location
30
Body Lubrication
31
Master Cylinder
31
Disc Brake Calipers
31
Rear Wheel Cylinders
31
Clutch Lever and Linkage
32
Exhaust System Inspection
32
Hood Hinge
32
Glove Box Latch and Hinge
32
Manual Steering Gear
33
Propeller Shafts
33
Steering Linkage
33
Sleeve Yokes
33
Transfer Case
34
Transmission
34
Double Cardan Joint
34
Transfer Cae Drain and Fill Plugs
34
Unscheduled Maintenance
35
Automatic Transmission Fluid Changes
35
Manual Transmission Fluid Change
35
Catalytic Converter
35
Fluid Capacities
36
Recommended Fluids and Lubricants
37
Power Plant
38
Emission Components
40
Emission Control Components - 49-State Light Duty Vehicles
40
Service Diagnosis—Mechanical
42
External Oil Leaks
42
Excessive Oil Consumption
42
No Oil Pressure
43
Low Oil Pressure
43
High Oil Pressure
43
Hard Starting
45
Diagnosis with Scope Analyzer
50
Cylinder Compression Pressure Test
50
Compression Pressure
50
Scope Diagnosis Patttrns
51
Cylinder Combustion Pressure Leakage Test
52
Cylinder Head Gasket Failure Diagnosis
52
Cyllnder-To-Cylinder Leakage Test
52
Engine Tune-Up
53
Intake Manifold Leakage Diagnosis
53
Cylinder-To-Water Jacket Leakage Test
53
Exterior Leak
53
Engine Assembly
53
Ignition System
54
Vacuum Fittings and Hoses
54
Spark Plugs
54
Spark Plug Condition
54
Spark Plug and Ignition Coll Wires
55
Wire Resistance Test
55
Ignition Coil
55
Electrode Gap Bridging
55
Distributor
56
Distributor Rotor Inspection
56
Distributor Cap Inspection
56
Ignition System Timing
56
Testing Distributor Advance Mechanisms
58
Adjustable Advance Control Timing Light Procedure
58
Testing Distributor Advance Mechanisms - off Engine
58
Fuel System
59
General Inspection
59
Carburetor Idle Speed Adjustment
59
Idle Speed Control
59
Adjustment Precautions and General Information
60
Diagnostic Connector
60
Idle Speed Adjustment Procedure
60
Choke Linkage
62
PCV Air Inlet Filter
62
Fuel Tank Vapor Emission Control System
62
Fuel Vapor Storage Canister Filter
62
Tune-Up Specifications—On-Vehicie
63
Distributor Curves
64
Distributor Wiring Sequence and Engine Firing Order
65
Four-Cylinder Engine
65
Six-Cylinder Engine
65
Eight-Cylinder Engine
65
Engine Replacement
67
Engine Mounting
67
Four-Cylinder Engine Assembly
68
Engine ID Code Locations
70
Four-Cylinder Engine Mounting
70
Valves and Actuating Compomnents
71
Rocker Arm and Push Rod
72
Valve Springs, Shields And/Or Seal Replacement
72
Compressing Valve Springs
72
Valve Spring Assembly
72
Camshaft and Drive
73
Valve Spring Tension Test
73
Camshaft Replacement
73
Testing Valve Spring—Typical
73
Removing Camshaft Timing Gear
74
Installing Camshaft Timing Gear
74
Measuring Thrust Plate End Clearance
74
Camshaft Bearings
75
Hydraulic Valve Tappets
75
Removing Center Camshaft Bearing—Typical
75
Crankshaft Vibration Damper Pulley Hub and Oil Seal Replacement
77
Leak-Down Test
77
Timing Case Cover Replacement
77
Intake Manifold
78
Cutting Pan Gasket
78
Oil Pan Seal Modification
78
Applying RTV Sealant
78
Exhaust Manifold
79
Intake Manifold Bolt Tightening Sequence
79
Exhaust Manifold Replacement
79
Cylinder Head Cover
80
Push Rod Cover
80
Valves and Seats
81
Valve Guide Bares
81
Cylinder Head Disassembly
81
Cylinder Head Tightening Sequence
81
Engine Lubrication System
82
Cylinder Head Assembly
82
Measuring Valve Guide Bore with Telescoping Gauge
82
Oil Pump Drive Shaft
83
Engine Lubrication System Diagram
83
Oil Pump
84
Oil Pan
84
Oil Pump Exploded View
84
Pistons and Connecting Rods
85
Removing Piston Pin
85
Connecting Rod Bearings
86
Installing Piston in Cylinder
86
Raised Notch Location
86
Piston Fit
87
Piston Pins
87
Connecting Rod Bearing Clearance
87
Measuring Connecting Rod Side Clearance
87
Main Bearings
88
Piston Rings
88
Piston Measurement Locations
88
Ring Side Clearance Measurement
88
Clearance Measurement
89
Crankshaft Removed from Engine
89
Measuring Bearing Clearance
89
Crankshaft Installed
89
Crankshaft Replacement
90
Rear Main Bearing Oil Seal Replacement
90
Cylinder Block
91
Cylinder Bores
91
Measuring Cylinder Bore with Bore Gauge
91
Normal Cylinder Bore Wear Pattern
91
Specifications
92
Torque Specifications
93
Identification
97
Build Date Code
97
Short Engine Assembly
97
Oversize or Undersize Components
97
Engine Mounting
97
Engine Holding Fixture
98
Engine Removal
98
Engine Installation
99
Valves and Actuating Components
99
Rocker Ana Assembly
99
Valves
100
Valve Refacing
100
Valve Seat Refacing
100
Valve Stem Oil Deflector Replacement
100
Valve Guides
101
Valve Stem-To-Guide Clearance
101
Valve Guide Reamer Sizes
101
Measuring Valve Seat Runout
101
Valve Springs
102
Valve Spring and Oil Deflector Removal
102
Oil Deflector and Valve Spring Installation
102
Camshaft and Bearings
103
Measuring Cam Lobe Lift
103
Valve Timing
103
Camshaft Removal
103
Camshaft Inspection
104
Camshaft Installation
104
Camshaft Bearing Replacement
104
Hydraulic Valve Tappet Components
105
Hydraulic Valve Tappet Operation
105
Hydraulic Valve Tappet Removal
105
Disassembly, Cleaning, Inspection and Reassembly
106
Hydraulic Valve Tappet Leak-Down Test
106
Timing Case Cover
106
Hydraulic Valve Tappet Leak-Down Rate Tester
106
Timing Case Cover Alignment
107
Oil Pan Front Seal Installation
107
Timing Case Cover Oil Seal Installation
107
Timing Chain
108
Timing Case Cover Oil Seal Removal
108
Timing Sprocket Alignment
108
Intake and Exhaust Manifolds
109
Intake and Exhaust Manifold Replacement
109
Intake and Exhaust Manifold Installation
110
Intake Manifold Replacement
110
Manifold Tightening Sequence
110
Cylinder Head and Cover
111
Cylinder Head Tightening Sentence
112
Lubrication System
113
Oil Filter and Oil Pomp Assembly
114
Oil Gear-To-Body Clearance Measurement
115
Connecting Rod and Piston Assemblies
116
Oil Pressure Gauge
116
Oil Pump Inlet Tube Installation
116
Connecting Rods
117
Side Clearance Measurement
117
Piston Installation
117
Connecting Rod Bearing Fitting Chart
118
Bearing Insert Pairs
118
Measuring Bearing Clearance with Plastigage
118
Measuring Bearing Clearance with Micrometer
119
Scoring Caused by Embedded Material
119
Locking Tab Inspection
119
Rod Beerlng Clearance Measurement with Plastigage
119
Pistons
120
Feeler Gauge Method
120
Ring Fitting
120
Micrometer Method
120
Ring Side Clearance
121
Piston Ring Gap Position
121
Ring Gap Clearance
121
Oil Control Ring Rail Installation
121
Compression Ring Installation
122
Typical Piston Ring Markings
122
Piston Pin Removal or Installation
122
Crankshaft End Play Measurement
123
Crankshaft Main Bearings
123
Measuring Crankshaft End Play
123
Main Bearing Fitting Chart
124
Fabricated Upper Main Bearing Removal Tool
124
Measuring Bearing Clearance with Plastigage (Crankshaft Installed)
125
Removing No. 4 Main Bearing Insert
125
Normal Main Bearing Wear Pattern
125
Rear Main Bearing Oil Seal
126
Measuring Main Bearing Clearance with Plastigage
126
Vibration Damper and Pulley
127
Flywheel/Drive Plate and Ring Gear Assembly
127
Ring Gear Replacement
127
Vibration Damper Removal
127
Cylinder Bore Reconditioning
128
Resurfacing Cylinder Bore
128
Six-Cylinder Engine Specifications
129
Engine Type and Build Date Code
133
Camshafts and Bearings
139
Valve Spring Tester
139
Cam Lobe Lift Measurement
139
Oil Pump Cover
153
Oil Pump and Filter Assembly
153
Oil Pressure Relief Valve
153
Gear End Clearance Measurement
153
Gear Tooth-To-Body Clearance
154
Cooling System Operation
175
Four-Cylinder Engine Cooling System Components
176
Six-Cylinder Engine Cooling System Components
177
Eight-Cylinder Engine Cooling System Components
178
Coolant Level
179
Coolant Level—Without Coolant Recovery
179
Coolant Level—With Coolant Recovery
179
Draining Coolant
179
Purging Air from Cooling System
180
Coolant Freezing Point Test
180
Removing Coolant from Crankcase
180
Water Pump Pulley Replacement
180
Removal—Six-Cylinder Engine
181
Installation—Six-Cylinder Engine
181
Removal—Eight-Cylinder Engine
181
Water Pump Tests
182
Installation—Eight-Cylinder Engine
182
Intake Manifold - Six-Cylinder Engine
183
Hoses
183
Thermostat
183
Thermostat Replacement
183
Thermostat Testing
184
Radiator
184
Thermostat Recess
184
Radiator Identification
185
Radiator Maintenance
185
Thermostat Calibrations
185
Testing Thermostat
185
Fan Assembly
186
Radiator Pressure Cap
186
Radiator Cap Operation
186
Tempatrol Fan
186
Tempatrol Fan Blade and Drive Unit Replacement
187
Tempatrol Fan Test
187
Fan Shroud
188
Coolant Recovery System
188
Coolant Recovery Operation
188
Disconnecting Tempatrol Spring Coil
188
Coolant Temperature Gauge
189
Cylinder Block Heater
189
Coolant Recovery Bottle Replacement
189
Cylinder Block Heater Installation
189
Cooling System Maintenance
190
Engine Flushing
190
Solvent Cleaning
190
Radiator Reverse Flushing
191
Transmission Fluid Cooler Repairs
191
Core Plugs
191
Cooling System Leakage Tests
191
Cooling System Diagnosis
191
Service Diagnosis
192
Coolant Loss
193
Low Engine Temperature Diagnosis Guide
195
Engine Overheating Diagnosis Guide
195
Internal Leakage Inspection
197
Combustion Leakage Test
197
Transmission Fluid Collar Leakage Test
197
Cooling System Pressure Test
197
Drive Belt Adjustments
198
General
198
Six-And Eight-Cylinder Engine
198
Alternator and Fan (Six-Cylinder Engine with Air Conditioner)
199
Four-Cylinder Engine Power Steering Pump Drive Belt Adjustment
199
Eight-Cylinder Engine Alternator Drive Belt Adjustment
199
Air Pump (Without Power Steering)
200
Power Steering Pump—Six- and Eight-Cylinder Engines
200
Air Pump (with Power Steering)
200
Air Conditioner Compressor
200
Serpentine Drive Belt Diagnosis
201
Serpentine Drive Belt Tension Test
201
Serpentine Drive Belt Adjustment
201
Engine Drive Belt Arrangements
206
Tools
209
Batteries
211
Battery Classifications, Ratings and Codes
211
Cold Crank Amps Rating
211
Battery Codes
211
Battery Replacement
212
Date Code Location—Typical
212
Frozen Electrolyte
213
Battery Storage
213
Dry Charge Battery
213
Activation Procedure
213
Slow Charge
214
Fast Charge
214
Booster Charging
214
Testing
215
Hydrometer Test
215
Hydrometer
215
Heavy Load Test
216
Specific Gravity
216
Trouble Diagnosis
216
Problem: Starter Motor Inoperative
217
Battery Specifications
219
Charging System
221
Alternator
221
Delco Alternator—Typical
221
Voltage Regulator
222
Energizing the System
222
Charging System Schematic—Typical
222
Operation
222
Voltage Output
223
Regulation
223
Basic Wire Connections
223
Troubleshooting
223
Testing—Off-Vehicle
224
Alternator Noise
224
Visual Inspection
224
Battery Discharge through Alternator
224
Rotor (Field) Winding Internal Short Test
225
Rotor (Raid) Winding Open Test
225
Stator Windings Short-To-Ground Test
225
Problem: Battery Undercharged
226
Problem: Battery Overcharged
228
Stator Windings Continuity Test
229
Stator Internal Short Circuit Test
229
Diode Trio Short Circuit Test
229
Test with Diode Trio Removed
229
Alternator Replacement
230
Bridge Rectifier Test
230
Testing Diode Trio
230
Alternator Overhaul
231
Alternator Components
232
Front Housing Bearing Assembly
232
Removing Pulley Nut
233
Brush Holder Assembly
233
Front Housing
233
Tightening Pulley Nut
233
Drive Belt Adjustment
234
Testing Belt Tension—Typical
234
Adjusting Belt Tension—Typical
234
Delco Charging System Specifications
235
Output Voltage Specifications
235
Starting Systems
237
Four-Cylinder Engine Starting System
237
Starter Motor Operation
237
Neutral Safety Switch
237
Service Diagnosis
237
Four-Cylinder Engine Starter Motor System
238
5MT Starter Motor-Exploded View
238
Starter Motor Test
239
No-Load Test
239
Starter Motor Shimming and Mounting
239
Starter Motor Noise Diagnosis
240
No-Load Test Connections
240
High Frequency
240
Starter Motor Replacement
241
Starter Motor Relay Replacement
241
Starter Motor Relay Test
241
Neutral Safety Switch Test
241
Removing Retainer from Slip Ring
242
Brushes and Brush Holders
242
Armature Windings
242
Field Windings
242
Solenoid Test Connections
243
Forcing Snap Ring over Shaft
243
Overrunning Clutch
243
Pinion Gear Clearance Test
244
Forcing Retainer over Snap Ring
244
Pinion Gear Clearance Measurement Test Circuit
244
Measuring Pinion Bear Clearance
244
Solenoid Does Not Energize
245
Slow Motor Operation, Solenoid Clicks or Chatters
246
Starter Motor
247
Drive Assembly
247
Starter Motor Solenoid
247
Starting System Circuits
248
Fusible Link
248
Moveable Pole Shoe Operation
248
Six- and Eight-Cylinder Engine Sterling System Schematic
249
On-Vehicle Testing
250
Starter Motor will Not Rotate
250
Starter Motor Solenoid Pull-In Winding Test
250
Starter Motor Cable and Ground Cable Tests (Voltage Drop)
250
Starter Motor Voltage Drop Tests
252
Voltage Drop Test
253
Off-Vehicle Testing
254
Starter Motor Full-Lad Current Test
254
Hold-In Coil Winding Resistance Test
255
Solenoid Contact Points Connection Test
255
Insulated Brush Connection Test
255
Terminal-To-Brush Continuity Test
255
Armature Tests
256
Grounded Armature Winding Test
256
Terminal Bracket Insulation Test
256
Armature Winding Internal Short Test
257
Armature Balance Test
257
Field Winding Replacement
259
Solenoid Contact Point Assembly Replacement
259
Flywheel/Drive Plate-To-Ring Gear Clearance
259
Neutral Safety Switch Replacement
260
Drive End Bushing
260
Drive Assembly Replacement
260
Commutator End Bushing
260
Ignition Systems
263
Four-Cylinder Engine Ignition System
263
Hei System Components
263
Ignition Timing
264
HEI Distributor-Exploded View
264
Ignition Systems
264
Distributor Holddown Clamp
265
Magnetic Timing Probe Socket and Timing Degree Scale
265
Secondary Wiring
265
On-Vehicle Service
266
Ignition System Troubleshooting Chart
267
Engine will Not Start
267
Intermittent Engine Operation or Misfire
268
Rotor Roplacement
269
Electronic Module Replacement
269
Distributor Components
269
Pickup Coil Assembly Replacement
270
Ignition Coil Replacement
270
Vacuum Advance Mechanism Replacement
270
Spark Plug and Ignition Coll Wire Replacement
270
Testing Electronic Module
271
Testing Pickup Coil
271
Testing Centrifugal and Vacuum Advance Mechanisms
271
Testing Ignition Coll
271
Test Procedures
271
Six- and Eight-Cylinder Engine Ignition System
273
Electronic Ignition Control Unit
273
Ignition Coil Connector
274
Pickup Coil and Trigger Wheel
274
Removing Coil Connector
274
Tachometer Connection
274
Ignition Advance
275
Cap and Rotor
275
Complete Failure Diagnosis
275
Operation
275
Secondary Circuit Diagnosis
276
SSI System Schematic
276
Intermittent Failure Diagnosis
277
Engine Spark Knock (Pre-Ignition) Diagnosis
288
Distributor Ignition Advance Tests
288
Centrifugal (Mechanical) Ignition Advance Test
288
Vacuum Ignition Advance Test
288
Distributor Replacement
289
Secondary Winding Resistance Test
289
Current Row Test
289
Ignition Coll Output Tests
289
Distributor Component Replacement
290
Trigger Wheel And/Or Pickup Coil
290
SSI Distributor Components—Typical
291
Rotor Silicone Dielectric Compound Application
292
Vacuum Advance Control Systems
294
Four-Cylinder Engine System
294
Vacuum Advance Coolant Temperature Override (CTO) Valve
294
Vacuum Advance CTO Valve Replacement
295
Vacuum Advance Control Delay Valve
295
Vacuum Advance Control System Operation
295
Chapter 1A For Applicable Engine Application
296
Vacuum Advance CTO Valve
297
Vacuum Advance CTO Valve Replacement—Six-Cylinder Engine
297
Regulated Vacuum Advance Control System
298
Forward Delay Valve
298
Non-Linear Vacuum Regulator Valve Operation
298
Reverse Delay Valve
299
Delay Valve Code
299
Forward Delay Valve Time Limits
299
Reverse Delay Valve Time Limits
299
Cruise Command
301
Electronic Regulator
301
Speed Sensor
302
Servo
302
Electronic Cruise Command Components
302
Release System
302
Operation
302
Circuitry Tests
305
Regulator Wire Harness Connector
305
Spied Sensor Test
305
Control Switch Continuity Test
306
Tester AM-PC-1-R
307
Harness Connector at Regulator
307
Cruise Command System Test
307
Cruise Command Diagnosis Chart
307
Centering Adjustment
309
Vacuum (Mechanical) Vent Valve
309
Regulator Replacement
309
Servo Replacement
309
Servo Chain Replacement
310
Servo Cable Replacement
310
Control Switch Replacement
310
Fuel Systems
313
Air Cleaners
313
Fuel Filters
313
General Information
313
Replacement—Four-Cylinder Engine
314
Fuel Tank Filter
314
Fuel Tanks
314
Fuel Systems
314
Fuel Tank Replacement
315
Fuel Gauge Sanding Unit
317
Fuel Vapor Control Systems
318
Fuel Tank Filler Neck
318
Fuel Tank Filler Cap
318
Vapor Canister
318
Rollover Check Valve
319
Carburetor External Bowl Vent
319
Fad Vepor Control Integrity Test
319
Fuel Return System
320
Fuel Gauge
320
Fuel Pump
320
Fabricated Manometer
320
Pressure Test
321
In-Line Check Valve
321
Fuel Return System—Typical
321
Capacity (Volume) Test
322
Vacuum Tests
322
Direct Connection Test
322
Indirect Connection Test
322
Fuel Economy Tests
323
Fuel Pump Replacement
323
Fuel Pump Specification Chart
323
Model 2SE Carburetor—Exploded View
324
Carburetor Circuits
325
Float Circuit
325
Idle Circuit
325
Main Metering Circuit
326
Power Enrichment Circuit
326
Model 2SE Carburetor—Idle Circuit
326
Model 2SE Carburetor—Main Metering Circuit
326
Pump Circuit
327
Choke Circuit
327
Model 2SE Carburetor—Pump Circuit
327
Model 2SE Carburetor—Choke Circuit
327
Sealed Idle Mixture Screw
328
Carburetor Replacement
328
Carburetor Overhaul
328
Cleaning and Inspection
333
Model 2SE Carburetor-Float Needle Poll Clip Location
334
Service Adjustment Procedures
337
Float Level Adjustment
337
Air Horn Screw Tightening Sequence
337
Choke Coil Lever Adjustment
338
Accelerator Pump Adjustment
338
Fast Idle Cam Position Adjustment
338
Fist Idle Adjustment
338
Air Valve Rod Adjustment
339
Primary Side Vacuum Break Adjustment
339
Choke Unloader Adjustment
339
Secondary Lockout Adjustment
340
Float Level Measurement
340
Idle Speed and Mixture Adjustment
340
Carb (Slow) Idle Speed Adjustment
341
Idle Mixture Adjustment
341
Fast Idle Speed Adjustment
341
Choke Mechanism Service
341
Electric Choke Heater
342
Carburetor Model 2SE Specifications
342
Carburetor Replacement
346
Slow (Curb) Idle Speed Adjustment Procedure
357
Fast Idle Speed Adjustment Procedure
358
Float (Fuel Inlet) Circuit
359
Idle (Low Speed) Metering Circuit
360
Main (High Speed) Metering Circuit
360
Main Metering Circuit Enrichment
360
Pump (Acceleration) Circuit
361
Choke Circuit Components
361
Accelerator Pump and Lever
364
Removing Piston and Metering Rods
364
Removing Air Horn
365
Main Metering Jets
365
Check Valve Ball Location
366
Accelerator Pump Test
366
Vacuum Piston and Metering Rod Assembly
367
Vacuum Piston Gap Adjustment
367
Vacuum Piston Adjustment
368
Initial Choke Valve Clearance Adjustment
368
Automatic Choke Adjustment (on or Oil Vehicle)
369
Fast Idle Cam Adjustment
369
Idle Metering (Low Speed) Circuit
372
Bowl Vent
372
Main Metering (High Speed) Circuit
373
Power Enrichment
373
Power Enrichment Valve
373
Fast Idle Cam Retainer
377
Float Assembly
377
Interior View of Fuel Bowl
377
Booster Venturi Assembly
378
Accelerator Pump Assembly
378
Power Valve
378
Altitude Compensator
379
Damper Spring Installation
380
Float Level Adjustment—Dry
380
Float Level Adjustment—Wet
380
Initial Choke Valve Clearance and Fast Idle Cam Linkage Adjustments
381
Automatic Choke Adjustment
382
Fast Idle Cam Linkage Adjustment
382
Unloader—Fast Idle Cam Clearance
382
Accelerator Pump Stroke Adjustment
383
Idle Speed and Mixture Adjustments
383
Idle Speed Adjustment
383
Exhaust Gas Recirculation System
385
E6R System—Eight-Cylinder Engine—Typical
386
EGR Valve with Back-Pressure Sensor
386
Valve Opening Test
386
Valve Closing Test
386
EGR Valve Replacement
387
EGR Valve Maintenance
387
EGR CTO Valve Functional Test
387
EGR CTO Valve Replacement
387
Thermal Vacuum Switch (Tvs)
388
TVS Replacement
388
Egr Vacuum Dump Valve
388
Vacuum Dump Valve Functional Test
388
Positive Crankcase Ventilation System
389
Vacuum Dump Valve Replacement
389
Positive Crankcase Ventilation (PCV) Valve
390
Pcv Valve Functional Test
390
PCV System—Four-Cylinder Engine
390
PCV System—Slx-Cytlnder Engine
390
Air Filter
390
Thermostatically Controlled Air Cleaner System
391
Pcv Valve Air Inlet Filter Maintenance
391
Four- and Six-Cylinder Engines
391
TAC System—Four-Cylinder Engine
392
Testing—Tac System
393
Air Cleaner with Trap Door
393
Thermal Sensor
394
Air Cleaner Trap Door
394
Trap Door
394
Replacement—Trap Door Vacuum Motor
394
Feedback Systems
395
System Operation
397
Component Replacement
399
Coolant Temperature Switch (or Sensor)
400
Diagnostic Procedures for C4 System
400
ECM Terminal Connections
407
C4 System Tests and Trouble Code Diagnosis
408
Dwell Fixed between 5 Degrees and 10 Degrees
409
Diagnostic Test
430
Continued from Previous Page
432
Exhaust Systems
453
Exhaust Manifolds
453
Exhaust Manifold Replacement
456
Muffler Replacement
457
Air Injection Systems
459
Reverse Delay
460
Catalyst Replacement
466
Engine Instrumentation
469
General Information
469
Constant Voltage Regulator (CVR)
470
CJ Vehicles
470
Ammeter
470
Voltmeter
470
Engine Instrumentation
470
Tachometer
471
Emission Maintenance Indicator Lamp
471
Instrumentation Diagnosis
471
Test Equipment
471
Ammeter Diagnosis
472
Voltmeter Diagnosis
472
Fuel Gauge Diagnosis
472
Tachometer Diagnosis
472
Coolant Temperature Gauge Diagnosis
473
Instrument Cluster Replacement
473
Gauge and Meter Replacement
473
Ammeter—Cherokee-Wagoneer-Truck Vehicles
473
Printed Circuit Board Replacement
475
Fuel Gauge Not Functioning Properly
477
Gauge Fuse Blown
486
Fuel Gauge and Coolant Temperature both Malfunction
488
Oil Pressure Gauge Not Functioning Properly
490
Oil Pressure Gauge Not Functioning Properly Cherokee/Wagoneer/Truck
494
Problem: Coolant Temperature Gauge Not Functioning Properly
501
Specifications
508
Ammeter Calibrations
512
Fuel Gauge Sending Unit Resistance (Ohms)
512
Coolant Temperature Gauge Sending Unit Resistance (Ohms)
512
Coolant Temperature Gauge Resistance (Internal)
512
Schematics—Cherokee-Wagoneer-Truckvehicles
513
Pin Terminals
513
Lamps
513
Ammeter Circuit—Cherokee-Wagoneer-Truck
514
Fuel Gauge Circuit
514
Coolant Temperature Gauge Circuit
514
Oil Pressure Gauge Circuit
514
Chassis
519
Clutch
520
Clutch Hydraulic System Operation
520
Clutch Hydraulic Fluid
520
General Information
520
Clutch Hydraulic Fluid Level
521
Throwout Bearing
521
Clutch Service
521
Service Diagnosis
521
Clutch Chatter
522
Clutch Slippage or Inadequate Clutch Linkage Free Play
523
Clutch Drag or Inadequate Release
524
Clutch Pedal Pulsation
525
Clutch Related Vibrations
525
Clutch Adjustments
526
Transmission Clutch Shaft or Countershaft Bearing Noise
526
Crankshaft Pilot Bushing Noise
526
Throwout Bearing Noise
526
Clutch Pedal Free Play Adjustment
527
Clutch Linkage Lubrication
527
Clutch Linkage
527
Clutch Removal
528
Clutch Installation
529
Shift Lever Removal—Models T-4, T-5
529
Throwout Bearing and Lever
530
Pilot Bushing Replacement
530
Flywheel Replacement
530
Transmission Clutch Shaft
531
Clutch Housing Alignment
531
Clutch Cylinder Service
531
Clutch Cylinder Location
531
Slave Cylinder Service
532
Clutch Cylinder Assembly
532
Clutch Hydraulic System Bleeding
533
Removing Valve Spring and Stem from Plunger
533
Slave Cylinder Push Rod, Plunger, and Spring Assembly
533
Specifications
534
Clutch Service
534
Clutch Cover
535
Clutch Inspection and Service
535
Transmission Front Bearing Cap
535
Crankshaft Pilot Bushing
536
Flywheel
536
Alignment Check—Without Transmission Adapter
536
Alignment Check—With Transmission Adapter
537
Shim Placement (Six-Cylinder Engine Shown)
537
Clutch Cover Release Lever Adjustment
538
Clutch Pedal Replacement
538
Mounting Gauge Plate J-1048
538
Compressing and Seating Release Levers
538
Overcenter Spring
539
Clutch Pedal
539
Measuring Release Lever Height
539
Clutch Specifications
540
Clutch Housing Alignment Specifications
540
Manual Transmission
542
Backup Lamp Switch
542
Gearshift Patterns
542
Transmission Gear Ratios
542
General Information
542
Manual Transmission
543
Transmission Lubricants
544
Transmission Removal
544
Jumps out of Gear
545
Transmission Installation
546
Shift Lever Removal—Model T-18A
546
Shift Lever Removal—Model T-176
546
4-Speed Transmission
547
Transmission Disassembly
547
T4 Four-Speed Transmission
548
Offset Lever Pin Removal
549
Offset Lever Spring and Ball
549
Offset Lover Removal/Installation
549
Disassembly—Output Shaft Geartrain
550
Transmission Cover Removal/Installation
550
Reverse Lever and Pivot Bolt
550
Reverse Lever C-Clip Removal/Installation
550
Clutch Shaft Removal/Installation
551
Output Shaft Bearing Race Removal
551
Output Shaft Removal/Installation
551
Countershaft Rear Bearing Removal
551
Disassembly—Transmission Cover Assembly
552
Countershaft Rear Spacer Removal/Installation
552
Reverse Idler Gear Shaft Removal/Installation
552
Clutch Shaft Bearing Removal
552
Second Gear Snap Ring Removal/Installation
553
Second Gear Thrust Washer Removal/Installation
553
Output Shaft Bearing Removal
553
Cleaning and Inspection
553
Transmission Assembly
554
Assembly—Transmission Cover
554
First Gear Thrust Washer Removal/Installation
554
Roll Pin Removal
554
Assembly—Output Shaft Geartrain
555
Assembling Shift Forks and Selector Arm Plates
555
Shift Rail Oil Seal Installation
555
Assembly—Transmission Case
556
Synchronizer Insert Spring Installation
556
First Gear Roll Pin Location
556
Rear Output Shaft Bearing Installation
556
Specifications
559
Countershaft Removal/Installation
566
Rear Bearing Removal
566
Clutch Shaft and Front Bearing Assembly
566
Speed Transmission
566
Disassembly Mainshaft Geartrain
567
Clutch Shaft Front Bearing Removal
567
Removing Front Bearing from Clutch Shaft
567
Countershaft Gear Assembly
568
Cleaning and Inspection
568
Model T-176 Four-Speed Transmission
569
Reverse Idler Gear Needle Installation
570
Reverse Idler Gear Installation
570
First Gear and Thrust Washer Installation
571
Tabbed Thrust Washer Installation
571
Checking Mainshaft Geartrain End Play
571
Shift Control Housing
572
Front Bearing Cap Seal Installation
572
Shift Control Housing—T-176
573
36 Manual Transmission
575
Mainshaft Geartrain Disassembly
576
Front Bearing Removal
576
First-Second Synchronizer Assembly
577
Reverse Idler Gear
577
Supporting First-Second Clutch Hub
577
Third-Fourth Synchronizer Assembly
578
Clutch Shaft Assembly
578
Mainshaft and Geartrain Assembly
578
Second Gear and Thrust Washer Installation
578
Transmission Case Assembly
579
Third-Fourth Synchronizer Installation
579
Adapter Plate Oil Seal Position
580
Front Bearing Installation
580
General Information
584
Automatic Transmission
585
Lockup Converter Control System
586
Fluid Capacity
586
Auxiliary Cooler
586
Lockup Torque Converter Operation
586
Auxiliary Cooler Service
587
Auxiliary Cooler Removal
587
Auxiliary Cooler Installation
587
Auxiliary Cooler Mounting
587
Transmission Components
588
Clutch-Band-Gear System
588
Lockup Torque Converter Identification
588
Transmission Code and Part Numbers
588
Power Flow
589
Torque Flow
589
Neutral-Park Position
589
Drive-First Gear
589
Drive-Second Gear
590
Drive-Third Gear
590
Torque How in Drive-Second Gear
590
Hydraulic Control System
591
Manual First Gear 1 Position
591
Manual Second Gear 2 Position
591
Reverse
591
Gearshift Lever Positions
592
Pressure Supply System
592
Pressure Regulating System
592
Shift Valves
592
Periodic Maintenance
593
Emergency Towing
593
Recreational Towing
593
Automatic Transmission with Quadra-Trac
593
Diagnosis and Test Procedures
594
Preliminary Diagnosis
594
Fluid Level and Condition
594
Vehicle Is Driveable
594
Flushing Oil Cooler and Cooler Lines
595
Throttle Linkage
595
Gearshift Linkage
595
Road Test
595
Hydraulic Pressure Tests
596
Analyzing the Road Test
596
Pressure Test Port Location
596
Clutch and Band Application Chart
596
Hydraulic Pressure Test Procedure
597
Pressure Port Locations
597
Test One
597
Air Pressure Test
598
Front Clutch Test
598
Rear Clutch Test
598
Converter Housing Fluid Leak Diagnosis
599
Front Servo Test
599
Rear Servo Test
599
Leak Diagnosis Procedure
599
Governor
600
Stall Test
600
Still Speed too High
600
Stall Speed too Low
600
Service Diagnosis
600
How to Use the Charts
601
Out of Vehicle Procedures
601
In-Vehicle Procedures
602
Out-Of-Vehicle Procedures
602
Hydraulic Pressure Test Specifications
604
Hydraulic Pressure Test Diagnosis
604
Lockup Torque Converter Service Diagnosis
605
In-Vehicle Service and Adjustment
608
Gearshift Linkage Adjustment
608
Front Band Adjustment
608
Rear Band Adjustment
609
Valve Body Service
609
Oil Filter Replacement
609
Valve Body Hydraulic Control Pressure Adjustments
609
Line Pressure Adjustment
610
Throttle Pressure Adjustment
610
Front and Rear Servos
610
Governor Valve Service
611
Governor Weight E-Clip Location
611
Governor Valve Assembly
611
Park Lock Component Replacement
612
Neutral Start and Backup Lamp Switch
612
Neutral Start Circuit
612
Park Lock Components
612
Throttle Linkage Adjustment
613
Throttle Linkage Adjustment—Six-Cylinder Engine
613
Nylon Washer
613
Throttle Linkage Adjustment—-Eight-Cylinder Engine
614
Band Adjustments
615
Fluid Levels
615
Out-Of-Vehicle Service and Overhaul
616
End Play Measurement
617
Oil Pump Seal Installation
617
Transmission Holding Fixture
617
34 Automatic Transmission
617
Valve Body
618
Oil Pump and Reaction Shaft Support
618
Front Band and Front Clutch
618
Input Shaft and Rear Clutch
618
Rear Band and Drum
619
Rear Servo
619
Oil Filter Removal
620
Pressure Regulator and Manual Controls
621
Transfer Plate Assembly
621
Check Ball Location
621
Valve Body Controls
622
Installing Detent Ball Retaining Tool
622
Shuttle Valve and Governor Plugs
622
Shift Valves and Pressure Regulator Valves
623
Accumulator Piston and Spring—Inspection
624
Adapter Housing Bearing and Seal Replacement
625
Park Lock Sprag
625
Pump Bushing Replacement
626
Reaction Shift Bashing Replacement
626
Measuring Rotor Clearance—Model 999
627
Pump Bushing Removal—Model 999
627
Pump Bushing Installation—Model 999
627
Oil Pump and Reaction Shaft Support—Model 727
629
Reaction Shaft Bushing Replacement
630
Pump Bushing Removal—Model 727
631
Reaction Shaft Bushing Removal—Model 727
631
Pump Bushing Installation—Model 727
631
Front Clutch—Model 999
632
Reaction Shaft Bushing Installation—Model 727
632
Front Clutch Snap Ring Removal/Installation—Model 999
632
Retainer Bushing Replacement
633
Clutch Retainer Bushing Removal—Model 999
633
Front Clutch—Model 727
634
Measuring Front Clutch Pack Clearance
634
Front Clutch Assembly—Model 727
635
Front Clutch Retainer Bushing Removal—Model 727
635
Rear Clutch—Models 999
636
Front Clutch Retainer Bushing Installation—Model 727
636
Front Clutch Piston Spring Location
636
Rear Clutch Assembly—Model 999
637
Measuring Rear Clutch Pack Clearance
637
Piston Spring and Wave Spring Installation
637
Rear Dutch Assembly—Model 727
638
Input Shaft Bushing Replacement
638
Planetary Gear Assembly—Model 999
639
Input Shaft Bushing Removal—Model 727
639
Input Shaft Bushing Installation—Model 727
639
Measuring Planetary Gear Assembly End Play
640
Wide Ratio Planetary Gear Assembly—Model 999
640
Planetary Gear Assembly—Model 727
641
Planetary Sear Assembly—Model 727
642
Cam and Spring Retainer
643
Cam Rivet Location
643
Overrunning Clutch Cam Removal
643
Output Shaft Support Alignment
643
Front Servo and Band
644
Kickdown Servo Front Servo Assembly
644
Front Servo Assembly—Model 727
644
Overrunning Clutch Cam Installation—Model 727
644
Rear Servo and Rear Band
645
Torque Converter Service
645
Front Servo
646
Overrunning Clutch and Rear Band Link
646
Planetary Gear Assembly and Output Shaft
647
Front and Rear Clutch Assemblies
647
Front Band
647
Governor and Park Gear
648
Output Shaft Bearing and Adapter Housing
648
Valve Body and Accumulator Piston
648
Specifications
649
Hydraulic Flow Charts
656
Transfer Case
675
General Information
675
Transfer Case Service
677
Transfer Case Shift Linkage
677
Transfer Case Installation
679
Transfer Case Removal
679
Model 208 Transfer Case
680
Transfer Case Shift Pattern
680
Four-Wheel Drive Indicator Lamp
680
Model 208 Shift Pattern—Manual Transmission
680
Lubrication
681
Model 208 Shift Pattern—Automatic Transmission
681
Service Diagnosis
681
In-Vehicle Service
682
Changing Lubricant
682
Rear Retainer Removal/Installation
685
Cleaning and Inspection
685
Detent Ball. Spring and Bolt Removal/Installation
687
Oil Pump Removal/Installation
687
Driven Sprocket Retaining Snap Ring Removal/Installation
687
Subassembly Overhaul
687
Front Output Shaft
687
Bearing/Bushing Replacement
688
Rear Output Bearing and Rear Seal Replacement
688
Sprocket and Chain Removal/Installation
688
Sprocket Carrier Stop Ring and Clutch Spring Removal/Installation
688
Detent Ball, Spring and Bolt Removal/Installation
689
Specifications
697
Service Diagnosis
700
Specifications
713
Shift Rod Oil Seal Replacement
714
Front—Rear Yoke Oil Seal Replacement
714
Propeller Shaft
725
Section Index
725
Driveline Vibration
726
Rear Propeller Shaft Assembly
726
Double Cardan Universal Joint
726
Single Cardan Universal Joint
726
Problem: Drive Line Vibration
727
Driveline Vibration Diagnosis
727
Universal Joint Angle Measurement and Adjustment
732
Lubricant Type
732
Lubrication Intervals
732
Lubrication Fittings
732
Universal Joint Service
733
Removal-Rear Shaft
733
Installation—Rear Shaft
733
Disassembly—Single Cardan Joint
733
Assembly—Single Cardan Joint
734
Disassembly—Double Cardan Joint
734
Assembly—Double Cardan Joint
734
Universal Joint Angle Chart
734
Axles - Front Hubs
737
Tire Noise Diagnosis
737
Wheel Bearing Diagnosis
737
Axle Test and Diagnosis
737
Front Axle
738
Axle Noisy on Pull and Coast
738
Axle Noisy on Pull
738
Axle Noisy on Coast
738
Axle Identification
739
Front Axis Assembly
739
Front Wheel Alignment
740
High Steering Effort
740
Ball Stud Preload Measurement
740
Axle Housing Service
740
Pinion Seal and Yoke
741
Ball Stud Preload Correction
741
Axle Shaft
742
Removal—Cj and Scrambler Models
742
Installation—Cj and Scrambler Models
742
Removal—Cherokee-Wagoneer-Truck
742
Axle Shaft Universal Joint
743
Installation—Cherokee-Wagoneer-Truck
743
Steering Knuckle Removal
744
Steering Knuckle Ball Studs
744
Lower Ball Stud Removal
744
Upper Ball Stud—Removal
744
Lower Ball Stud—Installation
745
Upper Ball Stud Installation
745
Upper Ball Stud Removal
745
Steering Knuckle Installation
746
Lower Ball Stud Installation
746
Tightening Upper Ball Stud Seat
746
Axle Shaft Seal
747
Spindle Bearing
747
Axle Housing Inner Oil Seal
747
Axle Removal
747
Axle Installation
748
Turning Angle Adjustment
748
Rear Axle
749
J-20 Truck Axle
749
Axle Housing
750
Axle Hub—Cj and Scrambler Models
750
Axle Ratio Code Location—Amc/Jeep Axle
750
Axle Hub Removal—Cj and Scrambler Axle
750
Original Hub Installation
751
Replacement Hub Installation
751
End Play Adjustment—Cj and Scrambler Axle Shaft
752
Axle Shaft Bearing Removal—Cj and Scrambler Models
752
Inner OH Seal Installation—Cj and Scrambler Models
752
Axle Shaft Bearing Replacement
753
Installation—Cherokee-Wagoneer-J-10 Truck
754
Removal—J-20 Truck
754
Installation—J-20 Truck
754
Pinion Seal Removal
754
Rear Axle Removal
755
Rear Axle Installation
755
Pinion Seal Installation
755
Standard Differential
757
Differential Operation
757
Differential Disassembly
757
Differential Bearing Removal
758
Ring Gear Removal
758
Pinion Mate Shaft Removal
758
Pinion Bearing Cup Removal
759
Pinon Gear Removal
759
Differential Assembly
760
Pinion Gear Installation and Depth Adjustment
760
Pinion Variance Chart
760
Ring and Pinion Gear Markings
761
Standard Setting Dimension/Pinion Depth Shim Location—Amc/Jeep Axle
761
Differential Bearing Preload Adjustment
766
Differential Installation
766
Pinion Gear Removal—Model 30-44-60 Axle
768
Pinion Rear Bearing Removal—Model 30-44 Axle
768
Pinion Rear Bearing Removal—Model 60 Axle
768
Specifications
775
Trac-Lok Differential
776
Service Replacement
783
Stop Vehicle
797
Rear Brakes
800
Brake Pedal
806
Parking Brake Adjustment
807
Service Brake Adjustment
809
Brakelamp Switch
809
Brakelining Inspection
810
Hydraulic System
811
Brake Fluid
811
Brake Fluid Level
812
Master Cylinder
812
Wheel Cylinder
814
Metering Valve
817
Combination Valve
817
Brake Bleeding
818
Specifications
820
Power Brake Units
820
Power Unit Installation
822
Drum Brakes
822
Disc Brakes
828
Specifications
842
Tire Construction
845
Wheels and Tires
846
Tire Repair
848
Wheel Balancing
850
Wheel Bearing Adjustment
850
Specifications
856
High Steering Shaft Effort
861
Signal Lights
865
Chapter 2C-Automatic Transmission
868
Steering Column Removal
869
Steering Shaft
870
Steering Column Installation
871
Pivot Pin
885
Ignition Switch
895
Specifications
898
Manual Steering Gear
902
Hard Steering
903
Loose Steering
903
Installation
904
Assembly and Adjustment
908
Specifications
911
Description and Operation
913
High Pressure
917
Hissing Noise in Steering Gear
918
Hydraulic Pressure Test
927
Specifications
930
Power Steering Gear
931
Specifications
948
Power Steering Pump
949
Pump Assembly
953
Steering Linkage
959
Connecting Rod
961
Steering Damper
961
Shock Absorbers
965
Stabilizer Bar
967
Front Spring
968
Rear Spring
970
Water Leaks
977
Static Test
985
Luggage Racks
987
Anti-Corrosion Protection
989
Instrument Cluster
995
Instrument Panel
995
Instrument Illumination
997
Cigar Lighter
998
System Controls
1003
Fresh Air Ventilation
1004
Heater Core
1006
Control Cables
1006
Blower Motor
1006
Defroster Duct
1007
Heater Control Panel
1009
Control Cable
1010
Air Conditioning
1014
Control Operation
1014
Control Panel
1014
Sight Glass
1015
Magnetic Clutch
1017
Refrigerant Safety Precautions
1021
Service Valves
1022
Discharging System
1027
Evacuating System
1027
Checking for Leaks
1028
Flushing System
1029
Compressor Replacement
1033
Front View
1038
Troubleshooting Chart
1039
Specifications
1040
Compressor Installation
1041
Frame Straightening
1057
Rear Quarter Panels
1058
Storage Compartment
1071
Lock Cylinder
1072
Hood Bumper
1077
Section Index
1079
Sealing System
1079
Window System
1079
Lock System
1080
Installation
1082
Section Index
1093
Outside Mirrors
1102
Electrically Operated
1108
Control Switch
1109
Motor Test
1111
Rear Quarter
1115
Trim Panel
1115
Section Index
1119
Power Sunroof
1126
Glass Panel
1126
Luggage Rack
1133
Side Rail
1134
Section Index
1137
Front Seats
1137
Seat Belts
1140
Rear Seats
1141
Power Seats
1142
Servicing Procedures
1143
Seat Assembly
1144
Wheelhouse Carpet
1145
Locked Position
1149
Rear Window
1152
Chapter 3K-Rear Quarter for CJ and Scrambler Sta Tionary Glass Removal or Installation
1152
Lighting Systems
1165
Cargo Lamp
1170
Side Marker Lamp Bulb
1170
Directional Signal Switch
1170
Stoplamp Switch
1173
Fog Lamps
1173
Interior Lighting
1175
Dome/Reading Lamp
1176
Lighted Vanity Mirror
1176
Instrument Cluster Lamps
1177
Chassis Wiring Harness
1177
Fuse Panel
1179
Circuit Breakers
1179
Horn Systems
1183
Specifications
1184
Wiper Blade Replacement
1185
Windshield Wipers
1186
Wiper Arm Replacement
1186
Wiper and Washer Control
1186
Washer Pump
1187
Wiper Blade Element Replacement
1188
Wiper Motor
1200
Windshield Washers
1203
Antenna Trimmer
1209
Premium Audio System
1212
Antenna Tuning
1213
Radio Replacement
1220
Bulb Replacement
1221
Alphabetical Index
1226
Wiring Diagrams
1269
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