1. DL manuals
  2. Jeep
  3. Automobile
  4. cherokee 1989
  5. Owner's Manual

Jeep cherokee 1989 Owner's Manual

Summary of cherokee 1989

  • Page 1

    Contents introductory pages about this manual 0-5 to the jeep cherokee and comanche 0-5 vehicle identification numbers 0-7 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...

  • Page 2

    The motor manual guy.

  • Page 3

    The motor manual guy.

  • Page 4: Vehicle

    Vehicle numbers modifications are a continuing and unpublicized process in vehicle of production, the gross vehicle weight rating and the certi- manufacturing. Since spare parts manuals and lists are compiled on fication statement. A numerical basis, the individual vehicle numbers are essential t o ...

  • Page 5

    The build date and serial number are stamped on the bottom of the ax manual transmission case number date number 1-363 the three-speed automatic transmission numbers are stamped on the edge of the left side of the case typical transfer case id tag ba 1015 manual transmission id number location trans...

  • Page 6

    Vehicle identification numbers 0-9 transmission identification number the id number on t 415 manual transmissions is located on a tag attached to the rear of the case. On ax 415 manual transmissions, there are t w o identification codes: a shipping date stamped on the shift tower and an eight digit ...

  • Page 7

    Maintenance techniques, tools and working facilities 0-1 1 fastener sizes for a number of reasons, automobile manufacturers are making wider and wider use of metric fasteners. Therefore, it is important t o be able t o tell the difference between standard (sometimes called u.S. Or and metric hardwar...

  • Page 8

    0-1 2 maintenance techniques, tools and working facilities while smaller studs carry a geometric code t o denote grade. It should be noted that many fasteners, especially grades through 2, have no distinguishing marks on them. When such is the case, the only way t o determine whether it is standard ...

  • Page 9

    Maintenance techniques, tools and working facilities 0-13 for 2 and grade 3 fasteners. Higher grades can tolerate higher torque values. Fasteners laid o u t a pattern, such as cylinder head bolts, oil pan bolts, differential cover bolts, etc., must be loosened or tightened in sequence t o warping th...

  • Page 10

    0-1 4 maintenance techniques, tools and working facilities caliper hand-operated vacuum pump timing light compression gauge with spark plug hole adapter hydraulic lifter removal tool ridge reamer wheel puller general purpose puller valve spring compressor valve spring compressor piston ring groove c...

  • Page 11

    - x - se awes) aq aq pue the motor manual guy.

  • Page 12

    0-16 maintenance techniques, tools and working facilities pliers - vise grip pliers - lineman's pliers - needle nose pliers - snap-ring (internal and external) cold chisel scribe scraper from flattened copper tubing) centerpunch pin punches steel 12 inch wrench set to or 4 to a selection of files wi...

  • Page 13: Jacking And  Towing

    Booster battery (jump) starting certain precautions must be observed when using a booster battery t o start a vehicle. Before connecting the booster battery, make sure the ignition switch is in the off position. Turn off the lights, heater and other electrical loads. Your eyes should be shielded. Sa...

  • Page 14

    0-18 jacking and towing sides facing in. Tighten them snugly, but wait until the vehicle is lowered t o tighten them completely. Note that some spare tires are designed for temporary use only - don't exceed the recommended speed, mileage or other restrictions accompanying the spare. Lower the vehicl...

  • Page 15

    Automotive chemicals and lubricants a number of automotive chemicals and lubricants are available for 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. Cl...

  • Page 16: Safety

    Safety first! Regardless of h o w enthusiastic you may be about getting o n w i t h the job at hand, take the time t o ensure that your safety is not jeopard- ized. A moment's lack of attention can result in an accident, as can failure t o observe certain simple safety precautions. The possibility o...

  • Page 17: Conversion Factors

    Conversion factors length (distance) inches (in) feet miles volume (capacity) cubic inches (cu in; in 3 ) lmperial pints (imp lmperial quarts (irnp lmperial quarts (imp us quarts (us lrnperial gallons (imp gal) lrnperial gallons gal) us gallons (us gal) mass (weight) ounces pounds force ounces-force...

  • Page 18: Troubleshooting

    Troubleshooting contents symptom section symptom section engine and performance alternator light fails to come on when key is turned on 1 3 alternator light stays on 1 2 battery will not hold a charge 11 engine backfires 1 8 engine diesels (continues t o run) after being turned off 21 engine hard t ...

  • Page 19

    Troubleshooting never overlook the obvious. Anyone can run the gas tank dry or leave the lights on overnight, so don't assume that you're exempt from such oversights. Finally, always establish a clear idea why a problem has occurred and take steps t o ensure that it doesn't happen again. If the elec...

  • Page 20

    0-24 troubleshooting 3 wet or damaged distributor components (chapter 1 4 short circuits in ignition, coil or spark plug wires. 5 sticking or faulty emissions systems (see chapter 6 clogged fuel filter foreign matter in fuel. Remove the fuel filter (chapter and inspect. 7 vacuum leaks at intake mani...

  • Page 21

    Troubleshooting 0-25 21 engine diesels (continues t o run) after being turned off 1 speed too high (chapter 1). 2 lgnition timing incorrect (chapter 1 3 lncorrect spark plug heat range (chapter 1). 4 intake air leak (see section 8 ) . 5 carbon build-up in combustion chambers. Remove the cylinder and...

  • Page 22

    0-26 troubleshooting chapters 1 and 2). 5 leak from coolant temperature switch (chapter 6 leak from damaged gaskets or small cracks (chapter 7 damaged head gasket. This can be verifed by checking the con- dition of the engine oil as noted in section 30. 30 internal coolant leakage note: lnternal coo...

  • Page 23

    Troubleshooting 8-27 air flow t o the transmission. 2 to pinpoint a leak, first remove all built-up dirt and grime from the transmission. Degreasing agents steam cleaning will achieve this. With the underside clean, drive the vehicle at low speeds so the air flow will not blow the leak far from its ...

  • Page 24

    0-28 troubleshooting 2 loose driveshaft bolts. Lnspect all bolts and nuts and tighten them securely. 3 worn or damaged universal joint bearings. Replace driveshaft (chapter 4 worn sleeve yoke and mainshaft spline. 60 noise when turning defective differential. 5 4 metallic grating sound consistent wi...

  • Page 25

    Troubleshooting 0-29 piston or damage. 5 brake pad t o rotor adjustment needed. Lnspect automatic adjusting mechanism for proper operation. 6 scored or out of round rotor. 7 loose caliper mounting bolts. 8 lncorrect wheel bearing adjustment. 67 noise (high-pitched squeal) 1 front brake pads worn out...

  • Page 26

    Troubleshooting 8 steering gear improperly adjusted. 9 loose, worn or damaged steering components. 1 0 damaged idler arm. 11 worn balljoint. 78 excessive pitching rolling around corners or during braking 1 defective shock absorbers. Replace as a set. 2 broken or weak leaf springs suspension componen...

  • Page 27: Chapter

    Chapter and routine maintenance contents air filter and pcv filter replacement 32 automatic transmission fluid and filter change 34 ....................................... Automatic transmission fluid level check 6 .................................................... Battery check and maintenance 8 ...

  • Page 28

    1-2 chapter 1 tune-up and routine maintenance capacities (continued) manual transmission (approximate) 4-speed 5-speed transfer case (approximate) ................................................................................... Selec-trac command-trac 7.5 pints 7.2 pints 3.0 pints 2.2 pints ignit...

  • Page 29: Jeep

    The following maintenance intervals are based on the assumption that the vehicle owner will be doing the maintenance or service work, as opposed t o having a dealer service department do the work. Although the intervals are loosely based on fac- tory recommendations, most have been shortened t o ens...

  • Page 30

    Engine compartment component checking points six-cylinder engine shown) 1 crankcase ventilation 7 drivebelt system hose and fitting 8 ccv fresh air hose 2 clutch fluid reservoir 9 engine oil filler cap 3 brake fluid reservoir 10 engine oil dipstick 4 windshield washer reservoir radiator hose 5 air c...

  • Page 31

    Typical engine compartment under side components vehicle shown) front driveshaft slip joint grease fitting 2 transmission 3 engine oil drain plug 4 exhaust pipe 5 brake 6 steering linkage 7 steering damper 8 front driveaxle 9 front disc brake caliper front driveshaft universal joint the motor manual...

  • Page 32

    The motor manual guy.

  • Page 33

    Chapter 1 tune-up and routine maintenance 1-7 2 introduction this chapter is designed t o help the home mechanic maintain the jeep cherokee or comanche with the of maximum economy, safety and reliability in included is a master maintenance schedule (page followed by procedures dealing specifically w...

  • Page 34

    1-8 chapter 1 tune-up and routine maintenance 4.6 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 tube on the driver's side o f the engine) - always make sure the area around this opening is clean before unscrewing the cap t ...

  • Page 35

    Chapter 1 tune-up and routine maintenance 1-9 4.14 the windshield washer fluid reservoir is located on the driver's side of the engine compartment - keep the level at or near the full line; fluid can be added after flipping up the cap windshield washer fluid refer to illustration 4.14 14 fluid for t...

  • Page 36

    1-10 chapter 1 tune-up and routine maintenance reservoir cap or cover with a clean rag t o prevent contamination of the brake clutch system before removing the cover. 2 0 when adding fluid, pour it carefully into the reservoir t o avoid spill- ing it onto surrounding painted surfaces. Be sure the sp...

  • Page 37

    Chapter 1 tune-up and routine maintenance 1-11 if a tire loses air o n a steady basis, check the valve core first t o make sure it's snug (special inexpensive wrenches are commonly available at auto parts stores) sometimes a tire will hold air pressure for a short time or leak down very slowly after...

  • Page 38

    1-12 chapter 1 tune-up and routine maintenance if additional fluid is required, add it directly into the tube using a funnel. It takes about one pint t o raise the level from the add mark t o the full mark with a warm transmission, so add the fluid a little at a time and keep checking the level unti...

  • Page 39

    Chapter 1 tune-up and routine maintenance has been installed, the following procedure can be used. 4 check the electrolyte level in each of the battery cells. It must be above the plates. There's usually a split-ring indicator in each cell t o indicate the correct level. If the level is low, add dis...

  • Page 40

    1-14 chapter 1 tune-up and routine maintenance 9 cooling system check refer to illustration 9.4 1 many major engine failures can be attributed t o a faulty cooling system. If the vehicle is equipped with an automatic transmission, the cooling system also cools the transmission fluid and thus plays a...

  • Page 41

    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 the strength necessary t o w...

  • Page 42

    Chapter 1 tune-up and routine maintenance 5 if this is your first oil change, get under the vehicle and familiarize yourself with the locations of the oil drain plug and the oil filter. The engine and exhaust components will be warm during the actual work, so note how they are situated t o avoid tou...

  • Page 43

    Chapter 1 tune-up and routine maintenance 1-17 1 9 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...

  • Page 44

    1-18 chapter 1 tune-up and routine maintenance 13.10 the slip joint grease fitting is located on the collar - pump grease into i t until it comes out of the slip joint seal 13.1 1 pump grease into conventional universal joints until it can be seen coming out of the contact surfaces 13. Use white lit...

  • Page 45

    Chapter 1 tune-up and routine maintenance 15 exhaust system check 1 with the engine cold (at least three hours after the vehicle has been driven), complete exhaust system from the manifold to the end of the tailpipe. Be careful around the catalytic converter, which may be hot even after three hours....

  • Page 46

    1-20 chapter 1 tune-up and routine maintenance 19.2 the recommended tire rotation patterns for these vehicles 1 9 tire rotation refer to illustration 19.2 1 the tires should be rotated at the specified intervals and whenever uneven wear is noticed. 2 refer to the accompanying illustration for the pr...

  • Page 47

    Chapter 1 tune-up and routine maintenance 1-21 20.14 peel the wheel cylinder boot back carefully and check for leaking fluid - any leakage indicates the cylinder must be replaced or rebuilt glazed (shiny surface) or contaminated with brake fluid. 1 3 make sure that all the brake assembly springs are...

  • Page 48

    1-22 chapter 1 tune-up and routine maintenance 25 thermostatic air cleaner check refer to and 1 some engines are equipped with a thermostatically controlled air cleaner which draws air to the carburetor from different locations, de- pending on engine temperature. 2 this is a visual check. If access ...

  • Page 49

    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- sion gauge, available at auto parts stores (see illustration). 5 if adjustment is needed, either to make the belt tigh...

  • Page 50

    1-24 chapter 1 tune-up and routine maintenance 2 7 check 1 check the seatbelts, buckles, latch plates and guide loops for any obvious damage or signs of wear. 2 make sure the reminder light comes on when the key is turned on. 3 the seatbelts are designed t o lock up during a sudden stop or im- pact,...

  • Page 51

    Chapter 1 tune-up and routine maintenance 1-25 31 fuel filter replacement vehicles equipped with a v6 engine refer to illustrations 3 1.6 and 3 1.8 1 on these models, the fuel filter is located inside the fuel inlet nut at the carburetor. It's made of either pleated paper or porous bronze and cannot...

  • Page 52

    1-26 chapter 1 tune-up and routine maintenance 3 2 air filter and pcv filter replacement refer to illustrations 32. 32.4 and 32.6 1 at the specified intervals, the air filter and (if equipped) filter should be replaced with new ones. The engine air cleaner also supplies filtered air t o the system. ...

  • Page 53

    Chapter 1 tune-up and routine maintenance 1-27 33.1 tools needed t o check and adjust the ignition timing vacuum plugs - vacuum hoses will, i n most cases, have to be disconnected and plugged. Molded plugs i n various shapes and sizes are available for this 2 inductive pick-up timing l i g h t - fla...

  • Page 54

    1-28 chapter 1 tune-up and routine maintenance screws filter 34.10 the automatic transmission fluid filter is held i n place by three screws transmission shown) 10 remove the filter from the transmission valve body (see illus- tration). 11 install a new filter. 12 make sure the gasket surface on the...

  • Page 55

    Chapter 1 tune-up and routine maintenance 36.8 carefully scrape the old gasket or sealant material off t o ensure a clean surface for the new gasket t o seal against 3 remove the fill plug from the differential. 4 if equipped with a drain plug, remove the plug and allow the dif- ferential lubricant ...

  • Page 56

    1-30 chapter 1 tune-up and routine maintenance 38.6 dislodge the dust cap by working around the outer edge w i t h a screwdriver or hammer and chisel 38.7 remove the cotter pin and discard it - use a new one when the hub is reinstalled and chisel (see illustration). 7 straighten the bent ends of the...

  • Page 57

    Chapter 1 tune-up and routine maintenance 1-31 38.1 1 use a screwdriver t o pry the grease seal from the 38.1 5 work the grease into each bearing from the rear o f the hub diameter side until grease oozes out the small-diameter side 2 5 using your hand (not a wrench of any kind), tighten the nut unt...

  • Page 58

    1-32 chapter tune-up and routine maintenance coolant temperature sensor drain plug 39.5 on four and six-cylinder engines, the block drain plug is located on the driver's side of the engine block, below the exhaust manifold; v 6 engines have t w o block drain plugs at the lower rear o f each side of ...

  • Page 59

    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 i n the engine and out to make sure it isn't stuck compartment - check the hoses connected t o i t...

  • Page 60

    1-34 chapter 1 tune-up and routine maintenance plug. Pull only on the boot at the end of the wire - d o not pull on the wire. A plug wire removal tool should be used if available (see illustra- tion). 7 if compressed air is available, use it t o blow any dirt or foreign ma- terial away from the spar...

  • Page 61

    : dry sooty deposits ich mixture or weak uses misfiring, hard recommendation: check for a clogged air cleaner, high float level, sticky choke and worn ig- nition points. Use a spark plug with a longer core nose for greater anti-fouling protection. Oil deposits symptoms: oily coating caused by poor o...

  • Page 62

    1-36 chapter 1 tune-up and routine maintenance damage. Closely examine the terminals on the inside of the cap for excessive corrosion and damage (see illustration). Slight deposits are normal. Again, if in doubt about the condition of the cap, replace it with a new one. Be sure to apply a small dab ...

  • Page 63: Chapter

    Chapter 2 part four-cylinder engine contents camshaft and bearings - removal, inspection and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 cylinder compression check. . . . . . . . . . . . . . . . See chapter 2 d cylinder head - removal and installation . . . . ....

  • Page 64

    2a-2 chapter 2 part a four-cylinder engine torque specifications 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 b...

  • Page 65

    Chapter 2 part a four-cylinder engine 2a-3 3.6 make a mark on the aluminum distributor body directly below the number one spark plug wire terminal on the distributor cap (arrow) of the distributor cap and ground it on the block with a jumper wire. On ignition systems with the ignition coil in the di...

  • Page 66

    2a-4 chapter 2 part a four-cylinder engine 4.6 remove the old sealant from the rocker arm cover flange and the cylinder head w i t h a gasket scraper, then clean the mating surfaces w i t h lacquer thinner or acetone 4.5 on 1 9 8 4 through 1 9 8 6 models, carefully pry the cover loose after breaking...

  • Page 67

    Chapter 2 part a four-cylinder engine 2a-5 rocker arm 5.3 rocker arm mounts exploded view 8 inspect the for cracks and excessive wear at the ends. Roll each across a piece of plate glass t o see if it's bent (if it wobbles, it's bent). Tallation 9 lubricate the lower ends of the with clean engine oi...

  • Page 68

    2a-6 chapter 2 part a four-cylinder engine 6.9 once the spring is depressed, the keepers-can be removed w i t h a small magnet or needle-nose pliers magnet is preferred t o prevent dropping the keepers) 6.17 apply a small dab of grease t o the keepers before installation - i t will hold them i n pla...

  • Page 69

    Chapter 2 part a four-cylinder engine 2a-7 intake manifold 7.9 remove the old intake manifold gasket w i t h a scraper - don't leave any material on the mating surfaces 7.12 intake and exhaust manifold bolt tightening sequence 9 cylinder head - removal and installation 8 exhaust manifold - removal a...

  • Page 70

    2a-8 chapter 2 part a four-cylinder engine 8 5 1 4 9.1 5 cylinder head tightening sequence 10 inspect the cylinder head for cracks and check it for refer t o chapter 2, part d, for cylinder head servicing procedures. 1 1 through four-cylinder engines use different head gaskets than 1988 and later mo...

  • Page 71

    Chapter 2 part a four-cylinder engine 2a-9 i f the bottom (foot) of any lifter is worn concave (shown here), scratched or galled, replace the entire set with new lifters the foot of each lifter should be slightly convex - the side of another lifter can be used as a straightedge t o check it; if it a...

  • Page 72

    Chapter 2 part a four-cylinder engine 12.2 the front crankshaft seal can be removed w i t h a seal removal tool or a large screwdriver (v6 engine shown - cylinder similar) 12.6 once the timing chain cover is removed, place it on a flat surface and gently pry the old seal out w i t h a large screwdri...

  • Page 73

    Chapter 2 part a four-cylinder engine bore with the lip (open end) of the seal facing in. A small amount of oil applied t o the outer edge of the new seal will make installation easier - don't overdo it! 8 drive the seal into the bore with a large socket and hammer until it's completely seated (see ...

  • Page 74

    2a-12 chapter 2 part a four-cylinder engine 14.3 the timing marks on the sprockets (arrows) should be lined up as shown 1 4 timing chain and sprockets - removal, inspection and installation refer to illustrations 14.3, 14.5, and 14. 1 set the number one piston at top dead center (see section 3). 2 r...

  • Page 75

    Chapter 2 part a four-cylinder engine the marks on the sprockets are still properly aligned (see illustration 14.3). 9 lnstall the camshaft sprocket retaining bolt and washer and tighten t o the specified torque. 1 0 to verify correct installation of the timing chain, turn the crankshaft to place th...

  • Page 76

    2a-14 chapter 2 part a four-cylinder engine 15.27 be sure t o apply moly-base grease or engine assembly lube t o the cam lobes and bearing journals before installing the camshaft by an automotive machine shop. 2 4 lnspect the distributor drive gear for wear. Replace the camshaft if the gear is worn....

  • Page 77

    Chapter 2 part a four-cylinder engine 5 3 detach the oil pump and strainer assembly from the block. 4 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 the original or attempt to rebuild it. 5 to install the pump, ...

  • Page 78

    Chapter 2 part a four-cylinder engine before installing the bolts, apply thread locking compound t o the threads. 10 wedge a screwdriver into the ring gear teeth to keep the driveplate from turning as you tighten the bolts t o the specified torque. After the initial torque has been reached, turn eac...

  • Page 79

    Chapter 2 part a four-cylinder engine 9 install the flywheel or driveplate. 1 0 if equipped with a manual transmission, reinstall the clutch disc and pressure plate. Reinstall the transmission as described in chapter 7. 20 engine mounts - check and replacement refer to illustration 20.8 1 engine mou...

  • Page 80: Chapter

    Chapter 2 part v6 engine contents air filter replacement. See chapter 1 oil pan - removal and installation 17 . . . . . . . . . . . . . . . . . . . Camshaft and bearings removal, inspection oil pump removal and installation 18 and installation 16 rear main oil seal - replacement 20 compression check...

  • Page 81

    Chapter 2 part b v6 engine bolts intake manifold-to-cylinder head bolts oil pan mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 x 1.0 m m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil pum...

  • Page 82

    Chapter 2 part 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 6 disconnect the rubber hose from the air injection manifold (the air injection manifold is the group of metal tubes which are screwed into the exhaust manifo...

  • Page 83

    Chapter 2 part b v 6 engine 5.10 the ends of the and the valve stems should be lubricated with moly-base grease prior to installation of the rocker arms 1 moly-base grease applied to the pivot balls will ensure adequate lubrication until oil pressure builds up when the engine is started 6 valve lash...

  • Page 84

    2b-4 chapter 2 part b v6 engine 8.17 use a 3116-inch diameter cutter t o form a groove in the manifold 8.13 i f a machined groove is not present o n the underside of the rear of the manifold, scribe marks t o outline the area t o be ground out 1 2 thoroughly clean all sealing surfaces, removing all ...

  • Page 85

    Chapter 2 part b v6 engine 9.7 right-side exhaust manifold - exploded view (left side similar) right side 1 remove the cable from the negative battery terminal. 2 raise the front of the vehicle and support it securely on jackstands. Block the rear wheels t o keep the vehicle from rolling. 3 remove t...

  • Page 86

    Chapter 2 part b v6 engine 11.5 use a puller that applies force t o the center o f the hub be sure the center puller bolt doesn't damage the crankshaft threads head, the gasket surfaces of both the head and the engine block must be clean and free of nicks and scratches. Also, the threads in the bloc...

  • Page 87

    Chapter 2 part b v6 engine driving the seal out of the front cover 12.9 installing the new oil seal w i t h a wood block and a hammer after the water pump is removed, t w o bolts and t w o studs secure the timing chain cover t o the engine block . , exert even pressure around the entire circumferenc...

  • Page 88

    28-8 chapter 2 part b v 6 engine t w o types of sealant as shown i bead of 2 bead of rtv sealant anaerobic sealant 14.8 the camshaft and crankshaft timing marks (arrows) should be in exact alignment before removing the timing sprockets and chain the mating surface where the cover engages the oil pan...

  • Page 89

    Chapter 2 part b v6 engine 2b-9 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). Install the timing chain over the camshaft sprocket with slack in the chain...

  • Page 90

    Chapter 2 part b v6 engine 16.10 long bolts can be threaded into the camshaft bolt holes t o provide a handle for removal and installation of the camshaft - support the cam near the block as it's withdrawn 16.1 1 a length of wire w i t h a hook on it can be used t o support the camshaft as you guide...

  • Page 91

    Chapter 2 part b v6 engine 1 using a straightedge, check for distortion at the 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). 1 2 replace the oil pan with part no. 895301 1840 (or eq...

  • Page 92

    2 chapter 2 part b v6 engine 20.3 using a packing tool t o pack the old rear main oil seal into the groove - rope-type seal engines 20.17 tap i n one side of the seal and pull the seal out from the other side w i t h pliers 3 using tool j-291 14-2, drive the old seal gently back into the groove, pac...

  • Page 93

    Chapter 2 part b v6 engine 2b-13 20.31 using a screwdriver, pry the rear main seal from the bore be careful not t o scratch the crankshaft seal surface or the edge of the seal bore 21 v6 engine mounts - exploded view plastic installation tool; if not, a tool may be fashioned from an old feeler gauge...

  • Page 94: Chapter

    Chapter 2 part c six-cylinder engine contents air filter and pcv filter replacement see chapter 1 intake manifold removal and installation 7 . Camshaft. Bearings and lifters removal. Inspection oil pan removal and installation 1 5 and installation 1 4 oil pump removal and installation 1 6 compressio...

  • Page 95

    Chapter 2 part c lnline six-cylinder engine oil pump mounting bolt short 1 0 long 17 rear main bearing cap bolts 8 0 rocker arm bolts 1 9 rocker arm cover-to-cylinder head bolts with rtv 28 in-lbs with permanent gasket 55 in-lbs tensioner bracket-to-block bolts 14 timing chain cover-to-block bolts 5...

  • Page 96

    2c-2 chapter 2 part c six-cylinder engine 4.1 view from above shows locations o f crankcase breather tube and hose (arrows) 4.4 use a soft-face mallet t o break the cover loose - do not pry between the cover and head 5.2 go back and forth between the intake and exhaust rocker arms, loosening each bo...

  • Page 97

    Chapter 2 part six-cylinder engine 5.4 store the in a box like this t o ensure reinstallation in the same location 3 remove the rocker arms, bridges and fulcrums (see illustration) and store them with their respective mounting bolts. Store each set of rocker arm components separately in a marked pla...

  • Page 98

    2c-4 chapter 2 part c six-cylinder engine 7.1 1 remove the bolts (arrows) and lift the heat shield off 11 remove the intake manifold heat shield (see illustration). 12 unbolt the intake manifold, referring to the accompanying illustra- tion and illustration 7.20. 1 3 remove the egr tube from the int...

  • Page 99

    Chapter 2 part c 7 position a new gasket on the locating dowels and slide the manifold over the studs. 8 install the attaching nuts on the studs finger tight. 9 reinstall the intake manifold (see section 7) and tighten all fasten- ers, in the sequence shown in illustration 7.20, t o the specified to...

  • Page 100

    2c-6 chapter 2 part c six-cylinder engine -- 592 sealant (or equivalent) and install the head bolts hand tight. Note: 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...

  • Page 101

    Chapter 2 part c six-cylinder engine 2c-7 1 1 . 3 gently drive the new seal into place with a hammer and large socket 1 2 timing chain cover removal and installation refer to illustrations 12.4, 12.7 and 12.13 1 disconnect the negative cable from the battery. 2 remove the fan, fan shroud, radiator a...

  • Page 102

    2c-8 chapter 2 part c six-cylinder engine 13.3 slip the oil slinger off the crankshaft, noting that the cupped side faces away from the engine 13.7 with the number one piston at top dead center, the timing chain sprocket index dots (arrows) are directly opposite each other 13.8 remove the thrust pin...

  • Page 103

    Chapter 2 part c six-cylinder engine . . . For the camshaft locating dowel (arrow) - be sure they are aligned properly during installation o'clock position. This positions the crankshaft sprocket timing mark where the adjacent tooth meshes with the chain at the three o'clock position. There must be ...

  • Page 104

    2c-10 chapter 2 part c six-cylinder engine cedure. Camshaft and bearing inspection are covered in chapter 2, part a, section 16. Be sure t o use the specifications provided in this part of chapter 2. 1 3 camshaft bearing replacement requires special tools and expertise that place it outside the scop...

  • Page 105

    Chapter 2 part c six-cylinder engine 2c-1 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. 1 7 slide the oil pan up under the engine and reinstall the oil pump and pickup tube, tighening the oil p...

  • Page 106: Chapter

    Chapter 2 part d general engine overhaul procedures contents crankshaft - inspection. Crankshaft - installation and main bearing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearancecheck crankshaft - removal cylinder compression check cylinder head - cleaning and inspection....

  • Page 107

    Chapter 2 part d general engine overhaul procedures crankshaft and connecting rods connecting rod journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diameter. Bearing oil clearance desired allowable connecting rod side clearance (end play). Main bearing journal . . . ....

  • Page 108

    2d-2 chapter 2 part d general engine overhaul procedures six-cylinder engine general cylinder compression pressure maximum variation between cylinders oil pressure a t idle ( 6 0 0 rpm) above cylinder head and valves l i m i t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum valve...

  • Page 109

    Chapter 2 part d general engine overhaul procedures 2d-3 remove the oil pressure sending unit (arrow) sands of miles of reliable service. Conversely, a neglected engine may require an overhaul very early in its life. Excessive oil consumption is an indication that piston rings, valve seals valve gui...

  • Page 110

    2d-4 chapter 2 part d general engine overhaul procedures 7 crank the engine over at least seven compression strokes and 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...

  • Page 111

    Chapter 2 part d general engine overhaul procedures 2d-5 5.56 remove the attaching screw and unplug the electrical connector remove the nut on the engine stud and disconnect the ground strap (arrow) 16 unbolt the exhaust system from the engine (see chapter 4). 17 if you're working on a vehicle with ...

  • Page 112

    2d-6 chapter 2 part d general engine overhaul procedures pull the engine forward as far as possible t o clear the transmission, . . . Slowly raise the engine out of the engine compartment (see illustra- tions). Check carefully t o make sure nothing is hanging up. 25 remove the flywheelidriveplate an...

  • Page 113

    Chapter 2 part d general engine overhaul procedures 2d-7 t h e block. Other considerations are cost, access t o machine shop facilities, parts availability, time required t o complete the project and the extent of prior mechanical experience on the part of the do-it-yourselfer. Some of t h e rebuild...

  • Page 114

    2d-8 chapter 2 part d general engine overhaul procedures 6 before beginning the disassembly and overhaul procedures, make sure the following items are available. Also, refer t o engine overhaul - reassembly sequence for a list of tools and materials needed for engine reassembly. Common hand tools sm...

  • Page 115

    Chapter 2 part d general engine overhaul procedures 9.12 check the cylinder head gasket surface for by trying t o slip a feeler gauge under the straightedge (see the specifications for the maximum allowed and use a feeler gauge of that thickness) that may have formed in them. 5 run an appropriate si...

  • Page 116

    2d-10 chapter 2 part d general engine overhaul procedures valve margin width 9.16 the margin width on each valve must be as specified (if no margin exists, the valve cannnot be reused) 16 measure the margin width on each valve (see illustration). Any valve with a margin narrower than specified will ...

  • Page 117

    Chapter 2 part d general engine overhaul procedures 2d-i 1 1 . 3 make sure the new valve stem seals are seated against the tops of the valve guides valve seated in tool 3 seal end of valve stem be sure 4 valve seal installation to deburr this area before (if you don't have this tool, a installing th...

  • Page 118

    2d-12 chapter 2 part d general engine overhaul procedures apply a small dab o f grease t o each keeper as shown here before installation it will hold them i n place on the valve stem as the spring is released 11.8 a special adapter and vacuum pump are required t o check the o-ring valve stem seals f...

  • Page 119

    Chapter 2 part d general engine overhaul procedures 2d-13 12.3 check the connecting rod side clearance w i t h a feeler gauge as shown exceeds the service limit, new connecting rods will be required. If new rods (or a new crankshaft) are installed, the end play may fall under the specified minimum (...

  • Page 120

    Chapter 2 part d general engine overhaul procedures use a center punch or number stamping dies t o mark the main bearing caps t o ensure that they're reinstalled in their original locations on the block (make the punch marks near one of the bolt heads) mark the caps in order from the front of the en...

  • Page 121

    'chapter 2 part d general engine overhaul procedures b on v6 engines. Remove the rear camshaft cover plate (arrow) 14.8 all bolt holes in the block - particularly the main bearing cap and head bolt holes - should be cleaned and restored w i t h a tap (be sure t o remove debris from the holes after t...

  • Page 122

    2d-16 chapter 2 part d general engine overhaul procedures 5 next, measure each cylinder's diameter at the same three locations 7 to check the clearance, select a feeler gauge and slip it into the across the crankshaft axis. Compare the results t o the specifications. Cylinder along with the matching...

  • Page 123

    Chapter 2 part d general engine overhaul procedures 2d-17 in place) with moderate pressure. 9 if it 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 ...

  • Page 124

    2d-18 chapter 2 part d general engine overhaul procedures the piston ring grooves can be cleaned w i t h a special tool, as shown here, . . . Of the ring grooves (see illustrations). 5 once the deposits have been removed, clean the pistonlrod assemblies with solvent and dry them with compressed air ...

  • Page 125

    Chapter 2 part d general engine overhaul procedures 2d-19 2.8 liter v-6 service pistons code 89.540-89.553 mm i n 90.001-90.014 3.5435-3.5438 in 90.014-90.027 mm 3.5438-3.5443 in 90.027-90.040 mm 3.5443-3.5448 i n 0.040 in 4 90.040-90.053 mm i n 1 b hi-limit pistons for v6 engines are available t o ...

  • Page 126

    2d-20 chapter 2 part d general engine overhaul procedures 2 bearing failure occurs because of lack of lubrication, the presence of dirt or other foreign particles, overloading the engine and corrosion. Regardless of the cause of bearing failure, it must be corrected before the engine is reassembled ...

  • Page 127

    Chapter 2 part d general engine overhaul procedures 2d-21 bearing selection (four and six-cylinder engines) refer to illustrations and 8 if you have a four or six-cylinder engine and the oil clearances are incorrect (see section 22) or you are replacing the original bearings, refer t o the accompany...

  • Page 128

    I crankshaft no. 1 main bearing i cylinder block no. 1 bearing journal color code and bore color code and diameter size i i yellow - mm yellow - mm in.) in.) (standard) black - mm 12.6915-2.6920 in.) orange - mm i yellow - mm (2.6910-2.6915 in.) in.) (0.0005 undersize) black - mm in.) black - mm i y...

  • Page 129

    Chapter 2 part general engine overhaul 20 engine overhaul - reassembly sequence before beginning engine reassembly, make sure you have all the necessary new parts, gaskets and seals as well as the following items on hand: common hand tools and drive torque wrenches piston ring installation tool pist...

  • Page 130

    2d-24 chapter 2 part d general engine overhaul procedures lnstalling the spacerlexpander in the oil control ring groove 7 repeat the procedure for each ring that will be installed in the first cylinder and for each ring in the remaining cylinders. Remember to keep rings, pistons and cylinders matche...

  • Page 131

    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 o f the engine) on all six-cylinder engines and number t w o on four-cylinder engines (v6 shown) 22.15 compare the width o...

  • Page 132

    Chapter 2 part d general engine overhaul procedures 2 7 retighten all main bearing cap bolts t o the specified torque, start- ing w i t h the center main and working out t o w a r d the ends. 2 8 on manual transmission equipped models, install a n e w pilot bear- ing in the end of the crankshaft (se...

  • Page 133

    Chapter 2 part d general engine overhaul procedures crankshaft oil pan gasket surface front \ a rear face of engine block engine block 23.9 installing the rear main oil seal - 1 9 8 4 v6 engine a tool rear of crankshaft b seal d alignment arrow {points do 2 4 pistonslconnecting rods installation and...

  • Page 134

    2d-28 chapter 2 part d general engine overhaul procedures 24.13 lay the plastigage strips o n each rod bearing journal, parallel t o the crankshaft centerline permanently bolted in place. 1 3 cut a piece of the appropriate size plastigage slightly shorter than the width of the connecting rod bearing...

  • Page 135: Chapter

    Chapter 3 cooling. Heating and air conditioning systems contents air conditioner and heater control assembly . Removal and installation 1 6 air conditioning system compressor . Removal and installation 1 4 air conditioning system condenser . Removal and installation 15 air conditioning system check ...

  • Page 136

    3-2 chapter 3 cooling, heating and air conditioning systems 1 general information engine cooling system all vehicles covered by this manual employ a pressurized engine cool- ing system with thermostatically controlled coolant circulation. An im- peller type water pump mounted on the front of the blo...

  • Page 137

    Chapter 3 cooling, heating and air conditioning systems 3-3 3 . 1 0 after the are removed, remove the bolts (arrows) and detach the housing from the engine - six-cylinder engine shown; others similar 3 . 1 4 before installing the gasket, apply a thin, uniform layer of rtv sealant to both sides of it...

  • Page 138

    Chapter 3 cooling, heating and air conditioning systems on six-cylinder models, use a torx-bit t o remove the hood safety catch, then unbolt the panel above the radiator on all six-cylinder models, remove the mounting bolts for the mechanical fan shroud, lift the shroud up until it clears the slots ...

  • Page 139

    Chapter 3 cooling, heating and air conditioning systems 3-5 5.8 the fan clutch is mounted with four nuts; two are visible in photo (arrows) mounting screws, lift the shroud up until it clears the slots in the bottom bracket of the radiator, then push the shroud over the fan. 8 remove the nuts attach...

  • Page 140

    3-6 chapter 3 cooling, heating and air conditioning systems for the indicator system. Warning: the vehicle is equipped with an electric cooling fan, stay clear of the fan blades. The fan can come on at any 2 if an overheating indication occurs, check the coolant level in the system and then make sur...

  • Page 141

    Chapter 3 cooling, heating and air conditioning systems 3-7 3 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! 4...

  • Page 142

    3-8 chapter 3 cooling, heating and air conditioning systems couple of bolts through the pump mounting holes to hold the gasket in place. 1 4 carefully attach the pump and gasket t o the engine and thread the bolts into the holes finger tight. 15 install the remaining bolts (if they also hold an acce...

  • Page 143

    Chapter 3 cooling, heating and air conditioning systems 3-9 8 cut the retaining strap that holds the gently on the right side of the dash and rotate the housing t o the heater core housing (see illustration). Down and toward the rear of the vehicle t o disengage the housing studs 9 disconnect the he...

  • Page 144

    3-10 chapter 3 cooling, heating and air conditioning systems 1 use the alignment tabs to position the housing and . . . 17 reinstall the remaining parts in the reverse order of removal. Be sure to use the alignment tabs (see illustrations) to position the hous- ings. Note: when installing the housin...

  • Page 145

    Chapter 3 cooling, heating and air conditioning systems 3-1 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.) ...

  • Page 146

    3-12 chapter 3 cooling, heating and air conditioning systems on four-cylinder and v6 models, the refrigerant line connections are located next to the battery on four-cylinder and v6 models, remove the screws (arrows) and pull off the cover to reach the mounting bolts 16.4 remove the four air conditi...

  • Page 147

    Chapter 3 cooling, heating and air conditioning systems 3-13 16.7 release the control cable locking tab with a screwdriver 2 detach the instrument panel bezel (see chapter 11 3 remove the radio (see chapter 12). 4 remove the four mounting screws from the air control panel (see illustration). 5 unplu...

  • Page 148: Chapter

    Chapter 4 fuel and exhaust systems contents air cleaner - removal and installation. 7 air and pcv filter replacement see chapter 1 carburetor - adjustments 8 carburetor choke check see chapter 1 carburetor - diagnosis and overhaul 1 0 carburetor - removal and installation 9 body mounting nut torque ...

  • Page 149

    Chapter 4 fuel and exhaust systems 4-1 2.5 to relieve the fuel pressure on an mpi-equipped vehicle, remove the cap from the pressure test port, place some shop towels underneath t o absorb sprayed fuel . . . 2.7 . . . Then depress the valve in the test port w i t h a small screwdriver or pin punch -...

  • Page 150

    4-2 chapter 4 fuel and exhaust systems pressure test 3.28 all system pressure tests on tbi-equipped vehicles require the removal of the pressure test port plug from the throttle body - in its place, install a special pressure test fitting (available at a dealer parts department) 1 1 position the fle...

  • Page 151

    Chapter 4 fuel and exhaust systems 4-3 3.35 to test the mpi fuel system pressure, you will need t o attach a 0-to-60 psi pressure gauge t o the test port pressure fitting on the fuel rail vacuum line attached to the regulator than with the vacuum line discon- nected. Fuel system pressure should be 3...

  • Page 152

    4-4 chapter 4 fuel and exhaust systems installation details of the mechanical fuel pump used on v6 models inlet 4 actuating rod (this may fall 2 fuel pump out of engine block when fuel 3 gasket pump is removed) 4.12 to remove the electric fuel pump from the fuel tank, detach the hoses and the electr...

  • Page 153

    Chapter 4 fuel and exhaust systems pump bracket nut the tbi fuel pumplsending unit assembly loose. A spark could cause an explosion! 16 extract the fuel unit assembly from the fuel tank. The fuel level float and sendina unit are delicate. Do not bump them into the during removal the accuracy of the ...

  • Page 154

    Fuel tank components (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 and mpi models) 4 air cleaner assembly components - exploded vi...

  • Page 155

    Chapter 4 fuel nd exhaust systems 4-7 7 siphon the fuel from the tank at the fuel feed line, not the return line. 8 support the fuel tank with a floor jack or jackstands. Position a piece of wood between the jack head and the fuel tank t o protect the tank. 9 disconnect the fuel tank retaining strap...

  • Page 156

    4-8 chapter 4 fuel and exhaust systems whichever comes first - see your dealer for details). 2 we don't recommend carburetor adjustments while it's still under warranty. If you are having problems related t o fuel delivery - and you have eliminated all other parts of the fuel delivery system as poss...

  • Page 157

    Chapter 4 fuel and exhaust systems 4-9 inexperienced mechanics can result in an engine which runs poorly or regulations, it isn't feasible t o include a step-by-step overhaul of each not at all. To avoid this, use care and patience when disassembling type. You'll receive a detailed, well illustrated...

  • Page 158

    Air horn components i air horn long screw 2 air horn large screw 3 air horn short screw 4 air horn medium screw 5 vent stack assembly 6 hot idle compensator screw 7 hot idle compensator 8 hot idle compensator screw 9 air horn assembly 10 air horn gasket i i pump retainer pump stem seal 13 stem seal ...

  • Page 159

    An exploded view of the carburetor used on california v6 engines air horn components mixture control solenoid 2 solenoid attaching screw assembly 3 solenoid-to-air horn gasket 4 solenoid spacer 5 solenoid-to-float bowl seal 6 solenoid seal retainer 7 air horn assembly 8 air horn-to-float bowl gasket...

  • Page 160

    4-12 chapter 4 fuel and exhaust systems 1 1 fuel injection system - general information quick-connect fittings fuel-injected vehicles are equipped with either a throttle body in- jection system (four-cylinder engine) or a multi-point lnjection system six-cylinder engine). Both systems use an elec- t...

  • Page 161

    Chapter 4 fuel and exhaust systems 4-13 fitting tab \ spacer \ o-rings retainer 12.10 cutaway of quick-connect fitting showing relationship of o-rings, spacer and retainer quick-connect fuel fitting i 12.14 once you've installed the new o-rings, spacer and retainer, push the fuel line into the fitti...

  • Page 162

    4 chapter 4 fuel and exhaust systems remove the accelerator cable and return spring 4 disconnect the isa motor harness connector (see illustration 13.33). 5 detach the fuel supply and return lines from the throttle body. 6 remove the accelerator cable and return spring (see illustration). 7 detach t...

  • Page 163

    Chapter 4 fuel and exhaust systems 4-1 5 retainer uppero-ring 14.9 an exploded view of tbi fuel injector components 1 4 . 1 0 gently grasp the center collar and carefully extract the injector by rocking it back and forth while lifting up - do not twist it during removal lock tabs and lifting up. 9 r...

  • Page 164

    4-16 chapter 4 fuel and exhaust systems 14.33 disconnect the motor harness connector; t o remove the motor, unscrew the three mounting nuts - use a back-up wrench t o avoid damaging the motor that the tps used on vehicles w i t h automatic transmissions has t w o connectors. 29 remove the tps mounti...

  • Page 165

    Chapter 4 fuel and exhaust systems 4-1 7 transmission pressure cable 15.7 if the vehicle is equipped with an automatic transmission, detach the line pressure cable at the throttle arm 7 if equipped with an automatic transmission, detach the line pres- sure cable at the throttle arm (see illustration...

  • Page 166

    4-18 chapter 4 fuel and exhaust systems detach the fuel supply hose from the fuel rail 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 pressure regulator 15.27 before installing the fuel rail mou...

  • Page 167

    Chapter 4 fuel and exhaust systems 4-19 15.33 be sure t o remove the old o-ring and seal from the injector replacement kit, available at a dealer, includes six 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 ill...

  • Page 168

    4-20 chapter 4 fuel and exhaust systems 1 6 exhaust system servicing - general information refer to illustrations 16. L a and 16. Warning: inspection and repair of exhaust system components should be done only after enough time has elapsed after driving the vehicle to allow the s components to cool ...

  • Page 169: Chapter

    Chapter 5 engine electrical systems contents .................................................. Alternator brushes - replacement 18 .............................................. Alternator - removal and installation 17 ....................................... Battery cables - check and replacement 4...

  • Page 170

    Chapter 5 engine electrical systems 3 lift out the battery. Be careful - it's heavy. 4 while the battery is out, inspect the carrier (tray) for corrosion chapter 1 5 if you are replacing the battery, make sure that you get one that's identical, with the same dimensions, amperage rating, cold crankin...

  • Page 171

    Chapter 5 engine electrical systems 5-3 the ignition coil on four and six-cylinder models is located on the right side of the engine compartment - when removing the coil, unscrew the mounting bracket bolts (arrows) terminals (see illustration). 3 using an ohmmeter set on the high resistance scale, c...

  • Page 172

    5-4 chapter 5 engine electrical systems 8.4 lgnition control module used on models 1 pickup coil assembly 3 ignition control module 2 module attaching screws 4 pickup coil connector 4 remove the t w o module attaching screws (see illustration) and lift the module up. 5 detach the pickup coil wire co...

  • Page 173

    Chapter 5 engine electrical systems 5-5 12.3 before removing the pick-up coil, unplug the lead from the ignition module replacement 7 detach the cable from the negative battery terminal. 8 remove the distributor cap and rotor (see chapter 1). 9 the following procedure is easier if you remove the dis...

  • Page 174

    5-6 chapter 5 engine electrical systems mount the distributor shaft in a soft-jawed vise and, using a drift punch and hammer, knock out the roll pin remove the shaft from the distributor 10 mark the distributor gear and shaft so they can be reassembled in the same position. 11 carefully mount the di...

  • Page 175

    Chapter 5 engine electrical systems 5-7 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 then mark the distributor base and the engine block (2) to ensure that the distributor is installed correctly ...

  • Page 176

    5-8 chapter 5 engine electrical systems front of engine o'clock p u m p gear shaft to seat the distributor on an six-cylinder engine, use a screwdriver to turn the oil pump gear shaft until the slot is slightly past the 11 o'clock position, . . . . . . Turn the rotor to the four o'clock position, th...

  • Page 177

    Chapter 5 engine electrical systems 5-9 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 through the distributor housing and remove the stator 15 charging system - general informa...

  • Page 178

    Chapter 5 engine electrical systems 17.2 to remove the alternator, detach the electrical connectors (arrows) from below, . . . . . . And remove the alternator pivot bolt (arrow) from below tab grounded any longer than necessary to obtain a voltmeter reading. If the alternator is charging, i t is run...

  • Page 179

    Chapter 5 engine electrical systems 1 with the through bolts removed, carefully separate the drive end frame and the rectifier end frame 18.4 after removing the nuts holding the stator assembly to the end frame, remove the stator 18.6 after removing the screws that attach the regulator and the resis...

  • Page 180

    5-12 chapter 5 engine electrical systems 18.10 to hold the brushes in place during reassembly, insert 21.3 before unbolting the starter motor assembly, detach the a paper clip through the hole in the end frame nearest to the wires (arrows) from the solenoid (or from the starter motor itself rotor sh...

  • Page 181

    Chapter 5 engine electrical systems 5-13 lower starter mounting bolt six-cylinder model upper starter mounting bolt six-cylinder model shown) view is from the rear, looking forward shown) - view is from the front, looking to the rear 22.3 before removing the solenoid from the starter motor, detach 2...

  • Page 182

    5-14 chapter 5 engine electrical systems motorcraft solenoid refer to illustration 22.7 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. 8 remov...

  • Page 183: Chapter

    Chapter 6 emissions and engine control systems contents air filter and pcv filter replacement see chapter i ...................................................................... Air injection systems 5 ......................................................................... Catalytic converter 7 c...

  • Page 184

    6-2 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 effect...

  • Page 185

    Vac r s v r v a c u u m switch assemrlv c distributor four-cylinder with manual transmission the motor manual guy.

  • Page 186

    Tac sensor to fuel tank egr canister 031 restrictor o m pcv'canister purge purge signal vacuum hose diagram for tbi-equipped four-cylinder models on) vacuum hose diagram for tbi-equipped four-cylinder models 9 8 6 ) vlv air cleaner the motor manual guy.

  • Page 187

    Purge vacuum hose diagram for 49-state v 6 models with manual transmission ( 1 9 8 5 and vacuum hose diagram for 49-state v 6 models with automatic transmission ( 1 9 8 5 and 1 9 8 6 ) the motor manual guy.

  • Page 188

    \ \ canister spark check vacuum hose diagram for canadian v 6 models ( 1 9 8 5 and 1 9 8 6 ) vacuum hoses 2 6 vacuum hoses m a p sensor bi-metal temp sensor egr solenoid front vehicle bi-metal temp egr solenoid vacuum hose diagram for six-cylinder models the motor manual guy.

  • Page 189

    Chapter 6 emissions and engine control systems 6-7 2 positive crankcase ventilation system refer to illustrations and 1 the positive crankcase ventilation system reduces hydro- carbon emissions by scavenging crankcase vapors. It does this by cir- culating fresh air from the air cleaner through the c...

  • Page 190

    6-8 chapter 6 emissions and engine control systems airstream flowing through the venturi. These vapors pass through the intake manifold into the combustion chambers, where they are con- checking sumed during combustion. 5 the fuel filler cap incorporates a t w o - w a y relief valve that is closed 6...

  • Page 191

    The motor manual guy.

  • Page 192

    6-10 chapter 6 emissions and engine control systems 4 thermostatic air cleaner (carburetor and tbi-equipped vehicles refer to 4. 1 and 4.24 general description 1 the thermostatic air cleaner (see illustration) provides heated intake air during then maintains the inlet air temperature within a t o op...

  • Page 193

    Chapter 6 emissions and engine control systems 6-1 1 4.24 to remove the heat duct valve vacuum motor, remove the air cleaner assembly, disconnect the hoses, then drill out the rivet (arrow) bi-metal temperature sensor 27 remove the air cleaner (see chapter 28 detach the t w o vacuum hoses from the s...

  • Page 194

    6-12 chapter 6 emissions and engine control systems and, with the engine operating at about 1 5 0 0 rpm, squeeze the hose. You should be able t o feel the air pulsing through the hose. Have an assistant increase the engine speed. There should be a proportional increase in air flow. If there is, the ...

  • Page 195

    Chapter 6 emissions and engine control systems 6-13 27 installation is the reverse of removal. Be sure t o 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 1 0 0 anti-seize the pump. Pound or equivalent. 3 1 i...

  • Page 196

    6-14 chapter 6 emissions and engine control systems 6 exhaust gas recirculation system general description 1 high combustion temperatures raise the level of (oxides of nitrogen) emissions in the exhaust. The exhaust gas recirculation system lowers levels by allowing small amounts of exhaust gas into...

  • Page 197

    Chapter 6 emissions and engine control systems 6-15 6.1 refer t o this schematic when testing the egr system on a four-cylinder model solenoid vacuum source 3 solenoid output port 2 intake manifold 4 egr vacuum hose vacuum fitting component replacement refer to illustrations 6.19 and 6.24 egr valve ...

  • Page 198

    6-16 chapter 6 emissions and engine control systems 25 remove the egr tube. 26 install the egr tube, but don't tighten the line nuts at this time. 27 tighten the intake manifold line nut, then the exhaust manifold line nut. Tighten them to the torques specified in chapter 2, part c. 28 tighten the e...

  • Page 199

    Chapter 6 emissions and engine control systems 6-1 7 furthermore, when diagnosing an engine performance, fuel econ- omy or exhaust emissions problem (which is not accompanied by a check engine light) do not automatically assume the fault lies in this system. Perform all standard troubleshooting proc...

  • Page 200

    6-18 chapter 6 emissions and engine control systems 9.3 wrap the threads of the coolant temperature sensor with teflon tape to prevent leaks 9 information sensors (v6 models) note: after performing any checking procedure to any of the informa- tion sensors, b e sure to clear the ecm o f all trouble ...

  • Page 201

    Chapter 6 emissions and engine control systems 6-19 replacement 16 refer to chapter 1 for the oxygen sensor replacement procedure. Throttle position sensor general description 17 the throttle position sensor (tps) is located on the carburetor float bowl. 18 by monitoring the output voltage from the ...

  • Page 202

    6-20 chapter 6 emissions and engine control systems trouble code chart 1991 and later models code 21 22 23 24 25 27 33 34 35 41 42 44 46 47 51 52 53 54 55 62 63 76 circuit or system oxygen sensor or circuit coolant temperature sensor or circuit mat sensor or circuit throttle position sensor (tps) se...

  • Page 203

    Chapter 6 emissions and engine control systems 6-21 11.4 the knock sensor (arrow) is located on the engine block (on six-cylinder models - shown) or on the intake manifold (four-cylinder models) timing light in accordance with the tool manufacturers instructions, then starting the engine. Have an as...

  • Page 204

    6-22 chapter 6 emissions and engine control systems 11.42 the crankshaft position sensor (cps) is mounted in the transmission bellhousing seal retainer adapter distance (speed) sensor installation details ied input voltage to the computer. The computer uses this information to alter the mixture. Che...

  • Page 205: Chapter

    Chapter 7 part a manual transmission contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General information 1 manual transmission overhaul general information 6 lubricant change. See chapter 1 manual transmission removal and installation 5 lubricant level check. See chapter 1 oil...

  • Page 206

    7a-2 chapter 7 part a manual transmission 2.1 1 before loosening the retaining bolt, mark the relationship between the speedometer adapter housing and the transmission or transfer case with white paint - the adapter is offset and must be installed in the same relationship (retaining bolt shown remov...

  • Page 207

    Chapter 7 part a manual transmission 7a-3 dust 'b oot cover . Upper bushing washer ax 415 and ba 1015 shift lever installation details 4 transmission mount - check and replacement refer to illustration 4.2 1 insert a large screwdriver or into the space between the transmission extension housing and ...

  • Page 208

    7a-4 chapter 7 part a manual transmission 6 manual transmission overhaul - general information refer to illustrations and 6.49 overhauling a manual transmission is a difficult job for the do-it- yourselfer. It involves the disassembly and reassembly of many small parts. Numerous clearances must be p...

  • Page 209

    Chapter 7 part a manual transmission 7a-5 during disassembly of the transmission, make careful notes of how before taking the transmission apart for repair, it will help if you have each piece comes off, where it fits in relation t o other pieces and what some idea what area of the transmission is m...

  • Page 210

    Ax 415 manual trans- mission output shaft, counter. Shaft and synchronizer - exploded view output shaft 2 snap-ring 3 snap-ring 4 5th gear 5 rear bearing retainer 6 synchronizer ring 4th gear 7 lnput shaft 8 counter gear 9 counter rear bearing 10 snap-ring spacer needle roller bearino 5th ax manual ...

  • Page 211

    Ax manual transmission output shaft exploded view 1 rear bearing 8 2nd gear 2 race 9 2nd gear needle roller bearing 3 1st gear needle roller bearing 10 output shaft 4 gear i 1 3rd gear 5 gear synchronizer ring 12 3rd gear synchronizer ring 6 hub sleeve no. 1 13 hub sleeve no. 7 2nd gear synchronizer...

  • Page 212

    Ba manual trans- mission - exploded view 5th gear lock ring 2 5th gear roller bearing 3 5th gear 4 5th gear snap-ring 5 reverse gear nut 6 washer used in all models) 7 reverse gear 8 rear bearing retainer 9 rear bearing race rear bearing rear bearing shirn shim washer gear bearing bearing spacer gea...

  • Page 213: Chapter

    Chapter 7 part b automatic transmission contents automatic transmission removal and installation 7 neutral start switch - check, adjustment bands adjustment (three-speed transmission) 5 and replacement 6 diagnosis general. 2 oil seal replacement see chapter 7a fluid and filter change see chapter 1 s...

  • Page 214

    7b-2 chapter 7 part b automatic transmission maintenance, adjustment and removal and installation procedures. If the transmission requires major repair work, it should be left t o a dealer service department or an automotive or transmission repair shop. You can, however, remove and install the trans...

  • Page 215

    7 part b automatic transmission 3.3 three-speed transmission shift linkage i jam nut 3 shift rod 2 trunnion 4 bellcrank but the starter operates in positions other than park or neutral, check the neutral start switch (see section 6). 1 1 check the steering wheel lock t o make sure it operates smooth...

  • Page 216

    7b-4 chapter 7 part b automatic transmission stop clamp retainer bolt bolt 4.8 v6 engine tv rod adjustment link details v6 engine refer to illustrations 4.8 and 4.12 8 remove the throttle control rod spring. Use the spring t o hold the adjusting link against the nylon stop, in the forward position (...

  • Page 217

    Chapter 7 part b automatic transmission 78-5 adjusting screw adapter , extension in-lb torque ,wrench 5.8 the rear band adjusting screw is accessible after removing the transmission pan 5.5 an adapter extension and inch-pound torque wrench are required t o adjust the front transmission band 5 bands ...

  • Page 218

    7b-6 chapter 7 part b automatic transmission switch terminal identification 6.9 the terminals for the four-speed transmission neutral start switch connector are shown above the chart shows when continuity should exist between the terminals: when i n park or neutral, continuity should exist between b...

  • Page 219

    Chapter 7 part b automatic transmission 7b-7 2 0 lower the transmission slightly and disconnect and plug the trans- mission fluid cooler lines. 21 remove the transmission dipstick tube. 22 move the transmission t o the rear t o disengage it from the engine block dowel pins and make sure the torque i...

  • Page 220: Ter

    Ter 7 part c transfer case contents general information 1 transfer case overhaul general information oil seal replacement see chapter 7 a transfer case removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift linkage adjustment 2 transmission mount check . . . . . . . ....

  • Page 221

    Chapter 7 part c transfer case 1 general information the transfer case is a device which passes the power from the engine and transmisssion t o the front and rear driveshafts. Several transfer cases were used on these models: new process 2071231 (command and 22812291242 trac is a part-time transfer ...

  • Page 222

    Chapter 7 part c transfer case 4 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 and case problems arise, it can be removed and installed by ...

  • Page 223

    Typical command-trac transfer case (new process 231 - exploded view front yoke nut, seal washer, yoke and oil seal 2 shift detent plug, spring and pin 3 front retainer and seal 4 front case 5 vacuum switch and seal 6 vent assembly 7 lnput gear bearing and snap-ring 8 low range gear snap-ring 9 lnput...

  • Page 224

    Typical selec-trac transfer case (new process - exploded view spacer 2 side gear 3 differential 4 pilot bearing rollers 5 o-ring seal 6 rear output shaft 7 oil pump 8 speedometer drive gear 9 shim kit 10 mainshaft mainshaft thrust washer spline gear 13 retaining ring 14 sprocket 15 spacer 16 sprocke...

  • Page 225

    Typical selec-trac transfer case (new process 229) exploded view 1 spacer 2 side gear 3 viscous coupling 4 pilot bearing rollers 15) 5 o-ring 6 rear output shaft 7 oil pump 8 drive gear 9 shims 10 mainshaft i 1 mainshaft thrust washer 12 spline gear 13 retaining ring 14 sprocket 15 spacer 16 sprocke...

  • Page 226

    Typical selec-trac transfer case (new process 2 4 2 ) - exploded view 1 front bearing retainer and seal 2 front case 3 shift sector 4 low range fork and inserts 5 shift rail 6 shift bracket 7 slider bracket 8 bushing and spring 9 mode fork and inserts 10 bushing fork spring 12 bushing 13 vent tube a...

  • Page 227

    Chapter 7 part c transfer case parts department and auto parts stores. At any rate, the time and money involved in an overhaul is almost sure t o exceed the cost of a rebuilt unit. Nevertheless, it's not impossible for an inexperienced mechanic t o rebuild a transfer case if the special tools are av...

  • Page 228: Ter

    Ter clutch and drivetrain contents clutch components removal. Inspection and installation . . . 3 removal and installation 1 2 clutch description and check 2 flywheel removal and installation see chapter 2 clutch fluid level check see chapter 1 front axle assembly removal and installation 1 8 clutch...

  • Page 229

    Chapter 8 clutch and drivetrain 8- 1 1 general information 2 clutch - description and check 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 w i t h in the previous chapter. F...

  • Page 230

    8-2 chapter 8 clutch and drivetrain release cylinder) and the clutch release (or throwout) bearing. Later models use a hydraulic release bearing, which is a combination release bearinglslave cylinder assembly mounted inside the clutch housing. 3 when pressure is applied t o the clutch pedal to relea...

  • Page 231

    Chapter 8 clutch and drivetrain 8-3 9 lnspect the pilot bearing (see section 1 0 lnspect the lining on the clutch disc. There should be at least inch of lining above the rivet heads. Check for loose rivets, distortion, cracks, broken springs and other obvious damage illustration). As mentioned above...

  • Page 232

    Chapter 8 clutch and drivetrain removal 1 following the appropriate procedure outlined in chapter 7, remove the transmission. Externally m o u n t e d release cylinder 2 unbolt the release cylinder from the clutch housing and pull it out of its recess. Hang it out of the way with a piece of wire (it...

  • Page 233

    Chapter 8 clutch and drivetrain 8-5 bearing seal must face the pilot bearing incorporates an o-ring seal which cannot be replaced separately. I f there is any indication that the seal is leaking, or i f the bearing is dry, replace it. The bearing must be installed w i t h the seal towards the transm...

  • Page 234

    8-6 chapter 8 clutch and drivetrain 6.11 pull the plunger assembly from the bore 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 end is down and tap it sharply against a block of wood. 12 inspect the b...

  • Page 235

    Chapter 8 clutch and drivetrain installation 2 6 position the cylinder against the 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. Since the cylinder is still loose, it can be wiggled around slig...

  • Page 236

    8-8 chapter 8 clutch and drivetrain 9 clutch pedal - removal and installation removal 1 disconnect the cable from the negative battery terminal. 2 remove the cotter pin and washer and detach the clutch master cylinder from the clutch pedal (see illustration 6.5). Remove the pedal return spring. 3 re...

  • Page 237

    Chapter 8 clutch and drivetrain 8-9 1 1 driveline inspection 1 raise the rear of the vehicle and support it securely on jackstands. 2 crawl under the vehicle and visually inspect the driveshaft. Look for any dents or cracks in the tubing. If any are found, the driveshaft must be replaced. 3 check fo...

  • Page 238

    Chapter 8 tch and drivetrain 13.2 a pair of needle-nose pliers can be used to remove the universal joint snap-rings 1 3 universal joints replacement refer to illustrations 13.2, 13.4 and 13.9 note: a press or large vise will be required for this procedure. It may be a good idea to take the driveshaf...

  • Page 239

    Chapter clutch and drivetrain 8-1 1 hold the pinion shaft yoke i n place and loosen the nut w i t h a torque wrench, noting the torque necessary t o loosen the n u t 2 loosen the rear wheel lug nuts, raise the vehicle and place it on jackstands. 3 remove the rear wheels and brake drums. 4 disconnect...

  • Page 240

    8-12 chapter 8 clutch and drivetrain service 5 due t o the special tools and expertise required t o separate and reassemble the hub and bearings, this job should be left t o a dealer service department or repair shop. Lnstalla 6 using sandpaper or emery cloth, clean the opening in the steering knuck...

  • Page 241

    Chapter 8 clutch and drivetrain 2 16.1 exploded view of the double offset joint 1 clamps 2 joint assembly 3 spacer ring note: the constant velocity outer front axle joint i s n o t repairable - if i t becomes worn, noisy or breaks, the entire joint must be replaced. The joint can and should, however...

  • Page 242

    8-14 chapter 8 clutch and drivetrain 1 6 . 1 4 align the inner race lands with check the inner race lands and check the cage for cracks, 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 ope...

  • Page 243

    Chapter 8 clutch and drivetrain 8-1 5 3 apply vacuum t o 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. 4 if the motor holds vacuum, connect the vacuum pump t o the rear ...

  • Page 244

    8-1 6 chapter 8 clutch and drivetrain 19.2 unscrew the four brake backing plate nuts using a socket on an extension passing through the hole i n the axle flange is the reverse of the removal procedure. When raising the axle into position, make sure the coil springs seat properly. Be sure t o use new...

  • Page 245

    Chapter 8 clutch and drivetrain 8-1 7 20 rear axle assembly - removal and installation 1 loosen the rear wheel lug nuts, raise the vehicle and support it securely on jackstands placed underneath the frame. Remove the wheels. 2 support the rear axle assembly with a floor jack placed underneath the di...

  • Page 246: Chapter

    Chapter 9 brakes contents anti-lock brake system general information 2 brake disc inspection, removal and installation 5 brake fluid level check see chapter 1 brake hoses and lines inspection and replacement 1 0 brake light switch replacement 1 7 brake pedal removal and installation 15 brake system ...

  • Page 247

    Chapter 9 brakes 9- 1 general information refer to illustration 7.2 the vehicles covered by this manual are equipped with hydraulically operated front and rear brake systems. The front brakes are disc type and the rear brakes are drum type. Both the front and rear brakes are self adjusting. The fron...

  • Page 248

    Chapter 9 brakes booster unit, an electric booster pump and motor assembly (which con- tains an accumulator), a pressure modulator and an accumulator and pressure switch assembly (see illustration). The electric pump provides hydraulic pressure t o charge the accumulator, which supplies pressure t o...

  • Page 249

    Chapter 9 brakes 9-3 2.4 front wheel sensor details 3 disc brake pads - replacement refer to illustrations 3.5 and through warning: disc brake pads must be replaced on both front wheels at the same time never replace the pads on only one wheel. Also, the dust created by the brake system may contain ...

  • Page 250

    9-4 chapter 9 brakes swing the upper end of the once the caliper i s removed from pry downward on the lower caliper out of the anchor plate, then the anchor plate, hang i t from the coil anti-rattle clip and remove the remove the caliper completely. Take this spring with a piece of wire - don't let ...

  • Page 251

    Chapter 9 brakes 9-5 4 disc brake caliper - removal, overhaul and installation warning: dust created by the brake system may contain asbestos, which is harmful to your health. Never blow i t out with compressed air and don't inhale any of it. An approved filtering mask should be worn when working on...

  • Page 252

    9-6 chapter 9 brakes 4.9 the piston seal should be removed w i t h a plastic or wooden tool t o avoid damage t o the bore and seal groove. A pencil will do the job 9 using a wood or plastic tool, remove the piston seal from the groove in the caliper bore (see illustration). Metal tools may cause bor...

  • Page 253

    Chapter 9 brakes use a dial indicator to check disc - if the reading exceeds the specified allowable limit, the disc will have to be machined or replaced using a swirling motion, remove the glaze from the disc surface with sandpaper or emery cloth 5 brake disc - inspection, removal and installation ...

  • Page 254

    9-8 chapter 9 brakes 7 on models, install the disc and hub assembly and adjust the wheel bearing (see chapter 1 if the disc has been machined on a 2wd model, thoroughly wash out the hub with solvent, then clean and repack the wheel bearing (see chapter 1 on 4wd models simply place the disc over the ...

  • Page 255

    Chapter 9 brakes pull back on the self-adjuster cable and push the adjusting lever toward the rear, unhooking i t from the secondary brake shoe remove the primary and secondary shoe retracting springs - the spring removal tool shown here can be purchased at most auto parts stores and greatly simplif...

  • Page 256

    9-10 chapter 9 brakes lubricate the brake shoe contact areas (arrows) w i t h high temperature grease lubricate the adjusting screw w i t h high temperature multi-purpose grease 6.4s . . . And the self-adjuster cable attach the new shoe t o the parking brake lever, install the spring washer and reta...

  • Page 257

    Chapter 9 brakes 9-1 1 hook the adjuster lever spring into the hole at the bottom of the primary shoe hook the adjuster lever spring and cable into the adjuster lever and pull the cable down and t o the rear, inserting the hook on the lever into the hole in the secondary shoe wiggle the assembly t o...

  • Page 258

    9-12 chapter 9 brakes 7.4 completely loosen the brake line fitting then remove the t w o wheel cylinder mounting (one is barely visible in this photo) removal refer to illustration 7.4 1 raise the rear of the vehicle and support it securely on jackstands. Block the front wheels t o keep the vehicle ...

  • Page 259

    Chapter brakes 9-13 8 . 7 use a phillips head screwdriver t o push the primary piston into the cylinder, then remove the snap-ring w i t h a pair o f snap-ring pliers 8.8 remove the primary piston assembly from the cylinder overhaul refer to illustrations 8.7, 8.8, 8.9, and 6 mount the master cylind...

  • Page 260

    Chapter 9 brakes piston assembly, remove one of the plugs completely. Before releasing the piston, however, instead of replacing the plug, simply put your finger tightly over the hole t o keep air from being drawn back into the master cylinder. Wait several seconds for the brake fluid t o be drawn f...

  • Page 261

    Chapter 9 brakes 9-15 lines to wheel brake 11.8 when bleeding the (bleed 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. All air must be expelled before moving to the next whee...

  • Page 262

    9-1 6 chapter 9 brakes 12.2 push down on the brake pedal, then start the engine - the brake pedal should go down slightly, indicating normal booster operation first 12.3 with the engine turned off, the pedal should gradually rise with each pump if the booster is functioning properly 12 power brake b...

  • Page 263

    Chapter 9 brakes 9-1 7 14.3 to disconnect the cable end from the parking brake lever, pull back on the return spring and maneuver the cable out of the slot i n the lever parking brake lever and operating rod \ cable spring 14.5 parking brake cable installation details (cherokee model shown, comanche...

  • Page 264

    9-18 chapter 9 brakes 6 position the pedal in the bracket and slide the pivot pin to the right, making sure it passes through the pedal bushings, install the nut and tighten it to the specified torque. 7 connect the booster to the brake pedal, inserting a new bolt from the right side on models with ...

  • Page 265: Chapter

    Chapter suspension and steering systems contents balljoints replacement 8 front axle suspension arms removal and installation 5 front coil removal and installation 6 front end alignment general information 2 0 front shock absorber removal and installation 3 front stabilizer bar and bushings . Remova...

  • Page 266

    The motor manual guy.

  • Page 267

    The motor manual guy.

  • Page 268

    Chapter 10 suspension and steering systems 1 general information refer to illustrations i. I and 1.2 of the vehicles covered by this manual utilize a solid front axle, suspended by t w o coil springs. Four control arms allow the axle to move vertically, and lateral movement is prevented by a track b...

  • Page 269

    Chapter suspension and steering systems 10-5 3.2 when removing the shock absorber stem nut (arrow), it may be necessary to hold the stem with an open end wrench or locking pliers to prevent it from turning - the brake master cylinder has been removed for clarity 3.3 the lower end of the shock absorb...

  • Page 270

    10-6 chapter suspension and steering systems 3 remove the arm-to-frame bracket bolt and remove the arm from the vehicle. 4 check the arm for distortion and cracks, replacing i t if either of these conditions are noted. 5 inspect the bushing in the axle housing (upper arm only) for crack- ing, hardne...

  • Page 271

    Chapter 10 suspension and steering systems 10-7 7.6 strike the steering knuckle at the top t o separate it from the balljoint studs - note that the castellated nuts are loosened, but not removed - this will prevent the knuckle from falling when it suddenly breaks loose 8 if the steering knuckle is b...

  • Page 272

    10-8 chapter 10 suspension and steering systems 10.2 remove the nut and bolt (arrow) that retain the stabilizer bar link to the spring tie plate 1 0 . 3 the stabilizer bar is connected to the frame rails with two brackets like this 1 0 rear stabilizer bar - removal and installation refer to illustra...

  • Page 273

    Chapter suspension and steering systems 10-9 remove the spring front eye-to-frame bracket b o l t (arrow) installation 8 installation is the reverse of the removal procedure. Be sure t o tighten the spring mounting bolts and the spring tie plate u-bolt nuts t o the specified torque. Note: the vehicl...

  • Page 274

    10-10 chapter suspension and steering systems 1 3 . 3 before removing the steering wheel, check to see if any relationship marks exist (arrows) - if not, use a sharp scribe or white paint to make your own marks 14.2 using white paint. Mark the relationship of the upper and lower universal joints to ...

  • Page 275

    Chapter 10 suspension and steering systems 10-1 1 1 5 . 4 before removing the arm, mark its relationship to the steering gear shaft the arm t o the shaft so it can be installed in the same position (see illustration). 5 separate the arm from the shaft w i t h a t w o - j a w puller (see illustration...

  • Page 276

    Chapter 10 suspension and steering systems 16.8 use a two-jaw puller t o detach the tie-rod end from the steering knuckle - notice the nut has been loosened but n o t removed; this will prevent the components from separating violently 8 using a two-jaw puller, separate the tie-rod ends from the stee...

  • Page 277

    Chapter 10 suspensia and steering systems 3 1 7 . 3 power steering pump front attaching bolts t o the return hose (if so, see chapter cap the ends of the lines t o prevent excessive fluid leakage and the entry of contaminants. 3 remove the front attaching bolts (see illustration) and the rear at- ta...

  • Page 278

    10-1 4 chapter suspension and steering systems 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 affecte...

  • Page 279: Chapter

    Chapter 11 body contents body - maintenance 2 body repair major damage 6 body repair - minor damage 5 bumpers removal and installation 11 . . . . . . . . . . . . . . Center console - removal and installation 1 7 dashboard panels removal and installation 1 6 door latch, lock cylinder and handle - rem...

  • Page 280

    11 -2 chapter body 3 at the same time, clean the engine and the engine compartment with a steam cleaner or water soluble degreaser. 4 the wheel wells should be given close attention, since undercoating can peel away and stones and dirt thrown up by the tires can cause the paint to chip and flake, al...

  • Page 281

    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. 1 7 at this point, the...

  • Page 282

    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. 1 if you can't access the backside of the body panel to hammer out the dent, pull ...

  • Page 283

    7 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 work the filler down until it's smooth and even. Work down to shape the filler finer grits of sandpaper - always using ...

  • Page 284

    11 -6 chapter 11 body 10.4 be sure t o remove and keep track of the adjusting shims before lifting the hood off - it's a good idea t o mark them so you know which side t o return them t o on installation 10.12 the hood bumpers, located at the front of the hood, can be screwed up or down t o adjust t...

  • Page 285

    Chapter body 11-7 1 1 the rear of the hood can also be adjusted up-and-down so it is flush with the fenders. To do this, loosen the hood-to-hinge bolts and add or subtract adjusting shims, which are available at your dealer. 12 finally, adjust the hood bumpers so the hood, when closed, is flush with...

  • Page 286

    11-8 chapter body 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 4 insert a flat, forked tool or a putty knife between the trim panel and the door and disengage the ribbed plastic retainers (see illus...

  • Page 287

    Chapter body 11-9 14.5 a #30 torx head tool will be required t o remove the hinge bolts 5 remove the hinge bolts torx head tool is necessary) and detach the from the vehicle (see illustration). 6 is the reverse of removal. Tighten the hinge bolts se- curely. 7 after installation, close the and make ...

  • Page 288

    61-10 chapter 11 body bezel attaching screws snap fit location \ snap fit locations 1 6 . 4 the instrument cluster bezel is held in place by four screws and is a snap fit instrument cluster bezel 4 remove t h e attaching screws and unsnap the bezel at the snap f i t locations in the dash (see illust...

  • Page 289

    Chapter 11 body 11-11 pry up on the corner of the transmission shift boot t o detach it (manual transmission shown, automatic transmission similar) if you have a 4wd vehicle, also detach the transfer case shift plate locations of the t w o front console retaining screws (arrows) 2 on vehicles with a...

  • Page 290

    11-12 chapter 11 body 18 door window glass - removal and installation refer to illustrations 18.5, 18.6, 18.8 and 1 remove the door trim panel and watershield (see section 12). 2 lower the window glass. 3 remove the door window hardware, weatherseal and moldings as necessary for access. Front door 4...

  • Page 291

    Chapter body 11-13 10 remove the window glass it t o detach the stud, then solenoid (see illustration). On power door locks, it will be necessary sliding the glass up and out of the door. T o drill out the rivets retaining the solenoid t o the door. 1 1 lnstallation is the reverse of removal. Tighte...

  • Page 292

    11-14 chapter 11 body 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 20 outside mirror - removal and installation refer illustration 20.2, 20.3 and 20.5 standard mirror 1 remove the door trim panel (see section 12)...

  • Page 293

    Chapter 11 body 11-15 . . . Tilt the cushion forward, then unlock the frame release lever (arrow) pull up on the bottom cushion release strap (arrow) . . . 5 to install the cushion, place the cushion assembly in position, insert the left pivot shaft into the receptacle, snap the release lever in pla...

  • Page 294: Chapter

    Chapter 12 chassis electrical system contents battery check and maintenance battery removal and installation bulb replacement brake light switch replacement and adjustment cruise control system . Description and check . Circuit breakers general information electrical troubleshooting . General inform...

  • Page 295

    Chapter 12 chassis electrical system 12-1 2 electrical troubleshooting general information a typical electrical circuit consists of an electrical component, any switches, relays, motors, fuses, fusible links or circuit breakers related t o that component and the wiring and connectors that link the c...

  • Page 296

    12-2 chapter 12 chassis electrical system needs a specific amount of protection. The amperage value of each fuse is molded into the fuse body. If the replacement fuse immediately fails, don't replace it again until the cause of the problem is isolated and corrected. In most cases, the cause will be ...

  • Page 297

    Chapter 12 chassis electrical system 12-3 extreme left. On tilt columns, the accessory position is on the extreme right. 9 connect the actuating rod t o the slider hole and install the switch with the screws finger tight. 1 0 hold the key lock in the accessory position, push the switch toward the bo...

  • Page 298

    12-4 chapter 12 chassis electrical system ferrule nut \ control shaft 10.4 headlight switch component layout 4 unplug the electrical connector, unscrew the ferrule nut and remove the switch from the instrument panel (see illustration). 5 to install the switch, plug in the electrical connector, place...

  • Page 299

    Chapter 12 chassis electrical system 12-5 front turn signallparking light bulb replacement details 13. B side marker light housing removal details cherokee tail light housing comanche tail light housing 13.1 e comanche license plate bulb removal details removal details replacement details gasket lic...

  • Page 300

    12-6 chapter 12 chassis electrical system 13.3 to remove a bulb housing, rotate the housing counterclockwise about and pull it out 2 on some lights the lenses are held in place by clips. The lenses can be removed either by unsnapping them or by using a small screwdriver t o pry them off. 3 some bulb...

  • Page 301

    Chapter 12 chassis electrical system 12-7 pivot pin screws 14.8 rear wiper motor installation details 1 5 lnstrument cluster - removal and installation instrument cluster attaching screws switch housings cigar lighter housing 15.3 lnstrument cluster, switch housing and cigar lighter screw locations ...

  • Page 302

    12-8 chapter 12 chassis electrical system or hoses get pinched between components when the instrument panel is rotated-back into position. 17 cruise control system - description and check the cruise control system maintains vehicle speed with a vacuum actuated servo motor located in the engine compa...

  • Page 303

    Legend of symbols used on wiring diagrams positive negative connector male connector female connector ground fuse denotes wlre continues elsewhere denotes wlre goes to one of two circuits splice splice identification gang fuses with buss bar circuit breaker thermal element i i tim e r multiple conne...

  • Page 304

    To switch 5- 79 79 assembly (see sh to 77 dimmer switch 1 to switch 5- 78 * 78 * assembly (see sh to 72 to chime module (see sh 67) (behind lh head lamp) left 76 16wt 76 16wt left park and turn signal lamp left marker lamp fog lamp relay (lh front engine compart- ment) front lighting (two-headlight ...

  • Page 305

    (behind lh lamp) to fog lamp * i 99 99 to heater 16bk blower motor to splice right 99 right -99 12bk 117 (optional) front lighting (two-headlight models) wiring diagram (continued) the motor manual guy.

  • Page 306

    To switch 5- 7 9 79 assembly to 77 dimmer switch 1 switch assembly * 78 * t o switch 5- 72 72 (behind signal lamp left i i marker lamp 16bk 99 (opitional) fog lamp relay (lh front engine compart- ment) front lighting (four-headlight models) wiring diagram the motor manual guy.

  • Page 307

    Right right fog 99 12bk lamp (optional) front lighting (four-headlight models) wiring diagram (continued) the motor manual guy.

  • Page 308

    To splice splice warning switch 98 i 29 to lh front i 98 door jamb , switch to lamp module 72 72 to i lps fuse to clock splice to chime 72 module radio clock 72 illumination re (lh of splice 0 76 to headlamps 76 16wt 16lg to headlamps cluster headlight switch wiring diagram (two-headlight models) th...

  • Page 309

    Rh front door jamb switch 98 *,-a 98 4 door only a rh rear door jamb switch splice fog lamp switch cigar radio illumination to radio clock illumination to instrument panel to instrument cluster splice to fog lamp relay delay module to power windows, door locks and mirrors instrument cluster to instr...

  • Page 310

    To splice splice to ignition key warning switch i 29 to lh front 29 98 switch switch 99 to lamp module dimmer switch (lh of column) (behind lh panel) to lh lamp to a7 splice 0 to chime module ice , to headlamps headlight switch wiring diagram (four-headlight models) cluster the motor manual guy.

  • Page 311

    77 switch i f5 i to a l l splice 0 fog lamp switch (on dash) indicator to glove lamp to instrument panel to instrument cluster to clock illumination to splice lighter to instrument cluster radio illumination to fog lamp relay 99 module headlight switch wiring diagram (four-headlight models) (continu...

  • Page 312

    Heater panel lamp - 52 to switch rheostat 99 99 52 r . Fog panel illumination wiring diagram the motor manual guy.

  • Page 313

    Instrument 52 52 to radio to illumination 52 relay 52 52 grounds on panel 99 20bk ash tray lamp a (under transfer center case console) lamp 52 splice ------ i 1 instrument panel illumination wiring diagram (continued) the motor manual guy.

  • Page 314

    To splice radio 15 amp 114 washer fluid level switch 6 instrument cluster illumination wiring diagram the motor manual guy.

  • Page 315

    Operated) (rh shock 4l manual tower) lamp delay transmission 107 trans- mission (above transfer (rh of case) transmission) instrument cluster illumination wiring diagram (continued) the motor manual guy.

  • Page 316

    (not used) to front lighting instrument cluster (behind rh side) . 18gy * column to rear lighting column to front lighting (black) and hazard system wiring diagram (cherokee models) the motor manual guy.

  • Page 317

    Turn 20 amp to rear defogger 15 amp hazard lamp flasher 80 i abs brake switch (above brake pedal) refer to cruise control i panel) 71 . . Column i i hazard normal switch stop lamp and hazard system wiring diagram (cherokee models) (continued) the motor manual guy.

  • Page 318

    Instrument cluster (behind rh side) to front lighting to rear lighting to front lighting and hazard system wiring diagram (comanche models) the motor manual guy.

  • Page 319

    To rear defogger turn signal flasher switch assembly (behind steering wheel) brake switch 15 amp refer to cruise hazard lamp flasher column column hazard normal switch a column column 78 stoplturn and hazard system wiring diagram (comanche models) (continued) strg column the motor manual guy.

  • Page 320

    To a5 splice windshield washer switch circuit breaker (on turn 4.8 amps signal stalk) wash switch i front motor front wipers wipers i cowl) up down front washer pump 99 i to rear 99 18bk under front i washer bottle , windshield wiring diagram (intermittent) the motor manual guy.

  • Page 321

    Splice i not used pk yl windshield wt i circuit breaker 4.8 amps washer wiper switch switch to lo (on turn off lo stalk) (not used) to a l l splice front washer pump (under washer bottle) front i wiper motor (under front \ up down cowl) \ i \ \ 99 16bk to rear 99 99 45 * 44 i i windshield washerlwip...

  • Page 322

    Splice r3 r4 rr wiper 25 amp i i i i l ------------- j , on to ,right of rear steering column wiper/ washer switch (left of kick behind panel) r-------- i- - - - - - - - ____- - - - (see sh 82) rear washerlwiper wiring diagram the motor manual guy.

  • Page 323

    To trans. Comfort switch illumination model 70) , , to cruise trans. Switch to wiper switch , fog lamp , to fog lamp illumination to rear defogger i i i i to rear i -99 20bk i i i i to rear defogger switch i i to rear defogger i i i i i to vanity mirror i i behind i i i i to reading lamp i i to left...

  • Page 324

    To radio (see sh lamp 16 99 lighter cigar i 99 to power door locks ground vanity lamps to he lay dome to keyless entry ground splice * without reading lamps dome lamp \ rh rear door jamb switch (above transfer splice case) 99 12bk interior lighting wiring diagram (cherokee models) the motor manual g...

  • Page 325

    Rh front door jamb switch interior lighting wiring diagram (cherokee (continued) the motor manual guy.

  • Page 326

    Radio cigar lighter to glove box lamp switch interior lighting wiring diagram (comanche models) the motor manual guy.

  • Page 327

    Rh off 148 to vanity lamp u cargo lh front door jamb switch i interior lighting wiring diagram (comanche models) (continued) the motor manual guy.

  • Page 328

    To gear 75 75 switch 71 n abs 71 to head- (black) lamp switch 5- 72 to turn/ trailer tower i lh lamp (lh of lift- gate) . 20bl 72 72 20bk lamp 99 20bk (behind license) rear lighting wiring diagram (cherokee models) the motor manual guy.

  • Page 329

    72 99 99 20bk rear lighting wiring diagram (cherokee models) (continued) the motor manual guy.

  • Page 330

    (behind rh rear panel) -75 71 72 (behind license) - 72 20bl 99 20bk rear lighting wiring diagram models) the motor manual guy.

  • Page 331

    (behind license) rear lighting wiring diagram (commanche models) (continued) rh turn lamp rh turn lamp rh backup lamp rh license lamp the motor manual guy.

  • Page 332: Index

    Index a about this manual, 0-5 air cleaner removal and installation, 4-7 thermostatic, check, 1-22 air conditioning system blower motor, removal and installation, 3-8 compressor, removal and installation, 3-1 1 condenser, removal and installation, 3-1 1 control assembly, removal and installation, 3-...

  • Page 333

    Index coolant level check, 1-8 general information, 3-2 reservoir, removal and installation, 3-6 temperature sending unit, check and replacement, 3-5 cooling system check, 1-14 general information, 3-2 servicing, 1-31 cooling, heating and air conditioning systems, 3-1 through 3-13 crankshaft front o...

  • Page 334

    Fixed glass, replacement, 11 -3 fluid automatic change, 1-27 automatic transmission, checking, 1-1 1 level checks, power steering checking, 1-12 four-cylinder engine, 2a-1 through 2a-17 front axle suspension arms, removal and installation, 10-5 front coil removal and installation, 10-6 front end ali...

  • Page 335

    Index oil change, 1-15 filter change, 1-1 5 level check, 1-7 pan, removal and installation four-cylinder engine, 2a-14 lnline six-cylinder engine, 2c-10 v6 engine, 28-10 pump, removal and installation four-cylinder engine, 2a-14 lnline six-cylinder engine, 2c-11 v6 engine, 2b-11 seal, rear main, ins...

  • Page 336

    Index fluid and filter change, 1-27 fluid level check, 1 general information, neutral start switch - check, adjustment and replacement, 7b-5 removal and installation, shift linkage, check and adjustment, 78-2 throttle valve linkage, adjustment, 78-3 manual general information, 7a-1 lubricant, level ...