Jeep Cherokee 16 1982 Technical & Service Manual Download

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Summary of Contents for Cherokee 16 1982

Page 1: ...p r p p r r p r p p p p r r p r r p r r p r p p P r p r p p mLW r St v p 1 r f jar r Jeep Jeep TECHNICAL SERVICE MANUAL...

Page 2: ...sonal injury and render the vehicle unsafe Detailed descriptions of standard workshop safety procedures are not included in this manual This manual does contain WARNINGS for some service procedures th...

Page 3: ...CASE 2E PROPELLER SHAFT 2F AXLES 2G BRAKES 2H WHEELS AND TIRES 2J STEERING COLUMNS 2K MANUAL STEERING GEAR 2L POWER STEERING GEAR AND PUMP 2M STEERING LINKAGE 2N SUSPENSION CHAPTERS 3A WATER LEAK WIND...

Page 4: ...pecial tools pertinent to that chapter Warnings and Cautions Detailed descriptions of standard workshop safety procedures are not included in this manual This manual does contain WARNINGS for some ser...

Page 5: ...pter for torques not listed in individual torque charts Note that torque spec ifications given in the chart are based on use of clean and dry threads Reduce torque by 10 percent when threads are lubri...

Page 6: ...i marily in available options CJ 7 models are available with an automatic transmission soft top with metal doors moulded hardtop and moon roof These options are not available on CJ 5 models The Renega...

Page 7: ...t Top with Metal Doors Cherokee Models For 1982 three Cherokee models are offered the base 2 door model 16 the Wide Track model 17 and the 4 door model 18 See figures A 5 A 6 and A 7 The 2 door model...

Page 8: ...5 have a 118 8 inch wheelbase models 26 and 27 have a 130 8 inch wheelbase The following chart outlines Truck differences by wheelbase and GVW ratings GENERAL INFORMATION A 5 Fig A 8 Wagoneer Model 15...

Page 9: ...umber Certain Jeep vehicles are built to special order with other than standard parts or equipment To assist the dealer in ordering correct replacement parts an SSR 0 number is assigned and a permanen...

Page 10: ...t P a Taw t aaiowairt Cawm Pan Tana P nTwia J PanorPaaTaaa W ttpaaam 1 MOM P 1 taaad uarwai PanTaxa P ttaaMWaavai n N ttpaaanawni Pan v Pa T aa I J C tSICa0rcta 1V OS War IV 1 4 Poatlac Motof Oxr M0Cu...

Page 11: ...the Zone office from the vehicle identification number If the ignition key is lost and the key code number is not available a new key can be made by removing a door lock and taking it to a locksmith T...

Page 12: ...ENERAL INFORMATION A 9 If ignition key is not available placefront wheels on a dolly Part Tims Transfer Case Automatic Transmission Do not exceed a towing speed of 30 mph 48km h and do not exceed a to...

Page 13: ...the correct position as outlined in the general touring iiistructions Rear Refer to Figure A 18 1 Attach J hooks around axle outboard of shock absorber brackets 2 Place towbar under bumper 3 Attach sa...

Page 14: ...three figures to the right Miles to Kilometers To change miles to kilometers multiply miles by 1 609 miles x 1 609 equals kilometers Kilometers to Miles To change kilometers to miles multiply kilomete...

Page 15: ...84 1764 70 0 177 8 Step Height Front Rear 18 1 48 5 20 4 51 8 18 1 48 5 20 0 50 8 18 1 48 5 20 0 50 8 20 6 52 3 21 0 53 3 21 4 54 4 Front Tread 58 4 150 8 65 3 165 8 58 4 150 8 58 4 150 8 63 3 160 8 6...

Page 16: ...2 73 3 31 2 73 3 31 Same Same Same Same Same 208 208 219 208 219 208 219 219 3 31 3 31 3 31 3 31 3 31 Wagoneer Model 15 6 258 2V 6 258 2V 6 258 2V 6 258 2V 8 360 2V 8 360 2V T 176 T 5 999 727 T 176 72...

Page 17: ...ue nswton meter N m Power Heat Flow Rate General use watt Bulbs kflowatt Alternator output Engineperformance Startermotor performance W kW QUANTITY EXAMPLES OF APPLICATIONS METRIC UNIT SYMBOL CelsiusT...

Page 18: ...719 43 64 0320 67 1015 38 5 16 2031 13 64 8 33 3281 21 64 17 46 6875 11 16 0330 66 2 6 1024 2040 6 8 4 3307 17 5 6890 85 0335 1040 37 5 2 2047 3320 Q 17 86 7031 45 64 0350 65 2 7 1063 2055 5 8 5 3346...

Page 19: ...NOTES fm t ftWPyA rsa T W...

Page 20: ...our service manual What is your general reaction to this manual In your judgment is it complete accurate well organized well written Is it easy to use What features are most useful What faults do you...

Page 21: ...and Staple BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 1117 DETROIT MICH POSTAGE WILL BE PAID BY ADDRESSEE JEEP CORPORATION ATTN SERVICE DEPT P O BOX 442 DETROIT MICHIGAN 48232 NO POSTAGE NECESSARY IF...

Page 22: ...e Engine Oil Number 1 tells you that the engine oil level should be checked at each fuel fill Number 2 tells you to change the engine oil every five months or 5 000 miles 8 000 km whichever comes firs...

Page 23: ...water thoroughly clean brakelinings brakedrums and front axle U joints and yokes to pre vent undue wear and unnecessary part failure CAUTION If the vehicle is driven throughwater deep enough tocover t...

Page 24: ...t Curb and Fast Idle Speed Check and Adjust Curb and Fast Idle Speed 8 Cytinder Check Distributor Vacuum and Centrifugal Advance Mechanism Check Distributor Vacuum and Centrifugal Advance Mechanism 8...

Page 25: ...water 34 F 36 C Freezing Point for cooling system corrosion protection during the summer season Replace air cleaner element once in between each normally scheduled change under heavy duty driving cond...

Page 26: ...rrect to specifications as necessary BRAKES Front and rear brakeliningsfor wear rearbrakeself adjustingmechanismforproper operation mastercylinder calipers wheel cylinders and differential warning val...

Page 27: ...ansmission Fluid Check Inspect fluid level at scheduled interval Check while the transmission is at normal operating temperature This occurs after at least 15 miles 25 km of expressway driving or equi...

Page 28: ...rake fluid as required and install cover Use only Jeep Heavy Duty Brake Fluid or equivalent meeting SAE Standard J1703 and Federal Standard No 116 DOT 3 Fluid Refer to Chassis Components for procedure...

Page 29: ...General Service and Diagnosis for detailed procedure 14 PCV Valve Replace PCV valve at scheduled interval Refer to Chapter 1J Fuel Systems for detailed procedures __ 15 Tune Up Certain items such as...

Page 30: ...ke fluid axle lubricant or other contaminants Refer to the following inspection procedures MAINTENANCE B 9 Front Brakelinings CJ and Scrambler Models Check both ends of the outboard lining by looking...

Page 31: ...ity Inspect cables for binds kinks or frays With the brake released the rear wheels should turn freely Adjust the parking brake if necessary as described in Chapter 2G Brakes Overall Brake Condition a...

Page 32: ...ambler Models 90902 Fig B 14 Door Latch and Lock Cherokee Wagoneer Truck Models MAINTENANCE B 11 5 Exhaust System Inspection Inspect the exhaust system at scheduled interval for the following conditio...

Page 33: ...t REMOVE BOLT TO LUBRICATE J42566 Fig B 19 Manual Steering Gear Fill Hole Location Sleeve Yokes Splines Apply grease gun pressure to sleeve yoke grease fit ting until lubricant appears at pressure rel...

Page 34: ...RAIN Fig B 21 Transfer Case Drain and Fill Plugs Model 300 MAINTENANCE B 13 BSBl FILL DRAIN Fig B 22 Transfer Case Drain and Fill Plugs Mods 208 FILL DRAIN Fig B 23 Transfer Case Drain and Fill Plugs...

Page 35: ...nual transmission and transfer case lubricating fluid should be changed at the same time as scheduled See Recommended Fluids and Lubricants at the end of this chapter for fluid specification andthe Fl...

Page 36: ...e 43 pints 43 pints 23 liters J 10 Truck Front Axle 33 pints 23 pints l 4Uters J 10 Truck Rear Axle 43 pints 43 pints 23 liters J 20 Truck Front Axle 33 pints 23 pints Milters J 20 Truck Rear Axle 63...

Page 37: ...Lubricant or equivalent lithium base chassis lubricant CHASSIS Continued COMPONENT SPECIFICATION Manual transmission Model T 176 Model T 18 SAE 85W 90 gear lubricant API GL5 Manual transmission Model...

Page 38: ...eneral Service and Diagnosis B Engines BJJ Cooling Systems Bf Batteries BE CHAPTER Charging System KH INDEX Starting System B Ignition System Q Cruise Command BE Fuel Systems KE Exhaust Systems E Engi...

Page 39: ...in Sole Vac Idle Control 1 Sole Vac TVS 1 1 1 1 1 Decel Valve 1 1 1 1 Microprocessor 1 1 1 1 Vacuum Switch Assembly Trap Door Air Cleaner PCV O p CD 2 Q M O 2 3 3 CD W 3 ST o 3 q 3 B3 OQ P fa s 3 ft r...

Page 40: ...TD M _ _ _ _ _ _ v _ _ _ _ _ _ _ _ _ 1S1 CID 2V 0 E s 38 C 49 C 100 F 120 F 220 F DR o HD M _ _ v _ 0 0 38eC 49 C 101 C STD M 115 F v 155 F R 46 C 68 C 115 F 155 F 220 F R e HD M v _ B JO E 46 C 68 C...

Page 41: ...Delay F Forward Delay DR Dual Reverse Delay Positive Crankcase Ventilation Thermostatically Controlled Air Cleaner vacuum or mechanical NOTE All vehicles have Fuel Tank Vapor Control Vacuum Operated T...

Page 42: ...place PCV valve 8 Timing case cover oil seal broken or improperly seated 8 Replace seaL 9 Oil pan drain plug loose or has stripped threads 9 Repair as necessary and tighten 10 Rear oil gallery plug lo...

Page 43: ...quality or improper grade 2 Drain and refill crankcase with correct grade oil 3 Oil pressure relief spring weak or sticking 3 Remove and inspect oil pressure relief valve assembly 4 5 Oil pickup tube...

Page 44: ...n or cocked valve springs 8 Stem to guide clearance excessive 9 Valve bent Correction 4 Tighten flywheel or drive plate bolts 5 Repair as necessary 1 Check for low oil level or low oil pressure 2 Chec...

Page 45: ...air as necessary i5i Float sticking 5 Repair as net es ir 6 Exhaust manifold heat valve stuck eight cylinder engine only 6 Lubricate or replace 7 Faulty fuel pump 7i Replace fuel pump 8 Incorrect chok...

Page 46: ...ulty ignition coil wire 8 Faulty distributor cap 11 Improper pump stroke t2 Incorrect ignition timing 3 Inoperative pump discharge check ball or needle 4 Faulty elastomer valve Eight cylinder engine o...

Page 47: ...entrifugal advance and repair as necessary 3 Faulty distributor vacuum advance 3 Check vacuum advance and repair as necessary 4 Low fuel pump volume 4 Replace fuel pump 5 Wrong spark plug gap wrong pl...

Page 48: ...appet s 9 Faulty valve spring s 9 Inspect and test valve spring tension repair as necessary 10 Worn lobes on camshaft 10 Replace camshaft 11 Air leak into manifold vacuum 11 Check manifold vacuum and...

Page 49: ...l octane rating excessively low 8 Heat riser stuck in heat ON position eight cylinder engine only 9 Sharp edges in combustion chamber 1 Low fuel level 2 Low fuel pump pressure or volume Correction 9 P...

Page 50: ...nd areas of the pattern significant for diagnosis The scope pattern displays the time duration horizon tally and voltage amplitude vertically Compare the scope pattern of the HEI system with the typic...

Page 51: ...M PICKUP 1 COIL 1 NO 1 CURRENT I FLOW 1 1 1 1 1 iftnA t SPARK PLUG FIRES PRIMARY WINDING ELECTROMAGNETIC FIELD COLLAPSES AND INDUCES HIGH VOLTAGE INTO SECONOARY WINOING UNUSED ENERGY OSCILLATIONS GRAD...

Page 52: ...akage Test Diagnosis CYLINDER HEAD GASKET FAILURE DIAGNOSIS A blown cylinder head gasket usually results in a loss of power loss of coolant and engine misfire A blown cylinder head gasket may develop...

Page 53: ...take manifold 2 Plug PCV valve hose fitting in manifold Allow PCV valve to hang free 3 Remove oil filler cap Cover filler tube with palm of hand If vacuum is felt crankcase is exposed to intake manif...

Page 54: ...that a problem exists in the cylinder from where it was removed Replace plugs at the mileage interval recommended in the Engine Maintenance Schedule Plugs that have less engine mileage may be cleaned...

Page 55: ...gine operation This suggests that a plug with a cooler heat range rating should be used Overadvanced ignition timing detonation and cooling system malfunctions can also cause spark plug overheating NO...

Page 56: ...er position Insert the wire terminals firmly into the towers Replace the cap if the terminal ends inside the cap are excessively eroded fig 1A 5 The vertical face of a terminal end will indicate some...

Page 57: ...D OR ERODED TERMINALS CARBON PATH R U 5 Dislrfbitar Ctfl EBSftetfM T 9i6al MAGNETIC TIMING PROBE SOCKET 70714 WORN OR DAMAGED ROTOR BUTTON FOUR CYLINDER ENGINE SIX CYLINDER ENGINE R 1A fl TtaltfDifrMS...

Page 58: ...direct line with fan Do not put hands near pulleys belts or fan Do not wear loose clothing 3 Start engine and allow to warm up to normal operating temperature Set parking brake place auto matic trans...

Page 59: ...ws are sealed on all carburetors figs 1J 8 1J 9 and 1J 10 The plugs or dowel pins must be removed before the idle mixture can be adjusted This effectively pre vents indiscriminate adjustments Do not r...

Page 60: ...nt with the air cleaner in stalled or with the air cleaner removed and associ ated vacuum hoses plugged and carburetor choke valve open The A C compressor clutch wire con nector must be disconnected a...

Page 61: ...idle speed rpm 8 Disconnect hose from exhaust gas recirculating EGR valve and plug 9 With fast idle speed screw fig 1A 8 on top step of fast idle speed cam adjust fast idle speed screw to obtain speci...

Page 62: ...er tube opening in the cap Do not apply oil to the filter If the filter is deteriorated replace the filler cap Fuel Tank Vapor Emission Control System The fuel tank filler cap fuel hoses and vent hose...

Page 63: ...650 50 800 50 15 1 Manual Hi ALT 600 70 750 50 900 50 19 1 3241333 8122802 9 5 13 Automatic Hi ALT 500170 650150 800 50 21 1 3241333 8122802 j 9 5 13 NOTE Automatic Adjusted in Drive Manual in Neutra...

Page 64: ...EGREES m O 5 2 C X o 0 1 1 1 1 P3IW5 2 9 0 j o kx I V S 1 1 1 A N I C 4 4 J S I X r A T E l M I S S s o st V In s CO V v I5 S 2 f r m 5 a X _ O z m_ o I z I 1 I 1 1 1 J ENGINE DEGREES k e co m ot 8 8...

Page 65: ...HICLES MANUAL TRANSMISSION 50 STATE J SERIES MANUAL AND AUTOMATIC TRANSMISSIONS r V J r 800 1600 2400 3200 4000 4800 5600 ENGINE RPM 8 10 12 14 1G 18 20 22 24 VACUUM IN HG 90185B Distributor Wiring Se...

Page 66: ...NOTES f vm sn...

Page 67: ...WO AC Page Cimshaft and Drive 1B 7 Crankshaft Replacement 1B 24 Crankshaft Vibration Damper Pulley Hub and OH Seal Replacement 1B 11 Cylinder Block 1B 25 Cylinder Hud 1B 14 Cylinder Head Cover 1B 14...

Page 68: ...YLINDER HEAD 12 CYLINDER HEAD STUD BOLT 13 VALVE SPRING AND OIL DEFLECTOR 14 PUSH ROD GUIDE 15 CYLINDER HEAD PLUG 16 CYLINDER HEAD CORE PLUG 17 EXHAUST MANIFOLD 18 EXHAUST MANIFOLD BOLT Rg IB 1 Foir C...

Page 69: ...ULLEY HUB 28 CRANKSHAFT PULLEY 29 CRANKSHAFT PULLEY HUB BOLT 30 CRANKSHAFT PULLEY BOLT 31 CRANKSHAFT TIMING GEAR 32 CAMSHAFT THRUST PLATE SCREW 33 CAMSHAFT THRUST PLATE 34 CAMSHAFT 36 CAMSHAFT BEARING...

Page 70: ...81044A Rg 1B 5 FoHr Cyllnder Eagtee IJoMtiii 19 Disconnect engine coolant temperature sender wire connector WARNING Do not loosen radiatordraincockwith sys tem hot and under pressure becauseserious bu...

Page 71: ...N m torque 14 Connect battery cable and solenoid wire to starter motor solenoid 15 Connect distributor wire connector 16 Connect exhaust pipe to exhaust manifold Tighten securing nuts with 35 foot pou...

Page 72: ...sert push rod through hole in head and into tappet seat 2 Install rocker arm pivot ball and capscrew Tighten capscrew with 20 foot pounds 27 N m torque Do not overtighten capscrew 3 Install cylinder h...

Page 73: ...r drives the camshaft through a plastic composition timing gear with a steel hub fig 1B 10 The cam lobes are ground hardened and tapered with the high side toward the rear This coupled with the spheri...

Page 74: ...igh quality engine oil supplement EOS 2 Install camshaft assembly in engine block Use care to prevent damaging bearings or camshaft 3 Turn crankshaft and camshaft so that valve timing marks on gear te...

Page 75: ...ll check valve and spring ball check valve retainer and retainer ring The tappet operates in a guide bore that intersects with the main oil gallery The operating cycle of the hydraulic tappet begins w...

Page 76: ...ard Hold tool firmly in hand with thumb over tappet body and sharply strike tool against block of wood until plunger falls out NOTE It may be necessary to soak a tappet that has a stuck plunger in cle...

Page 77: ...ower arm onto ram and turn handle slowly 1 revolution every 2 seconds Time indicator travel from lower line first line above set line to line marked 0 094 or 3 32 inch 2 39 mm while still rotating cup...

Page 78: ...ten two oil pan to timing case cover screws 15 Install timing case cover to block attaching screws 16 Tighten all cover attaching screws to specifica tions and remove centering Tool J 23042 17 Install...

Page 79: ...itions 14 Connect heater hose to intake manifold 15 Install bellcrankand throttle linkage brackets 16 Connect carburetor throttle linkage to brackets and bellcrank 17 Install carburetor spacerand tigh...

Page 80: ...lacement procedure CYUNDERHEAD The cast iron cylinder head is designed to provide a compression ratio of 8 2 1 It is cast with individual intake and exhaust ports for each cylinder The valve guides ar...

Page 81: ...s Tighten belt to specified tension Refer to Chapter 1C Cooling Systems for procedure 8 Connect fuel pipe to carburetor 9 Install heater hose and upper radiator hose tighten clamps 10 Connect vacuum h...

Page 82: ...ase compressing tool Ensure locks are seated properly in upper groove of valve stem 3 Install remaining valves according to procedure described above 4 Test each valve stem oil seal by placing Valve S...

Page 83: ...nator and upper bracket 2 Remove oil pump drive shaft retainer plate bolts and remove bushing and shaft assembly Installation 1 Install oil pump drive shaft assembly by turning shaft until it meshes w...

Page 84: ...t fit properly in body Assembly 1 Place drive gear and shaft in pump body 2 Install idler gear so that smooth side ofgear will be toward cover 3 Install cover and attaching screws Tighten screws with...

Page 85: ...long guide Disassembly CAUTION Use care at all times when handling and servicing connecting rods and pistons To prevent pos sible damage to these units do not clamp rod or piston in vise because they...

Page 86: ...and tighten rocker arm nuts Do not over tighten nuts 9 Install cvlinder head cover 90873 Fig 1B 32 Raised Notch Location Connecting Rod Bearings The connecting rod bearings are the precision insert t...

Page 87: ...sely coordinated If bore has been honed it should be washed thor oughly with hot soapy water and a stiff bristle brush Thoroughly oil bores after washing Using a cylinder measurement gauge measure the...

Page 88: ...of ring with feeler gauge fig 1B 36 Refer to Specifications NOTE An incorrect ring gap indicates that the wrong size rings are being used Ifrings are selected according to the size of the bore they s...

Page 89: ...ng is fitted to the minimum diameter and the journal is out of round in terference between the bearing and journal will result and rapid bearing failure will occur If the flattened Plastigage tapers t...

Page 90: ...of seal until it seats in groove Use care to prevent seal from binding on crankshaft and not seating properly 2 Attach flywheel drive plate to crankshaft and tighten bolts with 68 foot pounds 93N m to...

Page 91: ...pulley 15 Install spark plugs 16 Remove engine from stand 17 Install engine in vehicle CYLINDER BLOCK The cylinder block is manufactured from cast iron and has 4 in line cylinders that are numbered f...

Page 92: ...Bore Top 0 0635 0 0838mm 0 0025 in 0 0033 in Bottom 0 043 0 1041 mm 0 0017 in 0 0041 in Piston Diameter 101 519 101 580mm 3 9968 3 9992 in Compression Ring Side Clearance Top 0 0762mm 0 0030 in Compr...

Page 93: ...o Engine Bolts Flywheel to Crankshaft Bolt Fuel Pump to Block Bolt Intake Manifold to Cylinder Head Bolt Main Bearing to Block Bolt Oil Filter Oil Filter to Block Connector Oil Pan Drain Plug Oil Pan...

Page 94: ...NTAKE MANIFOLD INTAKE MANIFOLD HEATER ft F kd Qtfltnl 1B 28 3S k Hydrialtc Valve Tappets 1B 38 Intake and Extuest anlf riis 1B 43 5 k UirletHoi System 1B 47 f j Pistons 1B 54 Short Engine Assembly Sno...

Page 95: ...TRANSMISSION PILOT BUSHING WITH MANUAL TRANSMISSION MAIN BEARING CAP SEAL KIT REAR MAIN BEARING CAP REAR GASKET TIMING CASE COVER VIBRATION DAMPER Rg 1B 43 Six Cytlndor Esgloo Assembly Cylinder Block...

Page 96: ...TUBE AND SPRING OIL PAN TO BEARING CAP SEAL OIL PAN GASKET SET OIL PAN DRAIN PLUG GASKET OIL PAN DRAIN PLUG OIL PAN Rg 1B 44 Six Cylinder Engine Assembly OH Pin tadPomp OIL FILTER BY PASS VALVE SPRING...

Page 97: ...45 The letters are decoded as listed in the Oversize or Un dersize Components chart SHORT ENGINE ASSEMBLY SHORT BLOCK A service replacement short engine assembly short block may be installed whenever...

Page 98: ...ct throttle cable from engine 7 Disconnect throttle valve rod if equipped 8 Disconnect wiring harness from engine and al ternator and lay aside 9 Identify and tag vacuum hoses and disconnect from engi...

Page 99: ...en service port slightly Allow small amount of refrigerant to escape to purge compressor of air d Tighten port cap 20 Install battery if removed and connect cables 21 Install coolant WARNING Use extre...

Page 100: ...ectors 2 Remove valves and place in rack in same order as removed from cylinder head Cleaning and Inspection 1 Clean all carbon deposit from combustion cham bers valve ports valve stems and head 2 Cle...

Page 101: ...lescoping gauge into valve guide bore approximately 3 8 inch 9 525 mm from valve spring side of head fig 1B 51 with contacts crosswise to cylin der head Measure telescoping gauge contacts with microme...

Page 102: ...s and rocker arms 3 Remove push rods NOTE Retain push rods bridge and pivot assemblies and rocker arms in same order and position as removed 4 Remove spark plug from each cylinder NOTE Steps 5 through...

Page 103: ...st the cylinder block face Camshaft end play is zero during engine operation Measuring Cam Lobs Lift 1 Remove cylinder head cover 2 Remove bridge and pivot assemblies and rocker arms 3 Remove spark pl...

Page 104: ...ystems 10 Install fuel pump 11 Rotate crankshaft until No 1 piston is at TDC position on compression stroke 12 Install distributor and ignition wires Install distributor with rotor aligned with No 1 t...

Page 105: ...e tappet body leak down The cycle is completed as the cam lobe rotates back to the starting position and another charg ing cycle begins In this way zero valve lash is main tained and engine noise is r...

Page 106: ...es cease swing weighted arm away and allow plunger to rise to normal position 7 Adjust nose of ram to align pointer with SET mark on scale of tester and tighten hex nut 8 Slowly swing weighted arm ont...

Page 107: ...d position gasket on cylinder block 2 Cut end tabs off replacement oil pan gasket cor responding to pieces cut off original gasket Cement these pieces on oil pan 3 Coat oil pan seal end tabs generousl...

Page 108: ...t deflects more than 1 2 inch 13 mm The correct timing chain has 48 pins A chain with more than 48 pins will cause excessive slack Removal 1 Remove drive belt s 2 Remove engine fan and hub assembly 3...

Page 109: ...l crank Disconnect throttle valve rod if equipped 3 Disconnect PCV vacuum hose and heater wire from intake manifold WARNING Do not loosen radiator draincock with sys tem hot and under pressure because...

Page 110: ...ve belt s and tighten to specified ten sion Refer to Chapter 1C Cooling Systems 17 Install vacuum advance CTO valve vacuum hoses 18 Connect vacuum hose to EGR valve 19 Connect throttle cable and PCV h...

Page 111: ...ust valves with flash chrome stems Cylinder Head Cover CAUTION Cylinder head cover is molded plastic Use care when removing and installing ENGINES 1B 45 Removal 1 Remove air cleaner and PCV molded hos...

Page 112: ...m pound or equivalent to both sides of replacement head gasket and position gasket flush on block with word TOP facing upward 5 Install cylinder head Tighten bolts in sequence with 85 foot pounds 115...

Page 113: ...gine CJ vehicles If the long 5 44 inch 138 18 mm filter is used it may contact the engine support bracket or frame rail This can puncture the filter and result in a loss of oil and possible engine dam...

Page 114: ...SPRING RETAINER OIL PRESSURE RELEASE VALVE VALVE SPRING BYPASS VALVE OIL INLET TUBE AND SCREEN ASSEMBLY Rg 1B 70 Lubrication System RETAINER Rg 1B 71 Oil Filter and Oil Pomp Assembly DRIVE GEAR ASSEM...

Page 115: ...S si ENGINES 1B 49 AJ41902 Fig 1B 74 Oil Gear to Body Clearance Measurement 4 Remove cotter pin and slide spring retainer spring and oil pressure release valve plunger out of pump body Examine for sti...

Page 116: ...y generous amount of Jeep Gasket in a Tube RTV silicone or equivalent to gas ket ends 3 Coat inside curved surface of replacement oil pan rear seal with soap Apply generous amount of Jeep Gasket in a...

Page 117: ...ed connecting rod check rod alignment Replace misaligned or bent rods Side Clearance Measurement Slide snug fitting feeler gauge between connecting rod and crankshaft journal flange Correct clearance...

Page 118: ...s or dis coloration fig 1B 77 If bearing has spun in rod replace bearing and connecting rod and inspect crank shaft journal for scoring 3 Inspect for material imbedded in linings that may indicate pis...

Page 119: ...d to provide the correct clearance For example if the initial clearance was 0 003 inch 0 076 mm 0 001 inch 0 025 mm undersize inserts would re duce clearance by 0 001 inch 0 025 mm Oil clearance would...

Page 120: ...to bore clearance 3 333 in 84 6502mm 3 328 in 84 5312mm 3 339 in 84 8106mm 3 329 in 84 5566mm DIAMETER 1ST AND 2ND GROOVE DIAMETER 3RD GROOVE r 0 0805 in 2 0447mm 0 0795 in 2 0193mm 0 1895 in 4 8133mm...

Page 121: ...B 87 Insert expander ring first then side rails ENGINES 1B 55 TOP COMPRESSION RING BOTTOM COMPRESSION RING TOP OIL CONTROL RAIL OIL RAIL EXPANDER BOTTOM OIL CONTROL RAIL IMAGINARY LINE THROUGH CENTER...

Page 122: ...on pin UJ H V J 21872 3 J 21872 1 J 21872 3 U J 21872 2 n J 21872 1 J A 80048 Fig 1B 90 Piston Pin Removal orInstallation 3 Position piston so that pin bore is in vertical position Insert pin in bore...

Page 123: ...align the faces of the thrust bearings before the final tightening Crankshaft Main Bearings The main bearings are a steel backed micro babbitt precision type The main bearing caps are numbered front t...

Page 124: ...51mm Black 2 4991 to 2 4986 0 001 Undersize 63 4771 to 63 4644mm Yellow 2 6910 to 2 6915 68 3514 to 68 3641mm Black 2 6915 to 2 6920 68 3641 to 68 3768mm Black 0 001 inch Undersize 0 025mm Black 0 001...

Page 125: ...ction Inspection 1 Wipe lower insert clean and inspect for abnor mal wear pattern and for metal or other foreign mate rial imbedded in lining Normal main bearing wear pattern is illustrated in figure...

Page 126: ...rnal 2 Measure maximum diameter of journal with mi crometer Measure at two locations 90 degrees apart at each end of journal 3 Compare measurements obtained with journal diameters listed in Main Beari...

Page 127: ...per 3 Remove vibration damper retaining screw and washer 4 Use Vibration Damper Remover Tool J 21791 to remove damper from crankshaft fig 1B 97 ENGINES 1B 61 TOOL J 21791 WRENCH 41892 Fig lB 97 Vibrat...

Page 128: ...ter 1 Measure cylinder bore crosswise to block near top of bore Repeat measurement at bottom of bore 2 Determine taper by subtracting smaller dimen sion from larger dimension 3 Turn measuring device 1...

Page 129: ...fied Type In Line OHV Six cylinder Bore 3 75 95 25 Stroke 3 895 98 93 Displacement 258 cubic inches 4 2 liter Compression Ratio 8 6 1 Compression Pressure 120 150 psi 827 1034 kPa Maximum Variation Be...

Page 130: ...Compression both 0 010 0 020 0 25 0 51 Piston Ring Gap Clearance Oil Control Steel Rails 0 010 0 025 0 25 0 64 USA Inches Unless Otherwise Specified Piston Ring Side Clearance No 1 Compression 0 0017...

Page 131: ...40 47 34 54 Front Support Bracket to Block Eagle 45 40 50 47 34 54 Front Support Cushion to Bracket 33 27 38 45 36 52 Front Support Cushion to Crossmember 37 30 45 50 41 61 Fuel Pump Screws 16 13 19 2...

Page 132: ...ht Cylinder Engine Assembly The crankshaft supported by five two piece main bearing inserts rotates in a counterclockwise direction as viewed from the rear The camshaft is supported by five one piece...

Page 133: ...Undersize Components Code Single Letter B cylinder bore 0 010 inch 0 254mm oversize Single Letter M main bearings 0 010 tnch 0 254mm undersize Single Letter F connecting rod bearings 0 010 inch 0 254m...

Page 134: ...pressor refrigerant charge by slowly loosening ser vice valve fittings Remove service valves from compressor 8 Remove Cruise Command vacuum servo bellows and mounting bracket as an assembly if equippe...

Page 135: ...aporator lines to compressor CAUTION Both service valves must be open before the air conditioning system is operated 15 Purge compressor of air 16 If equipped with power steering connect hoses and fil...

Page 136: ...tely one turn at a time to avoid damaging bridge Tighten with 19 foot pounds 26 N m torque 4 Reseal and install cylinder head cover 5 Install retaining screws and washers Tighten screws with 50 inch p...

Page 137: ...gress to the size required ENGINES 1B 71 Valve Stem to Gulde Clearance Valve stem to guide clearance can be measured by either one of two methods Preferred Method 1 Remove valve from head and clean va...

Page 138: ...dy of a spark plug having the porcelain removed 6 Connect air hose to adapter and maintain at least 90 psi 620 kPa in cylinder to hold valves against their seats 7 Use Valve Spring Remover and Install...

Page 139: ...maintain zero camshaft end play during engine oper ation The rear camshaft bearing journal has two holes drilled through it to relieve pressure that could develop between the journal and camshaft plug...

Page 140: ...e retaining screw from camshaft Re move retaining screw from crankshaft 17 Remove distributor drive gear and fuel pump eccentric from the camshaft fig 1B 112 18 Remove crankshaft sprocket camshaft spr...

Page 141: ...l gallery The operating mode of the hydraulic tappet begins when the tappet is on the heel base circle of the cam lobe engine valve closed A groove in the tappet body aligns with the tappet oil galler...

Page 142: ...ger cap of tappet 3 Lift ram and place tappet with ball bearing in side tester cup POINTER 41891 Fig 1B 115 Hydraulic Tappet Leak Down Rate Tester J 5790 4 Lower ram then adjust nose of ram until it c...

Page 143: ...gallery The operating mode of the hydraulic tappet begins when the tappet is on the heel base circle of the cam lobe engine valve closed A groove in the tappet body aligns with the tappet oil gallery...

Page 144: ...er cap of tappet 3 Lift ram and place tappet with ball bearing in side tester cup POINTER 41891 Fig 1B 115 Hydraulic Tappet Leak Down Rate Tester J 5790 4 Lower ram then adjust nose of ram until it co...

Page 145: ...com pressor and bracket assembly from engine and move aside Do not disconnect air conditioner hoses 6 Remove alternator alternator mounting bracket and back idler pulley 7 Disconnect heater hose at wa...

Page 146: ...o not over tighten because oil pan will distort h Proceed to step 7 7 Install vibration damper Tighten retaining screw with 90 foot pounds 122 N m torque 8 Install damper pulley Tighten retaining bolt...

Page 147: ...block at point of maximum in ward chain deflection fig 1B 120 RIGHT SIDE OF ENGINE ROOT OF CAM SPROCKET TOOTH f PUSH CHAIN INWARD SCRIBE ON BLOCK TOTAL DEFLECTION 7 8 INCH MAX 22mm ENGINES 1D 79 z83 P...

Page 148: ...e cover using replacement gas ket Tighten retaining screws with 25 foot pounds 34 N m torque 10 Install vibration damper and pulley 20 PINS 41937 Fig 1B 122 Correct Timing Chain Installation Verificat...

Page 149: ...tall diverter valve and connect air pump out put hose 6 Connect air hoses to air injection manifolds 7 Identify and connect all disconnected hoses pipes linkages and wires to intake manifold and carbu...

Page 150: ...apscrews or e turn at a time to avoid damaging bridge 0J j 5 Remove push rods 7 x NOTE Retain rocker arms bridges pivots and push rods in the same order as removed to facilitate installa tion in origi...

Page 151: ...sses through the filtering element and on to an outlet passage in the oil pump cover From the oil pump cover passage the oil enters an adjoining passage in the timing case cover and is channeled into...

Page 152: ...1B 84 ENGINES OIL GALLERY Fig 1B 124 lubrication System CAMSHAFT BEARING PASSAGE IN CAMSHAFT SPROCKET 70001...

Page 153: ...ng screws and separate oil pump cover gasket and oil filter as an assembly from pump body timing case cover TIMING CASE COVER IDLER SHAFT IDLER GEAR OIL PRESSURE RELEASE VALVE ASSEMBLY OIL FILTER BYPA...

Page 154: ...gauge between gear tooth and pump body inner wall directly opposite point of gear mesh Select feeler gauge that fits snugly but can be inserted freely fig 1B 129 FEELER GAUGE 7 iftVjeWi 41940 Fig 1B 1...

Page 155: ...87 Removal 1 Remove cylinder head cover s 2 Alternately loosen bridge and pivot assembly capscrews one turn at a time to avoid damaging bridges Remove bridges pivots and rocker arms 3 Remove push rod...

Page 156: ...Side Clearance Measurement 1 Rotate crankshaft to position where connecting rod journal is at bottom of stroke 2 Insert snug fitting feeler gauge between con necting rods fig 1B 131 Fig 1B 131 Connect...

Page 157: ...a time at bottom of their stroke 4 Remove bearing caps and lower inserts 5 Remove upper insert by rotating insert out of connecting rod NOTE Do not interchange bearing caps Connecting rod and corresp...

Page 158: ...s specification install 0 001 inch 0 025 mm undersize bearing inserts and measure clearance as described in steps 1 through 5 above NOTE The measured clearance with 0 001 inch 0 025 mm undersize beari...

Page 159: ...The pistons used with all eight cylinder engines are aluminum alloy Autothermic pistons They are steel reinforced for strength and to control expansion The pistons are cam ground and are elliptical i...

Page 160: ...nce with correct size feeler gauge that fits snuglybetween ringland andring Slide ring around groove It must slide freely around circumferenceof groove fig 1B 139 Refer to Specifica tions for correct...

Page 161: ...AJ41914 Fig 1B 143 Compression Ring Installation AJ41913 Fig IB 144 Typical Compression Ring Marks 3 Install top compression ring using ring installer to expand ring around piston fig 1B 143 Piston Pi...

Page 162: ...ANKSHAFT The crankshaft is counterweighted and balanced inde pendently The associated components for the crank shaft are also individually balanced then the complete assembly is balanced as a unit Ser...

Page 163: ...nation with a 0 001 inch 0 025 mm un dersize lower insert to reduce the clearance by 0 0005 inch or 1 2 thousandth of an inch 0 013 mm Example Insert Incorrect Correct Upper Standard Standard Lower 0...

Page 164: ...L other bearing caps must remain tightened 2 Remove main bearing cap and lower insert 3 Wipe insert and exposed portion of crankshaft journal clean 4 Place strip of Plastigage across full width of bea...

Page 165: ...Main Bearing Journals with Micrometer Crankshaft Removed 1 Wipe main bearing journals clean 2 Measure each journal diameter with microme ter Note difference between maximum and minimum diameters of ea...

Page 166: ...equip ped and move aside 5 Remove damper pulley retaining bolts Remove damper pulley from damper 6 Remove damper retaining screw and washer and loosely install screw to prevent damage to screw threads...

Page 167: ...nditioner compressor if equipped 13 Remove damper pulley and vibration damper 14 Remove timing case cover 15 Remove oil pan 16 Remove camshaft 17 Remove connecting rod bearing caps and inserts and ret...

Page 168: ...ing rod bolts do not scratch connecting rod journals or cylinder walls Short lengths of rubber hose slipped over connecting rod bolts will provide protection during installation 9 Install connecting r...

Page 169: ...ches Unless Otherwise Specified Crankshaft End Play 0 003 0 008 Main Bearing Journal Diameter No 1 2 3 4 2 7474 2 7489 69 784 69 822 Rear Main 2 7464 2 7479 69 759 69 797 Main Bearing Journal Width No...

Page 170: ...ed preferred Oil Control 0 000 0 007 0 000 0 18 USA METRIC Inches Millimeters Unless Unless Otherwise Otherwise Specified Specified Piston Ring Groove Height No 1 and No 2 0 0795 0 0805 2 019 2 045 Oi...

Page 171: ...ront Cover Nut 7 4 9 Intake Manifold Screws 43 37 47 Main Bearing Capscrews 100 90 105 Oil Pump Cover Screws 55 in lbs 45 65 in lbs Oil Pan Screws 1 4 inch 20 7 5 9 5 16 inch 18 11 9 13 Oil Pressure R...

Page 172: ...ii annua ii J 24086 BT 7612 PISTON PIN TOOL o J 5569 PISTON RING COMPRESSOR 4 INCH J 23042 TIMING COVER SEAL ALIGNER AND INSTALLER J 22794 AIR LINE ADAPTER J 22330 VALVE SEAL INSTALLER AND TESTER f l...

Page 173: ...GRADUATION J 22700 OIL FILTER WRENCH SCREW TIMING CASE COVER CRANKSHAFT SEAL INSTALLER PART OF TOOL J 9163 J 22248 TIMING CASE COVER ALIGNMENT TOOL AND SEAL INSTALLER J 5601 PISTON RING COMPRESSOR 3...

Page 174: ...NOTES a r a sat SS...

Page 175: ...ugh the thermostat but flows to the front and through the intake INDEX Page General 1C 1 Hoses 1C 9 Intake Manifold Six Cylinder Engine 1C 9 Radiator 1C 10 Serpentine Drive Belt Diagnosis 1C 27 Specif...

Page 176: ...system pressure which raises the boiling point of the coolant The pressure cap maintains a pressure of 12 to 15 psi 42 7 to 103 4 kPa At 15 psi 103 4 kPa the relief valve in the cap allows pressurized...

Page 177: ...erature changes and with high torque engine operation or on hot days the coolant will be hotter and the gauge will indicate a higher engine temperature Unless the gauge pointer moves past the high end...

Page 178: ...unobstructed coolant flow for more efficient cooling During heat soak conditions after engine shutdown the higher boiling point helps prevent coolant loss be cause of boilover The higher boiling point...

Page 179: ...olant Level With Coolant Recovery The coolant level in the recovery bottle should be checked only with the engine at normal operating tem perature It should be between the FULL and ADD marks on the co...

Page 180: ...ges intake manifold radiator core rubber hoses and heater core The pump is driven from the engine crankshaft by a V type belt two belts for certain eight cylinder engines A single ser pentine drive be...

Page 181: ...of engine if re moved and install fan and hub assembly Tighten screws with 18 foot pounds 24 N m torque 3 Install fan shroud on radiator COOLING SYSTEMS 1C 7 4 Install drive belts and tighten to speci...

Page 182: ...aching screws 10 Install alternator drive belt and tighten to speci fied tension 11 Connect upper radiator hose to radiator 12 Connect battery negative cable 13 Fill cooling system with correct mixtur...

Page 183: ...t COOLING SYSTEMS 1C 9 be so excessive in length that coolant flow is restricted Replace fitting s if length is excessive 9 If intake manifold coolant passages are re stricted and cannot be cleared re...

Page 184: ...torque 7 Install hoses Ensure radiator draincock is tightly closed 8 Fill cooling system to correct level with required coolant mixture Refer to Coolant Fig 1C 7 Thermostat Recess Eight Cylinder Engin...

Page 185: ...2 Feb 2 1982 60336 Any one of several faults or defects can affect radiator operation bent or damaged tubes corrosion deposits restricting coolant flow cooling tubes restricted because of improper sol...

Page 186: ...per kPa of pressure RADIATOR FILLER NECK OVERFLOW TUBE VACUUM VALVE OPERATION PRESSURE VALVE OPERATION Fig 1C 9 Radiator Cap Operation Testing 41008 1 Remove cap from radiator 2 Ensure seating surfac...

Page 187: ...ications only DO NOT attempt to increase cooling capacity by installing a fan not intended for a given engine Fan or water pump damage and noise may result Replacement All Models 1 Disconnect fan shro...

Page 188: ...rforming the test outlined above to ensure against excessively high coolant temperature FAN SHROUD In some extreme situations the engine fan blades may contact the shroud An examination for proper eng...

Page 189: ...ylinder block heater is optional It consists of a 600W 120V heater element fitted into a core plug hole in the cylinder block a power cord and nylon tie straps Cylinder Slock Heater Installation NOTE...

Page 190: ...mp inlet fitting CAUTION Ensure heater control valve is closed heat off This will prevent coolant flow with scale and other deposits from entering heater core 4 Connect water supply and air supply hos...

Page 191: ...appear at connecting joints e g water pump thermo stat housing and cylinder head in the cooling system COOLING SYSTEMS 1C 17 These stains are almost always a sure indication of small leaks though ther...

Page 192: ...y thermostat 12 Replace thermostat 13 Water pump shaft broken or im peller loose 13 Replace water pump 14 Radiator tubes clogged 14 Flush radiator 15 Cooling system clogged 15 Flush system 16 I Castin...

Page 193: ...point to be too low 5 Antifreeze deteriorated because of age or contamination 6 Leaks because of loose hose clamps loose nuts bolts drain plugs faulty hoses or defective radiator 7 Faulty head gasket...

Page 194: ...emove belt to isolate Replace pump 7 Belt alignment 7 Check for improper pulley locations Shim power steering pump LOW TEMPERATURE INDICATION UNDERCOOLING 1 2 Thermostat stuck open Faulty gauge 1 2 Re...

Page 195: ...Sending Unit NOT OK L_ Adjust or Replace Belt I NOT OK Clean Fins of Radiator and or A C Condenser NOT OK 1 Replace or Reposition Air Seals r OK Check Thermostat Operation Replace Defective Thermostat...

Page 196: ...st Heat Valve if Equipped Repair or Replace as Necessary I NOT OK I Replace or Repair Radiator NOT OK I Reposition Hose Wire Cofl Stiffener or Replace Hose Check for Collapsed Lower Radiator Hose OK f...

Page 197: ...ing each spark plug to cylinder block Gauge pointer should stop or decrease vibration when spark plug for leaking cylinder is shorted to cylinder block because of the absence of combustion pressure Co...

Page 198: ...y and fan pulley Test belt tension according to manufac turer s instructions 2 Adjust belt tension to specification if less than 90 pounds force 400 N 3 Adjustment fig 1C 17 a Loosen alternator pivot...

Page 199: ...1C 25 Fig 1C 20 Eight Cylinder Engine Alternator Drive Belt Adjustment Alternator and Fan Six Cylinder Engine with Air Conditioner 1 Position Tension Gauge J 23600 or J 29550 on section of belt adjac...

Page 200: ...ension according to manufacturer s instructions 2 Adjust belt tension to specification if less than 90 pounds force 400 N 3 Adjustment a If equipped with idler pulley loosen clamp bolt and idler pulle...

Page 201: ...5mm block gauge may prove COOLING SYSTEMS 1C 27 ADJUSTMENT SLOT Fig 1C 25 Serpentine Drive Belt Adjustment 8071 OB useful to rapidly establish clearance between pumps Do not use power steering pump to...

Page 202: ...s Install correct belt NOISE OBJECTIONAL SQUEAL SQUEAK OR RUMBLE IS HEARD OR FELT WHILE DRIVE BELT IS IN OPERATION Continued 5 6 Driven component induced vibration System resonant frequency induced vi...

Page 203: ...eat and excessive slippage 1 Insufficient belt tension 2 Pulley s not within design tolerance 3 Foreign object s in grooves 4 Excessive belt speed 5 Pulley misalignment 6 Belt to pulley profile mismat...

Page 204: ...red 5 Replace belt 6 Excessive tension 6 Adjust belt tension 81102C SPECIFICATIONS Cooling System Specifications Four Cylinder Engine USA Metric Radiator Cap Relief Pressure 15 psi 103 kPa Thermostat...

Page 205: ...50 19 50 19 50 19 50 4 4 7 7 7 7 7 7 7 7 7 7 0 88 0 88 NOTE All radiator caps are rated at 15 psi 103 kPa 0 Not applicable to CJ 5 vehicles Not available in California Reverse Rotation if equipped wit...

Page 206: ...ATOR DRIVE PULLEY FAN AND WATER PUMP SIX CYLINDER ENGINE BASIC BELT ARRANGEMENT 70708A 80415A LEGEND FRONT BELT MIDDLE BELT REAR BELT POWER STEERING PUMP ALTERNATOR DRIVE PULLEY FOUR CYLINDER ENGINE W...

Page 207: ...LER PULLEY ALTERNATOR DRIVE PULLEY SIX CYLINDER ENGINE WITH SERPENTINE DRIVE ALTERNATOR AND AIR PUMP 80415J LEGEND FRONT BELT MIDDLE BELT REAR BELT AIR PUMP ALTERNATOR POWER STEERING PUMP DRIVE PULLEY...

Page 208: ...PUMP DRIVE PULLEY EIGHT CYLINDER ENGINE WITH ALTERNATOR AIR PUMP AND POWER STEERING NOTE 10 SI ALTERNATOR 1 BELT 15 SI ALTERNATOR 2 BELTS 90977F LEGEND FRONT BELT MIDDLE BELT REAR BELT FAN AND WATER P...

Page 209: ...Six and Eight Cylinder Thermostat Housing Four Cylinder Timing Case Cover to Block Eight Cylinder through Water Pump Water Pump to Block Screws Six Cylinder Water Pump to Block Four and Eight Cylinder...

Page 210: ...i i t t i r i i t i i i i i I i i t I i r r i i i f i i i i t t i i f i i i t en UJ...

Page 211: ...Battery Council International listings or applicable SAE standard the physical characteristics and electrical cri teria for the applicable battery INDEX Page Maintenance 1D 2 Specifications 1D 9 Test...

Page 212: ...ive terminals without stretching 4 Ensure tang at battery base is positioned in tray properly before tightening holddown CAUTION It is imperative that the cables are con nected to the battery positive...

Page 213: ...ly from local action when stored Batteries discharge faster when warm than when cold For example at 100 F 37 8 C a normal self discharge rate of 0 0024 specific gravity per day can be expected At 50 F...

Page 214: ...ken at one hour intervals indicate no increase in specific gravity Fast Charge CAUTION Always disconnect the battery cables be fore using a fast charger A battery may be charged at any rate that does...

Page 215: ...eter correctly hold it with the top sur face of the electrolyte in the hydrometer at eye level fig 1D 2 Disregard the curvature of the liquid where the surface rises against the float because of surfa...

Page 216: ...ig 1D 3 3 Turn selector knob to AMP position 4 Connect test leads as illustrated in figure 1D 3 5 Turn carbon pile rheostat knob clockwise until ammeter indicates correct test amperage 135 amperes for...

Page 217: ...EVEL TOO LOW FOR SPECIFIC GRAVITY TEST ADD WATER CHARGE BATTERY FOR 10 MIN AT 20 AMP RATE TEST SPECIFIC GRAVITY OK AVERAGE SPECIFIC GRAVITY 1 225 OR MORE CELLS ARE EQUAL WITHIN 0 050 50 POINTS r HEPLA...

Page 218: ...O 1 149 20 90 MIN 1 150 TO 1 174 20 70 MIN 1 175 TO 1 199 20 50 MIN 1 200 TO 1 224 20 30 MIN AVERAGE SPECIFIC GRAVITY 1 225 OR MORE CELLS ARE EQUAL WITHIN 0 050 50 POINTS REPLACE BATTERY AVERAGE SPECI...

Page 219: ...ues should ba usad forchecking a pra tlghtan d htm USA in lbs Metric Nm Service Service Service In Use Service In Use Set To Recheck Set To Recheck Torque Torque Torque Torque Battery Box Screw 145 95...

Page 220: ...NOTES l SS...

Page 221: ...ng The standard equipment alternator is rated at 42 amps and the optional heavy duty alternators are rated at 55 63 70 and 85 amps Alternator The alternator fig 1E 1 is belt driven by the engine Its m...

Page 222: ...avy duty typp Refer to Chapter ID Batteries OPERATION General Battery charging is accomplished by current supplied directly from the alternator output terminal heavy gauge red wire to the battery The...

Page 223: ...e This cycle repeats many times per second to limit the alternator output to a preset value Capacitor CI prevents abrupt voltage changes across R3 R4 prevents excessive back current through TRl at hig...

Page 224: ...ed from alternator 2 Connect test bulb jumper wires in series with output wire and alternator output terminal Connect battery negative cable Bulb should not light If bulb lights even dimly replace bri...

Page 225: ...resistance An alter nate test method is to determine the resistance of the field winding by connecting an ohmmeter to the two slip rings If the resistance is less than 2 2 ohms at 80 F 27 C the windi...

Page 226: ...MP BETWEEN CABLE AND BATTERY POST TEST VOLTAGE ACROSS POSTS WHILE STARTER MOTOR IS ENGAGED JUMPER BETWEEN WIRE COIL NEG TERMINAL AND GROUND IF VOLTAGE IS WITHIN 0 5 VOLT OF VOLTAGE AT ALTERNATOR IF VO...

Page 227: ...POINTER STOPS CHECK VOLTAGE REPLACE VOLTAGE REGULATOR OVERHAUL ALTERNATOR PLACE CARBUETOR THROTTLE ON HIGH STEP OF FAST IDLE CAM fe START ENGINE DO NOT TOUCH ACCELERATOR PEDAL IF VOLTAGE IS LOWER THA...

Page 228: ...NECT VOLTMETER ACROSS BATTERY TURN OFF ALL ACCESSORIES CHECK FOR GROUNDED BRUSH LEAD CLIP SEQUENCE RESULT S2HJ2S1 ZPTER VOLTMETER RADIATOR INLET AND p0 NTER STOPS IF NOT GROUNDED BATTERY REPLACE NOT O...

Page 229: ...djacent windings is difficult to locate without laboratory test equipment If all other electrical checks are normal and the alternator fails to supply the rated output shorted stator windings are prob...

Page 230: ...n insulated heat sink and each of three terminals Test torts Each combination of terminal and heat sink tested should have one high and one low resistance Replace bridge rectifier if any one pair of r...

Page 231: ...ddown screw 12 Disconnect capacitor wire terminal from bridge rectifier Remove capacitor CHARGING SYSTEM 1E 11 HjBmBVBMBlBKQ Sa 13 Remove bridge rectifier attaching screws and battery wire terminal sc...

Page 232: ...BOLT 23 BEARING AND SEAL ASSEMBLY 43105 7 Inspect condition of brush holder screw in sulating washers for broken or cracked insulation fig 1E 14 Assembly CAUTION Overfilling may cause the bearing to o...

Page 233: ...of rotor shaft Press seal in with lip away from bearing 11 Install springs and brushes into brush holder Brushes should slide in and out of brush holder without binding CHARGING SYSTEM 1E 13 NOTE Shou...

Page 234: ...Replace the belt if it is severely cracked or oil soaked 1 Install Belt Strand Tension Gauge J 23600 on longest accessible span of belt midway between pulleys fig 1E 17 NOTE Eight cylinder engines wi...

Page 235: ...Output Voltage Specifications Ambient Temperature in Degrees Fahrenheit C Acceptable Voltage Range 0 50 18 to 10 50 100 10 to 38 100 150 38 to 66 150 200 66to 93 14 3 15 3 13 9 14 9 13 4 14 4 13 0 14...

Page 236: ...NOTES m pm...

Page 237: ...return spring disengages the pinion gear To prevent excessive overrun the key switch should be released immediately after the engine starts Page Page General 1F 1 Starter Motor Operation 1F 1 Neutral...

Page 238: ...ANUAL TRANSMISSION ONLY 90558 Fig 1F 1 Four Cylinder Engine Starter Motor System SOLENOID SWITCH THROUGH BOLTS PLUNGER RETURN SPRING PLUNGER 1HIPT P N LEVER SHAFT LEVERS V RETAINING RING DRIVE END HOU...

Page 239: ...test procedures out lined below CAUTION Never operate the starter motor more than for a 30 second duration without pausing to allow it to cool for at least two minutes Overheating caused by excessive...

Page 240: ...re replacement normally corrects this condition 1 Replace starter motor armature 2 Low no load speed and high current flow indicate a Too much friction tight dirty or worn bearings bent armature shaft...

Page 241: ...G321 DowCorning 33Medium or equivalent on shaft underneath overrruning clutch assembly NOTE Avoid excessive lubrication STARTING SYSTEMS 1F 5 Starter Motor Removal Use the following procedure to remov...

Page 242: ...circuits are located by rotating armature in growler with steel strip e g hacksaw blade held above armature Steel strip will vibrate when at area of short circuit Short circuits between commutator bar...

Page 243: ...energized more than 15 seconds The current flow will decrease as the winding temper ature increases Overrunning Clutch Test the overrunning clutch action The pinion gear should turn freely in the ove...

Page 244: ...ion gear clearance follow the steps listed below 1 Disconnect starter motor field winding con nector from solenoid motor M terminal and THOR OUGHLY INSULATE IT 2 Connect battery between solenoid switc...

Page 245: ...GE FROM ENGINE BLOCK TO BATT NEG POST KEY IN START POSITION POS PROBE ON BLOCK LESS THAN 0 5 VOLT TEST VOLTAGE AT SOLENOID BAT TERMINAL 9 VOLTS OR MORE CHECK FUSIBLE LINK AND DASH CONNECTOR TURN ON RA...

Page 246: ...M BATTERY NEGATIVE TERMINAL TO ENGINE BLOCK POS PROBE ON BLOCK CHARGE AND CONNECT TEST BATTERY MEASURE VOLTAGE 0 5 VOLT OR MORE REPAIR GROUND CABLE AND CONNECTIONS 9 VOLTS OR MORE REPAIR STARTER MOTOR...

Page 247: ...etc Week A first week in month B second week etc FWi Windings Four field windings are used Each is wound around an iron pole shoe that concentrates the electromagnetic Sptdflcatlons StarterMotor Overh...

Page 248: ...and held in place by retaining nuts Loosening of the retaining nuts could cause the loss of iiiternal connections and necessitate replacementofthe solenoid Neutral Safety Switch The Neutral Safety Swi...

Page 249: ...USIBLE LINK 14 GAUGE RED CJ YELLOW CKE WAG TRK BATTERY STARTER MOTOR SOLENOID STARTING SYSTEMS IF 13 IGNITION RESISTANCE BYPASS TERMINAL M H GROUNDING CONTACTS NORMALLY CLOSED SOLENOID BRACKET GROUNt...

Page 250: ...motor rotates solenoid is defective and must be replaced If starter motor does not rotate in spect starter motor Starter Motor Solenoid Pull in Winding Test This test will determine if the solenoid pu...

Page 251: ...tarter motor 5 Starter motor rotates slowly with high load current 5 Inspect drive yoke pull down and point gap check for worn end bushings check ring gear clearance 6 Engine seized 6 Repair engine ST...

Page 252: ...VOLTMETER 1COMPARE AMPS FROM STEP 1 AND VOLTS TO CHART CONNECT ENGAGE TURN LOAD CONTROL OBSERVE HEAVY LOAD TESTER STARTER MOTOR FOR THREE SECONDS AND OBSERVE VOLTMETER UNTIL VOLTMETER INDICATES SAME V...

Page 253: ...500 VOLTS 0 3 V 0 5 V 0 6 V 0 9 V OK C isss V S SOLENC SOLENOID TO STARTER MOTOR CABLE VOLTAGE AT OR BELOW MAXIMUM VOLTAGE ABOVE MAXIMUM VOLTAGE DROP TEST NOTE TEST POINTS IN ILLUSTRATION MAXIMUM VOL...

Page 254: ...ety Switch Test Remove wire connector from switch and test for conti nuity between center terminal pin and transmission case Continuity should exist only when automatic transmission is in Park or Neut...

Page 255: ...ce is more than zero ohms solder joint has ex cessive resistance Repair by heating joint with 600 watt soldering iron INSULATED BRUSHES INOT CONTACTING ANY PART OF STARTER STARTING SYSTEMS 1F 19 1MB I...

Page 256: ...e bracket and cap Fig 1F 20 If the resistance is not infinite the insulator is faulty Repair by replacing the end cap TERMINAL BRACKET Fig 1F 20 Terminal Bracket Insulation Armature Tests 70877 Test T...

Page 257: ...tor from flywheel drive plate housing Installation 1 Position starter motor on flywheel drive plate housing NOTE Ensure mounting surfaces arefree ofburrs and debris 2 Install mounting screws and tight...

Page 258: ...cumference of the ring gear for damage when the teeth of the drive assembly pinion gear are damaged A normal wear pattern will be found in three places on 6 cylinderengine ring gears and fimr places o...

Page 259: ...d winding assembly in frame using original pole shoes and screws Apply drop of Loctite or equivalent to screw threads Tighten screws using arbor press and Starter Pole Screw Wrench J 22516 8 Install p...

Page 260: ...haft and install stop ring and original retainer Assembly 1 Insert armature into frame Install drive yoke and pivot pin Drive yoke must engage lugs on drive assembly 2 Insert drive yoke return spring...

Page 261: ...e Set To Torques should be used when assembling components Service In Use Recheck Torques should be used for checking a pre tightenod item USA ft lbs Metric N m Service Set To Torque Neutral Safety Sw...

Page 262: ...NOTES r S9 rs...

Page 263: ...Test Procedures 1G 9 IGNITION COIL CONNECTOR VACUUM ADVANCE MECHANISM 81178A HEI SYSTEM COMPONENTS The High Energy Ignition System distributor com bines all ignition components except the ignition co...

Page 264: ...ontrol unit to provide vacuum advance The trigger wheel is shifted about the shaft by conventional advance weights to provide centrifugal advance The electronic module automatically controls the dwell...

Page 265: ...sulator for the higher voltage provided by the HEI system The silicone rubber spark plug boots form a tight seal around the IGNITION SYSTEMS 1G 3 MAGNETIC TIMING PROBE SOCKET MOUNTED ON TIMING GEAR CO...

Page 266: ...OSIS HEI Distributor and Ignition Coll Refer to Ignition System Troubleshooting Chart Spark Plugs Faulty or dirty plugs may perform well at idling speed but at higher speeds they frequently fail Fault...

Page 267: ...WITH IGNITION ON CHECK TACH TERMINAL VOLTAGE MORE THAN 10 VOLTS CHECK FOR SPARK AT COIL OUTPUT TERMINAL WITH TOOL J 26792 WHILE CRANKING ENGINE VIEW A NO SPARK REMOVE PICKUP COIL CONNECTOR FROM MODULE...

Page 268: ...OUND CHECK FUEL COIL AND PLUG WIRES CAPAND PLUGS TACH TERMINAL ATTACH GROUND WIRE VIEW A B TERMINAL MODULE P TERMINAL TEST LAMP 4 TO BATTERY J 26792 CONNECTED TO COIL REMOVE PICKUP COIL CONNECTOR GREE...

Page 269: ...mp fig 1G 4 5 Note position of rotor then pull distributor up until rotor stops turning counterclockwise and again note position of rotor NOTE To ensure correct installation position of the distributo...

Page 270: ...TED ABOVE THROTTLE CABLE 2 Remove two vacuum advance unit attaching screws 3 Turn pickup coil clockwise and push rod end of vacuum advance mechanism down so that it will dis engage and clear pickup co...

Page 271: ...should indicate infinite resistance If not re place coil 2 Connect ohmmeter between positive and negative terminals Use low resistance scale Ohm meter should indicate zero or nearly zero If not re pl...

Page 272: ...k Torques should be used for checking e pre tighttned item Distributor Clamp Screw Spark Plugs USA ft lbs Metric Nm Service Set To Torqua Sarvlca In Usa Rachack Torqua Sarvlca Set To Torqua Sarvlca In...

Page 273: ...ration Fig 1G 10 Coll Connector COMPONENTS The SSI system consists of the following major com ponents ignition switch electronic ignition control unit ignition coil primary resistance wire and bypass...

Page 274: ...tion Coil Connector The coil terminals and coil connector are of unique design fig 1G 10 The connector is removed from the coil by grasping both sides and pulling connector away from coil fig 1G 13 Wh...

Page 275: ...airflow This causes a relatively lean mixture to enter the combustion cham bers Ignition must occur earlier because the lean mix ture requires a longer time to burn The vacuum ignition advance mechan...

Page 276: ...secondary winding all high voltage wires connected to the distributor cap coil and spark plugs distributor cap distributor rotor and spark plugs Secondary Circuit Diagnosis CAUTION When disconnecting...

Page 277: ...ed NOTE Do notperform Chart k tests until after Chart 1 tests have been completed Intermittent Failure Diagnosis Intermittent failure may be caused by loose or cor roded terminals defective or missing...

Page 278: ...from each other Check timing Adjust as required Check operation Repair as required Test system Repair as required ERRATIC TIMING ADVANCE 1 2 Faulty vacuum advance mechanism Centrifugal advance weights...

Page 279: ...cated NOTE Do notperform Chartk testsuntil after Chart 1 tests have been completed Intermittent Failure Diagnosis Intermittent failure may be caused by loose or cor roded terminals defective or missin...

Page 280: ...ystem s faulty 3 MCU microprocessor faulty 2 3 Check operation Repair as required Test system Repair as required ERRATIC TIMING ADVANCE qv Faulty vacuum advance 1 mechanism n Centrifugal advance weigh...

Page 281: ...AGE f_ i_r1 ACCEPTABLE O Ki 6V 5V VOLTAGE NOT x ACCEPTABLE lC_rX BATTERY VOLTAGE VOLTAGE NOT ACCEPTABLE BELOW 6V TURN IGNITION SWITCH TO START SEQUENCE CONNECT VOLTMETER TO COIL POSITIVE TERMINAL AND...

Page 282: ...CHECK SOLENOID AS OUTLINED IN CHAPTER1F IGNITION REMAINS ON OBSERVE VOLTAGE AT COIL POSITIVE TERMINAL CONNECT JUMPER BETWEEN COIL NEGATIVE TERMINAL AND GROUND VOLTAGE DROPS TO OK w VOLTAGE REPAIR DEFE...

Page 283: ...AND DASH CONNECTOR 13 RESISTANCE TOO HIGH 1 40 OHMS OR MORE RESISTANCE ACCEPTABLE 1 35 _ 05 OHMS CONNECT OHMMETER BETWEEN DASH CONNECTOR 13 AND IGNITION SWITCH TERMINAL 11 REPLACE IGNITION SWITCH OR...

Page 284: ...NNECTOR CONNECT OHMMETER FROM CENTER TOWER AND EITHER OR OK OK OK REPLACE COIL RESISTANCE ACCEPTABLE 1 13 TO 1 23 OHMS AT 75 F OR 24 C 1 5 OHMS AT 200 F OR 93 C RESISTANCE NOT WITHIN LIMITS OK REPLACE...

Page 285: ...T DISTRIBUTOR CONNECT OHMMETER TO D2 AND D3 TERMINALS OF 4 WIRE CONNECTOR OK OHMMETER NOW INDICATES 400 800 OHMS OHMMETER REMAINS OUTSIDE 400 800 OHMS DISCONNECT 4 WIRE CONNECTOR AT CONTROL UNIT SPARK...

Page 286: ...OES NOT INDICATE 400 800 OHMS OHMMETER INDICATES ZERO NOT ABOVE 0 002 OHM OHMMETER INDICATES ABOVE 0 002 OHM VOLTMETER FLUCTUATES INDICATING PROPER PICKUP COIL AND TRIGGER WHEEL OPERATION VOLTMETER DO...

Page 287: ...RE CONNECTOR AT CONTROL UNIT VOLTMETER INDICATES REPLACE BATTERY VOLTAGE CONTROL UNIT WITHIN 0 2V UNPLUG 2 WIRE CONNECTOR AT MODULE AND CONNECT VOLTMETER BETWEEN TERMINAL F 2 AND GROUND VOLTMETER DOES...

Page 288: ...eat Valve This is applicable to eight cylinder engines only If the heat valve sticks in the heat ON position the intakemanifold will beheated excessively TEST PROCEDURES Primary and Secondary Circuit...

Page 289: ...ps If current flow is not within specifications electronic control unit is defective IGNITION SYSTEMS 1G 25 Ignition Coll Output Tests 1 Connect oscilloscope to ignition coil Refer to test equipment m...

Page 290: ...ing Ensure pickup coil wire rubber grommet in distributor housing aligns with depression in distributor cap and that cap fits on rim of distributor housing NOTE Two different diameter screws are used...

Page 291: ...ing Install ground screw through tab and tighten 6 Install trigger wheel on shaft with hand pres sure Long portion of teeth must be upward When trig ger wheel and slot in shaft are properly aligned us...

Page 292: ...RED GREASE LICONE GREASE APPLIED TO BLADE 70871 Fig IG 17 Rotor Silicone Dielectric Compound Application SPECIFICATIONS SSI Distributor and Ignition Coil Specifications Distributor Pickup Coil Resista...

Page 293: ...INDER ENGINE J 26792 HEI SPARK TESTER J 24642 HEI MODULE TESTER IGNITION SYSTEMS 1G 29 LEFT BANK v v J CLOCKWISE ROTATION 1 8 4 3 6 5 7 2 RIGHT BANK Tools EIGHT CYLINDER ENGINE J 28509 TRIGGER WHEEL P...

Page 294: ...ant Depending on coolant temperature the CTO valve fig 1G 19 permits manifold vacuum with the delay function or manifold vacuum without the de lay function to control the distributor vacuum advance VA...

Page 295: ...lding by hot coolant System is pressurized 1 Drain coolant from radiator until level is below CTO valve 2 Identify tag and disconnect vacuum hoses from CTO valve 3 Place drain pan under engine directl...

Page 296: ...warms to a predetermined temperature Warm up driveability is improved by controlling the vacuum advance by manifold vacuum while the engine is cold This is accomplished by the vacuum advance control...

Page 297: ...ine cooling efficiency and reducing coolant boiling during idle speed engine operation IGNITION SYSTEMS 1G 33 Functional Test 1 Connect vacuum gauge to port D Dist ofheavy duty cooling system CTO valv...

Page 298: ...D PORTED VACUUM VACUUM H S cD VI CTO VALVE REGULATED OR MANIFOLD VACUUM o o o so o DISTRIBUTOR VACUUM ADVANCE MECHANISM 90063 Rg 16 26 Regulated Vacuum Advance Control System Typical Functional Test C...

Page 299: ...nces ignition timing When the engine is accelerated mani fold vacuum decreases causing the ignition timing to be retarded To prevent the sudden retarding of ignition timing during acceleration a one w...

Page 300: ...NOTES r r...

Page 301: ...the vehicle decelerates to the desired speed When the but ton is released the new selected speed will be maintained If a higher speed is desired accelerate to the desired speed depress the SET pushbut...

Page 302: ...pendent ly of the electronically controlled valves admits at mosphericpressureintothe servowheneverthebrakeor clutch pedal is depressed A hissing sound maybeheard momentarily OPERATION Servo The selec...

Page 303: ...ge valve solenoid is energized the valve opens and the diaphragm moves to pull the chain and throttle cable and the throttle is opened further As the throttle moves a throttle position sensor poten ti...

Page 304: ...r clutch switch defective 1 Improper linkage adjustment 2 Improper chain adjustment 1 Centering adjustment set wrong 1 No slack in bead chain 2 Vacuum hose connections reversed at servo 3 Servo defect...

Page 305: ...SPEED SENSOR DASH PANEL GROMMET DASH PANEL GROMMET TO BRAKE LAMPS 2 Connect voltmeter set on low AC scale to speed sensor wire connector terminals 3 Raise front and rear wheels of vehicle off ground a...

Page 306: ...place vent valve 80693C TESTING Perform the following tests as part of the service diagnosis to determine the cause of a malfunction and the correction required YELLOW CONTROL SWITCH IN OFF POSITION 1...

Page 307: ...l switch and associated wiring harness terminals and connectors Lamp 3 Brake or clutch pedal switch adjustment and associated wiring harness terminals and connectors Cruise Command Diagnosis Chart TES...

Page 308: ...Test 2 Lamp 4 Off Lamp 5 Off Check for defective connections at terminals 6 12 on regulator connector Replace defective servo Lamp 6 Off Check for defective connection at terminals 4 12 on regulator...

Page 309: ...lected vehicle speed turn the centering adjusting screw counterclockwise a small amount If engagement speed is two or more mph 3 2 or more km h below selected speed turn the cen tering adjusting screw...

Page 310: ...e between bellcrank lock clip and cable clip CONTROL SWITCH REPLACEMENT The Cruise Command control switch is integral with the turn signal switch lever The switch is not repair able The switch and wir...

Page 311: ...IP r NOTES fm _ f m...

Page 312: ...ever and control switch assembly 6 Install horn contact locking plate and lock ring CRUISE COMMAND 1H 11 anti theft cover 7 Install steering wheel and horn button insert 8 Install trim on steering col...

Page 313: ...The air cleaner intake duct contains the air valve for the Thermostatically Controlled Air Cleaner TAC Sys tem and trap door if equipped The operation and diag nosis of both systems are described with...

Page 314: ...1J 3 5 Install replacement filter element and spring with hole in filter element toward fitting 6 With new gasket on fitting install fuel inlet fittingandtighten with 25foot pounds 34 N m torque 7 In...

Page 315: ...ield and tank on jack and partially raise 2 Install fuel outlet hose return hose fuel gauge sending unit wires and tank vapor vent hoses 3 Raise shield and tank to installation position install screws...

Page 316: ...LINE FROM FUEL FILTER SIX CYLINDER ENGINE ONLY SENDING UNIT PICKUP TUBE AND RLTER FILLER HOSE Rg U 4 Fed Tank tnd Associated Feel System Components CJ Vehldss VENT HOSES FUEL GAUGE SENDING n UNIT WIR...

Page 317: ...re an integral unit that is mounted on a flanged opening on the fuel tank For all vehicles it is secured with a threaded retainer that must be tightened with a torque of 14 to 18 foot pounds 19 to 24...

Page 318: ...the normally closed position FUEL VAPOR CONTROL SYSTEMS The fuel vapor control system prevents raw fuel vapor from escaping into the atmosphere Fuel vapor from the fuel tank and carburetor bowl are c...

Page 319: ...s not operating fig U ll If the vent were not provided raw fuel vapor would enter the atmosphere Some would also enter the intake manifold and cause difficult hot restarts When the engine is operating...

Page 320: ...fuel filter must be posi tioned upward to ensure proper fuel system operation Some engine carburetor combinations are equipped with an inline check valve in the fuel return system near the fuel filte...

Page 321: ...engines is not clogged Pressure Test 1 Remove air cleaner assembly 2 Disconnect fuel inlet fitting or fuel filter at carburetor 3 Disconnect fuel return hose at fuel filter and plug nipple on filter...

Page 322: ...onforms to the specification while using the auxiliary fuel supply inspect for a restriction in the fuel supply line from the tank and for proper tank venting Vacuum Tests Two vacuum tests can be perf...

Page 323: ...ECIFICATIONS Fuel Tank Capacity Vehicle Gallons CJ 14 8 56 0 liters Optional 20 75 6 liters Cherokee Wagoneer 21 5 81 4 liters Truck 18 2 68 9 liters 80708 CARBURETOR MODEL 2SE 2 VENTURI Carburetor Ci...

Page 324: ...COIL ASSEMBLY THROTTLE BODY INSULATOR INTAKE MANIFOLD GASKET AIR HORN GASKET VENTSCREEN CHOKE VALVE VACUUM BREAK AND BRACKET IDLE SPEED SOLENOID VACUUM HOSE VACUUM BREAK LEVER VACUUM BREAK ROD AIR VAL...

Page 325: ...ented through a vertical vent cavity in the air horn Above this vent cavity is a removable vent stack assembly that has a small meshed screen at its top This vent stack provides the correct height for...

Page 326: ...ges in venturi vacuum and is more readily vaporized when discharged into the venturi fig 1J 23 Power Enrichment Circuit During heavy load or high speed operation the air fuel ratio must be enriched to...

Page 327: ...ir horn assembly provides a high vacuum both above and below the throttle valves when it is closed During engine start ing vacuum above the throttle valve causes fuel to flow from the main metering an...

Page 328: ...ace carburetor in position and loosely install attaching bolts and nuts 4 Connect vacuum hoses and loosely connect fuel pipe fitting 5 Tighten attaching bolts and nuts with 12 foot pounds 16 N m torqu...

Page 329: ...MS U l 7 INTERMEDIATE CHOKE ROD CHOKE LEVER 90658 Fig 1J 29 Model 2SE Carburetor Choke Rod Removal 5 If equipped remove two small screws that re tain hot idle compensator valve fig U 30 Remove valve a...

Page 330: ...embly 10 Remove air horn gasket Gasket is precut for easy removal around metering rod and hanger assembly fig 1J 33 11 Remove pump plunger from pump well 12 Remove pump return spring from pump well 13...

Page 331: ...tainers from choke cover and coil assembly Pull straight out ward and remove cover and coil assembly from choke housing MAIN METERING JET REMOVAL TOOL FUEL SYSTEMS 1J 19 1L i i 90666 Fig U 37 Model 2S...

Page 332: ...CHOKE HOUSING ATTACHING SCREWS 90670 Fig U 41 Model 2SE Carburetor Choke Housing Screws LOCATOR HOLE PLUG THROTTLE BODY ATTACHING SCREWS 90671 Fig U 42 Model 2SE Carburetor Throttle Body Screws c If r...

Page 333: ...xture Screw Removal Cleaning and Inspection The carburetor components should be cleaned in a cold immersion type carburetor cleaning solution CAUTION The solenoid choke cover and coil assem bly rubber...

Page 334: ...oper seat ing debris etc Also examine items listed within Flood ing above d Poor Engine Performance Poor Gas Mileage 1 Clean all fuel and vacuum passages in castings 2 Inspect choke valve for freedom...

Page 335: ...er holding fixture J 9789 118 CAUTION When properly installed hole in filter faces toward inlet Ribs on closed end offilter element FUEL SYSTEMS U 23 prevent filter from being installed incorrectly un...

Page 336: ...y in place using drift and small hammer 22 Install plastic filler block over float needle by pressing downward until properly seated flush with bowl casting surface 23 Install air horn gasket on float...

Page 337: ...Rotate solenoid bracket and insert end of vac uum break rod into inner slot and end of air valve rod into outer slot of vacuum break diaphragm plunger Install bracket over locating lugs on air horn In...

Page 338: ...Do not remove the rivets and retainers securing the choke cover and coil assembly unless it is necessary to inspect the choke coil lever adjustment If the rivets and cover are removed a choke cover re...

Page 339: ...tion to open valve to ensure all slack is removed between air valve rod and plunger slot 7 Bend air valve rod with Bending Tool J 9789 111 until bubble is centered 8 Remove gauge Primary Side Vacuum...

Page 340: ...cent to vent stack INTERMEIOATE CHOKE LEVER GAUGE CLEARANCE LOCKOUT LEVER TANG TO FAST IDLE CAM SECONDARY ACTUATING LEVER 90723 Rg U 57 Model 2SE Carburetor Seconder lockout AdJostBtst WARNING Use ext...

Page 341: ...temperature FUEL SYSTEMS 1J 29 5 Disconnect and plug EGR valve vacuum hose 6 Open throttle slightly and rotate fast idle cam until adjustment screw is against highest step of cam 7 Adjust fast idle s...

Page 342: ...n on and engine not started Repair wires and connections as necessary 3 If tests in steps 1 and 2 have normal results replace oil pressure switch Carburetor Model 2SE Specifications 17082300 17082381...

Page 343: ...factory adjusted rich mixture screw located at the end of the fuel supply channel in the float bowl In addition air metered to the idle circuit is controlled by the up and down movement of the mixtur...

Page 344: ...ts fuel leaks should vehicle roll over occur Idle Circuit Fuel for idle and partial throttle engine operation is provided by the idle circuit Fuel flows from the main well area into the idle tube and...

Page 345: ...chani cally supplies the fuel necessary to overcome this defi ciency fig 1J 65 Fuel is drawn into the pump cylinder from the fuel bowl past the pump piston on the upward movement of the accelerator pu...

Page 346: ...coil assembly must not be removed unless required during major carburetor over haul or replacement of the cover and coil assembly or choke housing is necessary The carburetor has a screw located in t...

Page 347: ...moving the carburetor from the engine Refer to Service Adjustment Procedures A complete carburetor overhaul includes disassembly thorough cleaning inspection and replacement of the gaskets and worn or...

Page 348: ...HOKE ROD Fig 1J 69 Carburetor Model E2SE Intermediate Choke Rod and Clip Removal 90658 7 Remove three mixture control solenoid screws in air horn Using slight twisting motion carefully lift solenoid o...

Page 349: ...ol lowed carefully If air horn replacement is required during carburetor service the new service air horn as sembly will include the secondary metering rod air valve assembly preset as required 15 It...

Page 350: ...discourage indiscriminate readjustment of the choke cover and coil assembly in thefield However it is necessary to remove the cover and coil assembly during normal carburetor disassembly for cleaning...

Page 351: ...eaning purposes The primary and second ary throttle valve screws are permanently staked in place and should not be removed The throttle body is serviced as a complete assembly fig U 82 LOCATOR HOLE FU...

Page 352: ...er and lower surface of carburetor castings for damage 3 Inspect holes in levers for excessive wear or out of round conditions If worn levers should be replaced Inspect plastic bushings on levers for...

Page 353: ...ect throttle lever and valves for binding nicks and other damage 5 Examine all diaphragms for possible ruptures or leaks CAUTION Clean plastic parts only in a low volatile cleaning solvent never in ga...

Page 354: ...e NOTE When installing a service replacement filter ensure the filter is the type that includes a check valve that conforms to U S Motor Vehicle Safety Standards M V S S NOTE When properly installed h...

Page 355: ...d install choke shaft choke valve and two attaching screws Tighten screws securely and stake lightly in place 27 If used install new pump plunger stem seal and retainer in air horn casting Lightly sta...

Page 356: ...r seal on stem is guided into recess in the bottom of the bowl and to prevent distortion or damage to the rubber seal 36 Prior to installing mixture control solenoid lightly coat rubber seal on end of...

Page 357: ...irect line with fan Do not put hands near pulleys belts or fan Do not wear loose clothing 3 With engine at idle speed and choke valve com pletely open carefully insert float gauge in air horn FUEL SYS...

Page 358: ...o not put hands near pulleys belts or fan Do not wear loose clothing 3 Start and warm engine to normal operating temperature 4 Disconnect and plug EGR valve vacuum hose 5 Open throttle slightly and ro...

Page 359: ...d The tag is attached to the carburetor and must remain with the carburetor to assure proper identification fig 1J 93 CARBURETOR CIRCUITS Five conventional circuits are used Float fuel inlet Idle low...

Page 360: ...essure in the venturi and the main metering system begins to discharge fuel Main High Speed Metering Circuit At partial throttle and cruising speed increased air flow through the venturi creates a low...

Page 361: ...rough a system of levers and assisted by the pump drive spring pushes the pump piston down Fuel is forced through a passage past the pump discharge check valve ball and out the pump discharge jets in...

Page 362: ...he air temperature is above 60 F 16 C the vacuum actuator is engaged when the engine idle speed drops below calibrated minimum speed AT 435 rpm MT 462 5 10 rpm The vacuum actuator moves the throttle p...

Page 363: ...S 1J 51 ox r 1 DIAPHRAGM CONNECTOR LINK 21 VENTURI CLUSTER SCREW 41 MIXTURE SCREW 2 SCREW 22 IDLE FUEL PICKUP TUBE 42 SPRING 3 CHOKE VACUUM DIAPHRAGM 23 GASKET 43 THROTTLE BODY 4 HOSE 24 VENTURI CLUST...

Page 364: ...cuum diaphragm Remove choke dia phragm linkage and bracket assembly Place dia phragm aside to be cleaned separately 8 Remove fast idle cam retaining screw Remove fast idle cam choke link and clip 9 Gr...

Page 365: ...ve idle mixture screws and springs from throttle body Cleaning and Inspection Debris gum water or carbon contamination in the carburetor or on exterior moving parts is often respon sible for unsatisfa...

Page 366: ...dhered to the gaskets 1 If removed install idle mixture screws and springs in body Turn screws lightly against their seats then back off number of turns recorded during dis assembly Install dowel pins...

Page 367: ...e cam and choke lever 23 Adjust initial choke valve clearance Refer to Service Adjustment Procedures 24 Adjust fast idle cam clearance Refer to Service Adjustment Procedures FUEL SYSTEMS 1J 55 25 Adju...

Page 368: ...to correct distance Tighten lock screw 6 Install cover and screws PUMP ARM LOCK SCREW rA5 ACCELERATOR PUMP SHAFT 80447 Fig U l 10 Accelerator Pump Adjustment Initial Choke Valve Clearance Adjustment...

Page 369: ...required direction Rich and lean are indicated by the arrow on the face of the cover Refer to Specifica tions for the correct position The specified position will be satisfactory for most driving con...

Page 370: ...tion Float Level Inches Vacuum Piston Gap Inches Initial Choke Valve Clearance Inches Fast Idle Cam Setting Inches Automatic Choke Cover Setting Notches Rich Accelerator Pump Dimensions Inches Choke U...

Page 371: ...COMPENSATION CIRCUIT CHOKE CHOKE COVER CHOKE DIAPHRAGM VACUUM SOURCE 81153 Fig 1J 114 Model 2150 Carburetor Assembly Choke Mechanism Service General Service Adjustment Procedures Specifications Page 1...

Page 372: ...e carburetor to the fuel vapor storagecanister A bell crank attached to the accelerator pump housing actuates the bowl vent fig U l17 At idle or solenoid Off position if equipped the vent opens permit...

Page 373: ...h the main air inlets mixes with the fuel through small holes in the sides of the main well tubes The main air inlets meter an in creasing amount of air whenever venturi vacuum in creases to maintain...

Page 374: ...tarting The choke shaft is connected by linkage to a bimetallic coil that winds up contracts when cold and unwinds expands when warm The position of the choke valve is controlled by the action of a va...

Page 375: ...lates the amount of air passed from the plenum into the com pensator body Air flows from the compensator body through two air passages bored into the main venturi tubes The opening and closing of the...

Page 376: ...CAP 2 48 IDLE MIXTURE SCREW 2 49 IDLE MIXTURE SCREW SPRING 2 50 RETAINER 52 FAST IDLE LEVER RETAINING NUT FAST IDLE LEVER PIN RETAINER LEVER AND SHAFT FAST IDLE CAM ROD 57 CHOKE SHIELD 58 CHOKE SHIEL...

Page 377: ...er with coil and gasket 9 Remove fast idle cam rod from fast idle cam lever 10 Remove choke housing assembly retaining screws housing assembly and gasket 11 Remove fast idle cam FUEL SYSTEMS 1J 65 12...

Page 378: ...procedure listed below does not involve the replacement parts included in the carburetor overhaul repair kit Install all gaskets and parts included in the repair kit when the carburetor is assembled...

Page 379: ...el bowl b Pull valve in until it seats in pump cavity wall Cut off tip forward of retaining shoulder c Remove tip from bowl 5 Install accelerator pump diaphragm return spring in chamber depression Ins...

Page 380: ...air horn attaching screws and carburetor identification tag Tighten attaching screws 40 Attach choke valve rod and retainer on choke shaft lever 41 Install air cleaner anchor screw 42 If equipped inst...

Page 381: ...or identification tag and attaching screws Ensure plastic dust seal on choke operating rod is positioned correctly and does not cause rod to bind Tighten screws Install air cleaner anchor screw and ti...

Page 382: ...tang to ensure it does not bind contact or stick on any part of AJ41660 Fig 14 136 Choke Unloader Adjustment 1 FAST IDLE CAM PIVOT CHOKE UNLOADER TANG FAST IDLE CAM AJ41661 Fig 14 137 Unloader Fast Id...

Page 383: ...carriage to ob tain 600 rpm 3 Disconnect solenoid wire connector and adjust curb idle screw to obtain 500 rpm curb idle speed 4 Connect solenoid wire connector 5 If equipped with dashpot with throttl...

Page 384: ...ng clean and insert into housing 5 Wipe fast idle cam clean 6 Install choke housing over choke shaft and in stall housing screws 7 Install choke lever and screw 8 Install choke cover connect heater co...

Page 385: ...n the air cleaner and is controlled by air cleaner air temperature The TVS controls the vacuum passage between the EGR CTO valve and the EGR valve At air temperatures below the calibrated value the TV...

Page 386: ...ack pressure level EGR oper ation is then dependent on exhaust back pressure and exhaust gas is a fixed percentage of the incoming charge EGR Valvo Functional Tests The mechanical condition of the exh...

Page 387: ...oil filler tube or at the right rear corner of the engine adjacent to the EGR valve for eight cylinder engines FUEL SYSTEMS 1J 75 The inner port s connects by hose to the EGR port at the carburetor po...

Page 388: ...uum applied to the EGR valve and by doing so prevents EGRoperation This improves cold engine driveability NOTE A TVS is also used with other systems whose operation is dependent onair cleaner air temp...

Page 389: ...stem is avoided FUEL SYSTEMS U 77 The black side of the valve is installed toward the EGR vacuum source Reverse Delay Valve A reverse delay valve is located between the EGR CTO valve and the manifold...

Page 390: ...gh the air intake filter into the crankcase After circulating through the crankcase the vapor filled air is forced through the PCV valve into the intake manifold The vapor mixes with the air fuel mixt...

Page 391: ...from air cleaner fig 1J 149 INLET FILTER AJ43048 Rg 1J 149 PCV Air Inlet Filler Four and Six Cylinder Engines 2 Clean filter in kerosene 3 Install filter and retainer in air cleaner Eight Cylinder Eng...

Page 392: ...ible duct to the ambient air inlet at the front of the engine compartment AIR CLEANER HOUSING CHECK VALVE COVER OPERATION TAC SYSTEM The position of the air valve is controlled by manifold vacuum oppo...

Page 393: ...f air temperature to provide maximum airflow TESTING TAC SYSTEM 1 Remove air cleaner assembly from carburetor and allow to cool to room temperature 2 After cooling sight through air cleaner duct to ob...

Page 394: ...ne is turned off by gradually allowing atmospheric pressure to enter the vacuum motor A check valve is also connected in the vacuum hose Functional Tests Trap Door 1 With the engine off remove air cle...

Page 395: ...em Diagnostic Procedures For C4 System General System Operation Page 1J 111 1J 83 u ee U 85 that is actually a voltage analog for the oxygen content in the exhaust gas As the oxygen content increases...

Page 396: ...bulb that will inform a technician of the need for ser vice If a malfunction exists the bulb will illuminate The ECM also incorporates a diagnostic program that will flash a trouble code that identifi...

Page 397: ...arting purposes Stepper Motor The Stepper Motor is integral with the model BBD carburetor It controls the metering pins that vary the FUEL SYSTEMS 1J 85 size of the idle and main air inlet orifices lo...

Page 398: ...SOR OR MCU i MCSOLENOID OR STEPPER MOTOR COMBUSTION and OPTIMUM A F MIXTURE EXHAUST CLOSED LOOP OPEN LOOP OPERATION ECM OR OXYGEN MCU SENSOR t L 1 MC SOLENOID OR STEPPER MOTOR 1 PRE DETERMINED A F MIX...

Page 399: ...ECM MCU The C4 system microprocessor CJ vehicles only is located in the passenger compartment on the left hand kick panel fig 1J 155 The six cylinderengine micro processor is located in the engine co...

Page 400: ...temperature sensor wire harness and electronic control module ECM The procedure for determining which of the three is at fault is located in the Trouble Code 14 chart For other trouble codes refer to...

Page 401: ...with a torque load FUEL SYSTEMS 1J 89 and the C4 System in closed loop operation before this code will be flashed Trouble Codes 44 and 45 at same time Faulty oxygen sensor Trouble Code 45 Voltage inpu...

Page 402: ...must be removed to prevent a potential fire hazard when fuel pipe is disconnected b Disconnect battery negative cable c Disconnect fuel pipe and vacuum hoses from carburetor Identify and tag hoses d...

Page 403: ...with a torque load FUEL SYSTEMS U 89 and the C4 System in closed loop operation before this code will be flashed Trouble Codes 44 and 45 at same time Faulty oxygen sensor Trouble Code 45 Voltage input...

Page 404: ...cable must be removed to prevent a potential fire hazard when fuel pipe is disconnected b Disconnect battery negative cable c Disconnect fuel pipe and vacuum hoses from carburetor Identify and tag ho...

Page 405: ...ool removed If unable to adjust to specification inspect idle circuit for leaks restrictions etc 11 Disconnect MC solenoid wire connector and ob serve tachometer for an engine speed change of at least...

Page 406: ...rminal A ignition terminal 1 to ECM and ECMterminal T to ground 2 Tach filter resistance should be 14 000 to 18 000 ohms between distributor and ECM terminals with one end disconnected and an open cir...

Page 407: ...M N ECM POWER GROUND TO ENG GRD _ T IGNITION POWER U CARBURETOR MIXTURE CONTROL W SOLENOID WIRE COLOR BLACK CONNECTOR A BLACK WHITE B BROWN C D LIGHT GREEN N WHITE BLACK E NOT USED F G YELLOW NOT USED...

Page 408: ...N METERING CIRCUIT SEE E2SE CARB CHAPTER U FIXED 5 10 FIXED 10 50 n SEE CHART 2 SEE CHART 3 T MORE THAN 100 RPM DROP REMOVE GROUND FROM DWELL LEAD CONNECT DWELL METER TO MC SOLENOID DWELL LEAD USE 6 C...

Page 409: ...WELL CHANGE CHECK FOR AIR LEAK r I NO AIR LEAK AIR LEAK SEE E2SE CARBURETOR CHAPTER U REPAIR RECHECK DISCONNECT OXYGEN SENSOR AND CONNECT TEST LIGHT FROM BAT TERMINAL TO PURPLE WIRE FROM ECM DWELL INC...

Page 410: ...XYGEN SENSOR CONNECTOR NO DWELL CHANGE DISCONNECT VACUUM SWITCH ASSEMBLY WIRE CONNECTOR AND CONNECT JUMPER WIRE BETWEEN WIRE HARNESS CONNECTOR TERMINALS F AND E r I 1 DWELL VARIES NO DWELL CHANGE REPL...

Page 411: ...R LEAK TO ENGINE MANIFOLD BUT NOT ENOUGH TO STALL THE ENGINE DWELL DECREASES NO DWELL CHANGE SEE E2SE CARBURETOR CHAPTER U DISCONNECT OXYGEN SENSOR WIRE CONNECTOR USE JUMPER WIRE TO SHORT CONNECTOR TE...

Page 412: ...NE ON HIGH STEP OF FAST IDLE CAM AND REMOVE VACUUM HOSES FROM WOT ADAPTIVE VACUUM SWITCHES AND CARB AND PLUG HOSES OBSERVE TEST BULB LIGHT REPLACE HOSES BEFORE RETURNING ENGINE TO IDLE BULB ON I SEE T...

Page 413: ...ST BULB CONNECTOR FOR PROPER CONNECTION WITH IGNITION ON AND ENGINE OFF CHECK VOLTAGE BETWEEN BULB CONNECTOR WHITE WIRE TERMINAL AND GROUND OVER 10 VOLTS CHECK VOLTAGE BETWEEN ECM TERMINAL R AND GROUN...

Page 414: ...TOR UNDER 10 VOLTS REMOVE VACUUM HOSE FROM SWITCH AND OBSERVE VOLTMETER UNDER 10 VOLTS CHECK FOR AN OPEN IN WIRE TO ECM CONNECTOR TERMINAL B IF NOT OPEN REPLACE ECM OVER 10 VOLTS NO MALFUNCTION FOUND...

Page 415: ...TACH FILTER WITH FILTER DISCONNECTED UNDER 4 VOLTS REPAIR OPEN IN WIRE BETWEEN FILTER AND TACH TERMINAL OF DISTRIBUTOR ran IGNITION ON ENGINE OFF USING A DIGITAL VOLTMETER CHECK VOLTAGE BETWEEN ECM SI...

Page 416: ...ECT OXYGEN SENSOR CONNECTOR AND CONNECT JUMPER WIRE BETWEEN CONNECTOR TERMINALS NOT OXYGEN SENSOR TERMINALS I S 10 DWELL 1 OVER 10 DWELL REPLACE OXYGEN SENSOR CONNECT JUMPER WIRE BETWEEN ECM TERMINALS...

Page 417: ...TO MC SOLENOID USE 6 CYL SCALE RUN ENGINE AT PARTIAL THROTTLE UNTIL DWELL STARTS TO VARY WITH ENGINE IDLING REMOVE CONNECTOR FROM COOLANT SENSOR 1 DWELL VARIES REPLACE COOLANT SENSOR REMOVE BLACK ECM...

Page 418: ...T JUMPER WIRE BETWEEN CONNECTOR TERMINALS DWELL VARIES DWELL UNCHANGED CHECK COOLANT SENSOR CONNECTION IF OK REPLACE SENSOR DISCONNECT VACUUM SWITCH ASSEMBLY WIRE CONNECTOR AND CONNECT JUMPER WIRE BET...

Page 419: ...SWITCH CONNECTOR IOVER 10 DWELL j CONNECT A TEST LIGHT BETWEEN ECM TERMINALS U AND C NOTE TERMINAL U IS VOLTAGE SOURCE CHECK VACUUM AT WOT SWITCH LIGHT NO LIGHT OVER 10IN HG UNDER 10 IN HG REMOVE BLAC...

Page 420: ...Y TERMINAL AND TERMINAL A OF VACUUM SWITCH FEMALE CONNECTOR AND GROUND TERMINAL B I LIGHT NO LIGHT REPLACE VACUUM SWITCH ASSEMBLY CONNECT TEST LIGHT BETWEEN BATTERY TERMINAL AND TERMINAL A ON ECM SIDE...

Page 421: ...INAL PINK LEAD AND GROUND CHECK VOLTAGE AT ECM TERMINAL W I LIGHT CONNECT TEST LIGHT BETWEEN SOLENOID CONNECTOR TERMINALS DO NOT USE VOLTMETER r NO LIGHT NO LIGHT CHECK FOR OPEN POWER CIRCUIT TO SOLEN...

Page 422: ...ELL CHANGE CHECK FOR AIR LEAK IN VACUUM HOSES I DISCONNECT OXYGEN SENSOR CONNECTOR AND CONNECT TEST LIGHT BETWEEN BATTERY TERMINAL AND TAN WIRE TERMINAL IN CONNECTOR NOT OXYGEN SENSOR TERMINALS NO LEA...

Page 423: ...T ENOUGH TO STALL ENGINE DWELL DECREASED NO DWELL CHANGE SEE E2SE CARBURETOR CHAPTER U DWELL DROPS TO 5 10 DISCONNECT OXYGEN SENSOR CONNECTOR CONNECT JUMPER WIRE BETWEEN WIRE CONNECTOR TERMINALS NOT O...

Page 424: ...GINE OBSERVE TEST BULB MORE THAN 20OHMS IGNITION ON ENGINE NOT STARTED DISCONNECT MC SOLENOID CONNECTOR CONNECT TEST LIGHT FROM GROUND TO DWELL LEAD ON MC SOLENOID DISCONNECT GRAY ECM CONNECTOR NO LIG...

Page 425: ...SYSTEMS 1J 111 lean limit altitude jumper wire is not installed Air is also diverted downstream if the WOT timer is activated Open Loop 3 Open Loop 3 is selected when the ignition advance vacuum leve...

Page 426: ...the ignition system is turned off the MCU is also turned off It has no long term memory circuit for prior operation As a result it has an initialization func tion that is activated when the ignition...

Page 427: ...ESSOR 02 SENSOR GROUND 4 IN Hg VACUUM SWITCH 10 IN Hg VACUUM SWITCH COOLANT TEMP SWITCH WOT SWITCH THERMOELECTRIC SWITCH TES ALTITUDE 02 SENSOR INPUT TACH INPUT 14 GROUND 20B l2 l1 9 15 ELECTRONIC IGN...

Page 428: ...TAN Rg 1J 16S Stepper Motor Coootctor COOLANT TEMPERATURE SWITCH 81144 OL1 SWITCH INTAKE MANIFOLD HEATER CONTROL SWITCH INSULATOR 81146 Rg 1J 166 Coolant Temperature Switch NORMALLY OPEN NO NATURAL j...

Page 429: ...FUEL SYSTEMS U 115 Bmanmmasmama BammBS9Bai mechanical engine operation i e plugs valves rings ignition System gaskets intake manifold carburetor or base plate loose vacuum hoses or fittings 1 4 IN HO...

Page 430: ...ITY TO GROUND CHECK HARNESS GROUND FOR TIGHT CONNECTION AT RIGHT SIDE OF CYLINDER BLOCK NO REPAIR AND START TEST OVER YES TURN IGNITION OFF LOCATE AIR CLEANER MOUNTED THERMAL ELECTRIC SWITCH TES AND D...

Page 431: ...EN IGNITION IS FIRST TURNED ON STEPPER MOTOR PINS MOVE TO FULL FORWARD RICH POSITION THEN BACK TO HALF WAY POSITION CONTD FUEL SYSTEMS U l 17 TURN IGNITION ON AND DISCONNECT STEPPER MOTOR CONNECTOR TE...

Page 432: ...YSTEMS YES CONTINUED FROM PREVIOUS PAGE NO REPAIR STEPPER MOTOR PIN BINDING DEFECT REPLACE MCU AND RETEST STEPPER MOTOR CONTINUED FROM PREVIOUS PAGE REPLACE STEPPER MOTOR REPAIR AND START TEST OVER 81...

Page 433: ...CU CONNECTOR PIN 14 DISCONNECT VACUUM HOSE FROM SWITCH 2 OF VACUUM SWITCH ASSEMBLY YES DISCONNECT VACUUM SWITCH ASSEMBLY WIRE CONNECTOR AND RETEST CONTINUITY DISCONNECT MCU HARNESS CONNECTOR AND RETES...

Page 434: ...YES DISCONNECT AND RETEST REPLACE MCU RETEST REPLACE VACUUM SWITCH ASSEMBLY AND RETEST NOTE ALSO DETERMINE IF CONTINUITY EXISTS BETWEEN VACUUM SWITCH CONNECTOR PIN B AND MCU CONNECTOR 7 DISCONNECT TES...

Page 435: ...ONTINUITY BETWEEN WOT SWITCH AND MCU CONNECTOR PIN 17 YES REPLACE WOT SWITCH AND RETEST REPAIR SHORT CIRCUIT IN TES WIRES AND RETEST DISCONNECT MCU AND RETEST OPEN CIRCUIT NO YES REPLACE WOT SWITCH AN...

Page 436: ...WITCH CONNECTOR HARNESS SIDE AND RETEST CONTINUITY BETWEEN PINS 1 AND 14 CONTD REPLACE COOLANT SWITCH AND RETEST DETERMINE IF PORTED VACUUM IS AT VACUUM SWITCH 2 THERE SHOULD BE NO VACUUM AT IDLE SPEE...

Page 437: ...CONTINUITY BETWEEN DIGNOSTIC CONNECTOR PIN 3 AND MCU CONNECTOR PIN 14 YES OPEN CIRCUIT NO TEST COMPLETE STOP ENGINE FUEL SYSTEMS U 123 DETERMINE IF MANIFOLD VACUUM IS AT SWITCH 1 REPAIR AND RETEST DI...

Page 438: ...TABILIZED REMOVE AIR COVER AND INCREASE ENGINE SPEED TO 2000 RPM AND MAINTAIN WHILE OBSERVING CARBURETOR STEPPER MOTOR METERING PINS NO YES PROCEED TO TEST 9 NO PERFORM TEST 5 YES PERFORM TEST 5 IF ST...

Page 439: ...LUE REFER TO CHAPTER 1A DISCONNECT JUMPER WIRE AND OBSERVE IGNITION TIMING IT SHOULD BE RETARDED AT LEAST 20 BTDC REPLACE IGNITION MODULE RETEST NO CONNECT IGNITION MODULE CONNECTOR DISCONNECT COOLANT...

Page 440: ...TIVE PROBE TO PIN 14 GROUND INCREASE ENGINE SPEED TO APPROXIMATELY 1200 RPM AND MAINTAIN CLOSE CHOKE VALVE AND OBSERVE VOLTMETER CLOSE VALVE FOR AT LEAST 15 SECONDS BUT DO NOT EXCEED 30 SECONDS YES NO...

Page 441: ...TEST COMPLETE CHECK FOR FAULTY SPARK PLUG S MISADJUSTED IGNITION TIMING AND MALFUNCTIONING IGNITION ADVANCE MECHANISMS REFER TO CHAPTER 1A ADJUST AND OR REPLACE COMPONENTS AS NECESSARY RETEST CHECK CA...

Page 442: ...T OXYGEN SENSOR CONNECTOR AND TEST VOLTAGE AT OXYGEN SENSOR INSPECT FOR LARGE AIR LEAK INTO MANIFOLD VACUUM IF OK REPLACE OXYGEN SENSOR START ENGINE AND OPERATE FOR 40 SECONDS INCREASE ENGINE SPEED TO...

Page 443: ...VE FOR APPROXIMATELY 30 SECONDS THEN EXHAUST FROM PORT B IF NO AIR EXHAUSTS INSPECT BASE OF DIVERTER VALVE FOR EXHAUST IF AIR EXHAUST FROM BOTH PORTS REPLACE AIR CONTROL VALVE AND RETEST SYSTEM AIR EX...

Page 444: ...500 RPM DETERMINE IF VACUUM IS BEING APPLIED TO DIVERTER VALVE PROCEED TO TEST 7 YES AIR INJECTION SYSTEM IS OPE RATING NORMALLY PROCEED TO TEST 7 CONTINUED FROM PREVIOUS PAGE REPLACE DIVERTER VALVE A...

Page 445: ...TERMINAL OF SOLENOID CONNECTOR REPAIR AND RETEST TURN IGNITION OFF DISCONNECT MCU CONNECTOR WITH OHMMETER MEASURE RESISTANCE BETWEEN PINS 20 AND 11 OF MCU WIRE HARNESS CONNECTOR NO CONNECT MCU CONNECT...

Page 446: ...NNECTOR PIN 14 IS GROUNDED DETERMINE IF VACUUM IS PRESENT AT PORT D YES REPAIR AND PROCEED TO TEST 6 REPLACE DIVERT SOLENOID AND PROCEED TO TEST 6 REPLACE MCU AND RETEST DIVERT SOLENOID DISCONNECT JUM...

Page 447: ...ENOID WITH JUMPER WIRE AND PROCEED TO TEST 6 TURN IGNITION OFF DISCONNECT MCU HARNESS CONNECTOR WITH VOLT OHMMETER MEASURE RESISTANCE BETWEEN PIN 12 AND PIN 20 OF WIRE HARNESS YES CONNECT MCU HARNESS...

Page 448: ...NEAND MEASUREVOLTAGE AT PIN12 DURING FIRST 30 SECONDS OF ENGINE OPERATION IF 30 SECONDS IS EXCEEDED TURN ENGINEOFF AND RESTART WAIT FOR 60 SECONDS AND RETEST VOLTAGE YES TURN ENGINE OFF RESTART ENGINE...

Page 449: ...E FROM SOLE VAC SOLENOID AND CHECK FOR VACUUM DURING THE FIRST 15 SECONDS OF ENGINE OPERATION YES VACUUM NO REPLACE SOLE VAC SOLENOID AND RETEST PERFORM VACUUM SWITCHING SOLENOID TEST 10 RETEST REPAIR...

Page 450: ...T DIAGNOSTIC CONNECTOR PIN 14 YES RESTART ENGINE AND TEST FOR BATTERY VOLTAGE ACROSS SOLENOID TERMINALS DURING FIRST 15 SECONDS OF ENGINE OPERATION REPLACE THE SOLENOID AND RETEST REPAIR VOLTAGE SUPPL...

Page 451: ...PIN 46 AND ENGINE GROUND NO REPAIR VOLTAGE SUPPLY MALFUNCTION AND RETEST YES DISCONNECT MCU HARNESS CONNECTOR AND TEST CONTINUITY BETWEEN PIN 85 AND MCU CONNECTOR PIN 10 YES YES DETERMINE IF VOLTAGE...

Page 452: ...U 138 FUEL SYSTEMS J 1137 BENDING TOOL J 10174 01 MAIN JET REMOVER AND INSTALLER Tools J 9789 C UNIVERSAL CARBURETOR GAUGE SET...

Page 453: ...igned to pre vent stress leakage and chassis contact If the system contacts any body panel it may amplify objectionable noises originating from the engine or the body When inspecting an exhaust system...

Page 454: ...ER HEAT SHIELD MUFFLER Fig 1K 1 Four Cylinder Engine Exhaust System CJ Vehicles HANGER SUPPORT BRACKET HANGER INSULATOR BRACKET CONVERTER AIR INJECTION TUBE CALIFORNIA ONLY MUFFLER HEAT SHIELD MUFFLER...

Page 455: ...ecreases below 16 in Hg 54 kPa restriction or blockage is in catalytic converter b If vacuum is normal muffler is restricted NOTE If the converter has failed always inspect the muffler to determine if...

Page 456: ...MANIFOLD HEAT VALVE Four and six cylinder engines are not equipped with heat valves Eight Cylinder Engine A thermostatically controlled heat valve mounted be tween the right exhaust manifold and exhau...

Page 457: ...onnect rear hanger if equipped 6 Heat catalytic converter or rear exhaust pipe to muffler joint with oxyacetylene torch until cherry red 7 Place block of wood against front of muffler and drive muffle...

Page 458: ...ched to the muffler cut the pipecloseto the muffler Collapse the part remaining in the muffler and remove Installation To install a tailpipe disconnect the mounting bracket and lower the front of the...

Page 459: ...State CJ vehicles and a dual air injection system used for California CJ vehicles and all Chero kee Wagoneer and Truck vehicles AIR INJECTION MANIFOLD AIR PUMP TO AIR PUMP DIVERTER VALVE VAICUUM HOSE...

Page 460: ...rt and rotate around the pivot pin which is located on the centerline REAR COVER HOUSING VENT HOLE DO NOT OIL FILTER FAN ROTOR SHAFT AND DRIVE HUB 42007 Fig 1K 11 Air Pump of the pump housing The roto...

Page 461: ...3 Remove pivot screw and brace screws 4 Remove pump Installation Eight Cylinder Engine 1 Position pump at mounting location and install pivot and brace attaching screws Do not tighten CAUTION Adjust t...

Page 462: ...onstructed of cold rolled steel with zinc plating They distribute air via the di verter valve from the air pump to each of the exhaust manifold inlet ports A check valve incorporating a stainless stee...

Page 463: ...reduce undesi rable emission into the atmosphere EXHAUST SYSTEMS 1K 11 Upstream Solenoid The air control valve circuit vacuum is controlled by the upstream solenoid mounted at the rear of the cylinder...

Page 464: ...efer to Chapter U Fuel Systems and test divert solenoid Air Control Circuit NOTE Engine must be at normal operating temperature Functional Test 1 Disconnect air hoses from ports A and B of air control...

Page 465: ...y fits unless otherwise specified 70296 CATALYTIC CONVERTER SYSTEMS Page Catalyst Replacement 1K 14 Conventional Oxidizing Catalytic COC Pellet Type Converter 1K 13 Dual Bed COC and TWC Monolithic Typ...

Page 466: ...n of the Feedback System used in conjunction with the converter ioor Rg IK 13 Optimum Air Fuel Ratio for Conversion Efficiency CATALYST REPLACEMENT THREE WAY CATALYTIC TWC PELLET TYPE CONVERTER D l Be...

Page 467: ...ing out on shop floor CAUTION Use care to prevent damaging converter housing when removing plug If the drain fill hole can not be sealed with the replacement plug the converter must be replaced 4 Remo...

Page 468: ...crew into bridge and position bridge inside opening Remove screw without disturbing bridge position b Insert screw through washer and plug c Carefully thread screw into bridge and tighten sufficiently...

Page 469: ...parate schematics for each gauge meter and lamp circuit Engine instrumentation includes all instrument panel gauges meters and lamps used to monitor the engine related systems included in part one of...

Page 470: ...operate on low voltage The constant voltage regulator CVR provides approximately 5 volts for this purpose Battery voltage is supplied to the CVR The CVR contains a small heat ing coil and thermostatic...

Page 471: ...ents or high resistance caused by loose or corroded connections ENGINE INSTRUMENTATION 1L 3 A common diagnostic procedure is to bypass a sus pected component wire printed circuit or connection with a...

Page 472: ...ndicating system Abnormal conditions all result from variations of four basic malfunctions pointer does not move pointer moves butindicates a fuel level that does not correspond with the actual fuel l...

Page 473: ...ble 2 Remove cluster retaining screws 3 Disconnect speedometer cable at cluster in ENGINE INSTRUMENTATION 1L 5 4 Disconnect cluster terminal pin plug by pulling straight off 5 Disconnect four terminal...

Page 474: ...Remove attaching nuts and fuel gauge 5 Install replacement fuel gauge and tighten nuts 6 Install mask and screws 7 Install printed circuit board and gauge assembly on bezel 8 Install cluster 9 With ig...

Page 475: ...es meters and cluster illumination lamps ENGINE INSTRUMENTATION 1L 7 Removal 1 Remove instrument cluster 2 Remove radio noise suppressor connector strip if not equipped with radio 3 Remove all illumin...

Page 476: ...re Gauge Not Functioning Properly 1L 33 Fml Gauge Not Functioning Properly 1L 9 FmJ Gaoge ni Coolant Traprnturt Gauge Both Malfunction 1L 20 Gauge Foil Blown 1L 18 Page OH Pressure 6auge Not Functioni...

Page 477: ...ING TEST ENGINE MUST BE WARM x FUEL TANK MUST BE W NEITHER COMPLETELY FULL NOR COMPLETELY EMPTY OBSERVE TEMPERATURE GAUGE POINTER DOES NOT MOVE POINTER MOVES TO INCORRECT POSITION POINTER MOVES TO MAX...

Page 478: ...E INSTRUMENTATION STEP 6 GROUND SENDING UNIT TERMINAL OF GAUGE LOCATE AND REPAIR OPEN CIRCUIT IN SENDING UNIT WIRE SEQUENCE POINTER MOVES POINTER DOES NOT MOVE r A REPLACE GAUGE Chart 1 RESULT HSTOP H...

Page 479: ...SSING REPAIR GROUND ENGINE INSTRUMENTATION 1L 11 SEQUENCE CHECK FOR PRESENCE OF VOLTAGE AT GAUGE INPUT VOLTAGE REPLACE NOT PRESENT CIRCUIT BOARD CHECK GAUGE NUTS FOR LOOSENESS AND CORROSION OK POINTER...

Page 480: ...TER REMAINS AT MAXIMUM GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING GAUGE INDICATIONS ACCURATE AT EACH OHM SETTING CONNECT ONE TESTER LEAD TO GROUND AND ONE LEAD TO SENDING UNIT WIRE TURN IGNITI...

Page 481: ...L TANK NOT DEFORMED M FUEL TANK DEFORMED oti NO LOOSE SOLDER b C LOOSE SOLDER PRESENT REMOVE INSTRUMENT CLUSTER DO NOT DISCONNECT WIRE HARNESS REPAIR OR REPLACE FUEL TANK O REPLACE SENDING UNIT REMOVE...

Page 482: ...TING SEQUENCE POINTER DROPS FROM MAXIMUM POINTER REMAINS AT MAXIMUM GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING REPAIR OR REPLACE SENDING UNIT WIRE Hd REPLACE GAUGE CJ REPLACE CIRCUIT BOARD CHE...

Page 483: ...UGE INDICATIONS NOT OBTAINED AT EACH OHM SETTING ALL INDICATIONS HIGHORALL INDICATIONS LOW GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING SOME INDICATIONS HIGH OR LOW SOME ACCURATE ENGINE INSTRUME...

Page 484: ...CORROSION REPLACE F NECESSARY AND TIGHTEN CONNECT JUMPER WIRE FROM CLUSTER CASE TO GROUND GAUGE INDICATIONS ACCURATE AT EACH OHM SETTING REPLACE SENDING UNIT WIRE GAUGE INDICATIONS NOT OBTAINED AT EA...

Page 485: ...UGE INPUT TERMINAL AND GAUGE SENDING UNIT TERMINAL COMPARE OHMMETER INDICATIONS WITH VALUES LISTED IN GAUGE RESISTANCE CHART GAUGE RESISTANCE CORRECT OK GAUGE RESISTANCE INCORRECT REPLACE CVR REPLACE...

Page 486: ...CONNECT SHORT TESTER J 8681 OK SHORT NOT INDICATED SHORT INDICATED SHORT REPAIR AS INDICATED NECESSARY DISCONNECT INSTRUMENT WIRE HARNESS CONNECTOR FROM PRINTED CIRCUIT BOARD CHEROKEE WAGONEER TRUCK...

Page 487: ...AMAGE ENGINE INSTRUMENTATION 1L 19 SEQUENCE A REPLACE SHORTED WIRE HARNESS CIRCUIT BOARD NOT DAMAGED CIRCUIT BOARD DAMAGED OK DAMAGE NOT EVIDENT OK DAMAGE EVIDENT REPLACE CVR DETERMINE CAUSE OF DAMAGE...

Page 488: ...ENT WIRE HARNESS CONNECTOR AND TO GOOD GROUND VOLTMETER INDICATION DIFFERENT FROM STEP 1 VOLTMETER INDICATION SAME AS STEP1 CHEROKEE WAGONEER TRUCK CJ REPAIR OR REPLACE INSTRUMENT PANEL WIRE HARNESS C...

Page 489: ...STEP 4 MOVE VOLTMETER CONNECTOR FROM CVR TERMINAL TO RADIO NOISE SUPPRESSOR OR CONNECTOR STRIP OUTPUT TERMINAL REPLACE CVR INTEGRAL WITH FUEL GAUGE rA REPLACE CIRCUIT BOARD REPLACE RADIO NOISE SUPPRE...

Page 490: ...NEITHER COMPLETELY FULL NOR COMPLETELY EMPTY POINTER DOES NOT MOVE POINTER MOVES TO INCORRECT POSITION POINTER MOVES TO MAXIMUM AND STAYS NOTE Indicated Oil Pressure Observed from Driver s Seat OBSER...

Page 491: ...ING UNIT CIRCUIT REPLACE GAUGE OK GROUND NOT OK OK GROUND OK Chart 4 RESULT STOP r i STOP STOP 80314B 1L 24 ENGINE INSTRUMENTATION STEP START ENGINE SEQUENCE DISCONNECT SENDING UNIT WIRE GAUGE INDICAT...

Page 492: ...T OHM VALUES LISTED IN SENDING UNIT RESISTANCE CHART OBSERVE GAUGE INDICATION AT EACH OHM SETTING GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING OK GAUGE INDICATIONS ACCURATE AT EACH OHM SETTING E...

Page 493: ...CH OHM SETTING GAUGE INDICATIONS ACCURATE lOsJ AT EACHOHMSETTING W GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING SEQUENCE REMOVE GAUGE AND DISCONNECT WIRES REPLACE WIRE TO TERMINAL REPLACE GAUGE...

Page 494: ...G TEST J X OIL PAN MUST BE FILLED f TO SPECIFICATION POINTER MOVES TO MAXIMUM AND STAYS 0 j v FUEL TANK MUST BE W NEITHER COMPLETELY FULL NOR COMPLETELY EMPTY POINTER PULSATES MORE THAN WIDTH OF POINT...

Page 495: ...NIT TERMINAL OF GAUGE GROUND GAUGE PIN TERMINAL ON CIRCUIT BOARD o CHECK BATTERY GROUND CABLE BROKEN MISSING i CORRODED lSCREWS LOOSE MISSING REPAIR GROUND POINTER DROPS FROM MAXIMUM POINTER REMAINS A...

Page 496: ...IGNITION SWITCH ON ADJUST TESTER TO SELECT OHM VALUES LISTED IN SENDING UNIT RESISTANCE CHART OBSERVE GAUGE INDICATION AT EACH OHM SETTING GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING OK GAUGE...

Page 497: ...LUSTER DO NOT DISCONNECT WIRE HARNESS POINTER DROPS FROM MAXIMUM CONNECT JUMPER iWIRE BETWEEN CLUSTER GROUND AND BODY POINTER DROPS FROM MAXIMUM POINTER REMAINS AT MAXIMUM POINTER REMAINS AT MAXIMUM R...

Page 498: ...ORROSION REPLACE IF NECESSARY AND TIGHTEN CONNECT JUMPER WIRE FROM CLUSTER CASE TO GROUND GAUGE INDICATIONS ACCURATE AT EACH OHM SETTING REPLACE SENDING UNITWIRE GAUGE INDICATIONS NOT OBTAINED AT EACH...

Page 499: ...ETER LEADS TO GAUGE INPUT TERMINAL AND GAUGE SENDING UNIT TERMINAL COMPARE OHMMETER INDICATIONS WITH VALUES LISTED IN GAUGE RESISTANCE CHART OK GAUGE RESISTANCE CORRECT GAUGE RESISTANCE INCORRECT A RE...

Page 500: ...LUSTER Wl CASE AND INSTRUMENT PANEL S l REMOVE CLUSTER DO NOT DISCONNECT INSTRUMENT CLUSTER WIRING CONNECTOR LOCATE AND REPAIR OPEN CIRCUIT IN SENDING UNITWIRE SEQUENCE POINTER MOVES POINTER DOES NOT...

Page 501: ...EST ENGINE MUST BE WARM j x FUEL TANK MUST BE W NEITHER COMPLETELY FULL NOR COMPLETELY EMPTY OBSERVE FUEL GAUGE POINTER DOES NOT MOVE POINTER MOVES TO INACCURATE POSITION POINTER MOVES TO MAXIMUM AND...

Page 502: ...CT SENDING UNIT WIRE FROM SENDING UNIT SEQUENCE POINTER MOVES POINTER DOES NOT MOVE POINTER DROPS FROM MAXIMUM POINTER REMAINS AT MAXIMUM POINTER DROPS FROM MAXIMUM POINTER REMAINS AT MAXIMUM ENGINE I...

Page 503: ...E GAUGE INDICATION AT EACH OHM SETTING REPLACE SENDING UNIT OBSERVE FUEL GAUGE DISCONNECT BATTERY NEGATIVE CABLE FUEL GAUGE POINTER IS AT MAXIMUM FUEL GAUGE POINTER INDICATES NORMALLY REMOVE INSTRUMEN...

Page 504: ...EQUENCE POINTER DROPS FROM MAXIMUM POINTER REMAINS AT MAXIMUM GAUGE INDICATIONS NOT ACCURATE AT EACH OHM SETTING GAUGE INDICATIONS ACCURATE AT EACH OHM SETTING ENGINE INSTRUMENTATION 1L 37 Chart 6 RES...

Page 505: ...T EACH OHM SETTING GAUGE INDICATIONS NOT OBTAINED AT EACH OHM SETTING REMOVE INSTRUMENT CLUSTER AND DISCONNECT INSTRUMENT WIRES CHECK GAUGE NUTS FOR CORROSION REPLACE IF NECESSARY AND TIGHTEN CONNECT...

Page 506: ...AUGE SENDING UNIT PINTERMINAL AND OTHER LEAD TO GROUND GAUGE INDICATIONS ACCURATE AT EACH OHM SETTING OK GAUGE INDICATIONS NOT OBTAINED AT EACH OHM SETTING OSC GAUGE INDICATIONS NOT ACCURATE AT EACH O...

Page 507: ...NAL AND GAUGE SENDING UNIT TERMINAL COMPARE OHMMETER RESISTANCE INDICATIONS WITH VALUES LISTED IN GAUGE RESISTANCE CHART r OK OHMMETER GAUGE RESISTANCE CORRECT REPLACE CVR INTEGRAL WITH TEMPERATURE GA...

Page 508: ...21 1 to A ZERO 1 to Ground 49 to 51 A to Ground 49 to 51 80671 Oil Pressure Gauge Sending Unit Resistance Ohms PSI 0 20 40 60 80 OHMS 234 246 149 157 100 5 105 5 65 69 32 5 34 5 80672 Coolant Temperat...

Page 509: ...L 5 VOLTMETER GROUND 6 FUEL GAUGE S TERMINAL 7 FUEL GAUGE A TERMINAL 8 FUEL GAUGE I TERMINAL 9 COOLANT TEMPERATURE GAUGE S TERMINAL 10 COOLANT TEMPERATURE GAUGE A TERMINAL FOUR CYLINDER ENGINE COOLANT...

Page 510: ...E GAUGE 1 m IIMIT FOUR CYLINDER ENGINE 80290 Coolant Temperature Gauge Circuit CJ ENGINE INSTRUMENTATION 1L 43 OIL PRESSURE GAUGE OIL PRESSURI SENDING UNIT RED W T 3 t IGNITION SWITCH STARTER MOTOR SO...

Page 511: ...1L 44 ENGINE INSTRUMENTATION IGNITION SWITCH 30 000 MILE BODY EMISSION 4 CYLINDER ENGINES GROUND MAINTENANCE CALIFORNIA ONLY 908468 Emission Maintenance Indicator Lamp Circuit CJ ff 5 fum s...

Page 512: ...80670 Fuel Gauge Resistance Internal S to A 19 to 21 ohms 80673 Oil Pressure Gauge Sending Unit Resistance Ohms PSI 0 10 60 80 OHMS 69 77 35 38 13 15 9 5 105 80678 Coolant Temperature Gauge Sending Un...

Page 513: ...MINATION B RIGHT TURN INDICATOR C LEFT TURN INDICATOR D BRAKE INDICATOR E EMERGENCY DRIVE INDICATOR QUADRA TRAC F FASTEN BELT INDICATOR G 4 WD INDICATOR MODEL 208 H HIGH BEAM INDICATOR OTHER A1 OIL GA...

Page 514: ...LENOID 80294 Coolant Temperature Gauge Circuit C herokee Wagoneer Truck ENGINE INSTRUMENTATION 1L 47 LOCATED ON PRINTED CIRCUIT BOARD FUEL GAUGE AMMETER FUEL GAUGE SENDING UNIT Fuel Gauge Circuit Cher...

Page 515: ...1L 48 ENGINE INSTRUMENTATION Tools J 8681 SHORT TESTER J 24538 UNIVERSAL GAUGE TESTER J 21008 CONTINUITY TEST LAMP...

Page 516: ...p IP e m pv ps pv m r r 1...

Page 517: ...m Ml l I t zm J Jeep Jeep 1 TECHNICAL SERVICE MANUAL...

Page 518: ...y and render the vehicle unsafe Detailed descriptions of standard workshop safety procedures are not included in this manual This manual does contain WARNINGS for some service procedures that could ca...

Page 519: ...APTER INDEX Clutch Manual Transmission Automatic Transmission Transfer Case Propeller Shaft Axles Brakes Wheels and Tires Steering Columns Manual Steering Gear Power Steering Gear And Pump Steering Li...

Page 520: ...bler Models A hydraulic clutch operating system is used on CJ and Scrambler models equipped with the 2 5 liter four cylin der engine fig 2A 4 The system consists of a clutch General Service Diagnosis...

Page 521: ...r cylinder throwout bearing contact face is slightly crowned The six and eight cylinder throwout bearing contact face is flat CLUTCH SERVICE On four cylinder CJ and Scrambler models the com ponents th...

Page 522: ...s clutch pedal to floor and release accelerator pedal 3 Shift transmission into reverse and repeat pro cedure outlined in step 2 4 If clutch chatter does not develop in either gear range increase engi...

Page 523: ...in good condition proceed to next step If one or more components were determined to be faulty repair as necessary and proceed to next step 15 Check clutch housing alignment as outlined in this chapte...

Page 524: ...wout bearing unless it is actually defective or damaged Refer to Clutch Area Noises CLUTCH 2A 5 12 Apply thin film of chassis grease to transmis sion clutch shaft splines Do not apply grease to shaft...

Page 525: ...t bearing makes initial contact with the clutch cover re lease levers clutch partially disengaged or at any time the bearing is in contact with the release levers Pulsa tion is usually caused by incor...

Page 526: ...Noises T rowoHt Bailing NoIm Throwout bearing noises can be described as whirring grating or grinding noises that occur when the clutch pedal is depressed clutch disengaged CLUTCH 2A 7 These noises u...

Page 527: ...to engage and disengage the clutch The bearing is actuated by a throwout lever mounted in the clutch housing The lever pivots on a steel ball mounted inside the clutch housing The bellcrank pivots on...

Page 528: ...floorpan and slide boot upward on lever 2 Remove bolts attaching transmission shift lever housing to transmission fig 2A 7 Lift shift lever and housing upward and secure assembly to floorpan with wire...

Page 529: ...nd in rotation to relieve spring tension on cover CAUTION The clutch cover bolts must be loosened evenly and in rotation to avoiddistorting the cover The cover is a steel stamping andcould be warpedif...

Page 530: ...of grease will force bushing out 5 Clean crankshaft bore if grease was used to re move old bushing Installation 1 Install pilot bushing lubricatingwick in bushing bore in crankshaft 2 Install replacem...

Page 531: ...fig 2A 9 Remove and discard push rod seal 5 Remove plunger valve spring and valve stem assembly from cylinder bore fig 2A 9 Tap cylinder body lightly on wood block to dislodge assembly from bore 6 Co...

Page 532: ...cement snap ring supplied in overhaul kit 10 Slide push rod seal up against push rod retainer and install dust cover on end of cylinder Be sure cover lip is seated in undercut on end of cylinder 11 Re...

Page 533: ...er and Spring Assembly Installation 1 Position heat shield on cylinder 2 Lubricate throwout lever socket with chassis lubricant 3 Align push rod with throwout lever position cylinder on clutch housing...

Page 534: ...AND EIGHT CYLINDER MODELS Metric N m Service In Use Set To Recheck Torque Torque 31 27 35 73 62 84 73 62 84 73 62 84 41 34 47 88 80 96 47 41 54 34 27 41 80072B Clutch Cover Release Lever Adjustment C...

Page 535: ...ate steel hub and cushion springs for distortion cracks orbreakage Replace the driven plate if it exhibits any of these conditions NOTE Do not replace the driven plate if the cushion springs only appe...

Page 536: ...ocedure CLUTCH ZA 17 CLUTCH HOUSING ALIGNMENT Clutch housing misalignment is caused by excessive face or bore runout of the clutch housing or housing to transmission adapter Misalignment will cause im...

Page 537: ...r support 6 Thread nut onto bolt until 10 to 12 threads are exposed 7 Thread bolt into flywheel attaching bolt hole and tighten nut to secure bolt 8 Install clutch housing and adapter assembly and tig...

Page 538: ...ransmission as outlined in Chapter 2B CLUTCH COVER RELEASE LEVER ADJUSTMENT NOTE Always check and correct the release lever height adjustment if necessary before installing an original or replacement...

Page 539: ...ch pedal stop 6 Check clutch release rod position Be sure rod has not become disengaged from throwout lever 7 Check and adjust clutch pedal free play if necessary Clutch Pedal Removal 1 Disconnect bat...

Page 540: ...Six Cylinder Engines Top Bottom Eight Cylinder Engines Top Bottom Clutch Housing to Engine Bolts Four Cylinder All Clutch Housing to Engine Dowel Bolt Nut 6 and 8 Cylinder Clutch Housing to Transmissi...

Page 541: ...IO r m r m oS to r m C Om m 3J rZJ roO to m m 3 C 8gfc HO o r o r o r o C 3...

Page 542: ...is located within the shift control housing which also serves as the transmission top cover The shift mecha nism does not require adjustment and can be serviced independently of the transmission GEARS...

Page 543: ...worn shift rail bores worn shift rail distorted oil seal or extension housing not aligned with case Repair as necessary 4 Remove disassemble and inspect transmission Replace worn or damaged components...

Page 544: ...dels with T 176 transmission press and turn transmission shift lever retainer counterclockwise to release lever Remove lever boot spring and seat as assembly fig 2B 3 SHIFT LEVER COVER AND HOUSING 811...

Page 545: ...ve disassemble and inspect transmission Replace worn or damaged components as necessary 7 Pilot bushing worn 7 Replace pilot bushing WILL NOT SHIFT INTO ONE GEAR 1 Gearshift selector plates inter lock...

Page 546: ...nose pliers to remove wick from bushing TRANSMISSION INSTALLATION 1 Install pilot bushing lubricating wick and align throwout bearing with splines in driven plate hub 2 Shift transmission into gear us...

Page 547: ...d with offset lever before tightening housing bolts 22 Position shift lever boot on floorpan and install boot attaching screws MODEL T4 4 SPEED TRANSMISSION Ginning tadInspection SpacJflcitlOM TRANSMI...

Page 548: ...COUNTERSHAFT BEARING DRAIN PLUG TRANSMISSION CASE TRANSMISSION COVER MANUAL TRANSMISSION 2B 7 THRUST WASHER REAR FIRST SECOND BEARING AND CUP SHIFT FORK SHIFT RAIL Rg 2B 4 T4 Four Speed Transmission D...

Page 549: ...ft n 81198C Fig 2B 6 Offset Lover Removal Installation 15 Remove countershaft rear bearing using brass drift and arbor press fig 2B 17 Note position of bear ing for assembly reference Bearing identifi...

Page 550: ...and hammer Fig 2B 9 Transmission Cover Removal Installation 1 81199N Fig 2B 10 Reverse Lever C Clip Removal Installation MANUAL TRANSMISSION 2B 9 23 Remove backup lamp switch from transmission case D...

Page 551: ...ence 4 Remove third fourth synchronizer insert springs remove inserts and remove sleeve from hub 5 Remove third gear from shaft 6 Remove snap ring retaining second gear on shaft fig 2B 22 and remove t...

Page 552: ...ON 2B 11 a CAUTION Do not attempt to remove the first second reverse hub from the output shaft The hub and shaft are assembled and machined as a matched set during manufacture to insure concentricity...

Page 553: ...and selector arm plates from shift forks Note position of inserts and plates for assembly reference CLEANING AND INSPECTION Thoroughly wash all parts in solvent and dry them with compressed air Do not...

Page 554: ...output or clutch shaft splines Bent distorted or weak snap rings Worn bushing in reverse idler gear Rough galled or broken front or rear bearing Worn shift fork inserts Broken cracked or worn shift fo...

Page 555: ...ate lip of oil seal with petroleum jelly and slide seal over protector and onto shift rail c Seat oil seal in transmission cover using Oil Seal Installer Tool J 26628 1 fig 2B 29 View B Assembly Outpu...

Page 556: ...d in the Model TU Transmission are metric sizes Do not attempt to substitute a different thread type bolt if the original ones are lost MANUAL TRANSMISSION 2B 15 J 2995 BEARING INSTALLER SPACER 81200K...

Page 557: ...g Installation 13 Install clutch shaft in case and engage shaft in third fourth synchronizer sleeve and blocking ring 14 Install replacement oil seal in front bearing cap using Tool J 26625 fig 2B 36...

Page 558: ...ial indicator from adapter housing 30 Remove adapter housing 31 Move shift forks on transmission cover and syn chronizer rings inside transmission to the neutral position 32 Apply bead of RTV sealant...

Page 559: ...Ift lbs Metric N m Service Set To Torque Backup Lamp Switch 15 Adapter Housing Bolt 13 RllPlug 20 Ront Bearing Cap Bolt 13 Reverse Lever Pivot Bolt 20 Shift Control Housing Bolt 10 Transmission Cover...

Page 560: ...FTH REVERSE LEVER PIVOT BOLT AND LAMP SWITCH O RING FIRST SECOND SHIFT FORK MANUAL TRANSMISSION 2B 19 THRUST WASHER REAR BEARING AND CUP FRONT BEARING CAP SNAP RING FIFTH SPEED DRIVEN GEAR IDENTIFICAT...

Page 561: ...asher and plasticfunnel may be found on the end of the countershaft or inside the adapter housing 6 Remove bolts attaching transmission cover and shift fork assembly and remove cover fig 2B 9 NOTE Two...

Page 562: ...Fig 2B 44 Fifth Gear Shift Fork and Synchronizer Sleeve Removal Installation MANUAL TRANSMISSION 2B 21 11 For assembly reference mark position of front bearing cap on front of transmission case Use h...

Page 563: ...op of transmission case to dis engage rail from reverse lever assembly Remove rail from rear of transmission case fig 2B 48 19 Remove reverse lever and fork assembly pivot pin detach reverse lever fro...

Page 564: ...all O ring in groove of shift rail oil seal 11 Install shift rail oil seal as follows a Install Oil Seal Protector Tool J 26628 2 over threaded end of shift rail fig 2B 29 View A b Lubricate lip of oi...

Page 565: ...g into offset lever Place steel ball in neutral guide plate detent fig 2B 7 Apply pres sure on steel ball with detent spring and offset lever and slide offset lever on shift rail and seat extension ad...

Page 566: ...r to pry seal out of cap 10 Remove locating ring and retaining snap ring from front bearing fig 2B 54 11 Remove clutch shaft and front bearing using Adapter J 29344 and Puller Set J 25152 fig 2B 55 12...

Page 567: ...sition of sliding gear for assem bly reference 20 Remove arbor tool from countershaft gear and remove needle bearings and bearing retainers fig 2B 59 Disassembly Mainshaft Geartrain 1 Remove third fou...

Page 568: ...e wear or damage of blocking rings Bent or broken synchronizer inserts Damaged needle bearings or bearing bores in reverse idler or countershaft gear Wear or galling of mainshaft countershaft clutch s...

Page 569: ...T SECOND GEAR CLUTCH ASSEMBLY 18 FRONT BEARING CAP 19 OIL SEAL 20 GASKET 21 SNAP RING 22 LOCK RING 23 FRONT BALL BEARING 24 CLUTCH SHAFT 25 ROLLER BEARING 26 DRAIN PLUG 27 FILL PLUG 28 CASE 29 GASKET...

Page 570: ...te mainshaft synchronizer assemb and gear bores with transmission lubricant 12 Assemble first second synchronizer hub and verse gear and sleeve fig 2B 60 a Install gear and sleeve on hub and p assembl...

Page 571: ...eeves will clear top of case when assembly is instated 23 Install locating snap ring on front bearing and install front bearing part way onto clutch shaft NOTE Do not install the beating completely at...

Page 572: ...to bind in Neutral position checkfor blockingrings sticking on tapered portion of gears Use screwdriver to free any sticking blocking rings 36 Fill transmission with 3 5 pints 1 7 liters of SAE 85W 9...

Page 573: ...10 While holding shift rails downward position shift rail retaining plates on housing and install plate attaching bolts and tabbed washers finger tight 11 Remove wood block and tighten shift rail ret...

Page 574: ...iscard transmission to transfer case gasket fig 2B 69 3 Position shift lever in reverse remove case cover bolts remove shift control housing 4 Punch alignment marks on the front bearing cap remove cap...

Page 575: ...2B 36 MANUAL TRANSMISSION Fig 2B 69 Model T 18A 4 Speed Transmission...

Page 576: ...MISSION 34 COUNTERSHAFT REVERSE IDLER SHAFT LOCKPLATE 35 REVERSE IDLER GEAR SHAFT 36 REVERSE IDLER GEAR SNAP RING 37 REVERSE IDLER GEAR THRUST WASHER 38 REVERSE IDLER GEAR 39 REVERSE IDLER GEAR BEARIN...

Page 577: ...ly Reverse Idler Gear 1 Install snap ring in one end of reverse idler gear 2 Install thrust washer in gear bore against snap ring 3 Insert sleeve in gear bore 4 Install 37 roller bearings in one end o...

Page 578: ...and in stall ring on clutch shaft Mainshaft and Geartrain Assembly 1 Install second gear from front of mainshaft fig 2B 74 2 Install second gear thrust washer so step bore in washer faces front end o...

Page 579: ...f case 10 Install mainshaft and geartrain assembly 11 Install mainshaft pilot bearing roller spacer on mainshaft pilot hub if not installed previously 12 Insert mainshaft pilot hub in clutch shaft bor...

Page 580: ...ng attaching bolts with nonhardening sealer and install bolts Tighten bolts to 12 foot pounds 16 N m torque 28 Shift gears through all positions to check operation 29 Assemble transfer case and transm...

Page 581: ...UAL TRANSMISSION SHIFT RAIL PLUGS THIRD FOURTH SHIFT FORK REVERSE PLUNGER AND SPRING REVERSE GATE Fig 2B 79 Shift Control Housing Transmission Model T 18A SHIFT RAIL PLUGS REVERSE RAIL REVERSE SHIFT F...

Page 582: ...il into housing until poppet ball engages in rail notch 11 Align and install roll pins that fasten first second shift fork and shift gate to shift rail 12 Insert third fourth shift rail through center...

Page 583: ...Refer to the Standard Torque Specifications and Capscrew Marking chart in Chapter A for torque values not listed above 80123 Transmission Gear Ratios ENGINE VEHICLE MODEL T4 T5 1st 2nd 3rd 4th REV 1s...

Page 584: ...e model 727 transmission is used in Cherokee Wagoneer and Truck models with six or eight cylinder engines An automatic transmission is not available in CJ 5 models or any Jeep model with a four cylind...

Page 585: ...ampen engine firing im pulses and absorb shock loads that occur during lockup When the transmission shifts into direct drive and vehicle speed reaches approximately 42 mph 68 km h transmission fluid i...

Page 586: ...duce lockup at a vehicle speed and governor pressure of ap proximately 42 mph 68 km h and 38 psi 263 kPa In operation governor pressure reaches lockup point and overcomes lockup valve spring tension w...

Page 587: ...hly along with the radiator cooler The radiator cooler flushing procedure is outlined in this chapter Refer to Flushing Oil Cooler and Cooler Lines If the auxiliary cooler must be removed and installe...

Page 588: ...filtered by a Dacron element filter attached to the valve body The filter is a ser viceable component and can be replaced whenever diag nosis or service requirements indicate the need Transmission Ven...

Page 589: ...nce clutch band application has not oc curred torque flow stops at the rear clutch retainer The rear clutch plates which are splined to the rear clutch retainer rotate with the retainer at engine spee...

Page 590: ...r which is splined to the driving shell are also held stationary fig 2C 10 Since the rear clutch is still applied engine torque continues to flow through the rear clutch retainer to the front annulus...

Page 591: ...to rotate in engine direction Since the rear planetary carrier is locked to the low reverse drum the rear band and over running clutch prevent the drum and carrier from rotat ing opposite engine direc...

Page 592: ...the front servo piston is released by spring tension and hydraulic pressure The accumulator controls hydraulic pressure on the apply side of the front servo during 1 2 shifts and serves to cushion fro...

Page 593: ...ront end raised Or disconnect rear propeller shaft at rear axle yoke be sure to mark the prop shaft and yoke for proper alignment at reassembly secure shaft to underside of vehicle and tow with front...

Page 594: ...Not Back Up or Move Forward 1 Check fluid level and condition 2 Check for broken or disconnected throttle linkage 3 Check for broken cooler lines and loose or miss ing pressure port plugs Page HydriBl...

Page 595: ...lines by flowing automatic transmission fluid through them 6 Cooler flow should now be checked by con necting cooler tubes and placing rear cooler tube into 1 quart container Overfill transmission by...

Page 596: ...ng unit and to check operation The key is proper use of the Clutch and Band Application Chart Although road test analysis will help determine the slipping unit the actual cause of a malfunction usuall...

Page 597: ...ER RETURN FITTING GOVERNOR PRESSURE REAR SERVO APPLY PRESSURE 41776 Fig 2C 16 Pressure Port Locations Test Two This test checks pump output pressure regulation and front clutch rear servo condition by...

Page 598: ...ill tube and fluid level was known to be correct 1 Install T fitting in transmission cooler line 2 Connect white test gauge hose to T fitting and turn test gauge selector handle to lubrication pressur...

Page 599: ...th as an oil pump seal leakor fluid may travel down the pump face into the converter housing Oil Pump to Case Bolt leaks past any one of these bolts are deposited on the inside of the converter housin...

Page 600: ...ission clutch slippage is occurring 9 Shift transmission into Neutral operate engine for 20 seconds stop engine shift transmission into Park and release brake 10 Compare test results with stall speed...

Page 601: ...res Lower case letters a through j denote Out Of Vehicle Procedures The numbers in the boxes adjacent to the Condition column cross reference each problem condition to the necessary service procedures...

Page 602: ...for nicks scratches burrs and rounded edges on valve lands Check bores for scratches springs for collapsed coils AUTOMATIC TRANSMISSION 2C 19 and all mating surfaces for nicks burrs or warpage Reasse...

Page 603: ...racks or scratches Service Diagnosis IN VEHICLE PROCEDURES CONDITIONS A B C D E F G II I Jk L M N O P Q R S T HARSH ENGAGEMENT R D 2 1 2 1 3 4 6 5 SLOW TO ENGAGE N R D 2 1 1 2 3 4 6 5 9 8 7 NO UPSHIFT...

Page 604: ...Pressure Test Diagnosis Condition Indication Line pressure OK during any one test Pump and regulator valve OK Line pressure OK in R but low in D 2 1 Leakage in rear clutch area servo clutch seals gove...

Page 605: ...pair or replace valve body or its internal components as necessary b Stuck lockup valve c Stuck fail safe valve STAYS LOCKED UP AT TOO LOW A 1 Sticking governor valve 1 Repair or replace as necessary...

Page 606: ...em 3 Engine needs tune up 3 Tune engine 4 Throttle linkage misadjusted 4 Adjust throttle linkage VIBRATION WHEN REVVED IN NEUTRAL 1 Torque converter out of balance 1 Replace torque converter OVERHEATI...

Page 607: ...Servlco In Uso Service In Use Set To Recheck Set To Recheck Torqua Torqua Torqua Torque 160 in lb 120 200 in lb 18 14 23 150 in lb 130 180 in ib 17 15 20 58 50 56 79 68 89 105 95 120 142 129 163 40 3...

Page 608: ...arshift lever to Park and Neutral posi tions and check engine starting Engine should start in these positions only Engine must not start in any gear position other than Park or Neutral If engine does...

Page 609: ...t fluid and filter for heavy accumulation of friction material or metal particles which indicate worn or damaged parts 4 Remove three screws attaching filter to valve body and remove filter 5 Install...

Page 610: ...mpletely bottomed in the valve body to obtain a correct adjustment Installation AUTOMATIC TRANSMISSION 2C 27 ALLEN WRENCH THROTTLE LEVER TOOL J 24031 Fig 2C 23 Throttle Pressure Adjustment 41783 1 Cle...

Page 611: ...E E CLIP FILTER SCREEN 60161 Fig 2C 25 Governor Valve Assembly Disassembly 1 Remove large snap ring from weight end of gov ernor body fig 2C 25 2 Remove weight assembly 3 Remove snap ring from governo...

Page 612: ...free move ment in the housing and sprag Check the sprag and control rod springs for loss of tension or distortion Check the square lug on the sprag for broken edges Check the lugs on the governor supp...

Page 613: ...lon washer fig 2C 28 3 Block choke open and set carburetor throttle off fast idle cam 4 Raise vehicle 5 Loosen both retaining bolts on throttle control adjusting link DO NOT REMOVE SPRING CLIP AND NYL...

Page 614: ...cle Throttle Linkage Adjustment Eight Cylinder Engine 1 Disconnect throttle control rod spring at carburetor 2 Raise vehicle 3 Use throttle control rod spring to hold transmis sion throttle valve cont...

Page 615: ...Torque Converter Bolts 6 Cylinder Adapter Housing to Transmission Case Bolt Governor Body Bolt Front Band Adjusting Screw Locknut Kickdown Lever Shaft Plug Rear Band Adjusting Screw Locknut Neutral S...

Page 616: ...ly and disconnect oil cooler lines at transmission 19 Remove bolts attaching transmission to engine 20 Move transmission and converter rearward to clear crankshaft 21 Hold converter in position and lo...

Page 617: ...5 Fill transmission to correct level as described in Fluid Level and Condition 26 Adjust gearshift linkage 27 Road test to check transmission operation TRANSMISSION DISASSEMBLY CAUTION Cleanliness dur...

Page 618: ...taining governor on output shaft AUTOMATIC TRANSMISSION 2C 35 5 Remove governor body and park gear from out put shaft Oil Pump and Reaction Shaft Support 1 Tighten front band adjusting screw until ban...

Page 619: ...ove screwdriver 7 Slowly release rod guide and remove rod guide springs and piston rod CAUTION Do not grasp the rod with pliers to remove it Ifthe rod sticks in the case tap it gently to release it 8...

Page 620: ...ngs Tag springs for assembly reference 10 Remove line pressure regulator and torque con verter control valves fig 2C 43 11 Remove transfer plate assembly retaining screws and remove transfer plate ass...

Page 621: ...ROTTLE VALVE THROTTLE VALVE SPRING MANUAL VALVE SPRING RETAINER AND ADJUSTING SCREW BRACKET KICKDOWN DETENT THROTTLE PRESSURE ADJUSTING SCREW Fig 2C 43 Pressure Regulator and Manual Controls PRESSURE...

Page 622: ...RIMARY SPRING SHUTTLE VALVE THROTTLE PLUG GOVERNOR PLUG AND SHUTTLE VALVE END PLATE AUTOMATIC TRANSMISSION 2C 39 park f A CONTROL MANUAL LEVER ASSEMBLY 60166 Fig 2C 48 Installing Detent Ball Retaining...

Page 623: ...Pressure Regulator Valves housing remove throttle plug from downshift valve re tainer and remove spring and limit valve from housing fig 2C 49 Tag spring for assembly reference 30 Remove 1 2 shift co...

Page 624: ...48 6 Install throttle lever assembly fig 2C 43 7 Install manual lever assembly on throttle lever shaft Position manual lever assembly so it engages manual valve and detent ball AUTOMATIC TRANSMISSION...

Page 625: ...the lock tabs and remove the four attaching bolts Inspection Thoroughly clean and dry all governor parts and check for free movement Do not use a caustic cleaning solution The weights and valve should...

Page 626: ...nt 1 Position pump housing with reaction shaft sup port mating surface facing downward on flat level surface 2 Remove bushing using Remover and Installer Tool J 24049 and Driver Handle J 8092 fig 2C 5...

Page 627: ...and J 6585 1 in remover tool fig 2C 56 4 Bump outward with slide hammers to remove bushing 5 Clean chips from reaction shaft support assembly 6 Grip old bushing with pliers and remove it from Tool J...

Page 628: ...during disassembly 2 Align and install reaction shaft support on pump housing and finger tighten attaching bolt 3 Insert two Slide Hammers J 6585 1 and Bolts J 7004 3 from back to front into threaded...

Page 629: ...to housing until tool bottoms Oil Pump and Reaction Shaft Support Model 727 Disassembly 1 Remove pump to support attaching bolts and remove support from pump fig 2C 60 2 Mark rotors with chalk for ass...

Page 630: ...housing with reaction shaft sup port mating surface facing downward on flat level surface 2 Remove bushing using Remover Installer Tool J 24055 and Driver Handle J S092 fig 2C 63 3 Install replacement...

Page 631: ...ads of tool in bushing 10 Install Slide Hammer Bolts Tool J 7004 3 and J 6585 1 into remover tool fig 2C 65 Bump outward with slide hammers to remove bushing 11 Thoroughly clean reaction shaft support...

Page 632: ...snap ring groove 5 Remove tool retainer and spring 6 Turn clutch retainer over and bump on wood block to dislodge and remove piston 7 Remove seal rings from piston and clutch re tainer hub AUTOMATIC T...

Page 633: ...n clutch retainer so open end faces upward 5 Install replacement bushing on tool and install bushing straight into retainer bore until bushing is flush with base of bore chamfer fig 2C 70 TOOL J 8092...

Page 634: ...as necessary Inspect the steel plate lug grooves in the clutch re tainer for smooth surfaces The plates must slide freely in the grooves Inspect the band application surface on the clutch retainer fo...

Page 635: ...e clutch plates with transmission fluid 10 Install one steel plate followed by one lined plate until correct number of plates are installed 11 Install pressure plate and waved snap ring Measure clutch...

Page 636: ...re worn or damage Inspect the steel plates and pressure plate surfaces for overheating scoring and for damaged drive lugs In spect all discs and plates for flatness Replace if necessary Inspect the st...

Page 637: ...and selective thick ness snap ring PISTON SPRING J h WAVE ING Fig 2C 78 Piston Spring and Wave Spring Installation 9 Measure rear clutch pack clearance Press down firmly on outer pressure plate and in...

Page 638: ...d piston retainer for nicks burrs and wear Inspect the rear clutch to front clutch thrust washer The washer should be 0 061 to 0 063 inches 1 55 to 1 60 mm thick Input Shaft Bushing Replacement 1 Clam...

Page 639: ...el plates have been installed 11 Install outer pressure plate and selective thick ness snap ring 12 Measure clutch pack clearance Press down I TOOL J 8092 41843 Fig 2C 82 Input Shaft Bushing Installat...

Page 640: ...from rear planetary assembly 9 Remove rear snap ring and No 8 steel thrust plate from sun gear 10 Remove sun gear from driving shell 11 Remove remaining snap ring and No 7 steel thrust plate from sun...

Page 641: ...d block and place assembly in upright position 3 Push rear annulus gear support downward on output shaft 4 Insert feeler gauge between rear annulus sup port and shoulder on output shaft fig 2C 83 Clea...

Page 642: ...r on rear hub of front planetary gear and engage planetary gear with front annulus gear 10 Install front planetary and annulus gear assem bly onto output shaft and mesh planetary pinions with sun gear...

Page 643: ...d with holes in case 10 Thread retaining screws and washers into cam 41849 Fig 2C 88 Overrunning Clutch Cam Removal NOTE Install the washers on the screws so that the inner diameter of the washer cont...

Page 644: ...ound setscrew 13 Remove Tool J 24042 TOOL J 24042 CAM 60176 Fig 2C 90 Overrunning Clutch Cam Installation Model 727 AUTOMATIC TRANSMISSION 2C 61 14 Install and tighten support retaining bolts to 150 i...

Page 645: ...h petroleum jelly and insert piston plug through plug spring and into piston 2 Compress piston spring and install snap ring Torque Converter Service If the transmission is being overhauled to correct...

Page 646: ...supported at two points by a reaction pin mounted in the case It is actuated at one point by the rear servo adjusting screw fig 2C 96 1 Install replacement O ring on reaction pin and insert pin into...

Page 647: ...ion end play was not within specifi cations 0 022 to 0 091 inch or 6 056 to 2 31 mm when measured at disassembly replace thrust washer with one that will provide proper end play Thrust Washer Chart Mo...

Page 648: ...ch 0 061 0 063 0 084 0 086 0 102 0 104 Color Natural Brown Red Yellow 60235 4 Install rubber seal ring in groove in outer flange of pump housing Be sure seal is not twisted 5 Coat seal ring with petro...

Page 649: ...pounds 4 N m torque only 3 Back off adjusting screw four turns on 999 and two turns on 727 4 Hold adjusting screw in position and tighten locknut to 35 foot pounds 47 N m torque 5 Install oil pan and...

Page 650: ...her Chart 7 9 iters Reverse 2 20 to 1 001 to 002 inch 009 to 044 inch 036 to 084 inch 060 to 062 inch 074 to 076 inch 088 to 090 inch 106 to 108 inch 055 to 059 inch 062 to 066 inch 70130 70122B Thrus...

Page 651: ...Shaft Support to Oil Pump Bolt Transmission to Engine Bolt Valve Body Screw Valve Body to Transmission Case Screw Service Service Service In Use Service In Use Set To Recheck Set To Recheck Torque Tor...

Page 652: ...TCH SPRING COMPRESSOR 999 J 24036 REACTION SHAFT BUSHING REMOVER 999 J 24041 INPUT SHAFT BUSHING REMOVER 727 m m M J 24037 REACTION SHAFT BUSHING REMOVER 727 J 24108 J 3387 2 PILOT STUDS J 24042 FRONT...

Page 653: ...NOTES em...

Page 654: ...NOTES SS s mi...

Page 655: ...NOTES em PC...

Page 656: ...AUTOMATIC TRANSMISSION 2C 71 PIS HYDRAULIC FLOW CHARTS fm...

Page 657: ...I I I i i I j r GOVERNOR VALVE A REAR CLUTCH REAR SERVO FRONT CLUTCH FRONT Drive Second Six and Eight Cylinder SELECTOR LEVER IN DRIVE SECOND HALF THROTTLE SERVO ACCUMULATOR LOCK UP ONLY TO LUBRICATIO...

Page 658: ...tCIOR LEVER IN DRIVE DIRECT Drive Direct Six and Eight Cylinder ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT CLUTCH LUBRICATION TORQUE CONVERTER PRIOt I I I I I I I I I I I I I I I I I I I I I I I I...

Page 659: ...U _ REGULATOR wra FilMK MANUAL VALVE SELECTOR LEVER IN NEUTRAL ENGINE RUNNING fl IJMfa0 c o og OIL PRESSURES LINE 0 30 PSI 1 1 PUMP SUCTION I Purh and Ntutral All TO LUBRICATION FRONT CLUTCH LUBRICATI...

Page 660: ...Qlock lag ri 1c UP VALVE A FAIL SAFE VALVE J CED n 7 to o o ft ft SWITCH VALVE TUBE COOLER TO LUBRICATION __ FRONT CLUTCH LUBRICATION r ntl OIL FILTER LINE 75 PSI _ PUMP SUCTION i I THROTTLE 40 PSI GO...

Page 661: ...I 1 I I I I I I I I I I I I I I I GOVERNOR VAIVE i REAR SERVO fAo S G SELECIOR LEVER IN DRIVE LOCK UP Drive Direct Lockup Six and Eight Cylinder ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT i p ciut...

Page 662: ...R IN DRIVE PART THROTTLE KICKDOWN Drive Part Throttle Kickdown Six and Eight Cylinder below 40 mph ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT CLUTCH LUBRICATION TORQUE CONVERTER PR106 J J I I J J 1...

Page 663: ...ERNOR VALVE A REAR CLUTCH jJ SE L FRONT CLUTCH GOVERNOR 30 73 PSI SELECTOR I EVER IN DRIVE FULL THROTTIE KICKDOWN HALF THROTTLE Drive Full Throttle Kickdown Six and Eight Cylinder FRONT SERVO ACCUMULA...

Page 664: ...SELECTOR LEVER IN 1 v T TWO MANUAL SECOND L E J 7X8 4 Selector Lever Two Six and Eight Cylinder closed throttle k Jo v yv 9 ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT Me CLUTCH Lubrication TORQUE...

Page 665: ...ILTER 1 i l l 1 1 1 1 1 1 1 i n 1 1 1 1 1 1 111 FRONT CLUTCH v y GOVERNOR 0 30 PSI I FRONT SERVO r SELECTOR LEVER IN ONE MANUAL LOW ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT 3 CLUTCH LUBRICATION r...

Page 666: ...verse Six and Eight Cylinder SELECTOR LEVER IN REVERSE FRONT SERVO LINE TO THROTTLE VALVE 50 100 PSI ACCUMULATOR LOCK UP ONLY TO LUBRICATION FRONT CLUTCH LUBRICATION PR110 i i i i i i i i i i i i i r...

Page 667: ...I i I i i i i i I I I i i i i i GOVERNOR VALVE REAR CLUTCH J AR SERVO FRQNT a JTCH o o j ro o o o r t o o W FRONT 3 Drive Breakaway Four Cylinder SELECTOR LEVER IN DRIVE BREAKAWAY HALF THROTTLE SERVO...

Page 668: ...Drive Second Four Cylinder FRONT 2 SI IK IOR LEVER IN DRIVE SECOND HALF THROTTIE SERVO ACCUMULATOR TO LUBRICATION FRONT CLUTCH LUBRICATION TORQUE CONVERTER PR11 I I I 1 I l t I I I I I I I I I t I I I...

Page 669: ...i I i i i I i l l I II GOVERNOR VALVE REAR SERVO Drive Direct Four Cylinder SERVO SELECTOR LEVER IN DRIVE DIRECT ACCUMULATOR V LOCK UP ONLY TUBE COOLER TO LUBRICATION FRONT CLUTCH LUBRICATION TORQUE...

Page 670: ...E A REAR SERVO Drive Part Throttle Kickdown Four Cylinder SELECTOR LEVER IN DRIVE PART THROTTIE KICKDOWN ACCUMULATOR LOCK UP ONLY PR115 I I I I I I I I I I I I I I I I I I I I I I I l I i I l l I 1 l...

Page 671: ...SCREEN C Ct 0 I v MANUAL VALVE DC n i toLJ f REGULArO VALV a K K j OIL FILTER a Fuil Thrortle Kickoowr xFour Cylinder ooooooooo THROTTLE VALVE T V AKICKDOWN VALVE r SWITCH VALVE LtNE 94 S PUMP SUCTION...

Page 672: ...VALVE C J C KP WN VALVE pS Ji oii OIL PRESSURES LINE 57 PSI j PUMP SUCTION EZD THROTTLE 40 PSI1 I GOVERNOR 6 57 PSI SELECTOR LEVER IN TWO MANUAL SECOND CLOSED THROTTIE CONVERTER 5 57 PSI j LUBRICATIO...

Page 673: ...1 1 REAR SERVO FRONT CLUTCH GOVERNOR 0 30 PSI SELECTOR LEVER IN ONE MANUAL LOW ClOSED 1HROTT1E Selector Lever One Four Cylinder FRONT 3 SERVO 1 1 1 1 1 1 1 1 1 1 ACCUMULATOR LOCK UP ONLY r 2 TO LUBRIC...

Page 674: ...GOVERNOR VALVE d Reverse Four Cylinder SELECTOR LEVER IN REVERSE TORQUE CONVERTER PR119 I I I I I J J 1 I I I I I I I I I I I I I I I I I I I I I I I I I I I I...

Page 675: ...e Wagoneer and Truck models with automatic transmis sion only This transfer case is also a four position unit providing four wheel high and low ranges a neutral position for towing and a four high loc...

Page 676: ...wheels and tow vehicle with front wheels raised Or disconnect rear propeller shaft at rear axle mark yoke for correct assembly secure shaft to underside of ve hicle and tow with front wheels raised R...

Page 677: ...in support bracket 3 Align lever bushing with holes in support bracket and install spring washer and shoulder bolt Tighten bolt securely 4 Slide shift lever into boot and into floorpanhole 5 Position...

Page 678: ...age operation If adjustment is neces sary adjust linkage at lower shift rod trunnion Loosen trunnion jamnuts and position trunnion on rod as re quired to obtain desired adjustment SUPPORT BRACKET STRA...

Page 679: ...ansmission remove shift lever knob trim ring and boot from transmission and transfer case shift levers 3 Remove floor covering if equipped and remove transmission access cover from floorpan 4 Raise ve...

Page 680: ...used in Cherokee Wagoneer and Truck models only Models equipped with the 208 transfer case are also equipped with manual locking front drive hubs as standard equipment The model 208 is a chain drive...

Page 681: ...ch Identification Tag and Drain and Fill Plug Location rear propeller shaft and axle In 2H range the sliding clutch remains in a neutral position and does not lock the drive sprocket to the mainshaft...

Page 682: ...pounds 47 N m torque 5 Remove drain pan 6 Fill transfer case to edge of fill plug opening with AMC Jeep Automatic Transmission Fluid or equivalent labeled Dexron IIR 7 Install fill plug Tighten plug t...

Page 683: ...l drain plug Tighten plug to 35 foot pounds 47 N m torque TRANSFER CASE 2D 9 13 Fill transfer case to edge of fill plug opening with AMC Jeep Automatic Transmission Fluid or equivalent labeled Dexron...

Page 684: ...rrection 1 Stop vehicle and shift into desired range Or reduce speed to 2 3 mph 3 4 km h before attempting to shift 2 Stop vehicle shift transmission to neutral shift transfer case to 2H mode and oper...

Page 685: ...ach oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue Inspect all gear teeth for signs of excessive wear or damage and check all gear splines for burrs...

Page 686: ...EAR SEAL 39 REAR YOKE 40 YOKE SEAL WASHER 41 YOKE NUT 42 DRAIN AND FILL PLUGS 43 FRONT OUTPUT SHAFT REAR BEARING 44 FRONT OUTPUT SHAFT REAR THRUST BEARING RACE THICK 45 CASE MAGNET 46 FRONT OUTPUT SHA...

Page 687: ...e If the case or input gear bearings require replacement refer to Bear ing Replacement in the Subassembly Overhaul section SUBASSEMBLY OVERHAUL Lockplate Replacement 1 Remove and discard lockplate att...

Page 688: ...ed to avoid covering the bearing oil feed holes After replacing any bearings check the bearing position to be sure the feed hole is not obstructed or blocked by the bearing Rear Output Bearing and Rea...

Page 689: ...the case or input gear bearings require replacement refer to Bear ing Replacement in the Subassembly Overhaul section SUBASSEMBLY OVERHAUL Lockplate Replacement 1 Remove and discard lockplate attachin...

Page 690: ...ering the bearing oil feed holes After replacing any bearings check the bearing position to be sure the feed hole is not obstructed or blocked by the bearing Rear Output Bearing and Rear Seal Replacem...

Page 691: ...ior of case 4 Install bearing retaining snap ring 5 Install new rear seal using Tools J 8092 and J 29162 fig 2D 26 Front Output Shaft Front Bearing Replacement 1 Remove bearing using Tools J 8092 and...

Page 692: ...ve both bearings simultaneously using Driver Handle J 8092 and Remover J 29170 fig 2D 31 2 Install new bearings one at a time Install rear bearing first then install front bearing Use Driver Handle J...

Page 693: ...J 8092 90676 Fig 2D 28 Front Output Shaft Front Bearing Installation 5 Fig 2D 26 Rear Seal Installation Fig 2D 27 Front Output Shaft Front Bearing Removal C CLAMP TOOL J 26941 TOOL J 2619 01 WOOD BLO...

Page 694: ...or petroleum jelly where indicated only Do not use any other type of lubricants 1 Install input gear race and thrust bearing in front case fig 2D 24 2 Install input gear 3 Install mainshaft thrust be...

Page 695: ...Engage range fork in annulus gear and install annulus gear over planetary assembly fig 2D 38 NOTE Be sure the range fork lug is fully inserted in the range sector slot fig 2D 21 11 Install annulus gea...

Page 696: ...the sprocket carrier has two ring grooves install the stop ring in the upper groove only Fig 2D 38 Annulus Gear and Shift Rail Installation 20 Install front output shaft front thrust bearing assembly...

Page 697: ...Torque Transmittal Mode Dual sprockets with installed at the Opposite ends Of the case n B interconnecting drive chain Low Range Reduction Ratio 31 Install rear output bearing in rear retainer and an...

Page 698: ...n tag is attached to the rear half of the transfer case fig 2D 3 This tag provides the transfer case model number low range reduction ratio and as sembly number The information on this tag is neces sa...

Page 699: ...ear output shaft gear teeth at differ ing speeds The viscous coupling functions as a torque biasing slip limiting unit If consists of an enclosed housing contain ing two sets of fixed clutch plates an...

Page 700: ...leeve is moved forward into engagement with the mainshaft Since the sleeve is still engaged with the side gear clutch it locks the side gear and drive sprocket which is splined to the side gear to the...

Page 701: ...hicle 2 Position drain pan under transfer case 3 Remove fill and drain plugs and drain lubricant 4 Install drain plug Tighten plug to 35 root pounds 47 N m torque 5 Fill transfer case to bottom edge o...

Page 702: ...case Insert screwdrivers in notches at caseends to pry rear case off front case fig 2D 42 NOTE The two case end bolts havefiat washers and tmi alignment dowels Note bolt dowel andwasher location for a...

Page 703: ...r clutch sleeve lockplate worn or damaged 3 Disassemble unit and replace worn or damaged components NOISY IN ALL DRIVE MODES 1 Insufficient or incorrect lubricant 1 Drain and refill with Jeep Dextron...

Page 704: ...e sector detent ball and spring re taining bolt and remove detent ball and spring fig 2D 10 gig 36 Remove range sector and operating lever attach ing nut and lockwasher and remove lever 37 Remove rang...

Page 705: ...6 CASE ALIGNMENT DOWEL 67 FRONT OUTPUT SHAFT REAR BEARING DIFFERENTIAL SHIM 0685 TRANSFER CASE 2D 29 68 MAGNET 69 FRONT OUTPUT SHAFT REAR THRUST BEARING RACE THICK 70 FRONT OUTPUT SHAFT REAR THRUST BE...

Page 706: ...etainer Replace any part that exhibits signs of e xcessive wear or damage If the case or input gear bearings require replacement refer co Bear ing Replacement in the Subassembly Overhaul section Inspe...

Page 707: ...fllffl Fig 20 52 Side Gear Clutch Gear Sprockets and Chain Assembly 90692 SNAP RINGS 90643 Fig 2D 53 Side Gear Components TRANSFER CASE 2D 31 SIDE GEAR CLUTCH 90694 Fig 2D 54 Side Gear Clutch Removal...

Page 708: ...Fig 2D 58 Annulus Gear Snap Ring and Thrust Washer Removal Installation Fig 2D 59 Annulus Gear and Range Fork Removal Installation 5 Coat new lockplate attaching bolts with Loctite 271 or equivalent...

Page 709: ...ing using Driver Handle J 8092 and Installer J 29163 fig 2D 30 3 Remove installer tools and check bearing posi tion to be sure oil feed hole is not covered Also be sure bearing is seated flush with ed...

Page 710: ...stall input gear thrust bearing on input gear and install gear and bearing in case fig 2D 62 4 Install mainshaft thrust bearing in bearing re cess in input gear fig 2D 61 5 Install planetary assembly...

Page 711: ...haft with clutch gear teeth facing downward fig 2D 54 Be sure gear teeth mesh with clutch sleeve 25 Install remaining short mainshaft needle bear ing spacer Install spacer carefully to avoid displacin...

Page 712: ...and install rear retainer on rear case Tighten retainer bolts finger tight only 48 Install yoke on rear output shaft Tighten yoke nut finger tight only 49 Mount Dial Indicator J 8001 on rear retainer...

Page 713: ...e Bolts All Rear Retainer Bolts Service Service Service In Use Service In Use Set To Recheck Set To Recheck Torque Torque Torque Torque 23 20 25 31 27 34 35 30 JO 47 40 54 120 90 130 163 122 176 18 15...

Page 714: ...put shaft and rear output shaft gear to the larger intermediate gear This inter mediate gear transmits torque to the front output shaft through the front output shaft gear which is meshed with the lar...

Page 715: ...14 01 to hold yoke rule tightening nut Rear Bearing Cjp Speedometer Drive Gear Service Removal i L Disconnect rear propeller shaft at transfer case yoke Tie shaft to frame with wire i2 Disconnect spee...

Page 716: ...rect lubricant 1 Drain and refill to edge of fill hole with SAW 85W 90 gear lubricant only Check for leaks and repair if necessary Note If unit is still noisy after drain i and refill disassembly and...

Page 717: ...ap cap into position i4 Tighten bearing cap bolts to 35 foot pounds 47 X nn torque 5 Install output shaft yoke and tighten locknut to 120foot pounds 163 N m torque Use Tool J 8614 01 to hold yoke whil...

Page 718: ...SHAFT CLUTCH GEAR FRONT OUTPUT 27 SHAFT BEARING FRONT OUTPUT SHAFT 28 REAR 29 RACE FRONT OUTPUT SHAFT 30 BEARING 31 END PLAY SHIMS FRONT OUTPUT 32 SHAFT 33 COVER PLATE 34 LOCK PLATE BOLT AND WASHER 3...

Page 719: ...gear 16 Remove rear bearing cap attaching bolts and remove cap Use plastic mallet to tap on output shaft to aid cap removal NOTE The rear bearing cap has been coated with a sealant Use a putty knife...

Page 720: ...utch gear and output shaft from case 30 Remove front output shaft rear bearing using arbor press and suitable press Tool fig 2D 81 CAUTION Be sure to support the case with wood blocks positioned at ei...

Page 721: ...haft and bearing in support and install new bearing snap ring 12 Install rear output shaft gear on input gear and install new gear retaining snap ring fig 2D 77 13 Measure clearance between input gear...

Page 722: ...0 005 inches 0 025 to 0 129 mm d If end play is not correct remove or add shims between cover plate and case If shims are added seat rear bearing cup as outlined in step a before checking end play ag...

Page 723: ...art time 4 wheel drive unit with integral low range Torque Transmittal Mode Constant mesh gearbox with layshaft gear arrangement Low Range Reduction Ratio 2 6 1 gear reduction Drive Positions and Shif...

Page 724: ...29168 Tools ft n TOOL J 29163 TOOL J 8092 TOOL J 29174 ft TOOL J 29179 TOOL J 25167 V TOOL J 7818 6 TOOL J 29169 i i m K TOOL J 8614 01 LA t f 1 J 2619 01 TOOL J 29185 TOOL J 25167 ft f TOOL J 29184 o...

Page 725: ...with a single cardan universal joint and to the transfer case yoke with a double cardan universal joint fig 2E 1 Fig 2E 1 Front Propeller Shaft Assembly Cherokee Wagoneer and Truck Models 80329 The f...

Page 726: ...be felt through the seats floorpan or steering wheel Audible vibrations are heard or sensed above normal road and background noise and may be accompanied by mechanical vibration In some cases audible...

Page 727: ...Refer to Chapter A General Information for details on how to use this DARS chart PROBLEM DRIVE LINE VIBRATION STEP O O 0 SEQUENCE WHEEL TIRE CONDITION 1 CHECK FOR BENT CRACKED WHEELS AND CUPPED OR DAM...

Page 728: ...HEEL RUNOUT LATERAL RADIAI 0 045 NO CORRECTION NEEDED CORRECTION NEEDED REPAIR OR REPLACE AS NECESSARY ROAD TEST 1 REMOVE REAR PROPELLER SHAFT ALIGN MARK SHAFT AND AXLE YOKE FOR ASSEMBLY REFERENCE 2 R...

Page 729: ...UNOUT USING DIAL INDICATOR MAXIMUM ALLOWABLE RUNOUT OF SHAFT IS 015 INCHES TOTAL INDICATOR RUNOUT AT ENDS AND CENTER OF SHAFT AT SHAFT ENDS MEASURE RUNOUT 3 INCHES FROM SHAFT WELD SEAMS SEQUENCE IF RU...

Page 730: ...OPERATION ROAD TEST 0 ADJUST ANGLES AS NEEDED I 1 REMOVE FRONT PROPELLER SHAFT ALIGN MARK SHAFT AND AXLE YOKES FOR ASSEMBLY REFERENCE 2 ROAD TEST WITH QUADRA TRAC IN 4H LOCK AND MODELS 208 AND 300 IN...

Page 731: ...INDEX YOKE AND RECHECK RUNOUT REPLACE YOKE IF REINDEXING DOES NOT CORRECT RUNOUT REINSTALL PROP SHAFT ROAD TEST 0 REINDEX SHAFT 180 AND RECHECK RUNOUT CHECK FRONT AXLE PINION AND FRONT PROPELLER SHAFT...

Page 732: ...llows EXAMPLE If the engine angle measures 5 degrees downward and the pinion angle measures 7 degrees up ward the pinion angle must by adjusted downward 3 degrees This changes the pinion downward angl...

Page 733: ...ble cardan universal joi serviced as assemblies Both universal joint types disassembled for inspection and replacement pur Disassembly Single Cardan Joint 1 If slip yoke universal joint is to be n pai...

Page 734: ...emove rear spider and socket yoke from link yoke Cleaning and Inspection Clean the yoke bearing cap bores with solvent and a wire brush Be sure to remove all rust dirt and corro sion from the bores Wa...

Page 735: ...rque Torque Torque Torque Pinion Yoke Nut Model 30 44 Axle 210 200 220 285 271 298 Model 60 Axle 260 250 270 352 339 366 AMC Jeep Axle Add 5 in lbs 0 56 N m torque measured at disassemble Refer to Pin...

Page 736: ...NOTES...

Page 737: ...test the noise is being produced by the engine exhaust system clutch transmission transfer case or by engine driven ac cessory equipment Before road testing check and correct the tire in flation press...

Page 738: ...ines or universal joints or rear axle shaft splines Chatter Trac Lok Differential Trac Lok chatter is usually caused by using non rec ommended lubricants If chatter occurs drain and refill the axle wi...

Page 739: ...DIFFERENTIAL PINION GEAR THRUST WASHER RING GEAR MOUNTING BOLTS DIFFERENTIAL BEARING 2 DIFFERENTIAL BEARING PRELOAD SHIMS DIFFERENTIAL CASE PINION MATE SHAFT PIN RING GEAR PINION GEAR SLINGER PINION B...

Page 740: ...components Damaged or contaminated parts should be replaced FRONT WHEEL ALIGNMENT Toe in and caster are the only adjustable front align ment angles Camber is built into the axle during manu facture a...

Page 741: ...re taining nut threads 8 Position steering knuckle on axle and install re placement lower ball stud jamnut finger tight only AXLES FRONT HUBS 2F 5 T B Ji ii i 9 Install and tighten upper ball stud sl...

Page 742: ...Scrambler Models 1 Clean all parts thoroughly 2 Install axle shaft and universal joint assembly Insert splined end of axle shaft into differential side gear and push shaft into place 3 Install axle s...

Page 743: ...de of the retainer facing toward the center of the vehicle b Push drive gear inward to provide clearance for axle shaft snap ring and install snap ring c Coat rotor hub cap rim with Permatex Ad hesive...

Page 744: ...STUDS Lower Ball Stud Removal 1 Remove lower ball stud snap ring 2 Clamp knuckle assembly securely in vise with upper ball stud pointing downward fig 2F 8 3 Attach Plate J 25211 1 to spindle mating s...

Page 745: ...lation 1 Invert steering knuckle in vise 2 Position replacement lower ball stud in steering knuckle 3 Place Adapter J 25211 4 over nut end of puller screw and against puller frame fig 2F 10 4 Insert n...

Page 746: ...only 3 Position and align Nut Wrench J 23447 Button J 25211 3 Plate J 25211 1 and Puller J 25212 fig 2F 12 4 Tighten screw of Puller J 25212 until lower ball stud is held firmly in its seat and insta...

Page 747: ...to spindle surfaces NEEDLE ROLLER BEARING AXLES FRONT HUBS 2F 11 J41079 Fig 2F 15 Spindle Bearing Location 2 Remove needle bearing using internal type puller 3 Clean dirt and foreign matter from spin...

Page 748: ...ke Align shaft and yoke using alignment marks made during removal 14 Install wheels 15 Remove support stands and lower vehicle 16 Tighten wheel retaining nuts and install wheel covers 17 Check front w...

Page 749: ...0 Track 2F 17 Axis Shaft and Bearing CJ and Scrambler 2F 15 Axis Shaft and Bearing J 20 Truck 2F 18 OsBtral 2F 13 Identification 2F 13 GENERAL CJ and Scrambler models are equipped with the AMC Jeep se...

Page 750: ...le shaft dust cap 2 Remove axle shaft nut and washer 3 Raise and support vehicle 4 Remove wheel and tire 5 Remove screws attaching brake drum to rear hub and remove drum 6 Install Puller Tool J 25109...

Page 751: ...ds 339 N m torque If cotter pin hole is not aligned tighten nut to next castellation and install cot ler pin Do not loosen nut to align cotter pin hole AXLES FRONT HUBS 2F 15 AXLE SHAFT AND BEARING CJ...

Page 752: ...axle end play shims oil seal as sembly and brake support plate Tighten attaching bolts to 35 foot pounds 47 m torque NOTE The oil seal and retainer are located on the outside of the brake support pla...

Page 753: ...tely 3 4 of ring thickness CAUTION Do not allow drill to contact axle shaft 3 Position chisel over drilled hole in retaining ring Cut deep groove in retaining ring using chisel This will enlarge ring...

Page 754: ...oot pounds 98 N m torque 8 Remove supports and lower vehicle Removal J 20 Truck NOTE It is not necessary to raise the wheels in order to remove the axle shafts on Model 60 full floating rear axles 1 R...

Page 755: ...Tighten nut to 210 foot pounds 285 N m torque on Model 44 axle and 260 foot pounds 352 N m torque on Model 60 axle 4 Align index marks on propeller shaft and yoke and install shaft Tighten strip clam...

Page 756: ...used when assembling components Service In Use Recheck Torques should be used for checking a pre tightened Item USA ft lbs Metric Nm Service Service Service In Use Service In Use Set To Recheck Set To...

Page 757: ...ht ahead driving the differential pinion gears do not rotate on the pinion mate shaft This occurs because input torque applied to the gears is divided and distributed equally between the two side gear...

Page 758: ...fferential 9 Tie differential bearing shims to their respective bearing caps and cups to prevent misplacement Differential Bearing Removal Use Puller J 29721 and adapters to remove the differ ential b...

Page 759: ...earing cup using Tools J 8092 and J 21787 CAUTION Keep the bearing cup remover tool seated squarely on the cup to prevent damaging the cup bores during removal Cleaning and Inspection Clean all parts...

Page 760: ...f the pinion is marked 2 the gear set varied from standard by 0 002 inches 0 05 mm and will require 0 002 inch 0 05 mm less shims than a gear set marked zero 0 When a gear set is marked plus the dista...

Page 761: ...mber in the intersecting box is 0 005 0 12 mm which represents the amount to be subtracted from the old shim thickness If the box number had been a figure this amount would be added to the old shim th...

Page 762: ...front bearing cup using Tools J 8092 and J 8611 01 9 Install pinion gear in rear bearing cup 10 Install front bearing rear universal joint yoke and original pinion nut on pinion gear Tighten pinion nu...

Page 763: ...Pinion Depth 2 550 6 47 cm StarterShim Thickness 0 098 2 48 mm TotalMeasuredPinion Depth 2 648 6 72 cm AXLES FRONT HUBS 2F 27 Step 3 Determine correct shim thickness Subtract desired pinion depth from...

Page 764: ...washers behind pinion gears and align pinion gear bores 4 Rotate differential side and pinion gears until pinion mate shaft bores in pinion gears are aligned with shaft bores in case 5 Install thrust...

Page 765: ...taching bolts Tighten bolts to 55 foot pounds 75 N m torque Ring and Pinion Gear Backlash Adjustment i Position thirat previously selected to remove differential bearing sideplay on bearing cups and i...

Page 766: ...erential is seated in housing CAUTION Do not distort the shims by hammering them into the housing 6 Install differential bearing caps Position caps according to alignment punch marks made at dis assem...

Page 767: ...INION REAR BEARING PINION GEAR THRUST IERS JWASHl DIFFERENTIAL SIDE GEAR Fig 2F 45 Model 60 Rear Axle y J YOKE v OIL SEAL PINION FRONT BEARING PINION FRONT BEARING CUP BEARING CONE PINION FRONT BEARIN...

Page 768: ...case as case will be damaged in process 19 Remove pinion mate shaft lockpin using small punch fig 2F 48 20 Remove pinion mate shaft and thrust block 21 Rotate pinion gears until gears are aligned wit...

Page 769: ...sure the differential case is secure When the bearing is removed the differ ential case can drop if not supported REMOVER TOOL J 29721 90180A Fig 2F 51 Differential Bearing Removil Model 60 Axle Pini...

Page 770: ...ing is determined identifying numbers are etched on the the ring and pinion fig 2F 36 The ring gear receives one number The pinion gear receives two numbers which are separated by a or sign The ring g...

Page 771: ...25122 and Installer J 25157 7 On front axle differentials install oil slinger on pinion gear Be sure slinger is seated on pinion head before installing rear bearing 8 Install rear bearing on pinion On...

Page 772: ...nion depth Add measured pinion depth to measure shim thickness Result is total measured pinion depth Measured Pinion Depth 2 601 66 0 mm StarterShim Thickness 0 107 2 71 mm Total Measured Pinion Depth...

Page 773: ...ial case and start two bolts in holes 180 degrees apart Tighten bolts evenly to seat ring gear 10 Install remaining bolts and tighten to 55 foot pounds 74 N m torque Differential Bearing Preload and R...

Page 774: ...ner oil seals If seal replace ment is required install replacement seals using ToolJ 28648 fig 2F 58 13 Mount Spreader Tool J 25102 and Dial Indicator J 8001 on housing Spread housing no more than 0 0...

Page 775: ...nd 60 axles clean cover and housing mating surfaces and ap 21 Raise spring and install front spring shackle to ply thin bead of Jeep Gasket In A Tube or equivalent spring attaching bolts silicone seal...

Page 776: ...Case Bolt 105 95 115 142 135 149 Rear Brake Support Plate Bolts 32 25 40 43 34 54 Axle Shaft to Hub Nuts CJ 250 min 250 min 339 min Clamp Strap Bolts 16 15 19 18 14 24 All Torque values given in foot...

Page 777: ...sealer to cover and housing mating surfaces Install cover and cover bolts Tighten cover bolts to 20 foot pounds 27 N m torque 6 Refill axle housing with specified lubricant only Refer to Specificatio...

Page 778: ...2F 42 AXLES FRONT HUBS THRUST WASHER 2 DIFFERENTIAL PINNION GEAR 2 THRUST WASHER PINION SHAFT DIFFERENTIAL SNAp SIDE GEAR 2 CLUTCH PACK Fig 2F 61 Trac Lok Differential AMC Jeep Axle 90755...

Page 779: ...UBS 2F 43 7 Remove differential case from axle shaft and remove ring gear 8 Remount differential case on axle shaft 9 Remove snap rings from pinion mate shaft fig 2F 64 Use two screwdrivers to disenga...

Page 780: ...ille springs by the forcing screw be fore the gears can be rotated in the case 18 Retain upper side gear and clutch pack in case by holding hand on bottom of rotating tool while remov ing forcing scre...

Page 781: ...ld them in place by hand while mounting case on axle shaft fig 2F 71 334 Fig 2F 71 Mounting Differential Case on Axle Shaft AXLES FRONT HUBS 2F 45 5 Mount case assembly on axle shaft fig 2F 72 CAUTION...

Page 782: ...ase Be sure snap ring grooves in shaft are exposed to allow snap ring installation fig 2F 76 J42339 Fig 2F 76 Pinion Mate Shaft Installation 19 Install pinion mate shaft snap rings NOTE On Model 60 Tr...

Page 783: ...s Model 60 Axle Differential Bearing Preload 015 in Differential Side Gear to Case Clearance 000 006 in Drive Gear to Pinion Backlash 005 009 in Drive Pinion Bearing Break Away Original Bearings 10 20...

Page 784: ...el to Hub Nuts 120 110 125 163 149 169 AMC Jeep Axle Axle Housing Cover Bolts 170 in lbs 150 190 in lbs 19 17 21 Brake Tube to Rear Wheel Cylinder 97 in lbs 90 105 in lbs 11 10 12 Differential Bearing...

Page 785: ...S NUT CLUTCH AXLES FRONT HUBS 2F 49 CLUTCH CUP RETAINING RING WEAR WASHER HUB SHAFT Hg 2F 77 Model M253 Front Drive Hub CJ and Scrambler Models COMPRESSOR SPRING RING CLUTCH SCREW 90306...

Page 786: ...T HUBS LOCK RING RETAINING RING HUB BEARING HUB BODY WEAR WASHER SOCKET HEAO CAPSCREW Fig 2F 78 Model M247 Front Drive Hub Cherokee Wagoneer Truck Models COMPRESSOR SPRING DIAL LABEL CLUTCH RING RETAI...

Page 787: ...er operation in sandy areas Service correction involves cleaning and lubricating the hubs However if inspection indicates the problem is the result of damaged internal components the damaged AXLES FRO...

Page 788: ...and rotate wheels Wheels should rotate freely If wheels drag check hub installation Also be sure control dials are fully engaged in 4 x 2 position 8 Lower vehicle Removal Model M247 1 Remove socket h...

Page 789: ...n pounds 3 N m Hub Bolts M253 30 foot pounds 41 N m Hub Control Dial Positions M247 Lock 4 WD Free 2 WD M253 4x4 4 WDM x 2 2 WD 90591 Tools AXLES FRONT HUBS 2F 53 TT J 2498 AXLE SHAFT REMOVER J 8001 D...

Page 790: ...23 20 GAUGE BLOCK AND PLUNGER O O J 5223 25 OR 26 DISCS J 5223 4 ARBOR J 5223 03 PINION DEPTH SETTING GAUGE SET J 22697 PINION REAR BEARING INSTALLER J 22912 01 r BEARING REMOVER ri mm J 24433 PINION...

Page 791: ...385 15 ADAPTER J 22888 BEARING PULLER SET J 29721 DIFFERENTIAL BEARING REMOVER TOOL SET J 8646 2 FORCING SCREW AND J 23781 3 GEAR ROTATINGTOOL J 8092 DRIVER HANDLE THREADED J 23781 7 STEP PLATE J 2510...

Page 792: ...2F 56 AXLES FRONT HUBS Tools Continued J 25180 PULLER J 8614 01 YOKE HOLDING TOOL I J 8614 2 J 8614 3 YOKE REMOVER TOOL J 25211 4 ADAPTEF n 8032 I...

Page 793: ...p models The valve consists of a one piece housing con taining a front brake metering valve pressure differen tial warning valve and rear brake proportioning valve Three power brake units are used CJ...

Page 794: ...everse stops Bleed system If unable to bleed system properly see Service Diagnosis If pedal is firm and maintains position and vehicle does not have power brakes Road test vehicle If problem still exi...

Page 795: ...functioning Inspect vacuum system components for loose broken collapsed vacuum hose faulty cheek valve restriction in vacuum hose fitting or manifold port TestS With engine running and brake released...

Page 796: ...Replace power unit GRABBING OR DRAGGING BRAKES 1 Bellcrank pivot pins binding CJ and Scrambler only 1 Remove clean lubricate and install pivot pins 2 Refer to PULLS and GRAB BING BRAKES in Service Di...

Page 797: ...quired 5 Master cylinder filler vent clogged 5 Clean vent or replace cap bleed brakes 6 Hoses lines collapsed kinked leaking 6 Replace as required 7 Master cylinder compensator port blocked 7 Disassem...

Page 798: ...e PULSATING BRAKE PEDAL 1 2 Drums out of round Loose brake drum on hub 1 2 Refinish or replace drums Tighten 3 Wom or loose wheel bearings 3 Replace or adjust 4 Bent shoes or linings 4 Replace shoe li...

Page 799: ...cylinder pistons sticking 5 Overhaul wheel cylinder ONE WHEEL DRAGS 1 1 Weak or broken brake shoe retracting springs 1 Replace the defective brake shoe springs and lubricate the brake shoe ledges 2 Po...

Page 800: ...shoes 1 Adjustment not correct 2 Parking brake cables frozen 3 Dirty lining 4 Wheel cylinder cups swollen or piston sticking 5 Weak retracting springs 6 Shoes binding on support plate Correction 1 Dr...

Page 801: ...ilar design and equal wear will be installed on the front wheels 7 Water mud or foreign matter in brakes 7 Remove foreign material from brake parts and inside of the drums Lubricate the shoe ledges an...

Page 802: ...support plate and snap back 1 Change drums side to side or turn drums in pairs 2 Holddown springs weak 2 Replace springs 3 Shoe bent 3 Replace shoes on both sides 4 Grooves in support plate ledges 4...

Page 803: ...ncorrect master cylinder 6 Check and replace if required EXCESSIVE PEDAL 1 Low fluid level 1 Add fluid as required TRAVEL 2 Leak in system 2 Inspect and correct as required 3 Air in system 3 Bleed bra...

Page 804: ...ination valve in stalled incorrectly 6 Check and correct as required Port marked inlet goes to mas ter cylinder port marked outlet goes to calipers 7 Bind in brake pedal or power unit bellcrank pivot...

Page 805: ...ken welds 8 Loose suspension parts 8 Inspect and correct as required 9 Front end out of alignment 9 Check and correct as required 10 Lining soaked with water after operation in heavy rains or flooding...

Page 806: ...ake adjustment Pedal free play should be 1 16 to 1 4 inch 1 58 to 6 35 mm Inadequate free play can result in brake drag or grab while excessive free play can produce a low pedal condition Free play on...

Page 807: ...ntacts This completes the electrical circuit between switch and warning lamp causing the lamp to light Unless the ignition lock cylinder is turned to the Off position the CLIP CLIP BRAKES 2G 15 lamp w...

Page 808: ...hose with Model 60 rear axle compress cable lock tabs at brake support plate using small hose clamp and remove cable On vehicles with Model 60 rear axle remove bolts attaching cable 1 On all vehicles...

Page 809: ...fig 2G 2 A spring loaded plunger in the switch opens and closes the stoplamp circuit When the brake pedal is in the released position the pedal arm contacts the switch plunger holding it in the off po...

Page 810: ...t BRAKELINING INSPECTION Disc Brakes The brakelining should be inspected whenever the wheels are removed for tire rotation or at the intervals specified in the Maintenance Schedule It is not necessary...

Page 811: ...fluid cmitaining mineral oil to clean or lubricate hydraulic Hydraulic System Inspection Mister Cylinder Specifications Wheel Cylinder Pigs 26 20 26 20 26 28 26 22 system components These materials w...

Page 812: ...s Repair as necessary MASTER CYLINDER A dual reservoir master cylinder is used on all Jeep vehicles The hydraulic system for the front brakes is completely separate from the rear brakes In the event o...

Page 813: ...Remove seat screw and washer Remove chips using brake cleaning solvent and compressed air Assembly 1 Install replacement tube seats if removed us ing spare tube fitting nuts to press seats into place...

Page 814: ...iron housing with a piston bore machined in it Two opposed pistons rubber piston cups and a compression spring with integral cup expanders are contained within the piston bore fig 2G 13 Rubber dust bo...

Page 815: ...COVER RESERVOIR DIAPHRAGM RESERVOIR SPRING RETAINER PRIMARY SEAL SECONDARY PISTON SECONDARY SEAL SECONDARY PISTON ASSEMBLY PRIMARY PISTON ASSEMBLY LOCK RING Fig 2G 11 Master Cylinder Cherokea Wagonear...

Page 816: ...s at any time orfor any reason 5 Inspect bleeder screw and screw threads in cyl inder Screw must turn freely Replace screw if dam aged or replace cylinder if cylinder threads are damaged 6 Inspect com...

Page 817: ...ull hydraulic fluid pressure to the front disc brakes until the rear drum brakes overcome return spring tension and the linings contact the drums When the brakes are not applied the metering valve per...

Page 818: ...master cylinder cover 3 Fill master cylinder if required and install cover 4 On vehicles equipped with type W combination valve remove dust cover from metering valve stem and install Tool J 26869 on s...

Page 819: ...osen valve front mounting bolt and insert slotted end of Tool J 23709 under bolt Push metering valve stem inward using tool to hold valve open and tighten mounting bolt to secure tool fig 2G 18 8 Blee...

Page 820: ...9 1 2 tandem diaphragm unit is used on J 20 Truck models Fig 2G 21 Power Brake Unit and Bellcrank CJ and Scrambler Models The power units consist of a two piece outer shell containing the single or d...

Page 821: ...LINDER PUSH ROD Fig 26 23 Single Diaphragm Power Unit Typical VACUUM CHECK VALVE OUTER SHELL PRIMARY DIAPHRAGM SECONDARY DIAPHRAGM CONTROL VALVE AIR VALVE Hg 26 24 Tandem Diaphragm Power Unit Typical...

Page 822: ...t power unit checkvalve 3 Remove nuts and washers attaching master cyl inder to power unit and move master cylinder aside Do not disconnect brake lines at master cylinder 4 On CJ and Scrambler models...

Page 823: ...act that the secondary brakeshoe linings are generally thicker and have more contact area When the brakes are released the return springs overcome the diminishing fluid pressure and return the brakesh...

Page 824: ...ment with the next tooth of the adjusting screw during reverse brake applications When the brakes are released the brakeshoes return to the anchor pin The adjuster mechanism utilizes movement of the s...

Page 825: ...lean the support plates using compressed air or dry cloths and polish the anchor pins with crocus cloth Also check the pins for being loose worn or damaged In spect the support plates for distortion o...

Page 826: ...ing rear drums 4 On Truck models with Model 60 full floating rear axle remove two screws that locate rear drums on hubs ffig 2G 28 J41135 Fig 2G 28 Brakedrum Locating Screw Removal Model 60 Axle 5 Rem...

Page 827: ...to machine drums with hard spots Replace drums with this condition Assembly and Adjustment NOTE When it is necessary to replace the brakelining on one wheel the lining must also be replaced on the op...

Page 828: ...er Models 10 060 inches 25 5 cm Cherokee Wagoneer J 10Truck 11 060inches 28 09cm J 20 Truck 12 060 inches 30 6 cm Brake Lining Wear Limits Riveted Lining Replacewhen worn to within 1 32 inch 0 79 mm o...

Page 829: ...ts the rotor surface making a high pitched noise to alert the driver fig 2G 33 DISC BRAKE OPERATION Operation The significant feature of disc brake operation is that the caliper is free to slide later...

Page 830: ...SOCKET HEAD WITH FRONT HUBS SCREW HUB AND ROTOR ASSEMBLY BEARING CUP OUTER BEARING SPRING CUP NOT USED WITH FRONT HUBS DRIVE GEAR LOCKNUT NOT USED WITH FRONT HUBS OUTER LOCKNUT PRESSURE SPRING NOT US...

Page 831: ...ic pressure is released the seal reverts to its original shape and re tracts the piston just enough to provide the necessary operating clearance As the linings wear piston travel begins to exceed the...

Page 832: ...boot Theforce ofcompressed air will unseat the boot Use shop cloths only Installation 1 Lubricate replacement bushings sleeves bush ing grooves and small ends of mounting bolts with silicone lubricant...

Page 833: ...move brake line bolt and copper gaskets Discard copper gaskets 7 Cap or tape open end of brake hose to prevent dirt entry 8 Remove caliper and remove brakeshoes from caliper NOTE Workon one caliper at...

Page 834: ...thoroughly with brake fluid or brake cleaning solvent if the bore was polished Assembly 1 Lubricate piston bore and replacement seal with brake fluid 2 Install seal in bore groove Work seal into groo...

Page 835: ...prior to disassembly Many brake parts contain asbestos fibers which can become airborne if dust is created during service oper ations Breathing dust containing asbestos fibers may cause serious bodil...

Page 836: ...ton bore If leakage is evident overhaul caliper Refer to Caliper Overhaul CJ and Scrambler Models 13 Inspect abutment sliding surfaces of caliper and anchor plate for rust or corrosion fig 2G 50 Clean...

Page 837: ...g thoroughly 6 Disconnect brake line at caliper Remove brake line bolt and washers Discard washers Cover open end of brake line with cloth or tape 7 Remove caliper and brakeshoes as outlined in Brakes...

Page 838: ...er if the bore is nicked scratched worn cracked or badly corroded However minor stains or corrosion can be removed us ing crocus cloth CAUTION Do not use emery cloth or similar abra sives on the pisto...

Page 839: ...tly rusted or scored proceed to step 5 If surfaces are severely scored cracked chipped exces sively worn or have hard spots a series of shiny or dark colored spots replace rotor 5 If rotor surfaces ar...

Page 840: ...grooves after machining fig 2G 58 41182 Rg 2G 58 Correct Rotor Finish Nondirectlonal Crosshatch Pattern NOTE Ifa rotor is glazed or highly polished sanding the rotor may not produce the required roto...

Page 841: ...2G 49 a Remove rotor hubcap b Remove drive gear snap ring and remove drive gear pressure spring and spring cup 6 On models with front hubs a Remove socket head screws attaching hub body to hub clutch...

Page 842: ...4 13 cm J 10 Truck 1 125 28 5 mm 12 0 Disc 30 48 cm 2 937 Single Piston 7 45 cm 11x2 Drum 27 94 x 5 08 cm 937 23 79 mm 9 1 2 Single Diaphragm 24 13 cm J 20 Truck 6800 GVW 1 125 28 5 mm 12 5 Disc 31 75...

Page 843: ...40 47 Wheel Bearing Outer Locknut All 50 min 68 min Wheel Bearing Inner Locknut Bearing Adjuster CJ Scrambler Tighten to 50 ft lbs 68N m and back off 1 6 turn while Cke Wag Trk Tighten to 50 ft lbs 6...

Page 844: ...NOTES...

Page 845: ...pecially important on vehicles equipped with the Quadra Trac full time four wheel drive transfer case TIRE CONSTRUCTION Three types of tire construction are currently in use They are referred to as bi...

Page 846: ...se letter number combinations such as H78 15 In this case letter H represents tire industry specifications for the load and inflation schedule for tires in this letter classification The number 78 in...

Page 847: ...ar occurs and the tires are still serviceable rotate the tires and inflate them to recom mended levels when they are cool Cracked treads are usually caused by underinflation or excessive high speed op...

Page 848: ...nt Tires should also be inspected frequently for cuts abrasions stone bruises blisters or for objects imbedded in the tire Weekly inspection intervals are recommended as a minimum More frequent inspec...

Page 849: ...ted tires on any vehicle Intermixing these tires will produce an adverse effect on vehicle handling and cornering stability In an emergency situation tires may be intermixed but only for the duration...

Page 850: ...obble Front Wheel Bearing Adjustment CJ and Scrambler Models 1 Raise vehicle 2 Remove bolts attaching front hub to rotor hub and remove hub body and gasket 3 Remove snap ring from axle shaft and remov...

Page 851: ...11 On models with front hubs a Install hub clutch assembly b Install small retaining ring on axle shaft Install large retaining ring on hub c Install hub body on hub clutch d Install socket head screw...

Page 852: ...e highly flexible sidewall An objectionable waddle condition can be reduced only by rotating the tires Wheel balancing will not alleviate this condition Proper mounting of radial tires is very importa...

Page 853: ...erated by a tire spinning at high speed could cause damage and personal injury Wheel and Tire Runout Excessive radial or lateral runout of a wheel or tire can cause roughness vibration tramp tire wear...

Page 854: ...floorpan or steering wheel and usually produce some visible motion in the rear view mirror fenders dash panel or steering wheel Audible vibrations are heard or sensed above normal background noise an...

Page 855: ...ibration WHEELS AND TllibS 2H 11 imaanr uiiifc ii um in mm UJ Universal Joints If needle bearings bearing cups or bearing ends of spiders are worn damaged over tightened or loc3e they will cause mecha...

Page 856: ...10 20 30 40 50 60 70 80 SO 16 km 32 km 48 km 64 km 80 km 96 km 112 km 128 km 144 km 1 TRRandSSC W TB WH TLR PSY UJand AN WB UJ and AN UJA UJA ES EA OEM Vibration Sensitivity Correction Codes For Audib...

Page 857: ...SL 31 31 28 28 35 35 32 32 15x6 Wheel 10R 15LT B 35 35 25 25 45 45 35 35 15x 7 15x 8 is 15x7 6800 3084 8 75 16 5 C 40 40 30 30 50 55 40 45 16 5x6 J 20 Truck 9 50 16 5 D 45 45 35 35 55 70 45 60 16 5 x...

Page 858: ...ing Adjustment CJ Scrambler Cke Wag J 10Trk J 20 Trk 8400 GVW Wheel Bearing Adjustment CJ and Scrambler Outer Locknut Inner Locknut Adjusting Nut Wheel Bearing Adjustment Cke Wag Trk Outer Locknut Inn...

Page 859: ...d to compress under impact The ignition lock cylinder and ignition switch are mounted on the column When the lock cylinder is turned to LOCK position the ignition switch and steer ing shaft cannot be...

Page 860: ...rack WILL STICK IN START 1 2 Remote rod deformed Ignition switch mounting bracket bent 1 2 Straighten or replace Straighten or replace KEY CANNOT BE REMOVED IN OFF LOCK 1 2 Ignition switch is not adj...

Page 861: ...ce snap ring Check for proper seating in groove 10 Shroud loose on shift bowl Housingloose on jacket will be noticed with ignition in off lock and when torque is applied to steering wheel 10 Position...

Page 862: ...in Lock shoe grooves have burrs or are filled with foriegn material 1 2 Replace lock shoes and pin Clean or replace lock shoes 3 Lock shoe springs weak or broken 3 Replace springs NOISE WHEN TILTING C...

Page 863: ...ION SWITCH WILL NOT ACTUATE MECHANICALLY 1 2 Defective ignition switch Defective lock sector 1 2 Replace switch Replace lock sector 3 Defective remote rod 3 Replace remote rod IGNITION SWITCH CANNOT B...

Page 864: ...terial or loose parts WILL NOT STAY impeding movement ofswitch if TURN POSITION yoke Defective switch HAZARD SWITCH tt oreign material between r A NNOT BE liazard support cancelling PULLED OUT legand...

Page 865: ...ssis wiring for opens grounds etc 5 Repair chassis wiring as required INSTRUMENT PANEL TURN INDICATOR LIGHTS ON BUT NOT FLASHING 1 Burned out or damaged front or rear turn signal bulb 1 Replace bulb 2...

Page 866: ...grounds opens etc 1 Burned out bulbs 2 High resistance to ground at bulb socket 3 Opens grounds in wiring harness from front turn signal bulb socket to indicator lights 1 High resistance ground at li...

Page 867: ...HTS WILL NOT FLASH TURN SIGNAL FUNCTIONS NORMALLY 1 2 Blown fuse Inoperative hazard warning flasher 1 2 Replace fuse Replace hazard warning flasher in fuse panel 3 Loose chassis to column harness conn...

Page 868: ...ble 2 Place front wheels in straight ahead position 3 On models with standard steering wheel re move horn cover attaching screws from underside of wheel and remove cover On models with sport steering...

Page 869: ...g wheel and install insulator attach ing screws 10 Align reference marks on steering shaft and wheel and install wheel 11 Install contact plate and horn button receiver Install receiver so horn button...

Page 870: ...24 UPPER BEARING PRELOAD SPRING 25 THRUST WASHER 26 TURN SIGNAL SWITCH SCREW 3 27 TURN SIGNAL SWITCH 28 TURN SIGNAL LEVER KNOB 29 TURN SIGNAL LEVER 30 m TURN SIGNAL LEVER SCREW UPPER BEARING HOUSING R...

Page 871: ...ansmission shift rod to steering col umn shift lever 13 On vehicles with automatic transmission check operation of gearshift manual linkage and adjust link age if necessary Refer to Chapter 2C Automat...

Page 872: ...n nector from bracket at lower end of steering column 13 Disconnect instrument panel harness connector from turn signal switch harness connector by lifting plastic lock tab on connector and separating...

Page 873: ...remove kev release lever and spring fig 2J 13 24 Remove lock rack and lock bolt assembly fig 2J 14 STEERING COLUMNS 2J 15 Fig 2J 11 Housing and Shroud Removal Installation Fig 2J 12 Removing Shroud Fr...

Page 874: ...oved previously 60G63 v Sl Wy S sli M160670 Fig 2J 15 Rack Preload Spring Removal installation 60671 Fig 2J 16 Lock Sector Removal 29 Remove spring clip from lower bearing retainer and remove retainer...

Page 875: ...lock rack in housing Mate block tooth of lock rack with block tooth of sector fig 2J 19 6 Install key release lever return spring over post in housing fig 2J 20 Insert release lever finger in lock rac...

Page 876: ...ket fig 2J 23 SPRING POC REMOTE ROD REMOTE ROD HOLE SWITCH SLIDER SWITCH POSITIONS 60679 Fig 2J 23 Positioning Ignition Switch b Move switch slider to extreme left to Ac cessory position c Move slider...

Page 877: ...is fully seated before removing tool 28 Install lock plate cover 29 Remove Support Fixture Tool J 23074 if installed 30 Install column mounting bracket Tighten bracket attaching bolts to 20 foot pound...

Page 878: ...SPRING STEERING SHAFT SNAP RING STEERING WHEEL NUT SHIFT TUBE PRELOAD SPRING RETAINER U WASHER LOWER BEARING 5 Remove steering wheel fig 2J 1 6 Remove lock plate cover fig 2J 26 Use two screwdrivers...

Page 879: ...adrant light wire in connector block and disconnect wire 17 Remove column lower bracket and plastic har ness protector 18 Remove column to instrument panel mounting bracket if turn signal switch is to...

Page 880: ...hicle the following steps can be performed only after the column has been removed BEARING LOCATOR CRIMP TYPICAL COLUMN JACKET TUBE UPPER END m NOTCH TYPICAL AJ42052 Fig 2J 31 Shift Bowl Lower Bearing...

Page 881: ...nstall upper housing Tighten housing attaching screws to 60 inch pounds 7 N m torque NOTE The shift bowl must be in theParkposition and the rack pulled downward before the upper housing can be install...

Page 882: ...nditioning duct if equipped and column to instrument panel bezel 37 Remove protective covering from painted areas of column 38 Connect battery negative cable TILT COLUMN OVERHAUL CHEROKEE WAGONEER TRU...

Page 883: ...olumn 27 Remove lock sector tension spring retaining screw Unhook spring from lock sector shaft and remove spring 28 Remove snap ring from lock sector shaft and remove lock sector sector shaft and ret...

Page 884: ...at 12 o clock position and removing plate bottom side first fig 2J 41 48 Remove wave washer and shift tube spring 49 Remove shift bowl from column jacket 50 Remove lower bearing retainer spring clip f...

Page 885: ...CTOR TENSION SPRING LOCK BOLT RELEASE LEVER PIN LOCK SECTOR GUIDE CLAMP Fig 2J 42 Till Steering Column Cherokee Wagoneer Truck Models STEEflING COLUMNS 2J 27 LOCK RACK REMOTE ROD 1 CONTACT BUTTON BUMP...

Page 886: ...nd into guide channel in left side of support 21 Engage lock rack in remote rod fig 2J 45 support LOCK RACK REMOTE ROD AJ70205 Fig 2J 45 Lock Rack and Remote Rod Position 22 Guide housing over steerin...

Page 887: ...ines and install lock plate Canceling cam shaft must protrude through opening in lock plate fig 2J 34 48 Install replacement steering shaft snap ring on sleeve of Compressor Tool J 23653 and install t...

Page 888: ...LOWER ILEVE BEARING SPRI UPPER BEARING disassembly is to be more extensive If the column is removed use Support Fixture J 2307k to mount the col umn in a visefor service operations fig 2J 5 Column Di...

Page 889: ...ght side of column jacket 13 Loosen all toeplate screws 14 Remove bolts attaching column mounting bracket to column jacket 15 Remove nuts attaching column mounting bracket to instrument panel bolts an...

Page 890: ...engage shoes and turn housing to one side to separate lock rack from remote rod 28 Remove tilt lever from housing 29 Remove tilt lever shield from housing fig 2J 54 30 Remove lock sector spring retain...

Page 891: ...are not reusable WEDGE STEERING COLUMNS 2J 33 LOCK shoes RELEASE LEVER Fig 2J 57 Relieving Lock Shoe Spring Tension 38 Disconnect steering shaft at intermediate shaft coupling 39 Remove steering shaf...

Page 892: ...g in lower end of column fig 2J 47 3 Install key release lever spring on lever and in stall assembled lever and spring in shroud fig 2J 62 4 Align and install shroud on column jacket fig 2J 61 5 Insta...

Page 893: ...fig 2J 52 gage retainer lock tabs with housing lugs by press retainer downward and turning clockwise us screwdriver 23 Install tilt lever shield in housing 24 Remove tilt lever 25 Install cover on ho...

Page 894: ...have this groove b If shaft has American threads use Com pressor Tool J 23653 as is to compress lock plate and unseat snap ring c If shaft has metric threads replace com pressor tool standard forcing...

Page 895: ...d disassembled and repaired or recoded if necessary STEERING COLUMNS 2J 37 Conditions Requiring Service Key Lost Key Code Number Known The key code may be converted to a five digit number that determi...

Page 896: ...AUTION Identify the steering shaft nut thread type before installing the compressor tool If the shaft has American threads use the tool as is However if the shaft has metric threads fig 2J 2 replace t...

Page 897: ...fig 2J 68 POSITIONS 12345 STAKING POINTS 12 3 4 5 KEY CODES AJ41049 Fig 2J 68 Key Coding Diagram 1 Place key over coding diagram with uncut side of key aligned exactly with diagram Each of five posi t...

Page 898: ...e Shaft 45 40 55 Clamp Bolt Steering Shaft U Joint 45 40 55 Column Mounting Bracket Bolt 20 15 25 Column Mounting Bracket to instrument Panel Bolts 20 15 25 Cover Screws Auto Col 60 in lbs 50 65 in lb...

Page 899: ...ER ft J 22635 PIN REMOVER AND INSTALLER T J 23653 LOCK PLATE COMPRESSOR J 23073 SHIFT TUBE INSTALLER TjJ J 22569 STEERING SHAFT SNAP RING REMOVER AND INSTALLER J 21232 STEERING WHEEL PULLER J 21854 1...

Page 900: ...NOTES im fW9s F...

Page 901: ...ions Sub Assembly Overhaul Tools 2K 2K 2K 2K 2K ON VEHICLE SERVICE Steering Gear Adjustment Adjustments are generally made to compensate normal wear in the gear or to correct a handling prob caused by...

Page 902: ...g alignment marks made at disassembly 20 Tighten pitman arm nut to 185 foot pounds 251 N m torque and stake nut to shaft threads in one place 21 Lower vehicle 22 Correct steering wheel to steering sha...

Page 903: ...proximately the same at both wheels Replace front springs if sagged 10 Frame bent or broken 10 Repair frame as necessary 11 Steering knuckle bent 11 Replace knuckle 12 Ball stud galled or too tight 12...

Page 904: ...on of the steering gear is impor tant Some of the following steps in gear installation require theapplication ofLoctite271 orsimilarmaterial to attaching bolt threads Wherever indicated use Loc tite 2...

Page 905: ...BEARING RETAINER MANUAL STEERING GEAR 2K 5 DISASSEMBLY 1 Mount steering gear in vise Clamp vise jaws on gear mounting bosses only 2 Place ball nut and pitman shaft in centered posi tion Rotate wormsh...

Page 906: ...wear scor ing cracks nicks or surface pitting and also check the upper bearing and ball bearings for flat spots If the upper bearing is damaged the upper bearing cup must also be replaced Assembly 1 P...

Page 907: ...is damaged both parts must be replaced Assembly 1 If lower bearing cup is to be replaced remove old cup and install replacement as follows a Install spare locknut on worm bearing ad juster and clamp...

Page 908: ...cified limit select and install a replacement shim that will provide the specified clearance Shims are furnished in four thicknesses 0 063 0 065 0 067 and 0 069 inch 1 60 1 65 1 70 and 1 75 mm and are...

Page 909: ...ll cover attaching bolts finger tight only do not attempt to seat cover on housing by tightening bolts PITMAN SHAFT SECTOR TEETH SHIM MANUAL STEERING GEAR 2K 9 DEEPSIOE OF BALL NUT TEETH ADJUSTER SCRE...

Page 910: ...m either the right or left turnstop positions 5 Tighten worm bearing adjuster locknut to 90 foot pounds 122 N m torque Recheck wormshaft ro tating torque and readjust if necessary 6 Record worm bearin...

Page 911: ...Metric N m Service Set To Torque Intermediate Shaft Coupling Clamp Bolt 45 Pitman Arm Nut 185 Steering Gear Mounting Bracket to Gear Bolts CJ 70 Steering Gear Mounting Bracket toTie Plate Bolt CJ 55 S...

Page 912: ...NOTES...

Page 913: ...open at 1500 psi 10 342 kPa The power steering gear is designed to operate man ually if a system malfunction should ever occur This feature provides the driver with continued steering con trol of the...

Page 914: ...develop system fluid pressure fig 2L 2 The pump has an integral reservoir that contains the system fluid supply The reservoir cap is vented to maintain atmospheric pressure within the reservoir and al...

Page 915: ...e spool valve rotates the spool valve fluid return grooves are closed off while the right turn grooves are aligned with high pressure fluid grooves in the valve body fig 2L 3 The spool valve left turn...

Page 916: ...RACK PISTON OIL PRESSURE OIL RETURN PORT PORT SPOOL VALVE VALVE BODY VALVE VALVE SPOOL BODY STUB SHAFT VALVE BODY TORSION BAR HIGH PRESSURE LOW PRESSURE RACK PISTON Fig 2L 3 Fluid Flow Right Turn Pos...

Page 917: ...ER STEERING GEAR AND PUMP 21 5 OIL PRESSURE PORT OIL RETURN PORT SPOOL VALVE VALVE BODY VALVE BODY STUB SHAFT HIGH PRESSURE I LOW PRESSURE VALVE BODY RACK PISTON Fig 2L 4 Fluid Flow Left Turn Position...

Page 918: ...for left and right turns In the straight ahead position onlythe tip of the long center tooth is in contact with the rack piston As a result initial movement of the rack piston in either direction pro...

Page 919: ...OVERING FROM A TURN CHIRP NOISE IN 1 Loose or damaged belt 1 Adjust belt tension or re STEERING PUMP place belt BELT SQUEAL 1 Loose or damaged belt 1 Adjust belt tension or re PARTICULARLY place belt...

Page 920: ...tuds are binding 5 Steering linkage binding 5 Replace rod ends 6 Ball studs binding 6 Replace ball studs 7 Tight or frozen steering shaft bearings 7 Replace bearings 8 Sticky or plugged spool valve 8...

Page 921: ...ring linkage rod ends wom 3 Replace rod ends 4 Worn poppet valve Gear 4 Replace poppet valve 5 Insufficient wormshaft bearing preload 5 Adjust to specification with gear out of vehicle 6 Insufficient...

Page 922: ...Pressure loss in cylinder due to 1 Remove gear for disassembly TO STEERING GEAR worn piston ring or badly wom housing bore and inspection of ring and housing bore 2 Leakage at valve rings valve body t...

Page 923: ...mbly 6 If leak occurs at side cover gasket or locknut replace gasket or locknut as necessary NOTE The locknut has a left hand thread POWER STEERING GEAR AND PUMP 21 11 RESERVOIR O RING PUMP SHAFT SEAL...

Page 924: ...als If seepage is observed between the torsion bar and stub shaft do not attempt repair The rotary valve assembly must be replaced ____ _ _______ ___ ___ Seat housing ball with blunt punch Spray ball...

Page 925: ...n and recheck If leak persists replace con nector seats b Remove hose and check sealing face for cracks If flare is cracked replace connector seats c Replace brass connector seats and reface hose flar...

Page 926: ...s If flare is cracked replace hose If not cracked replace connector seats c Replace brass connector seats and reface tube flare Check threads in pump housing and on fitting nut If nut threads are dama...

Page 927: ...PUMP 21 15 12 Check pump maximum output pressure as fol lows Close gauge valve completely for 2 to 3 seconds then open valve completely Perform this procedure three times in succession and record high...

Page 928: ...sure belt tension When checking tension with this gauge position the gauge at the center of the long est belt span to take readings Whenchecking tension of notched drive belts be sure the gauge finger...

Page 929: ...r r r POWER STEERING GEAR AND PUMP 2L i7 80084B...

Page 930: ...es service 4 to 5 inch pounds 0 45 to 0 56 N m in addition to worm bearing preload but not to exceed total of 18 inch pounds 2 03 N m Steering Ratio CJ 17 5 1 constant ratio Cke Wag Trk 13 16 1 variab...

Page 931: ...arings using filtered com pressed air Use lint free paper towels or cloths only to dry bearings During assembly operations use the recommended torque values and adjustment specifications only Fail ure...

Page 932: ...ig 2L 10 12 Seat single lip seal and washer using Snap Ring Tool J 21553 Install seal and washer only far enough to provide clearance for remaining seal backup washer retaining ring and for clearance...

Page 933: ...r Truck Models On Cherokee Wagoneer and Truck models the posi tion of the steering gear prevents on vehicle replace ment of the end plug O ring seal fig 2L 11 It is necessary to remove the gear to per...

Page 934: ...nd mounting brackets on frame and crossmember and in stall attaching bolts Tighten all attaching bolts to 55 foot pounds 75 N m torque f Remove support stands and lower vehicle g Install intermediate...

Page 935: ...ig 2L 14 NOTE The locknut has left hand threads 11 Remove side cover bolts and lockwashers 12 Remove side cover Unthread cover from ad juster screw by turning screw clockwise 13 Rotate stub shaft unti...

Page 936: ...2L 17 Use screwdriver to pry seal out of bore Discard sea 4 Remove backup washer and single lip seal fig 2L 17 Use screwdriver to pry seal out of bore Discard seal Do not damage seal bore when removi...

Page 937: ...aring and seal surfaces in the housing Replace the housing if any surface is worn or damaged Hose Connector Seat and Check Valve Replacement CAUTION Some steering gear units have metric thread fitting...

Page 938: ...remove any re maining chips and petroleum jelly Assembly 1 Lubricate housing bores and all replacement bearings and seals with power steering fluid 2 Install pitman shaft needle bearing using Tools J...

Page 939: ...conditions Assembly 1 Lubricate dust seal and O ring with petroleum jelly Lubricate all other components with power steer ing fluid 2 Position needle bearing on Tool J 6221 so bear ing manufacturers i...

Page 940: ...RING SHAFT CAP 60194 Fig 2L 26 Valve Body Components 2 Hold valve body assembly in both hands with stub shaft pointing downward Tap end of stub shaft lightly against wood block until shaft cap is fre...

Page 941: ...icks or does not rotate freely within the valve body Assembly 1 Lubricate all valve body components with power steering fluid 2 Install replacement backup O rings in seal ring grooves POWER STEERMG GE...

Page 942: ...ing or scoring fig 2L 32 Inspect the adjuster screw for looseness dam aged threads or distortion Replace the pitman shaft if any of these conditions are noted However light scor ing corrosion or scrat...

Page 943: ...direction when installing bearings and press each bearing downward to make room for following bearing INSTALL BALL BEARINGS WHILE ROTATING WORM SHAFT COUNTERCLOCKWISE RETURN GUIDE HALVES WORMSHAFT RE...

Page 944: ...nstall assembled valve body and wormshaft in housing Be sure wormshaft locating pin is still fully STUB SHAFT TOPS OF CONES MUST FACE BOTTOM OF GEAR LOWER THRUST BEARING 4 CONICAL THRUST BEARING RACES...

Page 945: ...n housing and install cover attaching bolts Tighten bolts to 45 foot pounds 61 N m torque Be sure cover gasket is properly seated before installing cover bolts 18 Thread adjuster screw locknut half wa...

Page 946: ...4 Turn adjuster plug counterclockwise and align adjuster plug hole with second mark made on housing 5 Install adjuster plug locknut Place spanner wrench on adjuster plug to prevent it from turning an...

Page 947: ...b shaft should face upward and be parallel with the side cover fig 2L J 3 In addition the master splineon the pitman shaft should be in line with the adjuster screw fig 2L U 42096 Fig 2L 43 Stub Shaft...

Page 948: ...th less than 400 miles service 4 to 8 inch pounds 0 45 to 0 90 N m in addition to worm bearing preload but not to exceed total of 14 inch pounds 1 58 N m Used gear with ever 400 miles service 4 to 5 i...

Page 949: ...1 2 inches 6 35 cm long around pump shaft Work shimstock under and past shaft seal until shimstock bottoms in seal bore fig 2L 47 b Cut metal body of shaft seal using sharp chisel and pry seal out of...

Page 950: ...e J 23600 to measure belt tension fig 2L 51 When using the gauge position it at the center of the longest belt span to check tension If check ing tension on a notched belt be sure the gauge finger is...

Page 951: ...nstall assembled valve and spring in pump bore spring end first 4 Install replacement O ring seal on pump union fitting and install fitting in pump Tighten fitting to 35 foot pounds 47 N m torque 5 If...

Page 952: ...in mounting bracket on engine and install pump to bracket attaching bolts and nuts 3 Fill pump reservoir with power steering fluid and turn pump pulley counterclockwise until bubbles no longer appear...

Page 953: ...for wear cracks scoring or pitting Also check the surfaces for flatness and for being parallel with the pump ring Replace any part that is worn or damaged NOTE A high polish will always be present on...

Page 954: ...gn thrust plate dowel pins with dowel holes in pump ring fig 2L 57 DOWEL PIN HOLE CROSSOVER HOLE Fig 2L 57 Pump Ring Dowel Hole Locations ARROW PUMP RING 42134 8 Install pump ring on dowel pins and ov...

Page 955: ...ig 2L 59 Rotor Vine Installation POWER STEERING GEAR AND PUMP 2L A3 Fig 2L 60 End Plate and Retaining Ring Installation 17 Insert hex end of flow control valve in valve springand install assembled val...

Page 956: ...aximum Pressure CJ Scrambler 1100 1200 psi 7584 8274 kPa Cke Wag Trk 1400 1500 psi 9653 10342 kPa Pressure Test Specifications Initial pressure engine at idle speed 80 125 psi 552 862 kPa Test pressur...

Page 957: ...EARING REMOVER AND INSTALLER J 21554 ADJUSTER PLUG SEAL _ _ INSTALLER 217 CONNECTOR SEAT INSTALLER A J 6632 PITMAN ARM PULLER J 7754 TORQUE WRENCH 0 25 INCH POUNDS J 7624 SPANNER WRENCH 80501 POWER ST...

Page 958: ...NOTES Ml...

Page 959: ...wheel alignment figs 2M 1 and 2M 2 STEERING KNUCKLE STEERING KNUCKLE ARM END ASSEMBLY INDEX Specifications Steering Damper Steering Wheel Spoke Alignment Tie Rod Page 2M 6 2M 3 2M 5 2M 3 The connectin...

Page 960: ...o the adjusting tube The tie rod has a large boss located about eight inches from the unthreaded end A tapered hole machined in this boss accepts the connecting rod Fig 2M 3 Tie Rod Assembly 41059 end...

Page 961: ...steering gear must be centered When the steering arm is correctly positioned install the con necting rod STEERING DAMPER The steering damper used on Cherokee Wagoneer and Truck models has mounting eye...

Page 962: ...3 64 to 3 32 inch 1 19 to 2 38 mm Fig 2M 7 Front Wheel Toe In Top View Typical To adjust toe in loosen the adjuster tube clamp bolts and turn the tie rod in or out with a small pipe wrench The tie ro...

Page 963: ...h stroke Higher STEERING LINKAGE 2M 5 resistance on extension stroke than compression stroke is normal condition Replace damper if lack of resistance is evident 6 Inspect tie rod ends Replace any tie...

Page 964: ...41 Upper Ball Stud Retaining Nut 100 136 Lower Ball Stud Jamnut 80 108 Upper Ball Stud Split Ring Seat 50 68 Tie Rod Clamp Bolt 5 16 24 CJ Scrambler 12 10 15 16 Tie Rod Clamp Bolt 7 16 14 Cke Wag Trk...

Page 965: ...ken or shifted leaves loose or missing clips and broken center bolts Squeaking noises can be generated when movement between the spring bushings and metal parts occurs This noise can usually be elimin...

Page 966: ...ilable as an option on Cherokee and J 10 Truck models The internal val ving of these shock absorbers is designed to increase the damping forces needed to cushion the loads encountered in off road oper...

Page 967: ...hout each stroke should be smooth and produce an equal amount of re sistance in each direction Shock Absorber Replacement 1 Raise vehicle 2 Position hydraulic jack under axle and raise axle to relieve...

Page 968: ...tion hydraulic jack under axle and raise axle to relieve springs of axle weight 4 Disconnect stabilizer bar if equipped 5 Remove spring U bolts and tie plates 6 Remove bolt attaching spring front eye...

Page 969: ...SPRING LEAVES SHOCK ABSORBER U BOLT Fig 2N 4 Rear Spring and Shock Absorber Cherokee Wagoneer Truck Models SUSPENSION 2N 5 60694...

Page 970: ...STABILIZER BAR SPRING TIE PLATE CONNECTING LINK PIN CONNECTING LINK 60696 Fig 2N 8 Stabilizer Bar Mounting 5 Remove hydraulic jack used to support axle weight 6 Remove support stands and lower vehicl...

Page 971: ...ue 4 Connect shock absorber to axle 5 Install wheel 6 Install fuel tank skid plate if removed 7 Remove hydraulic jack 8 Remove support stands and lower vehicle 9 Tighten spring attaching bolts to spec...

Page 972: ...nd aligns with the bushing The pipe section must butt against the spring eye so that bushing can pass through it The socket will act as a press ram and press the bushing out of the spring eye and into...

Page 973: ...t...

Page 974: ...e i K 4 ft it y _ mm 1 M I v HI1pit ix H a l V 38 J Jeep TECHNICAL SERVICE MANUAL S...

Page 975: ...injury and render the t rd vehicle unsafe Detailed descriptions of standard workshop safety procedures arc notincluded in 7 thismanual Thismanual does contain WARNINGS for some service procedures that...

Page 976: ...r Air Conditioning Body and Frame Components Hoods Litigates Tailgates Doors Rear Quarter Hardtop Enclosure Sun Roof Luggage Racks Seat Assemblies Windshield Rear Window Headlining Exterior Decais and...

Page 977: ...r mine the exact problem area Page Water In Rear Passenger Compartment 3A 6 Water off Headllner 3A 5 Water on Front or Rear Seats 3A 4 Do not rush the water spray test The water may have to flow awhil...

Page 978: ...Test vertical section of A pillar and across top of glass c Repeat steps a and b for other side of vehicle 3 If leaks are noted dry out suspect area as de scribed under Bonding Surface Preparation 4...

Page 979: ...uspect components and at taching hardware are properly installed If necessary WATER LEAK WIND NOISE DIAGNOSIS AND REPAIR 3A 3 apply 3M AU Around Autobody Sealant or equivalent to ensure a water tight...

Page 980: ...e lines described under Spray Test above a Starting at front lower corner of door spray water between door lower edge to rocker panel b Move slowly up door to roof level c Move to door lower rear corn...

Page 981: ...to rear quarter window or sun roof and turn switch on b Slowly pass listener around window opening WATER LEAK WIND NOISE DIAGNOSIS AND REPAIR 3A 5 c Mark any area where a meter reading of approximatel...

Page 982: ...e headliner if equipped 3 Close all windows doors and air vents 4 Using Listener Tool J 23455 01 perform ultra sonic test as follows a Place transmitter in vehicle adjacent to sus pect area and turn s...

Page 983: ...ped 12 Install rear seat if equipped Rear Doors and Glass An improperly adjusted door or defective sealing sys tem will allow water to leak onto the rear carpet or floorpan WATER LEAK WIND NOISE DIAGN...

Page 984: ...s due to excessive gaps and or lack of sealer Water can enter around rear taillamp housings or side marker lamps due to defective sealer gasket or dam aged housings Also leaking floorpan plugs will al...

Page 985: ...oor Adjustments 3A 10 General 3A 9 Uftgate Tallgate Adjustments 3A 10 GENERAL A systematic diagnosis is necessary to isolate interior wind noises The spot where the noise is heard may not be where the...

Page 986: ...m air pressure has an effect on the wind noise level Also drive the vehicle in both directions on the test road as prevailing wind conditions could change the noise level After determining where the m...

Page 987: ...dings that are not properly aligned or tightly seated to the fender can cause a wind noise If WATER LEAK WIND NOISE DIAGNOSIS AND REPAIR 3A 11 this is the case apply body tape to the suspected mould i...

Page 988: ...NOTES 5B5S...

Page 989: ...mix plastic body filler and hardener according to manufacturer s instructions 6 Apply plastic filler with rubber or plastic spreader Use firm pressure to aid in removing air bub bles which will show...

Page 990: ...e apply glazing putty according to the manufacturer s instructions f After glazing putty dries wet sand and clean area Apply final coat of primer and allow to air dry g Wet sand and wash area h Clean...

Page 991: ...silicone re mover such as DuPont Prep Sol Ditzler Acryli Clean or equivalent 6 Apply Ditzler Metalprep 79 DX 579 or equiva lent following manufacturer s instructions over bare metal 7 Apply Ditzler G...

Page 992: ...d first with a coat ofAMCaerosol polypropylene primer or equivalent according to the label instruc tions Failure to use the requiredprimer as directed will result in the color coat lifting orpeeling 1...

Page 993: ...1 16 quart 1 1 16 pint Available in pint cans 16 ounces Follow manufacturer s application instructions METAL REPAIR AND PAINTING 3B 5 DuPont Kit The DuPont Kit consists of Dexlar DuPont jobber mix of...

Page 994: ...NOTES A...

Page 995: ...el fig 3C 1 Fig 3C 1 Instrument Panel Instrument Cluster Instrument Illumination Instrument Panel Speedometer Pi 3C 3C 3C 3C INSTRUMENT CLUSTER Removal 1 Disconnect battery negative cable NOTE If equi...

Page 996: ...stall crash pad if equipped a Position crash pad on instrument panel and install attaching screws b Raise windshield to upright position c If equipped with a hardtop enclosure re move wood blocking su...

Page 997: ...g tabs Push the lamp INSTRUMENT PANELS AND COMPONENTS 3C 3 through the panel toward the steering wheel To install the molded lamps push into the panel until the retain ing tabs snap into place SPEEDOM...

Page 998: ...eedometer cable requires graphite grease for lubrication CLOCK The clock is attached to the instrument panel by a retaining bracket secured with two screws To reset the clock pull out the adjustment k...

Page 999: ...all steering column trim panel 4 Connect defroster hoses 5 Connect electrical connectors and courtesy lights INSTRUMENT PANELS AND COMPONENTS 3C 5 6 Install air vent cables 7 Install parking brake lev...

Page 1000: ...m the outside The assembly is held in place by a screw through the lockclamp cup and into the lock case 1 Insert key in lock and rotate cylinder counter clockwise to expose the tumblers 2 Remove key a...

Page 1001: ...e is obtained When installing the odometer the separators must straddle a cross bar to maintain proper number alignment INSTRUMENT PANELS AND COMPONENTS 3C 7 HOLD THIS END SIXTH DIGIT P F1RST SEPARATO...

Page 1002: ...NOTES...

Page 1003: ...ce Diagnosis for a list of the possible causes and recommended service procedures SYSTEM CONTROLS The heater and defroster controls consist of a fan control switch and three push pull knobs and cable...

Page 1004: ...utside air and heated air The defrost control knob must be pushed in for the DEFROSTER NOZZLE blended air to enter through the floor heat duct When the defrost control knob is pulled out completely al...

Page 1005: ...PEED ONLY 1 Faulty switch 2 Faulty resistor 1 Replace 8witch 2 Replace resistor FAN RUNS BUT DOES NOT CIRCULATE AIR 1 Intake blocked 2 Fan not secured to motor shaft 1 Clean intake 2 Tighten securely...

Page 1006: ...the instrument panel press the plastic tabs together and pull out the cable 2 Remove cable from instrument panel 3 Remove cable to damper door 4 Route replacement cable through hole in in strument pan...

Page 1007: ...sh panel 8 Install glove box 9 Install speedometer cable HEATER 30 5 10 Install screw attaching heater housing to bracket 11 Connect wiring to A C switch 12 Install evaporator housing to instrument pa...

Page 1008: ...witch Off Low Medium and High which regulates the blower motor and airflow for heat defrost and fresh air ventilation There has been a vacuum storage tank added to pre vent the heater doors from closi...

Page 1009: ...onnect electrical connectors from cluster 5 Disconnect vacuum hoses from vacuum control switch NOTE Tag hoses according to their numbered location for ease ofassembly 6 Remove cluster lamps 7 Disconne...

Page 1010: ...e is equipped with a turn buckle to simplify adjustment The turnbuckle is located in the engine compartment close to the vacuum can 1 Rotate turnbuckle counterclockwise to obtain complete closing of t...

Page 1011: ...ing 8 Remove heater core to housing attaching screws and remove core batailatfon 1 Position heater core in housing and install at taching screws HEATER 30 9 2 Seal and assemble two halves of heater co...

Page 1012: ...NOTES SB...

Page 1013: ...E 3 3E 2 70521 GENERAL Factory installed air conditioning is not available on CJ and Scrambler models equipped with the four cylin der engine All information in this section referring to CJ and Scramb...

Page 1014: ...bution by moving the louver levers left right up or down Airflow can be adjusted for quick delivery to a specificspot or for gentle diffusion of airthroughoutthe vehicle When the interior of the vehic...

Page 1015: ...f the system is dis charged it will be necessary to leak test repair as required evacuate and charge the system RECEIVER DRYER Removal 1 Discharge refrigerant from system as described in General Infor...

Page 1016: ...3E 4 AIRCONDITIONING HARNESS SWITCH FAN CONTROL KNOB TEMPERATURE CONTROL KNOB BLOWER MOTOR INSULATION DRAIN TUBE LOUVER Hg 3E 5 Evaporator Housing Assembly CJ and Scrambler GROMMET 70530...

Page 1017: ...insulation 9 Install evaporator housing assembly 10 Evacuate leak test and charge system as de scribed in General Information and Refrigerant Han dling section of this chapter COMPRESSOR The compresso...

Page 1018: ...two or three city blocks with at least one window open During this time place the TEMP control in the MAX position and the FAN control in the HI or PC position Thisjjermits the evapo rator to precool...

Page 1019: ...ine NOTE Plug all open connections to prevent entry of dirt and moisture AIR CONDITIONING 3E 7 6 From underside of vehicle disconnect receiv er dryer to evaporator hose at receiver dryer 7 Remove cond...

Page 1020: ...two attaching screws 2 Raise evaporator and install evaporator hous ing to instrument panel attaching screws and evapo rator to mounting bracket screw 3 Install hose clamps and grommet attaching screw...

Page 1021: ...gnetic Clutch as applicable GENERAL INFORMATION AND REFRIGERANT HANDLING Charging System Checking for Leaks Checking System Pressures Discharging System Evacuating System Page 3E 18 3E 16 3E 11 3E 15...

Page 1022: ...system and damage the compressor WARNING Always work in a well ventilated area Always maintain good ventilation in the working area Always discharge the refrigerant into the service bay exhaust syste...

Page 1023: ...and valve stems 2 Close both hand valves on gauge manifold set 3 Connect compound gauge hose to compressor suction service valve gauge port low side 4 Connect high pressure gauge hose to discharge se...

Page 1024: ...181 30 80 1500 41 16 214 w 90 42 22 234 wWfo 100 44 26 267 Grw 70 40 13 185 X MN 40 80 1500 42 18 220 J 90 43 23 243 100 44 26 278 fi w 70 40 14 189 50 80 1500 42 19 226 w S 90 44 25 251 100 46 27 289...

Page 1025: ...lace expansion valve 4 Drive belt slipping 4 Set belt tension LOW SIDE HIGH HIGH SIDE HIGH 1 Clogged condenser fins 1 Clean out condenser fins 2 Air in system 2 Evacuate leak test and charge system 3...

Page 1026: ...ct belt tension 1 Set belt tension Refer to Compressor Belt Tension 2 Clutch loose 2 Tighten clutch 3 Overcharged 3 Discharge evacuate and install correct charge 4 Pulley misaligned 4 Align pulley CON...

Page 1027: ...to lower the boiling point of any moisture in the system to a point lower than the ambient surround ing temperature to ensure that all moisture is boiled off At an ambient temperature of 75 F when the...

Page 1028: ...sure hand control valve on charging station 7 Start vacuum pump and open vacuum control valve note compound gauge reading 8 Operate pump minimum of 30 minutes after reaching lowest vacuum 9 Fill charg...

Page 1029: ...aks as required 6 Evacuate and leak test system after all leaks are corrected 7 Charge system Electronic Leak Detection External leaks are detected and located with the Elec tronic Leak Detector Tool...

Page 1030: ...ecolumn with thepressurehead ing of 70 and rotate shroudso the 70 column aligns with the sight glass 5 When refrigerant reaches desired level in sight glass close both the right hand valve at base of...

Page 1031: ...er ate and help pull refrigerant gas into suction side of system NOTE The refrigerant cans may be placed upright in warm water NO HOTTER THAN 125 F to speed up the charging process 8 When first refrig...

Page 1032: ...of operational check back seat suction and discharge service valves to their normal operating position by turning them fully counter clockwise 6 Disconnect high and low pressure charging hoses from c...

Page 1033: ...properly Loss ofpressure indicates a leaking compressor discharge valve or head gasket COMPRESSOR BELT TENSION For drive belt tension procedure refer to Section 1C ISOLATING THE COMPRESSOR It is not n...

Page 1034: ...lutch Plate Puller J 29636 and remove key from shaft fig 3E 21 4 Using snap ring pliers insert pliers into two holes in felt ring metal retainer and lift out felt ring 5 Remove clutch shims Use O ring...

Page 1035: ...ge and lift seal out fig 3E 24 10 Clean seal cavity thoroughly with lint free or synthetic cloth and clean refrigerant oil and then blow out with clean dry air NOTE Be sure all foreign materials are r...

Page 1036: ...be necessary to lightly tap the snap ring to seat it in its groove 17 Install clutch spacer shims 18 Tap new felt ring into place and install com pressor shaft key 19 Align front plate keyway to compr...

Page 1037: ...ds 30 to 35 N m torque following torque sequence fig 3E 2T CHECKING COMPRESSOR OIL LEVEL When there has been an obvious loss of compressor oil or a component has been replaced the oil must be checked...

Page 1038: ...ment and to correctly locate the lead wire 2 Support compressor by four mounting ears on rear of compressor Do not clamp compressor in vise with jaws on compressor body TOOL J 29637 SHAFT PROTECTOR AN...

Page 1039: ...st Check Compressor Mounting Components Check Engine Components Check for Intermittent or Slipping Gutcn Check for Proper Refrigerant Charge i Check Clutch Bearing t Oil Level Shaft Turning Smoothness...

Page 1040: ...The compressor increases the pressure and temper ature of the system refrigerant The heated refrigerant vapor is then pumped into the condenser where it cools by giving off heat to air passing over th...

Page 1041: ...now iso lated from the remainder of the system Service valves can be removed from compressor COMPRESSOR REMOVAL 1 Isolate compressor 2 Remove both service valves and place protective caps over compre...

Page 1042: ...hten the capscrews in a diagonal pattern to 6 foot pounds 8 N m torque 13 Turn compressor shaft by hand using clutch mounting bolt to seat seal 14 Install clutch and woodruff key 15 Install belt 16 Pu...

Page 1043: ...ot pounds 20 N m torque for attaching screws of flange type valve 14 Purge compressor of air 15 Leak test system Evacuate and charge if necessary BOTTOM PLATE GASKET REPLACEMENT 1 Isolate and remove c...

Page 1044: ...S MAX 1 3 16 1 3 4 AX1 1 8 X MIN7 8 THIS END FOR VERTICALLY MOUNTED COMPRESSORS AJ41503 Rg 3E 35 Oil Dipstick Fabrication Dimensions Indies 7 Install plug and tighten to 4 foot pounds 5 N m torque 8 P...

Page 1045: ...aft at taching bolt and washer 3 Install a 5 8 inch by 11 standard thread bolt in the threaded center of the clutch plate AIR CONDITIONING 3E 33 4 Tighten bolt and pull clutch from shaft CAUTION Do no...

Page 1046: ...nt air temperature as shown in Normal Operating Temp eratures and Pressures Chart BLOWER Check at all speeds System cools and cycles properly System does not cool or cycle System cycles but at Incorre...

Page 1047: ...at and disconnect red wire Turn thermostat on and contact jumper wire to red terminal Disconnect light blue wire at fuse block and connect jumper to terminal Clutch operates Connect jumper to red term...

Page 1048: ...ompressor Seal Plate 6 Compressor Back Plate 13 Compressor Head 15 Compressor Bottom Plate 15 Compressor Oil Filler Plug 4 All Torque values given in foot pounds and newton meters with dry fits unless...

Page 1049: ...23500 01 PORTABLE SERVICE STATION S gLgSSEBBBBQ J 6105 1 4 INCH RATCHET AppwwOel pwiMi J 29635 CLUTCH HOLDER J 5453 GOGGLES J 22974 SHAFT SEAL PROTECTOR J 6272 02 NO 4 MULTI REFRIGERANT CAN OPENER AIR...

Page 1050: ...i i i i i i i i i i i r r i i i t i i i i i C O O Q 5 Q s go CNJ 4...

Page 1051: ...ad noises Periodic inspection is necessary to determine the con dition of body spacers and holddown bolts Worn loose or fatigued spacers permit the body to settle causing body lean or possible interfe...

Page 1052: ...viding maximum resistance to torsional twist and strains In the event of collision damage it is important that the frame alignment be checked and realigned to frame dimensions shown on the individual...

Page 1053: ...B 1740 C 640 D 12 19 E 16 73 BODY AND FRAME COMPONENTS 3F 3 0 i SI 1447 K 3148 Q 13 76 4041 M 4142 R 2740 48 16 C J 7 N 3744 8 49 06 70 02 SCRAMBLER P 949 4340 Ftaj 3F 2 CJ 7 tadSeriwWar NMtJ Fran Wa...

Page 1054: ...MPONENTS A 12 06 0 14 03 M 6943 B 48 M 4646 N 46 76 C 10 60 J 6746 P 2348 D 944 K 24 68 0 4742 E 16 17 L 69 00 R 1748 F 1042 s 4344 T 4648 U 4240 V 1142 W 3 40 X 3442 Rg 3F 3 Ch rokwandWagofli rFnMOlB...

Page 1055: ...1146 D 944 E 1640 F 1246 G 16 78 H 4643 J 6742 K 9840 BODY AND FRAME COMPONENTS 3F 5 L 48 79 M 2348 N 46 72 P 4642 Q 4242 R 3240 S 1749 T 46 76 U 1746 V 1142 60584 Rg 3F4 TnickFnniDtit oiu 119 twfaWb...

Page 1056: ...INE A 11 97 B 5 39 C 11 35 D 9 94 E 15 92 F 12 57 G 16 78 H 45 23 J 56 47 K 9640 TV f ZZ3H I 1 I L 60 79 M 23 38 N 45 72 P 45 92 Q 42 52 R 32 40 S 17 69 T 46 7S U 17 06 V 11 52 Rg 3F 5 Truck Fnma DIbu...

Page 1057: ...nversion coating must be applied to these panels prior to painting to ensure good adhesion of the paint BODY AND FRAME COMPONENTS 3F 7 the vehicle halfway between the marks indicating front and rear w...

Page 1058: ...the baffle are welded together to form a maximum strength radi ator grille guard fig 3F 10 Removal 1 Remove front crossmember cover if equipped 2 Remove screws and washers attaching radiator and shro...

Page 1059: ...MBLER MODELS General The chrome grille applique is installed over the grille assembly requiring the use of well nuts and screws as BODY AND FRAME COMPONENTS 3F 9 well as using the headlight and parkin...

Page 1060: ...Paga Fender Extensions CJ and Scrambler Models 3F 11 Rear Fenders Sport Truck 3P 11 CJ AND SCRAMBLER MODELS Replacement 1 Remove or disconnect all items attached to apron of fender 2 Disconnect electr...

Page 1061: ...hed fender apron 11 Remove bolts and washers attaching fender apron to radiator support and two brackets on dash panel BODY AND FRAME COMPONENTS 3F 11 Installation 1 Spread sealer evenly over and alon...

Page 1062: ...e 3F 15 BV mirnr tm 1 8 INCH Wr HOLE 5 a 1 E fl 1 L Hifa jJbE Ls j fcj 81 004 A Fig 3F 15 Stop Drilling Cracks 3 Bevel edges of crack s using rotary file NOTE Edges should be beveled to ensure suffici...

Page 1063: ...r area 12 Use an air file or hand file board for shaping hardened Structural Adhesive a For initial shaping use grade 24 paper b For shaping and sanding contour in Struc tural Adhesive use grade 220 p...

Page 1064: ...RAIL 3 Remove horizontal bumper guards from bumper rail if equipped 4 Remove front air deflector fig 3F 19 if equipped 5 Remove nuts and bolts attaching bumper rail to frame mounted bumper brackets Re...

Page 1065: ...8 inch holes at marked locations 8 Position vertical bumper guards on bumper rail and install screws attaching bumper guards to bumper rail NOTE SomefiUng ofholes may be required for proper fit 9 Inst...

Page 1066: ...at desired locations and mark hole location on bumper rail 7 Center punch and drill 3 8 inch holes at marked locations 8 Position vertical bumper guards on bumper rail and install screws attaching bum...

Page 1067: ...install attaching pin 2 Position hinge spacer washers and carrier in upper and lower hinges and latch handle in latch bracket 3 Install hinge pin bolts and nuts in upper and lower hinges 4 Install sp...

Page 1068: ...ghten all attach ing hardware using Torx Bit Tool J 25359 C 4 Install left front seat assembly 5 Install carpeting if removed 6 Install hardtop or soft top if equipped SCRAMBLER MODELS Fife Sport Tric...

Page 1069: ...MPONENTS 3F 19 SPORT TRUCK Removal 1 Remove GB radio antenna from roll bar if equipped 2 Remove wooden side rails if equipped 3 Remove nuts washers and bolts attaching roll bar to bed of pickup box us...

Page 1070: ...MODELS GENERAL A soft top with metal doors is available on the CJ 7 and Scrambler models This option offers the conven ience of a soft top with the security of metal doors The adjustment of the doors...

Page 1071: ...to the body side panels for added security Removal 1 Open storage compartment and remove attach ing screws and washers shown in figure 3F 31 2 Remove storage compartment assembly 3 Remove rubber washe...

Page 1072: ...SPORT TRUCK MODEL GENERAL Wooden side rails are available for the Scrambler models equipped with a roll bar The rails are attached to the roll bar in front and the body side panel in back fig 3F 32 Wo...

Page 1073: ...ox BODY AND FRAME COMPONENTS 3F 23 2 Disengage side rails from roll bar bracket 3 Remove side rail assemblies 4 Remove front rail assembly Installation 1 Position front rail assembly in pickup box sta...

Page 1074: ...NOTES...

Page 1075: ...ood panel 2 Position hood panel assembly and align hinges with scribe marks on the respective mounting panels Tighten all attaching screws 3 Check hood alignment Adjust if necessary Alignment The hood...

Page 1076: ...to hood panel 2 If Cherokee or Wagoneer hood panel insulation pad has been removed clean off all loose cement and pad particles from panel to ensure good adhesion when recemented 3 Position hood pane...

Page 1077: ...k The hood lock assembly incorporates two locks and two strikers A safety catch is incorporated in the hood lock A cable controlled inside hood lock release is standard on all models It is located to...

Page 1078: ...3G 4 HOODS ft ftft Tools J 25359 C TORX BIT AND SOCKET SET...

Page 1079: ...phite brakefluid or wax on rubber sealer Replacement Replacement rubber sealers are coated with powder to prevent stickiness in storage Remove all powder with a cloth dampened with 3M General Purpose...

Page 1080: ...ty NOTE The ends of the cord should hang out over the outside surface ofthe glass approximately in the center ofthe upper weatherstrip 8 Place glass and weatherstrip into position in window opening wi...

Page 1081: ...IFTGATES TAILGATES 3H 3 HIN6E SYSTEM 1 Openliftgate supportto preventclosing 2 Remove screws attaching supports to liftgate and fold supports downward WARNING Never remove supports with liftgate close...

Page 1082: ...otate tailgate approximately 45 degrees from full up position and disengage right hinge 2 Rotate tailgate an additional few degrees and then disengage left hinge INSTALLATION 1 Hold tailgate at approx...

Page 1083: ...cess hole in the inner panel is for installing and servicing the window regulator and latch assemblies fig 3H 2 The torque rods serve to counterbalance and assist in opening as well as closing the tai...

Page 1084: ...UE ROD 28 COVER GASKET 29 ACCESS COVER 30 TAPPING SCREW 31 TAPPING SCREW 32 COVER PLATE 33 COVER PLATE 34 HINGE SCREW 35 BODY HALF HINGE 36 HINGE PIN 37 TAILGATE HALF HINGE 38 PLASTIC RIVET 39 DUST SE...

Page 1085: ...cargo area floor covering and mouldings TAILGATE Removal 1 Remove carpeting from tailgate if equipped LIFTGATES TAILGATES 3H 7 2 Remove tailgate access cover and disconnect wiring 3 Remove carpeting i...

Page 1086: ...ay sealer along complete bottom length of glass keeping sealer centered over edge of glass NOTE Do not wrap sealer around the bottom edge of the glass at this time 12 Remove second release paper from...

Page 1087: ...2 Using 12 vdc test lamp connect one end of test lamp to ground and place probe to red No 53 wire of switch If lamp lights voltage is present at switch If lamp does not light repair problem in feed c...

Page 1088: ...CK 18 JROUND INSTRUMENT PANEL TAILGATE WINDOW SWITCH 9G BLACK 18 47 BROWN 14 47 BROWN 14 48 TAN 14 9G BLACK GROUND 48 TAN UP 47 BROWN DOWN 46 RED W TR HOT 48B TAN 12 TAILGATE SWITCH 3 48 TAN 12 47 BRO...

Page 1089: ...is in the open position to avoid possible damage to glass channels and regulator Circuit Brokers The electric tailgate regulator motor and wiring har ness are protected by two 30 ampere circuit breake...

Page 1090: ...ng harness to motor 5 Position channel over regulator arm pins and install replacement retainers 6 Install access cover plate 7 Install carpet if equipped Motor Removtl 1 Remove tailgate window regula...

Page 1091: ...a notch and the two flat surfaces allow the tailgate to be removed quickly from the tailgate opening To remove open and lower the tailgate Remove the side supports and then raise the tailgate to about...

Page 1092: ...3H 14 LIFTGATES TAILGATES ft Tools J 25359 C TORX BIT AND SOCKET SET J 21008 CONTINUITY LAMP I...

Page 1093: ...x Bit Tool J 25359 C 2 Remove handle from door Installation 1 Position handle on door 2 Install attaching screws using Torx Bit Tool J 25359 C Trim Panel Trim panels consist of fiber board composition...

Page 1094: ...ble which regulates the amount of effort required to raise and lower the door glass The door glass division channel is adjustable fore and aft at the lower attachment point 1 Remove door trim panel an...

Page 1095: ...LOWER HINQE VENT GLASS HANDLE GLASS SLIDE CHANNEL Fig 3J 1 Front Door Exploded view CJ and Scrambler Models DOORS 3J 3 GASKET 9 LOCK TO CYLINDER 81170...

Page 1096: ...re move lock cylinder and gasket Installation 1 Install gasket and lockcylinder in door 2 Install lock cylinder spring retainer and install lock to cylinder rod and clip 3 Install door latch cover an...

Page 1097: ...stall screws using Torx Bit Tool J 25359 C 8 Check door alignment Adjust if necessary Re fer to Door Adjustment CHEROKEE WAGONEER TRUCK FRONT DOORS DOOR TRIM Door Trim Hinge System Lock System Page 3J...

Page 1098: ...Sealer The door rubber sealer is made of molded latex foam with a smooth rubber skin on the outside The door rubber sealer is attached to the body opening around the door opening Maintenance of Rubbe...

Page 1099: ...lass in rear channel and position front channel so glass can be inserted 3 Slide glass up channels and crank regulator arm down to align pin at end of regulator arm with slot in bottom channel 4 Insta...

Page 1100: ...skets Installation 1 Position gaskets and handle on door and secure with attaching screws 2 Install water shield and door trim panel Key Lock Removal 1 Remove rubber sealer along rear edge of door by...

Page 1101: ...ide lock assembly 5 Install water shield and door trim panel Locking Rod Removal 1 Remove door trim panel and water shield 2 Remove door lock push knob 3 Push nylon bushing on rod off bracket 4 Loosen...

Page 1102: ...on 1 Position gasket and mirrorondoor panel 2 Installscrews attachingmirrortodoor panel Remote Control Mirrors Removal 1 Remove door trim panel 2 Remove setscrew attaching mirror remote con trol assem...

Page 1103: ...ted before checking for current NOTE Before replacing the right side mirror check for current input at the motor LEFT MIRROR R L U O COMMON YELLOW HORIZONTAL DOORS 3J 11 Switch Removal 1 Remove door t...

Page 1104: ...15 3J 15 DOOR TRIM Window Regulator Handle Window Regulator handles are attached to the splined shaft of the window regulator with a 5 32 inch Allen head screw To remove the handle remove the screw a...

Page 1105: ...prevent stickiness in storage Before installation re move all powder with a cloth dampened with 3M Gen eral Purpose Adhesive Cleaner or equivalent 1 Carefully remove rubber sealer from door opening DO...

Page 1106: ...m bly from upper door frame 5 Lower top of vent assembly down to clear upper door frame 6 Pull vent assembly straight up until weather seals are clear of door panel and vent assembly can be rotated 7...

Page 1107: ...ol J 25359 C 6 Disconnect remote control arm and turn latch 90 7 Remove lock lever rod and bellcrank fig 3J 5 Installation 1 Position latch in door and install lock lever rod and bellcrank 2 Connect r...

Page 1108: ...or motors fig 3J 6 are of a two wire design using polarity of the circuit to change motor rotation An individual control switch is provided for each side window and is mounted in the door trim panel A...

Page 1109: ...ness to that window and back again to master switch are not defective It also indicates that individual door switch on master control is not defective 3 Disconnect white and green motor leads at ter...

Page 1110: ...position 5 Remove regulator arm retainer clip and remove arm from bottom window channel 6 Disconnect wires from motor 7 Remove nuts and bolts from inner door panel to regulator and remove regulator an...

Page 1111: ...st battery to either terminal 2 Connect negative lead from test battery to remaining motor terminal 3 Motor should now rotate in one direction to either move window up or down a If window happens to a...

Page 1112: ...battery voltage is pre sent remove circuit breaker and test with ohmmeter If circuit breaker is OK then check for battery voltage at circuit breaker connection on fuse panel If no battery voltage at...

Page 1113: ...tuator motor 6 Connect wires to actuator motor and connect rod to actuator 7 Install actuator in door panel using two 1 4 20 x 1 2 inch screws and locknuts or rivets and connect bell crank rod to bell...

Page 1114: ...NOTES l...

Page 1115: ...ive force on clips 2 Install trim panel attaching screws if equipped 3 Install armrest and armrest metal overlay strip if equipped 4 Install ash receiver holder and ash receiver if equipped PIVOT VENT...

Page 1116: ...erstrip into posi tion in window opening 8 With weatherstrip body flange in proper posi tion at bottom of window opening use wooden wand and walk weatherstrip to body flange into position 9 Clean exce...

Page 1117: ...3K 3 in glass cavity completely around weatherstrip using pressure type applicator fig 3K 2 2 With glass installed in weatherstrip and before installing glass and weatherstrip into opening insert a 1...

Page 1118: ...I I i I I i i I i t l l f l I I l f f I f f I i i w 2 CO 9E 5h UJ woo H w s EC Si t a ui nSSF cd a C J CCUJ ihQ...

Page 1119: ...enclosure for damage Replace if necessary 2 Carefully position hardtop enclosure on vehicle CAUTION When installing the hardtop enclosure avoid damaging foam sealer installed between the hard top encl...

Page 1120: ...ith plastic spreader use firm pres sure to remove air bubbles Allow resin to cure 9 Remove aluminum foil from cured resin 10 Use air file or hand file board for shaping cured fiberglass resin a Use gr...

Page 1121: ...ure to ensure sufficient surface areafor bonding 3 Clamp broken piece into place leaving 1 16 inch gap along break line 4 Mix Structural Adhesive according to manufac turer s instructions apply libera...

Page 1122: ...1 8 inch drill bit as shown in figure 3L 5 60825 Fig 3L 5 Stop Drilling Cracks 3 Bevel edges of crack s on both sides using rotary file NOTE Edges should be beveled on the inside and out side of the...

Page 1123: ...de 180 disc on a dual action sander or 220 grade paper on hand sanding block 3 Mix base coat same as any acrylic enamel paint using enamel reducer or lacquer thinner NOTE One paint repair kit is suffi...

Page 1124: ...he glass in storage compartment CLAMP RING COVER 90190A Rg 3L 9 Sun Root Component CJ Models with Htrdtop CJ MODELS Page Geoiral 3L 6 Sun Roof Glass The bayonets and handle assembly are retained by sc...

Page 1125: ...rseal Removal 1 Remove glass assembly 2 Apply 3M Release Agent or equivalent to weatherseal and allow several minutes for penetration 3 Apply second application and allow several min utes for adhesive...

Page 1126: ...ounding the roof open ing The forward hoses are routed downward through the A pillars The rearward hoses are routed downward through the D pillars HALO ASSEMBLY Removal 1 Open glass panel partially an...

Page 1127: ...TOR HARDTOP ENCLOSURE SUN ROOF AND LUGGAGE RACKS 3L 9 FRONT GUIDE SHOE REAR SLIDE TENSION SPRING SUNSCREEN DRIVE GEAR PLATE SEAL TRACK RETAINER SUNROOF CONTROL SWITCH AUXILIARY CRANK TOOL Fig 3L 11 Po...

Page 1128: ...o and Roar Tension Spring SUNSCREEN Removal 1 Remove halo assembly and glass panel Refer to Halo Assembly Removal and Glass Panel Removal procedures 2 Open sunscreen fully 3 Working from outside of ve...

Page 1129: ...fig 3L 11 6 Remove housing attaching nuts 7 Remove shims if equipped 8 Support housing and remove housing attaching hardware from brackets 9 Lower housing assembly away from reinforce ment ring and r...

Page 1130: ...inyl cover into crease line areas around roof using smooth fiber stick 15 Trim excess cover material from around drip rails windshield and rear window 16 Trim vinyl material around sun roof opening an...

Page 1131: ...e lease agent penetration CAUTION When removing the headlining use care to avoid separating the foam backingfrom the fabric If the fabric begins to separate from the backing make a second application...

Page 1132: ...eight adjustment fig 3L 17 4 Tighten front guide shoe attaching screws to 20 inch pounds 2 3 N m torque after adjusting panel height CAUTION Do not adjust the glass panel too high as it could be damag...

Page 1133: ...surface thoroughly using AMC Vinyl Cleaner or equivalent 2 Set heat control of household type flat iron to warm 3 Dampen a clean cloth with clean water and ap ply it over wrinkled area 4 With iron at...

Page 1134: ...orts and gaskets on roof 4 Coat screw threads with 3M Drip Check Sealer or equivalent and install screws Tighten screws to 28 inch pounds 3 N m torque 5 Install screws attaching end supports to side r...

Page 1135: ...P ENCLOSURE SUN ROOF AND LUGGAGE RACKS 3L 17 Installation CAUTION Exercise care not to damage painted or vinyl surfaces 1 Position roof slat on roof panel 2 Install screws attaching roof slat to roof...

Page 1136: ...fw NOTES F m i fw W a fww Z ritS frryffh fw fi xvifii tEw l w fm l i 5w O Jg t I fw tm 5 S iSBSA...

Page 1137: ...t back release The fore and aft seat adjuster mechanism for Chero kee Wagoneer Truck models and left front CJ and Scrambler seats has a turnbuckle to allow for slight dimensional variances during prod...

Page 1138: ...3M 2 SEAT ASSEMBLIES FOLDING SUPPORT SEAT Rg 3M 1 Backet Setts CJand Scrambler Models SEAT SLIDE 70506...

Page 1139: ...3 Remove screws attaching plastic bumpers using Torx Bit Tool J 25359 C and remove bumpers 4 Unzip upholstery and pull back 5 Remove spring retainers attaching latching rod fig 3M 2 6 Remove rod pawl...

Page 1140: ...ole in floorpan and in stall attaching screws 3 Close and latch console cover Console CoverSeal The console cover seal is attached to the console The foam seal may be replaced after opening the cover...

Page 1141: ...at assembly in vehicle 2 Install bolts attaching rear seat assembly to floorpan Seat Belts 3M 6 CHEROKEE WAGONEER SEATS The full width rear seat is attached to the floorpan by two hinges to allow the...

Page 1142: ...Torx Bit Tool J 25359 C 2 Remove seat belt 3 Obtain access to seat belt retractors by remov ing rear seat striker fig 3M 7 using Torx Bit Tool J 25359 C 4 Remove seat belt retractor 5 Inspect seat be...

Page 1143: ...ig 3M 10 and either light blue or orange connection in front sec tion Connect second covered jumper wire between black SEAT ASSEMBLIES 3M 7 terminal in center section and open connection in front sect...

Page 1144: ...ts back on clean surface 3 Remove motor mounting screws fig 3M 11 4 Carefully disconnect housings and cables from motor assembly Installation 1 Place motor assembly into position 2 Carefully connect c...

Page 1145: ...install the above items also When replacing the front floor carpet position the carpet in the vehicle and cut the openings in the carpet using a sharp knife or razor blade for such things as the floor...

Page 1146: ...NOTES...

Page 1147: ...ield glass In this case the mirror is simply transferred from the damaged windshield to the bracket on the replacement windshield If the replacement windshield does not have a bonded mirror bracketor...

Page 1148: ...lying glass and rubber cleaners and primers e Glass blackout primer f Rubber primer g Paint finish primer h Glass cleaner i Rubber cleaner 2 One six ounce hand operated Adhesive Gun J 24811 or equival...

Page 1149: ...oval 1 Cover adjoining painted surfaces to protect finish 2 Remove windshield wiper arms using wide blade screwdriver 3 On vehicles with stainless steel mouldings per form the following steps a Remove...

Page 1150: ...uding edge of glass 3 Using clean dauber apply 1 2 inch band of glass blackout primer around entire outside of glass and outer edge Allow primer to dry for 10 minutes CAUTION Use care not to spill or...

Page 1151: ...ly tapping top of moulding with rubber mallet This will lock moulding in weatherstrip retaining groove Continue process until moulding is installed in weatherstrip Repeat process with other bot tom mo...

Page 1152: ...dels 3N 6 Specifications 3N 6 m CJ 7 Witt Hardtop Endoscra and Charokaa Waionear Models 3N 6 Benersl 3N 6 6ENERAL The rear window is a one piece tempered glass The overall size of the glass varies wit...

Page 1153: ...A 0 is J 24811 DISPENSING GUN Tools J 25359 C TORX BIT AND SOCKET SET WINDSHIELD REAR WINDOW 3N 7 J 24709 01 HOT KNIFE ft J 24851 PLOW TYPE BLADE...

Page 1154: ...NOTES m twn OH...

Page 1155: ...retainer screws 5 Manuever headlining out of front and rear mouldings and remove headlining Installation 1 Position headlining into front and rear mouldings 2 Install retaining screws on right and le...

Page 1156: ...crews using Torx mK Bit J 25359 C s 3 Insert screwdriver through hole in roof bow and raise roof bow against roof panel 4 Tighten roof bow attaching screws using Torx tm BitJ 25359 C 5 Install headlin...

Page 1157: ...dge razor blade or X acto knife Scissors Sharp needle or pin Grease pencil Removal 1 Clean repair surfaces adjacent panels and open ings as required 2 Remove decal overlapping parts from affected pane...

Page 1158: ...Residua 12 Remove masking tape and paper 13 Wash entire panel with 3M General Purpose AdhesiveCleaner orequivalent If anyspotsof adhesive remain on panel hard rubbing during the washdown will remove...

Page 1159: ...NOT USE SOAP 2 Place the decal on clean flat surface with paper backing side up Bend corner of decal toward the decora tive face side and with flick of finger separate pape backing from decal Hold de...

Page 1160: ...equivalent Isopropyl alcohol rubbing alcohol Squeegee 4 to 5 inches wide plastic or hard rubber Water bucket and sponge Sandpaper No 220 360 or No 400 wet or dry type Heat Gun J 25070 or infrared hea...

Page 1161: ...2 Peeling Overlay from Panel 1 70514 Fig 3P 11 Spraying Remover on Overlay 70515 HEADLINING EXTERIOR DECALS AND OVERLAYS 3P 7 70516 Fig 3P 13 Using Squeegee toAssist In Removal of Overlay CAUTION Leav...

Page 1162: ...t lifted end squeegee progressively from middle with firm overlapping strokes b Lift upper area of overlay up to bonded area and working upward from bonded section at cen ter squeegee overlay into pla...

Page 1163: ...osition moulding on vehicle with backing tape attached and cut to fit HEADLINING EXTERIOR DECALS AND OVERLAYS 6 Peel away backing tape and press moulc panel with roller or heavy hand pressure paralle...

Page 1164: ...NOTES...

Page 1165: ...Engine Compartment Lamp Fog Lamps General Page 3R 5 3R 6 3R 6 3R 11 3R 9 3R 1 Headlamps License Plata Lamp Parking Side Marker and DIractlonal Lamps Rear DIractlonal Side Marker Stop and Taillamps Sto...

Page 1166: ...distance from center of each lamp to surface on which vehicle rests 10 Position marker tape horizontally on screen to cross vertical tapes at measured height of each lamp center respectively 11 Remov...

Page 1167: ...Marker Bulbs 1 Reach under fender and twist socket a quarter turn counterclockwise to remove from housing 2 Replace bulb Cherokee Wagoneer Truck Models The parking lamps are mounted in the panel just...

Page 1168: ...anel is attached with expandable clips Use care in prying these clips out of their recesses so panel is not bent or damaged 2 Disconnect taillamp harness 3 Remove two attaching nuts and push housing o...

Page 1169: ...t The lamp is removed by removing the lamp attaching screws and disconnecting the wire harness Truck with Tewaalde Pickup Box The license plate lamp is attached to the rear frame crossmember Bulb repl...

Page 1170: ...Chtrokaa CARGO LAMP A cargo lamp is offered on some Truck models fig 3R 11 The cargo lamp bulb is replaced by removing the outer lens DIRECTIONAL SIGNAL SWITCH The most frequent causes of failure in t...

Page 1171: ...n position and remove lever 11 Depress hazard warning light switch located on right side of column adjacent to the key lock and re move button by turning in a counterclockwise direction 12 Remove dire...

Page 1172: ...in position with directional signal canceling cam shaft protruding through dogleg opening in lock plate 5 Install snap ring 6 Install lock plate cover 7 Install steering wheel Align mark on steering...

Page 1173: ...mp switch is self adjusting and is the same for all models The switch is retained in its mounting bracket by a spring clip which engages the threaded portion of the switch housing fig 3R 14 The switch...

Page 1174: ...ampswitches 6 Install lamp stone shields Lamp Element Raplacamrat 1 Remove lampstoneshields fig 3R 16 2 Remove screws attaching bezel to lamp body Remove bezel from lamp body 3 Remove lens and reflect...

Page 1175: ...CJ and Scrambler Models CJ and Scrambler models equipped with the hardtop have a dome lamp located above the liftgate When removing the hardtop disconnect the wire connector located on the left C pill...

Page 1176: ...mounted at each end of the vanity mirror The lamp switch is located on the right side of the mirror assembly DOME READING LAMP Cherokee Wagoneer Models The dome reading lamp replaces the standard dom...

Page 1177: ...er bolt from the engine compartment side and the two attaching screws from the driver s side Be careful not to bend the male spade terminals when removing or installing the connector The center of the...

Page 1178: ...be tested and use either an ohmmeter or Continuity Light J 21008 Ignition switch slide bar positions can be easily identi fied by first locating the alignment hole located in the flat portion of the s...

Page 1179: ...witch as shown in figure 3R 25 2 Move slider to extreme right Accessory position NOTE The right side of the ignition switch is down ward from the steering wheel 3 Position actuator rod in slider hole...

Page 1180: ...amp circuit breaker located in the headlamp switch REAR VIEW T3 XT FRONT VIEW 902O Ff 3B 27 Fna PtMi Breiltrf ui Fm AppHnttM CNrakN Wt MNr TnKk IbfcU The tailgatewindow circuits are protected by two...

Page 1181: ...Directional Signal Switch Handle 25 3 Hazard Warning Knob Mounting Screws 5 0 5 AllTorque values given in inch pounds and newton meters with dry fits unless otherwise specified Tools llj J 23653 LOCK...

Page 1182: ...NOTES si iff...

Page 1183: ...gi 3S 1 3S 2 When a grounded circuit or overload occurs in th horn circuit damage will be limited to the fusible link HORN SYSTEM DIAGNOSIS AND REPAIR In case of horn system failure proceed as follows...

Page 1184: ...Turn only 1 10 of a turn at one time 1 Check for normal battery voltage about 12 6 volts 2 Connect ammeter in series between horn and battery and read current as shown in figure 3S 2 3 Adjust current...

Page 1185: ...l de Replacement 3T 1 m mm All CJ and Scrambler models are equipped with a two apeed electric wiper motor The motor is mounted on the lower left corner of the windshield fig 3T 1 WIPER BLADE REPLACEME...

Page 1186: ...2 Connect wiper motor drive link to left wiper pivot 3 Install right and left access hole covers 4 Raise windshield to upright position and install right and left windshield holddown knobs 5 Install n...

Page 1187: ...ot operate in low speed there is an o the green wire a defective internal motor connect a stuck low speed brush To obtain high speed connect a jumper wire be terminals 3 and B If wiper motor fails to...

Page 1188: ...irm surface with notched end of blade element backing strip as shown in figure 3T 6 2 Pull up and twist counterclockwise plastic back ing strip unlocking backing strip from retaining tab 3 Slide backi...

Page 1189: ...3T 8 2 Disconnect drive arm from motor crank 3 Remove individual links where necessary to re move pivot shaft bodies without excessive interference Installation without Air Conditioning 1 Install wipe...

Page 1190: ...gain access to right linkage clip and remove clip 7 Remove screws attaching left pivot shaft body 8 Remove left pivot shaft body and linkage assem bly through instrument cluster opening Installation w...

Page 1191: ...ONE SPEED ONLY BOTH SPEEDS CHECK FOR FOREIGN OBJECT INTERFERING WITH LINKAGE SYSTEM IS FREE NO LIGHT NO CONTINUITY OF CIRCUITRY TO THE WIPER MOTOR CHECK IGNITION SWITCH WIPER SWITCH HARNESS AND TERMI...

Page 1192: ...D LEAD NO PARK WITH IGNITION SWITCH ON AND WIPER SWITCH AT OFF PARK SETTING DO THE FOLLOWING AT THE WIRING HARNESS PLUG THAT CONNECTS TO MOTOR CONNECT A TEST LIGHT BETWEEN GROUND AND PINK W TR LEAD CH...

Page 1193: ...TOP STALLED MOTOR l u n u u i i o n c m i s c n u r c n o 1 T CLEAN GLASS AND OR REPLACE WIPER BLADES TEST CIRCUIT BREAKER REPEAT 5 CYCLE TEST STILL STOPS DURING TEST i STILL STOPS DURING TEST t REPLA...

Page 1194: ...TOP AND START IN MIDDLE OF CYCLE ERATICALLY NO TEST CIRCUIT BREAKER CHECK CONTINUITY OF WIPER SWITCH NOT OK OK REPLACE SWITCH CHECK CONTINUITY OF WIRING BETWEEN SWITCH GOVERNOR AND GROUND NOT OK OK RE...

Page 1195: ...ENT OR LOW SPEED WIPE CHECK CONTINUITY OF WIPER SWITCH NOT OK OK REPLACE WIPER SWITCH CHECK CONTINUITY OF WIRING BETWEEN SWITCH GOVERNOR WIPER MOTOR AND GROUND NOT OK REPAIR WIRING AS NECESSARY WIPER...

Page 1196: ...HOSE CHECK FOR DIRT OR ICE IN JET OPENINGS OK NOT OK REPLACE FUSE LIGHT ON RECONNECT PLUG IN TO MOTOR AND CHECK FOR TIGHT CONNECTION MOTOR DOES NOT RUN REPLACE WINDSHIELD WASHER PUMP ASSEMBLY OK DISCO...

Page 1197: ...ED W TR NOTE WIPER SWITCH OPERATES TWO SETS OF CONTACTS SIMULTANEOUSLY SWITCH POSITIONS WIPER MOTOR P OFF L LOW H HIGH NOTE IN RUN MODE MOTOR SWITCH CONTACTS MOVE TO INTERMITTENT PARK POSITION ONCE EV...

Page 1198: ...l SL VI 5 VI _VL V V SWITCH POSITIONS P OFF I INTERM L LOW H HIGH GROUND THROUGH INSTRUMENT PANEL INTERMITTENT GOVERNOR NOTE IN RUN MODE MOTOR SWITCH CONTACTS MOVE TO INTERMITTENT PARK POSITION ONCE E...

Page 1199: ...e is not operating but system does operate at both low and high speed resistance between number 4 and 5 terminals should be checked With switch control knob rotated to full counterclockwise position o...

Page 1200: ...aching motor adapter plate to dash panel 2 Separate wiper wiring harness connector at motor 3 Pull motor and linkage out of opening to expose drive link to crank stud retaining clip Raise up lock tab...

Page 1201: ...nd seal from gear housing 7 Remove brushes harness and springs from end head 8 Remove end head assembly 9 Remove parking lever pin from gear housing 10 Remove all old lubricant from gear housing and c...

Page 1202: ...S AND HARNESS 32 SEAL 41532 Rg 3T 17 Wlior Motor aid TruMlssJon Coapoioits 12 Install motor housing on armature holding ar mature worm gear to prevent magnetic field from pull ing armature out of posi...

Page 1203: ...case is grounded to the car body by a ground wire It is ener gized by a feed wire from the number 6 and 7 terminals on the control switch SPECIFICATIONS Torque Specifications Service Sot To Torques s...

Page 1204: ...NOTES f at...

Page 1205: ...lay and wire harness complete the circuit JZ3 Q INDEX Tilting Pigi 3U 2 Braided wire soldered to each bus bar at 2 1 2 inch intervals serves as the electrical feed and ground for the grid The grid fee...

Page 1206: ...period is too short or excessively long relay is defective 4 If relay did not energize connect jumper wire to known good 12 volt source in tailgate and probe relay P terminal If relay clicks when prob...

Page 1207: ...r particles mixedthroughout fluid Applycoat ing to break in grid with small brush furnished in kit Apply heavy coat of mixture extending approximately 1 4 inch on either side of break 5 Start engine a...

Page 1208: ...NOTES...

Page 1209: ...l AM FM stereo with cassette tape player above the manual station tuning knob Page General 3V 1 Premium Audio System 3V 5 Radio Interference Diagnosis 3V 9 Radio Replacement 3V 12 Speakers 3V 15 Speci...

Page 1210: ...ning the ring behind the manual sta tion tuning knob Pushbuttons To set the pushbuttons pull out on one button select a station with the manual station tuner and push in on the pushbutton to lock in t...

Page 1211: ...as follows Volume Control This knob controls On Off and volume Bass Treble Control This inner ring on the volume control adjusts the base or treble tone Manual Station Tuning Turning this knob selects...

Page 1212: ...nuts and radio bezel if equipped with CB radio 3 Remove instrument panel center housing at taching screws Remove housing 4 Disconnect wires from fader switch and lamp NOTE Disconnect the rear defogge...

Page 1213: ...control CHANNEL SELECTOR KNOB RADIO FUNCTION CONTROL S POWER METER ON I OFF VOLUME S TONE TREBLE BASS PUSH X TURN LEFT RIGHT BALANCE CHANNEL INDICATOR FADER 80239A FIg 3V 6 AM FM CB Radio CB Controls...

Page 1214: ...r left right volume balance Treble Bass Control Turn left right for treble con trol and push and turn for bass control Manual Tuning Control Trim to change radio fre quency When turned to the maximum...

Page 1215: ...slide the control to the center position Sliding the control to the left until it latches engages the fast forward mode When the end of the tape is reached the control returns to the center position...

Page 1216: ...bances that can affect an AM receiver Ignition noise is more prevalent when lis tening to weaker stations Noise also occurs if the radio is tuned off station slightly To improvereception make sure the...

Page 1217: ...re the noise source is a useful noise probe can be improvised from an antenna lead in cable To make the probe cut or remove the lead in from the antenna at the antenna remove approximately 2 inche of...

Page 1218: ...ace the entire cable If the noise in question sounds like one or two cylin ders and definitely not all of them then the problem is after the coil Using the fabricated noise probe which plugs into the...

Page 1219: ...0 001 mfd thumbnail type capacitor across each speaker 3 Remove ground wire from harness and ground each rear speaker at the rear of vehicle Speaker induced noise will normally not occur on front mou...

Page 1220: ...for Amserv AMX 386S Mobile CB Tester NOTES CAUTION Do not key microphone without antenna connected or antenna button in int posi tion if antenna is not connected RADIO UNDER TEST CONTROL SETTINGS Squ...

Page 1221: ...t through glove box opening 9 Install radio in instrument panel 10 Install radio attaching nuts and control knobs 11 Connect rear support bracket 12 Connect feed wire to fuse panel 13 Connect speaker...

Page 1222: ...should be closed 1 Disconnect coaxial cable at inline connection near splitterbox 2 Connect transmitter end of coaxial cable to a jumper coaxial cable NOTE Jumper should not exceed 18 inches 3 Connect...

Page 1223: ...V 15 Use a light to check the speaker openings If the entire speaker is not visible through the speaker grille openings remove the obstruction as follows Front Door Speakers 1 Remove door trim panel l...

Page 1224: ...er side speaker Cherokee Wagoneer Truck Models The AM speaker is located above the radio To remove the speaker remove the radio then remove the four attaching nuts from the speaker mounting studs On v...

Page 1225: ...pv ALPHABETICAL INDEX...

Page 1226: ...rambler 3E 2 Air conditioning discharging system 3E 15 Air conditioning evacuating system 3E 15 ALPHABETICAL INDEX Air conditioning evaporator housing assembly CJ and Scrambler 3E 3 Air conditioning e...

Page 1227: ...ulic system four cylinder 2A 14 Block eight cylinder 1B 97 Block four cylinder 1B 25 Block six cylinder 1B 60 Blower motor heater Cherokee Wagoneer Truck 3D 9 Blower motor heater CJ and Scrambler 3D 4...

Page 1228: ...Chassis wiringharness lightingsystems 3R 13 Chassiswiring harness specifications 3R 17 ALPHABETICAL INDEX Chatter Trac Lok 2F 2 Checking compressor oil level eight cylinder engine 3E 31 Checking compr...

Page 1229: ...ol panel air conditioning CJ and Scrambler 3E 2 Control panel heater Cherokee Wagoneer Truck 3D 7 Controls heater system CJandScrambler 3D 1 Controls radio 3V 2 Control switch cruise command 1H 10 Con...

Page 1230: ...and test procedures automatic transmission 2C 11 Diagnosis Trac Lok 2F 41 ALPHABETICAL INDEX Diagnosis trouble battery 1D 6 Diagnostic procedures for CEC system feedback 1J 111 Diagnostic procedures f...

Page 1231: ...hedule B 3 Engine mounting six cylinder 1B 29 Engine removal six cylinder 1B 30 Engine replacement four cylinder 1B 1 Engine service diagnosis mechanical 1A 4 Engine service diagnosis performance 1A 7...

Page 1232: ...Four cylinder engine starter motor overhaul 1F 5 Four cylinder engine starter motor replacement 1F 5 Four cylinder engine starter motor relay replacement 1F 5 Four cylinder engine starter motor servic...

Page 1233: ...liner water off 3A 5 Headlining 3P 1 Headlining Cherokee Wagoneer 3P 1 Headlining CJ 7 Limited 3P 2 Headlining exterior decais and overlays 3P 1 Headlining power sun roof 3L 12 Heat valve exhaust mani...

Page 1234: ...r 1L 5 Instrument duster Cherokee Wagoneer Truck instrument panel 3C 5 Instrument cluster CJ instrument panel 3C 1 Instrument duster lamps interior lighting system 3R 13 Instrumentation diagnosis 1L 3...

Page 1235: ...racks exterior wind noises 3A 11 M Magnetic clutch air conditioning eight cylinder engine 3E 32 Magnetic clutch six cylinder engine air conditioning 3E 25 Mainbearings four cylinder 1B 22 Maintenance...

Page 1236: ...kee Wagoneer Truck 2A 20 ALPHABETICAL INDEX Overhaul automatic transmission subassembly 2C 36 Overhaul starter motor six and eight cylinder engines 1F 21 Overlays exterior wood grain 3P 6 Paint option...

Page 1237: ...chart A 13 Preliminary diagnosis automatic transmission 2C 11 Premium audio system 3V 4 Pressure gauge and manifold assembly air conditioning 3E 11 Pressure test diagnosis automatic transmission hydr...

Page 1238: ...system CJ 7 liftgates 3H 1 Staling system CJ 7 and Scrambler hardtop endosure 3J 1 Seat assemblies 3M 1 Seat belts front 3M 4 Seats Cherokee Wagoneer Truck bench 3M 3 Seats CJ and Scrambler bucket 3M...

Page 1239: ...tch torque 2A 21 Specifications starter motor six and eight cylinder engines 1F 25 Specifications steeringlinkage 2M 6 Specifications suspension 2N 8 Specifications tune up 1A 25 Specifications vacuum...

Page 1240: ...removal 2J 10 Steering wheel spoke alignment 2M 5 Stoplampswitch exterior lightingsystem 3R 9 Storage compartment 3F 21 ALPHABETICAL INDEX Subassembly overhaul automatic transmission 2C 36 Sunroof 3L...

Page 1241: ...ilt column overhaul Cherokee Wagoneer Truck models 2J 24 Timing case cover eight cylinder 1B 75 Timing case cover four cylinder 1B 11 Timing case cover six cylinder 1B 38 Timing chain eight cylinder 1...

Page 1242: ...76 2B 33 Transmission specifications automatic transmission 2066 Transmission specifications modd T4 2B 18 ALPHABETICAL INDEX Transmission specifications modelT5 2B 26 Transmissionspecifications moddT...

Page 1243: ...ts interior wind noises 3A 10 Window rear 3N 6 Window rear CJ 7 and Scrambler with hardtop enclosure and Cherokee Wagoneer models 3N 6 Window rear pivot vent Cherokee 3K 1 Window rear Truck models 3N...

Page 1244: ...VACUUM LINE ROUTING DIAGRAMS...

Page 1245: ...MOTOR VACUUM SWITCH ASSEMBLY PCV VALVE AIR OUT TAC TEMPERATURE SENSOR BOWL VENT TO CANISTER SIGNAL CANISTER PURGE CANISTER PURGE TO FUEL TANK CANISTER y SIGNAL BOWL VENT REVERSE DELAY VALVE IGNITION A...

Page 1246: ...AIR IN REVERSE DELAY VALVE DENOTES COLOR _ CODED SIDE 0F_ c 3 DELAY VALVES TAC VACUUM MOTOR VACUUM SWITCH ASSEMBLY PCV VALVE AIR OUT TAC TEMPERATURE SENSOR i _ Li BOWL VENT TO CANISTER AIR CLEANER SIG...

Page 1247: ...ALVE AIR OUT TAC TEMPERATURE SENSOR V BOWL VENT TO CANISTER AIR CLEANER SIGNAL CANISTER PURGE CANISTER PURGE TO FUEL TANK CANISTER SIGNAL BOWL VENT REVERSE DELAY VALVE IGNITION ADVANCE CTO VALVE FRONT...

Page 1248: ...DELAY AND EGR VALVE DUAL CTO VALVE 1 1 I I TAC VACUUM MOTOR DENOTES COLOR CODED SIDE OF DELAY VALVES CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE PURGE SIGNAL CANISTER FRONT 6 CYL MANUAL TRANSMIS...

Page 1249: ...ERSE DELAY AND EGR VALVE v DUAL CTO VALVE v 1 t TAC VACUUM MOTOR NON LINEAR VALVE CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE PURGE SIGNAL CANISTER FRONT 6 CYL AUTOMATIC TRANSMISSION W W 0 AIR CO...

Page 1250: ...i VACUUM ADVANCE REVERSE DELAY AND EGR VALVE v DUAL CTO VALVE TAC VACUUM MOTOR HEAVY DUTY COOLING CTO VALVE CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE V PURGE SIGNAL IT CANISTER FRONT M4 6 CYL...

Page 1251: ...E h j i TAC VACUUM MOTOR f vV I I i 1 1 IK HEAVY DUTY COOLING CTO VALVE NON LINEAR VALVE CARBURETOR BOWL VENT TO FUEL TANK I CANISTER PURGE PURGE SIGNAL CANISTER V i FRONT I114SO 6 CYL AUTOMATIC TRANS...

Page 1252: ...I 1 1 1 1 FORWARD DELAY VALVE VACUUM ADVANCE REVERSE DELAY VALVE AND EGR DUAL CTO VALVE FORWARD DELAY VALVE ADAPTIVE VACUUM IOLE DECEL VACUUM SWITCH SWITCH TAC VACUUM MOTOR CARBURETOR BOWL VENT TO FUE...

Page 1253: ...TO VALVE REVERSE DELAY VALVE TAC VACUUM MOTOR CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE PURGE SIGNAL CANISTER EVAPORATIVE SYSTEM VACUUM MOTOR VACUUM SWITCH ASSEMBLY ADAPTIVE WARD DELAY VALVE VA...

Page 1254: ...1 1 1 1 1 1 1 FORWARD DELAY VALVE VACUUM ADVANCE REVERSE DELAY VALVE AND EGR DUAL CTO VALVE i FORWARD DELAY VALVE VACUUM SWITCH ASSEMBLY ADAPTIVE VACUUM IDLE DECEL VACUUM SWITCH SWITCH TAC VACUUM MOTO...

Page 1255: ...delay valve AND EGR t c DUAL CTO VALVE VACUUM RESERVOIR VACUUM SWITCH ASSEMBLY ADAPTIVE FORWARD DELAY VALVE VACUUM IDLE DECEL VACUUM SWITCH SWITCH TAC VACUUM MOTOR CARBURETOR BOWL VENT TO FUEL TANK CA...

Page 1256: ...E REVERSE DELAY VALVE AND EGR DUAL VACUUM SW TCH ASSEMBLY fig roRWAW aAY V LVE SWITCH IDLE DECEL VACUUM SWITCH TAC VACUUM MOTOR CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE f PURGE SIGNAL CANISTER...

Page 1257: ...DELAY AND EGR VALVE DUAL CTO VALVE VACUUM RESERVOIR VACUUM SWITCH ASSZR i B LV 2 FORWARD DELAY VALVESWITCH IDLE DECEL VACUUM SWITCH TAC VACUUM MOTOR CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE PU...

Page 1258: ...ALVES 1 1 1 1 1 1 1 VACUUM ADVANCE AND EGR DUAL CTO VALVE 1 1 1 1 1 1 1 1 1 REVERSE DELAY VALVE TAC VACUUM MOTOR CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE j A PURGE SIGNAL 1 fitCANISTER EVAPORA...

Page 1259: ...VALVE TAC VACUUM MOTOR NON LINEAR VALVE CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE PURGE SIGNAL CANISTER EVAPORATIVE SYSTEM VACUUM MOTOR 81 MM 6 CYL AUTOMATIC TRANSMISSION W W 0 AIR CONDITIONIN...

Page 1260: ...ANCE AND EGR DUAL CTO VALVE 1 1 1 1 1 1 1 1 1 1 1 1 REVERSE DELAY VALVE HEAVY DUTY COOLING CTO VALVE TAC VACUUM MOTOR CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE AV PURGE SIGNAL CANISTER EVAPORAT...

Page 1261: ...EVERSE DELAY VALVE HEAVY DUTY COOLING CTO VALVE TAC VACUUM MOTOR NON LINEAR VALVE CARBURETOR BOWL VENT TO FUEL TANK CANISTER PURGE PURGE SIGNAL FRONT CANISTER EVAPORATIVE SYSTEM VACUUM MOTOR I14SS 6 C...

Page 1262: ...D SOLE VAC DENOTES COLOR CODED SIDE OF c DELAY VALVES VACUUM SWITCH ASSEMBLY VACUUM ADVANCE REVERSE DELAY AND EGR VALVE DUAL CTO VALVE FORWARD DELAY VALVE ADAPTIVE IDLE DECEL VACUUM SWITCH VACUUM SWIT...

Page 1263: ...PUMP DISTRIBUTOR OIL FILLER CAP FRONT MODIFIED VACUUM f J MANIFOLD VACUUM f j PORTED VACUUM zj 1 360 8 CYL MANUAL AUTOMATIC TRANSMISSION W W 0 AIR CONDITIONING 49 STATE HIGH ALTITUDE CHEROKEE J 10 J...

Page 1264: ...AL CANNISTER AIR PUMP DISTRIBUTOR OIL FILLER CAP FRONT MODIFIED VACUUM j MANIFOLD VACUUM f j PORTED VACUUM 81148V 1 360 8 CYL MANUAL AUTOMATIC TRANSMISSION W W 0 AIR CONDITIONING 49 STATE HIGH ALTITUD...

Page 1265: ...J 1 5...

Page 1266: ...HI I I I I...

Page 1267: ...NOTES...

Page 1268: ...1111 I I r Q s I f DS m S s ill i 3 5 mum if fg fl I e ae CO as 3E f sf 3 S ES flffj a CO J 3 L T...

Page 1269: ...NNECTOR SO BLACK ItSXL TACHOMETER FEED S7S7CBAR 4CYL ENG IAUTO TRANS I 57SSS9 R 4 CYL ENC MANUAL TRANS I CIRCUITSYMM MANUAL TRANS AUTO TRANS ENGINE CHECK CARB SOLENIOO MIXTURE CONTROL WIRING DIAGRAM 4...

Page 1270: ..._ WIRING DIAGRAM 6 CYLINDER ENGINE CJ MODELS WIRING DIAGRAMS W 3...

Page 1271: ...majzoaki vmmw 3 i HaawuY3 a 2 Ml ID...

Page 1272: ...GROUNO 1S4A BLACK WHITE W TR J8 RADIO GREEN ORANGE W OOT 30 ORANGE REO W OOT 30 INK BLUE W OOT 30 uRAY BLUE W TR VELLOW BLACK W TR PINK BLUE W TR 30 PINK GREEN W TR 30 BLACK WHITE W TR 20 83TAN13 37 L...

Page 1273: ...a OWIHIW...

Page 1274: ...eflector Left Side Front E 2 Marker and Reflector Right Side Front A 2 Marker and Reflector Left Side Rear E 10 Marker and Reflector RightSide Rear B 10 Module Assembly Ignition D 3 Neutral Safety Gro...

Page 1275: ...hotadoj aino xvtaviosrwoa arajY3 a ZJ3CIOM 10 3RUTI 5J t Q e o...

Page 1276: ...f SWITCH HARNESS S r AM 8 10 11 raooHTta CTi WIRING DIAGRAM 6 CYLINDER ENGINE CJ MODELS 10 1 11 B...

Page 1277: ...f Aia DV rod zsm y J...

Page 1278: ...8 4 l itrl _ f Hil Kp L Ola OH J i l 9it jr naaow fa N3 HaONTIAO 9 aOVIQ 9KIHIM 9...

Page 1279: ...r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r r M BB...

Page 1280: ...WIRING DIAGRAM 8 CYLINDER ENGINE CHEROKEE WAGONEER TRUCK W 5...

Page 1281: ...MAHdAia Dmmw 0V13 3aVHIYD 8 XDU5IT aaririooAW aanoHUHD...

Page 1282: ...CO i 9 o Tcr t SI NMOBO V81 i i m e v K 01 NH0XHV0VM SIM011IA Vtt I I I I 36 1 i i i x I I I I t I S O s a 5 5 a is UIB O f ill J s o H Ml K 12 t o S 3 GO si I I I I H _ O H0 0 0 t I...

Page 1283: ...i i i i i i i i i i 1 i i t r i i i i t i i i i i i i i...

Page 1284: ...lector Lamp 16 17 18 Right Hand B 11 Marker and Reflector Lamp 16 17 18 Left Hand D 11 Marker and Reflector Lamp Left Side E 2 Markerand Reflector Lamp Right Side A 2 NOMENCLATURE LOCATION Marker and...

Page 1285: ...5U J aiHO TK3W0 IW0D araovia H3 miJY3 8 JHT H33VJ00AW 33XOH3H0 i a 8 A M A A 8 a fit...

Page 1286: ...B tcioa wijunv 8 CYLINDER ENGINE CHEROKEE WAGONEER TRUCK MJ mvnnr...

Page 1287: ...o J j I I I I I I J J J J J J...

Page 1288: ...f gfe WIRING DIAGRAM 4 X Ji 8 CYLINDER ENGINE CHEROKEE WAGONEER TRUCK 9 14 B 14...

Page 1289: ...I I t I I I I I I I I t I I I I 1 t I I t t t t t t t c t e t t c f 1 i...

Page 1290: ...WIRING DIAGRAMS FEEDBACK SYSTEM 6 CYLINDER ENGINE CJ CHEROKEE WAGONEER TRUCK MODELS WIRING DIAGRAMS W 7...

Page 1291: ...I I I I I I I I I I I I I I I I I I I I j I I I I I I I I I I I I I I I I I I I I...

Page 1292: ...WS W W 8 WIRING DIAGRAMS S S n CONTROL SWITCH 184 BLACK 12 183 RED W TR 12 CONTROL SWITCH 184 BLACK 12 183 RED W TR 12 POWER SEAT PASS SIDE HARNESS WIRING DIAGRAM POWER SEATS HARNESS TO SEAT MOTOR TO...

Page 1293: ...O Jl o Io o o J R C8f m jnw...

Page 1294: ...3SIOH3 3SrB 2 I a _ 73aoni 3NIQN3 X3W W3XSAS HDV wvaovia d D O 81 BfllE r 6l 8 S i 2 o o c o o o 81 ovT6 re I O 0 B E VCSI E ri 81 3tH6 Mt 5 NMOtJB BOS1 il Bl HV SCC 91 03b 9i 03t3JYs i soma 6 033d 3...

Page 1295: ......

Page 1296: ...WOT SWITCH ex TO BACK U SWITCH Era mabsess r NtuT LSAftrr iAC u SWITCH 4 0 INOICATC _ M SWITC ESD...

Page 1297: ...N i r 1 i i r r t i i i t l i t i t i i r r r r r r c r i A 1...

Page 1298: ...ACCESSORY DIAGRAMS CJ CHEROKEE WAGONEER TRUCK MODELS WIRING DIAGRAMS W 9...

Page 1299: ...i v h r4eMht vsi T M xkhck woDErz Cl CHEHOKEE MVCOIftEEB VCCE220KA DIVCBVW2...

Page 1300: ...to j 11 W0 i I ill e o T rr J A TOiGOWMMUniMi YJL Jaep Power Ooor Lseks 2 Door U MKIISM _4j ii in i a b i U l U l U AT 32ZJ t 1 U4t l ii ti ii_ T il T i Ml eeo Power Ooor L s ear ACCESSORY DIAGRAMS PO...

Page 1301: ...3 A...

Page 1302: ...N ffl irtO IO t 0 O T IM300 sc s A CaccI aPi U s 6 ii 3 i j 5 sec 5 3C IK mMKCwvi II 9 i t 5 ia iiui v wi r a 2 V CI S tS ta IT M Ml __ C il f U I I oo POWER OOOR LOCK OIAGOAM POWER DOOR LOCK DIAGRAM...

Page 1303: ...o r I J J J I I I I I I I I I I I I I J I I...

Page 1304: ...i i MIL MS ii11 ii S3 i cws 4 Door t Ml t WljTMH 11 irn Jl Hi LA7 f j S r a ll U H...

Page 1305: ...MgW...

Page 1306: ...10 11 12 10 11 12 13 13 14 WIRING DIAGRAM 8 CYLINDER ENGINE CHEROKEE WAGONEER TRUCK 14 B...

Page 1307: ...18 STB REO 16 u BLUE 18 203 LT GREEN 18 90 BLACK I8 COOLANT SWITCH TEMPERATURE OIL SENOER PRfSSURE 206C BROtW W TR 8 5C3 BROWN 16 H 1NK 14 E PINK 16 BROWN 24 2753 REO 16 27SC RED IB I75A RED 18 198C...

Page 1308: ...p j i r M f r mmutrn m WIRING DIAGRAM 8 CYLINDER ENGINE CHEROKEE WAGONEER TRUCK ipSg MrrC s i ii jin 11 I I i I ii n i 11 111 11 j 11 i j IT1 _ t...

Page 1309: ...3M31S X i A S O S l talrWOltt fiU 91 tOVTBOKl a mi 0 si i s 5 LEO HSJOJ TS tvuini r 9VS i Ili WClB Vtl i tu MOlaitl 3lt4 Bl X3VI8 3ttl nana r e O O VZ61 O 81 N33U0 191 O O jr imn dm I 81 X3VIB HS 1 Bl...

Page 1310: ...C XOlfl T L Tl tttrntomtn nnnrutm k a wtAAtot w i K n c n M i SI Ml murawmmiiitfci f Aj cBM r__jir 9 1A SMTtUH J A tO o om t i u i m i MUMItHKIV i li J l s 9ci t tm i h o to 3 q KfATt Wf m ma I CL UK...

Page 1311: ...S II EbFJ ES ril I L a i m w 3 c ls Jfi y Jf t j J V i i t u X i 111 A f 31 3S li ui a a via n 1 1 i F 1 1 u 1 J 3 1 J i K IDa V o 9 m i d I A X t li 1 i 5 3 n ir A A...

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Summary of Contents for Cherokee 16 1982

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Jeep Cherokee 16 1982, Technical & Service Manual

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Summary of Contents for Cherokee 16 1982

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