Jeep 1987 Wrangler Скачать руководство пользователя

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Содержание 1987 Wrangler

Страница 1: ...ailable at the time of publication American Motors Corpora tion and Jeep Corporation reserve the right to discontinue designs or change specifications without notice or incurring obligation Copyright...

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Страница 3: ...n P 1 C O M P O N E N T S Windshield C O M P O N E N T S Replacement P 4 Body And Frame Tailgate P 11 Components S 1 Hard Top Enclosure P 15 Frame Specifications S 4 Instrument Panel And Body Holddown...

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Страница 5: ...are also listed in the appropriate section of each chapter WIRING DIAGRAMS Wiring diagrams are printed separately and should be filed in the pocket at the back of the plastic binder The diagrams provi...

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Страница 7: ...R VIN 3 SAFETY CERTIFICATION LABEL 4 VEHICLE IDENTIFICATION PLATE 5 POWERTRAIN AVAILABILITY 5 FUEL FLUIDS LUBRICANTS 6 FLUID CAPACITIES 7 ADHESIVES AND SEALERS 8 TOWING BREAKDOWN RECOVERY 9 TOWING SAF...

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Страница 9: ...NSIONS A Overall length with Polyspare with Conventional Spare 386 cm 152 in 388 9 cm 153 in B Overall width 167 6 cm 66 in C Overall height empty Open Body Soft Top Hard Top 172 7 cm 68 in N A 175 2...

Страница 10: ...at 100 6 cm 39 6 in Rear seat 88 9 cm 35 0 in Shoulder Room Front 134 8 cm 53 1 in Rear 143 0 cm 56 3 in Hip Room Front 134 8 cm 53 1 in Rear 91 4 cm 36 0 in Usable Cargo Volume Rear seat folded 1 2 c...

Страница 11: ...PART TIME C MPV MANUFACTURING COUNTRY 2 CANADA B MANUFACTURER B JEEP CORP CANADA ENGINE TYPE C 258 CUBIC IN 4 2L 2V 1 6 AMC GASOLINE H 150 CUBIC IN 2 46L FUEL INJECTION I 4 AMC GASOLINE TRIM TYPE AND...

Страница 12: ...gler YJ models The label indicates that the vehicle conforms to Federal motor vehicle safety certification standards The label is locat ed on the driver door pillar GVWR j GAWR FRT I EE S N 0 T E S r...

Страница 13: ...ate is attached to the radiator support The plate displays the VIN paint code trim code fabrication sequence number and vehicle equipment code e g 49 State Canada California high altitude POWERTRAIN A...

Страница 14: ...uid or equivalent identified as FMVSS 116 DOT 3 and SAE J 17034 CAUTION Use recommended brake fluid only Engine Coolant All Use AMC Jeep Renault all season antifreeze or equivalent ethylene glycol bas...

Страница 15: ...ng System includes coolant overflow bottle 2 46 liter 1 4 4 2 liter 1 6 9 0 quarts 7 5 quarts 8 5 liters Cooling System includes coolant overflow bottle 2 46 liter 1 4 4 2 liter 1 6 10 5 quarts 8 7 qu...

Страница 16: ...ners are loosened and tightened Loctite 271 High strength Locks bolts nuts screws Must be reapplied if fastener is loosened Loctite 290 or Wick n Lock Medium strength penetrating Prevents loosening of...

Страница 17: ...regarding tow s p e e d s warning lights and nighttime illumination Do not attempt a towing operation that could jeopardize the operator bystanders or other motorists Do not exceed a towing speed of 4...

Страница 18: ...NI O i l l O i l 1 0 0 0 0 0 0 0 1 1 TOWING BREAKDOWN RECOVERY ROOOONi O i l l O i l 1 0 0 0 0 0 0 0 1 1 REAR TOWING Shift the transmission and transfer case into Neutral Raise and tow the vehicle at...

Страница 19: ...ckle or just behind the front spring shackle Be sure the jack or stand is positioned on a level section of the frame rail Hoist Wrangler YJ models can be raised with the fol lowing type of hoist Swive...

Страница 20: ...5 gear lubricant for top off or refill purposes Automatic Transmission Fluid and Filter Change the automatic transmission fluid and filter at 48 000 km 30 000 mile intervals Check fluid level every 1...

Страница 21: ...h If ll i MIGWELDER Ref Controlled Systems SAM S E T O F MZ T O W E R S Ref Celette MZ 450 u i MIGWELDER Ref Controlled Systems SAM if e S E T O F T O P S Ref Celette 488 300 DIE GRINDER Ref CP 9108...

Страница 22: ...Ref Kent Moore J 24595 B HEAT GUN Ref J 25070 Address Kent Moore USA 29784 Little Mack Roseville Ml 48066 2298 Telephone Number 313 774 9500 Address Kent Moore Canada 5466 Timberlea Blvd Mississauga O...

Страница 23: ...O i u O i l 1 O B 0 O O M l 1 ELECTRIC HOT KNIFE Ref Kent Moore J 24709 01 PNEUMATIC FLANGING AND PUNCH TOOL Ref Herkules 9158 Address USA P O Box 61 Southfield Ml 48032 Telephone Number 313 352 8172...

Страница 24: ...Ref 08105 USA and Canada WEATHERSTRIP ADHESIVE 3M Ref 08001 USA Ref 80010 Canada EPOXY CHROMATE Ref Ditzler DP 40 401 DuPont 6155 6165 Release Agent RELEASE AGENT 3M Ref 08931 USA Anti Corrosion Rust...

Страница 25: ...MATION 8 I I I N 0 l 1 ROOBfKi o O i l 1 V OOOOQ L PRODUCTS 8 I I I N 0 l 1 1 Adhesive j ADHESIVE 3M Ref 08105 US and Canada j Seam Sealant SEAM SEALANT 3M Ref 08646 US Ref 86464 Canada DOOR PANEL BON...

Страница 26: ...8 105 7538 98 132 8702 19 25 7605 39 52 8769 59 79 9933 79 107 1196 99 134 2260 20 27 1164 40 54 2327 60 81 3491 80 108 4654 100 135 5820 N m lb ft N m lb ft N m lb ft N m lb ft N m lb ft 1 7376 21 15...

Страница 27: ...3 8 375000 9 5250 7 8 875000 22 2250 25 64 390625 9 9219 57 64 890625 22 6219 13 32 406250 103188 29 32 906250 23 0188 27 64 421875 10 7156 59 64 921875 23 4156 7 16 437500 11 1125 15 16 937500 23 81...

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Страница 29: ...NSTRUMENT CLUSTER BEZEL 25 GLOVE BOX 25 DASH PANEL 27 FENDERS 32 FRONT FENDERS 32 FENDER EXTENSIONS 33 RADIATOR GRILLE 34 REMOVAL 34 INSTALLATION 35 GRILLE APPLIQUE 35 SOFT TOP 37 REMOVAL AND INSTALLA...

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Страница 31: ...DETACHABLE COMPONENTS GENERAL DESCRIPTION GENERAL INFORMATION The following illustration shows the compo nents that are detachable from the Wrangler YJ body P 1...

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Страница 33: ...Windshield Panel 29 Front Fender Bracket 10 Door Hinge Assembly 30 Splash Apron Front Fender 11 Door Assembly Hard Top 31 Tie Rod 12 Door Frame Assembly 32 Side Radiator Back Panel 13 Tailgate Hinge B...

Страница 34: ...DETACHABLE COMPONENTS WINDSHIELD REPLACEMENT SEE LS N O T E S A Glass B Urethane C Windshield Reveal Molding D Garnish Molding E Windshield Frame 10121S P 4...

Страница 35: ...procedures Short procedure This procedure is recommended when the windshield is removed intact and the body windshield opening does not require repairs After the glass has been removed a controlled a...

Страница 36: ...uring the cutting opera tion Excessive heat can cause permanent soft ening of the adhesive material Insert a electric hot knife under the edge of glass and cut the adhesive material as close to the in...

Страница 37: ...garnish molding must be replaced due to the urethane that remains on the molding from the original installation Remove the original urethane from the body opening around the perimeter of the opening...

Страница 38: ...hol dampened cloth to clean C the inside of the glass D 88369 Use a dauber E to apply the primer F around the entire perimeter of the glass G Allow the primer to dry for ten minutes 88371 NOTE If the...

Страница 39: ...or garnish molding CAUTION Install the garnish molding as soon as possible because the urethane will begin to cure soon after it is applied Clean the vehicle with a cloth dampened with a solvent such...

Страница 40: ...und the perimeter of the bracket to provide a guide for attaching it to the glass Apply the activator to the glass at the bonding area and allow a few minutes for drying SEE I S N o T E S I Apply an e...

Страница 41: ...e tailgate hinge screws using a Torx bit T 40 Disengage the latch and remove the tailgate Installation Tailgate Assembly Position and align the tailgate in the body open ing and engage the latches Ins...

Страница 42: ...holes in the tailgate and expand when they exit on the inside of the tailgate 101224 0 101225 When servicing the seal use a dampened cloth to clean any dirt from the seal Remove the screw from the end...

Страница 43: ...remove the screws A from the latch mechanism housing B Disconnect the linkage C by removing clip K Remove the latch to tailgate screws E Remove the retaining clip F from the lock cyl inder G 101226 10...

Страница 44: ...ic cover B Remove retaining clip F Disengage the lock cylinder G Remove clip K from the lock cylinder G and disengage it from lever L Installation Inspect all the plastic retaining clips and replace a...

Страница 45: ...TOP ENCLOSURE GENERAL INFORMATION A lightweight removable hard top enclosure is optional for the Wrangler YJ models This en closure is constructed of compressed molded fiberglass and is painted with a...

Страница 46: ...B C 0 F H a r d T o p t n Sea Sea...

Страница 47: ...ween the hardtop enclosure and the body panels 101279 Remove the screws A attaching the hardtop enclosure to the windshield frame Remove the nuts washers and screws B at taching the hardtop enclosure...

Страница 48: ...l Information The following material will be required to repair the hardtop fiberglass mat or cloth fiberglass resin and hardener structural adhesive 3M brand or equivalent glazing putty aluminum foil...

Страница 49: ...Prepare the area for color coat Color coat refer to Chapter T Paint and Trim Fracture Repair Use a grinder to remove the paint from both sides and to outline the damaged area Stop drill the crack s us...

Страница 50: ...liftgate hinge to top enclosure screws D Remove the liftgate E Installation Install the liftgate and hinge screws D Adjust the liftgate to fit the body opening Tighten the hinge screws Position the l...

Страница 51: ...m panel F by releasing the clips around the edge of the trim panel Remove the screw from the outside door han die G disconnect the linkage and remove the handle H G 101231 Remove the door latch mechan...

Страница 52: ...h end Position the latch to handle linkage and door latch and install the screws Install the trim panel Position the outside door handle connect the linkage and install the retaining screws Connect th...

Страница 53: ...NTS GENERAL INFORMATION The W R A N G L E R Y J instrument panel is con structed of formed sheet metal and is attached to the cowl dash panel The crash pad is attached to the instrument panel and stan...

Страница 54: ...DETACHABLE COMPONENTS INSTRUMENT PANEL AND COMPONENTS C Dash Panel D Glove Box E Assist Handle F Glove Box Door 101233 P 24...

Страница 55: ...nting holes are elongated to allow adjustment The hinge screws may be loosened and the door moved in the desired direction to best fit the door opening Remove the hinge to instrument panel attach ing...

Страница 56: ...Remove the glove box to instrument panel at taching screws Remove the striker Remove the assist handle Pull the glove box out of the instrument panel opening Glove Box Installation Position the glove...

Страница 57: ...PANEL AND COMPONENTS DASH PANEL Removal If equipped with a soft top Disconnect the snaps at the outer edge of the top and at the front corners as shown A Disconnect the upper door frame B from the fr...

Страница 58: ...windshield forward onto the hood Disconnect the battery negative cable Remove the instrument cluster bezel Remove the assist handle glove box door hinge and box assembly Remove the screws attaching t...

Страница 59: ...rive out the roll pin attaching the shift lever to the shift bowl and remove the shift lever Remove the instrument panel to dash panel at taching screws and remove the instrument panel Removal If equi...

Страница 60: ...sion shift lever if equipped Drive out the roll pin attaching the shift lever to the shift bowl and remove the shift lever Remove the instrument panel to dash panel at taching screws and remove the da...

Страница 61: ...dware Insert the soft top into the retainer on the top of the windshield Snap the top at the side rails Move the rear support to the upright position InstaW the soft top at the rear supports and lock...

Страница 62: ...rille panel bolts wash ers and nuts B Remove the bolts and washers attaching the fender and brace to the cowl panel Pull the fender outward and lift it from the vehicle Installation Position the fende...

Страница 63: ...emove the screws A attaching the reinforce ments and fender extension B to the fender Remove the reinforcements and fender exten sion from the fender Installation Position the fender extension and rei...

Страница 64: ...to the radiator grille guard panel Remove the bolts and washers attaching the grille guard panel to the fenders A 101245 Remove the radiator grille to frame cross member holddown assembly Note the s...

Страница 65: ...que Position the grille applique over the grille as sembly and press along the bottom CAUTION Screws are installed into well nuts do not overtighten Install the screws and bumpers Connect and position...

Страница 66: ...g the bottom on the backside of the applique Position the grille applique over the grille a s sembly and press along the bottom CAUTION Screws are installed into the well nuts do not overtighten Insta...

Страница 67: ...DETACHABLE COMPONENTS SOFT TOP REMOVAL AND INSTALLATION SEI I S N O T E S A Rear Curtain B Top Fabric C Side Curtain D Bottom Side Rails E Front Retainer 101247 P 37...

Страница 68: ...P Removal To remove the fabric upper section of the doors unsnap the snaps A and lift the section B from the door SEE I S N 0 T E S 101318 Unzip the side window curtains C first the rear zipper D then...

Страница 69: ...ont edge of the side curtain H down removing it from the retainer I on the front support bar 101321 Pull down the spreader bar J to release the tension between the front and rear support bars K 101322...

Страница 70: ...the side rails P Slide the lock on the drip rail forward then pull the drip rail off the lock pin on the windshield Repeat this procedure on the opposite side Slide the front support bow out of the s...

Страница 71: ...the retainer on the upper edge of the drip rail Snap the top down at the front corners and along the drip rails above the doors Position the rear window and zip the top and then the side zippers Clos...

Страница 72: ...er extensions and remove the extensions Remove the nuts and bolts attaching the front bumper rail to the frame Installation Position the front bumper on the frame extension Install the bolts and nuts...

Страница 73: ...Removal Remove the nuts and bolts A attaching the Sbumperettes B to the vehicle frame 101250 P 43...

Страница 74: ...MPERS Remove the rear bumperettes from the vehicle frame Install the bolts and nuts attaching the rear bumperettes to the vehicle frame Installation Position the rear bumperettes on the vehicle frame...

Страница 75: ...insulation hood light D hood side catch brackets E footman loop F and windshield bumpers G 101339 101251 ASSEMBLY AND INSTALLATION Finger tighten the related component parts and assemblies to the hoo...

Страница 76: ...avel The hood now may be raised with the release of the safety catch B by inserting fingers be tween the grille bars to the right of center and by pulling to the left on the catch 101330 Secure the ho...

Страница 77: ...nd latching components to be ad justed for trouble free operation The seat belts utilize quick release buckle latches The left front seat frame attaches to the seat slides D and the seat slides in tur...

Страница 78: ...bolts B to supports C which in turn are secured to the floorpan of the vehicle by bolts 101344 Removal Remove the bolts attaching the rear seat as sembly to the floorpan Remove the rear seat assembly...

Страница 79: ...emoval Open the console cover Remove the screws attaching the console to the floorpan Remove the console assembly from the vehicle Installation Position the console assembly in the vehicle Align the d...

Страница 80: ...ylinder Installation Manually set the latch to simulate the closed cover position Insert the key and cylinder F into the lock E and turn clockwise Release the latch and re move the key Position the as...

Страница 81: ...oft top or hard top enclosure as described in the appropriate section of this chapter Remove the screws A from the roll bar end of the extension bars Remove the screws from the windshield end of the e...

Страница 82: ...the floor pan where the roll bar sets Position the seat belts at the roll bar anchor point and tighten the retaining screws with 43 62 N n 32 46 ft lbs torque Position the roll bar extensions and inst...

Страница 83: ...hor bolt A C I 101346 Remove the seat belt Obtain access to the seat belt retractors by re moving the trim covers D Remove the shoulder belt guide cover B from the guide if equipped Remove the anchor...

Страница 84: ...ence of wear cuts or fraying Replace as required Install the seat belt and seat belt retractor anchor bolts Tighten with 34 47 N m 25 35 ft Ibs torque Position the shoulder belt guide on the B pillar...

Страница 85: ...tion by velcro strips 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 shifte...

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Страница 87: ...NDARD SEALANTS AND ADHESIVES U S A 1 STANDARD SEALANTS AND ADHESIVES CANADA 2 VEHICLE EXTERIOR WIND NOISE DIAGNOSIS 8 WATER LEAK DIAGNOSIS AND REPAIR 9 BASIC WATER LEAK TOOLS AND PRODUCTS 9 WATER LEAK...

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Страница 89: ...ted when dry 297 08646 W 08648 B 08656 CSS4 10280 CJ W CJ B BJ B Windshield sealer for rubber to glass 306 08511 08513 GMI 10220 BL R C Sealer for windows sunroof installation 307 08509 BGI 10255 BPP...

Страница 90: ...I 10220 C Sealer for windows sunroof installation 307 08509 BGI 10255 D Thumbable sealer strip calk permanent joints 503 08575 W 08578 B SPI 10310 B SP4 10320 W E Door skin flange kit 512 08109 F Meta...

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Страница 95: ...T APPLICATION 1 BODY WEATHERSTRIP TO LIFTGATE GLASS 2 WEATHERSTRIP LIFTGATE G L A S S TO TAILGATE 3 WEATHERSTRIP TAILGATE TO BODY 4 LIFTGATE GLASS SECTION AA SECTION BB SECTION CC SECTION DD SEE I S N...

Страница 96: ...hicle or search for the source s of the noise Road test the vehicle with the front windows closed and then open to determine for sure that the wind noise is originating from the outside of the vehicle...

Страница 97: ...SEALING 1 l gp WATER LEAK DIAGNOSIS AND REPAIR _ n L_l l op BASIC WATER LEAK TOOLS AND PRODUCTS R 9 101187...

Страница 98: ...int the source The vehicle exterior should be carefully ex amined for misaligned doors windows hardtop tailgate missing loose or damaged weatherstripping missing or loose grommets in doors floor pan o...

Страница 99: ...direction e g from the wet area back to the source Use the zone spray method Start at the bottom of the vehicle and work upward This method allows the elimination of each potential leak area in stage...

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Страница 101: ...MZ SPECIALIZED TOPS 26 WELDING PROCEDURES 28 HIGH STRENGTH STEEL HSS 32 REPLACEMENT PROCEDURES 33 REAR CORNER COLLISION REPAIR 41 GENERAL 41 REAR CORNER PANEL REMOVAL 41 REAR SIDE PANEL REMOVAL 43 WHE...

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Страница 103: ...ble from the chassis unit and are insulated from the frame by body spacers placed between the body and frame and held in position with body bolts Spacers are located between the body and chassis mount...

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Страница 105: ...L L h Z O L U 3 T CM CM CM OC LU Z Q P S CO 0 CO CM D C LU H C Q Q H J coco C O o D C UJ O X id CM CM DC z o D C LL o o LU Z LU DC C O L U 3 Z O S X O J O UJ _ U J 5 X D C I I CC j U J LU LL QL OC o...

Страница 106: ...WELDED COMPONENTS FRAME SPECIFICATIONS 101469 S 4...

Страница 107: ...WELDED COMPONENTS FRAME SPECIFICATIONS ZZQZ i i o in o o in Is m z o 5 o 3 o z o o S o cc LL C5 fz o CC OL CO UJ UJ cr zmz C O m o o in cr cr z C O LL UJ z o cr LL 101470...

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Страница 110: ...S 8...

Страница 111: ...ual Inspection Walk slowly around the vehicle and visually in spect for damage Inspect at every body location and note all dam age even if some of it appears to be minor Inspect for the following alig...

Страница 112: ...tioning of the units and freedom from excessive wear stress and strain The frame is constructed of heavy chan nel steel side rails and crossmembers The crossmembers maintain the proper posi tions of t...

Страница 113: ...s is a comparative check between body or frame sections that are parallel or diagonal The diagonals must be checked and compared as well as the parallels to ensure alignment accuracy HOW TO USE THE TR...

Страница 114: ...ODY REPAIR INFORMATION I N C O R R E C T S E T U P C O R R E C T S E T U P 101398 Compare the length of one side to the opposite side of the frame Do not disturb the pointers or the set length of the...

Страница 115: ...WELDED COMPONENTS BODY REPAIR INFORMATION n FRAME DIAGONAL COMPARISON MEASURING POINTS S 13...

Страница 116: ...WELDED COMPONENTS BODY REPAIR INFORMATION BODY MOUNTING POINTS Diagonal Measurements Comparison and Length and Width Location AF BE 101401 AD BC 101402 C F DE 101403 CD WIDE COTATION 101404 S 14...

Страница 117: ...nt showing the sight pins in line to establish the centerline These gauges are designed to determine the datum plane and centerline of the vehicle to assist in straightening operations Datum Plane Cen...

Страница 118: ...rom the datum plane sighting pin used to determine the center line of the vehicle lower bar self centering for width to form the datum plane and centerline VERTICAL ATTACHMENT BARS 3 REAR GAUGE 2 CENT...

Страница 119: ...ely reflect the true position of the parts to which they are attached This allows all structional misalign ments to be read centerline level and datum CENTER LINE AND DATUM LINE Before laying out a me...

Страница 120: ...PAIR INFORMATION Center Side Sway 31 1 12 1 REAR O F VEHICLE 101408 Frame Kick Up In a kick up condition the sight pins are out of line and the centering bars are not parallel or hortizontal FRONT O 8...

Страница 121: ...a lateral misalignment in either the front or rear ssection relative to the center section of the vehicle OUT OF LEVEL CONDITION Twist Any out of level condition detected within the center section of...

Страница 122: ...ary to maintain accuracy CAUTION When use only a M I G the frame welding frame components welder to prevent damaging REPAIR JIG BENCH CELETTE MUF 7 The Celette MUF 7 repair jig bench is available with...

Страница 123: ...surface at the front of the bench Move the level to the machined surface at the rear of the bench The level must be at the adjustable leg C side of the bench NOTE Place the level on the adjustable leg...

Страница 124: ...res on the bench REPAIR JIG BENCH CROSSMEMBER LOCATIONS FOR BODY CONTROL ON THE CELETTE BENCH o o o o o o o O 0 o o o o o w w o t O J a Oo o o o o o O o a u o Mo o o o o o o 0 0 0 0 0 0 o 0 0 O O U QO...

Страница 125: ...INFORMATION REPAIR JIG BENCH CROSSMEMBER LOCATIONS FOR FRAME CONTROL ON THE CELETTE BENCH 2 3 4 5 6 7 8 9 10 I I 12 3 M 15 IS 17 8 19 2 0 2 2 2 2 3 2 4 2 5 i 7 2 8 2 9 3 0 3 1 3 2 3 3 3 4 3 5 3 5 101...

Страница 126: ...WELDED COMPONENTS BODY REPAIR INFORMATION 9 lia3 at 1 1 i Z SJ MOUNTING TOPS 488 300 FOR FRAME CONTROL 101415 S 24...

Страница 127: ...WELDED COMPONENTS BODY REPAIR INFORMATION COMPLEMENTARY SET O F MOUNTING TOPS 488 309 FOR BODY CONTROL isi O 2 O I I J S 25...

Страница 128: ...and all the advantages of traditional fixtures or intregal beams Also the traditional beams remain unchanged and will continue to be useful in the future Universal MZ 450 Tower Kit Contents 6 MZ 80 To...

Страница 129: ...dings removeable tops that can be removed and placed back into position during use and diagnosis top locking features designed for locking the MZ assemblies during diagnosis and repair procedures vert...

Страница 130: ...ce E is determined by the thickness minimum of the metal being welded Use a feeler gauge to adjust the distance E After adjusting the distance test the pressure adjustment H with sample sections of sh...

Страница 131: ...that is based on the thickness of the panels to be welded Testing may be necessary to determine the cor rect wire speed that will produce a uniform bead Determine the weld penetration and adjust the i...

Страница 132: ...mparison to the MIG seam continuous welding adjustment For degreased steel the stitch weld distance interval D can be calculated according to the following formula i D 30 X E 85124B The stitch weld ti...

Страница 133: ...ended Tack Welding The adjustments are the same as for MIG seam continuous welding except the intensity amps is slightly increased to cause arcing When tack welding a butt joint the distance D between...

Страница 134: ...body vehicle Spot welding can be used to effectively dupli cate OEM quality welding 100434 HIGH STRENGTH STEEL HSS Welding Standard coated and lightweight high strength steel HSS are all used for the...

Страница 135: ...ed the application of any additional heat will cause disruption of the molecular structure and reduce the strength of the steel To assist in monitoring the temperature of a repair area use a temperatu...

Страница 136: ...welds quickly without damaging the mating surfaces There is no necessity for grinding because the weld is removed by the cutter 84556 NOTE Ensure that approximately 12 mm 15 32 in of stem remains afte...

Страница 137: ...USE A SPHERICAL TUNGSTEN CARBIDE BIT GRINDING USE A 7 IN OR 9 IN 24 GRIT DISC WELD FLANGE REMOVAL SPOTWELD USE A COMPRESSION TYPE RESISTANCE SPOTWELDER MIG PLUGWELDING OXYACETYLENE BRAZING WELD THRU S...

Страница 138: ...sed to de scribe the various replacement and repair pro cedures listed within this chapter Operation Symbol Indicates the type of operation that is required Tool Symbols Indicates the tools and materi...

Страница 139: ...Indicates the type of operation that is required I 131 t Tool Symbols Indicates the tools and materials required for the operation NOTE A zinc based sealant electric spotwelding or a zinc based primer...

Страница 140: ...ari ous replacement and repair procedures listed within this chapter REMOVAL CUTTING PROCEDURES Operations Tools and Materials Descriptions Chisel Cut Weld Flange Removal Grinding Smooth Basic Saw Cut...

Страница 141: ...ing Grinding Smooth Body Solder Application MIG Stitch Welding Zinc based Primer Application MIG Plug Welding Grinding Smooth Weld thru Sealant Application Spotwelding Oxyacetylene Welding The weld th...

Страница 142: ...ATIONS TOOLS DESCRIPTIONS Undercoating Stone Chip Protection Seam Sealer Application Structural Adhesive Application 100441 ANTI CORROSION PROCEDURES OPERATIONS TOOLS DESCRIPTIONS Anti Corrosion Prote...

Страница 143: ...t of the damage it may be advantageous to remove the body from the frame REAR CORNER PANEL REMOVAL Remove the rear corner panel detachable com ponents as necessary Refer to Chapter Detachable Componen...

Страница 144: ...MPONENTS REAR CORNER COLLISION REPAIR NOTE To remove the spotwelds attaching the corner panel to the side panel cut the corner panel 12 5 mm 1 2 in from the seam of the side panel E E s N o T E S I 10...

Страница 145: ...WELDED COMPONENTS REAR CORNER COLLISION REPAIR 43...

Страница 146: ...MPONENTS REAR CORNER COLLISION REPAIR WHEELHOUSE REMOVAL Remove the interior trim and other components as necessary Refer to Chapter P Detachable Components Remove the wheelhouse C as shown 101426 101...

Страница 147: ...er P Detachable Components Remove the crossmember D as necessary to replace the damaged section as shown 101428 REAR FLOOR PAN REMOVAL Remove the trim and detachable components from the rear floor pan...

Страница 148: ...LOOR PAN INSTALLATION PREPARATION Saw cut the replacement floor pan so that the replacement section is 25mm 1 in larger than the floor pan section NOTE The additional size Z for the section may vary a...

Страница 149: ...to be welded spotwelds weld through the sealant MIG welders weld through zinc based primer INSTALLATION FLOOR PAN Position the replacement floor pan section I and secure it for welding with locking p...

Страница 150: ...Sealing Seal the repaired area as necessary Refer to Chapter R SEALING WHEELHOUSE INSTALLATION PREPARATION Apply anti corrosive sealant primer to the areas to be welded spotwelds weld through the sea...

Страница 151: ...ing Seal the repaired area as necessary Refer to Chapter R SEALING SIDE PANEL INSTALLATION PREPARATION Saw cut the replacement side panel L so it is approximately 50mm 2 in larger than the dam aged si...

Страница 152: ...me time E Remove the replacement side panel section and apply anti corrosion sealant primer to the areas to be welded spotwelds weld through the sealant MIG plugwelds weld through the zinc based prime...

Страница 153: ...el section M in position abd secure it with locking pliers 101437 Weld the replacement corner panel section to the side panel and wheelhouse flange N and rear crossmember P as shown NOTE It may be eas...

Страница 154: ...SION PROTECTION PAINTING Refinish the repaired area and vehicle as necessary Refer to Chapter T PAINT AND TRIM Apply anti coating protection as necessary Refer to Chapter R SEALING Install all detacha...

Страница 155: ...the fender windshield and instrument dash panel as necessary Remove any detachable components that are in the damaged area Refer to Chapter P DE TACHABLE COMPONENTS SEE I S N O T E S Remove the damage...

Страница 156: ...WELDED COMPONENTS FRONT SIDE PANEL COLLISION REPAIR ggtiii 1 101441 FRONT SIDE PANEL INSTALLATION PREPARATION Straighten the dash panel C and floor panel D as required S 54...

Страница 157: ...iers 101445 4 Saw cut the replacement section and the origi nal panel at the same time to insure a proper fit for buttwelding Repeat this procedure as nec essary on the other edges of the replacement...

Страница 158: ...older to the buttwelds and adja cent areas and finish to a smooth contour S E E I S N O T E S 101446 101447 Apply body seam sealant as necessary Install the hinges and doors and all other de tachable...

Страница 159: ...the frame REAR FLOOR PAN CROSSMEMBER REMOVAL Remove the detachable components and trim as necessary Refer to Chapter P DETACHABLE COMPONENTS Remove the spotwelds from the damaged floor pan A and cross...

Страница 160: ...S 58...

Страница 161: ...of 4mm 0 15 in diameter holes spaced 36mm 15 in apart along the mating edge of the replacement floor pan section C 4 mm zzzzzzzzzzzzzzzz 100610 Remove the primer from the areas to be welded on the rep...

Страница 162: ...e floor pan reinforcements on the floor pan and spotweld them into place Position the replacement floor pan section D in place and spot weld it into position 101453 Place the rear crossmember E and F...

Страница 163: ...PAINT AND TRIM Apply body seam sealant as necessary Sealing Seal the body as necessary Refer to Chapter R SEALING Corrosion Protection Painting Refinish the repaired components and adjoining surfaces...

Страница 164: ...the damage it may be advantageous to remove the body from the frame 101456 FRONT SIDE BODY PANEL REMOVAL Remove the side panel detachable components as necessary Refer to Chapter Detachable Component...

Страница 165: ...S 1 63...

Страница 166: ...WELDED COMPONENTS SIDE BODY COLLISION REPAIR Remove the body side reinforcement B pillar panel C as necessary E E s N o T E S 101459 Remove the wheelhouse panel D and E as necessary 101460 S 64...

Страница 167: ...ber F as necessary 101462 Straighten the floor pan as required INSTALLATION PREPARATION Saw cut a section from the replacement cross member to replace the section removed INSTALLATION Position the rep...

Страница 168: ...WELDED COMPONENTS SIDE BODY COLLISION REPAIR Position the replacement wheelhouse panel H and secure it with locking pliers Weld the replacement wheelhouse panel into place as shown S 66...

Страница 169: ...ing pliers 6 Saw cut the replacement section and the origi nal panel at the same time to insure a proper fit for buttwelding Remove the replacement panel from the vehicle Remove the primer from the ar...

Страница 170: ...ocking pliers Weld the replacement panel in M position as shown 101468 Apply body solder to the buttweld and finish the existing contours Sealing Refer to Chapter R SEALING Corrosion Protection Painti...

Страница 171: ...13 APPLICATION 13 REFINISHING A REPLACEMENT DETACHABLE 15 BODY PANEL 15 REFINISHING MOLDINGS AND WHEELS 17 REFINISHING PLASTIC COMPONENTS 18 GENERAL INFORMATION 18 REFINISHING PLASTIC EXTERIOR COMPON...

Страница 172: ......

Страница 173: ...on System All colors are available from Ditzler DuPont Sherwin Williams and Rin shed Mason jobbers Option No 999 indicates special paint To ob tain information on special paint contact your Jeep Parts...

Страница 174: ...CTORY PACKAGE CODE FACTORY PACKAGE CODE FACTORY PACKAGE CODE FACTORY PACKAGE CODE FACTORY PACKAGE CODE COLOR CODE LAC EN CODE LAC EN CODE LAC EN CODE LAC EN CODE LAC EN BE Colorado Red 72812 to B8694...

Страница 175: ...4533 9 338 1 iS X 3 x a x a x a X 3 4M Charcoal Metallic 3618 a B84593 141998 9 337323 X X X 3 x a x a 5A Light Blue Metallic 3694 a B85J3a 152253 34342a X X x a X a 5B Medium Green Metallic 3693 a 9...

Страница 176: ...e either lighter or darker by using one of the following methods Lighten drier thinner reducer more reduction higher air pressure greater gun distance Darker wetter thinner reducer less reduction lowe...

Страница 177: ...CK METALLIC FLAKE 84220 B MIX EXAMPLES Red Blue Violet Yellow Red Yellow Orange Blue Blue Yellow Green Red Black Black Black SEE I S N O T E S 84220 C When using the tinting technique the type of ligh...

Страница 178: ...umination ENERGY I 1 1 I 400 500 600 700 nm 8 4 2 2 1 A color can be broken down into three areas coloration brightness or tone and purity coloration determined by pigments refer to the color chart br...

Страница 179: ...andpaper Clean the sanded areas with a wax and grease removal solution e g Ditzler DX 330 DuPont Prep Sol or an equivalent product Tack the areas to be sprayed Blend the paint into the adjacent body p...

Страница 180: ...er 320 Grit or Finer 280 Grit or Finer Polyurethane 360 Grit or Finer 280 Grit or Finer 220 Grit or Finer 84208 Normally the American Abrasive Standards provide sufficient information but because the...

Страница 181: ...at the end of each day 86363 Distributor Air Filters The distributor air filters must be purged two times per day to eliminate impurities that cause paint blistering and lack of luster 86364 Ingredie...

Страница 182: ...ities i e dust The spray gun must have a filter 86365 Equipment Cleaning The spray gun and associated equipment must always be clean to avoid spraying contaminated paint imperfect coloring and other u...

Страница 183: ...nation of dust For good paint application and coat tension the spray booth temperature must be maintained at a close vicinity of 20 C 68 F 86359 Vehicle Grounding The vehicle must be grounded i e at t...

Страница 184: ...inted must free of rub down material silicone and oil or grease It is essential to use a good quality degreaser to remove oil and grease 86361 BODY COMPONENT MATERIALS 101158 I A Reveal Molding Anodiz...

Страница 185: ...ommended for masking off a body panel in preparation for painting be tween two body panel lines NOTE It is advisable to remove the masking along the edges when using the turned over tape method if the...

Страница 186: ...ired and finish to obtain the proper contour Wash the repaired area with soap and water Next wash the repaired area with solvent e g Ditzler DX 330 Sikkens M 600 or an equivalent product Feather edge...

Страница 187: ...tack wipe Apply the top coat NOTE The clearcoat process requires a base coat of high pigment content and a clearcoat REFINISHING A REPLACEMENT DETACHABLE BODY PANEL E Dip Panels Sand the surface of th...

Страница 188: ...ual action sander Scuff sand the panel with 400 grit sandpaper Clean the panel with DuPont 3812 Enamel Re ducer or an equivalent product 101164 Scuff sand the panel with 400 grit sandpaper A 3M Scotch...

Страница 189: ...pply Ditzler DP 40 401 Epoxy Chromate Pri mer to the moldings Apply a semi gloss black top coat on the moldings Slightly scuff moldings with a scratch pad or 400 grit wet or dry sand paper to enhance...

Страница 190: ...rs bezels and ornaments PE Polyethylene is used for fender inner panels interior trim panels valances and spoilers PP Polypropylene is used for interior kick panels hard plastic trim fender aprons rad...

Страница 191: ...les door handles ABS THERMOPLASTICS protective strips bumpers spoilers interior trim PPO EPDM THERMOSETS hard top roofs bumpers UP THERMOSETS instrument panels armrests PUR 100730 The repair cost shou...

Страница 192: ...for the entire time of spraying and until all vapor and mist have dissipated Replacement Hard Top Panel SMC Wash the replacement panel with denatured alcohol Scuff sand the panel surface area with a...

Страница 193: ...l vapor and mist have dissipated Refinishable plastic interior trim components are divided into three general types acrylonitrile butadiene styrene plastic ABS m vinyl ABS PVC It is important that the...

Страница 194: ...that is to be refin ished is vinyl or not use the following copper wire test heat a copper wire C with a propane torch until the wire glows a red color touch the heated copper wire to the backside or...

Страница 195: ...astic components in volves the use of a special primer Because polypropylene PP plastic is rigid it can be color coated after priming with the ap propriate interior spray paint color plastic and vinyl...

Страница 196: ...d not exceed 2 mils film build to avoid cracking and splitting Hi Speed Primer Surfacer Platinum Dk Gray Red Oxide Multi Purpose Primer Surfacer Gray Red Oxide Fill N Sand Primer Surfacer Gray 30 S 70...

Страница 197: ...ts provides protection and beauty Lucite Acrylic Lacquer Centari Acrylic Enamel See Color Chart Code L Suffix Code A Suffix Alpha Cry Acrylic Lacquer Miracryl 2 Acrylic Enamel See Color Chart A Prefix...

Страница 198: ...C 85 F up 8093 S Miracryl 2 Reducer MS 7 Deltron Acrylic Urethane Hot Weather Reducer DTU 505 Gloss Guard Hot Weather Reducer R7K212 Autocryl M3 68 27 Extra Slow Acrylic Lacquer Thinner High Performan...

Страница 199: ...Lucite Flexible Additive Color Dexlar Flexible Finish 355 S 365 B with color B suffix 792 S Hardener Acrylic Lacquer Urethane Catalyst Flex Agent Color used also with Miracryl 2 891 Flexible Additive...

Страница 200: ...when applicable a sealant must also be applied to the joints and seams for cor rosion protection Corrosion protective material can be injected inside hollow sections of the vehicle via strate gically...

Страница 201: ...ada can be used if spray equipment is not available PROTECTIVE MATERIAL APPLICATION Vehicle Interior Anti corrosion wax should be applied to the in terior side of repaired or replaced panels NOTE Ensu...

Страница 202: ...otected apply Ditzler Metal Prep DX 579 or an equivalent conditioner to all bare metal sur faces if applicable prime the repaired area with an epoxy chro mate primer e g Ditzler DP 40 401 or a wash pr...

Страница 203: ...ress the decal or stripe firmly against the body panel It may be necessary to preheat the body panel slightly with heat gun to soften the adhesive Heat may also be used to remove small wrin kles and o...

Страница 204: ...only Observe manufacture s warnings printed on the label CAUTION Woodgrain and Stripe Remover from 3M is designed for use on acrylic enamel sur faces only Spray 3M Woodgrain and Stripe Remover or equi...

Страница 205: ...sking tape and paper Wash the entire panel with 3M General Purpose Adhesive Cleaner or equivalent If any spots of adhesive remain on the panel hard rubbing during washdown will remove them Installatio...

Страница 206: ...ls EE I S N O T E S 84213 I Lift the decal using masking tape as hinges 84214 Remove approximately six inches of the paper backing from one end 84215 NOTE To avoid pre adhesion or stretching of the de...

Страница 207: ...and with flick of a finger separate the paper backing from the decal Hold the decal firmly to the surface of table and remove the paper backing In hot humid conditions a slight jerking motion will aid...

Страница 208: ...bonded area and working downward from section at the center squeegee the decal into place NOTE If a wrinkle is trapped during the squee gee operations stop immediately Carefully lift affected section...

Страница 209: ...able at the time of publication American Motors Corpora tion and Jeep Corporation reserve the right to discontinue designs or change specifications without notice or incurring obligation Copyright 198...

Страница 210: ......

Страница 211: ...rs C 129 Rear Window Defogger C 133 Cruise Control C 136 instrument Panel C 151 C L U T C H Specifications D 1 Special Tools D 2 General Information D 3 Clutch Service D 4 GEARBOXES Specifications E 1...

Страница 212: ......

Страница 213: ...are also listed in the appropriate section of each chapter plastic binder The diagrams provide the loca tion of electrical components on the vehicle and how they are connected and or wired SAFETY NOTE...

Страница 214: ......

Страница 215: ...BEL 4 VEHICLE IDENTIFICATION PLATE 5 POWERTRAIN AVAILABILITY 5 FUEL FLUIDS LUBRICANTS 6 FLUID CAPACITIES 7 ADHESIVES AND SEALERS 8 TOWING BREAKDOWN RECOVERY 9 TOWING SAFETY PRECAUTIONS 9 FRONT TOWING...

Страница 216: ......

Страница 217: ...O l f N i 1 gO Ml Oil 1 V M M M t l J DIMENSIONS Overall length with Polyspare with Conventional Spare 386 cm 152 in 388 9 cm 153 in B Overall width 167 6 cm 66 in C Overall height empty Open Body Sof...

Страница 218: ...00 6 cm 39 6 in Rear seat 88 9 cm 35 0 in Shoulder Room Front 134 8 cm 53 1 in Rear 143 0 cm 56 3 in Hip Room Front 134 8 cm 53 1 in Rear 91 4 cm 36 0 in Usable Cargo Volume Rear seat folded 1 2 cubic...

Страница 219: ...URING COUNTRY 2 CANADA C TRIM TYPE AND GVWR 1 BASE 4001 5000 LBS 1815 2268 kg 3 SPORT 4001 5000 LBS 1815 2268 kg 4 LAREDO 4001 5000 LBS 1815 2268 kg J BASE 3001 4000 LBS 1361 1814 kg K SPORT 3001 4000...

Страница 220: ...The label indicates that the vehicle conforms to Federal motor vehicle safety certification standards The label is locat ed on the driver door pillar MFD BY JEEP CORPORATION GVWR GAWR FRT I L GAWR RP...

Страница 221: ...plate displays the VIN paint code trim code fabrication sequence number and vehicle equipment code e g 49 State Canada California high altitude POWERTRAIN AVAILABILITY SERIES ENGINE TRANSMISSION TRAN...

Страница 222: ...ault brake fluid or equivalent identified as FMVSS 118 DOT 3 and SAE J 17Q3 CAUTION Use recommended brake fluid only Engine Coolant All Use AMC Jeep Renault all season antifreeze or equivalent ethylen...

Страница 223: ...46 liter 1 4 4 2 liter 1 6 9 0 quarts 7 5 quarts 8 5 liters Cooling System includes coolant overflow bottle 2 46 liter 1 4 4 2 liter 1 6 10 5 quarts 8 7 quarts 9 9 liters Transmission BA10 5 Man AX5 M...

Страница 224: ...Loctite 271 High strength Locks bolts nuts screws Must be reapplied if fastener is loosened Loctite 290 or Wick n Lock Medium strength penetrating Prevents loosening of fasteners adjustment screws et...

Страница 225: ...speeds warning lights and nighttime illumination Do not attempt a towing operation that could jeopardize the operator bystanders or other motorists Do not exceed a towing speed of 48 km h 30 mph Avoid...

Страница 226: ...wheel lift equipment only when rear towing is necessary This is the only recommended method of rear towing Wrangler YJ models 101268 Shift the transmission and transfer case into Neutral Raise and to...

Страница 227: ...tioned on a level section of the frame rail CAUTION To avoid damaging the vehicle do not raise the vehicle with a floor jack positioned under the axle tubes body sheet metal steer ing linkage componen...

Страница 228: ...purposes Automatic Transmission Fluid and Filter Check fluid level every 12 000 km 7 500 miles Correct fluid level is between the Add and Full marks on the transmission dipstick Check the fluid level...

Страница 229: ...78 105 7538 98 132 8702 19 25 7605 39 52 8769 59 79 9933 79 107 1196 99 134 2260 20 27 1164 40 54 2327 60 81 3491 80 108 4654 100 135 5820 100 135 110 149 120 162 130 176 140 189 150 203 160 216 170 2...

Страница 230: ...2250 25 64 390625 9 9219 57 64 890625 22 6219 13 32 406250 10 3181 29 32 906250 23 0188 2I S4 421875 107156 59 64 921875 23 4156 7 16 437500 11 1125 15 16 937500 23 8125 29 64 453125 11 5094 61 64 953...

Страница 231: ...ponents 57 Vibration Damper and Pulley Removal 63 Vibration Damper and Pulley Installation 63 Timing Case Cover Removal 64 Timing Case Cover Installation 64 Timing Chain Removal 67 Timing Chain Instal...

Страница 232: ...t Manifold Cleaning and Inspection 147 Exhaust Manifold Installation 148 Lubrication System Oil Pan Removal 149 Lubrication System Oil Pan Installation 150 Lubrication System Oil Pump Removal 151 Lubr...

Страница 233: ...B Relay Fuel Pump Relay Installation 206 Canister Purge EGR Solenoid Removal 207 Canister Purge EGR Solenoid Installation 207 Wide Open Throttle WOT Switch Removal 207 Wide Open Throttle Switch Insta...

Страница 234: ...ch Installation 249 Air Cleaner Trap Door 249 Trap Door Functional Tests 249 Trap Door Vacuum Motor 250 Trap Door Vacuum Motor Installation 250 FUEL FEEDBACK SYSTEMS 251 Computerized Emission Control...

Страница 235: ...y The cylinders in the four cylinder engine are numbered 1 through 4 from front to rear The firing order is 1 3 4 2 The crankshaft rotation is clockwise when viewed from the front of the engine The cr...

Страница 236: ...789 D Universal Carburetor Gauge Set J 10174 01 Carburetor Main Jet Remover J 21791 01 Vibration Damper Remover J 21884 Hydraulic Valve Tappet Remover Seal Installer J 22248 Timing Chain Cover Alignme...

Страница 237: ...MM ENGINES OENERAL INFORMATION J 8520 J 21884 01291 B 3...

Страница 238: ...Air Cleaner F Forward EGR Exhaust Gas Recirculation PCV Positive Crankcase Ventilation R Reverse CTO Coolant Temperature Override 8 4 G 1 0 Q K COMPONENT OPERATING RANGE SPECIFICATION Coolant Tempera...

Страница 239: ...ce Diagnosis Performance chart for possible causes and corrections of malfunctions On four cylinder models refer to INJ R G service manual for fuel injection diagnosis Additional tests and diagnostic...

Страница 240: ...t 5 Replace gasket or repair opening in sealant inspect oil pan gasket flange for distortion 6 Oil pan front oil seal broken or improperly seated 6 Replace seal inspect timing case cover and oil pan s...

Страница 241: ...alve stems or valve guides worn 5 Measure stem to guide clearance and repair as necessary 6 Poorly fitted or missing valve cover baffles 6 Replace valve cover 7 Piston rings broken or missing 7 Replac...

Страница 242: ...or sending unit 2 Refer to Oil Pressure Gauge or Warning Lamp 3 Oil excessively thin because of dilution poor quality or improper grade 3 Drain and refill crankcase with recommended oil 4 Excessive o...

Страница 243: ...rive plate 6 Tighten flywheel or drive plate attaching bolts 7 Loose or damaged vibration damper 7 Repair as necessary CONNECTING R O D BEARING NOISE CI Insufficient oil supply 1 Inspect for low oil l...

Страница 244: ...Check for a Low oil level b Low oil pressure c Plugged push rods d Wrong hydraulic tappets e Restricted oil gallery f Excessive tappet to bore clearance 2 Push rods worn or bent 2 Replace worn or bent...

Страница 245: ...e Correction AL E ACTUATING 12 Missing valve lock 12 Install valve lock COMPONENT NOISE 12 Missing valve lock Continued 13 Push rod rubbing or contacting 13 Remove cylinder head and cylinder head remo...

Страница 246: ...e cover 8 Inadequate choke unloader adjustment 8 Adjust choke unloader 9 Faulty ignition coil 9 Test and replace as necessary 10 Improper spark plug gap 10 Adjust gap 11 Incorrect ignition timing 11 A...

Страница 247: ...place air cleaner tiller element 17 Fault choke vacuum diaphragm 17 Repair as necessary F A U L T Y LOW S P E E D OPERATION 1 Restricted idle transfer slots 2 Restricted idle air vents and passages 1...

Страница 248: ...e or restricted main jet 10 Restricted air cleaner 11 Faulty distributor rotor or cap 12 Faulty ignition coil 13 Improperly seated valve s 14 Faulty valve spring s 15 Incorrect valve timing Correction...

Страница 249: ...cessary 7 Faulty hydraulic tappet s 7 Clean or replace tappet s 8 Improper feedback system operation 8 Refer to Feedback System Diagnosis 9 Faulty valve spring s 9 Inspect and test valve spring tensio...

Страница 250: ...2 Repair as necessary 3 Defective E G R C T O valve 3 Replace E G R C T O valve 4 Defective T A C vacuum motor or valve 4 Repair as necessary 5 Lean air fuel mixture 5 Check float level or manifold v...

Страница 251: ...or 3 Adjust metering rod 4 Improper PCV valve air flow 4 Test PCV valve and replace as necessary 5 Air leak into manifold vacuum 5 Check manifold vacuum and repair as necessary 6 Incorrect spark advan...

Страница 252: ...gine malfunctions NOTE Ensure the battery is completely charged and the starter motor is in good operating condition Otherwise the indicated compression pressures may not be valid for diagnosis purpos...

Страница 253: ...st ment screw on the top step of the fast idle cam Calibrate the tester according to the manu facturer s instructions NOTE The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379...

Страница 254: ...on AIR ESCAPES THROUGH CARBURETOR THROTTLE BODY 1 Intake valve not seated properly 1 Refer to Valve Reconditioning MOT 2 46L or MOT 4 2L AIR ESCAPES THROUGH TAILPIPE 1 Exhaust valve not seated properl...

Страница 255: ...tion stroke of the cylinder Apply engine oil to the exposed gasket area EDGE between the manifold and the cylinder head INTAKE MANIFOLD LEAKAGE DIAGNOSIS An intake manifold air leak is characterized b...

Страница 256: ...pect the hoses for brittleness and cracks Thoroughly inspect the hose ends that are slipped onto nipples Engine performance may be adversely affected by air leaks into such unlikely places as the heat...

Страница 257: ...go driving When the engine is suddenly operated with a high torque load this material can liquefy and bridge the gap i e short circuit the electrodes Spark Plug Condition Scavenger Deposits Fuel scave...

Страница 258: ...ear relatively clean of deposits Determine if the spark plug has the correct heat range rating if the ignition timing is overadvanced or if other conditions are causing engine overheating NOTE The hea...

Страница 259: ...ered PLUGS IN THIS CONDITION MUST B E REPLACED 60770F The increase in electrode gap will be considerably in excess of 0 025mm per 1 609 km 0 001 in per 1000 mi of engine operation This suggests that a...

Страница 260: ...ngth of the particular wire Refer to the Spark Plug and Coil Wire Resistance Values chart Spark Plug and Coil Wire Resistance Values Cm Inches Ohms 0 38 0 15 38 63 15 25 63 90 25 35 over 90 Over 35 3...

Страница 261: ...n there is no scheduled maintenance for the distributor Refer to the Ignition Systems section within Chapter C for distributor service procedures Distributor Rotor Inspection Visually inspect the roto...

Страница 262: ...towers 3 charred or eroded terminals 4 and a damaged rotor button 5 Replace any cap that has any of these discrepancies When replacing a cap transfer one ignition wire at a time to the replacement ca...

Страница 263: ...ylinder engines have a magnetic timing probe socket 3 integral with the timing degree scale for use with a special magnetic timing probe This special probe detects the milled notch on the vibration da...

Страница 264: ...vacuum advance mechanism Connect the wire connector to the vacuum switch assembly The ignition timing can also be adjusted according to the following alternate procedure The Alternate Timing Procedure...

Страница 265: ...tch assembly Disconnect and plug the vacuum hose connected to the distributor vacuum advance mechanism Connect a timing light between the No 1 spark plug and wire Connect the timing light power wire c...

Страница 266: ...ance curve illustrations NOTE A defective FFB system MCU or ignition system ECU can alter the ignition timing Remove the timing light and tachometer Connect the spark plug wire Distributor Advance Mec...

Страница 267: ...2 u 0 28 UJ 1 24 z W 20 UJ u z Q o 3 K t r T r n r r T t T f t MECHANICAL ADVANCE 3242409 258 CID SIX CYLINDER ENGINE ALL APPLICATIONS 32 28 24 20 16 12 8 4 0 4 VACUUM ADVANCE 8134678 r 8 VACUUM ADVAN...

Страница 268: ...Holding Solenoid Energized Distributor Model Number Vacuum Advance Mechanism Centrifugal Degrees Advance at 2000 RPM Vacuum Advance Spark Plug Type and Gap 258 2V 49 State 81 82 M 9 2 680 1100 900 324...

Страница 269: ...r is designed to be main tenance free The in line filter located between the fuel pump and the carburetor throttle body requires periodic replacement The fuel filter is located on the left frame rail...

Страница 270: ...hen the engine coolant heats to approximately 71 C 160 F NOTE When adjusting the idle speed place manual transmissions in the NEUTRAL position and automatic transmissions in DRIVE Turn all accessories...

Страница 271: ...ly extend Curb die Speed Adjustment Open throttle for AT LEAST 3 0 SECONDS 1200 rpm then close throttle Set the speed using the curb idle adjustment screw on the throttle lever to obtain specified rpm...

Страница 272: ...R CYLINDER ENGINE Engine Displacement Bore mm in Stroke mm in Comp Ratio Injection System Oil Capacity In Line 4 Cylinder 2 46L 150 CID 98 3 876 80 3 188 9 2 1 Throttle Body 4 0 qts 3 8L 3 3 imp qts w...

Страница 273: ...h and 6th Characters Day 7 1987 8 1988 01 12 H 01 31 Letter Code CID Fuel Injection Compression Ratio H 150 Renix TBI 9 2 1 The example code identifies a 2 46 liter 150 CID engine with a throttle body...

Страница 274: ...rsize Components Letter Code Cod Letter Definition B All cylinder bores 0 254mm 0 010 inch oversize M All crankshaft main bearing journals 0 254mm 0 010 inch undersize P All connecting rod bearing jou...

Страница 275: ...ing Oil Wick With Manual Transmission 11 Main Bearing Cap Seal Kit Rear 12 Main Bearing Cap Rear 13 Connecting Rod Bearing 14 Connecting Rod Bearing Cap 15 Gasket 16 Timing Case Cover 17 Seal 18 Vibra...

Страница 276: ...ap 35 Ventilation Valve 36 Grommet 37 Cylinder Head Rocker Cover 38 Bridge 39 Pivot 40 Rocker Arm 41 Valve Spring 42 Oil Deflector 43 Cylinder Head Bolt 44 Cylinder Head Core Plug 45 Cylinder Head 46...

Страница 277: ...ENGINES 2 46 UTTER 150 CIBD TOIR CYLINPER ENGINE FOUR CYLINDER ENGINE CYLINDER HEAD EXPLODED 54 Intake Manifold Gasket 55 Exhaust Manifold 56 Heat Stove 57 Valve s B 43...

Страница 278: ...wn Nuts 19 N m 14 ft lbs 16 27 N m 12 20 ft lbs Coil Bracket to Chassis 9 6 N m 85 in lbs 6 7 10 1 N m 60 90 in lbs Connecting Rod Bolt Nuts 45 N m 33 ft lbs 41 47 N m 30 35 ft lbs Cylinder Head Capsc...

Страница 279: ...et 40 N m 30 ft lbs 23 47 N m 17 35 ft lbs Fuel Supply Tube to Throttle Body 4 Cyl TBI 18 N m 13 ft lbs 15 22 N m 11 16 ft lbs 5 16 in Inverted Flare Nut 18 N m 13 ft lbs 15 22 N m 11 16 ft lbs Intake...

Страница 280: ...32 ft lbs 34 52 N m 25 38 ft lbs Rear Support Cushion to Crossmember Bolts 19 N m 14 ft lbs 16 22 N m 12 16 ft lbs Rocker Arm Assembly to Cylinder Head Bolts 26 N m 19 ft lbs 22 35 N m 16 26 ft lbs S...

Страница 281: ...3 0 08 0 044 05 Preferred Side Clearance Maximum Twist Maximum Bend Crankshaft End Play Main Bearing Journal Diameter Main Bearing Journal Width No 1 No 2 No 3 45 Main Bearing Clearance Connecting Rod...

Страница 282: ...23 0 043 0030 0 033 Preferred 025 0 51 0 25 0 64 0 043 0 081 0043 Pref 0 043 0 081 0 043 Pref 003 0 20 0 08 Pref 2 019 2 045 4 78 4 80 USA Piston Ring Groove Diameter No 1 and No 2 Oil Control Piston...

Страница 283: ...ter S stamped on the same machined surface where the build date code is stamped for complete engine assemblies Installation includes the transfer of components from the defective or damaged original e...

Страница 284: ...ENGINES 2 46 LITER 150 CID FOUR CYLINDER ENGINE ENGINE MOUNT COMPONENTS 1 Thru Bolt Nut 4 Mount Retaining Nut 2 Thru Bolt 5 Engine Mount 3 Mount Retaining Bolt B 50...

Страница 285: ...oving the radiator draincock and cap Remove the radiator draincock and radiator cap to drain the coolant N O T E Do not waste reusable coolant If the solution is clean drain the coolant into a clean c...

Страница 286: ...the water pump flange to maintain the pulley and water pump in alignment when the crankshaft is rotated Remove the power brake vacuum check valve Irom the booster if equipped If equipped with power s...

Страница 287: ...vehicle Attach the exhaust pipe to the manifold Install and tighten the nuts Install the flywheel housing access cover Install the remaining flywheel housing screws Install the starter motor and conne...

Страница 288: ...ines A 101205 Before connecting the quick connect fuel lines replace the O rings D A 100485B Replace the O ring using the Coupling Repair Kit P N 8983 502 745 as follows Remove the two O rings E and t...

Страница 289: ...ssembly G by pushing the assembly into the quick connect fitting D until a click is heard 100486 Grasp the disposable plug H and remove it from the fitting D NOTE By removing ONLY the plastic plug H t...

Страница 290: ...ut your hands near the pulleys belts or fan Do not wear loose clothing Start the engine and inspect for leaks Check the automatic transmission fluid level Stop the engine and check the coolant and the...

Страница 291: ...the entire length of the cylinder head sealing l surface Before the sealant begins to cure position the cover on the cylinder head Do not allow the sealant to come into contact with the rocker arms o...

Страница 292: ...push rod end for excessive wear and replace as required If any push rod is excessively worn because of lack of oil replace it and inspect the corresponding hydraulic tappet for excessive wear A wear p...

Страница 293: ...allation Dip each tappet assembly in AMC Engine Oil Supplement EOS or equivalent Use Hydraulic Valve Tappet Removal and Installation Tool J 21884 to install each tappet in the same bore from where it...

Страница 294: ...NOTE Retain the push rods bridges pivots and rocker arms in the same order and position as removed 84174 Remove the spark plug s adjacent to the cylinder s below the valve springs to be removed Insta...

Страница 295: ...the cylinder head Disconnect the air hose Remove the adapter from the spark plug hole and install the spark plug Repeat the procedure for each remaining valve spring to be removed Install the push rod...

Страница 296: ...stall the rocker arms and bridge and pivot assemblies Alternately tighten the capscrews at each bridge one turn at a time to avoid damaging the bridges Install the spark plugs and connect the wire con...

Страница 297: ...separate the vibration damper pulley from the vibration damper Remove the vibration damper retaining bolt and washer Use Vibration Damper Removal Tool J 21791 01 to remove the damper from the cranksha...

Страница 298: ...iginal gasket Coat the front seal end tab recesses generously with RTV sealant AMC Gasket ln A Tube or equivalent and position the seal on the timing case cover Apply engine oil to the seal oil pan co...

Страница 299: ...he vibration damper hub contact surface of the seal With the key inserted in the keyway on the crankshaft install the vibration damper washer and bolt Lubricate and tighten the bolt with 108 N m 80 ft...

Страница 300: ...01 84179 Remove the crankshaft oil seal with Timing Cover Oil Seal Remover Tool J 9256 or equivalent Position a replacement oil seal on Timing Case Cover Alignment and Seal Installation Tool J 22248 w...

Страница 301: ...e crankshaft from turning Install the damper pulley Tighten the bolts with 27 N m 20 ft lbs torque Install the drive belt s and tighten to the specified tension Refer to the Cooling Systems section TI...

Страница 302: ...S 84185 TIMING CHAIN INSTALLATION Turn the tensioner lever 1 to the unlocked DOWN position Pull the tensioner block 2 toward the tensioner lever to compress the spring Hold the block and turn the ten...

Страница 303: ...mper bolt tightening torque value is attained the crankshaft can be prevented from turning by placing two 5 16x11 2 inch bolts into the damper pulley holes and wedging a bar between them Rotate the ba...

Страница 304: ...timing case cover Refer to the removal procedure Remove the crankshaft oil slinger 84874 Rotate the crankshaft until the zero degree 0 timing mark on the crankshaft sprocket is closest to and on the c...

Страница 305: ...he broken pin is a dowel type pin center punch it CAUTION Cover the open oil pan area to prevent metal chips from entering the pan Drill into the pin center with a 4mm 5 32 in drill bit Turn a self ta...

Страница 306: ...er to the installation procedure With the key inserted in the keyway on the crankshaft install the vibration damper washer and bolt Lubricate and tighten the damper bolt with 108 N m 80 ft lbs torque...

Страница 307: ...1 bridge 2 and pivot 3 assemblies and rocker arms 4 Alternately loosen each capscrew one turn at a time to avoid damaging the bridges Remove the push rods 5 NOTE Position all components on a work ben...

Страница 308: ...A 84184 Remove the timing chain and sprockets as an assembly B Remove the camshaft C 83109A CAMSHAFT INSTALLATION Lubricate the camshaft with AMC Engine Oil Supplement EOS or equivalent Install the ca...

Страница 309: ...he one o clock position This positions the crankshaft sprocket timing mark where the adjacent tooth meshes with the chain at the three o clock position Count the number of chain pins between the timin...

Страница 310: ...1 V2 inch bolts into the damper pulley holes and wedging a bar between them Rotate the bar until it contacts the frame member to prevent the crankshaft from turning Install the damper pulley Install t...

Страница 311: ...the complete installation procedure must be repeated Install the tappets using Hydraulic Valve Tappet Installer J 21884 J 21884 84175 Install the push rods Install the rocker arms and bridge and pivo...

Страница 312: ...ceptable for reuse drain it into a clean container Disconnect the fuel inlet and return hoses Disconnect the ISA motor wire connector Disconnect the coolant hoses from the intake manifold Disconnect t...

Страница 313: ...manifold 1 Install the remaining attaching hardware Tighten all the bolts and nuts according to the sequence depicted in the illustration Tightening torque is 31 N m 23 ft lbs 84178 Install the vacuu...

Страница 314: ...for the climate WARNING Use extreme caution when the engine is operating Do not stand in a direct line with the fan Do not put your hands near the pulleys belts or fan Do not wear loose clothing Star...

Страница 315: ...ER HEAD REMOVAL Disconnect the battery negative cable N O T E Do not waste reusable coolant If the solution is clean and is being drained only to service the engine or cooling system drain the coolant...

Страница 316: ...unit wire connector and battery negative cable Remove the cylinder head bolts 8 cylinder head 9 and gasket 10 CYLINDER HEAD CLEANING AND INSPECTION Thoroughly clean the machined surfaces on the cylind...

Страница 317: ...not allow sealing compound to enter the cylinder bore Apply an even coat of Perfect Seal sealing compound or equivalent to both sides of the replacement cylinder head gasket and position the gasket on...

Страница 318: ...19 ft lbs torque Install the cylinder head cover Refer to the installation procedure Connect the hoses to the thermostat housing and fill the cooling system to the specified level Refer to the Cooling...

Страница 319: ...ills Drain the engine oil Remove the starter motor Remove the flywheel housing access cover Remove the oil pan screws Remove the oil pan by sliding it to the rear Oil Pan Cleaning Clean the gasket and...

Страница 320: ...ition on the cylinder block Apply a generous amount of RTV sealant to the end tabs of the gaskets Apply engine oil to the oil pan contacting surface of the front and rear oil pan seals NOTE Tighten th...

Страница 321: ...with replacement gaskets and seals Refer to Oil Pan Installation Fill the oil pan with replacement engine oil to the specified level Oil Pump Overhaul NOTE Refer to MOT 2 46L manual for the oil pump...

Страница 322: ...nder Head Cover Removal for the procedure 84103 Remove the capscrews 1 bridge 2 and pivot 3 assemblies and rocker arms 4 CAUTION Alternately loosen the capscrews one turn at a time to avoid damaging t...

Страница 323: ...procedure Remove the bolts 1 oil pump 2 and gasket 3 Remove the connecting rod bearing caps and bearing inserts Retain them in the same order as removed to facilitate installation at their original l...

Страница 324: ...onnecting rod bolts do not scratch the crankshaft journals or cylinder walls Short pieces of rubber hose slipped over the connecting rod bolts will provide protection during installation Use Piston Ri...

Страница 325: ...nt seals 1 and 2 and gaskets 3 84190 Tighten the drain plug securely Refer to Oil Pan Installation for the procedure Lower the vehicle Install a replacement gasket and the cylinder head Refer to Cylin...

Страница 326: ...ush rods 5 rocker arms 4 bridge torque using the torque sequence outlined 2 and pivot 3 assemblies and capscrews 1 CAUTION Alternately tighten the capscrews at each bridge one turn at a time to avoid...

Страница 327: ...connecting rod bearing caps Remove the lower bearing inserts Remove the upper bearing inserts by rotating sliding them out of the connecting rods NOTE Do not intermix the bearing caps Each connecting...

Страница 328: ...nserts and caps around the journals and secure them with the retaining nuts Tighten with 45 N m 33 ft lbs torque Install the oil pump with a replacement gasket Refer to the installation procedure 8419...

Страница 329: ...in bearing cap and lower insert 83116 Remove the lower bearing insert from the bearing cap Remove the upper bearing insert by loosening all of the other bearing caps and inserting a small cotter pin t...

Страница 330: ...nual for the procedure CRANKSHAFT MAIN BEARINGS INSTALLATION Lubricate the bearing surface of the inserts with engine oil Loosen all the main bearing caps Install the main bearing upper insert Install...

Страница 331: ...on the dipstick REAR MAIN BEARING OIL SEAL REMOVAL The crankshaft rear main bearing oil seal is a one piece single lip seal that fits tightly between the cylinder block and the crankshaft NOTE When re...

Страница 332: ...smission If defective the entire drive plate and ring gear assembly must be replaced for engines with automatic transmissions NOTE Before removing the drive plate or fly wheel the transmission MUST B...

Страница 333: ...blocks equally spaced under the ring gear Press the flywheel down through the ring gear NOTE The ring gear can also be removed by breaking it with a chisel Apply heat to expand the inside diameter of...

Страница 334: ...LINDER ENGINE GENERAL INFORMATION Engine Displacement Bore mm in Stroke mm in Comp Ratio Carburetor Oil Capacity 6 Cylinder 4 21 258 CID 95 25 3 75 98 93 3 895 9 2 1 2 Venturi 3 8L 4 0 qts 3 3 imp qts...

Страница 335: ...ENGINES 4 2 LITER 258 CID SIX CYLINDER ENGINE 86349 B 101...

Страница 336: ...r and 9 2 1 com pression ratio that was built on April 9 1986 60257C Oversize or Undersize Components Some engines may be built with oversize or undersize components such as oversize cylinder bores un...

Страница 337: ...ge 6 Pivot 7 Rocker Arm 8 Push Rod 9 Cylinder Head Bolt 10 Cylinder Head Core Plug 11 Cylinder Head 12 Snap Ring 13 Tappet 14 Intake Manifold Gasket 15 Hose Fitting 16 Plug 17 Exhaust Manifold 18 Heat...

Страница 338: ...hedder Slinger 18 Crankshaft Sprocket 19 Crankshaft B 20 Connecting Rod Bearing 21 Connecting Rod Bearing Cap 22 Main Bearings 23 Vibration Damper Pulley 24 Washer 25 Vibration Damper 26 Seal 27 Timin...

Страница 339: ...Bearing Cap Seal 4 Dowel Pin 16 Oil Pump Idler Gear Shaft 5 Oil Pump to Cylinder Block Gasket 17 Cotter Pin 6 Oil Pump Body 18 Release Valve Plunger 7 Oil Pump Drive Shaft and Gear 19 Oil Pump Straine...

Страница 340: ...ad Cover Screws 6 2 N m 55 in lbs 5 0 8 5 N m 45 75 ft lbs Clutch Cover to Flywheel Bolts 54 N m 40 ft lbs 47 61 N m 35 45 ft lbs Crankshaft Pulley to Damper Bolts 27 N m 20 ft lbs 20 34 N m 15 25 ft...

Страница 341: ...25 35 ft lbs Oil Pan Screws 1 4 in 20 9 N m 7 ft lbs 7 12 N m 5 9 ft lbs Oil Pan Screws 5 16 in 18 15 N m 11 ft lbs 12 18 N m 5 11 ft lbs Oil Pump Cover Screws 8 N m 70 in lbs 7 9 N m 60 80 in lbs Oi...

Страница 342: ...to Cylinder Head Bolts 26 N m 19 ft lbs 18 34 N m 13 25 ft lbs Spark Plug 37 N m 27 ft lbs 30 45 N m 22 33 ft lbs Starter Motor to Cylinder Block Bolts 45 N m 33 ft lbs 38 51 N m 28 38 ft lbs Timing C...

Страница 343: ...lap 34 Intake Duration 262 Exhaust Duration 262 USA Inches Unless Otherwise Specified Connecting Rods Total Weight less bearings 695 703 Total Length center to center 5 873 5 877 Piston Pin Bore Diame...

Страница 344: ...ferred PMon Ring Gap O M r a i m Compression both 0 010 0 020 0 25 0 51 Piston Ring Gap Clearance Oil Control Steel Ralls 0 010 0 025 0 25 0 64 USA Inches Unless O t h e r w i s e Specified Piston Rin...

Страница 345: ...ft NOTE The camshaft must be procured separately and installed before the engine is installed in the vehicle NOTE For identification short engine assem blies have the letter S stamped on the same mach...

Страница 346: ...he transmission adapter housing and the rear support crossmember Replacement of a cushion may be accom plished by supporting the weight of the engine or transmission at the area of the cushion CAUTION...

Страница 347: ...iator draincock and radiator cap and drain the coolant NOTE Do not waste reusable coolant If the solution is clean drain it into a clean container for reuse Mark the hinge locations on the hood panel...

Страница 348: ...sconnect the fuel return hose from the fuel filter Disconnect the carburetor bowl vent hose from the fuel vapor canister Disconnect the throttle cable and remove it from the bracket Disconnect the thr...

Страница 349: ...g access cover mark the converter and drive plate location for installation reference and remove the converter to drive plate bolts rotate the crankshaft for access to each bolt remove the exhaust pip...

Страница 350: ...Lower the engine into the mount cushions Ensure the bolt holes are aligned and insert the motor mount thru bolts Install the thru bolt nuts and tighten with the specified torque Lift the vehicle and p...

Страница 351: ...le valve rod and retainer Connect the throttle cable and install the rod Install the throttle valve rod spring Connect the carburetor wire connectors Connect the oxygen sensor wire connector Install t...

Страница 352: ...luid Install the battery and connect the battery cables Start the engine and inspect for leaks Check the automatic transmission fluid level Stop the engine and check the coolant and engine oil levels...

Страница 353: ...e cover flange sealing surface and inspect the cover Replace the cover if it is cracked or damaged in any way If a replacement cover is installed transfer the PCV valve grommet and oil filler cap from...

Страница 354: ...r head as soon as the primer and sealer have set up Do not allow the sealer to contact the valve actuating or other components Avoid smearing the sealer Install and tighten the cylinder head cover nut...

Страница 355: ...for excessive wear and replace as required if any push rod is excessively worn because of lack of oil replace the push rod and inspect the corresponding hydraulic tappet A wear pattern along the lengt...

Страница 356: ...pets Installation NOTE It is not necessary to charge the tappets with engine oil They will charge themselves within a very short period of engine operation Dip each tappet in AMC Engine Oil Supplement...

Страница 357: ...ce around the valve stem by a retainer and a set of conical valve locks The locks can be removed only by compressing the valve spring Remove the cylinder head cover and gasket Refer to Cylinder Head C...

Страница 358: ...ir con ditioning use a flexible air adapter when servicing the No 1 cylinder Use Valve Spring Compressor Tool Set J 22534 to compress the spring and remove the locks 1 81066A Remove the valve spring 2...

Страница 359: ...ad cover Refer to Cylinder Head Cover Removal for the procedure Remove the capscrews bridge and pivot assemblies and rocker arms Alternately loosen each capscrew one turn at a time to avoid damaging t...

Страница 360: ...rom the front of the engine until the dial indicator pointer indicates 0 305mm 0 012 in travel distance lift The timing notch index on the vibration damper should be aligned with the TDC mark on the t...

Страница 361: ...tained the crankshaft can be prevented from turning by placing two 5 16x11 2 inch bolts into the damper front pulley holes and wedging a bar between them Rotate the bar until it contacts the frame mem...

Страница 362: ...cover screws and cover to cylinder block bolts Remove the timing case cover 2 front seal and gasket from the engine Cut off the oil pan side gasket end tabs flush with the front face of the cylinder b...

Страница 363: ...on the cylinder block Cut the end tabs A off of the replacement timing cover gasket corresponding to those cut off the original gasket Coat the front cover end tab recesses generously with RTV sealan...

Страница 364: ...the crankshaft with engine oil Position J 22248 with seal over end of crankshaft Insert tool J 22248 Install seai into the timing chain cover by gent ly tapping with rubber or plastic mallet Remove t...

Страница 365: ...an 12 7mm 1 2 in replace it The correct timing chain has 48 pins A chain with more than 48 pins will cause excessive slack Remove the drive belt s Remove the engine fan and hub or Tempatrol fan assemb...

Страница 366: ...procket with the timing marks 1 aligned 86210 With the key in the keyway on the crankshaft install the assembly on the crankshaft and camshaft Install the camshaft sprocket retaining bolt and washer a...

Страница 367: ...an assembly With the key in the keyway on the crankshaft install the vibration damper 3 washer and bolt Lubricate and tighten the bolt with 108 N m 80 ft lbs torque Install the drive belt s and tighte...

Страница 368: ...C system Remove the distributor and ignition wires Remove the cylinder head cover Refer to Cylinder Head Cover Removal for the procedure 86319 Remove the capscrews 1 bridge 2 and pivot 3 assemblies an...

Страница 369: ...ad Removal for the procedure 86320 Remove the hydraulic valve tappets using special tool J 21884 86214 Remove the vibration damper using special tool J 21791 01 procedure Refer to the removal J 21791...

Страница 370: ...icate the camshaft with AMC Engine Oil Supplement EOS or equivalent Install the camshaft carefully to prevent damaging the camshaft bearings Install the timing chain crankshaft sprocket and camshaft s...

Страница 371: ...he hydraulic valve tappets with special tool J 21884 86214 Install the cylinder head Refer to Cylinder Head Installation for the procedure Install the fan assembly and shroud Install the drive belt s...

Страница 372: ...tallation for the procedure Install the A C condenser and receiver drier assembly if equipped Refer to Chapter L Heating and Air Conditioning for additional information pertaining to the A C system CA...

Страница 373: ...de as a complete assembly remove the A C condenser attaching bolts and move the condenser and receiver drier assembly up and out of the way Remove the drive belt s Remove the crankshaft vibration damp...

Страница 374: ...when center punching the pin CAUTION Cover the opened oil pan area to prevent metal chips from entering the pan Drill into the pin center with a 4mm 5 32 in drill bit Insert a self tapping screw into...

Страница 375: ...nt to hold them in place Coat both sides of the replacement timing case cover gasket with gasket sealer Apply a 3mm 1 8 in bead of RTV sealant to the joint formed at the oil pan and cylinder block Loo...

Страница 376: ...turning Install the damper pulley if applicable If equipped with air conditioning install the A C compressor drive belt idler pulley install the alternator install the A C condenser and receiver drier...

Страница 377: ...system coolant temper ature sender wire connector located on the intake manifold Disconnect the vacuum hose from the EGR valve Disconnect the intake manifold electric heater 1 wire connector Remove t...

Страница 378: ...nstall the carburetor studs replacement gaskets and spacer Install the carburetor and connect the linkage and hoses Tighten the carburetor mounting nuts with 19 N m 14 ft lbs torque Connect the fuel p...

Страница 379: ...climate WARNING Use extreme caution when the engine is operating Do not stand in a direct line with the fan Do not put your hands near the pulleys belts or fan Do not wear loose clothing Start the eng...

Страница 380: ...EGR valve tube CYLINDER HEAD REMOVAL NOTE Do not waste reusable coolant If the solution is clean and is being drained only to service the engine or cooling system drain the coolant into a clean conta...

Страница 381: ...ket to cylinder head mounting screw NOTE The serpentine drive belt tension is released by loosening the alternator remove the bolts from the A C compressor mounting bracket and set the compressor asid...

Страница 382: ...ylinder head that are not included with the replacement cylinder head Do not install the temperature sending unit until the system is filled with coolant This permits trapped air to escape from the cy...

Страница 383: ...ivot assemblies in the order removed Loosely install the capscrews for each bridge and tighten alternately one turn at a time to avoid damaging the bridges Tighten the capscrews with 26 N m 19 ft lbs...

Страница 384: ...pan sump Install a replacement oil pan front seal 1 on the timing case cover and apply a generous amount of RTV sealant AMC Gasket in a Tube or equivalent to the recesses in the tab ends Cement the r...

Страница 385: ...e sill supports and jack Lower the vehicle WARNING Use extreme caution when the engine is operating Do not stand in a direct line with the fan Do not put your hands near the pulleys belts or fan Do no...

Страница 386: ...the oil pan with replacement engine oil to the specified level LUBRICATION SYSTEM Oil Pump Overhaul Refer to the MOT 4 2L manual for the oil pump overhaul procedure LUBRICATION SYSTEM Oil Pressure Gau...

Страница 387: ...n the engine oil Remove the oil pan gasket and seais Refer to Oil Pan Removal for the procedure Remove the connecting rod bearing caps and inserts Retain them in the same order as removed to facilitat...

Страница 388: ...edure Lubricate the pistons and rings with clean engine oil CAUTION Ensure that the connecting rod bolts do not scratch the crankshaft journals or cylinder walls Short pieces of rubber hose slipped ov...

Страница 389: ...tion Refer to the MOT 4 2L manual for the removal and installation procedure Connecting Roi Bearings Removal Drain the engine oil Remove the oil pan seals and gaskets Refer to Oil Pan Removal for the...

Страница 390: ...ighten with 45 N m 33 ft lbs torque Install the oil pan using the replacement gaskets and seals Tighten the drain plug securely Refer to Oil Pan Installation for the procedure Fill the crankcase with...

Страница 391: ...ance with Plastigage Crankshaft Installed Refer to the MOT 4 2L manual for the procedure Crankshaft Main Bearings Installation Lubricate the bearing surface of each insert with engine oil Loosen all t...

Страница 392: ...nly Remove the vibration damper and key with Tool J 21791 Refer to the removal procedure Remove the oil seal with Timing Cover Oil Seal Remover Tool J 9256 or equivalent Position the replacement oil s...

Страница 393: ...he rear main oil seal the transmission must be removed Refer to the applicable transmission removal procedure NOTE The crankshaft rear main bearing oil seal is a two piece single lip neoprene seal The...

Страница 394: ...earing cap 4 with RTV sealant AMC Gasket in a Tube or equivalent CAUTION Do not apply sealant to the cylinder block to bearing cap mating surface because this will alter the bearing to journal clearan...

Страница 395: ...eplacement ring gear Press the flywheel into the replacement ring gear NOTE For engines equipped with a manual transmission the flywheel is balanced as an individual component and also as part of the...

Страница 396: ...Fan and Pulley to Hub Bolts Four and Six Cylinder Engines 24 N m 18 ft lbs 16 34 Nm 12 25 ft lbs A T Fluid Cooler Pipe Flared Fitting Nuts 34 N m 25 ft lbs 20 41 N m 15 30 ft lbs A T Fluid Cooler Pipe...

Страница 397: ...oling System Capacities Refer to Cooling System Capacities Chart Fan Refer to Cooling System Components Chart Drive Belt Angle of V 3 8 Serpentine Belt 6 40 Ribs Width top of Groove 9 7 12 7 mm 0 38 0...

Страница 398: ...NGINE WITH SERPENTINE DRIVE AND ALTERNATOR CALIFORNIA ONLY SIX CYLINDER ENGINE WITH SERPENTINE DRIVE ALTERNATOR A C COMPRESSOR AND POWER STEERING PUMP CALIFORNIA AND 49 STATE SIX CYLINDER ENGINE WITH...

Страница 399: ...ENGINES US COOLING SYSTEMS US COOLING SYSTEM COMPONENTS 840155 B 165...

Страница 400: ...is necessary to check the level allow the engine to idle for a few moments Use a heavy rag or towel wrapped over the cap and turn the cap slowly to the first notch to relieve the pressure Then push do...

Страница 401: ...or to the top and install the radiator cap Add sufficient coolant to the recovery bottle to raise the level to the FULL mark After refilling the system or when air pockets are suspected purge the cool...

Страница 402: ...r Tempatrol fan and drive Remove the shroud Refer to Fan Replacement Remove the pulley Water Pump Pulley Installation Install the pulley Position the fan spacer or Tempatrol fan and drive and shroud I...

Страница 403: ...e it turns freely Position the shroud against the front of the engine if removed and install the fan assembly Tighten the screws with 24 N m 18 ft lbs torque Install the fan shroud if equipped on the...

Страница 404: ...ted Position the rod in the water pump inlet and attempt to hold the impeller while turning the fan blades If the impeller A is loose and can be held with the rod while the fan blades are turning the...

Страница 405: ...gth of 16mm 5 8 in inside diameter ID heater hose on the intake manifold front fitting and place the funnel in the hose The funnel must have a minimum outlet size of 9 5mm 3 8 in inside diameter ID Fi...

Страница 406: ...ming a hose inspection inspect the radiator lower hose for proper position and condition of the spring THERMOSTAT REMOVAL An arrow or the words TO RAD is stamped on the thermostat to indicate the prop...

Страница 407: ...system to the correct level with the required coolant mixture Refer to Coolant THERMOSTAT TESTING Remove the thermostat Refer to Thermostat Removal Insert a 0 076mm 0 003 in feeler gauge with a wire...

Страница 408: ...Jeep part number and the vendor build code number embossed on the upper tank Radiator Identification B6 Month Year A J a n 6 1986 B F e b 7 1987 Vendor Last Two Digits Vendor Month Year Modine of Vend...

Страница 409: ...surized because serious burns from the coolant can occur Position a drain pan under the radiator and remove the draincock Observe the WARNING above Remove the radiator cap Disconnect the radiator uppe...

Страница 410: ...ighest point The cap release pressure should be 82 7 103 4 kPa 1 2 1 5 psi NOTE The cap is satisfactory when the pressure holds steady or holds within the 82 7 103 4 kPa 12 15 psi range for 30 seconds...

Страница 411: ...oval The Tempatrol drive unit should be replaced if there is an indication of a fluid leak noise or if roughness is detected when turning by hand If the drive cannot be turned by hand or if the leadin...

Страница 412: ...t Dynamic Test CAUTION Ensure there is adequate fan blade clearance before drilling Drill 3 18mm 1 8 in diameter hole in the top center of the fan shroud CAUTION Ensure there is adequate clearance fro...

Страница 413: ...treme situations the engine fan blades may contact the shroud An examination for proper engine mounting should isolate the problem If not examine the shroud position To compensate for normal engine mo...

Страница 414: ...n plugs or loosen the radiator draincock with the system hot and pressurized because serious hums from the coolant can occur CYLINDER BLOCK HEATER INSTALLATION A factory installed cylinder block heate...

Страница 415: ...ostat housing Disconnect the upper radiator hose from the radiator and attach the flushing gun to the hose Disconnect the lower radiator hose from the water pump and attach a leadaway hose to the wate...

Страница 416: ...el and pry tool Apply a sealer to the edges of the replacement plugs and position the plugs with the lip toward the outside of the cylinder block Install with a hammer and suitable tool Refer to the C...

Страница 417: ...frequently it is considered normal Refer to the applicable diagnosis chart for specific cooling system faults Service Diagnosis Condition Possible Cause Correction HIGH TEMPERATURE G A U G E I N D I C...

Страница 418: ...nt 21 Repair or replace leaking component replace coolant 22 Replace unit 1 Replace thermostat 2 Repair or replace faulty component Refer to Overheating Causes in addition to the following items 1 Ove...

Страница 419: ...estricted return inlet in water pump 2 Heater h o M coHaptsd or restricted 3 Restricted hatter com 4 Restricted outlet in thermostat housing 5 Intake manifold bypass hols m cylinder head restricted 6...

Страница 420: ...NOT OK Tighten Housing Bolts With Specified Torque Replace Defective Thermostat Engine Overheating Diagnosis Guide Overheat Indicated on Gauge 1 1 1 r Check Coolant Level in Radiator and Coolant Reco...

Страница 421: ...or R e p l a c e as Necessary continued Coolant Low in Top Radiator Tank OK in Bottle Test Radiator Cap Visually Check Entire System for Leaks 3 OK Check Coolant Circulation at Heeler Hote by Feel Hes...

Страница 422: ...ect the cams on the outside of the filler neck If the cams are bent seating of pressure cap valve and tester seal will be affected Bent cams can be reformed if done carefully Attach a pressure tester...

Страница 423: ...ating Do not stand in a direct line with the fan Do not put your hands near the pulleys belts or fan Do not wear loose clothing Operate the engine without the pressure cap on the radiator until the th...

Страница 424: ...perating Do not stand in a direct line with the fan Do not put your hands near the pulleys belts or fan Do not wear loose clothing Start the engine and accelerate rapidly three times to approximately...

Страница 425: ...e belt Re test tension after the adjustment Alternator and Fan Adjustment Without Air Conditioner All Engines Position Tension Gauge Tool J 23600 B on the upper section of the belt midway between the...

Страница 426: ...th 38 N m 28 ft lbs torque tighten the pivot bolt and nut with 38 N m 28 ft lbs torque re test the tension Air Conditioner Compressor Adjustment Sii Cylinder Engine Position Tension Gauge Tool J 23600...

Страница 427: ...he bolts with 38 N m 28 ft lbs torque re test the tension Serpentine Drive Belt Adjustment Position Tension Gauge Tool J 23600 B on the longest accessible span of the belt Test the belt tension accord...

Страница 428: ...just belt 2 Locate and repair 3 Align belt pulley s 4 Install correct belt 5 Locate defective driven component and repair 6 Vary belt tension within specifications Replace belt RIB CHUNKING ONE OR MOR...

Страница 429: ...eplace pulley s 3 Remove foreign objects from grooves 4 Avoid excessiveengineacceleration 5 Align pulley s 6 Install correct belt 7 Replace belt BELT B R O K E N NOTE I D E N T I F Y AND CORRECT PROBL...

Страница 430: ...ey s 3 Excessive heat condition causing rubber to harden 3 Correct heat condition as necessary 4 Excessive belt thickness 4 Replace belt 5 Belt overcured 5 Replace belt 6 Excessive tension 6 Adjust be...

Страница 431: ...lated I S Notes Remove the upper bonnet assembly 1 r K 100450 Remove the lower bonnet assembly retaining bolts 2 and lower bonnet assembly 3 Remove the throttle cable and return spring Disconnect the...

Страница 432: ...ody 100451B Disconnect the fuel return pipe 8 from the throttle body Disconnect the vacuum hoses from the throttle body assembly Identify and tag the hoses for installation reference Disconnect thrott...

Страница 433: ...the components Install the throttle body to manifold retaining nuts 10 on the studs Connect the vacuum hoses Connect the fuel return pipe 8 to the throttle body Connect the fuel supply pipe 7 to the t...

Страница 434: ...d Refer to the Throttle Body Assembly Installation procedure FUEL PRESSURE REGULATOR REMOVAL Remove the throttle body assembly as outlined previously Remove the three retaining screws 1 that secure th...

Страница 435: ...e injector retainer clip screws Remove the injector retainer clip 1 Using a pair of small pliers gently grasp the center collar of the injector between electrical terminals and carefully remove the in...

Страница 436: ...n Install the retainer clip 1 and screws Install the injector wire connector Install the air inlet bonnet and hose THROTTLE POSITION SENSOR TPS REMOVAL Disconnect the wire connector from the sensor Re...

Страница 437: ...pring EGR VALVE REMOVAL NOTE The EGR valve is located on the intake manifold below the throttle body Disconnect the vacuum hose from the EGR valve 1 Remove the two EGR valve to intake manifold retaini...

Страница 438: ...wire harness connector 1 Disconnect the vacuum hose 2 Remove the retaining nuts 3 Remove the MAP sensor from the dash panel MANIFOLD ABSOLUTE PRESSURE MAP SENSOR INSTALLATION Position the MAP sensor...

Страница 439: ...re harness connector to the MAT sensor harness COOLANT TEMPERATURE SENSOR CTS REMOVAL Remove the wire harness connector from the coolant temperature sensor CTS 12 Note It is located at the rear of the...

Страница 440: ...R B RELAY FUEL PUMP RELAY REMOVAL Remove the power B relay 1 or the fuel pump relay 2 from the relay on the right side battery bracket POWER B RELAY FUEL PUMP RELAY INSTALLATION Connect the replacemen...

Страница 441: ...DE OPEN THROTTLE WOT SWITCH REMOVAL Remove the air inlet bonnet Disconnect the throttle return spring Disconnect the throttle cable Disconnect the wire harness connector from the WOT switch 6 Remove t...

Страница 442: ...onnect fitting D D A 100485A remove the retainer from the fuel tube and discard the O rings the spacer and the retainer install the retainer assembly G by pushing the assembly into the quick connect f...

Страница 443: ...tic plug H and remove it from the fitting D verify that the quick connect fitting assembly fits securely over the fuel lines by giving the fuel lines a firm tug 100487 push the fuel line B into the fi...

Страница 444: ...Place the filter 3 into position Install the inlet and outlet fuel hoses 2 and clamps Tighten clamps securely Install the filter retaining strap and bolt 1 Install protective plate B and retaining bo...

Страница 445: ...LLATION Position shield and tank on jack Partially raise Install fuel outlet hose and return hoses fuel gauge sending unit wires and tank vapor vent hoses Raise shield and tank to installation positio...

Страница 446: ...gauge sending unit retainer ring C with a screwdriver and remove 101287 Separate the sending unit 1 and pump 2 TBI MODELS SENDING UNIT FUEL PUMP TBI MODELS INSTALLATION Connect the fuel pump 2 to the...

Страница 447: ...Latch Relay 2 Ignition 3 Park Neutral 3 Ground 4 Power Latched Relay B 4 Start Solenoid 5 Air Conditioning Clutch Relay 5 Battery 6 Wide Open Throttle Switch 6 Fuel Pump 7 Ground 6 Fuel Pump 8 Air Mix...

Страница 448: ...tend Forward 7 System Power Relay Latch Relay 25 Closed Throttle Idle Switch 8 WOT Switch 26 Not Used 9 Not Used 27 Ignition Output 10 System Ground 28 Speed Sensor 11 Speed Sensor 29 Start 12 Park Ne...

Страница 449: ...WIRING DIAGRAMS The electrical circuitry for the 1987 Renix TBFI system is illustrated in the following wiring diagrams If u j i SEE I S N O T E S NOTE 1 ENGINE BLOCK GROUNDS ARE FASTENED AT THE SAME...

Страница 450: ...JSIS ENGINES THROTTLE BODY INJECTION FUEL SYSTEMS 1987 EMISSION CONTROL SYSTEM SCHEMATIC THROTTLE BODY INJECTION 050 RESTRICTOR PCV CANISTER PURGE PURGE SIGNAL 100481A B 216...

Страница 451: ...etically beginning with the letter A in January and ending with the letter M in December the letter I is not used The tag is attached to the carburetor and must remain with it to assure proper identif...

Страница 452: ...m 0 520 in 12 7 136 mm 0 500 0 540 in 7 1 mm 0280 in 1850 1950 1750 2nd Step ET TR 8384 81 Man 6 5 mm 0 25 m 5 56 7 14 mm 0 218 0 282 in 0 9 mm 0 035 in 0 5 1 3 mm 0 020 0 050 in 3 5 mm 0 140 in 3 18...

Страница 453: ...chanism on model BBD carburetors cannot be serviced with the carburetor on the engine The carburetor must be removed to properly service the choke components Note and record the color and position of...

Страница 454: ...index key Ensure that the key notch in the cover is aligned with the index key tang Install the choke cover retainer Secure the retainer and cover with screws Do not tighten the screws completely at t...

Страница 455: ...843 17...

Страница 456: ...t 86353 COMPLETE CARBURETOR OVERHAUL The following procedures apply to a complete overhaul with the carburetor removed from the engine N O T E A complete disassembly is not necessary for adjustments I...

Страница 457: ...the vacuum piston 3 and metering rods 4 straight up and out of the air horn as an assembly Remove the vacuum piston spring 840221 If the main body is to be immersed in cleaning solution perform follow...

Страница 458: ...the rivets Remove the gasket and baffle Remove the choke housing from the throttle body Remove the air horn retaining screws and lift the air horn 5 straight up and away from the main body Remove the...

Страница 459: ...the venturi cluster screws Lift the venturi cluster and gaskets away from the main body Discard the gaskets Do not remove the idle orifice tubes or main vent tubes from the cluster Clean the tubes wi...

Страница 460: ...nings or passages This may enlarge the passages and change the calibration of the carburetor Wash all the components except the vacuum break diaphragm solenoid bowl vent seal and stepper motor in clea...

Страница 461: ...stall the accelerator pump discharge check valve ball 13 in the discharge passage Test the accelerator pump 14 circuit pour clean no lead fuel into the carburetor bowl 13mm 1 2 in deep insert the pump...

Страница 462: ...of the plastic rod lifter tangs under the piston yoke Slide the accelerator pump lever shaft through the rod lifter and pump arm Install the locks and adjusting screws but do not tighten Install the f...

Страница 463: ...ch rich GREEN INDEX KEY set the choke index at two notches rich Install and tighten the choke cover replacement screws Install the stepper motor with a replacement gasket Install the carburetor Refer...

Страница 464: ...es are completely closed Count and record the number of turns so the screw can be returned to the original position Fully depress the vacuum piston A while holding moderate pressure on the rod lifter...

Страница 465: ...aining portion of the cover rivets Turn the cover to 1 4 turn rich position 1 Install and tighten one retaining screw Use a straight slot type screw for service Open the throttle valve slightly and pl...

Страница 466: ...orrect dimension Adjust by bending the fast idle cam link D down to increase the distance or up to decrease the distance Remove the choke housing cover retaining straight slot screw Adjust the choke c...

Страница 467: ...ast idle cam The bowl vent should just begin to open If the valve is not closed on high fourth or third steps of the cam bend the valve tab A until it is closed If the valve does not just begin to ope...

Страница 468: ...tions chart and adjust the engine speed for the correct RPM Adjust by turning the fast idle speed adjustment screw Disconnect the tachometer Idle Speed Adjustment Install the carburetor fuel pipe vacu...

Страница 469: ...ose to the vacuum actuator Remove the tachometer If disconnected connect the A C compressor clutch wire connector Idle Mixture Adjustment NOTE If is necessary to remove the carburetor to gain access f...

Страница 470: ...screws clockwise leaner to obtain the specified drop in engine idle RPM Turn both the idle mixture screws in small equal amounts until the specified IDLE DROP is achieved Refer to the Mixture Adjustm...

Страница 471: ...take manifold EGR SYSTEM FUNCTIONAL TESTS The condition of the exhaust system may affect EGR system operation Excessive back pressure caused by exhaust S E E system restrictions may create driveabilit...

Страница 472: ...or fan Do not wear loose clothing With the engine at normal operating temper ature and at curb idle speed manually depress the EGR valve diaphragm This should cause an immediate drop in engine RPM an...

Страница 473: ...front side of the intake manifold The dual function valve is also used for distributor vacuum advance control The outer port 1 connects by a hose to ported vacuum at the carburetor The inner port 2 c...

Страница 474: ...the coolant from the radiator Identify tag and disconnect the vacuum hoses from the valve Use an open end wrench to remove the valve from the intake manifold EGR SYSTEM CTO VALVE INSTALLATION Install...

Страница 475: ...e vacuum hoses from the TVS Remove the retaining clip s attaching the TVS to the air cleaner Remove the TVS EGR SYSTEM THERMO VACUUM SWITCH INSTALLATION Install the TVS in the air cleaner Install the...

Страница 476: ...be exercised to prevent oil or dirt from entering the valve because this will impair its functioning Replace the delay valve if the functional test indicated it to be defective Otherwise install the d...

Страница 477: ...air cleaner housing Six Cylinder Engine Carburetor PCV Valve PCV Air Out PCV Air In PCV Filter PCV Solenoid 840239 PCV VALVE FUNCTIONAL TEST Test the valve at idle speed for the correct flow rate l s...

Страница 478: ...line with the fan Do not put your hands near the pulleys belts or fan Do not wear loose clothing Start the engine and allow it to idle Observe the flow rate l s or cfm Refer to PCV Valve Flow Rate ch...

Страница 479: ...polyester nonwoven felt PCV air filter is located in the filter retainer in the air cleaner housing Rotate the retainer 1 and remove the retainer and filter 2 from the air cleaner housing PCV AIR INLE...

Страница 480: ...d of a heat stove that partially encloses the exhaust manifold a heated air tube a special air cleaner assembly equipped with a thermal switch a reverse delay valve a check valve and a vacuum motor an...

Страница 481: ...position and release The air valve should briefly remain stationary and then move toward the heat OFF position and back to heat ON position Loosely attach the ambient air duct to the air cleaner and...

Страница 482: ...e into the air valve assembly and position it in the snorkel Attach the motor to the snorkel with a rivet NOTE Ensure that the rivet does not interfere with the movement of the air valve Correct as ne...

Страница 483: ...ngines have air cleaners with spring loaded trap doors to close off the air cleaner carburetor when the engine is inoperative TRAP DOOR FUNCTIONAL TESTS With the engine off remove the air cleaner cove...

Страница 484: ...ed for atmospheric pressure to pass through valve and eliminate the vacuum Replace the valve if the time required to eliminate the vacuum is less than 4 5 seconds or more than 13 2 seconds NOTE Instal...

Страница 485: ...open throttle WOT engine operation When the engine is started the MCU determines which mode of operation closed loop or open loop is correct It can determine this by monitoring the input signals from...

Страница 486: ...Motor 9 Idle Relay 10 Sole Vac Throttle Positioner 11 Upstream and Downstream Solenoids 12 PCV Solenoid MItro Computer Unit MCU The MCU is a microprocessor that monitors various engine operating condi...

Страница 487: ...hrottle WOT Switch 6 Knock Sensor 7 Distributor Coolant Temperature Switch The coolant temperature switch 1 is located at the rear of the intake manifold It provides the MCU with the temperature of th...

Страница 488: ...nch Hg vacuum switch can be identified by its natural color The 10 inch Hg vacuum switch is green in color The 4 inch Hg vacuum switch is controlled by ported vacuum Its electrical contact is normally...

Страница 489: ...eater oxygen content in the exhaust gas and a rich air fuel mixture causes less oxygen content 4 85055 Wiie Open Throttle WOT Switch The wide open throttle WOT switch 5 is attached to the base of the...

Страница 490: ...on the input the MCU can selectively retard the ignition timing of any single cylinder or a combination of cylinders to eliminate the knock ping condition 85059 Distributor The MCU also changes the i...

Страница 491: ...ot altitude The jumper wire is normally not connected to engine ground For vehicles operated above 6 400 meters 4 000 feet the jumper wire must be connected to engine ground To connect the altitude ju...

Страница 492: ...tepper motor is an integral part or the Model BBD carburetor The MCU operates the stepper motor air metering pins visible from the top of the carburetor air horn in increments or small steps in reacti...

Страница 493: ...is attached to the carburetor The Sole Vac throttle positioner consists of a holding solenoid and a vacuum actuator The holding solenoid provides additional engine idle speed when the air conditioner...

Страница 494: ...cated on a bracket attached to the top of the cylinder head cover The idle solenoid is also located on the same bracket The upstream and downstream solenoids are energized by the MCU The MCU energizes...

Страница 495: ...vent air entering below the throttle plate This prevents engine dieseling 85069 Bowl Vent Solenoid The bowl vent solenoid 16 is located in line with the hose between the carburetor bowl vent and the c...

Страница 496: ...OPERATION Each C E C Fuel Feedback System has four modes of operation key on start up warm up cruise KEY ON MODE OPERATION In the key on mode the system operates as follows ignition switch ON MCU is...

Страница 497: ...tream and downstream solenoids con trolled by the MCU to distribute air to either the exhaust or the catalytic converter Sole Vac holding solenoid is activated if the air conditioner is in operation s...

Страница 498: ...engines shape a sheet of clear acrylic plastic at least 6 35mm 0 250 inch thick and 38cm x 38cm 15 inches x 15 inches Secure the acrylic sheet on top of the air cleaner with the wing nut after the ai...

Страница 499: ...EliflES API FUEL FEEDBACK SYSTEMS API SIX CYLINDER ENGINE C E C S Y S T E M WIRING DIAGRAM 90760A J B 265...

Страница 500: ...GINES FUEL FEEDBACK SYSTEMS C Vacuum Switch Solenoid 1 Common D 2 Normally Closed NC E 3 Springloaded Pin 4 Normally Open NO Vent A A Stepper Motor Connector 1 Orange 2 Tan 3 Violet 4 Red 5 Brown B 26...

Страница 501: ...ENGINES FUEL FEEDBACK SYSTEMS B Coolant Temperature Switch 1 Insulator en46 3 swi i n 1 4 in Hg Vacuum Switch 2 10 in Hg Vacuum Switch 3 Green Color 4 Natural Color 81147B B 2 7...

Страница 502: ...10 IN HG VACUUM SWITCH 10 THERMAL ELECTRIC SWITCH TES 11 STEPPER MOTOR B0 12 COOLANT TEMP SWITCH 13 IDLE SPEED RELAY 14 STEPPER MOTOR A0 15 4 IN HG VACUUM SWITCH 1 f I f i r o HI II HUTU 11 r IUUIIII...

Страница 503: ...DENOTES COLOR CODED SIDE VAPOR AIR HOSES V A C U U M HOSES DUAL CTO VLV CALIF ONLY T A C V A C MTR CARB BOWL VENT TO F TNK CAN PURGE PURGE SIG ADAPT IDLE DECEL VAC RESV F DELAY CANISTER to m...

Страница 504: ...UTOR FOR CONTINUITY PROCEED TO INITIALIZATION TEST DIAGNOSTIC TEST 2 NO REPAIR O P E N WIRE AND R E T E S T Y E S TEST MCU CONNECTOR PIN 18 AND DISTRIBUTOR VIOLET WIRE AT DISTRIBUTOR FOR CONTINUITY NO...

Страница 505: ...VOLTAGE TURN SWITCH OFF REPAIR OPEN WIRE AND RETEST REPAIR OPEN WIRE AND RETEST TEST MCU CONNECTOR PIN 58 AND THE S TERMINAL OF THE STARTER SOLENOID FOR CONTINUITY YE 5 REPAIR OPEN WIRE AND RETEST RE...

Страница 506: ...RING PINS SHOULD MOVE FULLY TOWARD THE FRONT OF ENGINE REVERSE DIRECTION AND MOVE BACK TOWARD REAR REVERSE DIRECTION AND MOVE TOWARD FRONT STOP AND REMAIN STATIONARY NO YES TURN IGNITION OFF LOCATE AI...

Страница 507: ...TOR REMOVED TURN ENGINE ON OBSERVE PIN MOVEMENT WHEN ENGINE IS FIRST TURNED ON STEPPER MOTOR PINS MOVE TO FULL FORWARD RICH POSITION THEN BACK TO HALF WAY POSITION TURN IGNITION ON AND DISCONNECT STEP...

Страница 508: ...GE CONTINUED FROM mE 10US PAGE SEE I S N 0 T E S Y E S NO REPAIR STEPPER MOTOR PIN BINDING DEFECT REPLACE MCU AND RETEST STEPPER MOTOR CONNECT MCU HARNESS CONNECTOR REPLACE STEPPER MOTOR CONNECT MCU H...

Страница 509: ...Y FROM THE DIAGNOSTIC CONNECTOR PIN 7 TO MCU CONNECTOR PIN 20 NO DISCONNECT VACUUM HOSE FROM SWITCH 2 OF VACUUM SWITCH ASSEMBLY YES TEST FOR CONTINUITY BETWEEN DIAGNOSTIC CONNECTOR PIN 12 AND MCU CONN...

Страница 510: ...NECT AND RETEST TEST FOR CONTINUITY BETWEEN DIAGNOSTIC CONNECTOR D2 PIN 9 AND VACUUM SWITCH CONNECTOR PIN B Prh CIRCUIT X NO YES REPLACE MCU RETEST REPLACE VACUUM SWITCH ASSEMBLY AND RETEST REPAIR SHO...

Страница 511: ...ETEST DISCONNECT WOT SWITCH CONNECTOR AND CONNECT JUMPER WIRE BETWEEN WIRE HARNESS CONNECTOR TERMINALS RETEST FOR CONTINUITY REPAIR OPEN CIRCUIT IN WOT SWITCH WIRE HARNESS ENSURE THERE IS CONTINUITY B...

Страница 512: ...OBLEM IN COOLANT SWITCH CIRCUIT ENSURE THAT CONTINUITY ALSO EXISTS AT MCU CONNECTOR PIN 56 RECHECK NO OK DISCONNECT VACUUM SWITCH ASSEMBLY AND PLACE JUMPER WIRE BETWEEN PLUGS A AND C OF VACUUM SWITCH...

Страница 513: ...IFOLD VACUUM IS AT SWITCH 1 10 IN HG SW REPLACE VACUUM SWITCH ASSEMBLY AND RETEST YES TEST COMPLETE STOP ENGINE DISCONNECT VACUUM SWITCH ASSEMBLY CONNECTOR AND PLACE A JUMPER WIRE BETWEEN PINS A AND B...

Страница 514: ...EANER START AND WARM ENGINE UNTIL COOLANT TEMPERATURE HAS STABILIZED REMOVE AIR COVER AND INCREASE ENGINE SPEED TO 2000 RPM AND MAINTAIN WHILE OBSERVING CARBURETOR STEPPER MOTOR METERING PINS NO YES N...

Страница 515: ...ENGINE TO RETURN TO IDLE SPEED CONNECT VACUUM SWITCH ELECTRICAL CONNECTOR INCREASE ENGINE SPEED TO 1600 RPM TIMING SHOULD ADVANCE 6 CHECK FOR VACUUM SWITCH FAILURE CHECK FOR ELECTRICAL CONTINUITY FRO...

Страница 516: ...GREATER THAN 1 MEGOHM INPUT IMPEDANCE TO PIN 8 AT HARNESS SIDE OF MCU CONNECTOR AND NEGATIVE PROBE TO PIN 20 OF CONNECTOR GROUND INCREASE ENGINE SPEEDTO APPROXIMATELY 1200 RPM AND MAINTAIN CLOSE CHOKE...

Страница 517: ...TEPPER MOTOR PINS ARE AT MIDWAY TO FULL RICH POSITION REPLACE MCU AND RETEST STEPPER MOTOR PIN POSITION REPAIR WIRE HARNESS INSPECT FOR LARGE AIR BETWEEN 0 2 SENSOR LEAK INTO MANIFOLD CONNECTOR AND MC...

Страница 518: ...WIRE TERMINAL OF SOLENOID CONNECTOR REPAIR AND RETEST NO VOLTAGE X OK l YES TURN IGNITION OFF DISCONNECT MCU CONNECTOR WITH OHMMETER MEASURE THE RESISTANCE BETWEEN MCU CONNECTOR PIN 1 PROBE AND MCU CO...

Страница 519: ...CTOR PIN 46 TO GROUND REPAIR OPEN CIRCUIT IN WIRE HARNESS AND RETEST YES DISCONNECT VACUUM HOSE FROM PORT D OF DOWNSTREAM SOLENOID TEST VOLTAGE BETWEEN MCU CONNECTOR PIN 1 AND CONNECTOR PIN 20 PIN 20...

Страница 520: ...T O H M M E T E R M E A S U R E T H E R E S I S T A N C E B E T W E E N M C U C O N N E C T O R P I N 1 P R O B E A N D M C U C O N N E C T O R PIN 45 P R O B E Y E S C O N N E C T M C U H A R N E S...

Страница 521: ...E UPSTREAM SOLENOID AND RETEST SEE I S N O T E S NO WAIT FOR 60 SECONDS AND RETEST VOLTAGE YES TEST MCU HARNESS CONNECTOR PIN 1 FOR BATTERY VOLTAGE TURN ENGINE OFF RESTART ENGINE AND CHECK PORT D FOR...

Страница 522: ...TO INTERMEDIATE POSITION FOR NEXT 45 SECONDS THEN DISENGAGE YES YES DISCONNECT VACUUM HOSE FROM SOLE VAC SOLENOID AND CHECK FOR VACUUM DURING THE FIRST 15 SECONDS OF ENGINE OPERATION YES TEST FOR BATT...

Страница 523: ...SOLENOID TERMINALS DURING FIRST 15 SECONDS OF ENGINE OPERATION SEE I S N O T E S REPAIR VOLTAGE SUPPLY PROBLEM AND RETEST TURN ENGINE OFF DISCONNECT THE MCU HARNESS CONNECTOR TEST CONTINUITY FROM MCU...

Страница 524: ...RNESS CONNECTOR AND TEST CONTINUITY BETWEEN PIN 85 AND MCU CONNECTOR PIN 43 REPAIR OPEN CIRCUIT AND RETEST YES r REPLACE MCU AND RETEST DETERMINE IF VOLTAGE IS APPLIED ACROSS PIN 30 51 AND ENGINE GROU...

Страница 525: ...LTY SPARK PLUG S MISADJUSTED IGNITION TIMING AND MALFUNCTIONING IGNITION ADVANCE MECHANISMS REFER TO GENERAL SERVICE AND DIAGNOSIS SECTION SEE I S N O T E S ADJUST AND OR REPLACE COMPONENTS AS NECESSA...

Страница 526: ...or the body When inspecting an exhaust system critically inspect for cracked or loose joints stripped screws bolt threads corrosion damage and worn or broken hangers Replace all components that are ba...

Страница 527: ...gine and proceed with the next step Disconnect the exhaust pipe at the manifold Start the engine and increase the speed to 2000 RPM Observe the vacuum gauge If the vacuum stabilizes at 53 88 70 73 kPa...

Страница 528: ...the port it can usually be chipped out If the flash cannot be removed replace the manifold Install the exhaust manifold F O U R C Y L I N D E R ENGINE E X H A U S T S Y S T E M 1 Upper Heat Shield 5 L...

Страница 529: ...ir Injection Tube Port 81193B EXHAUST MANIFOLDS Refer to the Engine Section of this manual MUFFLER REMOWAL NOTE All original equipment exhaust systems are manufactured with the rear exhaust pipe welde...

Страница 530: ...manifold FRONT EXHAUST PIPE INSTALLATION Connect the rear of the replacement pipe to the converter Clean the mating surface of the exhaust mani fold flange Connect the pipe to the manifold but do not...

Страница 531: ...am or downstream from the check valve Air is injected either into the front exhaust pipe upstream or into the catalytic converter downstream depending upon engine operating conditions The C E C System...

Страница 532: ...ve 8 Downstream Air Control Valve 7 Upstream Check Valve Hose 8 Downstream Vacuum Hose g Downstream Check Valve Hose 10 Upstream Check Valve 11 Downstream Check Valve 12 Downstream Tube To Converter 1...

Страница 533: ...he solenoid is controlled by the micro computer unit MCU VACUUM STORAGE TANK Vacuum is stored in the tank until released by the air switch solenoid MICRO COMPUTER UNIT MCU The MCU switches air either...

Страница 534: ...UAL BED TWO and COC MONOLITHIC TYPE CONWERTER Remove the converter NOTE It may be necessary to heat the rear exhaust pipe to facilitate converter removal CONWERTER INSTALLATION Install the replacement...

Страница 535: ...STARTING SYSTEM BOSCH 4 Cyl Engine 49 Specifications 49 Bosch Starter Motor and Solenoid Testing Specifications 49 Bosch Starter Motor Cold Cranking Specifications 49 Bosch Starter Motor 50 General I...

Страница 536: ...rmation 116 Fog Lamp Removal 118 Fog Lamp Installation 118 Fog Lamp Switch Removal 118 Fog Lamp Switch Installation 118 Fog Lamp Element Removal 118 Fog Lamp Element Installation 120 Fog Lamp Aiming 1...

Страница 537: ...al 148 Cruise Control Module Installation 1 4 8 Cruise Control Servo Removal 148 Cruise Control Servo Installation 148 Speed Sensor Removal 149 Speed Sensor Installation 149 Servo Cable Removal 149 Se...

Страница 538: ......

Страница 539: ...8 A Universal Gauge Tester J 24642 E HEI Ignition Module Tester J 25300 A Headlamp Aimer J 25359 C Torx Bit and Socket Set J 26792 HEI Spark Tester J 28509 A Distributor Trigger Wheel Puller J 34029 A...

Страница 540: ...C 2...

Страница 541: ...J 25359 C 84900C...

Страница 542: ......

Страница 543: ...km 15 000 mi In addition to the standard equipment 421 cold crank amps battery a 452 cold crank amps battery is optionally available for vehicles equipped with heavy duty equipment Both batteries are...

Страница 544: ...180 in lbs 6 11 N m 50 95 in lbs 7 10 N m 60 90 in lbs BATTERY SPECIFICATIONS The date code is decoded as follows month Jan Feb etc year 85 1985 86 1986 1ATTERY COOES 84899A Each battery is date coded...

Страница 545: ...fications to determine if the battery has the correct classification and rating for the vehicle Use a hydrometer to test the battery electrolyte Charge the battery if necessary Position the battery in...

Страница 546: ...d three corrected specific gravity tests taken at one hour intervals indicate no increase in specific gravity Apply a thin coating of petroleum jelly or silicone grease to the cable terminals and the...

Страница 547: ...c gravity of the electrolyte in each battery cell Example A battery is tested at 12 2 G 10 F and has a specific gravity of 1 240 The actual specific gravity is determined according to the following ex...

Страница 548: ...ic gravity variation is more than 50 points 0 050 at the end of the charge period replace the battery When the specific gravity of all cells is above 1 235 and variation between cells is less than 50...

Страница 549: ...FF position Connect the battery tester to the battery Turn the carbon pile rheostat knob clockwise until the ammeter indicates the correct test amperage 210 amperes for the 55 battery 75 reserve capac...

Страница 550: ...cylinder engines is rated at 56 amps The optional heavy duty electrical system alternators for the four and six cylinder engines are rated at 66 and 78 amps The actual alternator used depends upon the...

Страница 551: ...80 F Rotation Viewing Drive End Clockwise Pulley Size 6 18 cm 2 43 in V Belt Tension New Belt Set to 556 689 N 125 155 Ibf Used Beit Recheck 400 512 N 90 115 Ibf Serpentine Belt Tension New Belt 800 8...

Страница 552: ...ollar Inner 4 Bearing 5 Ft Housing 6 Collar Inner 7 Fan 8 Pulley 9 Lockwasher 10 Pulley Nut 11 Terminal Assembly 12 Bridge Rectifier 13 Regulator 14 Brush Assembly 15 Screw 16 Stator 17 Insulating Was...

Страница 553: ...polarity when connecting a charger or a booster battery to the battery connect the positive clamp to the positive battery terminal and the negative clamp to the engine block never drive the alternato...

Страница 554: ...0 to 160 lbs force for serpentine belt Replace the belt if necessary WARNING Use extreme caution when the engine is operating Do not stand in a direct line with the fan Do not put hands near the pulle...

Страница 555: ...the wires from No 1 and No 2 terminals of the alternator Connect the test bulb jumper wires between the No 1 terminal at the alternator and the battery positive post Connect the battery negative cabl...

Страница 556: ...at the BAT terminal of the alternator reconnect the battery negative cable turn on the radio windshield wipers lights high beam and blower motor on high speed connect a carbon pile across the battery...

Страница 557: ...alternator drive belt from the alternator pulley Remove the alternator from the mounting bracket TESTING OFF VEHICLE Rotor Field Winding Short Circuit to Ground Test Test Procedure To perform this te...

Страница 558: ...Procedure To perform this test remove the rotor and front housing assembly from the stator and rear housing assembly Refer to Alternator Overhaul for the procedure Perform the test with an ohmmeter se...

Страница 559: ...ication will vary slightly with winding temper ature changes Stator Windings Short Circuit to Ground Test Test Procedure To perform this test separate the rear housing and stator from the rotor and fr...

Страница 560: ...open windings Inspect the neutral junction splice for an inadequate solder connection Resolder the connection even if it appears to be electrically and mechanically good Retest for winding continuity...

Страница 561: ...ns are identical replace the voltage regulator A B 9 9 84914A Test with Diode Trio Removed Remove the diode trio from the rear housing assembly Use an ohmmeter having 1 Vi volt cell for the test Touch...

Страница 562: ...e terminals D Test Results Each combination of the terminal and heat sink tested should have one high and one low resistance Replace the bridge rectifier if any one pair of resistance indications is t...

Страница 563: ...ng terminal attaching nuts and washers and remove stator winding terminals from the bridge rectifier terminal studs Separate the stator from the rear housing Remove the diode trio strap terminal attac...

Страница 564: ...while holding the abrasive against the rings NOTE When using an abrasive support the rotor while spinning to clean the slip rings evenly Cleaning the slip rings without support may result in flat spo...

Страница 565: ...the inside of the rear housing with a hollow cylinder C A U T I O N Use extreme care to avoid misalignment or placing undue stress on the bearing Place a flat plate over the bearing and press the bear...

Страница 566: ...and rear housing together with the scribe mark aligned Install the four through bolts and tighten securely Remove the toothpick from the brush holder assembly Rotate the rotor ALTERNATOR INSTALLATION...

Страница 567: ...9 Drive Yoke 10 Solenoid Contact Point Actuator 11 Movable Pole Shoe 12 Spacer 13 Armature 14 Pivot Pin 15 Solenoid Contact Point Assembly 16 Drive Yoke Cover 17 Hold In Coil Terminal 18 Field Winding...

Страница 568: ...he drive assembly an overrunning clutch prevents the starter motor from being driven by the ring gear MOTORCRAFT STARTING SYSTEM SPECIFICATIONS Item Specifications Frame diameter 114 3 mm 4 5 in Brush...

Страница 569: ...ELECTRICAL STARTING SYSTEM MOTORCRAFT 6 Cyl Engine SIMPLIFIED STARTER MOTOR CIRCUIT REFER TO ETM SCHEMATIC I 1 841276A C 31...

Страница 570: ...ater motor either o rotates the engine too slowly will not rotate the engine or has abnormal drive engagement Fuel System Ignition System Problems If the starter motor rotating speed is normal and the...

Страница 571: ...d Repair or replace as necessary 3 Replace damaged gear s 4 Bench test starter motor 5 Inspect drive yoke pull down and point gap Check for worn end bushings Check ring gear clearance 6 Repair engine...

Страница 572: ...racket manual transmission or the ground terminal automatic transmission Ensure that a good connection is made If the solenoid energizes it was not properly grounded Remove any rust or corrosion and a...

Страница 573: ...r Motor Cable and Ground Cable Tests Voltage Drop Method The results of voltage drop tests will determine if there is excessive resistance in the high current circuit When performing these tests it is...

Страница 574: ...d NOTE The lower the available voltage the higher the amperage Disconnect and ground the ignition coil secondary wire Connect a remote control starter motor switch between the positive battery termina...

Страница 575: ...flow is not within 180 220 amperes for six cylinder engines at room temperature approximately 21 C TOT remove the starter motor from the engine for bench testing Neutral Safety Switch Test Remove the...

Страница 576: ...age is higher than specification and the starter motor RPM is less than the minimum RPM specification disassemble clean inspect and test the starter motor Hold In Coil Winding Resistance Test This tes...

Страница 577: ...ive resistance the Repair by resoldering the joint with a 600 watt soldering iron 84933 Field Winding Terminal to Brush Continuity Test This test will determine the condition of all the field winding...

Страница 578: ...ce the armature in the growler jaws and turn the power switch to the TEST position Touch one test probe to the armature core 1 touch the other probe to each commutator bar 2 one at a time and observe...

Страница 579: ...jaws If the steel blade vibrates at any area of the core the winding has a short circuit and the must be replaced 84937 Armature Balance Test Place the armature in the growler jaws and turn the power...

Страница 580: ...housing and drive yoke return spring Remove the pivot pin and drive yoke Remove the drive mechanism and armature MOTORCRAFT STARTER MOTOR CLEANING AND INSPECTION Use a brush or air to clean the start...

Страница 581: ...ansmission Inspect for foreign objects such as a converter balance weight in the converter housing automatic transmission S T A R T E R MOTOR P I N I O N G E A R D I S E N G A G E D E N G A G E D S T...

Страница 582: ...e Screw Wrench J 22516 Remove the pole shoes CAUTION Do not cut the solenoid contact point connection joint Cut the field winding terminal strap as close as possible to the solenoid contact point to f...

Страница 583: ...tact point to field winding joint Unsolder the hold in coil winding terminal wire from the terminal strip Remove the field winding screws with an arbor press and J 22516 Remove the pole shoes Cut the...

Страница 584: ...o each screw Solder the hold in coil winding terminal wire to the terminal strip Solder the field winding terminal strap to the upper contact 6 Use 500 600 watt soldering iron and rosin core solder Bu...

Страница 585: ...the drive mechanism Insert the drive yoke return spring into the recess in the drive housing Join the housing to the motor frame Install the brush holder 2 Ensure the depression in the holder aligns w...

Страница 586: ...tallation NEUTRAL SAFETY SWITCH REPLACEMENT Disconnect the wiring harness connector and remove the switch from the transmission Allow the fluid to drain into a container Move the automatic transmissio...

Страница 587: ...in MAXIMUM MINIMUM 2 3mm 1 27 in 31 2mm 1 23 in 0 03mm 0 001 in 0 08mm 0 003 in 0 05mm 0 002 in BOSCH STARTER MOTOR AND SOLENOID TESTING SPECIFICATIONS ENGINE STARTER NO LOAD TEST WITH 11 5 VOLTS SOL...

Страница 588: ...oid Switch 5 Retainer 6 Stop Ring 7 Bushing 8 Overrunning Clutch Drive 9 Fork 10 Bearing Pedestal 11 Sealing Rubber 12 Planetary Gear System 13 Armature 14 Stator Frame 15 Brush Holder 16 Gasket 17 Co...

Страница 589: ...re several procedures that must be followed when servicing this starter Unlike other starter motors this unit is highly sensitive to hammering shocks and external pressure CAUTION The Bosch starter mo...

Страница 590: ...STARTER MOTOR SIMPLIFIED CIRCUIT Refer to ETM for Complete Schematic Starting System 1 Starter 2 Solenoid 3 Relay 4 Ignition Switch 5 Battery Starter Relay Connections A Solenoid Terminal B Battery Te...

Страница 591: ...tor ignition start switch and battery including all ground connections Clean and tighten all connections as required Starter Motor Solenoid Relay and Ignition Start Switch Inspect the solenoid relay a...

Страница 592: ...be intermittent 1 2 Shim starter motor away from flywheel drive plate Inspect flywheel drive plate for damage bent unusual wear and excessive runout Replace flywheel drive plate as necessary 3 A LOUD...

Страница 593: ...complished by installing pads NOTE More than one pad may be required to accomplish this If the battery wiring switch solenoid relay and neutral safety switch are in satisfactory con dition and the eng...

Страница 594: ...and connect a voltmeter between the terminal and the battery negative post With the ignition switch in the start position the voltmeter should indicate battery voltage 12 volts If the battery voltage...

Страница 595: ...attaching screws and the relay from the dash panel lower RH side Bosch Starter Motor Relay Installation Install the replacement starter motor relay on the dash panel Connect wires to the starter motor...

Страница 596: ...rop at solenoid switch Refer to solenoid testing Starter Does Not Crank Engine Is starter solenoid engaging pinion meshes 7 NO Engaging noise is not audible and headlights remain bright no voltage at...

Страница 597: ...EXCEED 0 5V MAX This is measured with the engine cranking Solenoid Testing The solenoid can be tested electrically by connecting a battery of the specified voltage a switch and a voltmeter to the term...

Страница 598: ...ied because an accurate interpre tation can be made by recognizing that if the voltage is slightly higher the RPM will be proportionately higher with the current remaining the same However if the exac...

Страница 599: ...ove the starter motor 4 at the flywheel drive plate housing 101310 BOSCH STARTER MOTOR DISASSEMBLY General Information CAUTION Do not strike the thin wall stator frame with a hammer or other instrumen...

Страница 600: ...the screws on the rear closure cap 2 but do not remove them Remove the hexagon screws 3 running through the stator housing Remove the stator frame 4 with the cover plate armature and commutator end s...

Страница 601: ...mutator end shield Remove the retaining washer and shims from the armature shaft Remove the commutator end shield 9 100673 Brush Removal Slide KDAL 5048 1 onto the armature shaft Slide the brush plate...

Страница 602: ...m 3 when removing it from the overrun ning clutch 4 mount both assemblies onto Mounting Base KDAL 5047 5 and stand it up vertically Using KDAL 5028 6 and a rubber mallet drive the stop ring down the i...

Страница 603: ...from the planetary gear drive Remove the ring gear from the drive shaft Check the ring gear for cracks and wear Check the bushings in the ring gear for excessive play wear or for being out of round b...

Страница 604: ...lamp lights on any bar the armature has a short circuit to ground and must be replaced 84936 CAUTION Never operate the growler with the power switch in the growler T E S T position without an armature...

Страница 605: ...mutator bar with the adjacent bar until all bars have been tested NOTE Zero voltage indicates a short circuit in the particular pair If there is a short circuit indicated replace the armature 84936 Ar...

Страница 606: ...ve shaft SEE I S N O T E S 100679 100680 Seat the stop ring using KDAL 5487 Slide the stop ring onto the armature shaft CAUTION When installing the new retainer be careful not to scratch the armature...

Страница 607: ...h the pinion overrunning clutch fork lever and bearing pedestal 4 into the drive end bearing housing 100833 NOTE The bevelled part of the ring gear 5 points toward the bearing pedestal relay Insert th...

Страница 608: ...he gasket felt ring with 20W SAE oil and slide it on the commutator end of the drive shaft Slide the commutator end shield onto the armature shaft Set the armature end play with one shim 10 Insert the...

Страница 609: ...r frame Turn the pinion until the armature latches into the planet gears NOTE Be careful when turning the pinion Do not use force The groove on the stator frame fits onto the sealing rubber of the bea...

Страница 610: ...ap screws 4 to 1 4 BOSCH STARTER MOTOR INSTALLATION 2 0 N m 1 0 1 5 ft lbs torque Align the starter motor 4 at the flywheel drive plate housing Solenoid Switch Installation Install the attaching screw...

Страница 611: ...ELECTRICAL IGNITION SYSTEM RENIX 4 Cyl Engine TORQUE SPECIFICATIONS Component Service Set To Torque Service Recheck Torque Distributor Clamp Screw 23 N m 17 ft lbs 20 27 N m 15 20 ft lbs...

Страница 612: ...ELECTRODE GAP SPARK PLUG TIGHTENING TORQUE 2 5L RC 12 LYC 0 9 mm 0 035 in 37 N m 27 ft lbs 100694A FIRING ORDER IFRONT Q 84950 iEUEiAL HFORiATIOl The ignition system for 2 5L engines consists of solid...

Страница 613: ...to the ICM The ICM has only two outputs tach signal to the tachometer and diagnostic connector high voltage from the coil to the distributor cap Refer to the 2 5L fuel injection circuit schematic or...

Страница 614: ...the ICM The ignition signal from the ECU is received by the ICM in the form of a 5 Volt square wave As the leading edge of the wave contacts the ignition circuitry in the ICM the ICM charges the coil...

Страница 615: ...heel drive plate housing A Sensor B Sensor C Not Used 85441A Component Pin Outs IGNITION SYSTEM DIAGNOSIS Diagnostic Connector The diagnostic connector allows the following test to be conveniently mad...

Страница 616: ...harge battery Replace battery if charging does not restore battery specific gravity to minimum of 1 235 or if battery fails heavy load test 6 Low voltage across terminals A and B of the ICM connector...

Страница 617: ...g Use insulated pliers to hold the wire terminal 12mm 1 2 in from the engine cylinder head or block while rotating the engine with the starter motor Observe the wire terminal for an arc If an arc occu...

Страница 618: ...ctric compound on the rotor blade After a few thousand miles this compound becomes charred by the high voltage current flowing through the rotor This condition is normal Do not scrape the residue from...

Страница 619: ...NITION COIL SPECIFICATIONS Distributor Pickup Coil Resistance 400 to 800 ohms 24 C 75 F Ignition Coil Pnmary Resistance 113 to 1 23 ohms 24 C 75 F 15 ohms 93 C 200 F Secondary Resistance 7700 to 9300...

Страница 620: ...em consists of the following major components micro computer unit MCU electronic ignition control unit ignition coil resistance wire distributor knock sensor cap and rotor spark plugs and wires MOTORC...

Страница 621: ...caused by the silicone dielectric compound NOTE If the connector locking tabs weaken or break off do not replace the associated component Bind the connectors together with tape or a harness tie strap...

Страница 622: ...gnition situation The engine will not start If a complete failure occurs when the engine is operating it will not restart Intermittent failure is temporary The engine may not start on the first try bu...

Страница 623: ...ELECTRICAL IGNITION SYSTEM MOTORCRAFT 6 Cyl Engine IGNITION COIL PRIMARY CIRCUIT FUNCTION Connects Battery Voltage To Coil and Coil To Ground STEP SEQUENCE RESULT 8 0 6 9 9 A C 85...

Страница 624: ...A G E AT C O I L P O S I T I V E T E R M I N A L 6V t 5V R E P L A C E S T A R T E R MOTOR S O L E N O I D C O N N E C T JUMPER B E T W E E N C O I L N E G A T I V E T E R M I N A L AND G R O U N D V...

Страница 625: ...STANCE ACCEPTABLE 1 35 t 05 OHMS STOP CONNECT O H M M E T E R B E T W E E N D A S H C O N N E C T O R F W A N D IGNITION S W I T C H T E R M I N A L 11 IGNITION REMAINS OFF RESISTANCE ACCEPTABLE LESS...

Страница 626: ...N D T E R M I N A L S DISCONNECT COIL CONNECTOR O K R E S I S T A N C E A C C E P T A B L E 1 1 3 T O 1 2 3 O H M S A T 7 5 F O R 2 4 C 1 5 O H M S A T 2 0 0 F O R 9 3 C RESISTANCE NOT WITHIN LIMITS...

Страница 627: ...ENGINE WITH INSULATED PLIERS SPARK AT COIL WIRE NORMAL NO SPARK DISCONNECT J2 CONNECTOR FROM MCU AND CONNECT OHMMETER TEST LEADS TO PINS 3 AND S OF MCUD J2 CONNECTOR OK OHMMETER INDICATES 400 800 OHM...

Страница 628: ...ETER INDICATES ABOVE 0 002 OHM CONNECT OHMMETER BETWEEN TERMINAL 01 AND BATTERY NEGATIVE TERMINAL LOCATE AND REPAIR SOURCE OF BAD GROUNO GROUND CABLE RESISTANCE 0ISTRI8UT0R TO 8LOCK RESISTANCE OROUNO...

Страница 629: ...T W E E N T E R M I N A L F 2 A N D G R O U N D VOLTMETER DOES NOT INDICATE BATTERY VOLTAGE WITHIN 0 2V O K LOCATE AND REPAIR CAUSE OF VOLTAGE REDUCTION m CORRODED DASH CONNECTOR IGNITION SWITCH SPAR...

Страница 630: ...arch octane rating may vary in their anti knock characteristics for a given engine It may be necessary to retard the initial ignition timing not more than one degree from the specification or select a...

Страница 631: ...for vacuum advance curve information IGNITION COIL TESTS The ignition coil can be tested on any conventional coil tester or with an ohmmeter A coil tester is preferable because it can be used to detec...

Страница 632: ...pulleys belts or fan Do not wear loose clothing Start the engine Normal current flow with the engine operating is 2 0 2 4 amps If the current flow is not within specifications the control unit is defe...

Страница 633: ...gage connectors 4 Test coil Replace if faulty 5 Replace Electronic Control Unit 6 Replace cap 7 Replace rotor ENGINE BACKFIRES BUT FAILS TO START 1 Incorrect ignition timing 2 Moisture in distributor...

Страница 634: ...3 MCU microprocessor faulty 1 Check timing Adjust as required 2 Check operation Repair as required 3 Test system Repair as required ERRATIC TIMING ADVANCE 1 Faulty vacuum advance mechanism 2 Centrifu...

Страница 635: ...Ensure that the distributor shaft fully engages the oil pump drive gear shaft It may be necessary to slightly rotate bump the engine while applying downward hand force on the distributor body to fully...

Страница 636: ...ction Use the proper adapters Connect a timing lamp to the No 1 spark plug NOTE The timing case cover has a socket adjacent to the timing degree scale for use with a magnetic timing probe Ignition tim...

Страница 637: ...ewdrivers can be used to remove the trigger wheel from the shaft Remove the pin Remove the pickup coil assembly retainer and washers from the pivot pin on the base plate Remove the two pickup coil pla...

Страница 638: ...m hose from the vacuum advance mechanism protruding through the distributor housing It may be necessary to loosen the base plate screws for necessary clearance Vacuum Advance Mechanism Installation If...

Страница 639: ...all quantity of silicone dielectric compound on the rotor blade After a few thousand miles this compound becomes charred 1 by the high voltage current flowing through the rotor This is normal Do not s...

Страница 640: ...sted and use either an ohmmeter or Continuity Light J 21008 or equivalent Ignition Switch Positions Starting from the alignment hole end of the ignition switch the switch positions are ACCESSORY OFF L...

Страница 641: ...TART 1 1 B 1 S CONNECTED G 1 G 2 GROUNDED ON 1 1 B 1 CONNECTED A B 2 CONNECTFD l ci B 3 CONNECTED OFF OPEN OFF LOCK OPEN ACC A B 2 CONNECTED j NOTE B 1 B 2 B 3 ARE COMMON CONNECTION 84998 Ignition Swi...

Страница 642: ...COLUMN Hold the key in the ACCESSORY position and push the switch down the column slightly to remove slack in the actuator rod Tighten the attaching screws securely Connect the white connector to the...

Страница 643: ...the column away from the steering wheel to remove lash in the actuator rod while holding the key in the ACCESSORY position CAUTION Be careful not to move the slider out of the detent Tighten the attac...

Страница 644: ...Fusible links are harness wires covered with a special non flammable insulation The links protect circuits which are not normally fused due to carrying high amperage loads or because of their locatio...

Страница 645: ...ip Solder and cover with several layers of heat shrinking tubing Apply petroleum jelly to tubing ends Connect negative battery cable NOTE The solder joint MUST be made with rosin core solder ONLY DO N...

Страница 646: ...g Screws Steering Wheel Nut 3 N m 25 in lbs 1 N m 5 in lbs 47 N m 35 ft lbs 2 3 N m 15 30 in lbs 0 5 1 N m 2 5 in lbs 41 54 N m 30 40 ft lbs EXTERIOR LAMP SPECIFICATIONS Exterior Lamps Lamp Type Back...

Страница 647: ...F Retaining Ring G Trim Ring HEADLAMP REMOVAL Remove the four trim screws A 101353 A Trim Screw s Remove the four retaining ring screws B 101354 B Retaining Ring Screw s Disconnect the headlamp connec...

Страница 648: ...amp Aimer J 25300 A following the instructions supplied with the equipment for proper aiming If a screen is to be used preparation for aiming is as follows Locate the vehicle in a darkened area with a...

Страница 649: ...YSTEM HEADLAMP AIMING 84989 A Height of Lamp Centers B Horizontal Tape C Vertical Tape Left Lamp Center D Vertical Centerline Car Axis E Vertical Tape Right Lamp Center F Zone of Greatest Lamp Intensi...

Страница 650: ...tion the marker tape horizontally on the screen to cross the vertical tapes at the measured height of each lamp center respectively Clean the headlamps Turn the headlamps on LOW beam NOTE Cover the la...

Страница 651: ...ARKING AND DIRECTIONAL LAMP INSTALLATION Remove the lens attaching screws A Place the Lamp in the socket B Turn the Lamp assembly one quarter turn Turn the Lamp assembly one quarter turn Pull the defe...

Страница 652: ...turn clockwise Return assembly to location under the fender TAILLAMP REMOVAL Remove the lens attaching screws D taillamp tens E and lens gasket C Remove any defective lamps B F and or G located in the...

Страница 653: ...ponding screw holes Install the attaching screws D Connect the wiring REAR SIDE MARKER LAMP REMOVAL Remove the attaching screws D taillamp lens E and lens gasket C Pull the side marker lamp G straight...

Страница 654: ...the license plate FOG LAMP GENERAL INFORMATION The fog lamp switch is located to the right of the steering column Fog lamps are turned OFF by the circuit relay when the high beam driving lamps are tur...

Страница 655: ...The fog lamps will go back on when the high beams are switched OFF The indicator lamp on the fog lamp switch will go OFF when the high beams are ON ON when the high beam lamps are switched OFF 101359...

Страница 656: ...e plastic retaining fingers B Push the fog lamp switch A out of the bezel C 3 841264A FOG LAMP SWITCH INSTALLATION Depress fog lamp switch A into the bezel C until retaining fingers lock B behind the...

Страница 657: ...G SYSTEM 841263A FOG LAMP AIMING C D E Height of Lamp Centers Horizontal Tape Vertical Tape Left Lamp Center Vertical Centerline Car Axis Vertical Tape Right Lamp Center Zone of Greatest Lamp Intensit...

Страница 658: ...n the lamp attaching hardware Turn the headlamp and fog lamp switches ON Adjust the lamp beams as follows The horizontal distance between the lamp beams on the wall should be the same size as the dist...

Страница 659: ...itch Indicator Lamp 2182 Speedometer Tachometer 194 101358 Wrangler YJ vehicles are equipped with a dome lamp and courtesy lamps The dome lamp and courtesy lamps are operated by door pillar switches D...

Страница 660: ...mps will light but will not flash If a two lamp flasher is used on a vehicle having three lamps trailer towing the higher current draw will cause the lamps to flash too fast If there is no signal at a...

Страница 661: ...lasher switch knob Four Way Emergency Flasher Removal Refer to the Steering Column Section for the four way flasher switch removal procedure Four Way Emergency Flasher Installation Refer to the Steeri...

Страница 662: ...urn Hazard Switch Assembly Turn Signal Hazard Warning Connector Diagram A B C D E F G H J K 849950 A Stop Light Switch White B Right Rear Dark Green C Left Rear Yellow D Flasher Purple E Hazard Warnin...

Страница 663: ...ch A is mounted on the steering column THIS SWITCH IS ADJUSTABLE NOTE If the backup lamp switch is defective the switch must be replaced To adjust the backup lamp switch place the transmission shift l...

Страница 664: ...to the lamp side of the switch and ground one side of a test lamp When the test lamp lights the backup lamps are operating STOPLAMP SWITCH REMOVAL Refer to the Steering Column Section for removal pro...

Страница 665: ...column wiring harness horn ring and body sheet metal Wrangler YJ horns are located on the inner left wheelhouse TORQUE SPECIFICATIONS Component Service Set To Torque Service Recheck Torque Horn Bracke...

Страница 666: ...ICAL HORN SYSTEM SIMPLIFIED HORN CIRCUIT HORN REMOVAL Remove headlamp wire harness A Remove horn assembly screw B HORN INSTALLATION Attach the horn assembly screw B Attach the headlamp wire harness A...

Страница 667: ...om the pivot pin CAUTION Take care to insure that the wiper arm does not strike the windshield after the wiper blade has been removed 100375 WIPER BLADE INSTALLATION Place the wiper blade assembly on...

Страница 668: ...indshield frame Remove the left and right windshield holddown knobs and fold the windshield forward Remove the left and right access hole covers Disconnect the wiper motor drive link from the left wip...

Страница 669: ...eld forward Remove the left access hole cover Disconnect the drive link from the left wiper pivot Disconnect the wiper motor wire harness from the switch WIPER MOTOR INSTALLATION Position the wiper mo...

Страница 670: ...e rotate the wiper switch in that mode and measure the resistance between A D and A G wiper switch disconnected If the resistance is not 0 500K OHMS replace the wiper switch as outlined in the Steerin...

Страница 671: ...s Refer to the Electrical Troubleshooting Manual ETM for rear window defogger additional diagnostic information REAR WINDOW DEFOGGER SWITCH REMOVAL NOTE Refer to the Instrument Panel Section for infor...

Страница 672: ...break in the grid between the positive voltmeter lead and the ground No voltage drop 0 volts at the centerline indicates a break in the grid between the centerline and the voltage source or lead 8504...

Страница 673: ...r window defogger switch Run the engine until the defogger completes a cycle pilot light goes off Turn the ignition switch OFF Remove the tape from the inside of the rear window Check the repair grid...

Страница 674: ...C O A S T RESUME SPEED ACCELERATE CRUISE CONTROL COMPONENTS Cruise Control Switch 84968 The cruise control is a closed loop electro mechanical servo system that consists of the following components 8...

Страница 675: ...ral Information Whenever a cruise control malfunction occurs first verify that the cruise control wire harness is properly connected to the module before start ing normal diagnosis and repair procedur...

Страница 676: ...Defective servo ground connection 2 Control switch defective 1 Check servo ground wire connection and repair as necessary 2 Replace switch C A C C E L E R A T E FUNCTION INOPERATIVE 1 Accelerate circu...

Страница 677: ...switch 1 Repair connection 2 Check vacuum hose connection and repair as necessary 3 Repair linkage 4 Replace switch 1 ERRATIC OPERATION 1 Reverse polarity 2 Servo defective 3 Regulator defective 1 Ch...

Страница 678: ...6 TESTER 1 R 101151 Disconnect the wire harness connector from the cruise control module 84977A CAUTION When disconnecting the wire harness connectors do not pull on the wires PULL ONLY ON THE CONNEC...

Страница 679: ...Servo will pull throttle wide open Keep RPM at safe limit by releasing the cruise switch X X E CRUISE SWITCH RESUME ACCELERATE Engine Running WARNING Servo will pull throttle wide open Keep RPM at sa...

Страница 680: ...D T H R O U G H THE STOP UGHT IS INTERRUPTED BY EITHER OPENING THE CLUTCH SWITCH O R CLOSING T H E B R A K E SWITCH T CRUISE C O N T R O L IN LINE fuSE 4 A M P 0 PNK 1 CC C106 F f o y ir SWITCH M U L...

Страница 681: ...hms 280 430 ohms idle 4K 4000 ohms wide open throttle LAMP NO S OFF Resume Accelerate Vent Valve Check voltage from HAZ STOP and inline fuses cruise switch at Resume Accelerate at terminal 10 YEL to g...

Страница 682: ...ive by using the indicated settings Centering Adjustment Turn the centering adjustment to the 10 o clock position A Low Speed Switch Adjustment Turn the low speed switch adjustment to the 10 o clock p...

Страница 683: ...ADJUSTMENTS Cruise Control Servo B G 84971 A Throttle Position Potentiometer E Vacuum Vent Valve Solenoid Coil B Brake Pedal Vacuum Vent Valve F Atmosphere Vent Valve C Manifold Vacuum Source G Diaph...

Страница 684: ...ter to the wires i SEE I S N 0 1 E S SET COAST S C SW POSITION SLIDER 1 2 1 3 1 4 2 3 2 4 3 4 Normal Off 0 o o o 0 o Normal On 0 0 0 0 c o Normal R A c o c o c o Depressed Off o o o c o o Depressed On...

Страница 685: ...acuum valve assembly B forward as far as possible Release the brake pedal 101380 A Body Sled B Vacuum Valve Assembly C Tubular Clip D Cruise Control Harness E Fuse Panel l P Harness F Cruise Control M...

Страница 686: ...SE CONTROL SERVO REMOVAL Remove the remaining nuts and cable housing from the servo Release the cable clip from the servo cable Disconnect the vacuum hoses and connector Remove the mounting nut and se...

Страница 687: ...e two supporting nuts SERVO CASLE REMOVAL Remove the lock clip and washer from the pin on the bellcrank Remove the lost motion link Squeeze the tabs that retain the cable housing in the bracket Remove...

Страница 688: ...ol switch removal procedures are covered in the Steering Column Section of this workshop manual SEE I S N O T E S CRUISE CONTROL SWITCH INSTALLATION Cruise control switch installation procedures are c...

Страница 689: ...0 ohm Fuel Gauge Resistance Ohms Empty 1 ohm 1 2 full 44 ohm Full 89 ohm Voltmeter Calibration VOLTAGE INPUT POINTER POSITION TOLERANCE 8V 8V 0 5V 10V 10V 0 6V 12V 12V 0 5V 14V 14V 0 5V 16V 16V 0 75V...

Страница 690: ...EL 101334 A Gauge Nut s G Fuel Gauge B Gauge Contact Pins H Clock C Clock Screw s J Oil Pressure D Contact Spring s K Voltmeter E Gauge Housing Mounting Screws L Metal Shield F Coolant Temperature Gau...

Страница 691: ...etal Shield M Plastic Shield I N S T R U M E N T PANEL G A U G E INSTALLATION Insert gauge into gauge housing Place gauge contact pins B over gauge screw The gauge contact pins B will automatically be...

Страница 692: ...el C This will release the holding tabs A Indicator Panel I D 3 O o A 101337 A Holding Tab s INSTRUMENTATION SHROUD INSTALLATION Place the shroud under the steering column Slide the indicator panel ta...

Страница 693: ...NT PANEL INDICATOR BEZEL 101340A A Indicator Bezel Mounting Tabs E Rear Defogger Switch B Indicator Sockets F Fog Lamp Switch C Indicator Printed Circuit Connector G Illumination Rheostat D Indicator...

Страница 694: ...Switch G Illumination Rheostat H Headlamp Switch INDICATOR BEZEL INSTALLATION Fasten the five bezel screws A into the instrument panel Be sure the indicator wires are not pinched behind the bezel HEA...

Страница 695: ...Plug in the tachometer lead Install attaching screws A SPEEDOMETER REMOVAL NOTE The speedometer is mounted to the instrument panel with two screws Remove the attaching screws Pull out the meter and d...

Страница 696: ...ILLUMINATION RHEOSTAT INSTALLATION Disconnect negative battery cable Plug in the rheostat connector Remove the two rheostat attaching screws C Install the two rheostat attaching screws C Disconnect th...

Страница 697: ...DRIVEN PLATE 4 REMOVAL 4 INSTALLATION 4 PILOT BUSHING REPLACEMENT 5 CLUTCH MASTER CYLINDER REMOVAL 5 CLUTCH MASTER CYLINDER INSTALLATION 5 MASTER CYLINDER COMPONENTS 6 CLUTCH MASTER CYLINDER OVERHAUL...

Страница 698: ......

Страница 699: ...tting 15 N m 11 ft lbs 14 16 N m 10 12 ft lbs Crossmember To Frame Rail Bolt 41 N m 30 ft lbs 27 41 N m 20 30 ft lbs Rear Support To Crossmember Bolt 45 N m 33 ft lbs 37 52 N m 27 38 ft lbs Clutch Hou...

Страница 700: ...IAL TOOLS Tool Ref Description J 2619 01 Slide Hammer J 5822 Pilot Bushing Removal Tool J 33169 Clutch Alignment Tool J 5824 01 Clutch Alignment Tool CD J 5822 j 33169 K VA u an i Hi J 5824 01 101259...

Страница 701: ...ave cylinder The slave cyl inder is operated by the master cylinder which is connected to the clutch pedal The slave cylinder is mounted inside the clutch housing The master cylinder is mounted on the...

Страница 702: ...wick into the pilot bushing bore NOTE Avoid getting oil from the wick on the flywheel clutch surface Insert the clutch plate alignment tool in the driv en plate hub Use tool J 5824 01 on four cylin de...

Страница 703: ...the transmission and transfer case as outlined in Chapter E CLUTCH MASTER CYLINDER REMOVAL Disconnect the hydraulic line from the cylinder Cap the hydraulic line and cylinder to prevent dirt entry Rem...

Страница 704: ...LVE STEM 2 DUST BOOT 11 RETAINER SPRING 3 SNAP RING 12 SPRING RETAINER 4 WASHER 13 PLUNGER SPRING 5 MASTER CYLINDER 14 VALVE STEM RETAINER 6 RESERVOIR CAP 15 PLUNGER REAR SEAL 7 RESERVOIR 16 PLUNGER F...

Страница 705: ...e stem tip seal 9 from the valve stem 10 Discard the seal Clean all parts thoroughly with fresh brake fluid or brake system cleaner only Cylinder Inspection and Assembly Inspect the cylinder bore for...

Страница 706: ...lied in the overhaul kit Insert the push rod in the plunger Push the plunger and stem assembly into the cylinder bore Then seat the washer 4 in the bore and install the push rod snap ring 3 Install th...

Страница 707: ...from the slave cylinder inlet line 3 Remove the transmission and transfer case as outlined in Chapter E Slide the rubber insulator 5 out of the insulator bracket 4 and off the slave cylinder lines Re...

Страница 708: ...ulic lines 2 3 while removing them from the clutch housing CAUTION Do not remove the hydraulic lines from the cylinder and bearing The lines are not serviceable components and will leak if removal and...

Страница 709: ...line 7 to the slave cylinder inlet line 3 Fill and bleed the clutch hydraulic system as outlined in this section CLUTCH HYDRAULIC SYSTEM FLUID The only fluid recommended for use in the clutch hydraul...

Страница 710: ...d fluid if necessary Do not allow the cylinder reservoir to run out of fluid during bleeding operations Repeat the bleeding process until fluid entering the glass container is free of bubbles NOTE Be...

Страница 711: ...VAL 5 AX 5 TRANSMISSION INSTALLATION 6 BA 10 5 TRANSMISSION REMOVAL 7 BA 10 5 TRANSMISSION INSTALLATION 8 TRANSMISSION LUBRICATION 9 TRANSFER CASE 11 GENERAL SERVICE INFORMATION 11 TRANSFER CASE SERVI...

Страница 712: ......

Страница 713: ...ft lbs 37 52 N m 27 38 ft lbs Clutch Housing to Engine Bolt ALL 38 N m 28 ft lbs 30 41 N m 22 30 ft lbs Transfer Case to Transmission Nuts 35 N m 26 ft lbs 30 41 N m 22 30 ft lbs Universal Joint Clam...

Страница 714: ...e overhaul operations are detailed in the ap plicable component service manual Tool Ref Description J 5 8 2 4 0 1 Clutch Alignment Tool 4 Cyl J 8 0 0 1 Dial Indicator Set J 8 8 1 4 0 1 Y o k e Holder...

Страница 715: ...applications in Wrangler YJ models The Model 207 is a part time four wheel drive unit with three operating ranges plus a Neutral position A built in low range gear system pro vides a 2 6 1 reduction...

Страница 716: ...ar of manufacture e g 5 1985 6 1986 The second and third numbers indicate month of manufacture e g 01 Janu ary 02 February etc The next series of numbers is the transmission serial number 101278 BA 10...

Страница 717: ...shaft retainer C downward Rotate the retainer counterclock wise to release it from the lugs in the shift tow er Then lift the retainer stub shaft and shift lever up and out of the shift tower D NOTE...

Страница 718: ...on Install the slave cylinder and throwout bearing assembly Insert the shift lever into the transmission tower and shift the transmission into any forward gear Then remove the shift lever Mount the tr...

Страница 719: ...ots and remove both boots Remove the transmission shift tower dust boot NOTE On some BA 10 5 transmissions the shift lever stub shaft may be held in place with a snap ring instead of a retainer plate...

Страница 720: ...ngine bolts to 38 N 31m 28 ft lbs torque Connect the clutch slave cylinder inlet line to the master cylinder hydraulic line Remove the jack from under the transmission and mount the transfer case on t...

Страница 721: ...nt SAE 75W 90S API Grade GL 5 gear lubricant Lubricant Fill Level The correct lubricant refill or top off level for both the AX 5 and BA 10 5 transmissions is to the bottom edge of the fill plug hole...

Страница 722: ...GEARBOXES TRANSMISSIONS Lubricant Capacity Transmission lubricant capacities are AX 5 3 3 liters 7 0 U S pints BA 10 5 1 63 liters 3 5 U S pints E 10...

Страница 723: ...ice Manual Transfer Case Identification A circular identification tag is attached to the rear case of each Model 207 transfer case The tag A provides the transfer case model num ber assembly number se...

Страница 724: ...smission to neutral shift transfer case to 2H mode and operate vehicle in 2H on dry paved surfaces 3 Lubricate repair or replace linkage or tighten loose components as necessary 4 Drain and refill to...

Страница 725: ...inkage Connect the transfer case vent and vacuum hoses Connect the front and rear propeller shafts Tighten the U joint clamp bolts to 19 N 31m 170 in lbs torque NOTE Be sure to align the propeller sha...

Страница 726: ...equivalent Dexron II automatic transmission fluid Lubricant Fill Level The correct refill or top off lubricant level for the Model 207 transfer case is to the bottom edge of the fill plug hole Two Pie...

Страница 727: ...IO TIRE SIZE DRIVEN GEAR ASSEMBLY Number of Gear Teeth Gear Color 3 08 3 55 4 10 P205 75R15 P215 75R15 P225 75R15 P205 75R15 P215 75R15 P225 75R15 P205 75R15 P215 75R15 P225 75R15 21 21 20 19 18 18 22...

Страница 728: ......

Страница 729: ...CONDITION 8 LINKAGE ADJUSTMENT 9 ROAD TEST 10 HYDRAULIC PRESSURE TEST 11 HYDRAULIC PRESSURE TEST DIAGNOSIS 15 AIR PRESSURE TEST 16 GOVERNOR 17 STALL TEST 17 CONVERTER HOUSING FLUID LEAK DIAGNOSIS 18 G...

Страница 730: ...SEE I S N O T E S...

Страница 731: ...ing Screw Locknut 47 N m 35 ft lbs Neutral Safety Switch 33 N m 24 ft lbs Oil Filler Tube Bracket Bolt 17 N m 150 in lbs Oil Pan Bolt 17 N m 150 in lbs 12 18 N m 9 13 ft lbs Oil Pump Housing to Transm...

Страница 732: ...psi at 1600 RPM Governor D Range Closed Throttle Pressure should respond smoothly to changes in MPH and return to 0 7 kPa 0 1 1 2 psi when stopped with transmission in D 1 2 Pressure above 7 kPa 1 1...

Страница 733: ...fluid or an equivalent Dexron II transmission fluid only BAND ADJUSTMENT SPECIFICATIONS FRONT BAND Tighten screw to 8 N m 72 in lbs Back off screw 2 turns REAR BAND Tighten screw to 8 N m 72 in lbs Ba...

Страница 734: ...B 99 ISA Motor Exerciser Box J 5853 B 0 250 in lb Torque Wrench J 24027 Pressure Test Set J 24031 Kickdown Valve Gauge J 24033 Pump Rotor Alignment Tool J 24063 Kickdown Band Adjustment Adapter SEE I...

Страница 735: ...um adapter housing con nects the transmission to the transfer case models The Model 999 has two multiple disc clutches 3 4 two bands and actuating servos 7 18 an overrunning clutch 8 and two planetary...

Страница 736: ...4 Rear Clutch 5 Front Planetary Gear Set 6 Rear Planetary Gear Set 7 Rear Band 8 Overrunning Clutch 9 Governor 10 Bearing 11 Output Shaft 12 Seal 13 Adapter Housing 14 Parking Lock Assembly 15 Valve...

Страница 737: ...ber group 3 is the transmission serial number 84071 TORQUE CONVERTER IDENTIFICATION The torque converter has an identification decal attached to the converter The decal indicates converter type and st...

Страница 738: ...ttle linkage Check for broken cooler lines and loose or missing pressure test port plugs Raise the vehicle start the engine and shift the transmission into gear If the propeller shafts turn but the wh...

Страница 739: ...either case air in the fluid will cause overheating oxi dation and varnish buildup Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak Fluid condi...

Страница 740: ...uring the test an engine malfunction will effect transmission op eration Operate the transmission in all gear shift positions and check for slippage or shift variations Note if shifts are harsh or spo...

Страница 741: ...rear servo pressure in R and 1 positions only The low pressure gauge is used for all other readings The test set permits simultaneous connection to all the pressure ports for sequential or in dependen...

Страница 742: ...t and operate the engine at idle speed Move the gearshift lever to D range and note line pressure Pressure should be 372 to 414 kPa 54 to 60 psi Increase engine rpm to 1600 and slowly move the valve b...

Страница 743: ...ator port Servo pressure should not vary from line pressure by more than 21 kPa 3 psi Turn the test gauge selector to line pressure position Place the gearshift lever in 2 range and operate the engine...

Страница 744: ...to 10 kPa 0 to 1 1 2 psi when the throttle is closed Test Five This test checks lubrication pressure The test is especially important when the transmission is noisy when unexplained rear clutch failur...

Страница 745: ...low in R and 1 Leakage in rear servo Front servo pressure in 2 Leakage in servo broken servo ring or cracked servo piston Pressure low in all positions Clogged filter stuck pressure regulator valve wo...

Страница 746: ...air pressure to the rear clutch apply passage 2 Movement of the piston may be felt and a soft thud may be heard as the clutch applies Check for excessive air leakage while pressure is applied Front Se...

Страница 747: ...Stall Test Procedure Connect a tachometer to the engine Check and adjust transmission fluid level Start and operate the engine until the transmis sion fluid reaches operating temperature Block the fr...

Страница 748: ...HOUSING FLUID LEAK DIAGNOSIS Two facts must be established when diagnos ing converter housing leaks First it must be verified that a leak condition actually exists and secondly the real source of the...

Страница 749: ...ak pattern develops it indicates a damaged torque converter If a trickle type of leak develops it indicates an oil pump leak caused by one or more of the following conditions pump drainback hole obstr...

Страница 750: ...nced to the necessary service procedures Code letters in the boxes at the top of each chart identify the service procedures These let ters correspond to procedure descriptions that follow the charts C...

Страница 751: ...erse 1 2 3 4 5 Moves in Neutral Position Creeps in U N 1 2 Drags or Locks Up 1 2 3 4 5 6 7 8 Growling Grating or Scraping Noises 1 2 3 4 Buzzing Noise 1 2 3 4 Oil Blows Out Filler Tube 1 2 3 4 Overhea...

Страница 752: ...t and debris Inspect the body for cracks or warpage Check torque on the gover nor and output shaft support bolts M Oil Filter Inspect and replace if clogged N Valve Body Remove disassemble and clean t...

Страница 753: ...se 1 2 Moves in Neutral Position Creeps in N 1 Drags or Locks Up 1 2 3 4 5 Growling Grating or Scraping Noises 1 2 3 4 5 6 Buzzing Noise 1 2 Oil Blows Out Filler Tube 1 2 Overheats 1 Sluggish Accelera...

Страница 754: ...he band for wear and for a good bond of lining to band Inspect the lining for damage and wear Replace the band if worn or damaged h Overrunning Clutch Clean and inspect the clutch parts for brinnelled...

Страница 755: ...t Check for positive engagement of the park lock by attempting to rotate the propeller shaft The shaft will not rotate if the park lock pawl is fully engaged Adjust the shift rod trunnion to obtain a...

Страница 756: ...e end of the adjusting link 2 to elimi nate all lash Move the connecting clamp 6 rearward until the bolt attaching the control rod 5 to the clamp 6 bottoms against the rear of the slot in the control...

Страница 757: ...the vehicle Remove the oil pan and drain the fluid Note fluid condition while it is draining Inspect the filter and oil pan for friction material or metal particles A light accumulation of this mater...

Страница 758: ...filter attaching screws A and remove the filter B B 84460 Clean the old gasket material from the trans mission oil pan surface Install the replacement filter Tighten the filter screws to 4 N m 35 in...

Страница 759: ...p bolts Slide the levers up and off the valve body shafts Remove the neutral safety switch Remove the valve body attaching screws 1 Remove the valve body as follows Lower the valve body about one or t...

Страница 760: ...d throttle valve control levers on the valve body shafts Tighten the lever clamp bolts and verify free movement of the shafts The shafts must not bind at any point NOTE Do not use any sealer on the pa...

Страница 761: ...er cam A and kickdown valve B 84101A Push the gauge inward to compress the kickdown valve against the spring and bottom the kickdown valve in the valve body Maintain pressure on the spring and valve T...

Страница 762: ...move the bolts attaching the transfer case to the transmission adapter housing and remove the transfer case Remove the bolts attaching the adapter housing to the transmission and remove the adapter ho...

Страница 763: ...or weights may be polished out with cro cus cloth Inspect the weight spring 6 E clips 1 and 10 and snap rings 8 and 9 Replace any component if distorted collapsed or broken Clean the governor filter 1...

Страница 764: ...dometer cable Connect the propeller shafts Align the assem bly reference marks and tighten the U joint clamp bolts to 19 fskn 14 ft lbs torque Adjust the gearshift and throttle linkage Lower the vehic...

Страница 765: ...1 84105 Starting Circuit Test Remove the wiring connector from the switch 1 Check continuity between the center switch ter minal and the transmission case in all gearshift lever positions Continuity s...

Страница 766: ...main cooler lines Dislodge any foreign material in the inlet side of the main cooler with a small screwdriver Reverse flush the main and auxiliary coolers and lines with a combination of mineral spir...

Страница 767: ...ssion jack Remove the support stand previously installed under the transmission and reposition it under the engine rear main Remove the bolts attaching the transmission to the engine and remove the tr...

Страница 768: ...the support stand from under the en gine and reposition it under the transmission clutch housing Then remove the transmission jack from under the transmission transfer case assembly Install the rear c...

Страница 769: ...Columns 25 Service Diagnosis Tilt Column 26 Service Diagnosis Ignition Lock Mechanism 27 Steering Wheel Removal 28 Steering Wheel Installation 28 Steering Column Removal 28 Steering Column Installatio...

Страница 770: ...t 118 Ball Joint Replacement 119 Differential Removal 121 Front Axle Differential Components 123 Differential Disassembly 124 Differential Assembly and Adjustment 126 Differential Installation 132 PRO...

Страница 771: ...Wheel 33 32 to 33 Steering stops are non adjustable 101471 MANUAL STEERING GEAR SPECIFICATIONS Worm Bearing Preload Pitman Shaft Overcenter Preload Drag Torque Total Steering Gear Preload Manual Stee...

Страница 772: ...4 to 10 in lbs drag torque Refer to Steering Gear Adjustment Pitman Shaft Overcenter Drag Torque New Gear less than 400 miles 0 5 1 N m 4 to 8 in lbs in addition to worm bearing preload but not to ex...

Страница 773: ...Initial New Belt Reset Used Belt 6 Cyl Serpentine Belt 800 900 180 200 623 712 140 160 4 and 6 Cyl V Belt 534 712 120 160 400 512 90 115 100490A AXLE RATIO RING AND PINION TOOTH COMBINATIONS Axle Rat...

Страница 774: ...acity 2 5 pts 1 2 liters Lubricant Type SAE75W 90 GL5 add 5 ounces 148 ml to front axle shift housing 84678 RING AND PINION VARIANCE CHART O d Pinion New Pinion Marking Marking 4 3 2 1 0 1 2 3 4 0 008...

Страница 775: ...5 30 psi 207 kPa 2 P225 75R15 30 psi 207 kPa 2 3 Compact Spare Tire 60 psi 414 kPa 84859A WHEEL AID TIRE RUIOUT SPECIFICATIOIS Tire Radial Runout Radial Ply Tires 2 032 mm 0 080 in Conventional Tires...

Страница 776: ...k to Steering Knuckle 47 N m 35 ft lbs 34 61 N m 25 45 ft lbs Steering Tie Rod to Steering Knuckle 47 N m 35 ft lbs 34 61 N m 25 45 ft lbs Adjusting Tube Clamp Bolts 19 N m 14 ft lbs 16 22 N m 12 16 f...

Страница 777: ...lbs Column Bracket to Column Bolts 28 N m 21 ft lbs 20 40 N m 15 30 ft lbs Lock Cylinder Retaining Screw 4 5 N m 40 in lbs Housing to Jacket Screws 3 9 N m 35 in lbs 101520 TILT STEERING COLUMN TORQU...

Страница 778: ...g Gear to Frame Pitman Arm to Steering Gear Front Stabilizer Bar to Frame Sill Front Stabilizer Bar to Link Center Link to Pitman Arm 101 N m 75 ft lbs 251 N m 185 ft lbs 75 N m 55 ft lbs 36 N m 27 ft...

Страница 779: ...45 ft lbs 48 75 N m 35 55 ft lbs Centerlink to Pitman Arm 47 N m 35 ft lbs 34 61 N m 25 45 ft lbs Adjuster Plug Locknut 108 N m 80 ft lbs 102 129 N m 75 95 ft lbs Return Hose Fitting 28 N m 21 ft lbs...

Страница 780: ...m 25 35 ft lbs Power Steering Pump Bracket to Engine Bolts 45 N m 33 ft lbs 38 52 N m 28 38 ft lbs Pump Mounting Studs to Pump 47 N m 35 ft lbs 68 81 N m 50 60 ft lbs Pump Union to Pump 75 N m 55 ft...

Страница 781: ...et 75 N m 55 ft lbs 60 90 N m 44 66 ft lbs Wheel Lug Nuts 102 N m 75 ft lbs 81 122 N m 60 90 ft lbs Brake Caliper Mounting Pins 40 N m 30 ft lbs 34 47 N m 25 35 ft lbs Brake Caliper Mounting Bolts 105...

Страница 782: ...IONS PROPELLER SHAFT TORQUE SPECIFICATIONS Component Service Set To Torque Service Recheck Torque Universal Joint Clamp Bolt Slip Yoke Nut 19 N m 170 in lbs 74 N m 55 ft lbs 16 22 N m 140 200 in lbs 6...

Страница 783: ...J 2619 01 Slide Hammer or Equivalent J 5755 Bearing Cup Installer J 21553 Seal Installer J8092 Driver Handle J 21474 18 Long Nut J 21474 19 Bolt and Bearing J 23073 Shift Tube Installer Tool J 23072 S...

Страница 784: ...721 Differential Bearing Remover J 8614 01 Axle Yoke Holder and Remover J 9233 Pinion Oil Seal Remover J 5590 Bearing Cup Installer J 25104 Pinion Oil Seal Installer J 5223 4 Pinion Setting Gauge Set...

Страница 785: ...STEERING AND FRONT AXLE SPECIAL TOOLS J 22635 J 23653 A J 21854 1 J 29721 J 34503 84677C G 15...

Страница 786: ...ND FRONT AXLE fit s5 SPECIAL TOOLS fit J 23072 J 23073 J 22175 A J 5590 J 25104 J 5176 5 tiiUiiviimnniiiimmi E f 3 J 21474 18 J 34659 iiiimmmiiiiiiiiiiirfP Q f _ w 1 vT J 21474 19 j J 35581 1 J 35581...

Страница 787: ...h gears are recirculating ball design units Power Steering Pump A constant displacement vane type pump is used for power steering applications The pump is belt driven off the engine crankshaft Steerin...

Страница 788: ...and rear suspension com ponents for loose or damaged attaching bolts nuts Tighten or replace as necessary Check the steering knuckle ball studs steering linkage and front wheel bearings Repair or rep...

Страница 789: ...op Turn the steering wheel back to the right one half the number of turns and lock the wheel in position Set right wheel toe as follows Loosen the clamp bolts B at each end of the center link A Adjust...

Страница 790: ...AND FRONT AXLE O S FRONT WHEEL ALIGNMENT o Tighten the adjusting sleeve clamp bolts Position the sleeve D and clamp bolts E as shown The threaded ends of the bolts should face rearward and be angled...

Страница 791: ...the center link NOTE It is not necessary to remove the center link if only one of the rod ends is to be replaced Loosen the rod end clamp bolts and remove the rod ends from the link Assemble the repl...

Страница 792: ...this section Steering Damper Replacement Place the front wheels in a straight ahead position Remove the damper attaching bolt nuts and cotter pins Remove the damper Extend the damper piston enough to...

Страница 793: ...engaging Remove the dimmer switch 2 Disconnect the ignition switch wire harness Remove the ignition switch 1 Lift the switch upward until it clears the actuator rod and remove the switch Ignition Swit...

Страница 794: ...the switch on the column Remove the tape holding the actuator rod to the column Adjust the dimmer switch 2 as follows Compress the switch slightly and insert a 3 32 inch diameter drill into switch hol...

Страница 795: ...8 Replace snap ring Check for proper seating in groove 9 Position shroud over lugs on shift bowl Tighten mounting screws HIGH STEERING SHAFT EFFORT 1 2 3 4 5 Column misaligned Damaged worn upper or l...

Страница 796: ...rubbing in housing 1 Seating of lock bolt 1 None Click is normal characteristic sound produced by lock bolt as it seats HIGH SHIFT EFFORT 1 Column not correctly aligned 2 Lower bearing not aligned cor...

Страница 797: ...eplace ignition switch 3 Replace preload spring 4 Remove burr 5 Replace shaft 6 Replace lock rack 7 Replace rod 8 Straighten or replace 9 Replace lock rack STICKS IN START POSITION 1 Remote rod deform...

Страница 798: ...serviced STEERING WHEEL INSTALLATION Install the horn grounding pin holder 10 and pin 9 Install the steering wheel skirt 8 Align the steering wheel and shaft and install the wheel on the shaft Instal...

Страница 799: ...ermediate shaft could be damaged Cover the painted areas of the column Remove the speedometer tachometer trim cover Remove the bolts attaching the steering column mounting bracket B to the instrument...

Страница 800: ...e plate bolts at this time Position the toe plates on the floorpan and install the toe plate to floorpan bolts Do not tighten the bolts at this time Position the column mounting bracket B on the instr...

Страница 801: ...avy spring tension Compress the lockplate 3 with compressor tool J 23653 A and remove the steering shaft snap ring 2 Discard the snap ring It is not reusable J 23653 A 84692 Remove the compressor tool...

Страница 802: ...ss connector 7 from the bracket at the lower end of the steering column Attach a fish wire to the switch harness and tape the harness A to prevent snagging during removal 84694 Remove the turn signal...

Страница 803: ...lenose pliers or a paper clip B with a right angle bend NOTE Do not attempt to remove the buzzer switch 11 and clip 12 separately The clip could fall into the column jacket 101491 Remove the ignition...

Страница 804: ...SEE LS N O T E S 101497 Turn the housing and shroud assembly 19 over and remove the screws 20 that attach the shroud 21 to the housing 22 Separate the two components 101493 Disengage the ignition swit...

Страница 805: ...ase lever pivot Remove the key release lever 27 and lever spring 28 Remove the lock rack 30 and lock bolt 31 Remove the rack preload spring 84701A Remove the lock sector 32 through the lock cylinder h...

Страница 806: ...absorbing features of the steering column Use only the specified screws bolts and nuts and tighten them to specified torque during reassembly Incorrect size or length fasteners can prevent the column...

Страница 807: ...eload spring The bowed side of the spring must bear against the lock rack when the rack is installed Assemble the lock bolt 31 and lock rack 30 30 31 84705A Install the assembled lock bolt and lock ra...

Страница 808: ...f i n g e r of t h e k e y r e l e a s e l e v e r 27 in R a i s e t h e k e y r e l e a s e l e v e r s l i g h t l y a n d i n s t a l l t h e e n d of t h e r e l e a s e l e v e r s p r i n g 28...

Страница 809: ...roud on the housing 101494 Tape the dimmer switch actuator rod 23 to the shroud 21 to prevent the rod from disengaging Feed the wiper switch harness through the column Keep the wires flat Do not allow...

Страница 810: ...od on the column jacket Install the lower bearing adapter 36 lower bearing 35 retainer 34 and retaining ring 33 on the column jacket Insert the steering shaft through the lower bearing and guide the s...

Страница 811: ...n position Loosen the switch mounting screws Move the ignition switch downward to eliminate lash and tighten the switch screws only enough to hold the switch in position Compress the dimmer switch sli...

Страница 812: ...ce bracket J 23074 to the column J 23074 84691A Remove the lockplate cover 1 WARNING In order to remove the steering shaft snap ring 2 in the following step the lockplate 3 must be compressed Do not a...

Страница 813: ...the knob inward and turn it counterclockwise to remove it Remove the turn signal wiper lever by pulling it straight out of the column Remove the protective cover s from the column harness Disconnect...

Страница 814: ...Insert the ignition key in the lock cylinder and turn the key to ON position Remove the key warning buzzer switch and retaining clip 11 with needlenose pliers or a paper clip B with a right angle bend...

Страница 815: ...he disassembly procedure However if the column is still in the vehicle prepare the switch for removal as follows Loosen the column mounting bracket bolts about 3 4 turns Mark or tag the switch wires f...

Страница 816: ...ove the upper bearing race 20 and bearing seat 21 from the steering shaft 22 84745A Reinstall the tilt lever and place the column in the full upward tilt position WARNING The tilt spring guide 23 is u...

Страница 817: ...ull the pin from the housing 23 Repeat the procedure to remove the remaining pivot pin Raise the tilt lever to disengage the lock shoes and remove the tilt housing 25 Pull the housing upward to diseng...

Страница 818: ...the tilt housing 840338A Remove the tilt lever pin with a pin punch F or tool J 22635 Remove the lock shoe pin from the support with a pin punch or tool J 22635 and remove the lock shoes 27 springs 2...

Страница 819: ...On column shift models remove the shift gate degrees and separate the upper and lower screws and remove the shift gate halves at the U joint G Remove the steering shaft bearing assembly from the lowe...

Страница 820: ...341A TILT STEERING COLUMN ASSEMBLY CAUTION Be sure to preserve the energy absorbing features of the steering column Use only the specified screws bolts and nuts and tighten them to specified torque du...

Страница 821: ...Position the tool receiver J 23073 3 over the puller screw and install the tightening nut on the screw Tighten the tool nut against the reciever to pull the tube into the bowl Continue tightening the...

Страница 822: ...s and pin during installation Place the lock sector on the shaft Lightly tap the sector onto the shaft until the shaft snap ring groove is exposed Then install the sector snap ring Install the lock bo...

Страница 823: ...ide clockwise and seat the guide tabs in the housing Install the turn signal actuator arm clip 41 on the wiper switch 42 Be sure the clip is seated 101500 Install the wiper switch 42 and switch pin 44...

Страница 824: ...to help guide the wires into position Reinstall the switch con nector on the wires afterward Insert the wiper switch wires through the cover and housing and down the side of the column Use a fish wire...

Страница 825: ...ool onto the steering shaft Compress the lockplate and seat the snap ring 2 in the steering shaft groove Be sure the snap ring is completely seated before removing tool J 23653 A 84713 Install the til...

Страница 826: ...ch slightly and insert a 3 32 inch diameter drill into switch hole A The drill will prevent any horizontal movement of the switch Move the switch toward the steering wheel to remove actuator rod lash...

Страница 827: ...iver Check condition of the gear lubricant Replace the lubricant if contaminated Remove and overhaul the gear if the lubricant is full of metal particles Wrap the pitman shaft splines with shimstock t...

Страница 828: ...heel back 1 2 the total number of turns to center the gear Measure steering gear overcenter drag torque as follows 9 Turn the steering gear off center Install the socket and inch pound torque wrench o...

Страница 829: ...o 34 N m 25 ft lbs Align and connect the pitman arm to the shaft Install and tighten the pitman nut to specifications Stake the pitman nut to the shaft in two places CAUTION The pitman arm nut must be...

Страница 830: ...lines and repair as necessary Tighten attaching nut and stake in piace 2 Tighten adjust or replace faulty components 3 Inspect shaft splines and repair as necessary Tighten attaching nut and stake in...

Страница 831: ...y wheel 7 Make driver aware of condition VEHICLE LEADS TO ONE SIDE 1 Improper tire pressures 2 Front tires with uneven tread depth wear pattern or different cord design i e one bias ply and one belted...

Страница 832: ...Remove the steering gear mounting bolts and remove the gear MANUAL STEERING GEAR INSTALLATION Position the steering gear on the frame and install the gear mounting bolts Align and install the pitman a...

Страница 833: ...5 Cover Gasket 6 Adjuster Screw Pitman Shaft 7 Pitman Shaft 8 Gear Housing 9 Upper Bearing Race 10 Upper Bearing 11 Wormshaft 12 Ball Nut 13 Ball Bearings 50 14 Ball Guide Clamp and Screws 15 Ball Gu...

Страница 834: ...t 20 and remove the worm bearing adjuster 19 Remove the wormshaft 11 and ball nut 12 as an assembly CAUTION Do not allow the ball nut to rotate freely and bottom at either end of the wormshaft during...

Страница 835: ...er 8 4 7 5 5 A Remove the wormshaft lower bearing 17 from the bearing race in the adjuster Examine the lower bearing race 18 If the race is worn or damaged remove it from the adjuster as follows Insta...

Страница 836: ...aces for wear flat spots pitting cracks or other damage If either the bearing or race is damaged both parts must be replaced If the upper race is loose in the housing trial fit a replacement race If t...

Страница 837: ...late the lubricant Add additional grease as needed to lubricate the ball bearings thoroughly CAUTION Do not allow the wormshaft to bottom in either direction The tangs on the ball guide ends could bec...

Страница 838: ...s to the housing interior Rotate the wormshaft in one direction until ball nut travel ceases Pack the unobstructed housing end full of grease Then rotate the shaft in the opposite direction and repeat...

Страница 839: ...0 1 mm 0 005 inch thick shim stock or a single layer of thin tape around the pitman and wormshaft splines and threads to serve as a seal protector Lubricate the seals with chassis grease and start the...

Страница 840: ...ed to turn the shaft overcenter equals worm bearing preload J 7754 01 84764A Continue tightening the adjuster screw 6 until torque required to rotate the pitman shaft overcenter is increased by an add...

Страница 841: ...rce is identified Steering gear leaks can develop in the following areas hoses and fittings adjuster plug O ring stub shaft seals steering gear housing core plug torsion bar seal replace valve body as...

Страница 842: ...haft and seal areas with crocus cloth Lubricate the replacement seals with power steering fluid Apply a single layer of thin tape to the pitman shaft splines to avoid damaging the seals Install the si...

Страница 843: ...t turn the steering wheel any farther than necessary during the next step The ball bearings could drop out of the rack piston circuit and fall inside the rack piston chamber Turn the steering wheel sl...

Страница 844: ...ing column RATTLE OR CHUCKLE NOISE IN STEERING GEAR 1 Gear loose on frame 2 Steering linkage looseness 3 Pressure hose touching other parts of car 4 Loose pitman shaft over center adjustment NOTE A sl...

Страница 845: ...normal or heavier in opposite direction 1 Low oil level 2 Pump belt slipping 3 High internal leakage 1 Low oil level 2 Loose pump belt 3 Steering linkage hitting engine oil pan at full turn 4 Insuffic...

Страница 846: ...on with gear out of car HARD STEERING OR LACK OF ASSIST 1 Loose pump belt 2 Low oil level NOTE Low oil level will also result in excessive pump noise 1 Adjust belt tension to specification 2 Fill to p...

Страница 847: ...orn piston ring or badly worn housing bore 2 Leakage at valve rings valve body to worm seal Correction 1 Check for leak and correct Bleed system Extremely cold tempera tures will cause system aeration...

Страница 848: ...mbly reference Disconnect the center link from the pitman arm and remove the front stabilizer bar Disconnect the pitman arm with tool J 6632 01 Remove the steering gear mounting bolts and remove the g...

Страница 849: ...ner 6 Pitman Shaft 23 Valve Body 40 Spacer 7 Adjusting Screw 24 O Ring 41 Races 8 Gasket 25 Race 42 Bearing 9 Side Cover 26 Thrust Bearing 43 Thrust Bearing 10 Lock Nut 27 Race 44 O Ring 11 Housing 28...

Страница 850: ...e gear housing end plug retaining ring 1 until one end is positioned over the hole in the housing Unseat and remove the ring 1 with a punch 84772A Remove the housing end plug 2 Rotate the stub shaft 1...

Страница 851: ...NOTE Do not disassemble the pitman shaft components They are serviced as an assembly only Remove the rack piston 3 Insert arbor tool J 21552 into the rack piston until the tool stops against the end...

Страница 852: ...e out both the needle bearing and inner seal at the same time Discard the seal and needle bearing if removed in this fashion Remove the needle bearing 34 from the housing with tools J 21551 and J 8092...

Страница 853: ...acement of any valve component other than seals or rings is necessary the complete valve body assembly must be replaced To avoid possible damage to the assembly the valve body should not be disassembl...

Страница 854: ...l pliers 84788A Cleaning and Inspection Cleaning Clean the valve body components with solvent and dry them with compressed air only Do not use shop towels or similar lint producing materials Place the...

Страница 855: ...component exhibiting these conditions Inspect the side cover and pitman shaft Re place the cover if damaged Replace the shaft if the adjuster screw A sector teeth B or shaft bearing surfaces C are dam...

Страница 856: ...asher 35 into the housing bore Push the seal and washer into the housing bore with tool J 21553 Install the seal and washer only far enough to provide clearance for the remaining seal backup washer an...

Страница 857: ...nce for the dust seal 47 and retaining ring 48 Install the retaining snap ring Be sure the ring is properly seated 84785A Lubricate the O ring 44 with petroleum jelly and install it in the adjuster pl...

Страница 858: ...ng grooves 84790A NOTE The teflon rings may appear slightly loose or distorted after installation However the heat generated by the power steering fluid during operation will straighten them Lubricate...

Страница 859: ...17 with locating pin B and push the spool valve and stub shaft into the valve body 23 CAUTION Make sure the shaft cap notch E is mated with Jhe valve body pin before installing the valve body in the...

Страница 860: ...n Fill one ball return guide half 4 with petroleum jelly Install the six remaining ball bearings in the guide half 4 filled with petroleum jelly Be sure to alternate the silver and black bearings in t...

Страница 861: ...Align the notch in the valve body 23 with the locating pin H on the wormshaft and insert the valve body assembly into the gear housing Seat the valve body assembly in the housing by pushing it into pl...

Страница 862: ...n Turn the stub shaft clockwise to draw the rack piston into the housing Do not remove arbor tool J 21552 until the valve body piston ring has entered the housing bore Turn the stub shaft until the ra...

Страница 863: ...Power Steering Gear Adjustment CAUTION The following adjustment pro cedures must be performed exactly as described and in the sequence outlined Failure to do so can result in damage to the gear inter...

Страница 864: ...bs If torque is above or below specified adjust worm bearing preload by loosening or tightening the adjuster plug as needed NOTE If preload is incorrect the adjuster plug may have turned when the lock...

Страница 865: ...ag torque measured on or near center R 84807A Overcenter drag torque should be as follows On new steering gears drag torque should equal worm bearing preload plus an additional 0 45 to 0 90 N m 4 to 8...

Страница 866: ...the wheels to a full left turn position and stop the engine Add power steering fluid to the COLD mark on the dipstick Start and operate the engine at curb idle speed Recheck fluid level Add fluid if...

Страница 867: ...e pump or steering gear Connect the pump and steering gear to test gauge J 21567 Use adapter J 5176 5 to complete hose connection if necessary CAUTION Be sure the gauge pressure hose is connected to t...

Страница 868: ...g system is a closed system Contamination of fluid in either the pump or gear will be circulated into the other unit If the system is exceptionally dirty the pump and gear must be disassembled and cle...

Страница 869: ...rol valve 1 Pump shaft bearing scored 1 Loose pump belt 2 Low oil level in reservoir NOTE Low oil level will also result in excessive pump noise 3 Steering gear to column misalign ment 4 Lower couplin...

Страница 870: ...p belt 3 Steering linkage hitting engine oil pan at full turn 4 Insufficient pump pressure 5 Sticking flow control valve 1 Air in system Correction In order to diagnose conditions such as listed in 6...

Страница 871: ...by removing burrs varnish or dirt 5 Cracked or broken thrust or pres sure plate 5 Replace part 84811C DRIVE 1ELT ADJUSTMENT Serpentine Drive Belt Position the belt tension gauge on the belt and check...

Страница 872: ...MOVAL Loosen the pump drive belt and remove it from the pulley Remove the air cleaner if necessary Disconnect the pump hoses and cap the hose fittings Remove the pump front bracket to engine bolts Rem...

Страница 873: ...5 Pump Ring 6 Retaining Ring 7 Rotor and Vanes 8 Dowel Pin 2 9 Thrust Plate 10 Seal 11 Mounting Stud O Ring 12 Pump Body 13 Pump Shaft Seal 14 Reservoir O Ring 15 Mounting Stud O Ring 16 Pump Shaft 1...

Страница 874: ...ng downward Do not over tighten the vise jaws Remove and discard the reservoir O ring 14 Remove and discard the mounting stud seals 11 15 and the union seal 19 from the housing Remove the end plate re...

Страница 875: ...and dry them with compressed air only Do not use shop towels or rags Inspect the flow control valve to be sure it slides freely in the pump body bore Small burrs on the valve can be removed with crocu...

Страница 876: ...on the pump shaft 16 Install a replacement snap ring 6 on the pump shaft 16 Do not overspread the snap ring Open it only far enough to install it on the shaft Install the assembled pump shaft thrust p...

Страница 877: ...in a vise with the shaft end facing downward Do not overtighten the vise or the pump could be damaged Install the spring 20 in the center groove of the pressure plate 4 Lubricate the end plate outer...

Страница 878: ...Initial Operation Fill the pump reservoir Operate the engine until the system fluid reaches normal operating temperature of approximately 170 F 77 C Turn the wheels to a full left turn position and s...

Страница 879: ...ove the rotors Disconnect the vacuum harness A from the shift motor and the vent hose from the axle housing Mark the front propeller shaft and axle yokes H for assembly reference and disconnect the sh...

Страница 880: ...G 110...

Страница 881: ...rbers stabilizer bar links center link front propeller shaft Connect the axle vent hose and the axle shift motor vacuum harness A Install the rotors pads and calipers and the wheels Remove the support...

Страница 882: ...nstallation Install the replacement seal with tool J 22661 J 22661 84S30A Install the yoke Install the pinion washer and nut Tighten the nut to 285 N m 210 ft lbs torque Align and connect the propelle...

Страница 883: ...t the hose support the weight of the caliper Remove the axle hub nut cotter pin nut lock and the axle hub nut Remove the hub to knuckle attaching bolts and remove the hub assembly from the steering kn...

Страница 884: ...INER 3 NUT 4 WASHER 5 BRAKE ROTOR 6 HUB 7 OUTER BEARING SEAL 8 OUTER BEARING 9 OUTER BEARING RACE 10 BEARING CARRIER 11 INNER BEARING RACE 12 INNER BEARING 13 INNER BEARING SEAL 14 CARRIER SEAL 15 ROT...

Страница 885: ...ing knuckle temove the left side axle shaft isconnect the vacuum harness from the shift lotor temove the shift motor housing A and shift lotor B from the axle temove the right side axle shaft 101508 F...

Страница 886: ...moved The large socket will be the receiver Be sure this socket is larger than the bearing cap Tighten the vise C to press the cap out of the yoke Repeat the procedure to remove the remaining bearing...

Страница 887: ...the axle housing cover Install the shift collar outer axle shaft and shift motor housing A Do not install the motor B at this time Fill the axle with 1 2 liters 2 5 pts of JEEP axle lubricant or an e...

Страница 888: ...shaft caliper hub and wheel and lower the vehicle AXLE TUBE BEARING REPLACEMENT Bearing Removal Remove the intermediate shaft Insert tool J 34659 3 and 4 into the axle tube Working through the shift m...

Страница 889: ...9 2 from the tool rod Remove the tool through the axle opening Remove the remainder of the installer tools Install the intermediate shaft BALL JOINT REPLACEMENT Upper Ball Joint Removal Remove the ste...

Страница 890: ...p screw Position tool J 34503 3 on the ball joint Mount the C clamp on the tools and ball joint Tighten the C clamp screw to press the ball joint out of the knuckle J 34503 3 J 34503 1 84S66A Lower Ba...

Страница 891: ...assembly alignment reference Loosen the differential bearing cap bolts until only 2 or 3 threads are engaged Disconnect the tie rod from the left steering knuckle and disconnect the track bar from th...

Страница 892: ...ly reference Remove the differential assembly If the differential is still a fairly snug fit use a pry bar to ease the differential out of the bearing saddles Remove the spreader tool and clamps immed...

Страница 893: ...rential Case 8 Bearing Shim 9 Differential Bearing 10 Bearing Cup 11 Ring Gear Bolt 10 12 Ring Gear 13 Pinion Gear 14 Oil Slinger 15 Pinion Rear Bearing 16 Rear Bearing Cup 17 Pinion Shim 18 Baffle 19...

Страница 894: ...nd discard the ring gear attaching bolts 11 Remove the ring gear 12 from the case 7 CAUTION To avoid damaging the case do not attempt to wedge or chisel the gear off the case Mount the differential in...

Страница 895: ...A under the rear bearing 15 Insert the pinion gear and adapters in the base of toolJ 29721 Position the adapters A 180 apart Tighten the remover tool screw B to remove the bearing J 29721 84843A Remo...

Страница 896: ...ment Information The ring gear and pinion gear are serviced as a matched set only They are identified as a matched set by numbers etched on the two gears The first two numbers A on each gear identify...

Страница 897: ...l the pinion rear bearing cup 16 in the axle housing and on top of the starter shim Install the pinion front bearing cup 20 in the axle housing Install the oil slingei 14 on the pinion Install the rea...

Страница 898: ...uge block thumbscrew and allow the spring loaded plunger to contact gauge arbor J 5223 4 Tighten the gauge block thumbscrew securely Then loosen the holding screw and remove the gauge block Measure th...

Страница 899: ...is correct shim thickness total measured pinion depth 59 2 mm 2 331 in desired pinion depth 57 2 mm 2 254 in correct shim thickness equals 1 96 mm 0 077 in Install the required pinion depth shim 17 in...

Страница 900: ...se Install the pinion shaft pin 3 in the case Measure clearance between the case and side gears with two feeler gauges A Clearance should be 0 00 0 15 mm 0 00 0 006 in 84046A If clearance between the...

Страница 901: ...g shim pack on the drive tooth side of the ring gear The additional shim thickness will provide the necessary preload on the differential bearings Remove the differential bearings Install the shim pac...

Страница 902: ...t may be between the case and the gear or the ring gear bolts are loose Check and correct as necessary DIFFERENTIAL INSTALLATION Install the intermediate shaft and the shaft retaining clip 4 Install t...

Страница 903: ...ion caused by a propeller shaft may be the result of undercoating on the shaft tube missing shaft balance weight excessive shaft runout worn or damaged propeller shaft yokes or universal joints broken...

Страница 904: ...l replacement U joint clamps Install and tighten the U joint clamp bolts to 19 N m 170 in lbs torque UNIVERSAL JOINT REPLACEMENT Remove the propeller shaft Remove the U joint bearing cap retainers 1 8...

Страница 905: ...caps in the axle yoke is facing downward Install inclinometer tool J 23498 on the bearing cap and record the tool reading J 23498 84853A Turn the propeller shaft until one of the bearing caps in the...

Страница 906: ...valves E B 84856A f ACUUM SYSTEM DIAGNOSIS Diagnosis procedures for the vacuum system are outlined in diagnosis charts in Chapter D Gearboxes Refer to the Transfer Case section in this chapter Howeve...

Страница 907: ...has shifted into four wheel drive NOTE The axle must be completely engaged in four wheel drive mode in order to open port C to vacuum Check for vacuum at port D again If vacuum is now present at port...

Страница 908: ...shaft Install the motor in the housing and slide the shift fork onto the shaft Position the housing and motor on the axle and add 148 ml 5 ounces of axle lubricant to the shift motor housing Engage t...

Страница 909: ...ustained the following damage bulges or blisters ply separation broken or cracked beads fabric cracks or cuts tires worn to the fabric or if wear indicators are visible punctures larger than 6 35 mm 1...

Страница 910: ...3 000 mi under normal use Do not attempt to install standard size tires on the special wheel used with the compact spare WARNING To guard against bodily injury use caution when inflating or adding ai...

Страница 911: ...14mm 0 045 in Mark the high points of radial and lateral runout If tire runout either lateral or radial exceeds specified limits but wheel runout is within limits it may be possible to reduce runout...

Страница 912: ......

Страница 913: ...ASSEMBLY REMOVAL 13 REAR AXLE ASSEMBLY INSTALLATION 13 STANDARD DIFFERENTIAL OVERHAUL 14 STANDARD DIFFERENTIAL COMPONENTS 14 ASSEMBLY AND INSTALLATION PROCEDURES 15 INSTALLATION AND ASSEMBLY PROCEDUR...

Страница 914: ......

Страница 915: ...0 009 in 0 20 mm 0 008 in Perferred Differential Bearing Preload 0 20 mm 0 008 in Differential Case Face Runout 0 05 mm 0 002 in Differential Side Gear Clearance 0 00 0 18 mm 0 000 0 007 in 101300 RI...

Страница 916: ...02 0 003 0 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 1 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 0 005 2 0 002 0 001 0 0 001 0 002 0 003 0 004 0 005 0 006 3 0 001 0 0 001 0 002 0 003 0 004 0...

Страница 917: ...20 30 ft lbs U Joint Clamp Bolts 19 N m 170 in lbs 16 22 N m 140 200 in lbs Wheel Nuts 102 N m 75 ft lbs 81 122 N m 60 90 ft lbs Shock Absorber to Axle Nut 60 N m 44 ft lbs 50 70 N m 37 52 ft lbs Rea...

Страница 918: ...aft Puller J 22661 Pinion Oil Seal Installer J 22888 Bearing Puller J 22912 01 Bearing Remover J 23498 Pinion Angle Gauge Inclinometer J 23674 Bearing Remover J 5223 4 Gauge Arbor J 5223 20 Gauge Bloc...

Страница 919: ......

Страница 920: ...ehicle to bring the axle lubricant to normal operating temperature Raise the vehicle Remove the axle housing fill plug Remove the old lubricant from the housing with a suction gun Refill the axle with...

Страница 921: ...ttaching nuts evenly and in a cross pattern to 43 Nhm 32 ft lbs torque Install the brake drum and wheel Tighten the wheel nuts to 102 N m 75 ft lbs torque Lower the vehicle AXLE SHAFT BEARING AND RETA...

Страница 922: ...bearing surfaces Install the guide plate 2 seal retainer 3 and outer seal 4 on the shaft Install the inner seal 7 with tool J 9431 J 9431 100369 Lubricate the replacement bearing with JEEP wheel beari...

Страница 923: ...l 7 from the bore in the axle flange 100368A Lubricate the replacement seal lips with wheel bearing lubricant Install the replacement inner seal 7 with tool J 9431 100369 Install the replacement guide...

Страница 924: ...5853 B to measure the torque Record the torque reading for assembly reference Remove the pinion nut with a socket A and yoke holding tool J 8614 01 Discard the pinion nut It is not reusable J 8614 01...

Страница 925: ...Tighten the pinion nut in very small incre ments Check torque after each tightening operation Continue tightening the nut in small increments until preload is correct Align and connect the propeller s...

Страница 926: ...and seal if they are to be serviced Differential Installation Install the pinion gear bearings and seal if re moved Adjust pinion gear depth if required Refer to the procedure outlined in the overhau...

Страница 927: ...rings Remove the bolts attaching the springs to the shackles and lower the springs to the floor REAR AXLE ASSEMBLY INSTALLATION Support the axle assembly on a hydraulic jack and slide the axle into po...

Страница 928: ...m End Play Preload 6 Differential Bearing Cup 7 Differential Bearing 8 Ring Gear Bolt 8 reqd 9 Differential Case 10 Ring Gear 11 Pinion Gear 12 Pinion Gear Rear Bearing 13 Rear Bearing Cup 14 Pinion D...

Страница 929: ...Remove the pinion seal 18 with tool J 9233 Remove the pinion rear bearing cup 13 with driver handle J 8092 and tool J 21786 NOTE The pinion depth shim 14 is located under the rear bearing cup 13 Remo...

Страница 930: ...ckpin 21 with a punch 84125 Measure differential side gear clearance with two feeler gauge sets Insert an equal thickness gauge between each side gear 1 and the case 9 Continue checking until each fee...

Страница 931: ...racked chipped or broken Inspect the ring and pinion gears Replace the gears as a set if either is worn or damaged Inspect the differential case Replace the case if cracked or damaged Service and Adju...

Страница 932: ...im thickness needed for initial depth measurement NOTE The chart will only help determine starter shim thickness It will not provide the exact shim thickness required for final depth adjustment ASSEMB...

Страница 933: ...ion gear Tighten the pinion nut only enough to remove end play NOTE Do not install the pinion seal or preload spacer at this time Determine desired pinion depth as follows G Record depth variance mark...

Страница 934: ...e between the anvil A and plunger B of gauge block J 5223 4 with a mi crometer Record this dimension for final shim selection It represents initial pinion depth J 5223 20 Remove the differential beari...

Страница 935: ...3 Total thickness depth 55 77 mm 2 196 in Subtract desired pinion depth 53 11 mm 2 091 in Required shim thickness 2 66 mm 0 105 in Example II Step 1 Standard pinion depth setting 53 21 mm 2 095 in Add...

Страница 936: ...preload Correct preload is 2 3 N m 15 25 in lbs Preload is measured as the amount of torque required to turn the pinion gear with an inch pound torque wrench 84134 Install a replacement pinion nut 20...

Страница 937: ...01 on the axle housing Position the indicator stylus C so it contacts the ring gear mounting face of the dif ferential case 84137A Pry the differential case to one side and zero the dial indicator Rot...

Страница 938: ...measured at disassembly exceeded 0 18 mm 0 007 in Install the differential pinions 3 and thrust washers 4 in the case Be sure to align the pinions with the shaft bores in the case Recheck side gear c...

Страница 939: ...pro ceed to Differential Bearing Preload Adjustment If backlash is not within specified tolerance ad just backlash as follows To increase backlash use a thinner shim pack on the ring gear side of the...

Страница 940: ...the differential bearings cups gears and thrust washers with axle lubricant Install the bearing cups on the differential bearings Install the differential in the axle housing Tap the outer edges of t...

Страница 941: ...p Ring 15 Pinion Gear Rear Bearing 5 Clutch Pack Retainer Clips 2 per clutch 16 Rear Bearing Cup pack 17 Pinion Depth Shim a Clutch Pack 18 Pinion Bearing Preload Spacer 7 Differential Side Gear 19 Fr...

Страница 942: ...it from the front bearing 20 Remove the axle housing cover Remove the pinion gear 14 pinion bearings 15 20 and preload spacer 19 from the axle housing Discard the spacer It is not reusable Remove the...

Страница 943: ...of the shaft end ex tends above the vise jaws NOTE If the splined end extends more than 7 cm 2 3 4 in above the vise jaws the shaft will prevent installation of the clutch pack remover tools 84140 Mo...

Страница 944: ...ft 1 with two screwdrivers C Position the screwdriver blades against the snap ring ends and push the snap rings off the shaft 84142A Remove the pinion shaft 1 from the case with a brass drift and hamm...

Страница 945: ...de gears with the rotating tool until the pinions 3 can be removed through the case opening 84146A Remove the forcing screw and remove the ro tating tool upper side gear 7 and clutch pack 6 Remove the...

Страница 946: ...aged Service and Adjustment Information The clutch packs are serviced as sets only If one clutch pack is damaged both clutch packs must be replaced Pinion gear depth must be measured and ad justed bef...

Страница 947: ...helps determine starter shim thickness needed for initial depth measurement NOTE The chart will only help determine starter shim thickness It will not provide the exact shim thickness required for fi...

Страница 948: ...i nion nut 23 on the pinion gear Tighten the pinion nut only enough to remove end play NOTE Do not install the pinion seal or preload spacer at this time Determine desired pinion depth as follows Reco...

Страница 949: ...and plunger B of gauge block J 5223 4 with a mi crometer Record this dimension for final shim selection It represents the initial pinion depth J 5223 20 Remove the differential bearing caps and gauge...

Страница 950: ...196 in Step 3 Total thickness depth 55 77 mm 2 196 in Subtract desired pinion depth 53 11 mm 2 091 in Required shim thickness 2 66 mm 0 105 in Example II Step 1 Standard pinion depth setting 53 21 mm...

Страница 951: ...rush and hold at the set preload Correct preload is 2 3 N m 15 25 in lbs Preload is measured as the amount of torque required to turn the pinion gear with an inch pound torque wrench 84134B Install a...

Страница 952: ...tor stylus C so it contacts the ring gear mounting face of the dif ferential case J 8001 84137A Pry the differential case to one side and zero the dial indicator Rotate the differential case through s...

Страница 953: ...ubricant Assemble the clutch pack discs 6 as shown and install the retaining clips 5 on the ears of the discs Install the assembled clutch packs on the side gears 7 101331 Mount the differential case...

Страница 954: ...ng Gear Backlash Adjustment Ring Gear Backlash Adjustment NOTE Ring gear backlash establishes the run ning clearance between the ring and pinion gears Adjustment involves moving the ring gear toward o...

Страница 955: ...ks does not change The amount required for desired backlash is simply trans ferred from one side to the other as needed For example if measured backlash is 0 28 mm 0 011 in and the optimum setting of...

Страница 956: ...o 77 N m 57 ft lbs torque Recheck ring gear backlash to verify that it has not changed Install the axle housing cover Tighten the cover bolts to 19 N 31m 170 in lbs torque Refill the axle with 2 1 lit...

Страница 957: ...INSTALLATION Install the propeller shaft slip yoke on the trans fer case output shaft Align and install the propeHer shaft rear U joint in the axle yoke Secure the rear U joint to the yoke with replac...

Страница 958: ...e to hold the spider in position Start the remaining bearing caps in the yoke and onto the spider Seat the bearing caps in the yoke and on the spider using the small socket B as a driver and the vise...

Страница 959: ...earing caps is facing downward Place the inclinometer tool on the shaft yoke bearing cap Record the reading and remove the tool NOTE The inclinometer frame must face the same direction for both readin...

Страница 960: ...nts Inspect the joints for loose clamp bolts worn bearings damaged bearing cap retainers or damaged clamps Axle and Transfer Case Yokes Inspect the yokes for damaged bearing cap bores Check the pinion...

Страница 961: ...ATIONS 1 GENERAL INFORMATION 2 SUSPENSION COMPONENTS 2 SUSPENSION COMPONENT SERVICE 3 FRONT SHOCK ABSORBERS 3 REAR SHOCK ABSORBERS 3 STABILIZER BAR 4 TRACK BARS 5 FRONT SPRINGS 6 REAR SPRINGS 7 SPRING...

Страница 962: ......

Страница 963: ...ft lbs Stabilizer Bar To Link Bolts 61 N m 45 ft lbs 48 75 N m 35 55 ft lbs Stabilizer Bar Mounting Bracket Bolts 41 N m 30 ft lbs 34 48 N m 25 35 ft lbs Stabilizer Bar Link To Tie Plate Nuts 61 N m 4...

Страница 964: ...ck bar forms the remainder of the rear suspension components Track Bars The front and rear track bars are attached to brackets on the axle and frame rail The track bars maintain lateral positioning of...

Страница 965: ...e 6 in the spring tie plate bracket and install the lower mounting bolt and nut 4 finger tight Guide the upper mounting stud 4 into the stud hole in the frame bracket Tighten lower mounting bolt and n...

Страница 966: ...d install the lower bolt and nut B Tighten the upper nut A and lower bolt and nut B to 60 N m 44 ft lbs torqua Remove the jack supporting the rear axle and lower the vehicle STABILIZER BAR Removal Rai...

Страница 967: ...icle Align the stabilizer bar mounting brackets and install the attaching bolts 4 Do not tighten the bolts at this time Align the stabilizer bar with the links 2 and install the link bolts and nuts TR...

Страница 968: ...cle Remove the bolt and nut that attach the track bar 1 to the frame rail bracket 2 Remove the bolt and nut that attach the track bar to the axle bracket 3 Remove the track bar 101297 Rear Track Bar I...

Страница 969: ...frame bracket and front shackle Align the front spring center bolt with the locat ing hole in the front axle Lower the front axle until it it fully supported by the spring NOTE Be sure the spring cent...

Страница 970: ...E Be sure the spring center bolt is seated in the axle locating hole Realign the center bolt and locating hole if necessary Install the tie plate 3 U bolts 2 and U bolt nuts 1 Tighten the U bolt nuts...

Страница 971: ...OSTER INSTALLATION 15 FRONT BRAKE PAD REPLACEMENT 15 FRONT BRAKE ROTOR REMOVAL 18 FRONT BRAKE CALIPER REMOVAL 18 FRONT BRAKE ROTOR INSTALLATION 18 FRONT BRAKE CALIPER OVERHAUL 19 FRONT BRAKE CALIPER I...

Страница 972: ......

Страница 973: ...et heads DRUM BRAKES Wheel cylinder bore diameter 22 2 mm 0 875 in Drum diameter new 254 mm 10 00 in Maximum usable drum diameter 255 5 mm 10 060 in Drum width 44 45 mm 1 75 in Brakelining wear limit...

Страница 974: ...132 in lbs Caliper Mounting Pins 34 47 N m 25 35 ft lbs Caliper Anchor Bracket to Steering Knuckle Bolts 105 N m 77 ft lbs Wheel Nuts 102 N m 75 ft lbs Parking Brake Pedal Assembly to Dash Bolt 10 N m...

Страница 975: ...SPECIAL TOOLS Tool Ref Description J8002 Wheel Cylinder Clamps J33028 Caliper Piston Dust Boot Installer J34651 A Parking Brake Cable Adjustment Gauge J8057 Brake Spring Tool J21177 Drum to Brakeshoe...

Страница 976: ...malfunction is related to the mechanical hydraulic portion of the system or to the vacuum brake booster portion of the system Guide A checks the mechanical hydraulic por tion of the system Guide B ch...

Страница 977: ...brakes by making 10 to 15 hard brake applications alternating between forward and reverse stops Bleed system T If unable to bleed system properly see Service Diagnosis Test 3 Depress brake pedal and h...

Страница 978: ...function ing Inspect vacuum system components for loose broken collapsed vacuum hose faulty check valve restricticn in vacuum hose fitting or manifold port Tests With engine operating and no pressure...

Страница 979: ...ylinder bore is scored worn or corroded CORRECTION 1 Fill master cylinder Have helper apply brakes and check calipers wheel cylinders differential valve tubes hoses and fittings for leaks Repair or re...

Страница 980: ...d replace booster 1 0 1 3 4 2 E F SPONGY BRAKE PEDAL Pedal has soft springy spongy feel when pressed POSSIBLE CAUSES CORRECTION 1 Air in hydraulic system 1 Bleed brakes 2 Rear brakeshoes bent or disto...

Страница 981: ...ift transmission into neutral depress brake pedal and start engine c If pedal height decreases with foot pressure and less pressure is required to hold pedal in applied position booster vacuum system...

Страница 982: ...ts 3 Adjust cables Replace seized cables 4 Replace return springs Replace brakeshoe if necessary in axle sets 5 Repair or replace adjuster parts as required 6 Repair or replace parts as necessary 7 Us...

Страница 983: ...Worn brakelining shoes contacting drum or rotor 4 Broken or loose holdown or return springs 5 Rough or dry drum brake support plate 6 Cracked grooved or scored rotor s or drum s 7 Incorrect brakelini...

Страница 984: ...er YJ models BRAKE FLUID LEVEL The correct master cylinder fluid level is to with in 6 mm 1 4 in of the reservoir rim Use the recommended brake fluid only and do not overfill the reservoir CAUTION Avo...

Страница 985: ...cylinder if the bore is scored corroded or pitted Coat the master cylinder bore pistons and seals with clean brake fluid Install replacement seals 3 4 and 6 on the secondary piston CAUTION Be sure the...

Страница 986: ...mm 1 4 in of the rims and reinstall the cylinder cover Check brake operation BRAKE BOOSTER REMOVAL NOTE The brake booster is serviced as an as sembly only Do not attempt to disassemble the unit for s...

Страница 987: ...e moving the vehicle FRONT BRAKE PAD REPLACEMENT Brake Pad Removal Remove two thirds of the fluid from the master cylinder reservoirs Do not drain the reservoirs completely Loosen the wheel nuts Raise...

Страница 988: ...oard pad 7 and the top 5 and bottom 8 anti rattle springs 101361 Brake Pad Installation Inspect the caliper and rotor Replace or resur face the rotor if necessary Overhaul the caliper if it shows sign...

Страница 989: ...the caliper piston dust boot when installing the caliper If the boot is cut or torn the piston will be exposed to dirt and moisture from normal road splash Install the caliper on the anchor plate Ins...

Страница 990: ...RONT BRAKE ROTOR INSTALLATION Clean the mounting surfaces of the hub 1 and rotor 2 and mount the rotor on the hub Install the caliper and wheel Lower the vehicle and check brake operation FRONT BRAKE...

Страница 991: ...ressed air Apply small amounts of compressed air through the fluid inlet port to ease the piston out of the bore WARNING Do not attempt to catch the piston as it comes out of the bore and do not use f...

Страница 992: ...Install the seal 3 on the piston 2 Install the dust boot 1 on the piston 2 as follows Slide the metal retainer portion of the boot A over the piston Pull the boot rearward until the boot front lip B s...

Страница 993: ...AUTION Position the brake hose A so it is clear of any front axle and suspension components Bleed the brake system Refer to the procedure in this section Install the wheels and lower the vehicle Check...

Страница 994: ...1 on the sup port plate 5 Secure the shoes to the support plate with replacement holddown springs pins and retainers 3 Attach the parking brake cable to the lever 15 Install the strut 16 and spring 17...

Страница 995: ...and position gauge legs B on the brakeshoes Then adjust the brakeshoes to the gauge legs NOTE With the brake drums removed the ad juster screw can be turned by hand Lift the adjuster lever away from t...

Страница 996: ...d Then back off the adjuster screw until the wheel rotates freely Install the access slot covers and lower the vehicle 840655 Proceed to Final Adjustment Final Adjustment Complete rear brakeshoe adjus...

Страница 997: ...umulations of rust scale or corrosion Excessive honing can make the bore oversize or out of round Coat the cylinder bore pistons and replace ment cups with clean brake fluid Install the spring and exp...

Страница 998: ...ghten the cable nuts A at the equalizer C until the gauge pointer is in the blue band Tighten adjusting nuts A and remove the gauge Fully apply and release the parking brakes five times Recheck adjust...

Страница 999: ...racket retaining clip Lower the vehicle Roll back the front carpet and compress the lock tabs that retain the cabie in the parking brake pedal assembly with a hose clamp Disconnect the cable from the...

Страница 1000: ...he instrument panel Compress the front cable lock tabs 3 and dis engage the tabs Disconnect the front cable 4 from the pivot bracket 5 and remove the pedal assembly 6 PARKING BRAKE PEDAL INSTALLATION...

Страница 1001: ...to the dash bracket and remove the pedal 9 Remove the spacer 7 and bushings 6 from the pedal 84019A BRAKE PEDAL INSTALLATION Install the bushings 6 in the pedal Position the pedal in the dash bracket...

Страница 1002: ...the functioning system The piston will remain at the low pressure side until the malfunction is corrected The electrical switch is actuated by the differen tial piston Movement of the piston in eithe...

Страница 1003: ...on the bleeder tank Connect a bleed hose to the wheel cylinder or caliper bleed fitting insert the end of the bleed hose in a glass container partially filled with brake fluid Be sure the hose end is...

Страница 1004: ...ng operation until fluid flowing into the glass container is clear and free of air bubbles NOTE Do not allow the master cylinder to run out of fluid during the bleeding process Check the cylinder rese...

Страница 1005: ...UCT 11 FRESH AIR INTAKE DUCT 12 FRESH AIR DOOR VACUUM MOTOR 12 AIR CONDITIONING SYSTEM 14 GENERAL 14 SYSTEM OPERATION 14 SERVICE DIAGNOSIS 15 REFRIGERANT SAFETY PRECAUTIONS 20 SERVICE VALVES 21 PRESSU...

Страница 1006: ......

Страница 1007: ...2 N m 20 in lbs 2 3 N m 16 25 in lbs A C Receiver Screws 1 N m 9 in lbs 1 2 N m 6 12 in lbs A C Evaporator To Receiver Hose Coupling 14 N m 10 ft lbs 11 16 N m 8 12 ft lbs Magnetic Clutch Nut 37 N m 2...

Страница 1008: ...t and Socket Wrench Set J 23575 Pressure Gauge and Manifold J 5453 Goggles J 6105 1 4 inch Ratchet J 6272 02 Multi Refrigerant Dispenser J 2964240 Service Valve Alignment Tool J 29642 11 Service Valve...

Страница 1009: ...SPECIAL TOOLS J 29642 A J 6272 02 J 25499 J 25359 C J 29642 10 J 29547 101177 L 3...

Страница 1010: ...rmines air flow through the heater core The lever operates the heater housing blend air door which con trols air flow through the core The blower motor is operated by the control switch 4 The switch p...

Страница 1011: ...only when the lever is in the Vent position HEATING SYSTEM DIAGNOSIS Service Diagnosis Condition Possible Cause Correction BLOWER MOTOR 1 Blown fuse 1 Replace fuse WILL NOT TURN 2 Loose connection 2...

Страница 1012: ...AND AIR CONDITIONING HEATING SYSTEM BATING SYSTEM COMPONENTS 1 Defroster Nozzle 6 Blower Motor 2 Defroster Duct 7 Fan 3 Heater Core 8 Heater Housing 4 Seal 9 Cable 5 Hose 10 Heater Housing Cover 8120...

Страница 1013: ...H AIR INTAKE SYSTEM COMPONENTS 1 Drain Cap 2 Tie Strap 3 Drain Hose 4 Clamp 5 Insulator 6 Air Intake Grille 7 Gasket 8 Fresh Air Intake Duct 9 Air Door Vacuum Motor 10 Vacuum Lines 11 Vent Cable and B...

Страница 1014: ...and electrical wires from the control panel Remove the control panel 101170 Installation Connect the electrical wires vacuum hoses and cables to the control panel Position the control panel in the in...

Страница 1015: ...ther and lift the cable upward to disengage it from the lever Remove the cable Installation and Adjustment NOTE The clip on the cable wire has two func tions It attaches the cable to the vent door and...

Страница 1016: ...ut from under the instrument panel Remove the heater housing cover from the housing Remove the heater core from the housing Installation Install the heater core in the housing and install the cover on...

Страница 1017: ...ean container Disconnect the heater hoses Remove the nuts attaching the heater housing studs to the engine compartment side of the dash panel Disconnect the speedometer cable Remove the glove box Tilt...

Страница 1018: ...s Align the motor lever with the air door lever and install the lever retaining clip Connect the vacuum hose to the motor Install the glove box and assist handle FRESH AIR INTAKE DUCT Re noval WARNING...

Страница 1019: ...Install the seals on the blower motor and heater core inlet and outlet tubes Install the attaching nuts on the heater housing studs CAUTION Do not over tighten the attaching nuts The housing could be...

Страница 1020: ...ansferring heat to the air passing over the condenser fins The receiver dryer is a reservoir that supplies pressurized liquid refrigerant to the expansion valve at all times The receiver dryer also op...

Страница 1021: ...check condition of the condensor and radiator fins Air flow blockage of either component caused by dirt foreign material or insects will affect the air condition ing and engine cooling systems equall...

Страница 1022: ...eck the air distribution doors ensure that there are no obstructions in the vent channels Test the drive belt tension Replace the fuse No r Apply 12V directly to the blower motor Yes Replace the blowe...

Страница 1023: ...SIVE VIBRATION 1 Incorrect belt tension 1 Adjust the belt tension 2 Clutch loose 2 Tighten the clutch 3 Overcharged 3 Discharge evacuate and install the correct charge 4 Pulley is misaligned 4 Align t...

Страница 1024: ...fective 3 Replace the expansion valve 4 Drive belt slipping 4 Adjust the belt tension LOW SIDE HIGH HIGH SIDE HIGH 1 Condenser fins obstructed 2 Air in the system 1 Clean the condenser fins 2 Evacuate...

Страница 1025: ...a d L e a k G a s k e t L e a k Oil Filler Plug L e a k Cracked Cylinder Block Front Housing O Ring L e a k Adiust Air G a p n R e p l a c e or R e p a i r Broken L e a d Wire Clutch Coil Defect Inter...

Страница 1026: ...olution of boric acid Call a doctor imme diately even if irritation has ceased after first aid treatment WARNING Never heat a container of R 12 above 51 7 C 125 F Before charging or adding R 12 to the...

Страница 1027: ...water However it can dis color chrome and bright metal trim Keep R 12 refrigerant away from these items R 12 becomes highly corrosive when com bined with water and can damage painted and unpainted met...

Страница 1028: ...isolate the compressor from the system The stem is turned clockwise to place it in this position In position C the valve stem is mid positioned and the gauge port is open This position is used for pr...

Страница 1029: ...sides of the system The gauge and manifold can also be used to recharge or add refrigerant to the system in conjunction with refrigerant can holder J 6272 02 4 5 1 Compound Gauge Suction 2 High Side G...

Страница 1030: ...e degrees Observe the gauge pressures High side dis charge pressure should be approximately two times ambient temperature Low side suction pressure should be approximately 10 of high side pressure For...

Страница 1031: ...ure For example at an of altitude of 300 meters 1000 ft a vacuum of 96 kPa 28 5 in Hg will be equivalent to 99 kPa 29 5 in Hg at sea level When this vacuum level is attained a min imum evacuation time...

Страница 1032: ...is still charged refrigerant can enter and damage the vacuum pump Connect the vacuum pump hose to the vacuum pump inlet Open the low and high pressure control valves on the charging station Start the...

Страница 1033: ...HEATING AND AIR CONDITIONING AIR CONDITIONING SYSTEM L 27...

Страница 1034: ...is held near the leak point for an extended period Repair leaks as required Leak Testing With Electronic Detector J 21547 NOTE Leak detector J 29547 will locate R 12 leaks as small as one half ounce...

Страница 1035: ...side of the areas being tested Watch for a change in flame color as the hose is moved under various components A flame col or change indicates a leak WARNING When R 12 refrigerant contacts an open fla...

Страница 1036: ...ventilated area can displace the air and cause suffocation When the charging cylinder is empty close the valve on the station control panel Check and adjust compressor oil level A replacement receiver...

Страница 1037: ...uch refrigerant has entered the system NOTE If an accurate scale is available weigh the refrigerant cans during the charging proce dure to verify the amount of refrigerant added When the system is ful...

Страница 1038: ...valves on the charg ing station are closed The low pressure gauge could be damaged if the valves are open Close all the valves on the charging station and close the refrigerant drum valve when all th...

Страница 1039: ...and tilt the bottom of the condenser toward the engine NOTE Plug all the condenser openingsto pre vent entry of dirt or moisture Working from under the vehicle disconnect the receiver dryer to evapor...

Страница 1040: ...ittings from the receiver dryer Remove the receiver dryer attaching screws and remove the receiver dryer Installation Install the receiver dryer Connect the evaporator and condenser hose fittings to t...

Страница 1041: ...wer the evaporator housing and pull the hoses and hose grommet through the dash opening NOTE The blower motor blower motor hous ing evaporator core control switches and ex pansion valve can all be ser...

Страница 1042: ...sing 4 Grommet 5 Hose 6 Capillary Tube 7 Expansion Valve 8 Insulation 9 Evaporator Core 10 Lower Housing 11 Louver Panel 12 Louver 13 Drain Tube 14 Temperature Control Knob 15 Fan Control Knob 16 Nut...

Страница 1043: ...tubing Mark the capillary tube location on the evapora tor tubing Disconnect the inlet and outlet hose fittings and remove the capillary tube clamp Disconnect and remove the expansion valve Installati...

Страница 1044: ...the plate is magnetically angaged with the pulley and turns the compres sor shaft i s m o w a l Assert two pins of Front plate spanner J 29635 to any two bolt holes in the front clutch plate 84430 Ho...

Страница 1045: ...rely on the front housing hub Use a suitable tool to drive the rotor onto the shaft Install the internal bearing snap ring then the external bearing snap ring NOTE The snap rings have a flat edge and...

Страница 1046: ...d manifold J 23575 Front seat the suction and discharge service valves by turning them clockwise Discharge refrigerant remaining in the com pressor by slowly opening the suction service valve Open the...

Страница 1047: ...valve Loosen the oil level check plug slowly to re lease any internal pressure in the compressor The compressor is now isolated from the re mainder of system The service valves can be removed from th...

Страница 1048: ...nal magnetic clutch to the new compressor Install the compressor on the mounting bracket Install the drive belt Tighten the drive belt to specified tension Connect the discharge and suction hoses Conn...

Страница 1049: ...R COMPONENTS 1 CYLINDER HEAD 10 FELT RING 2 GASKETS 11 SNAP RING 3 OIL FILL PLUG 12 FRONT PLATE 4 O RING 13 SHIMS 5 COMPRESSOR HOUSING 14 SNAP RING 6 KEY 15 ROTOR PULLEY 7 SHAFT SEAL 16 SNAP RING 8 O...

Страница 1050: ...and remove the pulley nut SEE I S N O T E S 84434 Remove the clutch plate with puller J 29636 and remove the key from the compressor shaft J 29636 86918 Insert snap ring pliers into the two holes in t...

Страница 1051: ...01 84436 Remove the front seal with tool J 29639 Insert the tool into the seal bore Press the tool down against the seal spring Then twist the tool until it engages in the slots in the seal cage and l...

Страница 1052: ...er installer tool J 29639 in the slots in the seal cage Insert the seal assembly firmly into place in the compres sor seal cavity 81077B Twist tool J 29639 in the opposite direction to disengage the t...

Страница 1053: ...ng into place and in stall the compressor shaft key Align the front plate keyway with the compres sor shaft key Install the front plate Use clutch face installa tion tool J 29641 to tap the front plat...

Страница 1054: ...place ment clutch on a replacement compressor that previously did not have a clutch use 1 02 0 51 and 0 13 mm 0 040 0 020 and 0 005 in shims Cylinder Head Waive Plate and Gasket Removal Remove the cyl...

Страница 1055: ...ny way Replace the service port O rings if damaged Installation Coat the valve plate gasket with clean compres sor oil Install the valve plate gasket Align the gasket with the locating pin holes and t...

Страница 1056: ...the oil from the replacement compres sor into a clean container Drain the oil from the original compressor into a measuring cup or graduated beaker Note the amount of oil drained Refill the replacemen...

Страница 1057: ...t compressor oil level as necessary CAUTION Do not overfill the compressor Ex cessive amounts of oil in the system will hinder compressor operation and reduce cooling efficiency 81203C Insert dipstick...

Страница 1058: ......

Страница 1059: ...ENTS RADIO REMOVAL INSTALLATION 1 Radio Removal 1 Radio Installation 1 RADIO SPEAKERS 2 Speaker Removal 2 Speaker Installation 2 Radio Speaker Testing 2 STANDARD RADIO ANTENNA 3 General Information 3...

Страница 1060: ......

Страница 1061: ...ble Disconnect the radio wire harness Remove the radio RADIO INSTALLATION Install the radio Connect the radio wire harness Connect the radio antenna cable Install the radio attaching screws Install th...

Страница 1062: ...aker attaching screws Reinstall the water dam sheet Install the door trim panel RADIO SPEAKER TESTING Radio speakers can be checked for grounds measuring speaker impedance with ohmmeter Connect the oh...

Страница 1063: ...M o 1 OM 0 H 4 0 0 T OM 85118 Mast To Ground Test 1 Test 1 determines if the antenna is making electrical contact with the radio and if the antenna mast is insulated from the base Procedure is as foll...

Страница 1064: ...check the braided ground strap connected to the engine and vehicle body for being loose corroded or damaged Repair as necessary SEE I S N O T E S Body Iround To Ciaiial Shield Test 4 Test 4 checks co...

Страница 1065: ...i o n 3E BRAKES Parking Brake Cable Noise 4E ELECTRICAL A l t e r n a t o r No Charge 5E ENGINE I d l e Speed V a r i a t i o n 6E ENGINE New Crankshaft Rear Main Bearing O i l S e a l 7E ENGINE A l...

Страница 1066: ......

Страница 1067: ...ign procedures involving safety related elements Vehicles involved in this campaign were built between the following Vehicle Identification Numbers VIN 2 B X X X X X X X X X 5 3 0 2 1 9 and VIN 2 B X...

Страница 1068: ...ERING ADJ 2 The road speed should not fluctuate more than 2 mph 3 km h This k controlled by the SENSITIVITY ADJ b Slow the vehicle to 15 mph 24 km h c Press slide button of control switch to RESUME AC...

Страница 1069: ...to increase NOTE Changes in the sensitivity setting affect centering so if sensitivity is changed check the centering again and adjust as required PARTS INFORMATION DESCRIPTION QUANTITY PART NUMBER RE...

Страница 1070: ...s letter to your dealer when you take your vehicle in for this service I f you no longer own the vehicle identified on the form or you have moved please complete the pre addressed postage paid Change...

Страница 1071: ...was corrected on vehicles built after May 28 1986 and starting with sequence number 9086 Service correction involves inspecting for this condition and repositioning the hose as follows PROCEDURE Repl...

Страница 1072: ...hose 4 Position the heater hose on the intake manifold fitting 5 Install the heater hose clamp NOTE Inspect to be sure the hose is now routed over the cylinder head cover and away from the dash panel...

Страница 1073: ...on 1987 Wrangler YJ models have been updated The new specifications are as follows WINDSHIELD WIPER ARM AND BLADE POSITIONING When installing the wiper arms and blades on a 1987 Wrangler YJ model pos...

Страница 1074: ...each lamp lens FILING INSTRUCTIONS Record the information in this I S note on the indicated pages and file it in M R 279 Record the wiper position specifications on page C 130 and the fog lamp aimimg...

Страница 1075: ...caused by the parking brake cable rubbing the edge of the right rear wheel rim Service correction involves the installation of a parking brake cable locating clip to prevent cable movement PROCEDURE 1...

Страница 1076: ...floorpan at the original location FRONT Fig 2 PARTS INFORMATION DESCRIPTION QUANTITY PART NUMBER CLIP Locating 1 8983 100 048 SRT TIC INFORMATION OPERATION DESCRIPTION NUMBER TIME TIC CO CLIP LOCATING...

Страница 1077: ...jumper harness When indications of a low battery are noted e g voltmeter below normal or slow cranking the jumper harness gray connector should be in spected Service correction involves inspecting the...

Страница 1078: ...MATION OPERATION DESCRIPTION OPERATION NUriBER TIME TIC CO CONNECTOR ALTERNATOR REPAIR Inc test on vehicle 0803 0 3 8 993 FILING INSTRUCTIONS Record this I S Note on page C 16 of M R 279 and file it i...

Страница 1079: ...increased tem peratures and or mileage The vehicle should be tested with the MS 1700 Diagnostic Tester Because the condition is intermit tent the MS 1700 may not be able to detect the fault If the veh...

Страница 1080: ...ygen 1 8953 002106 SRT TIC INFORMATION OPERATION DESCRIPTION OPERATION NUMBER TIME TIC CO SENSOR OXYGEN REPLACE 1664 0 3 1 977 FILING INSTRUCTIONS Record this I S Note on page B 197 of M R 279 and pag...

Страница 1081: ...released for the 2 46 Liter four cylinder engine Install the new seal P N 8933 004 143 using the new seal installation tool J 36306 A The installation tool is a required tool for installing the rear...

Страница 1082: ...tool J 36306 until it contacts the nut NOTE Install the shim B ONLY if the old style seal is used 5 Lightly lubricate the inside and outside edges of the seal 6 Install the new seal on tool J 36306 w...

Страница 1083: ...tightened to the specific torque place the specially marked socket over each bolt 14 Use a pencil to draw a small mark on the surface of the flywheel or converter drive plate reinforcing ring in line...

Страница 1084: ...43 SRT TIC INFORMATION OPERATION DESCRIPTION OPERATION NUMBER TIME TIC SUPPLIER CODE CO SEAL REAR MAIN BEARING OIL REPLACE INC R R TRANSMISSION and FLYWHEEL DRIVE PLATE 1817 2 9 1 026 669 FILING INSTR...

Страница 1085: ...Control Information Update Label attached next to the original Vehicle Emission Control Information label The adjustment procedures and update labels must be made available at no cost to independent...

Страница 1086: ...E EMISSION SCHEMATIC r EPA CERTIFICATION SEQUENCE SPECIFICATIONS TRANS IGNITION TIMING RPM SPEC ALTITUDE APPLICATION FAST IDLE RPM SPEC V CURB IDLE RPM SPEC X CURB IDLE RPM SPEC IGNITION TIMING BASE I...

Страница 1087: ...proper adjustment 5 Disconnect the battery ground cable 6 Remove the radio bezel B 103822 7 Remove the radio C 103823 NOTE This will give access to the MCU harness D the two terminal connector E 1038...

Страница 1088: ...speed to the original specification and remove the Vehicle Emission Control Information Update label Vehicles With 4 2L Engines and Automatic Transmissions Built for Operation ABOVE 4 000 Feet Now Bei...

Страница 1089: ...E F 8980 010 601 Position the Update label next to the original label NOTE Whenever this vehicle is returned to operation ABOVE 4 000 feet reconnect the MCU jumper wire reset the ignition timing to 16...

Страница 1090: ...to the two terminal connector 103825 9 install the radio 10 Install the radio bezel 11 Connect the battery ground cable 12 Connect the idle decel switch to the carburetor EGR port as follows Remove t...

Страница 1091: ...when the vehicle is returned to use BELOW 4 000 feet Install a vacuum cap J P N 813 2325 over the open end of the T connector 2 J 2259 103827 Connect one end of a 106 8 cm 42 1 8 inch long vacuum hose...

Страница 1092: ...to 9 BTDC reset the idle speeds to the original specifications and remove the Vehicle Emission Control Information Update label Vehicles With 4 2L Engines and Manual Transmissions Built for Operation...

Страница 1093: ...ent for reinstallation when the vehicle is returned to operation ABOVE 4 000 feet 9 Tape the two terminal connector to the MCU harness 10 Install the radio 12 Connect the battery ground cable 13 Conne...

Страница 1094: ...t the Idle speeds to the settings specified on the original Vehicle Emission Control Information label 16 Attach the Vehicle Emission Control Information Update label P N E F 8980 010 601 Position the...

Страница 1095: ...I S NOTE 11E M R 253 I S NOTE 13E M R 279 I S NOTE 7E EF 8980 010 600 103902 F l AMC I Jeep Corporation Vehicle Emission Control Information Update Label This 1987 vehicle was originally sold for prin...

Страница 1096: ...o sections of the fuel line with new fuel lines that are wrapped with convoluted tubing One section of line runs from the frame to the fuel pump The other section runs from the fuel pump to the fuel f...

Страница 1097: ...ng pump bracket with a new clip L PN 4007428 Torque the power steering bracket bolt M to 40 5 N m 30 ft lbs J K 0572A NOTE The new fuel line K is routed around the oil pan If the vehicle is equipped w...

Страница 1098: ...nd the fuel pump Use two clamps R PN 318 1643 to secure the hose 18 Remove the front fuel pump attaching bolt 19 Attach a clip PN 4007428 T to the fuel line and secure the clip to the fuel pump with t...

Страница 1099: ...Frame to Fuel Pump FUEL PUMP 1 1 1 8953 005 137 8953 005 138 324 0172 SRT TIC INFORMATION OPERATION DESCRIPTION OPERATION NUMBER TIME TIC CO FUEL LINE FRAME TO PUMP PUMP TO FILTER REPLACE 0107 0 7 1...

Страница 1100: ...n loop on the hood The fol lowing procedures outline installation of this shield kit PROCEDURES Front Splash Shields 1 Raise the vehicle with a frame contact hoist 2 Remove both front wheels and tires...

Страница 1101: ...the engine compartment Keep drill from contacting components inside the engine compart ment 11 Using Ditzler DP 40 401 Sikkens Washpri mer or Sherwin Williams E2Y36 prime bare metal areas exposed by d...

Страница 1102: ...ng a trim panel removal tool remove fasteners and lower hood insulation pad if equipped from underside of hood 5 Remove both footman loop nuts K Fig 4 located at the center of the hood Fig 4 6 Install...

Страница 1103: ...Front 2 8955 019 470 Fastener Panel 12 400 4919 Deflector Assembly Ambient Air Duct 1 8953 005120 Screw 2 9421073 Nut 2 1150 2722 Nut W Sealed Washer 2 400 0220 SRT TIC INFORMATION Operation Descript...

Страница 1104: ...the transfer case to skid plate clearance and replacing the skid plate if necessary PROCEDURE Clearance Check 1 Raise and support the vehicle 2 Measure the clearance A between the rear of transfer cas...

Страница 1105: ...skid plate into position 7 Install bolts B and torque to 41 N m 30 ft lbs 8 Install nuts C and torque to 45 N m 33 ft lbs 9 Install nut D and torque to 41 N m 30 ft lbs 10 Remove the safety stands and...

Страница 1106: ...ollowing items must be adjusted IGNITION TIMING CURB IDLE SPEED FAST IDLE SPEED SOLE VAC THROTTLE POSITIONER Refer to the adjustment procedures listed below ADJUSTMENT PROCEDURES The engine must be at...

Страница 1107: ...to the specification listed on the Emission Control Information label Tighten the distributor hold down clamp and verify that the ignition timing is correct Turn the ignition switch OFF and remove th...

Страница 1108: ...djust by turning the fast idle speed adjustment screw E 8 Remove the fast idle speed adjustment screw from the fast idle cam and allow the engine to return to curb idle speed 7 Turn the ignition switc...

Страница 1109: ...pm for 3 to 5 seconds and allow the engine to return to curb idle speed 9 With the Sole Vac throttle positioner fully extended turn the vacuum actuator adjustment screw L on the throttle lever until t...

Страница 1110: ...17 Remove the plug and connect the vacuum hose to the vacuum actuator 18 Disconnect the tachometer 19 If disconnected connect the A C compressor clutch wire connector 20 Install the air filter assembl...

Страница 1111: ...rangler YJ models are outlined in this I S Note All other service information in the M R 279 remains unchanged Service information in the M R 279 affected by these updates revisions include General En...

Страница 1112: ...EST 11 ARMATURE SHORT TEST 11 ARMATURE BALANCE TEST 12 ARMATURE RUNOUT 12 STARTER OVERHAUL 13 STARTER DISASSEMBLY 13 STARTER CLEANING AND INSPECTION 16 STARTER ASSEMBLY 17 GEARBOXES MODEL 231 TRANSFER...

Страница 1113: ...WR Range 3001 4000 J Wrangler Base K Wrangler Sport L Wrangler Laredo M Wrangler Sahara 4001 5000 1 Wrangler Base 2 Wrangler Sahara 3 Wrangler Sport 4 Wrangler Laredo Model Year 1988 Serial Number Ass...

Страница 1114: ...is now recommended for use in all Wrangler YJ auto matic transmissions This same fluid is also rec ommended for use in transfer case Models 207 and 231 Mercon is compatible with Dexron II and can be...

Страница 1115: ...re identified by the two bottom coils B which are flush New valve spring retainers and keepers locks are also used to accomodate the new design valve springs 2516 The new valve springs can be removed...

Страница 1116: ...ters 82 500 miles Emission Maintenance Timer Service The life cycle of the timer coincides with the emission maintenance interval of 133 000 kilometers 82 500 miles The timer can not be reset after re...

Страница 1117: ...e starter magnetic field is produced by six permanent magnets The magnets are mounted in the armature frame and positioned according to polarity They are permanently attached to the frame and are not...

Страница 1118: ...n will damage the starter magnets seri ously enough to require replacement Ensure cleanliness during starter repair Metal chips are attracted by the starter mag nets Be sure all chips are removed with...

Страница 1119: ...078 0 196 in 0 3 0 7 mm 0 012 0 028 in Min 28 4mm 1 118 in max 29 5 mm 1 161 in 0 03mm 0 001 in 0 08mm 0 003 in 0 58mm 0 023 in NO LOAD TEST WITH 1 1 2 VOLTS SOLENOID SPECIFICATIONS AMPS RPM HOLD IN W...

Страница 1120: ...ter Test Lamp Inductive Ammeter Defective starter no armature braking effect Remove and repair overrunning clutch and planetary gear system Check solenoid switch and fork assembly operation Starter Cr...

Страница 1121: ...ion the starter in the housing and install the mounting bolts finger tight Be sure the bolt at the rear of the housing goes through the pulse air bracket Tighten the starter mounting bolts to 45 N m 3...

Страница 1122: ...utch pinion shaft to measure arma ture speed Connect an ammeter C between the battery positive post and terminal 30 of the solenoid Verify that the test battery is at specified test voltage Charge the...

Страница 1123: ...prings or spring holders Protruding insulation between commutator bars Solenoid terminals damaged Brush connecting wire damaged If tests indicate an armature problem check the armature on the growler...

Страница 1124: ...osition Place the contact fingers of the meter test lead D across adjacent commutator bars Adjust the growler voltage control until the pointer indicates highest voltage on scale Test each commutator...

Страница 1125: ...be broken and the frame dented or deformed if mishandled If the starter is to be mounted in a vise during repair use only the mounting flange on the housing for clamping purposes Disconnect the brush...

Страница 1126: ...ELECTRICAL 6 CYLINDER STARTER MOTOR 1 4...

Страница 1127: ...nto the socket 19 Leave the socket in position in the brush holder for inspection and assembly 2643 Remove the seal ring 21 from the planetary gear assembly 22 Remove the planetary gears 23 Remove the...

Страница 1128: ...ning clutch solenoid and brush holder assem bly with clean dry cloths or compressed air only Do not use liquid solvents to clean these components Use mineral spirits or similar sol vents to clean the...

Страница 1129: ...STARTER ASSEMBLY Install the planetary annulus gear 30 on the gear carrier and pin on shaft 31 2647 Lubricate the pinion shaft 32 and the bushing in the overrunning clutch housing with S A E 20W moto...

Страница 1130: ...e 36 after installing the snap and stop rings Remove small burrs or scratches on this surface with crocus cloth or 400 600 grit sandpaper Lightly lubricate the bushing in the overrunning clutch housin...

Страница 1131: ...errunning clutch housing Position the largest lug on the seal ring at the top If replacement brushes were installed in the holder reinsert the socket 43 through the holder 44 to keep the brushes in po...

Страница 1132: ...armature brush holder and shield 51 Be sure to align and seat the brush connector wire grommet in the frame during installation Install the ball in the splined end of the armature shaft Use chassis g...

Страница 1133: ...rque Tighten the brush holder attaching screws to 2 N m 18 in lbs torque Install the solenoid on the housing as follows Engage the solenoid plunger in the clutch fork w Install the plunger return spri...

Страница 1134: ...r entiated Differential action between the front rear axles does not occur in the four wheel drive ranges Two Wheel Drive Operation Two wheel drive range is for on road highway operation or whenever t...

Страница 1135: ...ow range ratio The transfer case serial number also repre sents the date of build For example a serial number of 8 7 87 would represent August 7 1987 iENERAL SPECIFICATIONS Transfer Case Type Part tim...

Страница 1136: ...xtension housing bolts 41 N m 30 ft lbs 35 46 N m 26 34 ft lbs Drain fill plugs 47 N m 35 ft lbs 41 54 N m 30 40 ft lbs Detent plug 20 N m 15 ft lbs 16 24 N m 12 18 ft lbs Front bearing retainer bolts...

Страница 1137: ...into desired range Or reduce speed to 3 4 km h 2 3 mph before attempting to shift 2 Stop vehicle shift transmission to neutral shift transfer case to 2H mode and operate vehicle in 2H on dry paved su...

Страница 1138: ...31 Com ponent Service Manual TRANSFER CASE SHIFT LINKAGE ADJUSTMENT Remove the transfer case shift knob locknut A and remove the shift knob B Remove the boot attaching screws C and remove the shift bo...

Страница 1139: ...t and the shift knob Tighten the locknut securely FRONT YOKE SEAL REPLACEMENT Mark the front propeller shaft yokes for assem bly alignment reference Remove the front propeller shaft Remove the front y...

Страница 1140: ...ft and yoke have been removed Mark the rear propeller shaft yokes for assem bly alignment reference Remove the rear propeller shaft Remove the extension housing bolts Remove the extension housing 2 by...

Страница 1141: ...ng and rear case thoroughly Then apply a 3mm 1 8 inch wide bead of RTV type sealer to the extension housing seal surface Align and install the housing on the rear case Tighten the housing bolts to 41...

Страница 1142: ...fluid recommended for use in the Model 231 transfer case is Mercon automatic trans mission fluid TRANSFER CASE REM0 AL Raise and support the vehicle Drain the transfer case fluid Mark the front and re...

Страница 1143: ...r case on the transmission Install the transfer case to transmission attach ing nuts Connect the range lever linkage rod Connect the speedometer cable and the vent and vacuum hoses to the transfer cas...

Страница 1144: ...c A notification is also provided in current owner s manuals to make customers aware of these adjustments The Emission Control Information Update labels and technical information are available from My...

Страница 1145: ...ginal label This adjustment applies to 1985 Cherokee Wagoneer 49 State Canada 2 8L models that were originally sold for principal use at altitudes below 4 000 feet Refer to the Vehicle Emission Contro...

Страница 1146: ...ontrol Information label in the engine com partment to identify these vehicles NOTE Whenever these vehicles are returned to operation at altitudes below 4 000 feet the MCU circuit jumper wire must be...

Страница 1147: ...ompartment and reset the engine idle speed to the setting indicated on the same label 5 Install Vehicle Emission Control Information Update label P N E F 8980 000 743 next to the original label These...

Страница 1148: ...ctor and reinstall the carpet 4 C o n n e c t the i d l e d e c e l switch to the carburetor E G R port as follows Fig 1 a Disconnect vacuum line 1 from idle decel switch and from tee connector 2 Fig...

Страница 1149: ...low 4 000 feet the ignition timing must be retarded 7 engine idle speed reset and the MCU jumper wire removed In addition the idle decel switch must be connected to the carburetor spark port instead o...

Страница 1150: ...7 from the setting specified on the original Vehicle Emission Control Information label and reset idle speed to the setting on the same label 6 Install Vehicle Emission Control Information Update labe...

Страница 1151: ...and engine idle speed must be reset to original specifications and the Vehicle Emission Control Information Update label removed On 1985 Grand Wagoneer Truck 49 State California Canada 5 9L models ori...

Страница 1152: ...150 c i 2 8L 173 c i 4 2L 258 c i 5 9L 360 c i 1 4L C3J 1 4L C2J CANADA 1 7L F3N 2 1 LTD J8S 2 2L J7T M16X1 5 M 1 8 X 1 5 13 16 x 16 UNF 13 16 x16 UNF M20x1 50 M20X1 50 M20X1 50 M20x1 50 M20X1 50 813...

Страница 1153: ...The adjustment procedures and unique labels must be made available at no cost to independent repair facilities and the general public A notification is also provided in current owner manuals to make...

Страница 1154: ...ion Update label part number E F 8980 000 818 next to the original label This adjustment applies to 1986 Cherokee Wagoneer Comanche 49 State and Canada 2 8L models that were originally sold for princi...

Страница 1155: ...6L engine originally sold for principal use at altitudes below 4 000 feet Refer to the Vehicle Emission Control Information label in the engine compartment to identify these vehicles NOTE Whenever the...

Страница 1156: ...engine idle speed to the setting indicated on the same label 4 Install Vehicle Emission Control Information Update label part number EF 8980 000 818 next to the original label These adjustments apply...

Страница 1157: ...re is in the MCU harness located near the ignition coil Remove the tape covering the eyelet on the ground wire and attach the eyelet to the engine ground screw near the ignition coil 3 C o n n e c t t...

Страница 1158: ...R REMOVING LINE 1 3 EGR PORTTO EGR CTO VACUUM LINE INSTALL TEE CONNECTOR 3210891 IN THIS LINE ABOUT 1 1 4 INCHES FROM EGR CTO END OF LINE 4 75 INCH LINE 1 8 INSIDE DIAMETER VACUUM LINE USED TO RECONNE...

Страница 1159: ...nts apply to 1986 AMC Jeep 49 State California Canada 4 2L models with manual transmission originally sold for use at altitudes above 4 000 feet Refer to the original Vehicle Emission Control Informat...

Страница 1160: ...nada 5 9L models originally sold for principal use at altitudes above 4 000 feet Refer to the Vehicle Emission Control Information label in the engine compartment to identify these vehicles NOTE Whene...

Страница 1161: ...Plug the black lamp into an electrical outlet and turn the switch to the ON position When it is ready to use it will glow 5 Aim the black lamp at the components of the cooling system to pinpoint leaks...

Страница 1162: ...eriod of time 3 Plug the black lamp into an electrical outlet and turn the switch to the ON position When it is ready to use it will glow 4 Raise the vehicle 5 Aim the black lamp at the areas that are...

Страница 1163: ...2 8L V6 engine 5 9L V8 engine Convenor replacement at 105 000 miles 169 000 km is indicated in the 1985 Eagle Jeep Warranty and Maintenance Guides supplied to U S and Canada owners Please advise owne...

Страница 1164: ...vicing the clutch hydraulic system PROCEDURE 1 Inspect the system to determine which clutch hydraulic cylinder is leaking a If the slave cylinder is leaking remove clean and overhaul the cylinder b If...

Страница 1165: ...ER HOSE Master Cylinder To Slave Cylinder 70 Series Gas Eng 70 Series Diesel Eng CJ 4 Cyl CJ 6 Cyl Eagle All 8953 004 247 8953 004 161 8953 004 162 8953 004 164 8953 004 167 FILING INSTRUCTIONS File t...

Страница 1166: ...516 during overhaul or when replacing the viscous coupling in a 1982 85 Jeep model 229 transfer case CAUTION The 1986 mode sleeve is wider and the range sleeve narrower than previous shift sleeves Do...

Страница 1167: ...eak has developed Leakage from the ball plug A can be verified using the following test procedure Ball Plug Leak Test 1 Clean the ball plug area of the housing 2 Start and operate the engine at idle s...

Страница 1168: ...to engage Leave mode selector in the 4WD position Turn off engine If equipped with automatic transmis sion place gear selector in park position If equipped with manual transmission shift into gear Wi...

Страница 1169: ...require that the cylinder head be drilled and tapped for a 1 4 x 20 threaded insert Obtain locally a Helicoil Time Sert or equivalent threaded insert kit NOTE 1981V2 models can be identified by havin...

Страница 1170: ...ER TIME TIC Co Kit Cylinder Head Cover Install 1981V2 1983 models 0117 1 7 hrs 1 141 1983 1986 models 0113 1 3 hrs 1 141 FILING INSTRUCTIONS Record this I S Note in M R 251 page B 133 M R 252 page B 1...

Страница 1171: ...be affected The general result is either rough engine operation and backfire or a no start condition Check for suspected trigger wheel damage as follows Check trigger wheel radial runout on inner sur...

Страница 1172: ...t of liquid soap to the inside of the shift lever insulator A 2 Position the shift lever on the tranmission stub shaft B 3 Apply a small amount of grease to the tool threads 4 Install tool J 36044 as...

Страница 1173: ...too far down on the stub shaft There should be approximately 6 35 mm 1 A inch of stub shaft exposed when the shift lever is properly installed 6 Remove tool J 36044 and install the outer shift lever b...

Страница 1174: ...found to be broken off from the distributor housing It is not necessary to replace the distributor housing for service correction PROCEDURE N O T E Perform this procedure with the distributor removed...

Страница 1175: ...DISTRIBU TOR REPAIR Inc R R Distributor and Gasket and Holddown Flange 0106 0 6 1 771 SUPPLIER Ford CODE 613 FILING INSTRUCTIONS Record this information on the noted pages and file in the MR 171 Comp...

Страница 1176: ...WITH CRUISE CONTROL 1 Disconnect the battery negative cable 2 On tilt columns place the steering wheel in the full up position 3 Place the combination lever A in the right turn position 4 On models w...

Страница 1177: ...E To remove the lever pull it straight out of column with the fish wire the switch 9 The lever is serviced as an assembly only Do CAUTION Do not bend or twist the lever during not attempt to disassem...

Страница 1178: ...an be broken if misalignment occurs during installation 6 Remove the fish wire and connect the cruise control harness to the main harness 7 Connect the battery negative cable PARTS INFORMATION 1 _ Tur...

Страница 1179: ...sed at manifold retaining bolt positions 3 through 10 NOTE The new clamp washer also can be used on all I 6 engines built from 1964 onward Do not reuse the old clamp washers when the manifolds or gask...

Страница 1180: ...UANTITY PART NUMBER CLAMP WASHER Manifold 8 8933 004 255 FILING INSTRUCTIONS Record this I S Note in the following workshop manuals and file it in the M R 171 binder MANUAL PAGES M R 251 B 131 M R 253...

Страница 1181: ...229 The new rear output shaft seal is easily identified The new rear seal A has only one seal spring B The previous rear seal C has two seal springs D Be sure to install the new rear seal whenever re...

Страница 1182: ...229 1 8983 502 508 FILING INSTRUCTIONS Record this I S Note in the following manuals and file it in the M R 171 binder M R 244 page E 62 E 100 1982 AMC Technical Service Manual page 2D 21 M R 251 page...

Страница 1183: ...special tool set PN 8980 002 647 is available to remove the bearing assemblies from the drive hub The new tools are designed for use with an arbor or hydraulic press and Kent Moore bearing remover too...

Страница 1184: ...TOOL SET 8980 002 847 Bearing Race Installer 5077 Press Plate 5073 Bearing Installer 5078 Press Pin 5074 Seal Installer 5079 KENT MOORE BEARING REMOVER J 22912 01 NOT PART OF KIT Fig 1 2...

Страница 1185: ...EARING RACE 6 7 10 11 12 13 INNER BEARING 14 INNER BEARING SEAL B 15 CARRIER SEAL B 16 ROTOR SHIELD 17 BEARING CARRIER BOLTS C 18 AXLE SHAFTTO BEARING SPACER D 19 AXLE SHAFT DUST SLINGER 20 AXLE SHAFT...

Страница 1186: ...t allow the brake hose to support caliper weight Be sure to secure the caliper to the chassis 4 Remove the disc brake rotor 5 Fig 2 5 Remove the cotter pin 1 nut retainer 2 axle nut 3 and washer 4 Fig...

Страница 1187: ...er tool J 22912 01on the inner bearing D Fig 6 4 Cut and remove the plastic bearing cage C Fig 5 from the hub inner bearing Use diagonal pliers or tin snips to cut the bearing cage Discard the bearing...

Страница 1188: ...ep on tool 5078 is facing downward toward the hub 10 On Eagle models position bearing race remover tool 5075 between inner and outer bearing races H Fig 9 11 On Jeep models position bearing race remov...

Страница 1189: ...nward toward bearing carrier One end of bearing installer is marked Eagle the other end is marked Jeep 5 Rotate assembled press plate with bearing carrier and repeat steps 3 and 4 for inner race CAUTI...

Страница 1190: ...Q 103657 Fig 15 13 Place hub S Fig 16 and bearing carrier T Fig 16 on bearing race installer 5077 Fig 16 on press 14 Position inner bearing U Fig 16 in bearing carrier T Fig 16 15 On Jeep models place...

Страница 1191: ...Fig 2 8 Install nut retainer 2 and cotter pin 1 Fig 2 NOTE Do not loosen the nut to fit the retainer Tighten the nut to the next available slot 9 Install wheel and tire assembly 10 Lower vehicle HUB...

Страница 1192: ...in a copy of this I S Note Insert a copy in the kit sleeve for future reference SRT TIC INFORMATION OPERATION D E S C R I P T I O N N U M B E R T I M E T I C S U P P L I E R C O D E CO BEARING FRONT W...

Страница 1193: ...hen replacing the boots thoroughly clean all components with mineral spirits NOTE On Renault models do not allow any mineral spirits to come in contact with the trunion bearing Inspect all metal parts...

Страница 1194: ...output shaft seal PN 8983 505 290 has been released for service use on transfer case models 128 129 208 228 229 and 242 Because the new seal is a uni directional design it must be used in the front o...

Страница 1195: ...PARTS INFORMATION DESCRIPTION QUANTITY PART NUMBER SEAL Transfer C a s e Front Output Shaft Model 128 129 208 228 229 242 1 8983 505 290 FILING INSTRUCTIONS File this I S Note in the M R 171 binder...

Страница 1196: ......

Страница 1197: ...in this manual are based on the latest data available at the time of publication American Motors Corporation and Jeep Corporation reserve the right to discontinue designs or change specifications wit...

Страница 1198: ......

Страница 1199: ...ecifications 3 SPECIAL TOOLS 4 SERVICE DIAGNOSIS 5 SHIFT LINKAGE 6 Linkage Adjustment 6 TRANSFER CASE FLUID LEVEL 7 Two Piece Fill Plug 7 OVERHAUL 8 Transfer Case Disassembly 10 Mainshaft Disassembly...

Страница 1200: ......

Страница 1201: ...surfaces covered by snow ice or similar low traction elements SHIFT MECHANISM Transfer case operating ranges are selected with a floor mounted shift lever The shift lever is connected to the transfer...

Страница 1202: ...of each Model 207 transfer case The ID tag B provides the transfer c a s e model number assembly number serial number and low range ratio The transfer case serial number also represents the date of bu...

Страница 1203: ...ion fluid or equivalent marked D E X R O N II To bottom edge of pipe plug hole TORQUE SPECIFICATIONS Component Service Set To Torque Service Recheck Torque Bolt Low Range Lock Plate Nut Front Yoke Vac...

Страница 1204: ...et Bearing Installer J 33829 Mainshaft Pilot Bearing Installer J 33830 Input Gear Bearing Installer J 33831 Input Gear Seal Installer J 33832 Output Shaft Rear Bearing Installer J 33833 Output Shart F...

Страница 1205: ...eed to 3 4 km h 2 3 mph before attempting to shift 2 Stop vehicle shift transmission to neutral shift transfer case to 2H mode and operate vehicle in 2H on dry paved surfaces 3 Lubricate repair or rep...

Страница 1206: ...shift lever A and the forward edge of the shift lever gate C Secure the lever and spacer in position Loosen adjusting link D enough to allow linkage rod E to slide freely in the link Move the transfer...

Страница 1207: ...ecked at the small pipe plug 1 To check the fluid level remove the small pipe plug 1 from the main plug 2 The correct fluid level is to the bottom edge of the pipe plug hole N O T E If the transfer ca...

Страница 1208: ......

Страница 1209: ...r C a s e I S 17 Input Gear 54 Oil Pump N 18 Input Gear Cup Plug 55 Speedometer Drive Gear O T 19 Mainshaft Pilot Bearing 56 Pump Housing Seal E 20 Planetary Thrust Washer 57 Oil Pump Housing S 21 Ann...

Страница 1210: ...bead Then remove the housing C A U T I O N To avoid damaging the sealing surfaces of the extension housing and rear retainer do not attempt to pry or wedge the housing off the retainer 84283 Remove th...

Страница 1211: ...53 from the front case 10 u s i n g two s c r e w d r i v e r s Insert the screwdrivers A into the slots cast into the case ends Then gently pry upward to break the sealer bead and separate the case h...

Страница 1212: ...J 2619 01 J 29369 1 S E E I S N O T E S 84298 Lift the mainshaft and geartrain assembly B upward and out of the front case 84290 R e m o v e the annulus and planetary gear assembly C and the range fo...

Страница 1213: ...iscard the following oil seals Input gear oil seal 12 front output shaft oil seal 4 extension housing oil seal 63 MAINSHAFT DISASSEMBLY Remove the synchronizer hub snap ring 26 Mark position of the sy...

Страница 1214: ...for wear stretch or distortion Inspect all of the transfer case bearings and thrust washers for wear roughness pitting or galling Inspect the shift sector shift rail range and mode fork bushings and p...

Страница 1215: ...Gear Bearings Remove both bearings from the front case simultaneously with driver handle J 8092 and toolJ 33841 84299 Install the replacement bearings one at a time with driver handle J 8092 and tool...

Страница 1216: ...4393 Tap the front bearing out of the front case with a rawhide mallet Install the replacement front bearing with driver handle J 8092 and tool J 33833 NOTE The front bearing is fully seated when the...

Страница 1217: ...it is flush with the front surface of the sprocket J 8 0 9 2 J 33828 84396 Install the replacement rear bearing in the sprocket as follows Reverse tool J 33828 on the driver handle T h e stop flange D...

Страница 1218: ...ment bearing with driver handle J 8092 and tool J 33833 84321 Extension Housing Bushing Remove the bushing with driver handle J 8092 and tool J 33839 J 8 0 9 2 J 33839 84394 Install the replacement bu...

Страница 1219: ...ponents on the mainshaft Align the hub and mainshaft splines and tap the hub into place with a rawhide mallet Be sure the stop ring is properly engaged in the synchronizer hub and sleeve before seatin...

Страница 1220: ...shaft oil seal 4 in the front case with tool J 33834 J 33834 84401 Install a replacement input gear oil seal 12 in the front case with tool J 33831 Install sector detent spring 69 and detent bolt 70...

Страница 1221: ...case Be sure the planetary thrust washer is aligned before attempting to install the mainshaft Position the assembled mode fork 49 in the synchronizer sleeve 31 Align the mode and range forks and ins...

Страница 1222: ...bolts Install the remaining front case to rear case attaching bolts Tighten all of the front case to rear case bolts to 30 Mm torque Install a replacement oil seal 56 in the pump housing 57 with tool...

Страница 1223: ...liters 4 5 pints of Jeep automatic transmission fluid or equivalent marked Dexron II Install and tighten the fill plug 64 to 47 N m 35 ft lbs torque N O T E Adjust the transfer case shift linkage and...

Страница 1224: ......

Страница 1225: ...N O T E S...

Страница 1226: ...N O T E S...

Страница 1227: ...tion and specifications in this manual are based on the latest data available at the time of publication American Motors Corporation and Jeep Corporation reserve the right to discontinue designs or ch...

Страница 1228: ......

Страница 1229: ...ifications 2 GENERAL INFORMATION 3 Description 3 Operating Ranges 3 Shift Mechanism 3 Two Wheel Drive Operation 4 Four Wheel Drive Operation 4 Identification 4 SERVICE DIAGNOSIS 5 OVERHAUL 6 Transfer...

Страница 1230: ......

Страница 1231: ...taller J 29170 Sprocket Bearing Tool J 33829 Mainshaft Pilot Bearing Installer J 33830 Input Gear Bearing Installer J 33831 Input Gear Seal Installer J 29369 2 Bearing Remover J 33833 Output Shaft Bea...

Страница 1232: ...t lbs Detent plug 20 N m 15 ft lbs 16 24 N m 12 18 ft lbs Front bearing retainer bolts 21 N m 16 ft lbs 16 27 N m 12 20 ft lbs 101641 8ENERAL SPECIFICATIONS Transfer C a s e Type Torque Transfer Mode...

Страница 1233: ...d Two wheel drive range is used for on road highway operation The four wheel drive ranges are for off road operation or when the vehicle is driven on paved road surfaces covered by snow ice or similar...

Страница 1234: ...provide four wheel drive operation A vacuum shift motor connects the right hand axle shaft and a synchronizer assembly engages the transfer case front output shaft The shift motor is operated by a va...

Страница 1235: ...ed to 3 4 km h 2 3 mph before attempting to shift 2 Stop vehicle shift transmission to neutral shift transfer case to 2H mode and operate vehicle in 2H on dry paved surfaces 3 Lubricate repair or repl...

Страница 1236: ...y are not reusable Move the transfer case range lever all the way rearward to the four wheel low position Remove the extension housing attaching bolts Tap the extension housing 2 in a clockwise direct...

Страница 1237: ...e The surfaces could be damaged 101646 Remove the bolts attaching the rear c a s e to the front case Retain the bolts and the washers used at the dowel bolt locations Separate the rear case from the f...

Страница 1238: ...T C 231 TRANSFER CASE OVERHAUL Remove the oil pump 8 and rear case 9 as an assembly tube 11 101649 8...

Страница 1239: ...g 13 from the gear housing 14 Note position of the pump gears 15 and 16 in the gear housing and remove the gears 101650 Remove the mode spring 17 101651 Tap the front output shaft 18 upward with a raw...

Страница 1240: ...om the front case as an assembly 101653 Remove the mode fork and shift rail 22 from the synchronizer sleeve 23 Mark position of the sleeve 23 for assembly reference 101654 Remove the synchronizer slee...

Страница 1241: ...28 from the mainshaft 101657 Remove the drive sprocket 29 from the mainshaft 101658 Slide the range fork pin 30 out of the slot in the sector 31 101659 Remove the range fork 32 and shift hub 33 as an...

Страница 1242: ...the lever attaching nut and washer Remove the shift sector 34 SEE i S N O T E S 101661 Remove the sector shaft bushing 35 and CD ring 36 101662 Remove the shift detent pin 37 spring 38 and plug 39 10...

Страница 1243: ...th a screwdriver Position the screwdriver in the slots 42 cast into the retainer 101665 Remove the input gear snap ring 43 101666 Press the input and low range gear assembly 44 out of the input gear b...

Страница 1244: ...es Clean the oil pickup screen with solvent and dry it with compressed air Also use compressed air to remove solvent residue from all oil feed passages and channels Inspect the case halves extension h...

Страница 1245: ...with a plastic mallet Install the replacement bearing with driver handle J 8092 and tool J 33833 The bearing is fully seated when tool J 33833 contacts the front case Install the bearing snap ring 1...

Страница 1246: ...J 29170 and a wood block Install the bearing far enough into the case to seat the snap ring 2 against the case 101672 Replace the input gear pilot bearing as follows Remove the pilot bearing with slid...

Страница 1247: ...with automatic transmission fluid Start the input gear shaft into the bearing in the front case Press the input gear shaft into the front bearing with tool J 33829 and an arbor press Be sure the tool...

Страница 1248: ...3831 101705 Apply a 3 mm 1 8 inch wide bead of sealer to the seal surface of the front bearing retainer 11 Use Jeep Gasket ln A Tube sealer or an equivalent RTV type sealer Install the front bearing r...

Страница 1249: ...shaft Tighten the attaching nut to specified torque Install the detent 15 detent spring 16 and detent plug 17 in the case 101710 Install replacement pads 18 and shift rail bushings 19 in the range for...

Страница 1250: ...arbor press and tool J 29170 Press the bearing in until flush with the edge of the bore as shown Install the replacement rear bearing B with an arbor press and tool J 29170 Press the bearing in until...

Страница 1251: ...earings and install the sprocket 26 on the mainshaft Install the synchronizer stop ring 27 on the mainshaft Seat the ring on the drive sprocket Install the synchronizer hub 28 on the mainshaft Align a...

Страница 1252: ...the mainshaft assembly 32 in the case N O T E Be sure the mode fork shift rail is seated in both of the range fork bushings Assemble and install the output shaft and drive chain Lift the mainshaft sli...

Страница 1253: ...5 J 33835 101718 Assemble the oil pump Lubricate and install the two gears 34 in the gear housing 35 Align and install the feed housing 36 on the gear housing Install and tighten the pump s c r e w s...

Страница 1254: ...and that the mainshaft splines are engaged in the oil pump inner gear Install and tighten the front case to rear case attaching bolts to specified torque N O T E Be sure to install a washer under each...

Страница 1255: ...sion housing bushing as follows Remove the rear extension housing seal if not removed previously R e m o v e the bushing with driver handle J 8092 and tool J 33839 J 8092 J 33839 84394 Install the rep...

Страница 1256: ...of J e e p automatic transmission fluid or an equivalent D e x r o n II fluid after installation Install and tighten the fill plug to specified torque Apply a 3 mm 1 8 inch wide bead of sealer to the...

Страница 1257: ...27...

Страница 1258: ...izer hub and inserts 18 Synchronizer sleeve 19 Synchronizer stop ring 20 Snap ring 21 Output shaft front bearing 22 Output shaft front 23 Drive sprocket 24 Drive chain 25 Drive sprocket bearings 26 Ou...

Страница 1259: ...tion and specifications in this manual are based on the latest date available at the time of publication American Motors Corporation reserves the right to discontinue designs or change specifications...

Страница 1260: ...AUTOMATIC TRANSMISSIONS OVERHAUL GENERAL INFORMATION 1 General 1 Special Tools 3 Special Tools 5 OVERHAUL 1 0 Transmission Disassembly 10 Subassembly Overhaul 14 Transmission Assembly 85...

Страница 1261: ...e element torque converter is used for all applications A manually operated gear shift linkage is used to select the desired gear range Transmission shift points are controlled by an externally mounte...

Страница 1262: ...Planetary Gear Set 9 Rear Planetary Gear Set 10 Low and Reverse Rear Band 11 Overrunning Clutch 12 Governor 13 Bearing 14 Output Shaft 15 Seal 16 Adapter Housing 17 Parking Low Assembly 18 Valve Body...

Страница 1263: ...7 J 24049 A Oil Pump Bushing Remover Installer J 24055 Oil Pump Bushing Remover Installer 727 J 24063 01 Kickdown Band Adjustment Adapter J 24064 Front Clutch Bushing Remover Installer J 24108 A Pilot...

Страница 1264: ...Required Recommended J 24032 Reaction Shaft Bushing Installer J 24033 Pump Rotor Alignment Tools J 24036 A Reaction Shaft Bushing Remover J 24037 A Reaction Shaft Bushing Remover 727 J 24038 Reaction...

Страница 1265: ...AUTOMATIC TRANSMISSIONS OVERHAUL SEE I S N J 24045 84449 5...

Страница 1266: ...ATIC TRANSMISSIONS OVERHAUL D J 9617 J 24040 A J 21055 01 J 23327 J 24036 A J 24041 A J 24037 A J 24108 A J 3387 2 L J 24042 J 21232 01 J 24032 J 24063 01 J 24026 J 24048 J 24033 I 24033 U 4 J 8001 84...

Страница 1267: ...4 3 4 MODEL 904 HO MODEL 998 MODEL 999 MODEL 727 U S Metric U S Metric U S Metric U S Metric Measure Measure Measure Measure Measure Measure Measure Measure Torque Converter Diameter 260 mm 10 2 in 1...

Страница 1268: ...sting Screw Locknut 47 N m 35 ft lbs Neutral Starter Switch 33 N m 24 ft lbs Oil Filler Tube Bracket Bolt 17 N m 150 in lb Oil Pan Bolt 17 N m 150 in lb 12 18 N m 9 13 ft lbs Oil Pump Housing to Trans...

Страница 1269: ...Front Annulus Support to Front Planetary Gear No 5 048 to 050 No 4 059 to 062 Driving Shell to Front Annulus Gear No 5 060 to 062 Front Planetary Gear to Driving Shell No 6 048 to 050 Sun Gear and Dr...

Страница 1270: ...ill indicate whether a thrust washer change is required and save time at assembly R e m o v e the transfer c a s e from the transmission Mount the transmission in Holding Fixture J 24026 84453 Remove...

Страница 1271: ...m the piston Identify the spring with a tag for assembly reference Remove the piston from the case Adapter Housing Rear Bearing and Seal Remove the housing attaching bolts and remove the housing Remov...

Страница 1272: ...ing screw and remove the band strut and band Remove the front clutch assembly Input Shaft and Rear Clutch Remove the input shaft and rear clutch assembly by grasping the input shaft and pulling the as...

Страница 1273: ...a No 2 Phillips screwdriver 2 into the pressure port Slowly r e l e a s e the rod guide against the screwdriver Remove the servo retaining snap ring C o m p r e s s the rod guide and remove the screwd...

Страница 1274: ...oth When removing and installing valves or plugs slide them in or out very carefully Do not use force to remove or install valves NOTE When disassembling the valve body identify all valve springs with...

Страница 1275: ...AUTOMATIC TRANSMISSIONS OVERHAUL 84461 15...

Страница 1276: ...g force while removing the last screw Remove the spring retainer line 2 and the throttle pressure adjusting screws 3 Do not disturb the screw settings Remove the line p r e s s u r e 4 and torque conv...

Страница 1277: ...om the manual lever Remove the retainer tool detent ball and spring Tag the spring for assembly reference Remove the manual valve 14 Remove the kickdown detent 15 kickdown valve 16 throttle valve spri...

Страница 1278: ...AUTOMATIC TRANSMISSIONS OVERHAUL Remove the check balls from the valve body Turn the valve body 1 over and remove the shuttle valve cover plate 2 18...

Страница 1279: ...the governor plug end plate 1 shuttle valve throttle plug 2 and spring 3 and the 1 2 A and 2 3 B shift valve governor plugs Remove the shuttle valve E clip 4 shuttle valve secondary spring 5 spring gu...

Страница 1280: ...lug 4 and spring 5 Remove the downshift valve housing end plate A Remove downshift valve housing B remove throttle plug C and downshift valve retainer D and remove spring E and limit valve from the ho...

Страница 1281: ...res in the valve body for corrosion s c o r e s burrs s c r a t c h e s pits and other irregularities Inspect all valves and plugs for burrs nicks and I scores R e m o v e slight irregularities using...

Страница 1282: ...ove c Insert the throttle plug C into the bore d Position the downshift housing end plate A on the housing and insert the retaining screws e Position the downshift housing assembly N against the shift...

Страница 1283: ...rip AUTOMATIC TRANSMISSIONS rip OVERHAUL 84469 23...

Страница 1284: ...the shuttle valve 7 primary spring 3 and the throttle plug 2 Install the governor plug end plate 1 and tighten the screws to 4 N m 35 in lbs torque Install the spring guides 6 shuttle valve secondary...

Страница 1285: ...ate on the transfer plate 4 84471 Position the transfer plate assembly on the valve body and install the retaining screws finger tight N O T E Before tightening the retaining screws be sure the pressu...

Страница 1286: ...ng 8 in the valve body Install the Retainer Tool J 24044 around the detent ball casing to retain the ball and spring Install the throttle lever assembly 12 Install the manual lever assembly 13 on the...

Страница 1287: ...l the line pressure adjusting screw assembly 2 on the spring retainer bracket 1 and position it on the valve body Attach the bracket to the side of the valve body and tighten the retaining screws only...

Страница 1288: ...AUTOMATIC TRANSMISSIONS OVERHAUL 8447S 28...

Страница 1289: ...mp any part of the valve body or transfer plate in a vise Any slight distortion of the body or plate will cause sticking valves or excessive leakage or both When removing and installing valves or plug...

Страница 1290: ...TRANSMISSIONS OVERHAUL Remove the rear clutch check ball 2 from the transfer plate and remove the pressure regulator valve screen 3 from the separator plate 4 Remove check balls A and B from the valv...

Страница 1291: ...emove the shuttle valve cover plate Remove the governor plug end plate 1 shuttle valve throttle plug 2 and spring 3 and 1 2 A and 2 3 B shift valve governor plugs Remove the shuttle valve E clip 4 shu...

Страница 1292: ...force while removing the last screw Release the pressure applied to the spring retainer and remove the spring retainer and line pressure adjusting screw assembly 2 and throttle pressure adjusting scr...

Страница 1293: ...ever assembly 12 Remove the E clip and park control rod from the manual lever A C A U T I O N The detent ball retainer tool is holding the ball against spring pressure Shield the ball casing area with...

Страница 1294: ...emove the sleeve 2 line pressure regulator valve plug 3 and throttle pressure regulator valve plug 4 and spring 5 Remove the downshift valve housing end plate A R e m o v e the downshift valve housing...

Страница 1295: ...ery slight warpage or distortion may be corrected by abrading the surface on a sheet of crocus cloth Position the cloth on a surface plate or flat piece of glass and use very light pressure Be sure al...

Страница 1296: ...ve G and spring N into the valve body Assemble and install the downshift housing assembly in the following sequence a Install the limit valve F and spring E b Slide the spring retainer D into the groo...

Страница 1297: ...AUTOMATIC TRANSMISSIONS OVERHAUL SEE I S N O T 84482 37...

Страница 1298: ...AUTOMATIC TRANSMISSIONS OVERHAUL 84483 38...

Страница 1299: ...ll the seal 10 washer 9 and E clip 8 on the throttle lever shaft Remove the detent ball retainer tool Install the line pressure regulator valve 6 and spring 4 and install the converter control valve 7...

Страница 1300: ...stall the shuttle valve 7 primary spring 3 and the throttle plug 2 Install the governor plug end plate 1 and tighten the screws to 4 N m 35 in lbs torque Install the spring guides 6 shuttle valve seco...

Страница 1301: ...the transfer plate assembly on the valve body and install the retaining screws finger tight NOTE Before tightening the retaining screws be sure the pressure regulator filter screen is properly aligne...

Страница 1302: ...Pressure Adjustment Measure the distance from the valve body to the inner edge of the adjusting screw using the accurate steel scale The distance measured should be 33 4 mm 1 5 16 inches If adjustmen...

Страница 1303: ...parts Adapter Housing Bearing and Seal Replacement Remove the seal from extension housing using a screwdriver or punch Remove the snap rings and remove the bearing from the housing Install the replac...

Страница 1304: ...rod for excessive wear nicks burrs and free turning If necessary replace the park gear as outlined under Governor and Support Disassembly and Assembly Assembly Install the reaction plug and pin assem...

Страница 1305: ...snap ring 3 Install weight assembly into body Install snap ring 1 Inspection Thoroughly clean and dry all governor parts and check for free movement Do not use a caustic cleaning solution The weights...

Страница 1306: ...0 Series Disassembly Remove the bolts 1 attaching the pump 2 to Remove the O ring 6 seal 7 using a blunt the support 3 and remove the support punch Mark the pump rotors 4 5 for assembly Remove the fro...

Страница 1307: ...the pump body Place straightedge across the rotor faces and pump body Using a feeler gauge measure the clearance between the straightedge and pump rotors Clearance limits are 0 02 to 0 07 mm 0 001 to...

Страница 1308: ...e careful to keep the tool straight in the bore during removal Position replacement bushing on Installer Tool J 24049 A Turn the pump housing over and install the bushing straight into the housing unt...

Страница 1309: ...he bushing three or four additional turns to fully engage the threads of the tool in the bushing Install the Slide Hammer Tools J 7004 3 and J 6585 1 into remover tool Clean the chips from the reactio...

Страница 1310: ...bolts should be threaded into the support until the ends of bolts are 1 6 mm 1 16 inch below front machined surface of pump housing A J 7004 3 84499 84500 Install one Pilot Stud Tool J 3387 2 into the...

Страница 1311: ...to support attaching bolts 1 and remove the support 2 from pump 3 Mark the rotors for a s s e m b l y alignment reference Remove the rotors 4 5 Remove the O ring seal 6 from the pump body flange A Rem...

Страница 1312: ...on a straightedge A across the rotor faces and pump body and use a feeler gauge B to m e a s u r e the c l e a r a n c e b e t w e e n the straightedge and rotors Clearance limits are 0 02 to 0 07 mm...

Страница 1313: ...ent Place the pump housing with the reaction shaft support mating surface facing downward on a flat level surface Remove the bushing using Remover Installer Tool J 24055 and Driver Handle J 8092 84504...

Страница 1314: ...re is worn or grooved replace the entire support assembly CAUTION Do not clamp any part of the reaction shaft or support in a vise Thread Bushing Remover Tool J 24037 A to the bushing as far as possib...

Страница 1315: ...s Assembly Install the pump rotors in the housing Install the reaction shaft support and tighten the attaching bolts to 18 N m 160 in lbs torque Install the O ring seal around the pump housing flange...

Страница 1316: ...AUTOMATIC TRANSMISSIONS OVERHAUL Front Clutch 900 Series Disassembly Remove the large waved snap ring 1 which secures the pressure plate 2 in the clutch retainer 3 Remove the steel plates plates B 56...

Страница 1317: ...aged driving lugs Replace any worn damaged parts Inspect the steel plate lug grooves in the clutch retainer for smooth surfaces The plates must slide freely in the grooves Inspect the band application...

Страница 1318: ...until the bushing is flush with the base of the bore chamfer 84512 Assembly Lubricate the inner seal with petroleum jelly and install the seal on hub of clutch retainer N O T E Be sure the seal lip i...

Страница 1319: ...ler gauge A 84513 Insert the gauge between the pressure plate and snap ring Refer to the Clutch Plate Clearance in the Specifications for tolerances If the clutch plate clearance is not within specifi...

Страница 1320: ...AUTOMATIC TRANSMISSIONS 1 OVERHAUL 1 Front Clutch Model 727 Disassembly Remove the large waved snap ring 1 that retains the pressure plate 2 in the clutch piston retainer 3 60...

Страница 1321: ...e p l a c e a s necessary Inspect the steel plate lug grooves in the clutch retainer for smooth surfaces The plates must slide freely in the grooves Inspect the band application surface on the clutch...

Страница 1322: ...the Tool J 24039 and install the bushing straight into the retainer bore until the bushing is flush with the base of the bore chamfer 84517 Assembly Lubricate the inner seal with petroleum jelly and i...

Страница 1323: ...led Install the pressure plate and waved snap ring Measure the clutch pack clearance using the feeler gauge 84519 Refer to the clutch plate clearance in the Specifications section for tolerances If th...

Страница 1324: ...ing and determines clutch pack clearance Lift the pressure plate 2 clutch plates 3 4 and inner pressure plate 5 out of the retainer 6 Remove the wave spring 7 and the clutch piston spring 8 Turn the r...

Страница 1325: ...ge Inspect the seal ring grooves in the input shaft and piston retainer for nicks burrs and wear Inspect the rear clutch to front clutch thrust washer The washer should be 1 09 to 1 14 mm 0 043 to 0 0...

Страница 1326: ...the outer pressure plate and the selective thickness snap ring C Measure the rear clutch pack clearance Press down firmly on the outer pressure plate and insert the feeler gauge D between the pressur...

Страница 1327: ...es clutch pack clearance Remove the pressure plate 2 clutch plates 4 5 and inner pressure plate 6 Remove the wave spring 7 spacer ring 8 and clutch piston spring 9 Turn the retainer over and bump on a...

Страница 1328: ...he piston spring wave spring and spacer for distortion or breakage Inspect the seal ring grooves in the input shaft and piston retainer for nicks burrs and wear Inspect the rear clutch to front clutch...

Страница 1329: ...d Bushing Installer Tool J 24040 onto Driver Handle J 8092 Position the replacement bushing on the installer tool and install the bushing straight into the shaft until the tool bottoms Clean the assem...

Страница 1330: ...on spring 9 in the clutch retainer with the spring fingers touching the piston Install the spacer ring 8 Be sure piston spring and ring are centered in the retainer recess Install one end of the wave...

Страница 1331: ...in o b t a i n i n g p r o p e r c l u t c h engagement and shift quality Planetary Gear Assembly 900 Series End Play Measurement Measure the end play of the planetary assembly before removing compone...

Страница 1332: ...rom the forward end of the output shaft Removethe front planetary gear assembly 2 Remove the snap ring and the thrust washer 8 from the forward hub of the front planetary assembly Remove the front ann...

Страница 1333: ...gear 14 to separate the support 15 from the gear Inspection Inspect the bearing surfaces on the output shaft for nicks burrs scores or other damage Light scratches nicks or burrs can be removed with...

Страница 1334: ...13 Install the rear annulus gear assembly on the output shaft 10 Install the thrust washer 12 on the output shaft Position the rear planetary gear assembly 9 in the rear annulus gear Install the thru...

Страница 1335: ...the sun gear Install the thrust washer A on the output shaft Install the selective snap ring 1 and measure the assembly end play N O T E If necessary adjust the clearance by using selective thickness...

Страница 1336: ...move the thrust washer A from the toward end of the output shaft 1 Remove the snap ring 2 and front planetary assembly 3 from the output shaft Remove the front annulus gear 4 from the planetary assemb...

Страница 1337: ...he thrust plate F from the rear annulus gear Inspection Inspect the bearing surfaces on the output shaft for nicks burrs scores and other damage Light scratches nicks or burrs can be removed with croc...

Страница 1338: ...planetary gear assembly 7 in the rear annulus gear and install the thrust washer E on the forward side of the gear assembly Insert the sun gear through the forward side of the driving shell 6 and inst...

Страница 1339: ...llers for smooth round surfaces They must be free of flat spots and chipped teeth Inspect the roller contact surfaces in the cam and race for brinelling and inspect the springs for distortion wear or...

Страница 1340: ...gn material from the case and be sure the cam area is free of burrs and chips Install the replacement cam and spring retainer in the case with the bolt holes in the cam and retainer aligned with the h...

Страница 1341: ...rom the case Remove the bolts attaching the output shaft support to the rear of the case Insert a punch through the bolt holes and drive the cam A out of the case N O T E Move the punch from one bolt...

Страница 1342: ...e cam in the case Be sure the cam is completely seated Install the cam retaining setscrew and stake the case around the setscrew Remove Tool J 24042 Install and tighten the support retaining bolts to...

Страница 1343: ...servo components If they do not assemble easily investigate and correct the cause before proceeding with the assembly Apply petroleum jelly to the piston rod O ring A and install the piston rod 1 in t...

Страница 1344: ...case for scores or other damage Inspect the springs for distortion Inspect the band lining for poor bonding to the band and for excessive wear If the lining is so excessively worn that the grooves ar...

Страница 1345: ...iner 2 Install the clutch spring 3 and rollers 4 so the springs rest against the retainer post and the rollers rest against the spring and with both s p r i n g s a n d r o l l e r s i n s t a l l e d...

Страница 1346: ...h the gasket surface Position the band 3 in the case so both band lugs rest against the reaction pin Install the low reverse drum in the overrunning clutch hub and into the rear band Install the band...

Страница 1347: ...nect the long link and anchor 3 in the band Thread the band adjusting screw 4 inward just enough to hold the band strut in place Be sure the long link and anchor assembly are installed a s shown to pr...

Страница 1348: ...ion Lubricate the O ring A with petroleum jelly and install it on the piston rod 1 Install the rod in the piston 3 Install the spring 5 flat washer 4 and snap ring 2 Insert the servo piston assembly i...

Страница 1349: ...ert the ouput shaft into the hole and support the transmission in an upright position on the output shaft support flange S00 Series Apply a thin coat of petroleum jelly to the selective thrust washer...

Страница 1350: ...clutch inner splines Install the clutch assemblies Grasp the input shaft and lower the clutch assemblies into the case to install them Install clutch assemblies using a twisting motion to engage the...

Страница 1351: ...the c a s e If necessary tap the pump assembly lightly with a rawhide mallet to install Install the four pump attaching bolts finger tight Remove the pilot studs and install the remaining pump attach...

Страница 1352: ...attaching bolts to 20 N m 175 in lbs torque Recheck shafts for free rotation If a bind exists loosen the bolts and tighten the bolts alternately and evenly to 20 N m 175 in lbs torque Governor and Par...

Страница 1353: ...O T E Before installing the valve body be sure the neutral start switch h a s not yet been installed Place the valve body manual lever in the Drive position P l a c e the v a l v e body a s s e m b l...

Страница 1354: ...o the specified torque Install the oil pan and gasket Front Band Adjustment Loosen the locknut and back the nut off five turns Be sure the band adjusting screw turns freely in the case Lubricate the s...

Страница 1355: ...cations in this manual are based on the latest data available at the time of publication American Motors Corporation and Jeep Corporation reserve the right to discontinue designs or change specificati...

Страница 1356: ...I...

Страница 1357: ...al 11 Front Case Disassembly 13 Input Shaft Mainshaft Disassembly 16 Shift Fork Rail and Detent Ball Removal 18 Cleaning and Inspection 20 Transmission Assembly 20 Shift Fork Rail and Detent Ball Inst...

Страница 1358: ......

Страница 1359: ...is contained in three case sections The input shaft 1 cluster gear 14 and the first through fourth gear assemblies are located in the front case 15 The fifth reverse gear assemblies are located in the...

Страница 1360: ...IZER 7 FIRST GEAR 8 REVERSE GEAR 9 MAINSHAFT 10 FIFTH GEAR 11 FIFTH INTERMEDIATE GEAR 12 FIFTH GEAR SYNCHRONIZER 13 INTERMEDIATE SHAFT 14 CLUSTER GEAR 15 FRONT CASE 16 INTERMEDIATE CASE 17 REAR CASE A...

Страница 1361: ...case 15 The plate provides the Jeep identification part number a the manufacturer s reference number b and the transmission serial number c If the plate is removed during service operations it is imp...

Страница 1362: ...Capacity dry fill Lubricant Type Recheck Fill Level Bearing Preload Cluster Gear Input Shaft Intermediate Shaft End Play First Second Third Fourth Fifth Reverse 4 03 1 2 39 1 1 52 1 1 00 1 0 72 1 3 76...

Страница 1363: ...nt Case Bolts 18 N m 13 ft lbs Rear Case To Intermediate Case Bolts Nuts 18 N m 13 ft lbs Rear Bearing Retainer Plate Allen Screws 10 N m 8 ft lbs Rear Bearing Retainer Plate Countersunk Screw 8 N m 6...

Страница 1364: ...Bearing Race B V L FM 11 Bearing and Race Remover Installer B V I FM 12 Bearing Installer Cluster Gear B V I FM 13 Bearing and Race Installer B V L FM 14 Bearing and Race Installer B V I FM 15 Bearing...

Страница 1365: ...B V I FM 04 B V I FM 05 B V I FM 06 B V I FM 02 B V I FM 07 B V I FM 10 B V I FM 1 1 B V I FM 08 B V I FM 09 B V I FM 12 S E E I S N O T E S B V I FM 13 B V I FM 14 BV I FM 15 BVI FM 16 B V I FM 17 B...

Страница 1366: ......

Страница 1367: ...REVERSE SHIFT FORK 20 MAINSHAFT 63 FIFTH REVERSE SHIFT RAIL 21 THIRD GEAR BEARING 64 FIRST SECOND SHIFT RAIL 22 THIRD GEAR 65 ROLL PIN 23 THIRD FOURTH SYNCHRONIZER 66 FIRST SECOND SHIFT FORK 24 SYNCHR...

Страница 1368: ...shift lever may be held in place with a snap ring instead of a retainer plate Mount the transmission on repair stand B V I FM 02 with the rear case 52 upward F M 02 101063 Remove the rear c a s e atta...

Страница 1369: ...Remowal Remove the fifth gear lock ring 1 from the mainshaft 101067 Remove the fifth gear 3 and roller bearing 2 from the mainshaft with tools B V I FM 04 B V I FM 05 and a universal type puller B B V...

Страница 1370: ...0 Remove the fifth intermediate gear bearing 47 from the intermediate shaft Remove the fifth gear snap ring 4 from the mainshaft Mark position of the fifth reverse synchronizer 45 and hub 44 for assem...

Страница 1371: ...e 83 Front Case Disassembly Remove the transmission from the repair stand T u r n the s t a n d o v e r a n d r e m o u n t the transmission in a horizontal position on the repair stand legs as shown...

Страница 1372: ...Remove the front mounting studs 36 from the front case with a stud remover or two nuts E as shown 101076 101077 Remove the oil seal 35 from the front bearing retainer 34 Discard the seal Remove the bo...

Страница 1373: ...ve the cluster gear front bearing 38 and rear bearing 41 with an arbor press and remover tools B V I FM 07 and B V I FM 08 Tag the bearings for assembly reference 101079 Remove the front bearing prelo...

Страница 1374: ...ont bearing 31 Remove the front bearing from the input shaft 30 with an arbor press and tools B V I FM 07 and B V I FM 09 B V L FM 07 101087 Remove the pilot bearing race 29 from the input shaft 30 wi...

Страница 1375: ...assembly reference J 22912 01 101090 Remove the snap ring 26 and spring washer 25 from the mainshaft 101091 Remove the third fourth synchronizer hub 24 third gear 22 and third gear needle bearing 21 f...

Страница 1376: ...Then remove shim 11 spacer 12 first gear 15 first gear needle bearing 13 bearing spacer 14 first second synchronizer 16 synchronizer hub 17 second gear 19 and second gear bearing 18 N O T E Mark or no...

Страница 1377: ...nd detent plug 71 and spring 72 101083 Remove the fifth reverse detent plug 79 spring 80 and ball 81 101103 Remove the first second shift rail and fork 64 66 and the third fourth shift rail and fork 6...

Страница 1378: ...each of the transmission c a s e s for cracks stripped threads distortion or damaged bearing or sealing surfaces Also inspect the shift rail bores in each case for wear or scoring Repair or replace an...

Страница 1379: ...lf of the front case 78 in repair stand B V I FM 02 as shown Install the idler shaft 59 Secure the shaft with a roll pin 58 Assemble and install the reverse idler gear 60 and fifth reverse shift rail...

Страница 1380: ...h sealer before installation and tighten it to 13 N m 10 ft lbs torque Insert the lock finger 75 into the detent bore at the top of the c a s e Push the lock finger downward until it seats in the fift...

Страница 1381: ...r 75 is seated in the third fourth shift rail detent and against the lock pin 69 Refer to the Shift Component Location Chart Install the interlock ball 74 in the detent bore at the top of the case Pus...

Страница 1382: ...e plug threads with sealer before installation and tighten it to 13 N m 10 ft lbs torque 101109 Install the shift fork roll pins 65 67 101110 Install the first second lock ball and spring 57 101154 In...

Страница 1383: ...d first second synchronizer 16 on the mainshaft Install the synchronizer with pins a toward the rear of the mainshaft Install the original or a replacement rear bearing preload shim 11 on the mainshaf...

Страница 1384: ...ut do not install the synchronizer at this time Position a replacement spring washer 25 and lock ring 26 on the mainshaft 101099 Seat the lock ring 26 as follows Mount the mainshaft in an arbor press...

Страница 1385: ...total thickness of 2 80 mm 0 110 in if any of the above components have been replaced Install the pilot bearing 28 on the mainshaft with an arbor press and tool B V I FM 14 B V L FM 14 28 101101 Inst...

Страница 1386: ...ly Install the front bearing 38 but not the preload shim on the cluster gear Use an arbor press and tool B V I FM 15 to press the bearing all the way onto the shaft N O T E Do not install the preload...

Страница 1387: ...case in a vertical position in the repair stand The cluster gear front bearing should be facing upward Place tool B V I FM 15 over the cluster gear front bearing and push the cluster gear rearward Mai...

Страница 1388: ...or support base B V I FM 16 as follows Position the indicator stylus on the c a s e surface N next to the bearing race Zero the dial indicator MOT LM 101117A Move the indicator stylus to the surface o...

Страница 1389: ...in the rear bearing retainer 8 is countersunk Be sure the countersunk side of the retainer is facing out and toward the rear of the case 20 5 O T E S Tighten the reverse gear nut 5 to 65 N m 48 ft lbs...

Страница 1390: ...cing upward input Shaft Bearing Preload Adjustment Seat the bearing race 32 on the front bearing 31 with tool B V I FM 17 and a rawhide mallet 101119 Check runout of the bearing race 32 with dial indi...

Страница 1391: ...nstall the alignment dowels 77 in the front case B V I FM 18 101122 Coat the mounting surface of the front bearing retainer 34 with Jeep silicone sealer Align and install the front bearing retainer 34...

Страница 1392: ...tion Install the alignment dowels 56 in the intermediate case Remount the transmission in the repair stand so the shift rail ends are facing upward Carefully move the fifth reverse shift rail into fif...

Страница 1393: ...reference marks made during disassembly B V L FM 06 101125 Secure the shift fork 62 to the shift rail 63 with a roll pin 61 Use tool B V I FM 06 to hold the fork in position while installing the roll...

Страница 1394: ...th gear bearing race or the intermediate shaft roller bearing in the rear case at this time Wipe the rear c a s e and intermediate c a s e mounting surfaces clean Mount the rear case 52 on the interme...

Страница 1395: ...ion for the next measurement Remove the rear case Install the intermediate shaft roller bearing 55 in the rear case 52 with tool B V I FM 11 and an arbor press B V L FM 11 101131 Install the fifth gea...

Страница 1396: ...le until it contacts gauge block B V I FM 20 MOT LM B V I FM 16 MOT LM 99 B V L FM 20 101135 Note the dial indicator reading and remove the indicator and gauge block Select the required end play shim...

Страница 1397: ...els into place Coat the edges of the intermediate shaft access plug 86 with Jeep silicone sealer and install the plug in the rear case Coat the fill plug drain plug and backup light switch threads wit...

Страница 1398: ...oad Input shaft bearing preload and the method of selecting the desired preload shim have been revised Make a note of the revisions on page 33 of the manual The new input shaft preload is 0 05 mm 0 00...

Страница 1399: ...2 693 is now available for this purpose CAUTION Because of the design of BA 10 5 transmissions for 2WD applications do not use any other type of puller tool to remove the 5th speed gear and bearing as...

Страница 1400: ...is properly positioned over the end of the shaft 4 Turn bolt C clockwise while holding the tool body stationary to extract the 5th speed gear and bearing assembly from the output shaft B VL F m 05 267...

Страница 1401: ...ft 5 Turn screw F clockwise until it seats against the end of the output shaft 6 Turn nut G clockwise to force the 5th speed gear and bearing assembly into the correct position 7 Remove tool B Vi FM 1...

Страница 1402: ...N O T E S...

Страница 1403: ...da Edition 8980 010 422 All information and specifications in this manual are based on the latest data available at the time of publication American Motors Corporation and Jeep Corporation reserve the...

Страница 1404: ......

Страница 1405: ...28 Timing Case Cover Removal 28 Camshaft Removal 28 Lubrication System 30 Oil Pan Oil Pump Removal 29 Connecting Rod and Piston Removal 34 Crankshaft Removal 34 Piston Pin Removal 36 CYLINDER BLOCK AS...

Страница 1406: ...SEE I S N 0 T E S...

Страница 1407: ...1...

Страница 1408: ......

Страница 1409: ...ot 5 Rocker Arm 6 Push Rod 7 Cylinder Head Bolt 8 Cylinder Head Core Plug 9 Cylinder Head 10 Snap Ring 11 intake Manifold Gasket 12 Intake Manifold 13 Intake Manifold Bolts 14 Exhaust Manifold 15 Exha...

Страница 1410: ...GENERAL DESCRIPTION IP ENGINE IDENTIFICATION INFORMATION IP CYLINDER HEAD ASSEMBLY COMPONENTS 4 2L 86157B 4...

Страница 1411: ...7 Rocker Arm 8 Push Rod 9 Cylinder Head Bolt 10 Cylinder Head Core Plug 11 Cylinder Head 12 Snap Ring 13 Tappet 14 Intake Manifold Gasket 15 Hose Fitting 16 Plug 17 Exhaust Manifold 18 Heat Stove 19 I...

Страница 1412: ...GENERAL DESCRIPTION ENGINE IDENTIFICATION INFORMATION C Y L I N D E R B L O C K C O M P O N E N T S 4 0 L 4 2 L 6 86158A...

Страница 1413: ...Sprocket 14 Keys 15 Washer 16 Timing Chain 17 Oil Shedder Slinger 18 Crankshaft Sprocket 19 Crankshaft 20 Connecting Rod Bearing 21 Connecting Rod Bearing Cap 22 Main Bearings 23 Vibration Damper Pull...

Страница 1414: ...te Code is located on a machined surface on the right side of the cylinder block between the No 2 and No 3 cylinders The numbers of the code identify the year month and day that the engine was built L...

Страница 1415: ...boss B between the ignition coil C and distributor D 86161A Oversize or Undersize Code Component Letter Explanation The letters are decoded as follows Code Letter Definition B All cylinder bores 0 01...

Страница 1416: ...nd Rod Extension J 6042 1 4 5 Valve Guide Reamer Set J 8056 Valve Spring Tester J 8062 Valve Spring Compressor Tool J 8520 Dial Indicator Set J 21872 1 2 3 Piston Pin Remover and Installer J 21882 Oil...

Страница 1417: ...GENERAL DESCRIPTION API SPECIAL TOOLS J 2 4 4 2 0 B J 2 1 8 8 4 J 22248 J 2 1 8 8 2 J 5 9 5 9 4 J 8 0 5 6 J 2 1 8 7 2 1 2 3 J 8 5 2 0 J 5 7 9 0 i J 5 2 6 8 J 8 0 6 2 J 5 6 0 1 J 6 0 4 2 1 4 5 86223A...

Страница 1418: ...17 25 in lbs Camshaft Sprocket Screw 68 N m 50 ft lbs 61 75 N m 45 55 ft lbs Carburetor Hold Down Nuts 19 N m 14 ft lbs 16 27 N m 12 20 ft lbs Coil Bracket to Cylinder Head Bolt 19 N m 14 ft lbs 14 2...

Страница 1419: ...33 ft lbs 36 52 N m 27 38 ft lbs Front Support Cushion to Crossmember 50 N m 37 ft lbs 41 61 N m 30 45 ft lbs Fuel Pump Screws 22 N m 16 ft lbs 18 26 N m 13 19 ft lbs Idler Arm Bracket to Sill 68 N m...

Страница 1420: ...Screw 38 N m 28 ft lbs 34 47 N m 25 35 ft lbs Power Steering Pump Pressure Hose Nut 52 N m 38 ft lbs 41 61 N m 30 45 ft lbs Power Steering Pump Pulley Nut 79 N m 58 ft lbs 54 88 N m 40 65 ft lbs Rear...

Страница 1421: ...Case Cover to Block Screws Timing Case Cover to Block Studs Thermostat Housing Bolt Vibration Damper Bolt Lubricated Water Pump Bolt 7 N m 5 ft lbs 22 N m 16 ft lbs 18 N m 13 ft lbs 108 N m 80 ft lbs...

Страница 1422: ...155 62 Piston Pin Bore Diameter 0 9288 0 9298 23 59 23 62 Connecting Rod Bore less bearings 2 2085 2 2080 56 09 56 08 Bearing Clearance 0 001 0 003 0 03 0 08 0 0015 0 002 0 044 05 preferred preferred...

Страница 1423: ...n Pin Bore Diameter Piston Pin Diameter Piston to Pin Clearance Piston to Pin Connecting Rod 1 651 1 655 41 94 42 04 0 0009 0 0017 p 023 0 043 0 0012 0 0013 0 030 0 033 preferred preferred 0 010 0 020...

Страница 1424: ...877 149 17 149 28 0 9288 0 9298 23S9 23 62 Connecting Rod Bore 25085 2 2080 56 09 56 08 0 001 0 003 0 03 0 08 0 0015 0 002 0 044 05 preferred preferred 0 010 0 019 055 0 48 0 025 per 25 4 mm 0 0005 0...

Страница 1425: ...653 122 034 Valve Stem Diameter 0 3715 0 3725 9 436 9 462 Stem to Guide Clearance 0 001 0 003 0 03 0 08 Intake Valve Head Diameter 1 782 1 792 4556 45 52 29 Exhaust Valve Head Diameter 1 401 1 411 35...

Страница 1426: ...E M O V A L EXHAUST M A N I F O L D R E M O V A L Remove the intake manifold retaining bolts A Remove the exhaust manifold retaining bolts A Remove the intake manifold B Remove the exhaust manifold B...

Страница 1427: ...e R T V sealant with a putty knife or razor blade 4 0L 102303A N O T E Do not pry the cover upward until the seal has been completely broken N O T E Some 1986 4 2L engines and all 4 0L engines use a n...

Страница 1428: ...aging the bridge Remove the bridges pivots and corresponding p a i r s of r o c k e r a r m s D P l a c e t h e s e components on the bench in the order in which they were removed Remove the push rods...

Страница 1429: ...urfaces of the cylinder head and block Remove all gasket material and cement A Remove carbon deposits from the combustion chambers and from the top of the pistons Use a straightedge and a feeler gauge...

Страница 1430: ...ce valves displaying any damage VALVE REFACING Use a valve refacing machine to reface the intake and exhaust valves to the specified angle After refacing a margin of at least 0 787 mm A 0 031 in must...

Страница 1431: ...d 0 762 mm 0 030 in stem sizes Valve Guide Reamer Size 4 0L Reamer Tool Number Size J 26590 L 0 076 mm 0 003 in Oversize Valve Guide Reamer Size 4 2L Reamer Tool Number Size J 6042 1 J 6042 5 J 6042 4...

Страница 1432: ...2 mm 0 003 in ream the guide bore to accom modate the oversize valve stem Alternate Method U s e D i a l Indicator T o o l J 8 5 2 0 A or equivalent and a C Clamp and Rod Extension Tool J 5959 4 or eq...

Страница 1433: ...return spring G CLEANING AND INSPECTION Clean the components of each tappet assembly in cleaning solvent to remove all varnish gum and sludge deposits Inspect for indications of scuffing on the side a...

Страница 1434: ...he vibration damper Use Vibration Damper Tool J 24420 B A or equivalent 86174A TIMING CASE COVER REMOVAL Remove the timing case cover seal using a screwdriver or suitable tool A Remove the timing case...

Страница 1435: ...amshaft Oil is siphoned into the pump through an inlet tube and strainer assembly that is pressed into the pump body T h e pump incorporates a non adjustable pressure relief valve to limit maximum pre...

Страница 1436: ......

Страница 1437: ...l Pump Idler G e a r 9 Oil Pump Cover 10 Oil Pan Timing C a s e Cover Seal 11 Oil Pan 12 Oil Pan Drain Plug 13 Oil Pan Drain Plug Gasket 14 Oil Pan Gasket Set 15 Oil Pan to Bearing C a p Seal 16 Oil P...

Страница 1438: ...pressed Plastigage with the scale on the Plastigage envelope T h e correct c l e a r a n c e by this method is 0 051 0 152 mm 0 002 0 006 in T h e preferred measurement is 0 051 mm 0 002 in Alternate...

Страница 1439: ...he preferred clearance is 0 051 mm 0 002 in If the gear to body clearance is more than specified replace the idler gear the idler shaft and the drive gear assembly Remove the cotter pin and slide the...

Страница 1440: ...8 5 R e m o v e the c o n n e c t i n g rod a n d piston assemblies through the top of the cylinder bores NOTE Be sure that the connecting rod bolts do not scratch the crankshaft journals or cylinder...

Страница 1441: ...ceed 0 025 mm 0 001 in the cylinder bore can be trued by honing If the cylinder bore taper or out of round condi tion exceeds these maximum limits the cylinder must be bored and then honed to accept a...

Страница 1442: ...e d from a connecting rod With the pin removed from the piston and connecting rod clean and dry the piston pin bores and the replacement piston pin Position the piston s o that the pin bore is in the...

Страница 1443: ...mm OS o x 4 7752 mm to 4 8133 mm f 0 188 in to 0 1895 in MEASURE PISTON AT THIS AREA FOR FITTING 41909A 4 2L 3 333 in to DIAMETER t 3 328 in 1ST AND 84 6502 mm to 2ND 84 5312 mm 3 339 in to 3 329 in 8...

Страница 1444: ...ce with a feeler gauge A fitted snugly between the ring land and ring Rotate the ring in the groove It must move freely around the circumference of the groove 86190A PISTON RING SIDE CLEARANCE MEASURE...

Страница 1445: ...e ring installer to expand the ring around the piston N O T E B e sure that the upper and lower c o m p r e s s i o n rings a r e installed with the markings that indicate the top side of the ring fac...

Страница 1446: ...torque N O T E The bearing caps are numbered front to rear CRANKSHAFT END PLAY MEASUREMENT The crankshaft end play is controlled at the No 3 main bearing which is flanged for this purpose Attach a dia...

Страница 1447: ...tion The main bearing journal size diameter is identified in production by a color coded paint mark on the adjacent cheek toward the flanged rear end of the crankshaft except for the rear main journal...

Страница 1448: ...cation A 0 051 mm 0 002 in undersize bearing insert and a 0 025 mm 0 001 in undersize insert would r e d u c e the original c l e a r a n c e an additional 0 013 mm 0 005 in and the clearance would th...

Страница 1449: ...With Green and Red Coded Crankshaft Journals Use Yellow Coded Cylinder Block Bores Only Crankshaft Main Bearing Journals 2 6 Color Code and Diameter Journal Size Bearing Insert Color Code Crankshaft M...

Страница 1450: ...er block N O T E T h e lip of the seal faces toward the front of the engine Install the rear main bearing cap Tighten all main bearing bolts to 108 N m 80 ft lbs torque Coat both sides of the lower se...

Страница 1451: ...le faces the camshaft when the connecting rod is installed correctly Misaligned or bent connecting rods can cause abnormal wear on pistons piston rings cylinder walls connecting rod bearings and crank...

Страница 1452: ...odes used to indicate journal sizes are listed in the bearing fitting chart When required upper and lower bearing inserts of different sizes may be used a s a pair A standard s i z e insert is sometim...

Страница 1453: ...ll shift resulting in an inaccurate indication NOTE The Plastigage must not crumble in use If brittle obtain fresh stock Remove the bearing cap and determine the amount of bearing to journal clearance...

Страница 1454: ...a n c e a n additional 0 013 mm 0 0005 in The clearance would then be 0 038 mm 0 0015 in SIDE CLEARANCE MEASUREMENT Example B E A R I N G I N S E R T P A I R S Insert Correct Incorrect Upper Standard...

Страница 1455: ...Size Yellow 53 2257 53 2079 mm Yellow Standard Yellow Standard 2 0955 2 0948 in Standard Orange 53 2079 53 1901 mm Yellow Standard Black 0 025 mm 0 001 in 2 0948 2 0941 in Undersize 0 0007 Undersize B...

Страница 1456: ...sealant or equivalent around the end of the tube U s e the Oil Pump Inlet Tube Installer Tool J 21882 A to drive the tube into the body Ensure that the support bracket is properly aligned Install the...

Страница 1457: ...helical cut of the gear holds the camshaft sprocket thrust face against the cylinder block face Camshaft end play is zero during engine operation CAMSHAFT INSTALLATION Lubricate the camshaft with AMC...

Страница 1458: ...cover bolts to 7 N m 5 ft lbs torque a n d the oil pan to cover bolts to 13 N m 11 ft lbs torque Apply Perfect Seal or equivalent to the outside diameter of the timing cover seal Install the seal int...

Страница 1459: ...the rear main bearing cap Install the oil pan side gaskets B in position on the engine block Apply a generous amount of AMC Gasket in a Tube or equivalent to the side gasket contacting surface of the...

Страница 1460: ...damper pulley and retaining bolts Tighten the bolts to 27 N m 20 ft lbs torque VALVE INSTALLATION Thoroughly clean the valve stems and the valve guide bores Lubricate the stem lightly Install the val...

Страница 1461: ...ring valve D Plunger cap C Compress the plunger assembly by exerting force on the plunger cap with the push rod Install the snap ring A 86172A HYDRAULIC VALVE TAPPET LEAK DOWN TEST After cleaning insp...

Страница 1462: ...g the weighted arm away and allow the plunger to rise to the normal position Adjust the nose of the ram to align the pointer F with the S E T mark on the scale of the tester and tighten the hex nut Sl...

Страница 1463: ...the cylinder head Tighten the cylinder head bolts to 115 N m 85 ft lbs torque following the proper tightening sequence N O T E Coat the threads of the stud bolt in the number 11 sequence position with...

Страница 1464: ...t plunger cap seat Install the rocker arms B pivots C and bridge D above each cylinder from where they were originally removed Loosely install the capscrews E through each bridge At e a c h bridge t i...

Страница 1465: ...f R T V sealant along the entire length of the cylinder head sealing surface Before the sealant begins to cure install the cover on the cylinder head Do not allow the sealant to come into contact with...

Страница 1466: ...all the intake manifold B Tighten the intake and exhaust manifold bolts in proper sequence to 31 N m 23 ft lbs torque Connect E G R tube 4 0L 101935A 4 2L 101935B EXHAUST MANIFOLD INSTALLATION install...

Страница 1467: ...Edition 8980 010 380 All information and specifications in this manual are based on the latest data available at the time of publication American Motors Corpora tion reserves the right to discontinue...

Страница 1468: ......

Страница 1469: ...re Harness Connectors 43 Diagnostic Connectors 44 ECU Connectors 45 Code Interpretation and Diagnosis 48 Manifold Air Fuel Temperature MAT Sensor Test 55 Coolant Temperature Sensor Test 55 Wide Open T...

Страница 1470: ...mponent Diagnosis 100 Manifold Air Fuel Temperature MAT Sensor Test 107 Coolant Temperature Sensor CTS Test 108 Wide Open Throttle WOT Switch Test 109 Closed Throttle Idle Switch Test 109 ISA Motor Di...

Страница 1471: ...anifold Air Fuel Temperature MAT Sensor Test 146 Coolant Temperature Sensor CTS Test 147 Closed Throttle Idle Switch Test 148 ISA M o t o r Diagnostic Test 148 Manifold Absolute Pressure MAP Sensor Te...

Страница 1472: ......

Страница 1473: ...CIAL TOOLS Tool Ref Description Ele A B 99 kjle Speed Actuator Exercisor Tool J 23738 A Hand Vacuum Pump J 25359 C Torx Bit and Socket Set J 26701 A Choke Angle Gauge J 34730 1 Port Fuel Injection Tes...

Страница 1474: ...ceives inputs from several sensors and other engine associated equipment The inputs represent the engine s instanta neous operating conditions Based on the inputs the E C U generates outputs that chan...

Страница 1475: ...ast resistor 1983 1986 Renault Electric Fuel Pump The purpose of the fuel pump is to deliver and maintain the fuel at s t a n d a r d operating pressure The pump is located inside the fuel tank and is...

Страница 1476: ...ntial pressure between the injector nozzle and the spring chamber is the same the volume of fuel injected is dependent only on the length of time the injector is energized The fuel pump delivers fuel...

Страница 1477: ...throttle tore from above the throttle plate 87039 B Solenoid C Bali Valve D Valve Seat E Spray Nozzle 87040A BALLAST RESISTOR 1983 1986 Renault The ballast resistor is attached to the right side of t...

Страница 1478: ...ent panel On Wrangler YJ models the E C U is located behind the glove box The E C U controls the injector injection time and changes the air fuel mixture ratio according to inputs received from sensor...

Страница 1479: ...n Jeep models the sensor is mounted on the dash panel above the engine The MAP sensor reacts to absolute pressure in the intake manifold and provides an input voltage to the E C U Manifold pressure is...

Страница 1480: ...nce when the coolant is cold inhibit the E G R system when the coolant is cold 87044 Manifold Air Fuel Temperature MAT Sensor 1985 1 7L The manifold air fuel temperature MAT sensor is located in the i...

Страница 1481: ...nd Alliance Encore 1 7L TBI systems The new sensors have an integral wire harness a smaller diameter boss and different calibration for use with the 1986 1987 system Knock Sensor 1985 1987 1 7L 1987 2...

Страница 1482: ...er Cherokee C o m a n c h e 2 4 6 L engines T h e s e n s o r is equipped with a heating element that keeps the sensor at proper operating temperature during all operating modes Maintaining correct se...

Страница 1483: ...le information to the E C U The flywheel drive plate has a large trigger tooth and notch located 90 degrees before each top dead center TDC position There are 12 small teeth between the notch and T D...

Страница 1484: ...ill be at the TDC position 12 teeth later The ignition timing for the cylinder is either advanced or retarded as necessary by the E C U according to the sensor inputs Starter Motor Relay The starter m...

Страница 1485: ...and not in Park or Neutral Refer to the T A M for t e s t i n g a n d r e p l a c e m e n t information Power Steering Pressure Switch 2 46L Engine A pressure sensing switch is included in the power s...

Страница 1486: ...nsor provides the ECU with an input signal of up to 5 volts to indicate throttle position 83036 ECU Outputs The following components are controlled by the ECU system power relay fuel pump control rela...

Страница 1487: ...A N G L E R Y J This relay is initially energized during engine start up and remains energized until 3 to 5 seconds after the engine is stopped This enables the E C U to extend the idle speed actuato...

Страница 1488: ...G THROTTLE BODY FUEL INJECTION SYSTEM HiG m G GENERAL INFORMATION HiG Renault Wagoneer Cherokee Comanche 1985 1987 R E N A U L T Renault 87054A Jeep Wrangler YJ 100454 101289 1983 1985 1 4L 83045B 16...

Страница 1489: ...t is energized when a ground is provided by the E C U When energized voltage is applied to the fuel pump A C Compressor Clutch Relay The E C U controls the A C compressor clutch via the A C compressor...

Страница 1490: ...e stop angle by being a moveable idle stop The E C U controls the ISA motor by providing the appropriate voltage outputs to produce the idle speed or throttle stop angle required for the particular en...

Страница 1491: ...d Swap Relay 2 46L Engine A load s w a p relay is u s e d in 1986 J e e p Wagoneer Cherokee Comanche 2 46L models with air conditioning and power steering The relay works in conjunction with the power...

Страница 1492: ...vely controlled by the E C U The injection time duration is based on the engine operating conditions which are provided to the E C U by the input sensors EGR Valve Canister Purge Solenoid The vacuum f...

Страница 1493: ...started up The indicator lamp will be illuminated during engine operation according to engine speed and load A switch located on the transmission prevents the lamp from being illuminated when the tra...

Страница 1494: ...by the E C U Voltage is applied to the injector and the E C U controls the length of injection time The E C U determines the proper ignition timing according to the input from the speed sensor N O T...

Страница 1495: ...p e d with a m a n u a l transmission the up shift indicator lamp is controlled by the E C U according to engine speed and load Deceleration Mode During deceleration the following inputs are received...

Страница 1496: ...all fuel injection stops The E C U causes the ISA to fully extend for the next start up The E C U deactivates engine speed throttle position exhaust gas oxygen content engine detonation knock When th...

Страница 1497: ...THROTTLE BODY FUEL INJECTION SYSTEM n G m G 1 4L 1983 1985 n G POSITIVE CRANKCASE VENTILATION PCV SYSTEM A Throttle body B Orifice C PCV outlet to canister D Canister E PCV outlet F Air filter 85415...

Страница 1498: ...83034 The system consists of a pressure vent fuel tank filler cap A a hose B connecting the fuel tank C and the canister D a one way rollover valve E The vapoV that accumulates in the upper part of t...

Страница 1499: ...m G THROTTLE BODY FUEL INJECTION SYSTEM m G m G 1 4L 1983 1985 m G TBI SYSTEM WIRING DIAGRAM 83077 27...

Страница 1500: ...ip screws Remove the injector retainer clip A Using a pair of small pliers gently grasp the center collar of the injector between electrical terminals and carefully remove the injector B with a liftin...

Страница 1501: ...ng twisting motion Align the wire terminals in the proper orientation Install the retainer clip A and screws Install the injector wire connector Install the air cleaner assembly Throttle Position Pote...

Страница 1502: ...he pressure regulator B to the fuel body C Install the throttle body assembly a s described in this section Operate the engine and inspect for leaks Adjust the fuel pressure regulator as outlined in t...

Страница 1503: ...rottle cable to ISA WOT mounting bracket and throttle body ISA motor and W O T switch wires Install the air cleaner Extend the ISA motor plunger as follows N O T E The ISA motor plunger must be fully...

Страница 1504: ...the solenoids and the mounting bracket 1983 1985 1 4L 83041A Installation Install the replacement solenoids and the mounting bracket Connect the wire harness connectors to the solenoids Connect the va...

Страница 1505: ...ness connector A Disconnect the vacuum hose B Remove the retaining nuts C Remove the MAP sensor from the plenum chamber panel 83040A Installation Position the MAP s e n s o r on the plenum chamber pan...

Страница 1506: ...ness connector from the MAT sensor A R e m o v e the MAT s e n s o r from the intake manifold Clean the threads in the manifold 85988 Installation Wrap the replacement MAT sensor threads with Teflon t...

Страница 1507: ...e the sensor Wide Open Throttle WOT Switch Removal Remove the air cleaner and disconnect the ISA motor and W O T switch wires Disconnect and remove the throttle and cruise control if equipped cables f...

Страница 1508: ...s burns from coolant can occur Remove the C T S from the cylinder head and rapidly plug the hole to prevent loss of coolant 83044 Installation Install the replacement C T S in the cylinder head Connec...

Страница 1509: ...ve the throttle body to manifold retaining nuts F from the studs Remove the throttle body assembly from the intake manifold If the throttle body assembly is being replaced transfer the following compo...

Страница 1510: ...dy C Remove the original gasket and discard 83047 Installation Install the replacement fuel body B on the throttle body C using a replacement gasket Install the 3 body to throttle retaining Torx head...

Страница 1511: ...the battery cables Remove the fuel from the tank Disconnect the wire harness connector A A Wire Harness Connector 83048 N O T E 1984 1985 models have connector A located underneath the vehicle Positio...

Страница 1512: ...sion complaints only after normal tests and inspections of other engine components have been performed An integral self diagnostic system within the E C U detects common malfunctions that are most lik...

Страница 1513: ...test equipment MS 1700 Diagnostic Tester before return to the manufacturer In the following procedures no specialized service equipment is necessary It is necessary however that the service technicia...

Страница 1514: ...omponent without turning off the ignition switch With the engine stopped and the ignition on the fuel pump should not be operating The fuel pump is controlled by the E C U Voltages greater than 12V or...

Страница 1515: ...NECTORS A Fuel pump relay B B Relay C Engine compartment harness D Engine ground E 0 2 S e n s o r F Evaporator EGR solenoids G Wide open throttle switch H Idle speed control motor I Injector J Coolan...

Страница 1516: ...l Switch 4 Starter motor relay 4 B power relay 5 Battery 5 AC on 6 Fuel pump 6 WOT switch 7 Sensor ground 8 Air temp sensor 9 EGR solenoid 10 Canister purge solenoid 11 ISC motor forward 12 Coolant te...

Страница 1517: ...C ISA Motor Extend forward 3 Not Used D ISA Motor Retract reverse 4 Trigger Tach Signal E Injector 5 Park Neutral Signal F Power Ground 6 Heater A C G A C Clutch 7 Not Used H Evaporator Solenoid 8 Da...

Страница 1518: ...ition and provides an indication that the E C U is functional After the initial illumination the E C U will cycle through and flash a single digit code if any system malfunctions have been detected by...

Страница 1519: ...problems are detected the E C U can be suspected Again because of the cost involved and the relative reliability of the E C U the E C U should never be replaced without testing with an MS 1700 If the...

Страница 1520: ...ssure MAP sensor failure Simultaneous WOT switch and manifold absolute pressure MAP sensor failure Inoperative oxygen sensor CORRECTION Replace the MAT sensor if not within specifications Refer to the...

Страница 1521: ...el pump relay has short Check J1 K for a short circuit to circuit to ground ground with the key off and fuel SEI circuit to ground pump relay disconnected I S Repair the wire harness short N circuit O...

Страница 1522: ...he resistor Replace the fuel pump Connect positive battery voltage to the pump contact on trv starter motor relay If the pump operates repair or replace the starter motor relay If the pump does not op...

Страница 1523: ...hould flash Close the throttle so the speed drops well below normal idle speed The light should flash Note Improper handling of the ISC motor outputs can result in system damage Never connect to groun...

Страница 1524: ...ermine if it opens and closes Check for 12V to the solenoid valve coil Replace the valve Repair the wiring harness Test the ECU with MS 1700 tester Follow the procedure above EGR for the canister purg...

Страница 1525: ...t Correct as necessary Replace the fuel filter Repair or replace as necessary Position a spark plug with ignition wire on the cylinder block Engage the starter motor and observe the spark Repair or re...

Страница 1526: ...erative Check the fuel pump Ignition system malfunction Check the ignition system Repair as necessary Check the start signal after engaging the starter motor Voltmeter from D1 Pin 4 to D1 Pin 3 should...

Страница 1527: ...l Temperature MAT Sensor Test Disconnect the wire harness connector A from the MAT sensor A 83056 Test the resistance of the sensor with a high input i m p e d a n c e digital ohmmeter T h e resistanc...

Страница 1528: ...of the W O T switch with a high input impedance ohmmeter Open and close the switch manually The resistances should be infinite when the throttle is closed A low resistance should be indicated when at...

Страница 1529: ...is always more than 2 volts test for an open circuit in the wire harness between the E C U and the switch connector and between the switch connector and ground R e p a i r or replace the wire h a r n...

Страница 1530: ...tained THEN ISA motor is OK Per form test sequence No 4 4 Move the exerciser switch in the RETRACT direction for 5 seconds Watch the ISA motor action ISA motor should close throttle and stop automatic...

Страница 1531: ...ISA motor should operate smoothly and ratchet click at end of EXTEND travel It should stop automatically at end of RETRACT travel IF desired results were obtained THEN ISA motor is OK Do not replace I...

Страница 1532: ...has a short circuit to 12 volts correct this condition before replacing the E C U CC r i 1 1 cc 1 A Ground B Output Voltage C 5 Volts 83024A IDLE SPEED ACTUATOR ISA MOTOR ADJUSTMENT Adjustment of the...

Страница 1533: ...the ISA wire harness connector Turn the ignition off for 10 seconds The ISA motor should move to the fully extended position Start the engine The engine speed should be approximately 3500 RPM for a s...

Страница 1534: ...ntacts the throttle cam Stop rotating the switch when the lever starts closing the switch plunger plunger will make a click sound at this point Then tighten the switch screws 90 N m 8 8 in lbs torque...

Страница 1535: ...head adjustment screw B on the bottom of the regulator to obtain 1 bar 14 5 psi of pressure C O N N E C T O R 0 2 C O N N E C T O R 0 1 I I FRONT OF VEHICLE 83051 SEE I S N o T E S 83053A Install a le...

Страница 1536: ...1987 1 7L 2 46L m G VACUUM AND WIRING DIAGRAMS FUEL EVAPORATIVE CONTROL SYSTEM 4L S E E I S N 0 T E S A B C D E F G H Fuel filler cap Fuel tank vent line Fuel tank Canister Rollover valve Canister pu...

Страница 1537: ...m G THROTTLE BODY FUEL INJECTION SYSTEM m G m G 1 4L 1986 1987 1 7L 2 46L m G FUEL EVAPORATIVE CONTROL SYSTEM 1 7L TO F U E L TANK CANISTER P U R G E 870O3A...

Страница 1538: ...R GTHROTTLE BODY FUEL INJECTION SYSTEM m G T R G 1 4L 1986 1987 1 7L 2 46L m G FUEL EVAPORATIVE CONTROL SYSTEM 2 46L TAC SENSOR 031 RESTRICTOR 050 RESTRICTOR PCV CANISTER PURGE PURGE SIGNAL 100481A 6...

Страница 1539: ...THROTTLE BODY FUEL INJECTION SYSTEM 1 G 1 4L 1986 1987 1 7L 2 46L 1 G TBI SYSTEM WIRING DIAGRAM 1986 1987 1 4L ENGINE SEE I S N o T E S 100621 67...

Страница 1540: ...i G THROTTLE BODY FUEL INJECTION SYSTEM i G i G 1 4L 1986 1987 1 7L 2 46L i G TBFI SYSTEM WIRING DIAGRAM 1985 1 7L ENGINE SEE I S N O T E S 87004...

Страница 1541: ...SIGNAL m s g m S3 S IGNITION 22 MODULE 1 S I PARK NEUTRAL SWITCH VV AUTO TRANS A C LOW P R E S S U R E SWITCH 31 O HI 30 O HI H i r m 00 o k CO OD CD r S CO oo o 4 OS p 12m CO HI m 31 O 0 m H o z to...

Страница 1542: ...GTHROTTLE BODY FUEL INJECTION SYSTEM m G G 1 4L 1986 1987 1 7L 2 46L m G TBI SYSTEM WIRING DIAGRAM 1986 1987 2 46L ENGINE 70...

Страница 1543: ...r clip screws Remove the injector retainer clip A Using a pair of small pliers gently grasp the center collar of the injector between the electrical terminals and carefully remove the injector B with...

Страница 1544: ...A and screws Connect the injector wire connector Install the air cleaner assembly Fuel Pressure Regulator Removal R e m o v e the throttle body a s s e m b l y a s described in this section Remove th...

Страница 1545: ...sensor B from the throttle shaft lever 83036 Installation Position the throttle position sensor B over the throttle shaft lever C Install the 2 Torx head screws A to retain the sensor Adjust the T P S...

Страница 1546: ...C from the E bracket D s ATTACHING NUTS B Installation Install the ISA motor C on the mounting bracket D Connect the following c r u i s e control cable if equipped throttle return spring throttle cab...

Страница 1547: ...may be dislodged if the studs disengage and the motor cap comes off Remove the motor to bracket retaining nuts A Use a backup wrench to prevent the studs which hold the ISA motor together from turnin...

Страница 1548: ...lenoid Connect the vacuum hoses A to the solenoid EGR alve Renault N O T E The E G R valve is located on the intake manifold below the throttle body Removal Disconnect the vacuum hose from the E G R v...

Страница 1549: ...ated on the intake manifold below the throttle body Disconnect the vacuum hose from the E G R valve A Remove the 2 E G R valve to intake manifold retaining bolts R e m o v e the E G R valve from the i...

Страница 1550: ...ng nuts C Remove the MAP sensor from the plenum chamber panel 83040A Installation Position the MAP s e n s o r on the plenum chamber panel Install the MAP sensor to plenum chamber panel nuts C Connect...

Страница 1551: ...t support the ECU below the glove box Remove the ECU Disconnect the wire harness connectors from the ECU 83042A Installation Connect the wire harness connectors to the replacement ECU Position the rep...

Страница 1552: ...he E C U is located under the instrument panel to the right of the steering column 101859 Removal Remove the E C U retaining screws Lower the E C U from under the instrument panel Disconnect the E C U...

Страница 1553: ...the wire harness connector to the MAT sensor Manifold Air Fuel Temperature MAT Sensor Jeep Removal Disconnect the wire harness connector from the MAT sensor harness A R e m o v e the MAT s e n s o r f...

Страница 1554: ...revent loss of coolant A RENAULT M O D E L S N O T E 1986 and later models use a C T S with a pigtail harness and a connector Connect the wire harness connector to the C T S Coolant Temperature Sensor...

Страница 1555: ...emove the 0 2 sensor C l e a n the threads in the adapter exhaust manifold RENAULT 82047 J E E P 100616 Installation Antiseize sealer is already applied to the threads of replacement 0 2 sensors Hand...

Страница 1556: ...switch adjusted install the throttle body assembly as described in this section Wide Open Throttle WOT Switch Jeep Removal Remove the air inlet bonnet Disconnect the throttle return spring Disconnect...

Страница 1557: ...elay Removal Remove the power B relay A or the fuel pump relay B or the A C clutch relay C from the right inner fender panel N O T E Some models will have a fog lamp relay F and some 1 71 engines may...

Страница 1558: ...lay Removal Remove the cold start relay D from the right fender panel if equipped E E s N O T E S 0 I J j 1985 1987 R E N A U L T 87053A Installation Connect the replacement relay to the wire harness...

Страница 1559: ...e Remove the throttle body to manifold retaining nuts F from the studs Remove the throttle body assembly from the intake manifold If the throttle body assembly is being replaced transfer the following...

Страница 1560: ...Body Assembly Jeep Removal Remove the upper air inlet bonnet A Remove the lower air inlet bonnet retaining bolts B and lower bonnet C 100450A Remove the throttle cable and return spring Disconnect the...

Страница 1561: ...100451B Disconnect the fuel return pipe H from the throttle body Disconnect the vacuum hoses from the throttle body assembly Identify and tag the hoses for installation reference Disconnect the T P S...

Страница 1562: ...supply pipe G to the throttle body Connect the wire harness connector to the WOT switch E Connect the wire harness connector to the ISA motor F Connect the T P S wire connector I Install the throttle...

Страница 1563: ...ve the hose clamps and hoses 83915 Installation N O T E When installing ensure that the fuel flow is in the correct direction Install the fuel filter retaining strap Connect the hoses and tighten the...

Страница 1564: ...e and support the vehicle Remove protective plate retaining bolts A Remove protective plate B Remove filter retaining strap bolt C Install clamp MOT 453 01 or equivalent to the inlet side of the filte...

Страница 1565: ...and lower the tank gradually with the jack Disconnect the fuel supply return and vent hoses Turn the fuel gauge sending unit retainer ring with a screwdriver and remove Separate the sending unit B an...

Страница 1566: ...urn Hoses D Sending Unit B Sending Unit Wires E O Ring Seal C Sending Unit Retaining F Fuel Pump Lock Ring 84629A Disconnect the fuel line hose G from the fuel pump H Disconnect the wires I from the f...

Страница 1567: ...unit B and pump C Installation Connect the fuel pump C to the sending unit B Install the sending unit pump assembly in the tank and secure with the retaining ring A N O T E Ensure O ring is properly p...

Страница 1568: ...ement O Ring Replacement Separate the quick connect fuel line tubes at the right inner fender behind the engine on Renault or the left inner fender panel on Jeep by squeezing the 2 retaining tabs A th...

Страница 1569: ...embly into the quick connect fitting D until a click sound is heard D G H 100486 grasp the disposable plastic plug H and remove it from the fitting D N O T E By removing O N L Y the plastic plug H the...

Страница 1570: ...atfch Relay B 5 Air Conditoning Clutch Relay 6 WOT Switch 7 Ground 8 Air Fuel Temperature 9 M P A Ignition Output 10 EGR Canister Purge Solenoid 11 ISA Motor Forward 12 Coolant Temperature Sensor 13 C...

Страница 1571: ...23 ISA Motor Retract reverse 7 System Power Relay latch relay 24 ISA Motor Extend forward 8 W O T Switch 25 Closed Throttle idle Switch 9 Not Used 26 Not Used 10 System Ground 27 Ignition Interference...

Страница 1572: ...pump relay and check for a short circuit Replace the relay Test the ECU with MS 1700 tester FUEL PUMP WILL NOT Open circuit Connect a jumper wire across the OPERATE FOR ONE fuel pump relay SECOND WIT...

Страница 1573: ...nd the pump side of the ballast resistor Check to determine if the pump operates one second with the ignition switch on ISA IDLE SPEED ACTUATOR MOTOR DOES NOT EXTEND ON ENGINE SHUTDOWN SYMPTOM SLOW UN...

Страница 1574: ...to a speed well above normal idle speed The lamp should flash Close the throttle so the speed drops well below normal idle speed The lamp should flash NOTE Improper handling of the ISA motor outputs...

Страница 1575: ...id valve coil Replace the valve Repair the wiring harness Test the ECU with MS 1700 tester Check the pump for proper voltage nominally 7 5V Check the fuel filter Replace the filter Replace the fuel pu...

Страница 1576: ...ound With key on engine stopped voltage should be close to battery voltage Check the harness and connectors between the ECU and the ignition power module Service the ignition power module as necessary...

Страница 1577: ...TARTS BUT WILL NOT IDLE Fuel pump inoperative Check the fuel pump Ignition system malfunction Check the ignition system Repair as necessary Check the start signal after engaging the starter motor Volt...

Страница 1578: ...ter Replace as necessary EGR valve malfunction Check the EGR valve and hoses Repair or replace Canister purge malfunction Check the canister purge function Repair as necessary S E E S U M M A R Y i s...

Страница 1579: ...be less than 1000 ohms with the engine warm Refer to the resistance chart Manifold Air Fuel Temperature Sensor Temperature to Resistance Values Approximate F C Ohms 212 100 185 160 70 450 100 38 1 600...

Страница 1580: ...tance should be less than 1000 with the engine warm Refer to the resistance chart Coolant Temperature Sensor Temperature to Resistance Values Approximate F C Ohms 212 100 185 160 70 450 100 38 1 600 7...

Страница 1581: ...than 2 volts if not at the W O T position If no voltage is present in either position test for a short circuit to ground in the wire harness or switch Check for an open circuit between terminal 8 E C...

Страница 1582: ...g N O T E The following test must be performed using Exerciser tool Ele AB 99 N O T E If the ISA motor is to be tested off the vehicle the ISA motor shaft must be lightly preloaded to avoid having the...

Страница 1583: ...position The tip of the ISA should be in contact with but no more than 0 50 mm 0 20 in away from throttle lever A when ISA motor has stopped movement see the illustration The throttle linkage should...

Страница 1584: ...stop automatically at end of RETRACT travel IF the movement is intermittant slow or gritty sounding THEN replace ISA motor 6 Move the ISA motor in the EXTEND and RETRACT direction 2 or 3 times ALWAYS...

Страница 1585: ...onnector terminal A and E C U connector terminal 17 R e p a i r the wire h a r n e s s if necessary Test the MAP sensor ground circuit at the E C U connector between terminal 17 and terminal 2 with an...

Страница 1586: ...f The ISA motor plunger should move to the fully extended position With the ISA motor plunger fully extended d i s c o n n e c t the I S A motor wire h a r n e s s connector and start the engine With...

Страница 1587: ...ablish the initial position of the switch after it has been replaced Block or tie the throttle linkage in the wide open throttle position Attach Angle Measuring Gauge J 26701 to the flat surface of th...

Страница 1588: ...arts Department C O N N E C T O R 0 2 C O N N E C T O R 0 1 FRONT OF VEHICLE 83051 Connect an accurate fuel pressure gauge to the fuel body pressure test fitting A W A R N I N G U s e extreme caution...

Страница 1589: ...lead seal ball to cover the regulator adjustment screw B after adjusting the pressure to specification Turn the ignition off Disconnect the tachometer Disconnect the fuel pressure gauge and install th...

Страница 1590: ...rness Move and hold the throttle plate in the wide open position Be sure the throttle linkage contacts the stop Note the voltmeter reading Input voltage at terminals B and C should be 5 0 volts at wid...

Страница 1591: ...SS POWER SUPPLY CIRCUIT BETWEEN THE ECU AND THE TPS AND RETEST YES NO TPS SWITCH AND ADJUSTMENT OK REPAIR TPS WIRE HARNESS GROUND CIRCUIT BETWEEN THE ECU AND THE TPS AND RETEST ADJUST OUTPUT VOLTAGE T...

Страница 1592: ...SWITCH FOR A SHORT CIRCUIT TO GROUND TEST THE TRANSMISSION SWITCH FOR CONTINUITY WITH THE TRANSMISSION IN THE NEUTRAL POSITION CONNECT THE SWITCH CONNECTOR TURN THE IGNITION SWITCH OFF DISCONNECT THE...

Страница 1593: ...ART THE ENGINE WITH THE CLUTCH DEPRESSED REPAIR THE OPEN CIRCUIT IN THE WIRE HARNESS AND REPEAT THE TEST TEST FOR CONTINUITY IN THE WIRE HARNESS BETWEEN ECU CONNECTOR TERMINAL 18 AND THE TRANSMISSION...

Страница 1594: ...TBI SYSTEM V A C U U M D I A G R A M B Canister C a p and Hose Assembly C Crankcase Vent Tube D P C V Hose E Canister Purge Hose F Transducer Mounting G E G R Valve and Trans Assembly H Air Cleaner A...

Страница 1595: ...IO CO m 1 2 n 3 3 no...

Страница 1596: ...101799 Installation Lubricate with light oil and install a replacement lower O ring D in the housing bore Lubricate with light oil and install a replacement upper O ring C in the housing bore Install...

Страница 1597: ...Position Sensor TPS Removal Remove the e air inlet bonnet throttle body assembly as described in this section 2 Torx head retaining screws A throttle position sensor B from the throttle shaft lever 10...

Страница 1598: ...ve the motor from the bracket ATTACHING NUTS B Installation Install the ISA motor on the mounting bracket Connect the following throttle return spring ISA motor switch wires Install the air inlet bonn...

Страница 1599: ...ocated on the intake manifold below the throttle body Removal Disconnect the vacuum hose from the E G R valve A Remove the 2 E G R valve to intake manifold retaining bolts R e m o v e the E G R v a l...

Страница 1600: ...s o r on the plenum chamber panel Install the MAP sensor to plenum chamber panel nuts C Connect the vacuum hose B Connect the wire harness connector A Electronic Control Unit ECU Removal Remove the r...

Страница 1601: ...anifold Connect the wire harness connector to the MAT sensor Coolant Temperature Sensor CTS N O T E The C T S sensor A is located at the rear of the intake manifold Removal Remove the wire harness con...

Страница 1602: ...m 20 25 ft lbs torque C A U T I O N Ensure that the wire terminal ends are properly seated in the connector prior to joining the connectors Connect the wire harness connector C A U T I O N Do not push...

Страница 1603: ...arness connector from the T P S B wire harness connector from the ISA motor C fuel supply pipe D from the throttle body fuel return pipe E from the throttle body Disconnect the vacuum hoses from the t...

Страница 1604: ...ctor to the T P S B wire harness connector to the ISA motor C cruise control cable if equipped throttle return spring throttle cable Install the air inlet bonnet and spacer Fuel Body Assembly Removal...

Страница 1605: ...alling ensure that the fuel flow is in the correct direction Install the fuel filter retaining strap Connect the hoses and tighten the hose clamps Remove the MOT 453 clamps Lower the vehicle Fuel Tank...

Страница 1606: ...Install the tank with the retaining bolts Connect the wire harness connector Connect the battery cables N O T E T h e fuel tank is equipped with a pressure vacuum filler cap Quick Connect Fuel Lines...

Страница 1607: ...ct fitting D D A n 100485B Replace the O ring using the Coupling Repair Kit PN 8983 502 745 as follows remove the 2 O rings E and the spacer F from the fitting D N O T E This can be done by using a pa...

Страница 1608: ...osable plastic plug H and remove it from the fitting D verify that the quick connect fitting assembly fits securely over the fuel lines by giving the fuel lines a firm tug 100487 push the fuel line B...

Страница 1609: ...5 6 CONNECTOR D1 F R O N T O F V E H I C L E D1 D2 1 Tach 1 Data Output 2 Ignition 2 Latch Relay 3 E C U Ground 3 Shift Lamp 4 Start 4 B Latch 5 Battery 5 A C Relay 6 Fuel Pump Relay 6 Not Used 7 Igni...

Страница 1610: ...ISA Motor Forward 5 6 7 Battery 8 Ignition 9 10 Latched B 11 Power Ground 12 Power Ground D 1 Speed Sensor 2 A C Clutch Request 3 Start 4 Neutral Safety Switch 5 6 MAP Sensor Output 7 Throttle Positio...

Страница 1611: ...relay and check for a short circuit Replace the relay Test the ECU with MS 1700 tester FUEL PUMP WILL NOT Open circuit Connect a jumper wire across the OPERATE FOR ONE fuel pump relay SECOND WITH THE...

Страница 1612: ...of the ballast resistor ISA IDLE SPEED ACTUATOR MOTOR DOES NOT EXTEND ON ENGINE SHUTDOWN SYMPTOM SLOW UNSATISFACTORY IDLE AFTER COLD START ECU wire harness or motor Check to determine if the pump ope...

Страница 1613: ...mal idle speed The lamp should flash Close the throttle so the speed drops well below normal idle speed The lamp should flash NOTE Improper handling of the ISA motor outputs can result in system damag...

Страница 1614: ...valve out of harness to 12V and determine if it opens and closes Check for 12V to the solenoid valve coil Replace the valve Repair the wiring harness Test the ECU with MS 1700 tester Check the pump f...

Страница 1615: ...h key on engine stopped voltage should be close to battery voltage Check the harness and connectors between the ECU and the ignition power module Service the ignition power module as necessary No batt...

Страница 1616: ...uel pump inoperative Check the fuel pump Ignition system malfunction Check the ignition system Repair as necessary Check the start signal after engaging the starter motor Voltmeter from D1 Pin 4 to D1...

Страница 1617: ...filter Replace as necessary EGR valve malfunction Check the EGR valve and hoses Repair or replace Canister purge malfunction Check the canister purge function Repair as necessary SUMMARY It should be...

Страница 1618: ...chart Manifold Air Fuel Temperature Sensor Temperature to Resistance Values Approximate F c Ohms 212 100 185 160 70 450 100 38 1 600 70 20 3 400 40 4 7 500 20 7 13 500 0 18 25 000 40 40 100 700 87061...

Страница 1619: ...ce chart Coolant Temperature Sensor Temperature to Resistance Values Approximate F C Ohms 212 100 185 160 7 450 100 38 1 600 70 20 3 400 40 4 7 o00 20 7 13 500 0 18 25 000 40 40 100 700 87062 Replace...

Страница 1620: ...connector and between the switch connector and ground R e p a i r or r e p l a c e the wire h a r n e s s a s necessary ISA Motor Diagnostic Test WARNING After testing the operation of the ISA motor...

Страница 1621: ...closed throttle switch light on the exerciser will go out when ISA motor reaches closed throttle position The tip of the ISA should be in contact with but no more than 0 50 mm 0 20 in away from throt...

Страница 1622: ...moothly and ratchet click at end of EXTEND travel It should stop automatically at end of RETRACT travel IF the movement is intermittant slow or gritty sounding THEN replace ISA motor 6 Move the ISA mo...

Страница 1623: ...lace the wire harness a s necessary Test the E C U with Diagnostic Tester MS 1700 if necessary Test the MAP sensor ground circuit at sensor connector terminal A and E C U connector terminal D 3 R e p...

Страница 1624: ...Test The oxygen sensor heating element can be tested with an ohmmeter as follows Connect the ohmmeter test loads to connector terminals A and B of the sensor connector C Resistance should be between 5...

Страница 1625: ...ition off The ISA motor plunger should move to the fully extended position With the ISA motor plunger fully extended d i s c o n n e c t the I S A motor wire h a r n e s s connector and start the engi...

Страница 1626: ...essure regulator is necessary to establish the correct pressure after a replacement has been installed Remove the air inlet bonnet C o n n e c t a tachometer to the diagnostic connector terminals D1 1...

Страница 1627: ...stall a lead seal ball to cover the regulator adjustment s c r e w B after adjusting the pressure to specification Turn the ignition off Disconnect the fuel pressure gauge and install the cap on the t...

Страница 1628: ...voltage at terminals B and C should be 5 0 volts at wide open throttle Return the throttle plate to closed throttle position Check sensor output voltage Disconnect the voltmeter positive lead from sen...

Страница 1629: ...D PIN B OF THE TPS CONNECTOR REPAIR THE TPS WIRE HARNESS POWER SUPPLY CIRCUIT BETWEEN THE ECU AND THE TPS AND RETEST NO TPS SWITCH AND ADJUSTMENT OK ADJUST OUTPUT VOLTAGE TO 4 6 4 7 VOLTS YES REPAIR T...

Страница 1630: ......

Страница 1631: ...cessary replacing the fuel injector DIAGNOSIS PROCEDURE 1 The vehicle must be currently exhibiting the condition That is vehicle will stall after starting when the engine is cold 2 Disconnect field wi...

Страница 1632: ...at backup ring J fits above upper O ring G 101799A 6 Lubricate the replacement upper G and lower H O rings with Lithium base grease Install the O rings in the housing bore N O T E Make certain that lo...

Страница 1633: ...d reinstall the injector Return to Step 2 and continue the injector replacement procedure 13 Install the air cleaner assembly RARTS INFORMATION DESCRIPTION QUANTITY PART NUMBER INJECTOR Fuel 1 8933 00...

Страница 1634: ......

Страница 1635: ......

Страница 1636: ......

Страница 1637: ...ation and specifications in this manual are based on the latest data available at the time of publication American Motors Corpora tion reserves the right to discontinue designs or change specification...

Страница 1638: ......

Страница 1639: ...ER BLOCK 19 OIL PUMP 22 CRANKSHAFT AND CONNECTING RODS 26 CYLINDER BORE RECONDITIONING 29 PISTON PINS 29 PISTON FITTING METHODS 31 PISTON RINGS 32 CYLINDER BLOCK 36 ENGINE ASSEMBLY 37 MAIN BEARINGS 37...

Страница 1640: ......

Страница 1641: ...4 Cylinders 2 5L 2465 cc 150 cu in 98 mm 3 876 in 80 mm 3 188 in 9 2 1 Premier 111 BHP 4750 rpm 142 ft lbs torque 2500 rpm Jeep 121 BHP 5250 rpm 141 ft lbs torque 3250 rpm Wrangler 117 BHP 5250 rpm 1...

Страница 1642: ...0 03 mm max 0 001 in max Cam Lobe Lift Jeep Intake 265 in Exhaust 265 in Cam Lobe Lift Premier Intake 240 in Exhaust 250 in Valve Lift Jeep Intake 424 in Exhaust 424 in Valve Lift Premier Intake 384...

Страница 1643: ...02 in Connecting Rod Journal Diameter 53 17 53 23 mm 2 0934 2 0955 in Connecting Rod Journal Width 27 18 27 33 mm 1 070 1 076 in Maximum Out of Round All Journals 0 013 mm 0 0005 in Maximum Taper All...

Страница 1644: ...0 9309 in Piston to Pin Clearance 0 008 0 013 mm 0 0003 0 0005 in Preferred Loose 0 013 mm Loose 0 0005 in Piston Pin to Connecting Rod 8 9 kN Press fit 2000 Ibs f Press fit Rocker Arms Push Rods and...

Страница 1645: ...0 50 ft lbs 6 0 Fuel Pump Boss Plate 22 16 ft lbs Intake Manifold Coolant Fittings 27 20 ft lbs Intake Manifold Bolts 31 23 ft lbs Main Bearing Bolts 108 5 80 ft lbs Oil Filter Connector to Block 23...

Страница 1646: ...kPa 75 psi Oil Pump Gear to Body Clearance R a d i a l 0 051 0 102 mm 0 002 0 004 in Preferred 0 051 mm 0 002 in Gear End Clearance Plastigauge 0 051 0 152 mm 0 002 0 006 in Preferred 0 051 mm 0 002 i...

Страница 1647: ...94 P N 8980 002 281 HARMONIC B A L A N C E R P U L L E R R E F J 24420 B P N 8980 002 513 C CLAMP AND R O D E X T E N S I O N R E F J 5959 4 P N 8980 002 551 0 DIAL INDICATOR S E T R E F J 8520 P N 89...

Страница 1648: ...O V E R INSTALLER R E F J 21872 P N 8980 002 254 o OIL PAN ALIGNMENT PLATES R E F MOT ML 04 P N 8981 320 993 TIMING C A S E C O V E R ALIGNMENT TOOL AND S E A L INSTALLER R E F J 22248 P N 8980 002 00...

Страница 1649: ...dy Injection 9 2 1 Compression Ratio 01 1st Day 02 2nd Day 3 1 9 8 3 0 12 Jan Dec H 2 5L 150 cu in Throttle Body Injection 9 2 1 Compression Ratio 01 1st Day 02 2nd Day 4 1 9 8 4 0 12 Jan Dec U 2 5L 1...

Страница 1650: ...s the 150 CID 2 5L liter engine with 1V carburetor and 9 2 1 com pression ratio built on September 27 1982 NOTE Vehicles built for sale in Georgia and Tennessee have an additional nonrepeating number...

Страница 1651: ...in M All crankshaft main bearing journals 254 mm 010 in PM All camshaft main bearing journals and one or more 254 mm connecting rod journals 010 in B All cylinder bores 254 mm All cylinder bores 010...

Страница 1652: ...retaining nuts Detach the cover from cylinder head by break ing the RTV sealant with a putty knife or razor blade NOTE To avoid damaging the cover do not pry cover upward until the seal has been compl...

Страница 1653: ...Use a straight edge and feeler gauge to check to flatness of cylinder head and block mating surfaces Check the flatness across the entire length of the cylinder head Refer to Specifica tions for cyli...

Страница 1654: ...ve The valve stem tip can be resurfaced and rechamfered when worn Do not remove more than 0 010 inch 0 25 mm 1 3 2 I N C H 0 7 8 7 m m V A L V E M A R G I N C O R R E C T V A L V E F A C I N G N O M A...

Страница 1655: ...for both the intake and exhaust valve stems The seals marked INT are for intake valve stems The seals marked EXH are for exhaust valve stems Replace the valve stem seals when service is performed or i...

Страница 1656: ...uide bore to accommo date an oversize valve stem Compare the measured valve guide bore diam eter with diameter listed in the Specifications If the measurement differs from specification by more than 0...

Страница 1657: ...ation Thoroughly clean the valve stems and valve guide bores Lightly lubricate the stem and install the valve in original valve guide bore from where it was removed Install replacement valve stem oil...

Страница 1658: ...oned across base If the base is concave the corresponding lobe on camshaft is also worn Replace the camshaft and defective tappets Tappet Assembly and Leak down Test Install the plunger return spring...

Страница 1659: ...r and tighten hex nut Slowly swing weighted arm onto push rod Rotate the cup by turning handle at base of the tester clockwise one revolution every two seconds Observe the leak down time interval from...

Страница 1660: ...a drift punch into the slot A in the back of the cover and tap the old seal out 2739 Remove the timing chain bumper B Remove the oil slinger from crankshaft Remove the camshaft retaining bolt and rem...

Страница 1661: ...ear for wear NOTE If the camshaft appears to have been rubbing against the timing case cover examine the oil pressure relief holes in the rear cam jour nal to assure they are free of debris Remove the...

Страница 1662: ...OIL PUMP RETAINER FILTER VALVE SPRING BYPASS VALVE OIL PRESSURE RELEASE SPRING OIL INLET TUBE AND SCREEN ASSEMBLY OIL PAN GASKET SET OIL PAN TO BEARING CAP SEAL OIL PAN TIMING CASE COVER SEAL OIL PAN...

Страница 1663: ...2 5L 1 4 ENGINE OVERHAUL JP1 ENGINE DISASSEMBLY 2740 23...

Страница 1664: ...the oil pump assembly and gasket from cylinder block CAUTION If the oil pump is not to be serviced do not disturb position of oil inlet tube and strainer assembly in pump body If tube is moved within...

Страница 1665: ...point of gear mesh Select feeler gauge which fits snugly but freely Rotate gears to measure each tooth to body clearance in this manner Correct clearance is 0 051 to 0 102 mm 0 051 mm preferred 0 002...

Страница 1666: ...nd of tube Use Tool J 21882 to drive the tube into body Assure support bracket is prop erly aligned Install the idler shaft idler gear and drive gear assembly NOTE To assure self priming of the oil pu...

Страница 1667: ...rubber hose slipped over the connecting rod bolts will pro vide protection during removal Inspect the connecting rod bearings for scoring and bent alignment tabs Check the bearings for normal wear pa...

Страница 1668: ...re numbered 1 through 5 front to rear 83116 83117 Remove the crankshaft and upper bearing in serts Inspect the crankshaft for scoring Check the bearings for normal wear patterns scoring grooving fatig...

Страница 1669: ...rued by honing If the cylinder bore taper or out of round condition exceeds these maximum limits the cylinder must be bored and then honed to accept an oversize piston NOTE A slight amount of taper al...

Страница 1670: ...ved from a connecting rod With the pin removed from the piston and con necting rod clean and dry piston pin bores and the replacement piston pin Position the piston so that the pin bore is in vertical...

Страница 1671: ...d in rod 0 7 9 2 mm 0 0 3 1 2 inch PISTON FITTING METHODS Piston Fitting Micrometer Method Measure the inside diameter of the cylinder bore at a point 58 725 mm 2 5 16 inches be low top of bore Measur...

Страница 1672: ...ton is too small for cylinder bore Pistons up to 0 102 mm 0 004 inch undersize may be en larged by knurling or shot peening Replace pistons that are 0 102 mm 0 004 inch or more undersize Measure the r...

Страница 1673: ...rings Install the oil control rings according to instruc tions in the package It is not necessary to use a tool to install the upper and lower rails Insert expander ring first then side rails The two...

Страница 1674: ...he second compression ring black cast iron Using a ring installer install the ring with the has two dots F on the top surface and a cham dots facing up and the chamfer facing down fer G on the bottom...

Страница 1675: ...ring installer install the top ring with the dot and chamfer facing up Ring Gap Position Position the ring end gaps on the piston as shown TOP COMPRESSION RINQ BOTTOM COMPRESSION RINQ TOP OIL CONTROL...

Страница 1676: ...to clean out the galley at the oil filter adaptor hole A the filter by pass hole B 2746 The front C and rear D oil galley holes 2747 2748 the feed holes for the crankshaft main bearings Apply Loctite...

Страница 1677: ...t sizes may be used as a pair A stan dard size insert is sometimes used in combina tion with a 0 025 mm 0 001 inch undersize in sert to reduce the clearance by 0 013 mm 0 0005 inch Example Bearing Ins...

Страница 1678: ...0 002 preferred SCALE COMPRESSED PLASTIGAGE 41907A Plastigage should indicate the same clearance across the entire width of insert If clearance varies it may indicate a tapered journal or for eign mat...

Страница 1679: ...or machining to true bore If diameter for journals 1 through 5 is less than 2 4981 inches replace crankshaft or grind down to accept appropriate under size bearing inserts Measuring Main Bearing Jour...

Страница 1680: ...en 0 002 inch Undersize 0 051 mm Red 2 4901 to 2 4896 0 010 Undersize 63 2485 to 63 2358 mm Yellow 2 6910 to 2 6915 68 3514 to 68 3641 mm Red 0 010 inch Undersize 0 254 mm Red 0 010 inch Undersize 0 2...

Страница 1681: ...to the cyl inder block at either the front or rear of the engine Position the dial indicator rod so that it is paral lel to the center line of the crankshaft Pry the crankshaft forward position the d...

Страница 1682: ...d color coded bearing in serts as listed in the bearing fitting chart The color code appears on the edge of the bearing insert NOTE The size is not stamped on inserts used for production of engines Th...

Страница 1683: ...the center of bearing cap Install bearing cap and connecting rod on the journal and tighten nuts with 45 N m 33 ft lbs torque NOTE Do not rotate crankshaft Plastigage will smear resulting in inaccurat...

Страница 1684: ...t bearing inserts are stamped on the backs of the inserts Repeat the Plastigage measurement to verify your bearing selection prior to final assembly Once you have selected the proper insert install th...

Страница 1685: ...from the front bearing larg est to the rear bearing smallest This permits easier removal and installation of the camshaft The camshaft bearings are pressure lubricated NOTE It is not advisable to att...

Страница 1686: ...ket timing mark at approximately the on o clock position This positions crankshaft sprocket timing mark where the adjacent tooth meshes with the chain at the four o clock posi tion Count number of cha...

Страница 1687: ...tall the tensioner on the cylinder block and tighten the bolts to 19 N m 14 ft lbs torque Turn the tensioner lever to the unlock down position Be sure the tensioner is released before installing the t...

Страница 1688: ...daub of Jeep Eagle Gasket in a Tube where the side rail gaskets meet the seals 2752 Ensure all connecting rod nuts main bearing cap bolts oil pump mounting bolts and timing chain t e n s i o n e r bol...

Страница 1689: ...p Apply a daub of Jeep Eagle Gasket in a Tube where the side rail gasket meet the seals Ensure all connecting rod nuts main bearing cap bolts oil pump mounting bolts and timing chain t e n s i o n e r...

Страница 1690: ...nstall each tappet in the original bore 41890A CYLINDER HEAD AND CYLINDER HEAD GASKETS 1984 87 2 5L engines use different cylinder head gasket than 1988 2 5L engines The two gaskets are N O T intercha...

Страница 1691: ...5 N m 85 ft lbs 1988 Engines 1988 2 5 liter engines use a composition cylin der head gasket that is installed dry WITHOUT any gasket sealing compound Install the head gasket with the word top facing t...

Страница 1692: ...ews alter nately one turn at a time to avoid damaging the bridge Tighten to 19 ft lbs 28 N m torque CYLINDER HEAD COVER INSTALLATION 1984 1988 A room temperature vulcanizing RTV silicone rubber sealan...

Страница 1693: ...e exhaust manifold mounting studs in the cylinder head NOTE Exhaust manifold must be centrally lo cated over the end studs and spacer ALIGNMENT SPACER TORQUE SEQUENCE NUMBERS ALIGNMENT SPACER CYLINDER...

Страница 1694: ...When the distributor is fully engaged in the proper position the rotor should be at the 6 o clock position With the leading edge of the rotor inline with the tower C of distributor cap I A Right Hand...

Страница 1695: ...ical fuel pump and gasket Tighten the bolts to 22 N m 16 ft lbs torque Align key slot on the vibration damper with the crankshaft key and tap damper onto the crankshaft Install the vibration damper re...

Страница 1696: ......

Страница 1697: ......

Страница 1698: ......

Страница 1699: ......

Страница 1700: ...I...

Страница 1701: ...n Key Warning Buzzer 22 Indicator Lamps 38 Instrument Panel Illumination Lamps 40 Park Lamps 46 Power Distribution 2 5L 7 Power Distribution 4 2L 8 Radio 28 Rear Defogger 20 Seat Belt Warning B u z z...

Страница 1702: ...provide additional information about the circuits and trou bleshooting hints The flow of current is often used to describe the circuit operation By following the schematic of the circuit as you read t...

Страница 1703: ...SYMPTOMS 1 Localizing the Trouble After conducting operational checks Step 2 the trouble will always lie between a check which resulted in negative symptoms and a check which resulted in a positive sy...

Страница 1704: ...ure resistance The following procedure is recommended 1 Disconnect the source of voltage from the resistance being tested 2 Bring the test leads together and adjust the zero adjust knob until the need...

Страница 1705: ...IS REPEATED WHERE CURRENT PATH CONTINUES A WAVY LINE MEANS A WIRE IS TO BE CONTINUED ORWILL NO LONGER BE USED CIRCUIT BREAKER RELAY SHOWN WITH NO CURRENT FLOWING THROUGH COIL 14 LT BLU I B I C216 FUSI...

Страница 1706: ...WDW White 25 AMP Rear Window Defogger Grids 5 FAN HTR White 25 AMP Heater Blower Motor 6 GAUGES Light Blue 15 AMP Key Buzzer Defogger Relay Gauge Pack Defogger Switch Tachometer Indicator Lamps 7 W WI...

Страница 1707: ...ENGINE 4 RED I E 1 FUSE PANEL NOT USED CIGAR LIGHTER RADIO CRUISE CONTROL BLOWER MOTOR HEATER INSTRUMENT PANEL ILLUMINATION LAMPS DEFOGGER DEFOGGER GAUGE GRIDS RELAY IGN PACK Power Distribution 2 5L 7...

Страница 1708: ...POWER DISTRIBUTION 4 2L 4 RED 4 BLK BLOWER A C MOTOR COMPRESSOR CLUTCH INSTRUMENT PANEL ILLUMINATION LAMPS DEFOGGER DEFOGGER GRIDS RELAY IGN Power Distribution 4 2L 8 Power Distribution 4 2L...

Страница 1709: ...INSTRUMENT PANEL TO BODY HARNESS TACHOMETER ILLUMINATION GAUGE PACKAGE ILLUMINATION DEFOGGER SWITCH ILLUMINATION FOG LAMP SWITCH ILLUMINATION HEATER CONTROL ILLUMINATION SPEEDOMETER ILLUMINATION WINDS...

Страница 1710: ...OTE 1 ALL CIRCUITS ARE EC ENGINE CONTROL UNLESS OTHERWISE INDICATED 2 D1 DIAGNOSTIC CONNECTOR 1 3 D2 DIAGNOSTIC CONNECTOR 2 NOTE 4 FOR DIAGNOSTIC PROCEDURE REFER TO MS1700 RESISTANCE WIRE TO ALTERNATO...

Страница 1711: ...m 18 LT GRN D2 11 18 LT GRN 18 BRN D2 14 18 BRN IDLE SPEED M O T O R CLOSED THROTTLE SWITCH 4 BATTERY W I D E O P E N SYSTEM THROTTLE G R O U N D SIGNAL 10 8 B LATCHED SERIAL D A T A O U T P U T J AUT...

Страница 1712: ...FROM FUSE LINK B4 2L 1 IGNITION NOTE 1 ALL CIRCUITS ARE EC ENGINE CONTROL UNLESS OTHERWISE INDICATED 2 D1 DIAGNOSTIC CONNECTOR 1 3 D2 DIAGNOSTIC CONNECTOR 2 NOTE 4 FOR DIAGNOSTIC PROCEDURE REFER TO M...

Страница 1713: ...r motor Power within the starter motor is divided into the field winding armature and hold in windings The bendix clutch is momentarily thrown into the ring gearbyamovable pole shoeand one of thefield...

Страница 1714: ...Terminal D to clean chassis ground Zero ohms Next step Check transmission shift linkage adjustment Properly adjusted Replace neutral safety switch 4 RED BATTERY 4 BLK I E 4 BLK STARTER MOTOR 14 GRN W...

Страница 1715: ...rminals Clean and tight Repair as required Battery state of charge Refer to MR279 for specific gravity and load test procedures Battery passes test Charge or replace battery as required Inspect drive...

Страница 1716: ...ure reaches 160 F 70 C At this tem perature the heater switch contacts open the relay coil ground circuit and the relay contacts open TROUBLESHOOTING ON TEST OK NOT OK Terminal 86 12 volts Repair open...

Страница 1717: ...er to the ignition module which controls the ignition coil primary circuit The engine speed input signal is measured by the tach ometer solid state circuits and converted to needle move ment across th...

Страница 1718: ...umination 1 LAMP Headlamp switch ON TEST OK NOT O K Across bulb terminals Zero ohms Replace bulb Battery side of bulb socket 0 12 volts Repair open from fuse panel Ground side of bulb socket Zero ohms...

Страница 1719: ...tation of the steering wheel TROUBLESHOOTING TROUBLESHOOTING 1 ACCESSORY FUSE Ignition ON TEST OK NOT OK Inspect fuse Not blown Replace fuse Battery side of fuse 12 volts Repair open from ignition swi...

Страница 1720: ...L 4 2L 14 BRN W TN 2 5L 12 BLK I E 20 BLK I IP 14 BLK I IP HOT IN RUN AND START FROM IGNITION SWITCH I 1 FUSE 12 BLK I E G301 18 WHT W TR T 0 SEAT BELT B SWITCH SEE GROUND DISTRIBUTION GRIDS C 2 5L K...

Страница 1721: ...the rear window should become warm After 10 minutes the system should automatically shut off After the initial warm up operation of the rear defog ger will be limited to 5 minutes TROUBLESHOOTING TEST...

Страница 1722: ...T R O L INPUT KEY IN IGNITION O U T P U T G R O U N D 6 3 BUZZER MODULE PLUGS I N T O FUSE PANEL 18 WHT W TR I IP 20 BLK IP C158 18 BLK CL 7 LH DOOR JAMB SWITCH 14 BLK I IP 2 5L SEE GROUND DISTRIBUTI...

Страница 1723: ...nal will cause the module to sound the buzzer The module will also illuminate the seatbelt indicator lamp by providing a path to ground Operation of the seatbelt por tionof thecircuitislimitedtoaspeci...

Страница 1724: ...H i _ H I WIPERS WIPERS UP DOWN 2 5L 18 BLK WIPER MOTOR F3 18 VIO W TR C100 FL 14 BLK 1 IP SEE GROUND DISTRIBUTION WASHER PUMP 4 2L 18 BLK 12 BLK I E 12 BLK 1 E FL 1 16 BLK 12 BLK I E SEE GROUND 12 BL...

Страница 1725: ...on switch side of connector C145 A B non intermittent or C145B intermittent TEST OK NOT OK Connector terminal E wiper switch in LO and mist intermittent 12 volts Replace switch Connector terminal C wi...

Страница 1726: ...UND TEST OK NOT O K Terminal B at pump to clean chassis ground Zero ohms Repair open to ground G305 306 2 PUMP SWITCH CIRCUIT Ignition ON washer switch tab rotated forward TEST OK NOT OK Connector 145...

Страница 1727: ...h position as indicated TEST OK NOT OK Terminal A blower switch in any position 12 volts Test microswitch Terminal C blower switch in LO 12 volts Replace switch Teminal D blower switch in MED 12 volts...

Страница 1728: ...PARK 18 BLU SIDEMARKER LAMPS I SWITCH s OFF 8 1 ILLUMINATION I RHEOSTAT I SWITCH C139 IP 18 BLU I O C149 IP Y 1 L J L J 18 BLU M IP I 18 BLU I C111 18 BLU IP PANEL INTENSITY INPUT BATTERY MEMORY DIM D...

Страница 1729: ...tion switch TROUBLESHOOTING Noisy Reception 1 ANTENNA MAST TO GROUND Lead in cable disconnected for second step only TEST OK NOT OK Antenna mast to clean chassis ground Infinite resistance OPEN Replac...

Страница 1730: ...G Memory Does Not Operate Electronically Tuned 1 FUSE TEST OK NOT OK Inspect DOME COURTESY fuse Not blown Replace fuse Battery side of DOME COURTESY fuse 12 volts Repair open from fuse link J 2 5L A 4...

Страница 1731: ...m minimun to max imum several times and listen for engagement and disen gagement of the clutch 3 BLOWER MOTOR Ignition ON blower switch position as indicated tests made on blower motor side off connec...

Страница 1732: ...H HOT IN RUN A N D START 1 FUSE TO COURTESY LAMP CARGO LAMP RADIO 4 V i 12 BLK 1 E SEE GROUND 12 BLK DISTRIBUTION G301 SEE GROUND DISTRIBUTION G301 SENDER 260 F 80 OHMS 180 F 309 OHMS 100 F 1600 OHMS...

Страница 1733: ...kage Inoperative 1 GAUGE PACKAGE GROUND TEST OK NOT OK Terminal 3 to clean chassis ground Zero ohms Repair open to ground G301 TROUBLESHOOTING Clock 1 FUSE TEST OK NOT OK Inspect dome courtesy fuse No...

Страница 1734: ...cuit connection at gauge sender unit terminals 12 volts Replace gauge 4 GAUGE CALIBRATION VALUES TEST OK NOT OK Using the following charts the calibration of the gauge can be checked Indicator needle...

Страница 1735: ...CRUISE CONTROL HOT AT ALL TIMES FROM FUSE LINK J2 5L A4 2L HOT IN RUN FROM IGNITION SWITCH TO THROTTLE LINKAGE Cruise Control 3 5 Cruise Control 35...

Страница 1736: ...elease cruise switch back to ON and vehicle will hold the new faster speed if set speed button has been pressed Tap brake pedal and vehicle will decelerate Slide cruise switch momentarily R A and vehi...

Страница 1737: ...open Next step Connector CI 13 across Terminals G and F while moving throttle from idle to wide open 240 4K ohms 280 430 ohms at idle 4K 4000 ohms at wide open Replace control servo If resistance val...

Страница 1738: ...l be illu minated by the ECU The numerous inputs received by the ECU enable it to indicate through the lamp the best time to upshift to a higher gear The brake indicator is a dual function lamp It wil...

Страница 1739: ...1st gear TEST OK NOT OK Jumper wire from diag nostic connector terminal D2 1 to a clean chassis ground Lamp ON Lamp OFF proceed to switch test Lamp ON proceed to ECU test Indicator Lamps 39 2 UPSHIFT...

Страница 1740: ...2D AMP IP U B1 X 25 AMP CIRCUIT BREAKER _ HEAD HEADLAMP SWITCH TO TO TAILLAMPS C103 1 8 BLU PARKING SIDE MARKER W LAMPS 18 O R N IP F C157 IP PANEL n F U S E LAMPS I PANEL F U S E J 5 AMP C t C149 B...

Страница 1741: ...h ON TEST OK NOT O K Across bulb terminals Zero ohms Replace bulb Battery side of bulb socket 12 volts Repair open to battery side of bulb socket Ground side of bulb socket Zero ohms Repair open to Gr...

Страница 1742: ...H BACK UP 1 TURN FLASHER T i HAZARD BRAKE SWITCH FLASHER 18 GRY 18 I PL 18 VIO W TR 18 BRN fit C1Q4 HAZARD SWITCH Y Y V I T U R N LEFT 4 TURN V RIGHT 18 YEL M 18 GRY W TR 18 GRY W TR C137 18 DK GRN N...

Страница 1743: ...smission equipped vehicles the backup lamp switch is incorporated into the neutral safety switch In either case the switch is closed only when the transmission is shifted into reverse TROUBLESHOOTING...

Страница 1744: ...erminals M and N 12 volts Replace turn signal switch TROUBLESHOOTING One Lamp Out NOTE Refer to park lamps or stop lamps for a one lamp out condition 1 FUSE TEST OK NOT OK Check operation of STOP lamp...

Страница 1745: ...CKUP LAMPS 1 LAMP Ignition ON transmission selector lever in reverse TEST OK NOT OK Install replacement bulb Lamp ON Next step Battery side of bulb socket 12 volts Proceed to switch tests Ground side...

Страница 1746: ...LAMPS HEAD TAIL SIDEMARKER FOG PARK 1 FUSE PARK TAIL J PANEL G305 306 46 Lamps Head Tail Sidemarker Fog Park 46 Lamps Head Tail Sidemarker Fog Park...

Страница 1747: ...ARKER PARK LAMPS Battery side of lamp connector 12 volts Repair open to battery side of wiring connector TAIL SIDEMARKER PARK LAMPS TROUBLESHOOTING One Lamp Out Ground side of lamp connector to clean...

Страница 1748: ...E5 16 P N K W TR Theunderhood lamp circuitbegins at thehazard flasher battery terminal and extends into the engine compartment through the dash panel connector At approximately the center of the dash...

Страница 1749: ...terminals Zero ohms Replace bulb Battery side of bulb socket 12 volts Repair open from splice E Ground side of bulb socket Zero volts Repair open to door jamb switch TROUBLESHOOTING ASS Lamps Out 1 FU...

Страница 1750: ...cyl GROUND 302 Behind ignition coil GROUND 304 Dipstick mounting bolt GROUND 305 Radiator support to right of right headlamp GROUND 306 Radiator support to left of left headlamp GROUND 307 Behind lef...

Страница 1751: ...h Top of receiver dryer located in right front corner of engine compartment C108 Air management solenoid assembly Top of valve cover near dash panel C109 A C blower motor Plugs on fuse panel o is C110...

Страница 1752: ...ater relay Rt of battery 86 85 87 C127 Oxygen sensor Behind left engine mount 4 cyl Below EGR valve 6 cyl C128 Throttle position sensor Rear of throttle body near bottom C129 Power steering switch Rig...

Страница 1753: ...F G A ES C D E F G C146 Wiper motor Lower left corner of windshield housing M i l l C147 Diagnostic connector D1 Right of battery 3 C148 Diagnostic connector D2 Right of battery i 0 63 i5 16 C149 Rad...

Страница 1754: ...low and to the left of steering column X L JT_ C157 Illumination rheostat Behind rheostat L r i ji C158 LH courtesy lamp harness Below left speaker V C159 Headlamp dimmer switch Turn signal lever stal...

Страница 1755: ...ENGINE ENGINE CONTROL 2 5L OXYGEN SENSOR C127 DIAGNOSTIC CONNECTOR D1 C147 DIAGNOSTIC CONNECTOR D2 C148 B LATCH RELAY C136 COOLANT TEMPERATURE SENSOR B R A K E PRESSURE SWITCH 55...

Страница 1756: ...0 V A C U U M S W I T C H A S S E M B L Y C 1 1 0 C O O L A N T T E M P E R A T U R E S E N D E R D I A G N O S T I C C O N N E C T O R D1 C 1 4 7 D I A G N O S T I C C O N N E C T O R D2 0 1 4 8 M A...

Страница 1757: ...FRONT LIGHTING...

Страница 1758: ...BATTERY STARTER 2 5L BATTERY POSITIVE TERMINAL BATTERY STARTER SOLENOID 58 58...

Страница 1759: ...BATTERY STARTER 4 2L BATTERY POSITIVE STARTER TERMINAL SOLENOID STARTER SOLENOID TO STARTER MOTOR 59 59...

Страница 1760: ...MP SWITCH C156 INDICATOR LAMPS C121 RIGHT COURTESY LAMP INSTRUMENT PANEL TO BODY C118 INSTRUMENT PANEL TO BODY c m HORN RELAY C102 A C COMPRESSOR CLUTCH A C BLOWER MOTOR C109 A C BLOWER MOTOR GROUND R...

Страница 1761: ...BODY ROOF REAR DEFOGGER BATTERY CARGO BODY HARNESS CHASSIS GROUND G307 EARLY PRODUCTION 61...

Страница 1762: ...TRANSMISSION ENGINE SPEED SENSOR UPSHIFT BACK UP LAMP LAMP SWITCH SWITCH 62...

Страница 1763: ...CRUISE CONTROL BRAKE SWITCH C113 63...

Страница 1764: ......

Страница 1765: ......

Страница 1766: ......

Страница 1767: ......

Страница 1768: ......

Страница 1769: ...on Key Warning Buzzer 2 4 Indicator Lamps 41 Instrument Panel Illumination Lamps 43 Park Lamps 49 Power Distribution 2 5L 7 Power Distribution 4 2L 8 Radio 3 0 Rear Defogger 2 2 Seat Belt Warning Buzz...

Страница 1770: ...often used to describe the circuit operation By following the schematic of the circuit as you read the circuit description you can understand how the circuit works INDICATES THAT ALL WIRES FROM THIS...

Страница 1771: ...E SYMPTOMS 1 Localizing the Trouble After conducting operational checks Step 2 the trouble will always lie between a check which resulted in negative symptoms and a check which resulted in apositive s...

Страница 1772: ...s to be opened and the ammeter is inserted in series C OHMMETER Ohmmeters are used to measure resistance The following procedure is recommended 1 Disconnect the source of voltage from the resistance b...

Страница 1773: ...REPEATED WHERE CURRENT PATH CONTINUES A WAVY LINE MEANS AWIRE IS TO BE CONTINUED OR WILL NO LONGER BE USED CIRCUIT BREAKER RELAY SHOWN WITH NO CURRENT FLOWING THROUGH COIL 14 LT BLU I B I C216 FUSIBLE...

Страница 1774: ...Window Defogger Grids 5 FAN HTR White 25 AMP Heater Blower Motor 6 GAUGES Light Blue 15 AMP Key Buzzer Defogger Relay Gauge Pack Defogger Switch Tachometer Indicator Lamps 7 W WIPERS 6 7 AMP Circuit...

Страница 1775: ...L ENGINE 4 RED 1 FUSE PANEL CIGAR LIGHTER RADIO CRUISE CONTROL BLOWER MOTOR HEATER INSTRUMENT PANEL ILLUMINATION LAMPS TACHOMETER EMISSION INDICATOR MAINTENANCE TIMER LAMPS Power Distribution 2 5L 7 P...

Страница 1776: ...POWER DISTRIBUTION 4 2L i ALTERNATOR 4 RED l i s INSTRUMENT PANEL ILLUMINATION LAMPS EMISSION INDICATOR MAINTENANCE LAMPS TIMER Power Distribution 4 2L 8 Power Distribution 4 2L...

Страница 1777: ...LUMINATION SPEEDOMETER CONNECTOR PANEL LAMP DIMMER SWITCH BODY HARNESS RADIO ILLUMINATION RELAY GAUGE PACKAGE ILLUMINATION HEATER CONTROL ILLUMINATION DEFOGGER SWITCH CONNECTOR WARNING INDICATORS CIGA...

Страница 1778: ...S FROM FUSE LINK K HOT IN START FROM IGNITION SWITCH NOTE 1 D1 DIAGNOSTIC CONNECTOR 1 2 D2 DIAGNOSTIC CONNECTOR 2 3 FOR DIAGNOSTIC PROCEDURE REFER TO MS 1700 RESISTANCE WIRE TO ALTERNATOR G302 Engine...

Страница 1779: ...TR 18 PNK W TR 18 PNK W TR C D2 1 C153 I I INJECTOR C O N T R O L G R O U N D EXTEND 24 RETRACT 23 CLOSED THROTTLE SIGNAL 25 4 BATTERY SYSTEM W I D E O P E N T H R O T T L E G R O U N D S W I T C H S...

Страница 1780: ...FUSE LINK B4 2L 1 IGNITION NOTE 1 D1 DIAGNOSTIC CONNECTOR 1 2 D2 DIAGNOSTIC CONNECTOR 2 3 D3 FOR DIAGNOSTIC PROCEDURE REFER TO MS 1700 18 v r W T VIO rV TB D1 5 G U N D V 3UTI0N 1 4 i SOLENOID 12 Eng...

Страница 1781: ...rter solenoid coil is energized pulling the heavy contacts closed Battery voltage is applied to the starter contacts at all times When the starter solenoid is energized battery voltage is applied thro...

Страница 1782: ...Y Parking brake fully engaged automatic transmission in PARK or NEUTRAL turn ignition switch to OFF TEST OK NOT OK C243 terminal G to C192 terminal B Zero ohms Repair open from start relay Park neutra...

Страница 1783: ...4 BLK B S G100 10 RED 10 RED FUSE LINK K2 5L B4 2L 18 GRN H SEE POWER DISTRIBUTION 12 RED D4 C100 12 RED IP A 103 ACCY 1 IGNITION SWITCH p START ACCY RUN 13 LOCK y S T A RUN J n WC103 14 YEL 14 YEL 2...

Страница 1784: ...sion Drive belt serviceable Tension or replace belt as required Inspect connection at starter relay solenoid Clean and tight Repair as required ALTERNATOR CONNECTIONS All connectors removed from alter...

Страница 1785: ...TIMES FROM FUSE LINK B 1 14 RED I E E 1 I 14 ORN TO IDLE RELAY ENGINE CONTROLS 16 BLU W TR 20 LT GRN W TR BI METALLIC 14 PNK MANIFOLD HEATER SWITCH OPENS ABOVE F 160 F 70 C Asa MANIFOLD Carburetor Cir...

Страница 1786: ...RUN for voltage tests turn ignition switch to OFF for resistance tests TEST OK NOT OK C126 cavity 5 Battery voltage Repair open from ignition switch C126 cavity 4 Battery voltage Repair open from fuse...

Страница 1787: ...rcuits and converted to needle move ment across the gauge face TROUBLESHOOTING Tachometer 1 GAUGES FUSE Turn ignition switch to RUN TEST OK NOT OK Check operation of gauge package Gauge package operat...

Страница 1788: ...a clean chassis ground Zero ohms Repair open between C155 and G301 2 LAMPS Turn headlamp switch to ON TEST OK NOT O K Measure voltage at C155 terminal C Battery voltage Repair open from headlamp swit...

Страница 1789: ...Inspect fuse Not blown Replace fuse Battery side of fuse Battery voltage Repair open from ignition switch 2 CIGAR LIGHTER ELEMENT TEST OK NOT OK Substitute heater element Lighter works Next test 3 CIG...

Страница 1790: ...REAR DEFOGGER 4 2L 14 BRN W TN 2 5L 12 BLK 1 E 20 BLK 14 BLK I IP ND START SWITCH I 12 BLK I E G301 18 WHT W TR TO SEAT BELT SWITCH 12 BLK IP SEE GROUND DISTRIBUTION 22 Rear Defogger 22 Rear Defogger...

Страница 1791: ...splice B seat belt buzzer will also be inoperative 2 DEFOGGER SWITCH C115 separated from defogger switch turn igni tion switch to RUN for voltage tests turn ignition switch to OFF for resistance tests...

Страница 1792: ...CONTROL INPUT KEY IN IGNITION OUTPUT GROUND 6 3 BUZZER MODULE SOLID STATE PLUGS INTO FUSE PANEL r 18 WHT I W TR P IP C171 20 BLK I IP T C C158 12 BLK I IP 2 5L SEE GROUND DISTRIBUTION 4 2L 18 BLK W T...

Страница 1793: ...or voltage tests turn ignition switch to OFF for resistance tests TROUBLESHOOTING 1 BUZZER MODULE C171 separated from buzzer module open driver s door turn ignition switch to RUN for voltage tests tur...

Страница 1794: ...301 SEE GROUND 12 BLK E DISTRIBUTION I SEE GROUND DISTRIBUTION G301 FL SEE GROUND DISTRIBUTION G 3 0 5 3 0 6 WINDSHIELD i Mi WiPER WASHER j CIRCUIT BREAKER i SEE POWER DISTRIBUTION INTERMITTENT 18 LT...

Страница 1795: ...ield Wipers Inoperative 1 CIRCUIT BREAKER Turn ignition switch to RUN TEST OK NOT OK Measure voltage at battery side of circuit breaker Battery voltage Repair open from ignition switch Measure voltage...

Страница 1796: ...terminal B to a clean chassis ground Zero ohms Repair open between C206 and G305 306 2 PUMP SWITCH CIRCUIT Turn ignition switch to RUN washer switch tab rotated forward TEST OK NOT OK Measure voltage...

Страница 1797: ...lace heat off microswitch 2 BLOWER SWITCH Turn ignition switch to RUN place selector lever in heat mode TEST OK NOT OK Measure voltage at C151 terminal A Battery voltage Repair open from C219 to C151...

Страница 1798: ...mm M mL mm mm mm mm MM C F l jf Dj C cW v J i J V l T f S K ii zm mm iy L A DOME COURTESY 15 AMP 1 EMU I PANEL SEE POWER DISTRIBUTION 18 PNK IP SEE POWER DISTRIBUTION SEE GROUND DISTRIBUTION 30 Radio...

Страница 1799: ...und Infinite resistance OPEN Replace antenna lead in cable 2 ANTENNA MAST TO CENTER CONDUCTOR Lead in cable discon nected from radio TEST OK NOT OK Measure resistance from antenna mast to tip of cente...

Страница 1800: ...d Headlights operating normally 1 RADIO ILLUMINATION LAMPS Headlamp switch OFF TEST OK NOT OK Measure voltage at C172 terminal 4 Battery voltage Repair open from ACCY fuse Measure voltage at C172 term...

Страница 1801: ...to the evaporator housing When the temperature of the evaporator drops below the set temperature the thermostatic control opens the clutch circuit The circuit remains open until evaporator temperatur...

Страница 1802: ...e at C109 terminal A blower switch in HIGH Battery voltage Repair open from blower switch If battery voltage replace motor TROUBLESHOOTING Compressor Clutch Inoperative 1 A C COMPRESSOR CLUTCH TEST OK...

Страница 1803: ...OM IGNITION SWITCH T IN RUN A N D START TO COURTESY LAMP CARGO LAMP RADIO 260 F 55 1 O H M S 220 F 93 5 O H M S 100 F 1365 O H M S 12 BLK I E SEE GROUND 12 BLK 1 E S E E GROUND DISTRIBUTION DISTRIBUTI...

Страница 1804: ...cuit mounted on the back of the gauge housing TROUBLESHOOTING Gauge Package Inoperative 1 GAUGE PACKAGE GROUND Separate C144 from gauge package TEST OK NOT OK Measure resistance from C144 terminal 3...

Страница 1805: ...rminal A to a clean chassis ground Zero ohms Repair open from C138 to G301 If zero ohms replace sender NOTE Includes voltmeter sender unit TEST OK NOT OK Measure resistance from gauge package terminal...

Страница 1806: ...CRUISE C U N I K U L HOT AT ALL TIMES FROM FUSE LINK J2 5L A4 2L SEE GROUND DISTRIBUTION TO THROTTLE LINKAGE 38 Cruise Control 38 Cruise Control...

Страница 1807: ...ehicle will hold the new faster speed if set speed button has been pressed 6 Tap brake pedal and vehicle will decelerate 7 Slide cruise switch momentarily to R A and vehicle will accelerate to former...

Страница 1808: ...e Not blown Replace fuse Measure voltage at battery side of ACCY fuse Battery voltage Repair open from ignition switch Measure resistance between C105 terminals 2 and 11 while moving throttle from idl...

Страница 1809: ...circuit the indicator lamp will be illu minated by the ECU The numerous inputs received by the ECU enable it to indicate through the lamp the best time to upshift to a higher gear The upshift lamp is...

Страница 1810: ...diagnostic connector C152 terminal D2 1 to a clean chassis ground Lamp ON Lamp OFF proceed to upshift lamp switch test Lamp ON test ECU 42 Indicator Lamps 2 UPSHIFT LAMP SWITCH Ignition in RUN transmi...

Страница 1811: ...LLUMINATION LAMPS HOT AT ALL TIMES FROM FUSE LINK J2 5L A4 2L T FUSE 18 ORN W TR 18 ORN W TR A A C182 HEATER CONTROL SEE GROUND DISTRIBUTION Instrument Panel Illumination Lamps 43 Instrument Panel Ill...

Страница 1812: ...BULB BULB SOCKET Headlamp switch in HEAD for voltage tests headlamp switch OFF for resistance tests illumination rheostat switch ON C144 separated from indicator lamp panel TEST OK NOT OK Measure res...

Страница 1813: ...RN SIGNAL STOP HAZARD BACKUP HOT IN RUN A N D ACCY FROM IGNITION SWITCH HOT AT ALL TIMES FROM FUSE LINK J2 5L A4 2L 18 YEL W TR Lamps Turn Signal Stop Hazard Backup 45 Lamps Turn Signal Stop Hazard Ba...

Страница 1814: ...s shifted in to reverse 3 S W I T C H C 1 0 4 separated from turn hazard switch assembly switch in left or right turn position as required TEST OK NOT OK Measure resistance between C104 terminals L an...

Страница 1815: ...ST OK NOT O K Measure resistance from C104 terminal P to terminals M and N Zero ohms Replace turn hazard switch Stop Lamps 47 TROUBLESHOOTING One Lamp Out NOTE Refer to park lamps or stop lamps for a...

Страница 1816: ...OUBLESHOOTING All Lamps Out 1 BACK UP LIGHT SWITCH Manual Transmission Ignition switch in RUN transmission in REVERSE TEST OK NOT OK Measure voltage at C225 terminal A Battery voltage Repair open from...

Страница 1817: ...K TAIL j p L SEE POWER DISTRIBUTION NOT USED J HI 4 4 OPERATED BY TURN SIGNAL 18 BLU IP TO RADIO ILLUMINATION RELAY 1 8 8 L U C157 I 11 I ILLUMINATION RHEOSTAT SWITCH G305 306 Lamps Head Tail Sidemark...

Страница 1818: ...lown Replace fuse Measure voltage at battery side of fuse Battery voltage Repair open from fuse link J 2 5L A 4 2L 3 HEADLAMP SWITCH Headlamp switch in HEAD TEST OK NOT OK Measure voltage at C156 term...

Страница 1819: ...of the dash panel the wire extends from the wiring harness and joins the lamp connector The metallic lamp body serves as the ground connection and contains a mercury switch When the hood is up the mer...

Страница 1820: ...Zero ohms except filament resistance Replace bulb Measure voltage at battery side of lamp connector Battery voltage Repair open from splice E Measure resistance from ground side of bulb terminal to a...

Страница 1821: ...Behind ignition coil GROUND 303 Dipstick mounting bolt GROUND304 Dipstick mounting bolt GROUND 305 Radiator support to right of right headlamp GROUND 306 Radiator support to left of left headlamp HAZ...

Страница 1822: ...R 11 ISC Extend 12 Coolant Temperature Sensor 13 Closed Throttle Switch 14 ISC Retract 15 Not Used Terminal Function 1 Tach Signal 2 Elec Choke Switch 3 Ground 4 Start Signal 5 Idle Solenoid 6 Not Use...

Страница 1823: ...ssure switch Top of receiver dryer located in right front corner of engine compartment C108 Air management solenoid assembly Top of valve cover near dash panel C109 A C blower motor Plugs on fuse pane...

Страница 1824: ...fold heater relay Rt of battery C127 Oxygen sensor Behind left engine mount 4 cyl Below EGR valve 6 cyl C128 Throttle position sensor Rear of throttle body near bottom C129 Wide open throttle switch L...

Страница 1825: ...E F G J A B C D E F G C146 Wiper motor Lower left corner of windshield housing C147 Diagnostic connector D1 Right of battery i C148 Diagnostic connector D2 Right of battery 63 9 C149 Radio Behind rad...

Страница 1826: ...Upper rear of engine C164 Transmission jumper Near transmission automatic __n C168 Wide open throttle switch On throttle body L B r C165 Engine coolant temperature sensor 2 5L LH rear of engine l C169...

Страница 1827: ...e Near multi function lever C224 Radio lamp Behind radio face A B 0 0 C179 Air temperature sensor Top of intake manifold C206 Windshield washer pump On washer fluid reservoir C215 Upshift switch On tr...

Страница 1828: ...52 Emission maintenance timer Behind sidemarker lamp Below radio A B C C232 RH sidemarker lamp Behind sidemarker lamp C233 Seat belt switch In driver s seat belt buckle C246 Power steering switch Left...

Страница 1829: ...t door iamb switch C188 Near blower motor C205 At LH door jamb switch C247 At A C compressor clutch C189 At filter capacitor C209 At RH door jamb switch C248 At fuse panel C190 At knock sensor C210 At...

Страница 1830: ...HARNESS ROUTING VIEWS 62 Harness Routing Views 62 Harness Routing Views...

Страница 1831: ...ENGINE CONTROL 2 5L DIAGNOSTIC CONNECTOR D1 C147 DASH PANEL C100 COOLANT TEMPERATURE SENSOR C165 BRAKE PRESSURE SWITCH C150 FUEL INJECTOR C163 Engine Engine Controls 2 5L 63 Engine Engine Controls 2...

Страница 1832: ...10 VACUUM SWITCH ASSEMBLY C110 COOLANT TEMPERATURE SENDER C211 DIAGNOSTIC CONNECTOR D1 C147 DIAGNOSTIC CONNECTOR D2 C148 MANIFOLD HEATER RELAY C126 DASH PANEL C100 MANIFOLD HEATER C195 BRAKE PRESSURE...

Страница 1833: ...FRONT LIGHTING Front Lighting 65 Front Lighting...

Страница 1834: ...2 5L BATTERY POSITIVE TERMINAL BATTERY NEGATIVE TERMINAL ENGINE HARNESS C170 ENGINE BLOCK GROUND G301 303 304 BATTERY TO STARTER RELAY BATTERY TO STARTER STARTER SOLENOID Battery Starter 2 5L 66 Batte...

Страница 1835: ...2L BATTERY POSITIVE TERMINAL BATTERY NEGATIVE TERMINAL STARTER RELAY STARTER SIDE ENGINE BLOCK GROUND G100 STARTER RELAY BATTERY SIDE STARTER RELAY TO STARTER SOLENOID Battery Starter 4 2L 67 Battery...

Страница 1836: ...G LAMP SWITCH LAMP C181 BRAKE SWITCH C174 GAUGE PACKAGE C144 INDICATOR LAMPS C121 RIGHT COURTESY LAMP C176 INSTRUMENT PANEL TO BODY C118 INSTRUMENT PANEL TO BODY c m A C BLOWER MOTOR GROUND BLOWER MOT...

Страница 1837: ...BODY ROOF REAR DEFOGGER CARGO BATTERY L A M P C203 C234 C235 Body Roof 69 Body Roof...

Страница 1838: ...TRANSMISSION ENGINE SPEED SENSOR 2 5L ONLY C133 UPSHIFT BACK UP LAMP LAMP SWITCH SWITCH C215 C225 Transmission...

Страница 1839: ...CRUISE CONTROL Cruise Control 71 Cruise Control...

Страница 1840: ......

Страница 1841: ......

Страница 1842: ......

Страница 1843: ...erature Switch 4 2L I 2 Engine Speed Sensor 2 5L F 10 Diagnostic Connector D1 B 3 Dimmer Switch N 10 Diode Fuse Assembly 4 2L I 3 Distributor 2 5L E 7 Distributor 4 2 L H 1 Filter Capacitor 4 2L G 1 N...

Страница 1844: ...tch Assembly 4 2L I 2 Washer Pump 0 2 0 3 Wide Open Throttle Switch 2 5L F 11 Wide Open Throttle Switch4 2L I 2 Windshield Wiper Washer Circuit Breaker M 1 M 3 Wiper M o t o r N 1 N 3 Wiper Switch M 1...

Страница 1845: ...MP RELAY I i I J FROM PARK TAIL DIAGNOSTIC jCONNECTOR r f T H ELECTRONIC f 0 H B I j CONTROL jLAT UNIT j REL 1 I I LATCH RELAY FUSE C157 A ILLUMINATION I J RHEOSTAT I SWITCH i TO HEADLAMPS 14 RED 14 R...

Страница 1846: ...L ENGINE TURN SIGNAL SWITCH DEFOGGER DEFOGGER GAUGE GRIDS RELAY IGN PACK 9 DEFOGGER SWITCH 1987 J E E P Part Number 8980 010 391 Copyright 1986 American Motors Corporation All Rights Reserved Litho in...

Страница 1847: ...J 4 BLK E START SOLENOID 18 GRN I EMI LINK C 14 RED tC126 r l F T MANIFOLD I 1 HEATER 1 RELAY 12 RED 1 FROM PARK TAIL FUSE I C15S B1 X 25 AMP CIRCUIT BREAKER OFF HEAD f k 18 BLU C157 J X HEADLAMPS HEA...

Страница 1848: ...POWER DISTRIBUTION 4 2L BLOWER A C MOTOR COMPRESSOR A C CLUTCH DEFOGGER DEFOGGER GRIDS RELAY IGN 6...

Страница 1849: ...AT ALL TIMES FROM BATTERY NOTE 1 ALL CIRCUITS ARE EC ENGINE CONTROL UNLESS OTHERWISE INDICATED 2 D1 DIAGNOSTIC CONNECTOR 1 3 D2 DIAGNOSTIC CONNECTOR 2 NOTE 4 FOR DIAGNOSTIC PROCEDURE REFER TO MS1700...

Страница 1850: ...4 4 18 LT GRN 0 2 1 1 18 LT GRN BATTERY WIDE OPEN SYSTEM THROTTLE GROUNO SIGNAL 10 8 LATCH RELAY B LATCHED 14 BLK 02 13 ENGINE SPEED SENSOR CLOSED CLOSED I L f f C V THROTTLE V LE M P SWITCH PEED OPEN...

Страница 1851: ...E T I C P I C K U P PICK U P K N O C K S E N S O R SELECT G R O U N D G R O U N D I N P U T 17 6 0 2 0 5 1 4 7 TIDING O U T P U T E N G I N E C O O L A N T T E M P E R A T U R E I N P U T 56 14 BLK W...

Страница 1852: ...nMnuiwu o i o i c m UAKbUKtlUK U 8 H U U I T 5 DUP IM iR OGGER DM I I0NING 01 5 I0ID 4 RED HOT AT ALL TIMES FROM FUSE LINK B TO ENGINE CONTROLS SWITCH OPENS ABOVE 160 F 70 C MANIFOLD HEATER LH MOl BAS...

Страница 1853: ...A N E L INTENSITY I N P U T B A T T E R Y M E M O R Y V D I M D I S P L A Y S I G N A L Y P A N E L INTENSITY I N P U T V SOLID STATE E L E C T R O N I C A L L Y T U N E D R A D I O O N L Y I 1 1 Q A...

Страница 1854: ...NTROL 14 WHT C151 14 ORN W TR F4 m C100 14 ORN W TR 1 E LOWER BLOWER SWITCH 14 LT GRN 14 WHT W TR C154 JSJHL 85i L BLOWER RESISTOR H I FUSE FAN HTR I PANEL 16 BRN 16 BRN 16 GRN 16 I 1987 J E E P W M A...

Страница 1855: ...SE P A N E L 18 WHT B SWITCH DEFOGGER RELAY GRIDS I C 2 5L K 4 2L 12 BLK E G301 HOT AT ALL TIMES FROM FUSE LINK K2 5L B4 2L B E 5 P l IGNITION SWITCH yK I START L JbL i 14 VIO NOTE JUMPER INSTALLED WI...

Страница 1856: ...E SEE GROUND SEE GROUND DISTRIBUTION DISTRIBUTION G301 G301 HOT IN RUN AND ACCY FROM IGNITION SWITCH 18 WHT W TR 18 WHT 18 WHT i o cm 18 WHT IP SEATBELT SWITCH SIGNAL r C120 18 WHT W TR FASTEN SEATBE...

Страница 1857: ...A N E L SEE GROUND DISTRIBUTION SEE GROUND DISTRIBUTION i l G 3 0 1 G301 2 5L HOT AT ALL TIMES FROM FUSE LINK J TO COURTESY LAMP CARGO LAMP RADIO 18 LT BLU 1 IP F5 I I 18 LT GRN 1IP SEE GROUND DISTRI...

Страница 1858: ...CRUISE CONTROL HOT AT ALL TIMES FROM FUSE LINK J2 5L A4 2L 11 12 SIDE 2 OF 2...

Страница 1859: ...T UP DOWN vL FRONT WIPER MOTOR BLK 1 Agi46 18 BLK 14 ILK 2 5L 18 VIO W TR F3 m C100 FRONT WASHER PUMP B5 Jfr C100 4 2L 12 GLK 12 BL 12 ILK 20 BLK I FL Q Zl f TT3 ZHTj 12 ILK il G201 i i 3 0 1 G305 306...

Страница 1860: ...IIMUIUAIUK LAM Kb IIM l ttUMCH i r HOT IN RUN AND ACCY FROM IGNITION SWITCH HOT AT ALL TIMES FROM FUSE LINK J2 5L A4 2L I FUSE OPERATED...

Страница 1861: ...AMPS m ILLUMINATION RHEOSTAT SWITCH RADIO 16 LT GRN fC116 B ON OFF r l INDICATOR 7 X LAMP P J A jT FOG LAMP SWITCH SEEGROUNO DISTRIBUTION 2 5L BS CIOO 4 2 L 12 BLK SEE GROUND DISTRIBUTION 14 BLK 12 BL...

Страница 1862: ...LAMPS HEAD TAIL SIUfcMAKl ttt ruuArMnrv 18 GRN FUSE LINK J2 5L A4 2L FUSE PARK TAIL i 10 AMP 1 ILLUMINATION H 6305 308 I D E 1 OF 3 11 1...

Страница 1863: ...L W TR A C140 MANUAL TRANSMISSION 18 YEL W TR 1 T AUTOMATIC TRANSMISSION 18 PNK W TR 18 PNK W TR T U R N LEFT f f R N RIGHT LC121 C 1 2 0 7 1 INDICATOR IS _ V BRAKE SWITCH r CLOSED W I T H B R A K E P...

Страница 1864: ...ROM FUSE LINK J2 5L A4 2L 1 FUSE BRAKE SWITCH CLOSED W I T H BRAKE PEDAL DEPRESSED TO BUZZER MODULE HOT AT ALL TIMES FROM FUSE LINK J2 5L A4 2L OJS FX HAZARD I S 15 A M P LI 18 PNK W TR 2fi HAZARD FLA...

Страница 1865: ...ODULE 20 BLK C D I 3 OXYGEN SENSOR G303 WIDE OPEN THROTTLE SWITCH 20 BLK D2 7 ITCH 20 BLK 4 18 BLK x 14 BLK ELECTRONIC CONTROL UNIT IDLE SPEED ACTIVATOR CONTROL MOTOR G304 TO BODY HARNESS INSTRUH 14 B...

Страница 1866: ...NNECTOR RADIO B5 A C100 ENGINE COMPARTMENT 14 BLK STARTER RELAY N N G L K TRANSMISSION JUMPER G301 DI 3 G301 G302 4 2L ENGINE CONTROLS 18 BLK CONTROL UNIT MCU 20 BLK DI 7 20 BLK THERMO ELECTRIC SWITCH...

Страница 1867: ...ment C110 Vacuum switches Behind valve cover on dash panel C108 Air management solenoid assembly Top of valve cover near dash panel C1Q9 A C blower motor Plugs on fuse panel o C111 Body harness Above...

Страница 1868: ...Oxygen sensor Behind left engine mount 4 cyl Below EGR valve 6 cyl 128 Throttle position sensor Rear of throttle body near bottom C129 Power steering switch Right of power steering pump 130 Ignition...

Страница 1869: ...ndshield housing C147 Diagnostic connector D1 Right of battery I 0148 Diagnostic connector D2 Right of battery 0 I 0149 Radio Behind radio n n H C150 Radio Behind radio H ii i r A C151 Blower switch L...

Страница 1870: ...tat Behind rheostat j U 1 j 0153 LH courtesy lamp harness Below left speaker C159 Headlamp dimmer switch Turn signal lever stalk 1 2 3 C160 Defogger relay Lower LH shroud E D s 1987 JEEP WMANGLEM YJ P...

Страница 1871: ...t solenoid assembly Top of valve cover near dash panel C109 A C blower motor Plugs on fuse panel o V3 C110 Vacuum switches Behind valve cover on dash panel C111 Body harness Above parking brake 07 0 0...

Страница 1872: ...ft engine mount 4 cyl Below EGR valve 6 cyl C128 Throttle position sensor Rear of throttle body near bottom C129 Wide open throttle switch Left of throttle body C130 Ignition module 2 5L Below windshi...

Страница 1873: ...c connector D2 Right of battery C149 Radio Behind radio u u u u 1 1 1 1 1 1 CZ1 CZ3 CZJ G f c t 3 CZ3 CZD CZ3 CZJ CZJ N x n a C150 Brake pressure switch At master cylinder C151 Blower switch Left of h...

Страница 1874: ...ture sensor 2 5L LH rear of engine xm C166 High altitude jumper Near microprocessor control unit MCU C167 Thermo Electric switch On air cleaner housing C168 Wide open throttle switch On throttle body...

Страница 1875: ...Near multi function lever C224 Radio lamp Behind radio face A B SS SB C228 Hazard flasher Above fuse block C175 Brake switch On brake pedal lever C179 Air temperature sensor Top of intake manifold C2...

Страница 1876: ...noid C198 Near radio C183 Near defogger relay C199 Near cigar lighter C184 At fuse panel C200 Near underhood lamp C185 Upshift light disconnect C201 At horn C186 At thermostatic control C202 At horn s...

Страница 1877: ...se panel 1 pressure sender C249 At oxygen sensor 4 2L olant temperature sender C250 At fuse panel cruise control module C251 At radio connector irk brake switch ECU rnimand trac switch At heat off mic...

Страница 1878: ...uum Solenoid 3 02 Sensor 4 Ignition 5 Down Stream Solenoid 6 WOT Switch 7 Ground 8 Up Stream Solenoid 9 Vacuum Switch 10 Thermo Electric Switch 11 Stepper Motor 12 Coolant Temperature Switch 13 Idle R...

Страница 1879: ...nostic Connector D1 B 3 Dimmer Switch N 10 Diode Fuse Assembly 4 2L 1 3 Distributor 2 5L E 7 Distributor 4 2L H 1 Filter Capacitor 4 2 L G 1 NAME DIAGRAM ZONE Fog Lamp Relay 0 9 Fog Lamp Switch N 10 F...

Страница 1880: ...uum Switch Assembly 4 2L I 2 Washer Pump 0 2 0 3 Wide Open Throttle Switch2 5L F 11 Wide Open Throttle Switch4 2L I 2 Windshield Wiper Washer Circuit Breaker M 1 M 3 Wiper Motor N 1 N 3 Wiper Switch M...

Страница 1881: ...CH O F F R U N 14 GRN 14 GRN C103 14 YEL G5 C CIOO C238 7 S O L vi G START RELAY TO ENGINE CONTROLS S O C170 14 GRN 1 B S STARTER W TR 1 n SOLENOID 301 50s k _ C P U L L I N i H O L D I N C W I N D I...

Страница 1882: ...RUN LOCK J T RUN L _FLA i o r _ A 1 r _ _ _ 4 i _ _ ACCY LOCK 1 IGNITION SWITCH 1 J START RUN CIGAR LIGHTER RADIO CRUISE CONTROL BLOWER MOTOR HEATER D E F O G G E R D E F O G G E R G A U G E R E L A...

Страница 1883: ...REAR DEFOGGER CIGAR LIGHTER HORN HOT IN RUN AND START FROM IGNITION SWITCH I 1 FUSE TO SEAT BELT SWITCH 12 BLK _i 301 SEE GROUND G 3 0 1 DISTRIBUTION 12 ILK 1 3...

Страница 1884: ...TR 18 WHT SEATBELT SWITCH SIGNAL FASTEN SEATBELTS INDICATOR CONTROL KEY IN IGNITION INPUT KEY IN IGNITION OUTPUT 6 GROUND 3 1 8 W H T W T R C ft C 1 5 8 1 8 B L K W T R C 1 7 1 2 0 B L K I I P 1 2 B L...

Страница 1885: ...DISTRIBUTION 4 2L 12 BLK ft E 12 BLK SEE GROUND DISTRIBUTION G301 C171 BUZZER MODULE SOLID STATE PLUGS INTO FUSE PANEL SEE GROUND DISTRIBUTION FROM FUSE LINK J FROM IGNITION SWITCH HOT IN RUN AND STA...

Страница 1886: ...OM FUSE LINK J2 5L A4 2L HOT IN RUN FROM IGNITION SWITCH 1 FUSE PANEL SEE GROUND DISTRIBUTION 1988 J E E P WEANGLEE YJ Part Number 8980 010 719 Copyright 1987 American Motors Corporation All Rights Re...

Страница 1887: ...STARTER 4 2L FUSE LINK B 18 GRN m SEE POWER DISTRIBUTION 12 RED I E D 4 S C 1 0 0 12 RED IP AC103 1 IGNITION INSTRUMENT PANEL ILLUMINATION LAMPS 18 WHT W TR DEFOGGER DEI RELAY REI...

Страница 1888: ...D 12 RED D4 12 RED C100 A ACCY START ACCY ACCY f START ACCY I L O C K JL RUN LOCK RUN LOCK RUN LOCK J T R U N I L 0 F F JLI 3 0 F F s n 0 F F S I i L A J 1 IGNITION SWITCH TO CARBURETOR S CIRCUITS A C...

Страница 1889: ...E ECU 14 BLK D1 3 L 18 O R N B 14 BLK O X Y G E N S E N S O R 14 GRN W TR W E G303 1 I 5 j JHC135 RE IDLE S P E E D C O N N E C T O R 14 LT G R N 3 IGNITION COOLANT TEMP INPUT 15 35 INPUT SENSOR 29 ST...

Страница 1890: ...ED W TR S E N S O R G R O U N D 28 i r j f c i S EXTEND 24 RETRACT 23 CLOSED THROTTLE SIGNAL 25 7 LATCH RELAY 19 B LATCHED SYSTEM WIDE OPEN THROTTLE GROUND SWITCH SIGNAL 10 8 GROUND GROUND 1 2 1 ELECT...

Страница 1891: ...ENGINE CONTROLS 4 2L HOT AT ALL TIMES FROM FUSE LINK B4 2L NOTE 1 D1 DIAGNOSTIC CONNECTOR 1 2 02 DIAGNOSTIC CONNECTOR 2 3 D3 FOR DIAGNOSTIC PROCEDURE REFER T O MS 1700 18 GRY...

Страница 1892: ...UITS 1 2 ER IDLE SPEEDUP RELAY FROM REAR DEFOGGER FROM AIR NDITIONING 1 0 ft C D1 5 1 llMPID 4 RED T FUSE GAUGES j pA N EL 15 AMP I m I SEE POWER DISTRIBUTION SEE GROUND DISTRIBUTION 2 5L 12 BLK 12 BL...

Страница 1893: ...Y SIGNAL PANEL ILLUMINATION IGNITION B A T T E R Y M E M O R Y i i I SOLID STATE ANTENNA LEFT LEFT LEFT LEFT RIGHT RIGHT RIGHT RIGHT G R O U N O ANTENNA R E A R FRONT FRONT R E A R R E A R FRONT FRONT...

Страница 1894: ...WITCH PART O F H E A T E R C O N T R O L 14 WHT I IP C219 C151 BLOWER SWITCH C 14 LT G R N A F4 C100 C220 BLOWER MOTOR 10 BLOWER RESISTOR A C BLOWER MOTOR M V 1 H G 11 OK BLU A C FIELD JUMPER RED H S...

Страница 1895: ...GRN W TR WIPER WASHER SWITCH WHT C145B CI45A F E A C G B D D P A R K L O W PULSE M O D E H I G H PULSE M O D E W A S H E R P U M P WIPER WASHER BATTERY SELECT O U T P U T INPUT SIGNAL INPUT INPUT TIM...

Страница 1896: ...RY A C 2 1 7 A A C215 UPSHIFT SWITCH OPEN IN HIGH GEAR W C215 zCOMMAND TRAC SWITCH VACUUM OPERATED C100 18 TAN W TR C fit C140 ACCY LOCK 5 START IGNITION SWITCH RUN GROUNDS 1 DURING CRANKING FOR BULB...

Страница 1897: ...L L U I V 1 I I I M I IVJTH 1 M M r O HOT AT ALL TIMES M FUSE LINK J2 5L A4 2L F U S E J 4 PARK TAIL j pftNlL c 20 AMP j S E E p 0 W E R DISTRIBUTION 14 RED N IAL l H ILLUMINATION 16 LT GRN 12 BLK 1...

Страница 1898: ...PARK 18 GRN o 12 RED f l E E 4 C 1 0 0 FUSE LINK J2 5L A4 2L SEE POWER DISTRIBUTION M N O 1988 JEEP WEANGLEM YJ Part Number 8980 010 720 Copyright 1987 American Motors Corporation All Rights Reserved...

Страница 1899: ...18 BRN W TR 6 w c m 18 BRN W TR A A C137 LH BACK UP LAMP C6 C100 TURN BU j 15 AMP 18 YEL W TR 1 FUSE HAZARD 1 PANEL J SEE POWER 15 AMP J DISTRIBUTION 18 PNK W TR 18 YEL W TR C227 18 GRY 18 PPL H 18 L...

Страница 1900: ...L A M P HOT AT A L L TIMES FROM FUSE LINK J2 5L A4 2L SHAKE SWITCH CLOSED WITH BRAKE PEDAL DEPRESSED TO BUZZER MODULE HOT AT ALL TIMES FROM FUSE LINK J2 5L A4 2L 1 FUSE HAZARD I PPFUSE J E S S i I I...

Страница 1901: ...OXYGEN SENSOR WIDE OPEN THROTTLE SWITCH 20 BLK D2 7 14 BLK 10 ELECTRONIC CONTROL UNIT IDLE SPEED ACTIVATOR CONTROL MOTOR A G304 INSTRUMi EMISSION MAINTENANCE TIMER RADIO 14 BLK DEFOGGER SWITCH ILLUMI...

Страница 1902: ...CTOR WARNING INDICATORS CIGAR LIGHTER WINDSHIELD WIPER SWITCH WINDSHIELD WIPER MOTOR TACHOMETER ILLUMINATION SEATBELT KEY BUZZER MODULE 2 5L ENGINE COMPARTMENT 12 BLK STARTER RELAY TRANSMISSION JUMPER...

Страница 1903: ...M R 280 1987 1988 8980 010 298 U S A Canada Edition Jeep W R A N G L E R S...

Страница 1904: ...W R A N G L E R Wl...

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Jeep 1987 Wrangler, Руководство по ремонту

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