1989 Jeep XJ Cherokee & Comanche Service Manual – PDF DOWNLOAD
FILE DETAILS:
1989 Jeep XJ Cherokee & Comanche Service Manual – PDF DOWNLOAD
Language : English
Pages : 336
Downloadable : Yes
File Type : PDF
Size: 27.7 MB
INDEX:
1989 Jeep XJ Cherokee & Comanche Service Manual – PDF DOWNLOAD
A
About this manual, 0-5
Air cleaner
removal and installation, 4-7
thermostatic, check, 1-22
Air conditioning system
blower motor, removal and installation, 3-8
compressor, removal and installation, 3-1 1
condenser, removal and installation, 3-1 1
control assembly, removal and installation, 3-12
general information, 3-2
receiver-drier, removal and installation, 3-1 1
system, check and maintenance, 3-10
Air filter and PCV filter replacement, 1-26
Air injection systems, 6-1 1
Alternator
brushes, replacement, 5-1 0
removal and installation, 5-10
Anti-lock brake system (ABS), general information, 9-1
Antifreeze, general information, 3-2
Automatic transmission, 7B-1 through 78-7
bands, adjustment (three-speed transmission), 7B-5
diagnosis, 7B-2
fluid and filter change, 1-27
fluid level check, 1-1 1
general information, 78-1
neutral start switch, check, adjustment and replacement, 7B-5
removal and installation, 7B-6
shift linkage, check and adjustment, 78-2
throttle valve linkage – adjustment, 7B-3
Axle
front axle assembly, removal and installation, 8-15
front axleshafts, removal, overhaul and installation, 8-12
front hub and bearings, removal, service and installation, 8-1 1
front shift motor, check, removal and installation, 8-14
general information, 8-8
rear axleshaft and bearing assembly, removal and installation, 8-16
rear, removal and installation, 8-17
Balljoints, replacement, 10-7
Battery
cables, check and replacement, 5-2
check and maintenance, 1-1 2
jump Starting, 0-1 7
removal and installation, 5-1
Body, 11-1 through 11 -15
general information, 11 -1
maintenance, 11 -1
repair
major damage, 11 -3
minor damage, 11 -2
Brakes, 9-0 through 9-18
booster, check, removal and installation, 9-16
cables (parking), replacement, 9-1 7
caliper, removal, overhaul and installation. 9-5
check, 1-20
combination valve, check and replacement, 9-14
disc, inspection, removal and installation, 9-7
fluid level check, 1-9
general information, 9-1
height sensing proportioning valve, general information, 9-1 8
hoses and lines, inspection and replacement, 9-14
light switch, replacement, 9-18
master cylinder, removal, overhaul and installation, 9-12
pads, replacement, 9-3
parking, adjustment, 9-16
pedal, removal and installation, 9-17
shoes, replacement, 9-8
system bleeding, 9-15
system check, 1-20
wheel cylinder, removal, overhaul and installation, 9-1 1
Bulb replacement, 12-5
Bumpers, removal and installation, 11 -7
Buying parts, 0-10
C
Caliper (brake), removal, overhaul and installation, 9-5
Camshaft and bearings, removal, inspection and installation
Four-cylinder engine, 2A-13
Inline six-cylinder engine, 2C-9
V6 engine, 28-9
Carburetor
adjustments, 4-7
choke check, 1-21
diagnosis and overhaul, 4-8
removal and installation, 4-8
Catalytic converter, 6-16
Center console, removal and installation, 11-10
Centrifugal advance mechanism, check and replacement, 5-5
Charging system
alternator brushes, replacement, 5-10
alternator, removal and installation, 5-10
check, 5-9
general information and precautions, 5-9
Chassis electrical system, 12-0 through 12-8
Chassis lubrication, 1-1 7
Chemicals and lubricants, 0-19
Circuit breakers, general information, 12-2
Clutch and drivetrain, 8-0 through 8-17
components, removal, inspection and installation, 8-2
description and check, 8-1
general information, 8-1
hydraulic system bleeding, 8-7
master cylinder, removal, overhaul and installation, 8-5
pedal, removal and installation, 8-8
release bearing, removal, inspection and installation, 8-3
release cylinder, removal, overhaul and installation, 8-7
Coil spring, removal and installation, 10-6
Combination valve, check and replacement, 9-14
Compressor (air conditioning), removal and installation, 3-11
Computer Command Control System (CCCS) and trouble codes
v6 models), 6-16
Conversion factors, 0-21
The Motor Manual Guy
Index
Coolant
level check, 1-8
general information, 3-2
reservoir, removal and installation, 3-6
temperature sending unit, check and replacement, 3-5
Cooling system
check, 1-14
general information, 3-2
servicing, 1-31
Cooling, heating and air conditioning systems, 3-1 through 3-13
Crankshaft
front oil seal, replacement
Four-cylinder engine, 2A-10
lnline six-cylinder engine, 2C-6
V6 engine, 2B-6
inspection, 2D-19
installation and main bearing oil clearance check, 20-24
removal, 2D-13
Cruise control system, description and check, 12-8
Cylinder compression check, 2D-3
Cylinder head
cleaning and inspection, 2D-8
disassembly, 2D-8
reassembly, 2D-11
removal and installation
Four-cylinder engine, 2A-7
lnline six-cylinder engine, 2C-5
V6 engine, 2B-5
Cylinder honing, 2D-17
Dashboard panels, removal and installation, 11-9
Dent repair
major damage, 1 1-3
minor damage, 11 -2
Diagnosis, 0-22
Differential
general information, 8-8
lubricant change, 1-28
lubricant level check, 1-19
Disc (brake), inspection, removal and installation, 9-7
Disc brake caliper, removal, overhaul and installation, 9-5
Distributor cap and rotor check and replacement, 1-37
Distributor, removal and installation, 5-6
Door
latch, lock cylinder and handle, removal and installation, 11-13
removal, installation and adjustment, 11 -8
trim panel, removal and installation, 11-7
window glass, removal and installation, 11-12
Drivebelt check, adjustment and replacement, 1-22
Driveline inspection, 8-9
Driveshafts
differentials and axles, general information, 8-8
removal and installation, 8-9
Drum brake shoes, replacement, 9-8
Electrical
circuit diagrams, general information, 12-8
general information, 12-0
troubleshooting, general information, 12-1
Emergency battery jump starting, 0-17
Emission maintenance timer, replacement, 1-36
Emissions and engine control systems, 6-1 through 6-22
Engine
block
cleaning, 2D-14
inspection, 2D-15
camshaft and bearings, removal, inspection and installation
Four-cylinder engine, 2A-13
Inline six-cylinder engine, 2C-9
V6 engine, 2B-9
compression check, 2D-3
Crankshaft
inspection, 2D-19
installation and main bearing oil clearance check, 2D-24
removal, 2D-13
Cylinder head
cleaning and inspection, 2D-8
disassembly, 2D-8
reassembly, 2D-11
removal and installation
Four-cylinder engine, 2A-7
lnline six-cylinder engine, 2C-5
V6 engine, 2B-5
Cylinder honing, 2D-17
Initial start-up and break-in after overhaul, 2D-28
Main and connecting rod bearings, inspection, 2D-19
mounts, check and replacement
Four-cylinder engine, 2A-17
Inline six-cylinder engine, 2C-11
V6 engine, 2B-13
oil change, 1-15
overhaul
disassembly sequence, 20-7
general information, 2D-2
reassembly sequence, 2D-23
piston rings – installation, 2D-23
pistons/connecting rods
inspection, 2D-17
installation and rod bearing oil clearance check, 2D-27
removal, 2D-12
rear main oil seal installation, 2D-26
rear main oil seal, replacement
Four-cylinder engine, 2A-16
lnline six-cylinder engine, 2C-11
V6 engine, 28-1 1
rebuilding alternatives, 2D-6
removal and installatio.n, 2D-4
removal, methods and precautions, 2D-4
repair operations possible with the engine in the vehicle
Four-cylinder engine, 2A-2
lnline six-cylinder engine, 2C-1
V6 engine, 2B-1
Engine cooling fan and clutch, check and replacement, 3-4
Engine electrical systems, 5-1 through 5-14
Engine identification number, 0-7
Engine mounts, check and replacement
Four-cylinder engine, 2A-17
lnline six-cylinder engine, 2C-11
V6 engine, 28-13
Evaporative emissions control system check, 1-32
Exhaust system servicing, general information, 4-20
Exhaust Gas Recirculation (EGR) system, 6-14
Exhaust Gas Recirculation (EGR) system check, 1-32
Exhaust manifold, removal and installation
Four-cylinder engine, 2A-7
lnline six-cylinder engine, 2C-4
V6 engine, 2B-4
Exhaust system check, 1-19
Fan, engine cooling, check and replacement, 3-4
Fault finding, 0-22
Filter, fuel, replacement, 1-25
The Motor Manual Guy
Fixed glass, replacement, 11 -3
Fluid
automatic transmiss~onc, hange, 1-27
automatic transmission, checking, 1-1 1
level checks, 1-7
power steering checking, 1-12
Four-cylinder engine, 2A-1 through 2A-17
Front axle suspension arms, removal and installation, 10-5
Front coil spring(s), removal and installation, 10-6
Front end alignment, general information, 10-14
Front shock absorber, removal and installation, 10-4
Front stabilizer bar and bushings, removal and installation, 10-4
Front wheel bearing check, repack and adjustment
(2WD models), 1-29
Fuel and exhaust systems, 4-0 through 4-20
evaporative control system, 6-7
filter replacement, 1-25
injection system, general information, 4-12
injector, replacement, 4-1 9
lines and f~ttings,in spect~ona nd replacement, 4-12
pressure regulator, replacement, 4-19
pressure rehef (fuel-injected) vehicles, 4-1
pump, removal and installation, 4-4
pumplfuel pressure, check, 4-1
system check, 1-21
system, general information, 4-0
tank, cleaning and repair, 4-7
tank, removal and installation, 4-5
Fuses, general information, 12-1
Fusible links, general information, 12-2
G
General engine overhaul procedures, 2D-1 through 2D-36
Glass, door window, removal and installation, 11-12
Glass, replacement, 11 -3
Grille, removal and installation, 11 -3
Hazard flashers, check and replacement, 12-2
Headlight
adjustment, 12-4
removal and installation, 12-4
switch, removal and installation, 12-3
Heater
blower motor, removal and installation, 3-8
control assembly, removal and installation, 3-12
core, replacement, 3-8
Height sensing proportioning valve, general information, 9-18
Hinges and locks, maintenance, 11-3
Hood, removal, installation and adjustment, 11 -3
Hoses, check and replacement, 1-14
Idle speed check and adjustment (carbureted models), 1-24
ignition
coil, check and replacement, 5-2
control module, check and replacement, 5-3
distributor, removal and installation, 5-6
pick-up coil (V6 engines only), check and replacement, 5-5
stator, replacement (inline six-cylinder models only), 5-8
switch, removal and installation, 12-2
system
check, 5-2
general information, 5-2
timing check and adjustment, 1-26
trigger wheel and/or pickup coil assembly, removal
and installation, 5-4
Information sensors
1991 and later models, 6-20
V6 models, 6-1 8
lnline six-cylinder engine, 2C-0 through 2C-11
Instrument
cluster, removal and installation, 12-7
panel, removal and installation, 12-7
Intake manifold, removal and installation
Four-cylinder engine, 2A-6
Inline six-cylinder engine, 2C-3
V6 engine, 2B-3
lntroduction to routine maintenance, 1-7
lntroduction to the Jeep Cherokee and Comanche, 0-5
J
Jacking, 0-17
Jump starting, 0-17
Leaf spring bushing, check and replacement, 10-9
Leaf spring, removal and installation, 10-8
Lifters, removal, inspection and installation
Four-cylinder engine, 2A-8
Inline six-cylinder engine, 2C-9
V6 engine, 2B-9
Liftgate, removal, installation and adjustment, 11-8
Lubricant
change
automatic transmission, 1-30
differential, 1-28
manual transmission, 1-28
transfer case change, 1-29
level check
automatic transmission, 1-1 1
differential, 1-1 9
manual transmission, 1-19
transfer case, 1-1 9
Lubrication, chassis, 1-17
Maintenance schedule, 1-3
Manifold, exhaust, removal and installation
Four-cylinder engine, 2A-7
Inline six-cylinder engine, 2C-4
V6 engine, 2B-4
Manifold, intake, removal and installation
Four-cylinder engine, 2A-6
Inline six-cylinder engine, 2C-3
V6 engine, 2B-3
Manual transmission, 7A-1 through 7A-8
general information, 7A-1
lubricant change, 1-28
overhaul – general information, 7A-4
removal and installation, 7A-3
shift lever, removal and installation, 7A-2
Master cylinder (brake), removal, overhaul and installation, 9-12
Mirror, outside, removal and installation, 11 -14
Multi-Point Fuel Injection (MPI), component replacement, 4-16
N
Neutral start switch, check, adjustment and
replacement, 1-27,7B-5
The Motor Manual Guy
Index
Oil
change, 1-15
filter change, 1-1 5
level check, 1-7
pan, removal and installation
Four-cylinder engine, 2A-14
lnline six-cylinder engine, 2C-10
V6 engine, 28-10
pump, removal and installation
Four-cylinder engine, 2A-14
lnline six-cylinder engine, 2C-11
V6 engine, 2B-11
seal, rear main, installation, 2D-26
Outside mirror, removal and installation, 11 -14
Oxygen sensor, 6-21
Oxygen sensor and emission maintenance timer replacement
(1988 and later 49-state models), 1-36
Pads (brake), replacement, 9-3
Parking brake cables, replacement, 9-17
Parking brake, adjustment, 9-16
Pilot bearing, inspection and replacement, 8-4
Pinion oil seal, replacement, 8-10
Piston rings, installation, 2D-23
Pistonslconnecting rods
inspection, 2D-17
installation and rod bearing oil clearance check, 2D-27
removal, 2D-12
Positive Crankcase Ventilation (PCV) system, 6-7
Positive Crankcase Ventilation (PCV) valve or Crankcase Ventilation
(CCV) hose check, cleaning and replacement, 1-32
Power brake booster, check, removal and installation, 9-16
Power door lock system, description and check, 12-8
Power steering fluid level, check, 1-12
Power steering pump, removal and installation, 10-12
Power steering system, bleeding, 10-13
Power window system, description and check, 12-8
R
Radiator grille, removal and installation, 11-3
Radiator, removal and installation, 3-3
Rear main oil seal installation, 2A-16,2B-11,2C-11,2D-26
Rear leaf spring bushing, check and replacement, 10-9
Rear leaf spring, removal and installation, 10-8
Rear shock absorber, removal and installation, 10-7
Rear stabilizer bar, removal and installation, 10-8
Relays, general information, 12-2
Repair operations possible with the engine in the iehicle
Four-cylinder engine, 2A-2
lnline six-cylinder engine, 2C-1
V6 engine, 2B-1
Rocker arm cover, removal and installation
Four-cylinder engine, 2A-3
lnline six-cylinder engine, 2C-2
V6 engine, 2B-1
Rocker arms and pushrods, removal, inspection and installation
Four-cylinder engine, 2A-4
lnline six-cylinder engine, 2C-2
V6 engine, 28-2
Rotor (brake), inspection, removal and installation, 9-7
Routine maintenance, 1-1
S
Safety, 0-20
Seatbelt check, 1-24
Seats, removal and installation, 11 -14
Self-diagnosis codes (1991 and later models) – description and
code retrieving, 6-19
Shock absorber – removal and installation
front, 10-4
rear, 10-7
Spare tire and jack check, 1-24
Spark plug replacement, 1-32
Spark plug wire check and replacement, 1-34
Stabilizer bar – removal and installation
front, 10-4
rear, 10-8
Starter
motor, removal and installation, 5-12
motor, testing in vehicle, 5-12
solenoid, removal and installation, 5-13
Starting system, general information and precautions, 5-12
Steering
check, 1-18
gear, removal and installation, 10-1 0
intermediate shaft, removal and installation, 10-1 0
knuckle, removal and installation, 10-6
linkage, inspection, removal and installation, 10-1 1
power steering system, bleeding, 10-1 3
pump, removal and installation, 10-12
wheel, removal and installation, 10-9
Suspension and steering systems, 10-1 through 10-14
Suspension, check, 1-18
Tailgate, removal and installation, 11-9
Temperature sending unit, check and replacement, 3-5
Thermostat, check and replacement, 3-2
Thermostatic Air Cleaner (TAC) (carburetor and TBI-equipped
vehicles, 6-10
Thermostatic air cleaner check, 1-22
Throttle body injection (TBI), component replacement, 4-14
Throttle body, removal and installation, 4-13
Throttle linkage inspection, 1-21
Timing chain and sprockets, inspection, removal and installation
Four-cylinder engine, 2A-12
lnline six-cylinder engine, 2C-8
V6 engine, 2B-8
Timing chain cover, removal and installation
Four-cylinder engine, 2A-11
lnline six-cylinder engine, 2C-7
V6 engine, 2B-7
Tire, checking, 1-10
Top Dead Center (TDC) for number one piston, locating
Four-cylinder engine, 2A-2
lnline six-cylinder engine, 2C-1
V6 engine, 28-1
Towing, 0-17
Track bar, removal and installation, 10-5
Transfer case, 7C-0 through 7C-7
general information, 7C-1
lubricant change, 1-28
lubricant level check, 1-19
overhaul, general information, 7C-2
removal and installation, 7C-1
shift linkage, adjustment, 7C-1
Transmission
automatic
band adjustment (three-speed transmission), 78-5
diagnosis, 7B-2
The Motor Manual Guy
Index
fluid and filter change, 1-27
fluid level check, 1-1 1
general information, 78-1
Neutral start switch – check, adjustment and replacement, 7B-5
removal and installation, 78-6
shift linkage, check and adjustment, 78-2
Throttle valve (W) linkage, adjustment, 78-3
manual
general information, 7A-1
lubricant, level check, 1-19
oil seal replacement, 7A-1
overhaul, general information, 7A-4
removal and installation, 7A-3
shift lever – removal and installation, 7A-2
Transmission mount, check and replacement, 7A-3
Trouble codes, retrieving
1991 and later models, 6-1 9
V6 engine, 6-16
Troubleshooting, 0-22
Tune-up and routine maintenance, 1-1 through 1-36
Tune-up, general information, 1-7
Turn signal and hazard flashers, check and replacement, 12-2
Turn signal switch, removal and installation, 12-3
Underhood hose check and replacement, 1-14
Universal joints, replacement, 8-10
Upholstery and carpets, maintenance, 11 -2
V6 engine, 28-0 through 28-13
Vacuum advance mechanism, check and replacement, 5-4
Valve cover – removal and installation
Four-cylinder engine, 2A-3
Inline six-cylinder engine, 2C-2
V6 engine, 28-1
Valve spring, retainer and seals, replacement
Four-cylinder engine, 2A-5
lnline six-cylinder engine, 2C-3
V6 engine, 28-3
Valves, servicing, 2D-10
Vehicle identification numbers, 0-7
Vibration damper, removal and installation
Four-cylinder engine, 2A-9
Inline six-cylinder engine, 2C-6
V6 engine, 2B-6
Vinyl trim, maintenance, 11 -2
Water pump
check, 3-6
replacement, 3-7
Wheel cylinder, removal, overhaul and installation, 9-11
Wheels and tires, general information, 10-13
Windshield
motors, removal and installation, 12-6
wiper blade inspection and replacement, 1-1
TABLE OF CONTENTS:
1989 Jeep XJ Cherokee & Comanche Service Manual – PDF DOWNLOAD
Introductory pages
About this manual 0-5
Introduction to the Jeep Cherokee and Comanche 0-5
Vehicle identification numbers 0-7
Buying parts 0-10
Maintenance techniques, tools and working facilities 0-10
Booster battery (jump) starting 0-17
Jacking and towing 0-17
Automotive chemicals and lubricants 0-19
Safety first! Q-20
Conversion factors 0-21
Troubleshooting 0-22
Chapter 1
Tune-up and routine maintenance 1-1
Chapter 2 Part A
Four-cylinder engine 24-1
Chapter 2 Part B
V6 engine 28-0
Chapter 2 Part C
Inline six-cylinder engine 2C-0
Chapter 2 Part D
General engine overhaul procedures 2D-0
Chapter 3
Cooling, heating and air conditioning systems
Chapter 4
Fuel and exhaust systems 4-0
Chapter 5
Engine electrical systems
Chapter 6
Emissions and englne control systems
Chapter 7 Part A
Manual transmission
Chapter 7 Part B
Automatic transmission
Chapter 7 Part C
Transfer case
Chapter 8
Clutch and drive train
Chapter 9
Brakes
Chapter 10
Suspension and steering systems
Chapter 11
Body
Chapter 12
Chassis electrical system
Wiring diagrams 12-9
Index IMD-1
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