1994 JEEP CHEROKEE Service Repair Manual by 1639849

GROUP TAB LOCATOR PAGE NOTE: Groups with the suffix “-S” are supplements to the original service manual publication.

IN 0 2 3 5 6 7 8 9 11 13 14 16 19 21 22 23 24 24-S 25

Introduction Lubrication and Maintenance Front Suspension and Axle Rear Suspension and Axles Brakes Clutch Cooling System Electrical Engines Exhaust System and Intake Manifold Frame and Bumpers Fuel System Propeller Shafts Steering Transmissions and Transfer Cases Wheels and Tires Body Components Heating and Air Conditioning Air Conditioning Emission Control Systems Index Index Supplement

Service Manual Comment Forms

(Rear of Manual)

INTRODUCTION

INTRODUCTION CONTENTS page

DESIGNATIONS, LABELS/PLATES, CODES AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . 1

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SPECIFICATIONS

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DESIGNATIONS, LABELS/PLATES, CODES AND DIMENSIONS INDEX page Engine and Transmission/Transfer Case Identification International Vehicle Control and Display Symbols Major Component Identification . . . . . . . . . . . . . . Tire Inflation Pressure Label . . . . . . . . . . . . . . . . Vehicle Code Plate . . . . . . . . . . . . . . . . . . . . . . .

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page Vehicle Vehicle Vehicle Vehicle Vehicle

Designations . . . . . . . . . . . . . . . Dimension Data . . . . . . . . . . . . Identification Number (VIN) Plate Load Data ................ Safety Certification Label .....

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VEHICLE DESIGNATIONS The Vehicle Designation Codes chart lists the vehicle description(s) and the corresponding vehicle designation code for each type of Jeept vehicle (Figs. 1, 2, and 3 ). The vehicle designation codes are different from the Vehicle Identification Number (VIN) or body-type/style codes.

VEHICLE DESIGNATION CODES

Fig. 1 YJ—Wrangler Multi-Purpose Vehicle (With Hard Top) • • • •

VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label (Fig. 4) is attached to each Jeept vehiclee. The label also lists the: • gross vehicle weight rating (GVWR) and the gross front and rear axle weight ratings (GAWR’s) based on a minimum tire rim size and a maximum cold tire inflation pressure;

month and year of vehicle manufacture; vehicle identification number (VIN); type of vehicle and month, day and hour (MDH) of final assembly. The label is located on the driver’s side door edge.

VEHICLE IDENTIFICATION NUMBER (VIN) PLATE The vehicle identification number (VIN) plate is attached to the top left side of the instrument panel at the base of the windshield. Each VIN contains 17 alpha-numerical characters. Refer to the decoding chart to determine the actual identification of a Jeept vehicle.

INTRODUCTION

Fig. 2 XJ—Cherokee 2-Door Multi-Purpose Vehicle

Fig. 4 Vehicle Safety Certification Label

VEHICLE CODE PLATE

Fig. 3 XJ—Cherokee 4-Door Multi-Purpose Vehicle

A metal vehicle code plate is attached to the left (driver) side of the dash panel in the engine compartment (Fig. 5). There can be a maximum of seven rows of vehicle information imprinted on the plate. The information should be read from left to right, starting with line 1 at the bottom of the plate up through line 7 (as applicable) at the top of the code plate. Refer to the decoding chart to decode lines 1 up through 3. Lines 4 through 7 (if used) on the vehicle code plate are imprinted on the plate (in sequence) according to the following: • 3-character sales code, • 3-digit numerical code, and • 6-digit SEC code.

VEHICLE IDENTIFICATION NUMBER (VIN) DECODING

INTRODUCTION

engine identification data. Refer to Group 21—Transmissions for all transmission/transfer case identification data.

MAJOR COMPONENT IDENTIFICATION When required, refer to the applicable service information group for major component identification data.

TIRE INFLATION PRESSURE LABEL The tire inflation pressures label is located on the glove box door inside panel (Fig. 6). The tires should also be inspected for visible wear. Also, inspect the tires for cracks, bulges and other road hazard damage. Refer to Group 22—Tires And Wheels.

VEHICLE DIMENSION DATA Fig. 5 Vehicle Code Plate

The vehicle dimension data charts list the exterior and interior dimensions for each type of Jeept vehicle.

VEHICLE CODE DECODING

If there is not enough space left in the row for all of the 6-digit SEC code (if used): • the unused space will remain blank, and • the code will be listed in the next row. The last nine positions of row 7 will contain a 2-digit code, when applicable, and a 6-digit gateline serial number (same as the last 6 numbers of the VIN). The last code imprinted on a vehicle code plate will be followed by the imprinted word END. When two vehicle code plates are required, the last available spaces on the first plate will be imprinted with the letters CTD (for continued). When a second vehicle code plate is necessary, the first four spaces on each row will not be used because of the plate overlap.

ENGINE AND TRANSMISSION/TRANSFER CASE IDENTIFICATION When required, refer to Group 9—Engines for all

Fig. 6 Tire Inflation Pressures Label—Typical

VEHICLE LOAD DATA The Vehicle Load Data chart lists the following information: • the gross vehicle weight rating (GVWR), • the gross axle weight ratings (GAWR), • the cargo weight, and • the passenger weight for each Jeept type/body style.

INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS Most of the graphic symbols illustrated in the following chart are used to identify various instrument controls and displays.

INTRODUCTION

J VEHICLE DIMENSION DATA

INTRODUCTION

J XJ VEHICLE LOAD DATA

INTRODUCTION

J YJ-VEHICLE LOAD DATA

INTRODUCTION

J VEHICLE CONTROL AND DISPLAY SYMBOLS

INTRODUCTION

J SPECIFICATIONS

SPECIFICATION NOTATIONS All torque specifications listed in this service manual are in both metric system and SAE/English system. WARNING: THE USE OF INCORRECT ATTACHING HARDWARE CAN RESULT IN COMPONENT DAMAGE AND/OR PERSONAL INJURY. During all procedures, it is important to retain the original attaching hardware. If the hardware is not reusable, replace new hardware with equivalent specifications.

METRIC SYSTEM NOTATION The following conversion chart will assist in converting SAE/English units to equivalent metric units.

TORQUE SPECIFICATIONS TORQUE CHARTS If applicable, torque chart(s) for screws, bolts and nuts is/are provided at the end of each service information group. Refer to the Standard Torque Specifications chart and the bolt grade/class identification illustrations (Figs. 7 and 8). It is important to be aware that the torque values listed in the chart are based on clean and dry bolt threads. Reduce the applicable listed torque value by 10 percent when the bolt threads are lubricated with engine oil and by 20 percent if new, plated bolts are being tightened.

Various sizes of (Torx) head fasteners are used as attaching hardware for numerous components in Jeept vehicles.

BOLT THREAD AND GRADE/CLASS IDENTIFICATION THREAD IDENTIFICATION SAE and metric bolt/nut threads are different. The difference is described in the Thread Notation chart. GRADE/CLASS IDENTIFICATION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. The grade identification is determined by the line marks on the top of each bolt head (Fig. 7). The actual bolt strength grade corresponds to the number of line marks plus 2. For example: • a grade 2 bolt has no line marks on top of the bolt head; • a grade 5 bolt has 3 line marks on top of the bolt head; • a grade 7 bolt has 5 line marks on top of the bolt head; and • a grade 8 bolt has 6 line marks on top of the bolt head. The most commonly used metric bolt strength classes are 9.8 and 12.9. The metric strength class identification number is imprinted on the head of the bolt (Fig. 8). The higher the class number, the greater the bolt strength. Some metric-dimension nuts are also imprinted with a single-digit strength class identification number on the nut face.

CONVERSION FORMULAS AND EQUIVALENT VALUES

INTRODUCTION

J STANDARD TORQUE VALUES

Fig. 7 SAE Bolt Grade Identification THREAD NOTATIONâ&#x20AC;&#x201D;SAE AND METRIC

Fig. 8 Metric Bolt Class Identification

INTRODUCTION

J TORQUE CONVERSION

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LUBRICATION AND MAINTENANCE

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LUBRICATION AND MAINTENANCE CONTENTS page

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CHASSIS AND BODY COMPONENTS . . . . . . . 30 DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . 13

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 JUMP STARTING, HOISTING AND TOWING . . 7 MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 5

GENERAL INFORMATION INDEX page Classification of Lubricants . . . . . . . Components Requiring No Lubrication Fluid Capacities ............... Fuel Requirements . . . . . . . . . . . . .

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INTRODUCTION Jeept lubrication and maintenance is divided into required and recommended service tasks. The recommendations and procedures listed in this group are intended for Jeept Dealer Service Personnel. Because conditions vary, it is necessary to schedule service tasks according to a time interval as well as a distance interval. It is the owner’s responsibility to have vehicle serviced. Owner is to pay for labor and necessary parts that are not covered by the warranty. Additional lubrication and maintenance information is listed in the Owner’s Manual, which is included with the vehicle.

SEVERE DRIVING CONDITIONS When a vehicle is subjected to a severe driving condition, time between recommended maintenance should be decreased. Refer to Engine Maintenance for the engine oil and filter maintenance interval when involved with a severe driving condition. A severe driving condition is defined as either: • frequent short trip driving less than 24 km (15 miles); • frequent driving in a dusty environment; • trailer towing; • extensive engine idling; • sustained high-speed operation; • desert operation; • frequent starting and stopping;

page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Recommended Lubricant and Replacement Parts . 3 Routine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 • cold-climate operation; • off-road driving; or • commercial service. To service a Jeept vehicle for a severe driving condition, change all the lubricating fluids and lubricate: • the body components, • all the driveline coupling joints, and • the steering linkage more often than for a normal driving condition to prevent excessive wear of the components. DUSTY AREAS Driving in an area with dust-filled air increases the risk of particles entering the engine and crankcase. With this type of severe driving condition, attention should be given to the engine and crankcase components. OFF-ROAD (4WD) OPERATION After completion of off-road (4WD) operation, the underside of the vehicle should be thoroughly inspected. Examine threaded fasteners for looseness. HARSH SURFACE ENVIRONMENTS After vehicle operation in a harsh surface environment, the following components should be inspected and cleaned as soon as possible: • brake drums, • brake linings, • front wheel bearings (2WD vehicles only), and • axle coupling joints. This will prevent wear and/or unpredictable brake action.

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LUBRICATION AND MAINTENANCE

ROUTINE SERVICE The following routine vehicle service is highly recommended on a monthly basis. TIRES—Inspect the tires for unusual wear/damage and determine if the inflation pressure is acceptable for the vehicle load. BATTERY—Inspect and clean the terminals. Tighten the terminals, if necessary. FLUIDS—Determine if the coolant, brake fluid, power steering, automatic transmission, and clutch fluid level are acceptable. Add fluid, if necessary. LIGHTS/ELECTRICAL—Test all the electrically operated systems in the vehicle for proper operation. It is also recommended that the engine oil level and the windshield washer fluid level be determined (and corrected) during each fuel fill-up.

FUEL REQUIREMENTS All Jeept engines require the use of unleaded gasoline. In addition, the fuel must have a minimum octane rating of 87. CAUTION: UNLEADED FUEL ONLY must be used in vehicles equipped with a catalyst emission control system. All vehicles have reminders printed on the instrument panel (Fig. 1) and on the fuel filler door (Fig. 2). Vehicles also have fuel filler tubes that are designed to accept only the small-diameter unleaded gasoline nozzles. It is illegal to defeat the design of an unleaded fuel filler tube.

Fig. 2 Unleaded Fuel Only Reminder—Fuel Filler Door • American Petroleum Institute (API), and • National Lubricating Grease Institute (NLGI).

ENGINE OIL SAE VISCOSITY GRADE An SAE viscosity grade is used to specify viscosity of engine oil. SAE 30 specifies a single viscosity engine oil. Engine oils also have multiple viscosities (Fig. 3).

CLASSIFICATION OF LUBRICANTS Lubricating fluids and chassis component lubricants are classified and graded according to standards recommended by the: • Society of Automotive Engineers (SAE),

Fig. 3 SAE Oil Viscosity Grade & API Service Grade The viscosity grade of an oil is an indicator of its thickness or flow capability. The lower the number, the better the flow. The second viscosity grade number (without a W suffix) is the warm/hot-temperature viscosity. The viscosity increases with engine temperature. With a single viscosity grade, the oil viscosity is valid only for one narrow temperature range.

Fig. 1 Unleaded Fuel Only Reminders—Fuel Gauge

LUBRICATION AND MAINTENANCE

J Above that temperature range the viscosity will decrease, and below that range the viscosity will increase. An engine oil with an SAE 5W-30 viscosity grade provides good flow capability for fast cold weather engine starts. The viscosity will then increase with engine temperature to provide good high-temperature engine lubrication.

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CHASSIS COMPONENT AND WHEEL BEARING LUBRICANTS The chassis component and wheel bearing lubricants are identified by the NLGI Certification Symbol (Fig. 5).

API SERVICE GRADE The API Service Grade specifies the type of engine/ operating conditions for which the oil is intended. The API Service Grade specifications also apply to energy conserving engine oils (Fig. 3). The API certification mark is also used indicating that the oil is certified to meet the most critical requirements established by the manufacturer (Fig. 4).

Fig. 5 NLGI Lubricant Certification/Identification Symbol The letter G indicates wheel bearing lubricant and the letter L indicates chassis lubricant. When the letters are combined the lubricant can be used for dual applications. The suffix letters C and B indicates quality level of the lubricant. Use only lubricants that display the NLGI Certification Symbol.

Fig. 4 The API Engine Oil Certification Mark For maximum protection, use API Service Grade SG, SG/CD or SG/CE engine oil in Jeept engines.

GEAR LUBRICANTS A dual SAE viscosity grade is also used to specify the viscosity of multipurpose gear lubricants. The API lubrication quality grade designation identifies gear lubricants in terms of recommended usage.

RECOMMENDED LUBRICANT AND REPLACEMENT PARTS Jeept vehicles are engineered to provide many years of dependable operation. When necessary, MOPAR brand lubricants and genuine replacement parts are highly recommended.

COMPONENTS REQUIRING NO LUBRICATION There are many components that should not be lubricated. The components that should not be lubricated are: • air pumps; • generator bearings; • drive belts; • drive belt idler pulleys; • rubber bushings; • starter motor bearings; • suspension strut bearings; • throttle control cables; • throttle linkage ball joints; and • water pump bearings.

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LUBRICATION AND MAINTENANCE FLUID CAPACITIES