1989 Jeep Wrangler (YJ) Service & Repair Manual
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Jeep
ENGINE, CHASSIS, AND BODY
SERVICE MANUAL
1989 JEEP VEHICLES
To order the special service tools used and illus-
trated, please refer to the instructions on inside
back cover.
^CHRYSLER
W MOTORS
SERVICE & PARTS
OPERATIONS
NO PART OF THIS PUBLICATION MAY BE RE-
PRODUCED, STORED IN A RETRIEVAL SYS-
TEM, OR TRANSMITTED, IN ANY FORM OR
BY ANY MEANS, ELECTRONIC, MECHANI-
CAL, PHOTOCOPYING, RECORDING, OR
OTHERWISE, WITHOUT THE PRIOR WRIT-
TEN PERMISSION OF CHRYSLER MOTORS.
Jeep/Eagle reserves the right to make changes In design or to make additions
to or improvements in its products without imposing any obligations upon itself
to install them on its products previously manufactured.
Litho in U.S.A. Copyright © 1988 Jeep/Eagle Corporation 25M888
FOREWORD
The information contained in this service manual has
been prepared for the professional automotive techni-
cian involved in daily repair operations. Information in
this manual is divided into groups. Each group covers
a general vehicle system (brakes, steering, body, etc.).
Each group is further divided to address individual com-
ponents or systems within the group.
The Component and System Index will assist you in
locating the correct group for the component or system
you require.
These groups contain general information, diagnosis,
testing, adjustment, removal and installation, assem-
bly and disassembly procedures for the components.
The diagnosis charts are designed to help you locate
and correct problems with a systematic approach. The
tab locator at the right side of this page will help you
quickly locate the first page of each group. The first
page of each group contains an alphabetical index to
assist in the location of the component or system.
The information, description, testing procedures and
specifications were in effect at the time this manual was
released for printing.
Chrysler Motors reserves the right to change testing
procedures, specifications, diagnosis, or repair methods
at any time without prior notice or incurring obligation.
The information describing the operation and use of
standard and optional equipment is included in the
Operating Instructions and Product Information man-
ual located in the glove box.
NOTE: FOR ELECTRICAL INFORMATION, REFER
TO THE “ELECTRICAL SERVICE MANUAL” -
JEEP VEHICLES.
GROUP TITLE INDEX
— INTRODUCTION
■? * '- 1
0 LUBRICATION AND MAINTENANCE
m m
1 ACCESSORIES
■ , ■
2 FRONT SUSPENSION
m m
3 REAR AXLE
■
5 BRAKES
m m
6 CLUTCH
m m
7 COOLING SYSTEM
9 ENGINE
11 EXHAUST/INTAKE MANIFOLD
m s *
13 FRAME
m m
14 FUEL SYSTEM
16
PROPELLER SHAFT AND
UNIVERSAL JOINTS
17 SPRINGS—SHOCK ABSORBERS
19 STEERING
m m m
21 TRANSMISSION
" ,
**
__________________________________________________________________________________________ it__
22 WHEELS AND TIRES
23 BODY
m i
24 HEATING AND AIR-CONDITIONING
1 1
25 EMISSIONS CONTROL SYSTEMS
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VEHICLE SAFETY CERTIFICATION LABELS
A safety certification label (Fig. 1) is attached to all
vehicles to certify that they conform to Federal motor
vehicle safety certificate standards. The label lists the
month and year of manufacture, gross vehicle weight
rating (GVWR) and gross axle weight rating (GAWR).
The label is located on the driver side door pillar.
TIRE INFLATION LABEL
Check the tires for visible signs of wear which may
indicate underinflation or a need for front-end align -
ment, tire rotation or wheel balancing. Also check for
bulging, cracks or other road hazard damage. Check
and adjust the inflation pressures according to the spec-
ifications listed in the tire pressure sticker on the glove
box door (Fig. 2).
JiEP CHEROKEE
TIRE INFLATION
PRESSURES p.t.l.
inflate tirt&cottf Mo**ntnm§
OO NOT rgO itcopr*ft8U7»If
ruiucm-
« m* mmmm IIIO**.
m* • 490*» *#•»<#
4 s®eyi,
1*9See
PlM/TSHli
*wm/nn®
*tl«/TSfll«
FUU
LOAD
Haar
10 S8
J® M
sf m
SF 8952 000 713
«6»
nt»/M O t« (SfM ) CO * t . l .
GLOVE BOX
DOOR
Fig. 2 Tire inflation Pressures
J891N-3
VEHICLE IDENTIFICATION NUMBER (VIN)
The Vehicle Identification Number (VIN) is located
on the left side of the instrument panel at the base of the
windshield. All VENPs contain 17 characters in a com-
bination of letters and numbers that provide specific
information about the vehicle (Fig. 3).
VEHICLE IDENTIFICATION PLATE
A metal Vehicle Identification Plate (Fig. 4) is at-
tached to the driver’s side of the radiator support in the
engine compartment.
The plate contains codes for the following items:
• Vehicle Identification Number (VIN).
• Order Number.
• Fabrication (FAB) Sequence Number.
• Center Armrest.
• Trim Package.
• Flipper Window.
• Roof Rack.
• Outside Mirror.
• Trailer Towing Package.
• Sun Roof.
• Export Package.
• Swing Away Spare Tire.
• Emission Certification.
• Paint.
• Paint Gun.
• Trim.
J89IN-5
Fig. 4 Vehicle Identification Plate
ENGINE BUILD DATE CODE
The engine Build Date Code is located:
• 2.5L Engine - On a machined surface on the right side
of the cylinder block between the No. 3 and No. 4 cyl-
inders.
• 4.0L and 4.2L Engines - On a machined surface on the
right side of the cylinder block between the No. 2 and
No. 3 cylinders.
• 5.9L Engine - On a plate attached to the right bank
cylinder head cover.
The digits of the code identify the year (1st), month
(2nd & 3rd), engine type/fuel system/compression ratio
(4th), and day (5th & 6th) of engine build (Fig. 5).
Engines built for sale in Georgia and Tennessee have
an additional, nonrepeating number, located on the
right side of the engine above the build date code (Fig.
6).
EXAMPLE: 9 0 3 M X 0 3
1st 2nd/3rd 4th 5th/6th
Digit Digit Digit Digit
(Year) Pont h) (type) (Day)
7-1987 01-12 HX 01-31
8-1988 MX
9-1989 CX
NX
Letter C1D Fuel Comp.
Code Liter System Ratio
HX 150-2.5L TBI 9.2:1
MX 243-4.0L MPI 8.8:1
CX 258-4.2L 2V 9.2:1
NX 360-5.9L 2V 8.25:1
J8909-6
Fig. 5 Engine Identification and Build Date Code
GEORGIA &
TENNESSEE
J8909-53
Fig. 6 Engines Built for Georgia and Tennessee
1989 SERIES IDENTIFICATION CHART
VEHICLE NAME DESCRIPTION
MODEL
CODE
SERIES
CODE
GRAND WAGONEER 4 Door 4 Wheel Drive 15
10
COMANCHE (SHORT BED) 2 Door 4 Wheel Drive 63
60
COMANCHE (SHORT BED) 2 Door 2 Wheel Drive 64
COMANCHE (LONG BED) 2 Door 4 Wheel Drive 65
COMANCHE (LONG BED) 2 Door 2 Wheel Drive 66
CHEROKEE 2 Door 2 Wheel Drive 73
70
CHEROKEE 4 Door 2 Wheel Dr ive 74
WAGONEER 4 Door 4 Wheel Drive 75
CHEROKEE 2 Door 4 Wheel Drive 77
CHEROKEE 4 Door 4 Wheel Drive 78
WRANGLER 2 Door 4 Wheel Drive 81
80
J891N-6
The Series Identification Chart identifies descriptive to describe types and models. These Series codes are not
codes for all Jeep vehicles. These codes are used in to be confused with the Vehicle Identification Number
captions and references throughout this service manual (VIN) coding or other body style references.
1989 MAJOR DIMENSIONS
MODEL NAME MODEL
WHEEL
BASE
cm/in
TRACK
FRONT REAR
cm/in
LENGTH
OVERALL
WIDTH
cm/in
HEIGTH
Grand Wagoneer 15 276.1 150.9 146.8 473.5 190.0 168.7
4 DR-4 WD 108.7 59.4 57.8 186.4 74.8 66.4
Comanche (Short Bed) 63 286.8 144.8 144.8 455.2 182.2 164.4
2 DR-4 WD/6" Wheels 112.9 57.0 57.0 179.3 71.7 64.7
(Short Bed) 286.8 147.3 147.3 455.2 182.2 164.4
7" Wheels 112.9 58.0 58.0 179.3 71.7 64.7
Comanche (Short Bed) 64 287.3 144.8 144.8 455.2 182.2 162.1
2 DR-2 WD/6" Wheels 113.1 57.0 57.0 179.3 71.7 63.8
(Short Bed) 287.3 147.3 146.3 455.2 182.2 162.1
7" Wheels 113.1 58.0 58.0 179.3 71.7 63.8
Comanche (Long Bed) 65 303.3 144.8 144.8 496.6 182.2 164.4
2 DR-4 WD/6" Wheels 119.4 58.0 58.0 195.5 71.7 64.7
(Long Bed)
303.3 144.8 144.8 496.6 182.2 164.4
7" Wheels 1194 58.0 58.0 195.5 71.7 64.7
Comanche (Long Bed) 66
303.8
144.8 144.8 496.6 182.2 162.1
2 DR-2 WD/6" Wheels
119.6
58.0 58.0 195.5 71.7 63.8
(Long Bed)
303.8
144.8 144.8 496.6 182.2 162.1
7" Wheels
119.6
58.0 58.0 195.5 71.7 63.8
Cherokee-6" Wheels 73 257.6 144.8 144.8
420.0 179.1 161.0
2 DR-2 WD 101.4 58.0 58.0
165.3 70.5 63.4
7" Wheels 257.6 144.8 144.8 420.0 179.1 161.0
101.4 58.0 58.0 165.3 70.5 63.4
Cherokee-6" Wheels 74
257.6 144.8 144.8 420.0 179.1 161.0
4 DR-2 WD 101.4 57.0 57.0 165.3 70.5 63.4
7" Wheels 257.6 147.3 147.3 420.0 179.1 161.0
101.4 58.0 58.0 165.3 70.5 63.4
Wagoneer 75 257.6 147.3 147.3 420.0 179.1 161.5
4 DR-4 WD 101.4 58.0 58.0 165.3 70.5 63.6
Cherokee-6" Wheels 77 257.6 144.8 144.8 420.0 179.1 161.0
2 DR-4 WD 101.4 57.0 57.0 165.3 70.5 63.4
7" Wheels 257.6 147.3 147.3 420.0 179.1 161.0
101.4 58.0 58.0 165.3 70.5 63.4
Cherokee-6" Wheels 78 257.6 144.8 144.8 420.0 179.1 161.0
4 DR-4 WD 101.4 57.0 57.0 165.3 70.5 63.4
7" Wheels 257.6 147.3 147.3 420.0 179.1 161.0
101.4 58.0 58.0 165.3 70.5 63.4
Wrangler 81 237.2 147.3 147.3 387.6 167.6 176.5
2 DR-4 WD/Hardtop 93.4 58.0 58.0 152.6 66.0 69.5
1989 MAJOR DIMENSIONS
MODEL MODEL
HEAD
FRONT REAR
cm/(iit)
LEG
FRONT REAR
cm/fin)
SHOULDER
FRONT REAR
cm/(in)
HIP
FRONT REAR
cm/(in)
Grand 15 94.2 93.5 102.9 94.0 148.1 148.1 153.7 154.7
Wagoneer 37.1 36.8 40.5 37.0 58.3 58.3 60.5 60.9
Comanche 63 100.1
..
109.2 140.5 140.5
(Short Bed) 39.4 — 43.0
—
55.3 -- 55.3
—
Comanche 64 100.1
_
109.2
..
140.5
..
140.5
(Short Bed) 39.4 — 43.0 — 55.3 -- 55.3 —
Comanche 65 100.1
_
109.2
_
140.5
_
140.5
__
(Long Bed) 39.4
--
43.0 — 55.3 -- 55.3 —
Comanche 66 100.1
_
109.2
_
140.5
_
140.5
..
(Long Bed) 39.4 — 43.0 -- 55.3 -- 55.3 --
Cherokee 73 97.3 96.5 105.7 89.7 139.7 140.2 140.5 113.0
i
38.3 38.0 41.6 35.3 55.0 55.2 55.3 44.5
Cherokee 74 97.3 96.5 105.7 89.7 139.7 140.2 140.5 113.0
38.3 38.0 41.6 35.3 55.0 55.2 55.3 44.5
Wagoneer 75 97.3 96.5 104.4 89.7 140.5 140.5 140.5 113.0
38.3 38.0 41.1 35.3 55.3 55.3 55.3 44.5
Cherokee 77 97.3 96.5 105.7 89.7 139.7 140.2 140.5 113.0
38.3 38.0 41.6 35.3 55.0 55.2 55.3 44.5
Cherokee 78 97.3 96.5 105.7 89.7 139.7 140.2 140.5 113.0
38.3 38.0 41.6 35.3 55.0 55.2 55.3 44.5
Wrangler 81 102.1 102.9 100.1 88.9 134.8 143.0 134.8 91.4
(Hardtop) 40.2 40.5 39.4 35.0 53.1 56.3 53.1 36.0
TORQUE REFERENCES
Individual Torque Charts appear at the end of many
Groups. Refer to the Standard Torque Specifications
and Bolt Identification Chart in this Group for torques
not listed in the individual torque charts (Fig. 7).
Note that the torque specifications given in the chart
are based on the use of clean and dry threads. Reduce
the torque by 10 percent when the threads are lubri-
cated with engine oil and by 20 percent if new plated
bolts are used.
Various sizes of internal and external hex-lob-
ular (Torx) head fasteners are used as attaching
hardware on numerous components and assem-
blies in Jeep vehicles. Due to the ever-changing
usage and application of automotive fasteners,
Torx-head fasteners may not be identified as such
throughout this manual.
METRIC THREAD AND GRADE IDENTIFICATION
Metric and SAE thread notations differ slightly. The
difference is illustrated in Fig. 8.
Common metric fastener strength property classes
are 9.8 and 12.9 with the class identification embossed
on the head of each bolt (Fig. 9). Some metric nuts will
be marked with single digit strength identification
numbers on the nut face.
SAE strength classes range from grade 2 to 8 with line
identification embossed on each bolt head. Markings
corresponding to two lines less than the actual grade
(Fig. 10). For Example - Grade 7 bolt will exhibit 5
embossed lines on the bolt head.
INCH
5/16-18
METRIC
MS X 1.25
THREAD
MAJOR
DIAMETER
IN INCHES
NUMBER
OF
THREADS
PER INCH
THREAD DISTANCE
MAJOR BETWEEN
DIAMETER IN THREADS IN
MILLIMETERS MILLIMETERS
PR6Q6B
Fig. 8 Thread Notation (Metric and SAE)
METRIC BOLTS— IDENTIFICATION CLASS NUMBERS
CORRESPOND TO BOLT STRENGTH— INCREASING NUMBERS
REPRESENT INCREASING STRENGTH. J89IN-10
Fig.9 Metric Bolt identification
BOLT TORQUE
BOLT
SIZE
©RADI 5
M°m ft-lbs
(in-lbs)
GRADES
N»m ft-lbs
(in-lbs)
1/4-20 11 (95) 14 (125)
1/4-28 11 (95) 17 (150)
5/16-18 23 (200) 31 (270)
5/16-24 27 20 34 25
3/8-16 41 30 54 40
3/8-24 48 35 61 45
7/16-14 68 50 88 65
7/16-20 75 55 95 70
1/2-13 102 75 136 100
1/2-20 115 85 149 110
9/16-12 142 105 183 135
9/16-18 156 115 203 150
5/8-11 203 150 264 195
5/8-18 217 160 285 210
3/4-16 237 175 305 225
J89IN-9
SAE CLASSIFICATION
GRADE 5 GRADE 8
120°
MARKINGS FOUND
ON TOP OF BOLT
HEAD INDICATE
GRADE
fC T >
l^ p J
60°
^^RADE^
(SAE) BOLTS—IDENTIFICATION MARKS CORRESPOND
TO BOLT STRENGTH— INCREASING NUMBERS
REPRESENT INCREASING STRENGTH.
J89IN-11
Fig. 7 Grade 5 and 8 Standard Torque
Specifications
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Fixing problems on your 1989 Jeep Wrangler (YJ) is made easier with this comprehensive repair manual. It includes troubleshooting and replacement procedures, step-by-step instructions, clear images, and exploded-view illustrations. Whether you're a professional mechanic or a DIY enthusiast, this manual provides the manufacturer's recommended charts and procedures to help you maintain and repair your vehicle, saving on costs and increasing reliability.
The manual is available in .pdf format, making it accessible and printable on various electronic devices, including PC, Mac, Android, and Apple devices. It's a valuable resource for keeping your Jeep Wrangler in top condition.
