1990 Jeep Service & Repair Manual

1 9 9 0 SERVICE MANUAL

Jeep ELECTRICAL SERVICE MANUAL 1990 JEEP VEHICLES To order the special service tools used and illustrated, please refer to the instructions on inside back cover. ^fe 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 © 1989 Jeep/Eagle Corporation 25M889

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 components or systems within the group. The Component and System Index, located at the back of this manual, 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, disas- sembly and assembly 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 manual located in the glove box. NOTE: FOR MECHANICAL INFORMATION, REFER TO THE "ENGINE, CHASSIS & BODY SERVICE MANUAL 59 - JEEP VEHICLES. GROUP TITLE — Introduction 8A Battery SB Storting System 8C Charging System 8P Ignition 8E Instrument Panel 8F iadio f Antenna & Speakers 8G Horns 8H Cruise Control 8J Multi-Function Switch & Hazard SEC Windshield Wipers & Washers 8L Lamps 8M Seat Belt Warning Systems 8N Rear Window Defogger 8P Power Door Locks 81 Power Seats 8S Power Windows ST Power Mirrors 8W Wiring Diagrams J901N-6

INTRODUCTION pu 70 13 INTRODUCTION 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 door pillar (driver's side). 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 specifications. The tire pressure specification sticker is located on the glove box door (Fig. 2). JEEP CHEROKEE. TIRE INFLATION PRESSURES p.s.i. inflatetirescoldbeforerunning DO NOT reduce pressure If tires are warm. Sf 8952 000 713 USA FULL «*«cyi. 10 AO pits/rsftis 30 m piH/KKi m to »tlf/7SRlf a» s® GLOVE BOX DOOR Fig. 2 Tire Inflation Pressures J891N-3 VEHICLE IDENTIFICATION NUMBER (WIN) The Vehicle Identification Number (VIN) is located on the left side of the instrument panel at the base of the windshield. All VIN's contain 17 characters in a com- bination of letters and numbers that provide specific information about the vehicle (Fig. 3). J89IN-2 Fig. 1 Safety Certification Labels

INTRODUCTION 3 Country 1= U.S. 2 = Canada Make J = Jeep Vehicle type 4 = MPV 6 = Incomplete 7 = Truck GVWR E = 3001-4000 F = 4001-5000 G = 5001-6000 H = 6001-7000 Line J = Cherokee - 4WD T = Cherokee-2WD N = Wagoneer - 4WD Y = Wrangler - 4WD S = Grand Wagoneer - J = Comanche - 4WD T = Comanche - 2WD 4WD 7 L Series 1 = "S" (E) 2 = Base (L) 3 = Pioneer/Islander (M) 4 = Sahara (H) 5 = Laredo/Grand (P) 6 = Eliminator (S) 7 = Limited (X) Engine E = 2.5 Litre, 1-4 L = 4.0 Litre, 1-6 T = 4.2 Litre, 1-6 7 = 5.9 Litre, V-8 Sequential Serial Number Six Digit Numbers z Check Digit Number or Letter Body 6 = 2-Dr. Pickup 7 = 2-Dr. Wagon 8 = 4-Dr. Wagon 9 = 2-Dr. Open Body L 000001 1 Plant Location J = Brampton L = Toledo #1 P = Toledo #2 J901N-3 Fig. 3 Vehicle Identification Number (VIN) BODY CODE PLATE A metal Body Code Plate is attached to the driver's side of the dash panel in the engine compartment (Fig. 4). There are up to seven (7) lines of information on this plate. Information reads from left to right, starting with line 1 at the bottom of the plate to line 7 at the top. Refer to the body code plate chart (lines 1 thru 3) for detailed information. PRIMARY SECONDARY PAINT PAINT VINYL ROOF CODE VEHICLE ORDER- NUMBER PAINT- (3) PROCEDURE (2) 0) XXX >XXXXX) X XXX xxxxxx xxx xxxx XXXX XXXX XXX VEHICLE MODEL •NUMBER ENGINE —CODE TRANSMISSION VEHICLE IDENTIFICATION CODE NUMBER MARKET U-C-B-M CODE Fig. 4 Body Code Plate INTERIOR TRIM CODE 90IN-3 Lines 4 thru 7, of the body code plate, are sequenced on the plate as follows: • 3 digit sales codes • 3 digit numeric codes • 6 digit SEC codes Line #1 Digits 1, 2, 3 Transmission Sales Code Digit 4 Open Space Digit 5 Market Code-U-C-B-M Digit 6 Open Space Digit 7 thru 23 Vehicle Identification Number Line #2 Digits 1, 2, 3 Paint Procedure Digit 4 Open Space Digits 5, 6, 7, 8 Primary Paint Digit 9 Open Space Digits 10, 11, 12, 13 Secondary Paint Digit 14 Open Space Digits 15, 16, 17, .18 Trim Code Digit 19 Open Space Digits 20, 21, 22 Engine Sales Code Digit 23 Open Space Line #3 Digits 1 thru 12 Vehicle Order Number Digit 13 Open Space Digits 14, 15, 16 Vinyl Roof Code (Door Combo Code— Pillette) Digit 17 Open Space Digits 18 thru 23 Model

When there is an SEC code to be punched on the body code plate and there is not enough room left on a line to punch the full 6 digits, the balance of that line will be left blank and the SEC code will be punched on the next line. The last nine positions of line #7 will contain a two digit species, when applicable, and a six digit gateline sequence number (the last six numbers of the VIN). The last code shown on either plate will be followed by END. When two plates are required, the last code space on the first plate will show CTD (for continued). When a second plate is required, the first four spaces of each line will not be used due to overlap of the plates. 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 cylinders. • 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 & 5th), and day (6th & 7th) of engine build (Fig. 5). EXAMPLE: 903MXO3 1st 2nd/3rd 4th/5th 6th/7th Digit Digit Digit Digit (Year) (Month) (Type) (Day) 7-1987 01-12 HX 01-31 8-1988 AAX 9-1989 CX 0-1990 NX Letter CID 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 1990 MODEL IDENTIFICATION CHART The Model Identification Chart identifies descriptive codes for all Jeep vehicles (Fig. 6). These codes are used in captions and references throughout this service manual. These Model codes are not to be confused with the Vehicle Identification Number (VIN) coding or other body style references. VEHICLE NAME MODEL GRAND WAGONEER - 4DR/4WD SJ COMANCHE (SHORT BED) - 4WD COMANCHE (SHORT BED) - 2 WD MJ COAAANCHE (LONG BED) - 4 WD COMANCHE (LONG BED) - 2WD CHEROKEE - 2DR/4WD CHEROKEE - 4DR/4WD CHEROKEE - 2DR/2WD XJ CHEROKEE - 4DR/2WD WAGONEER - 4DR/4WD WRANGLER - 4 WD YJ J901N-9 Fig. 6 Model Identification Chart J901N-8 Fig. 5 Engine Identification and Build Date Code

J INTRODUCTION 5 WHEEL TRACK OVERALL MODEL NAME MODEL BASE PRONT REAR LENGTH WIDTH HEI6TH cm/in cm/in cm/in Grand Wagoneer SJ 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) MJ 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) AAJ 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 58.0 179.3 71.7 63.8 Comanche (Long Bed) MJ 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 119.4 58.0 58.0 195.5 71.7 64.7 Comanche (Long Bed) MJ 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 XJ 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 XJ 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 XJ 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 XJ 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 XJ 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.d 58.0 165.3 70.5 63.4 Wrangler YJ 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 J901N-4 1990 EXTERIOR DIMENSIONS

6 INTRODUCTION 1990 INTERIOR DIMENSIONS MODEL MODEL HEAD FRONT REAR cm/(in) LEG FRONT REAR cm/(in) SHOULDER FRONT REAR cm/(in) HP FRONT REAR cm/(in) Grand Wagoneer SJ 94.2 93.5 37.1 36.8 102.9 94.0 40.5 37.0 148.1 148.1 58.3 58.3 153.7 154.7 60.5 60.9 Comanche (Short Bed) MJ 100.1 -- 39.4 - 109.2 — 43.0 - 140.5 55.3 - 140.5 55.3 - Comanche (Short Bed) MJ 100.1 - 39.4 ~ 109.2 « 43.0 - 140.5 - 55.3 « 140.5 - 55.3 -- Comanche (Long Bed) MJ 100.1 - 39.4 - 109.2 - 43.0 - 140.5 55.3 - 140.5 --. 55.3 « Comanche (Long Bed) MJ 100.1 - 39.4 - 109.2 - 43.0 140.5 55.3 140.5 -- 55.3 -- Cherokee XJ 97.3 96.5 38.3 38.0 105.7 89.7 41.6 35.3 139.7 140.2 55.0 55.2 140.5 113.0 55.3 44.5 Cherokee XJ 97.3 96.5 38.3 38.0 105.7 89.7 41.6 35.3 139.7 140.2 55.0 55.2 140.5 113.0 55.3 44.5 Wagoneer XJ 97.3 96.5 38.3 38.0 104.4 89.7 41.1 35.3 140.5 140.5 55.3 55.3 140.5 113.0 55.3 44.5 Cherokee XJ 97.3 96.5 38.3 38.0 105.7 89.7 41.6 35.3 139.7 140.2 55.0 55.2 140.5 113.0 55.3 44.5 Cherokee XJ 97.3 96.5 38.3 38.0 105.7 89.7 41.6 35.3 139.7 140.2 55.0 55.2 140.5 113.0 55.3 44.5 Wrangler (Hardtop) YJ 102.1 102.9 40.2 40.5 100.1 88.9 39.4 35.0 134.8 143.0 53.1 56.3 134.8 91.4 53.1 36.0 J901N-5

INTRODUCTION 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%when the threads are lubricated with engine oil and by 20%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. BOLT TORQUE BOLT SIZE GRADES N-m ft-lbs (in-lbs) GRADE 8 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 Fig. 7 Grade 5 and 8 Standard Torque Specifications METRIC THREAD AND GRADE IDENTIFICATION Metric and SAE thread notations differ slightly. The difference is illustrated in Fig. 8. INCH METRIC 5/16-18 M8 X 1.25 THREAD MAJOR DIAMETER IN INCHES NUMBER OF THREADS PER INCH THREAD MAJOR DIAMETER IN MILLIMETERS DISTANCE BETWEEN THREADS IN MILLIMETERS 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. METRIC BOLTS—IDENTIFICATION CLASS NUMBERS CORRESPOND TO BOLT STRENGTH— INCREASING NUMBERS REPRESENT INCREASING STRENGTH. J89IN-10 Fig. 9 Metric Bolt Identification 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. SAE CLASSIFICATION GRADE 5 GRADE 8 MARKINGS FOUND ON TOP OF BOLT HEAD INDICATE GRADE 120° 60° GRADE 2 GRADE 5 GRADE 8 (SAE) BOLTS—IDENTIFICATION MARKS CORRESPOND TO BOLT STRENGTH—INCREASING NUMBERS REPRESENT INCREASING STRENGTH. J89IN-11 Fig. 10 SAE Bolt Identification PR606B Fig. 8 Thread Notation (Metric and SAE)

1990 Jeep Service & Repair Manual

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