1979 Jeep Cj5 Renegade Service & Repair Manual

1979 SERVICE MANUAL

1979 JEEP TECHNICAL SERVICE MANUAL Maintenance | CHAPTERS 1A GENERAL SERVICE AND DIAGNOSIS 1B ENGINES 1C COOLING SYSTEMS 1D BATTERIES 1E CHARGING SYSTEM 1F STARTING SYSTEM 1G IGNITION SYSTEM 1H CRUISE COMMAND 1J FUEL SYSTEMS 1K EXHAUST SYSTEMS " 1L POWER PLANT INSTRUMENTATION 2E 2J 2K2L CHAPTERS 2A CLUTCH 2B MANUAL TRANSMISSION 2C AUTOMATIC TRANSMISSION 2D TRANSFER CASE 2E PROPELLER SHAFT 2F AXLES 2G BRAKES - 2H WHEELS AND TIRES 2J STEERING COLUMNS 2K MANUAL STEERING GEAR - 2L POWER STEERING GEAR AND PUMP 2M STEERING LINKAGE 2N SUSPENSION 3N 3C 3J 3A 3B 3D CHAPTERS 3A WATER LEAK/WIND NOISE DIAGNOSIS AND REPAIR 3B METAL REPAIR AND PAINTING 3C INSTRUMENT PANELS AND COMPONENTS 3D HEATER 3E AIR CONDITIONING 3F BODY AND FRAME COMPONENTS 3G HOODS 3H LIFTG ATES—TAILGATES 3J DOORS 3K REAR" QUARTER 3L LUGGAGE RACKS 3M SEAT ASSEMBLIES 3N WINDSHIELD-REAR WINDOW 3P HEADLINING - HARDTOP ENCLOSURE - EXTERIOR DECALS AND OVERLAYS 3R LIGHTING SYSTEMS 3S HORN SYSTEMS 3T WINDSHIELD WIPERS 3U TAILGATE WINDOW DEFOGGER 3V RADIO SOUND SYSTEMS Jeep Corporation Service Department Copyright ©1978 Jeep Corporation All Rights Reserved Litho in U.S.A. Alphabetical Index Vacuum Line Routing Diagrams Wiring Diagrams

mm mmm pip Page 1979 Model Jeep Vehicles A -3 Power Train Combinations—1979 CJ Models A-12 Conversion of English and Metric Measures A -10 Power Train Combinations— Decimal Equivalents A -14 1979 CherokN-Wagoneer-TncK Models A -12 General Dimensions A -13 Standard Torque Specifications ani Capscrew Markings A -2 How To Use This Manual A -1 Towing A -8 Keys and Locks A -7 Vehicle Identification A-6 Metric System—SI A -11 HOW TO USE THIS MANUAL Orgaiizatiei This manual is divided into three major sections: Sec- tion 1—Power Plant, Section 2—Chassis, and Section 3—Body. These sections are comprised of chapters per- taining to the section topic. The Section Index at the front of this manual has a locator tab for each section. The first page of each chapter in this manual contains a black tab in a position corresponding to the tab on the Chapter Index page for each section. To locate a desired chapter, simply fold back the manual slightly so that the outside edges of the pages are exposed. Find the black tab that aligns with the tab on the Chapter Index page and open to the desired chapter. Each chapter begins with an alphabetical index of subjects. Locate the desired subject and turn to the appropriate page. If the subject is broad, the chapter is divided into sections and a subject index of each section is also included. An alphabetical index of all subjects is located at the back of this manual. Each chapter ends with specifications, torque charts and special tools pertinent to that chapter. Warnings anl Gamins Detailed descriptions of standard workshop safety procedures are not included in this manual. This manual does contain WARNINGS for some service procedures that could cause personal injury, and CAUTIONS for some procedures that could damage the vehicle or its components. Please understand that these WARNINGS and CAUTIONS do not cover all conceivable ways which service might be done or all possible hazardous con- sequences of each conceivable way. Anyone using service procedures or tools (whether or not recommended by Jeep Corporation) must satisfy himself that neither personal nor vehicle safety will be jeopardized by the procedures or tools selected. Diagnosis And Repair Simplification (DAIS) Charts In several places throughout this manual, Jeep Corpo- ration's new Diagnosis and Repair Simplification (DARS) charts provide a graphic method of diagnosis and troubleshooting through the use of pictures and symbols. The DARS charts are different from the ones you have used before. They are not "go-no go" decision trees or tables. Cond ition Possible Cause Correction 80371 A Instead, the new DARS charts use pictures plus a few words to help you solve a problem. . . STEP SEQUENCE RESULT O CAUTION DO NOT TOU ANY OTHER <$>< OTHER IGNITION SYSTEM WIRES CHECK FOR FUEL SYSTEM OR MECHANICAL ENGINEPROBlEM 80371B

A-2 GENERAL INFORMATION and symbols and words help guide you through each step. .. CHECK CONNECT DISCONNECT REPAI R O R REPLACE 80371C A sequence could be checking pressure in all tires and inflating to specified pressures. If the problem is solved, the symbol @) will send you to @ . I f the problem is not solved, the symbol @) will send you through another sequence of checks which ends with a result and tells you the next step to go to. Work through each_step of the DARS charts until the system is repaired The charts are divided into three sections: step, sequence and result. Always start at the first step and go through the complete sequence from left to right. CONNECT VOLTMETER TO COIL POSITIVE TERMINAL AND TO GROUND TURN IGNITION ON CONNECT JUMPER BETWEEN COIL NEGATIVE TERMINAL AND GROUND VOLTAGE ABOVE UNCOUPLE AND 8 VOLTS COUPLE CONNECTORS AT CONTROL UNIT AND DISTRIBUTOR VOLTAGE BETWEEN 4.9 AND 7.9 VOLTS OiQ VOLTAGE DISCONNECT RADIO BELOW INTERFERENCE CONDENSER 4.8 VOLTS ' 8 -0 VOLTAGE BETWEEN 4.9 AND 7.9"' VOLTS REPLACE VOLTAGE CONDENSER BELOW 4.8 VOLTS © o © o Service Olaposis Charts You will also find Service Diagnosis Charts throughout this manual. These charts list causes of specific problems in descending order of probability. It is more likely that a problem would result from the first listed "possible cause" than the fourth, for instance. Visual inspection often leads directly to the correct solution. All service procedures should begin with a careful visual inspection of any suspected part assembly. or 80371D Torque Information Individual torque charts appear at the end of each chapter. Torque values are expressed two ways, Set-To and In-Use Recheck. The Set-To value is used when assembling components. The In-Use Recheck value is used to check pre-tightened items. Refer to the Standard Torque Specifications and Cap- screw Markings Chart in this chapter for torques not listed in individual torque charts. Note that torque specifications given in the chart are based on use of clean and dry threads. Reduce torque by 10 percent when threads are lubricated with engine oil and by 20 percent if new, plated capscrews are used. Standard Torque Specifications and Capscrew Markings Chart SAE GRADE 1 or 2 SAE GRADE 5 SAE GRADE 6 or 7 SAE GRADE 8 (Used Infrequently) (Used Frequently) (Used at Times) (Used Frequently) CAPSCREW BODY SIZE Torque Torque Torque Torque inches — Thread Ft-Lb Nm Ft-Lb Nm Ft-Lb Nm Ft-Lb Nm 1/4-20 5 6.7791 8 10.8465 10 13.5582 12 16.2698 -28 6 8.1349 10 13.5582 14 18.9815 5/16-18 11 14.9140 17 23 0489 19 25.7605 24 32.5396 -24 13 17.6256 19 25.7605 27 36 6071 3/8-16 18 24.4047 31 42.0304 34 46.0978 44 59.6560 -24 20 27.1164 35 47.4536 49 66.4351 7/16-14 28 37.9629 49 66.4351 55 74.5700 70 94.9073 -20 30 40.6745 55 74.5700 78 105.7538 1/2-13 39 52.8769 75 101.6863 85 115.2445 105 142.3609 -20 41 55.5885 85 115.2445 120 162.6960 9/16-12 51 69.1467 110 149.1380 120 162.6960 155 210.1490 -18 55 74.5700 120 162.6960 170 230.4860 5/8-11 83 112.5329 150 203.3700 167 226.4186 210 284.7180 -18 95 128.8027 170 230.4860 240 325.3920 3/4-10 105 142.3609 270 366.0660 280 379.6240 375 508.4250 -16 115 155.9170 295 399.9610 420 569.4360 7/8- 9 160 216.9280 395 535.5410 440 596.5520 605 820.2590 -14 175 237.2650 435 589.7730 675 915.1650 1- 8 235 318.6130 590 799.9220 660 894.8280 910 1233.7780 -14 250 338.9500 660 894.8280 990 1342.2420 CAPSCREW HEAD MARKINGS Manufacturer's marks may vary. Three-line markings on heads shown below, for example, indi- cate SAE Grade 5. SAE 1 or 2 SAE 5 SAE 6 or 7 SAE 8 70090

r -y • -: ~^mm • —Tare""~—: i^rz^zr^iZL '^aasr- Ton-lead Fasteners Various sizes of internal and external hex-lobular (Torx) head fasteners are used as attaching hardware on numerous components and assemblies in 1979 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. However, these fasteners may be removed or installed using Tool Set J -25359-02. Service manual liprof eients You are encouraged to report any errors, omissions, or recommendations for improving this publication. A form provided for this purpose is included at the end of this chapter. 197S MODEL JEEP VEHICLES GENERAL INFORMATION A-3 w '•mm^^^^^^^mm^^^ Fly .A -1 CJ -i Modal OJ Models Two CJ models are available for 1979: the 83.5-inch wheelbase CJ-5, model 83, and the 93.5-inch wheelbase CJ-7, model 93. See figures A-l and A-2. Beyond the 10- inch difference in wheelbase, CJ-5 and CJ-7 differ pri- marily in available options. CJ-7 models are available with an automatic transmission, Quadra-Trac full-time 4-wheel drive, and a molded hardtop. These options are not available on CJ-5 models. The Renegade Package continues to be offered on CJ models for 1979. It features new 9-inch by 15-inch tires mounted on 8-inch wide, styled-steel wheels along with unique exterior and interior trim. The Golden Eagle trim package continues to be available on 1979 CJ models. The package includes unique exterior paint and decals, 9-inch by 15-inch tires mounted on 8-inch wide, slotted-steel wheels, rear mounted spare tire, roll bar, and deluxe interior with a clock and tachometer. Refer to the Power Train Combinations Chart in this section for engine and transmission availability. Fig. A -2 CJ -7 Modal Cherokee Models For 1979, three Cherokee models are offered: the base 2-door model 16, the Wide Track model 17, and the 4- door model 18. See figures A-3, A-4, and A-5.

A-4 GENERAL INFORMATION % A-3 Cherokee Model 16 Fig. A-4 Cherokee Model 17 Fig. A-5 Cherokee Model 18 Wagoiieer Model For 1979, one Wagoneer model is offered: the model 15. The 4-door Wagoneer station wagon features deluxe interior trim and carpeting, chrome bumpers, power steering, and automatic transmission with Quadra-Trac full-time 4-wheel drive as standard. See figure A-6. A luxury trim package, the Limited, is offered. It features a leather and corduroy interior, unique exterior wood- grain with vinyl surround mouldings, and forged alumi- num wheels. Refer to the Powgr Train Combinations Chart in this section for engine availability. Truck Models Three Truck models are available in two series: the J- 10 Series model 25 and model 45 and the J-20 Series model 46. See figures A-7 and A-8. The 2-door model 16 is a dual purpose vehicle in the sports/utility class featuring an all-steel top, front disc brakes and fold-un rear seat as standard. The Wide Track model 17 features steel wheel opening extensions to accommodate 10-inch by 15-inch tires mounted on 8-inch wide, styled-steel wheels. The 4-door model 18 features the convenience of rear doors in a station wagon-type vehicle. The model 18 has the same grille and taillamps as other Cherokee models. Two trim packages are offered for 1979 Cherokee models. The 'S' package is available on all Cherokee models. The Chief package is available on the model 17. Both trim packages feature deluxe interior trim and carpeting, chrome bumpers, and unique exterior trim. Refer to the Power Train Combinations Chart in this section for engine and transmission availability.

GENERAL INFORMATION A-5 Fig A-6 Wagoneer Model 15 The J-10 differs from the J-20 Series in Gross Vehicle Weight (GVW) Ratings. For 1979, the J-10 Series GVW for models 25 and 45 has been increased to 6200 while the J-20 model 46 GVW remains at 6800 with optional GVW ratings of 7600 and 8400. Truck models are also identified by wheelbase. The model 25 has a 119-inch wheelbase; the model 45 and model 46 have a 131-inch wheelbase. The following chart outlines Truck differences by wheelbase and GVW rating. Truck Model Identification Series Model Number Wheelbase (Inches) Gross Vehicle Weight Rating Series Model Number Wheelbase (Inches) Standard Option 1 Option 2 J-10 25 119 6200 - - J-10 45 131 6200 - - J-20 46 131 6800 7600 8400 60532 Four trim packages are available on Truck models: Custom, Honcho, 10-4, and Golden Eagle. The Custom package is available on all Trucks and features deluxe interior and exterior trim. The Honcho package is only available on model 25 and features denim interior, unique exterior trim, and 10-inch by 15-inch tires mounted on 8-inch wide, styled-steel wheels. The 10-4 package features unique exterior decals. The Golden Eagle trim package is available on 1979 J- 10 Truck models. The package includes unique exterior paint and decals, 10-inch by 15-inch tires mounted on 8- inch wide, slotted-steel wheels, tubular steel grille guard, rear step bumper, off-road driving lamps and deluxe interior. Refer to the Power Train Combinations Chart in this section for engine and transmission availability. F5g. A-7 J -10 Truck Model 25 Fig. A-8 J-20 Truck Model 46

A-6 GENERAL INFORMATION VEHICLE IDENTIFICATION Vehicle Identification Plate A metal vehicle identification plate is affixed to the left-hand side of the dash panel under the hood (fig. A- 9). The plate shows the Sales Order Number; the Vehicle Identification Number (VIN); Special Sales Request & Order (SSR&O) Number; Paint Option Number; Trim Option Number; and the Jeep Model Number. Vehicle Identification Number (VIN) All Vehicle Identification Numbers contain 13 charac- ters in a combination of letters and numbers that provide specific information about the vehicle. VIN's for all Jeep vehicles can be decoded using the following chart. Special Sales Request and Order (SSR&O) Number Certain Jeep vehicles are built to special order with other than standard parts or equipment. To assist the O JEEP CORP. TOLEDO, OH USA Sales Order N SSR & 0 No • Paint Trim Option No. Option No. Vehicle Identification (VIN) Number Jeep Model No. o 60534 * Disregard — for factory use only Fig. A-9 Vehicle identification Plate dealer in ordering correct replacement parts, an SSR&O number is assigned and a permanent record of the devia- tion is maintained by the factory. The SSR&O number is embossed on the Vehicle Identification Plate as shown in figure A-9. Parts ordering procedure for SSR&O parts is detailed in the Jeep Parts Catalog. VIN Decoding Chart Transmission Jeep A - Auto F — 3-Speed M — 4-Speed Model WB (in) 15—Wagoneer—4-Door Station Wagon 109 16—Cherokee—2-Door Station Wagon 109 17—Cherokee—Wide Track 2-Door Station Wagon 109 18—Cherokee—4-Door Station Wagon 109 25-Truck-J-IO 119 45-Truck-J-IO 131 46-Truck-J-20 131 83-CJ-5 83 93-CJ-7 93 Gross Vehicle Weight Rating GVW/Model A 3750 83, 93 E 4150 83, N -6200 15 P-6800 46 S-7600 46 Y-8400 46 93 HD 16, 17, 18, 25, 45 Plant of Manufacture and Serial No. 000.001 - 699,999 Toledo Built 700.001 - 999,999 tampion Built 000001 Engine C 258 CID, Six, 2-V H 304 CID, V-8, 2V N- -360 CID, V-8, 2-V

GENERAL INFORMATION A-7 Paint Option Number The Paint Option Number is embossed on the Vehicle Identification Plate in the location shown in figure A-9. Paint is not available from the factory. All colors shown below are available from Ditzler or Du Pont paint jobbers by requesting the paint intermix formula. All colors are available from Sherwin-Williams in factory package cans. Option No. 999 indicates special paint. To obtain information on special paint, contact your Jeep Parts Distribution Center and provide the Vehicle Iden- tification Number (VIN). Paint Option Numbers Paint Option Number Color P1 Classic Black 6P Firecracker Red 9A Alpaca Brown Metallic 9B Olympic White 9C Russet Metallic 9E Wedgewood Blue 9H Cumberland Green Metallic 9J Arrowhead Silver Metallic 9K Sable Brown Metallic 9L Saxon Yellow 9N Morocco Buff 9P Bordeaux Metallic 9T Ensign Blue 9W Mandarin Orange 80379 Trim Option Number The Trim Option Number is embossed on the Vehicle Identification Plate as shown in figure A-9. Consult your Jeep Parts Catalog for trim ordering procedure. Special trim is indicated by trim option number 999. To obtain information on special trim, contact your Jeep Parts Distribution Center and provide the Vehicle Identi- fication Number (VIN). Safety Certification Sticker A safety sticker is placed on all vehicles to show that they meet federal motor vehicle safety certification standards (fig. A-10). It lists the VIN, month and year built, Gross Vehicle Weight Rating (GVWR), and Gross Axle Weight Rating (GAWR). The sticker is placed on the instrument panel on CJ-5 and CJ-7 models. On Cherokee-Wagoneer-Truck models, it is on the door lock pillar on the driver's side. DATE GVWR: -RAIN.TIRE SIZE GAWR. FRT. MIN. TIRE SIZE M GAWR. RR. MIN. TIRE SIZE MAX. COLD TIRE PRESS. FRT. RR. RIM SIZE 1 VEHICLE NUMBER I TYPE Fig, Safety Sticker 80384 KEYS AND LOOKS Two square-headed and two oval-headed keys are provided, as applicable, with each vehicle. The square- headed (code D) key operates the ignition switch, front door locks, and and Cherokee-Wagoneer tailgates. The oval-headed (code E) key operates the glove box lock. Each key has a code number stamped on the knock-out plug. In the event a key is lost, a new key can be made by converting the key code number to a key bitting number. Key bitting numbers can be obtained from a key cutting machine manufacturer's cross-reference list or by con- tacting your Zone office. If a key is lost and the key code number is unknown, the correct number can be identified by the Zone office from the vehicle identification number. If the ignition key is lost and the key code number is not available, a new key can be made by removing a door lock and taking it to a locksmith. The locksmith can determine the key bitting by inserting a blank key into the lock cylinder and cutting the blank to match the tumblers. If the ignition switch lock is defective and the key is available, the cylinder and individual tumblers can be ordered and matched to the existing key. To determine the tumbler arrangement, place the key over the template (fig. A-ll). Starting from the left, read across the horizontal lines and record first digit (number 1 position) of the key code. Continue this process for sub- sequent numbers 2 through 5. NOTE: The template shown in figure A-ll may be used to determine the key bitting code of a key for which the key code number is unknown. POSITIONS 12345 f P — ^ i— ^ 12 3 4 5 KEY CODES 41049 Fig. A-11 Key Coding Template

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1979 Jeep Cj5 Renegade Service & Repair Manual

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