1994 Jeep Wrangler (YJ) Service & Repair Manual

CHRYSLER CORPORATION SERVICE MANUAL and SUPPLEMENT 1994 JEEP T To order the special service tools used and illustrated, please refer to the instructions on inside back cover. Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any ob- ligations upon itself to install them on its products previously manufactured. NEXT PAGE '

FOREWORD The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain general information, diagnosis, testing, adjustments, removal, installation, disassembly, and assembly procedures for the components. To as- sist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents section that lists major topics within the group. If you are not sure which Group contains the information you need, look up the Component/System in the alphabetical index located in the rear of this manual. A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler Corporation with your comments and suggestions. Tightening torques are provided as a specific value throughout this manual. This value represents the midpoint of the acceptable engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures using the correct OEM fasteners. When re- placing fasteners, always use the same type (part number) fastener as removed. Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation. NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in this manual may have changed from prior publications. These new terms are in compliance with S.A.E. recommended practice J1930. NEXT PAGE '

NOTE: Groups with the suffix “-S” are supplements to the original service manual publication. GROUP TAB LOCATOR PAGE IN Introduction 0 Lubrication and Maintenance 2 Front Suspension and Axle 3 Rear Suspension and Axles 5 Brakes 6 Clutch 7 Cooling System 8 Electrical 9 Engines 11 Exhaust System and Intake Manifold 13 Frame and Bumpers 14 Fuel System 16 Propeller Shafts 19 Steering 21 Transmissions and Transfer Cases 22 Wheels and Tires 23 Body Components 24 Heating and Air Conditioning 24-S Air Conditioning 25 Emission Control Systems Index Index Supplement Service Manual Comment Forms (Rear of Manual)

CHRYSLER CORPORATION SERVICE MANUAL 1994 JEEP T To order the special service tools used and illustrated, please refer to the instructions on inside back cover. NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, ME- CHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION. Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any ob- ligations upon itself to install them on its products previously manufactured. Litho in U.S.A. Copyright © 1993 Chrysler Corporation 20M1193

FOREWORD The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. This manual does not cover theory of operation, which is addressed in service training material. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. This manual is designed as a supplement to be used along with the 1994 Jeep Cherokee/Wrangler Service Manual, 81-370-4146. It includes information related to 1994 vehicles built after December, 1993. It should be used in conjunction with the initial manual for complete vehicle coverage. This contains general information, diagnosis, and testing procedures for the new R134a refrigerant system. The Component and System Index of th is manual identifies the correct page for the component or system to be serviced. In addition, a Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler Corporation with your comments and suggestions. Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair methods, or vehicle wiring at any time without prior notice or incurring obligation. HEATING AND AIR CONDITIONING 1 INDEX 1 Service Manual Comment Forms (Rear of Manual) NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in this manual may have changed from prior publications. These new terms are in compliance with S.A.E. recommended practice J1930.

INTRODUCTION CONTENTS page page DESIGNATIONS, LABELS/PLATES, CODES AND DIMENSIONS ..................... 1 SPECIFICATIONS ........................ 8 DESIGNATIONS, LABELS/PLATES, CODES AND DIMENSIONS INDEX page page Engine and Transmission/Transfer Case Identification .3 International Vehicle Control and Display Symbols .3 Major Component Identification ............... 3 Tire Inflation Pressure Label ................. 3 Vehicle Code Plate ........................ 2 Vehicle Designations ....................... 1 Vehicle Dimension Data .................... 3 Vehicle Identification Number (VIN) Plate ....... 1 Vehicle Load Data ........................ 3 Vehicle Safety Certification Label ............. 1 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 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 al- pha-numerical characters. Refer to the decoding chart to determine the actual identification of a Jeept vehicle. VEHICLE DESIGNATION CODES Fig. 1 YJ—Wrangler Multi-Purpose Vehicle (With Hard Top) J INTRODUCTION 1

VEHICLE CODE PLATE A metal vehicle code plate is attached to the left (driver) side of the dash panel in the engine compart- ment (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) accord- ing to the following: • 3-character sales code, • 3-digit numerical code, and • 6-digit SEC code. Fig. 2 XJ—Cherokee 2-Door Multi-Purpose Vehicle Fig. 3 XJ—Cherokee 4-Door Multi-Purpose Vehicle Fig. 4 Vehicle Safety Certification Label VEHICLE IDENTIFICATION NUMBER (VIN) DECODING 2 INTRODUCTION J

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 engine identification data. Refer to Group 21—Trans- missions 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 dam- age. Refer to Group 22—Tires And Wheels. VEHICLE DIMENSION DATA The vehicle dimension data charts list the exterior and interior dimensions for each type of Jeept vehicle. 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. Fig. 5 Vehicle Code Plate VEHICLE CODE DECODING Fig. 6 Tire Inflation Pressures Label—Typical J INTRODUCTION 3

VEHICLE DIMENSION DATA 4 INTRODUCTION J

1994 Jeep Wrangler (YJ) Service & Repair Manual

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