engine JEEP CHEROKEE 1988 Service Manual PDF
[x] Cancel search | Manufacturer: JEEP, Model Year: 1988, Model line: CHEROKEE, Model: JEEP CHEROKEE 1988Pages: 1378, PDF Size: 19.9 MB
Page 119 of 1378
are continually republished. In addition to these, standards for Drive
Train and Transmissions have recently been promulgated. Participating
shops utilize these Uniform Inspection & Communication Standards as
part of the inspection process and for communicating their findings to
their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
Page 136 of 1378
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Refer to manufacturer's diagnostic trouble code
procedure and require repair or replacement of
affected component(s).
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement. Check for accepted cleaning procedure.
( 4) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable.
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COOLANT
COOLANT INSPECTION \
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Condition Code Procedure
Acidity (pH) incorrect .. 1 ........... Suggest correction or
replacement.
Contaminated ............ B ...... ( 1) Require replacement or
recycling. Further
inspection required.
Level incorrect ......... B .......... ( 2) Require filling to
proper level.
Maintenance intervals ... 3 ........ ( 3) Suggest replacement.
Mixture incorrect ....... B ........... Require correction or
replacement.
Type incorrect .......... B ............ Require replacement.
( 1) - Determine source of contamination and require correction
prior to coolant replacement.
( 2) - Determine source of incorrect level and suggest repair.
( 3) - The system should be drained and/or flushed and
refilled with correct coolant according to OEM
recommended service interval and procedures.
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COOLING FAN BLADES
COOLING FAN BLADE INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Page 157 of 1378
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A/C S YSTE M D IA G NO SIS
1988 J e ep C hero ke e
1988 AIR CONDITIONING & HEAT
A/C General Servicing
Diagnostic Procedures
Jeep; All Models
DIAGNOSTIC PROCEDURES
Diagnosis is an important first step in A/C system servicing.
To save time and effort, systems should be carefully checked to
identify the causes of poor performance. By using the following
diagnostic charts, defective components or system damage can be
quickly located. To identify problems that are specific to one system,
refer to the repair section of this manual. The charts in this section
apply to all systems.
PREPARATION FOR TESTING
1) Attach Low and High side gauges.
2) Start engine and allow it to warm up.
3) Set system to COOL and blower to HIGH.
4) Open car doors and hood.
5) Run at fast idle for 2-3 minutes.
ALTITUDE PRESSURE VARIATIONS TABLE
ALTITUDE PRESSURE VARIATIONS TABLE \
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Altitude Absolute Gauge Altitude
(Ft.Above Pressure Of Correction
Sea Level) Atmosphere (psi) (1) (psi)
0 .......................... 14.7 .............................. 0
1000 ....................... 14.2 ............................ 0.5
2000 ....................... 13.7 ............................ 1.0
3000 ....................... 13.2 ............................ 1.5
4000 ....................... 12.7 ............................ 2.0
5000 ....................... 12.2 ............................ 2.5
6000 ....................... 11.7 ............................ 3.0
7000 ....................... 11.3 ............................ 3.4
8000 ....................... 10.9 ............................ 3.8
9000 ....................... 10.5 ............................ 4.2
10,000 ..................... 10.1 ............................ 4.6
( 1) - Add correction shown from gauge readings
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ALTITUDE VACUUM VARIATIONS TABLE
ALTITUDE VACUUM VARIATIONS TABLE \
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Altitude Complete Gauge Altitude
(Ft.Above Vacuum Correction
Sea Level) (In. Hg) (1) (In. Hg)
0 .......................... 29.92 ............................. 0
1000 ....................... 28.92 ........................... 1.0
Page 162 of 1378
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A/C S YSTE M G EN ER AL S ER VIC IN G
1988 J e ep C hero ke e
1988 AIR CONDITIONING & HEAT
A/C General Servicing
Diagnostic Procedures
Eagle & Jeep
* PLEASE READ THIS FIRST *
CAUTION: When discharging air conditioning system, use only approved
refrigerant recovery/recycling equipment. Make every attempt
to avoid discharging refrigerant into the atmosphere.
INTRODUCTION
This article is to be used for general service and diagnosis.
For specific repair or replacement procedures, use the appropriate
repair article in this section.
R-12 REFRIGERANT - SAFETY PRECAUTIONS
1) Always work in a well-ventilated, clean area. Refrigerant
(R-12) is heavier than oxygen, and will displace oxygen in a confined
area. Always wear eye protection when working around air conditioning
systems and R-12. The system's high pressure can cause severe injury
to eyes and skin if a hose were to burst. R-12 evaporates quickly
when exposed to atmosphere, freezing anything it contacts.
2) Use care when handling refrigerant containers. Do not
drop or strike containers. Do not expose refrigerant containers to
excessive heat. Containers must never be heated more than 125
F.
Never expose R-12 directly to open flame.
CAUTION: When R-12 is exposed to an open flame, drawn into a running
engine, or detected with a Halide (propane) leak tester,
poisonous phosgene gas is formed. Keep work areas
ventilated and keep vehicles with running engines away.
USING INDIVIDUAL R-12 CANS
Disposable refrigerant cans (referred to as one pound cans)
have a flat type seal or a screw type seal, and the proper can tap
must be used for each type. Be sure sealing gasket on can tap is in
good condition. A proper safety can tap will prevent refrigerant from
flowing back into open can, as the tap has a one-way flow control.
NOTE: Recent findings by the EPA indicate that R-11, R-12 and
R-113 are harmful to the Earths' protective Ozone layer.
Make every attempt possible, to avoid discharging R-11, R-12
or R-113 into the atmosphere.
USING MULTI-CAN DISPENSING VALVES
A multi-can dispensing valve allows the attachment of
several cans of refrigerant, and is a good substitute when a bulk
container is not available. Cans are installed onto each leg of the
multi-can dispensing valve in the same manner as the individual cans,
and each leg has its own can tap.
Page 163 of 1378
CAN TAP INSTALLATION
FLAT TYPE SEAL CANS
On cam-lock or one-piece can taps, first turn the handle out
to the fully open position. Securely engage the locking lugs over the
flange of the can, and lock them in place by turning the cam lock or
locking nut. Screw the tap assembly into the adapter so the sealing
gasket is fully seated against the can top. Turn the tap inward to
pierce the can and close the tap. DO NOT open the tap until ready to
purge the service hose or dispense refrigerant into the system.
On 2-piece can taps, be certain the tap handle is turned
fully in, so it is closed. Check that the locking base is turned to
its outer limit. Securely engage the locking lugs over the can
flange. Turn the entire tap assembly (without disturbing the closed
setting) down into the locking base to pierce the can. Do not open
the tap until ready to dispense into system.
SCREW TYPE SEAL CANS
Ensure can tap is fully closed. Screw refrigerant can into
can tap fitting until tight. This will pierce the can. Connect tap to
center hose on manifold gauge set. DO NOT open tap until ready to
dispense R-12 into system.
WARNING: DO NOT open high side hand valve while air conditioning
system is in operation. This high pressure could rupture
can or possibly burst fitting at safety can valve,
resulting in damage and physical injury.
COMPRESSOR OIL CHECK
GENERAL PROCEDURES
Some models have compressor-mounted service valves that allow
oil checking by isolating the compressor. On all others, system must
be discharged, using approved refrigerant recovery/recycling
equipment, and compressor may need to be removed to check oil. After
oil level is checked and adjusted, A/C system must be evacuated and
recharged.
ISOLATING COMPRESSOR
1) Connect manifold gauge set to service valves on the
compressor. Close both gauge valves. Open both service valves to
themid-position.
2) Start engine and operate air conditioning. Turn suction
service valve slowly clockwise toward front-seated position. When
suction pressure is reduced to zero or less, stop engine and quickly
close suction service valve (front-seated).
3) Front-seat the discharge valve. Loosen oil check plug
slowly to release any internal pressure. Service valves can now be
removed from compressor and compressor removed from vehicle (if
necessary). Purge compressor after servicing.
PURGING COMPRESSOR
1) Remove gauge set and place caps on service valve ports.
Back-seat the suction service valve to allow refrigerant to enter
compressor.
Page 165 of 1378
Information pertaining to Sanden compressors in this article,
will be found in earlier articles under Sankyo compressors.
AMERICAN MOTORS & JEEP WITH 5-CYLINDER COMPRESSOR
Compressor Overhaul
1) After the compressor and system have been run, stop the
engine. Slowly discharge system using approved refrigerant
recovery/recycling equipment. Clean and cool dipstick with R-12.
2) Loosen the compressor mounting bolts, remove the drive
belt, and move the compressor to a bench for easiest and most accurate
measurement. Position the compressor so that the oil fill plug is at
top dead center.
3) Thoroughly clean the oil fill plug and the area around it.
Loosen the fill plug slowly to allow trapped refrigerant pressure to
escape through the loosened threads.
4) The front plate hub has a lobe, which is indexed (notched)\
180
from TDC of the cam rotor. Rotate the hub plate lobe until the
index notch is 110 from bottom center. See Fig. 1. Check this
position by looking through the oil fill hole and noting that the ball
end of the top piston rod lines up with the fill hole.
5) Looking at the front end of the compressor, insert the
dipstick diagonally from upper left to lower left until the dipstick
stop contacts the filler hole surface. Remove dipstick and note oil
level. Oil level should be between the 4th and 6th increment on the
dipstick (3-4 ounces). Add oil as necessary.
Compressor Replacement
If system was opened by a leak or so quickly that oil was
lost, install new compressor with all the oil it contains. If system
was opened slowly and oil was not lost, drain oil from new compressor
and measure. Reinstall 6 ounces of oil back into new compressor prior
to installation.
Component Replacement
If a hose, receiver-drier, condenser, expansion valve or
evaporator core requires replacement, add 1 ounce of new oil for each
new component installed.
Compressor Oil Check
1) Discharge system, using approved refrigerant
recovery/recycling equipment, or isolate compressor. Remove oil filler
plug. Look through oil filler plug hole and rotate clutch front plate
to position piston connecting rod in center of oil filler plug hole.
2) Insert dipstick (J-29642-12) through oil filler plug hole\
to the right of piston connecting rod until dipstick stop contacts the
compressor housing.
3) Remove dipstick and count number of increments covered
with oil. If compressor is properly filled, oil will cover 4-6
increments on the dipstick. Adjust oil level as necessary.
Page 167 of 1378
Isolating Compressor
1) Connect manifold gauge set to service valves on
compressor. Close both gauge valves. Open both service valves to the
mid-position.
2) Start engine and operate air conditioning. Turn suction
service valve slowly clockwise toward front-seated position. When
suction pressure is reduced to zero or less, stop engine and quickly
close suction service valve (front-seated).
3) Front-seat the discharge valve. Loosen oil check plug
slowly to release any internal pressure. Service valves can now be
removed from compressor and compressor removed from vehicle (if
necessary). Purge compressor after servicing.
Purging Compressor
1) Remove gauge set and place caps on service valve ports.
Back-seat the suction service valve to allow refrigerant to enter
compressor.
2) Loosen discharge port valve slightly. Loosen valve port
cap to allow refrigerant to force out air from compressor. Back-seat
the discharge valve and tighten the port cap. Compressor is ready for
service.
Compressor Oil Check
1) Operate system for 10 minutes, then stop and isolate
compressor. Loosen filler plug slowly to release any pressure in
crankcase.
2) Use dipstick to check oil level. See Fig. 2. Add oil as
necessary. Install plug with new "O" ring. Purge compressor of air.
Fig. 2: York Compressor Oil Level Dipstick
Check oil with shaft keyway facing head.
SYSTEM SERVICING CAUTIONS
Page 169 of 1378
Fig. 3: Assembling Ford Spring-Coupling Fitting
3) Lubricate both sides of fitting with clean refrigeration
oil. Assemble the fitting by pushing together with a slight twisting
motion. Check to make sure spring is over flared end of female
fitting.
PLACING SYSTEM IN OPERATION
After component replacement and/or system servicing has been
completed and all connections have been made, proceed as follows:
1) Evacuate the system using vacuum pump.
2) Charge the system with R-12. See REFRIGERANT CAPACITY in
the A/C SYSTEM SERVICE SPECIFICATIONS in this article.
3) Leak test the system, with particular attention to all new
connections and components.
4) Make a performance test of the system. Never assume that a
recharging has automatically corrected a problem.
DIAGNOSTIC PROCEDURES
Diagnosis is an important first step in A/C system servicing.
To save time and effort, systems should be carefully checked to
identify the causes of poor performance. By using the following
diagnostic charts, defective components or system damage can be
quickly located. To identify problems that are specific to one system,
refer to the repair sections of this article. The charts in this
article apply to all systems.
PREPARATION FOR TESTING
1) Attach Low and High side gauges.
2) Start engine and allow it to warm up.
3) Set system to COOL and blower to HIGH.
4) Open car doors and hood.
5) Run at fast idle for 2-3 minutes.
Page 178 of 1378
During engine warm-up, temperature sensor switch applies
vacuum to vacuum motor. Air diverter valve is held to "ON" position.
Exhaust manifold heated air flows to air cleaner. As temperature of
incoming air increases to 90
F (32 C), temperature sensor opens
vacuum line to atmosphere allowing spring pressure to push valve to
"OFF" position. Air now flows from outside, through air cleaner duct
to carburetor.
AIR CLEANER TRAP DOOR
On California vehicles, spring-loaded trap door is built
into air cleaner to close off air cleaner when engine is shut off.
Door is vacuum operated.
REVERSE DELAY VALVE
Reverse delay valve is installed in vacuum line in some
vehicles to prevent trap door from closing during low engine vacuum
periods. Valve provides about 9 seconds delay before allowing trap
door to close.
Fig. 2: Cutaway View of Thermostatic Air Cleaner Assembly
Courtesy of Chrysler Motors.
Page 179 of 1378
TESTING
VACUUM MOTOR & TEMPERATURE SENSOR
1) Remove air cleaner assembly from vehicle and allow to
cool to room temperature. Look through air cleaner duct and observe
position of air diverter valve. It should be fully open to outside
air.
2) Reinstall assembly on carburetor and connect hot air duct
and manifold vacuum hose. Start engine and observe position of air
valve in snorkel. It should be fully closed to outside air.
3) Move throttle lever rapidly to 1/2 to 3/4 opening and
release. Air diverter valve should open and then close again. Allow
engine to warm to operating temperature and observe position of air
valve in snorkel. It should be fully open to outside air.
4) If valve does not move to fully close off outside air at
83
F (28 C) or less with vacuum applied, check for binding of duct,
vacuum leaks in hose connections or disconnected vacuum motor. If
valve mechanism operates freely and no vacuum leaks are detected,
connect hose from intake manifold vacuum source directly to vacuum
motor.
5) If air valve now moves to close off outside air, replace
thermal sensor switch. If valve still does not move to close off
outside air, replace air cleaner assembly and vacuum motor assembly.
TRAP DOOR
1) With engine off, remove air cleaner and check position of
trap door. It should be closed.
2) Remove vacuum hose from intake manifold vacuum source and
apply an external vacuum source of approximately 2-4 in. Hg vacuum.
Trap door should open.
3) If door does not open, apply vacuum directly to vacuum
motor. If door does not open, check for binding and adjust as
necessary. If door swings freely, replace vacuum motor.
4) If door opens during step 3), check vacuum hose for
blockage, cracks or leaks. Correct as necessary and retest as
specified in step 2).
5) If hoses are not defective, remove reverse delay valve,
join vacuum hose and retest from step 2). If door opens, replace
reverse delay valve.
REVERSE DELAY VALVE
1) Connect external vacuum source to port on White side of
delay valve. Connect one end of 24" (610 mm) section of rubber hose
to vacuum gauge and other end to port on colored side of valve.
2) With a constant 10 in. Hg vacuum applied, note time
required for vacuum gauge pointer to move from 0-8 in. Hg.