Jeep Cherokee & Comanche 1984–1993 OEM Service Manual

• Covers 1984–1993 Jeep Cherokee and Comanche models equipped with 2.5L four-cylinder, 2.8L V6, and 4.0L inline six-cylinder engines.
• Contains 47 exploded-view component diagrams and 15 torque specification tables for critical fasteners.
• Details factory-specified lubricants, fluid capacities, and electrical reference values for the complete drivetrain.
• Includes comprehensive Wiring diagrams, detailed troubleshooting procedures, diagnostic trouble code charts, vacuum hose routing diagrams, and metric tire size code charts.
• Explains teardown and assembly for Command-Trac and Selec-Trac transfer cases, Multi-Point Injection (MPI), ABS brakes, emissions and engine control systems, and suspension and steering.

Manual Documentation Overview

This PDF service manual delivers a structured technical breakdown of maintenance and overhaul operations for the 1984–1993 Jeep Cherokee and Comanche. Introductory sections define vehicle identification numbers, fluid compatibility, and baseline safety procedures. Please note that automotive maintenance carries inherent physical risks; always verify factory lifting points and stabilize the vehicle on professional-grade jack stands before beginning any undercarriage work.

Technical chapters segment the four-cylinder, V6, and inline six-cylinder engine configurations. You will find complete structural overviews of disassembly sequences, cooling system servicing, and cylinder head torque specifications. To maximize bay efficiency and reduce vehicle downtime, this manual equips technicians with factory-exact tolerances, like the main bearing selection charts, directly at the vehicle, eliminating the need to hunt for crucial sub-assembly specifications during an active rebuild. Instead of outsourcing labor to specialized shops, mechanics and DIYers can utilize the step-by-step guides to tackle complex tasks in-house, ensuring a reliable fix. The documentation provides straightforward instructions for replacing the timing chain and sprockets, overhauling the front axle hub and bearings, and swapping out the heater core. Detailed sections also cover manual and automatic transmission variants, transfer case operations, and brake system maintenance schedules tailored to specific model years.

When servicing these specific Jeep platforms, technicians often encounter a few notorious repair traps. The closed cooling system on the early 4.0L inline-six is highly prone to air locks; failing to properly purge the system via the coolant pressure bottle often results in severe overheating. Additionally, the Peugeot-sourced BA 10/5 manual transmission utilizes a split-case design that tends to flex under high torque loads, making careful housing and bearing inspection mandatory during clutch service.

Engine and Component Specifications

Precision matters when rebuilding or servicing these classic Jeeps. Torque values are thoroughly documented in multi-stage sequences to ensure proper component seating. Engine oil capacity is specified at 4 quarts for the four-cylinder and V6 units, whereas the 4.0L inline six requires 6 quarts. The cooling system holds 10 quarts for four-cylinder models and 12.5 quarts for the larger V6 and inline six variants.

Transmission fluid requirements strictly call for Mercon ATF for AW-4 units. For the transfer case, the manual dictates SAE 75W-90 GL-5 gear lubricant. Front wheel hub and bearing components exploded views and other detailed schematics guide you through the trickiest assemblies.