Jeep Cherokee XJ & Comanche 1989 Repair Manual

This Haynes aftermarket automotive repair manual covers Cherokee, Wagoneer, and Comanche service information from 1984 through 1993, including the 1989 model year and 2WD/4WD configurations. It is not a Jeep OEM factory service publication. Match the year-specific sections to the vehicle’s installed engine, fuel system, transmission, and driveline.

PDF Search, Bookmarks, and Wiring Detail

Chapter access and diagram detail: Most chapter text is searchable, although OCR errors and some illustration captions limit searches. Twenty embedded bookmarks provide access to the main sections and index. Small wiring labels require zooming, and isolated characters overlap nearby diagram details.

The ZIP contains one printable English-language PDF with 337 pages, including one added cover page and 336 pages of manual content. Two HTML shortcut files and a short readme are also included.

Engine Overhaul, Drivetrain Service, and Electrical Diagnosis

The following selected repair topics show the manual’s range; additional subjects include cruise-control checks and power-window troubleshooting.

• Engine repair: Step-by-step procedures for cylinder-head service, timing components, camshafts, valvetrain work, oil pumps, seals, engine removal, internal inspection, and rebuilding.

• Fuel and emissions: Fuel-pressure testing, pump replacement, carburetor diagnosis, injection-component service, emissions-system checks, and configuration-specific trouble-code information.

• Transmission and clutch: External seal replacement, transmission removal and installation, automatic-transmission adjustments, clutch-component service, hydraulic bleeding, and transfer-case linkage adjustment.

• Brakes: Caliper, wheel-cylinder, and master-cylinder overhaul; disc and drum service; hydraulic bleeding; parking-brake adjustment; and ABS system descriptions.

• Suspension and driveline: Coil and leaf springs, steering linkage, power-steering bleeding, driveshafts, U-joints, axle shafts, hubs, and wheel bearings.

• Cooling and heating: Thermostat and water-pump checks, radiator replacement, fan and clutch inspection, heater-core replacement, and blower-motor service.

• Electrical troubleshooting: Ignition, charging, and starting-system tests, circuit fault tracing, and wiring diagrams for lighting, instruments, wipers, and body electrical equipment.

The manual is suited to experienced DIY owners and general repair technicians equipped for safe lifting, precision measurement, and electrical testing; specialist operations require additional equipment and expertise.

Engine Inspection and Rebuilding

Separate in-vehicle repair chapters cover the four-cylinder, 2.8L V6, and 4.0L inline-six engines. The overhaul material extends to compression and oil-pressure checks, cylinder-head disassembly, valve service, block and crankshaft inspection, bearing-clearance measurement, piston and ring fitting, reassembly, and initial start-up.

Component-specific torque tables, bore and journal dimensions, oil clearances, wear limits, and sealant notes accompany the work. Identification pages help establish the installed engine, gearbox, transfer case, and axle before the appropriate procedures or replacement parts are selected.

Tools and seal precautions: Engine sections reference J-21791, J-23042-A, J-29114-1, and J-29114-2. The V6 damper section explains how a common jaw-type puller can separate the outer portion from its hub. The four-cylinder rear-main-seal section distinguishes the revised seal fitted after December 8, 1986 and warns that the old-design installer shim can damage the replacement seal and cause leakage.

Carburetion, Injection, and Engine Controls

Fuel coverage distinguishes early Carter YFA carburetion, later four-cylinder TBI, 2SE/E2SE V6 carburetors, and inline-six MPI. It includes pump and tank service, pressure relief, fuel-pressure and leak-down tests, injector and throttle-body component replacement, and exhaust work.

Carburetor material provides diagnosis, general overhaul guidance, and exploded views; detailed rebuilding instructions for each carburetor are supplied with the appropriate overhaul kit.

Ignition, charging, and starting sections cover distributor service, alternator checks and brush replacement, starter testing, and solenoid replacement. Emissions coverage includes EGR, air injection, evaporative controls, PCV/CCV systems, and catalytic converters. V6 CCCS code retrieval, 1991-and-later self-diagnosis, and MAP, MAT, TPS, CPS, oxygen, knock, and coolant-temperature sensor checks are distinguished by application.

Cooling, Heating, and A/C Service

Cooling procedures address the radiator, thermostat, water pump, reservoir, cooling fan, and fan clutch. Heating material includes the heater core, blower motor, and control assembly.

A/C coverage provides basic checks and component replacement, including the compressor, condenser, and receiver-drier. In-depth A/C diagnosis and repair require separate information and specialist equipment; refrigerant discharge, evacuation, charging, and leak testing are assigned to equipped service facilities.

Transmission, Transfer Cases, and Axles

Transmission illustrations identify T4, T5, AX4/AX5, and BA units. Service material covers external seals, shift linkage, neutral-start switches, removal, and installation. Automatic-transmission references include AW-4, 727, and 999 units, with band adjustment for three-speed transmissions.

Overhaul limits: Internal manual-transmission work is presented mainly through general guidance and exploded views. Automatic-transmission internal overhaul is outside the repair coverage.

Transfer-case material distinguishes New Process 207/231 Command-Trac from 228/229/242 Selec-Trac assemblies, with exploded views and removal and installation procedures. Clutch coverage adds pressure-plate, release-bearing, pilot-bearing, master-cylinder, and slave-cylinder service.

Driveline sections cover front axle-shaft CV/U-joints, rear axle shafts and bearings, hub service, and pinion-seal replacement. Differential disassembly and setup are referred to specialists.

Brake Hydraulics, Steering, and Suspension

ABS and non-ABS hydraulic schematics distinguish the brake layouts. Detailed ABS diagnosis requires the specified electronic tester, and ABS repair is assigned to equipped service personnel.

The Comanche height-sensing proportioning valve receives a separate explanation of load-dependent rear braking; its diagnosis and service require specialist tools and skills. Steering and suspension coverage includes ball joints, steering gear, linkage, springs, and alignment principles, with precision alignment assigned to an equipped shop.

Body Repairs and Circuit Diagrams

Body procedures distinguish the Cherokee liftgate from the Comanche tailgate and cover doors, window glass, dashboard panels, seats, locks, and exterior hardware.

Wiring diagrams separate two- and four-headlamp front lighting, instrument-panel and cluster illumination, and Cherokee/Comanche stop, turn, hazard, and rear-lighting circuits. Interior lighting and intermittent and standard wiper systems have their own diagrams.

Brake, fuel, refrigerant, and under-vehicle work require suitable support equipment and pressure precautions. Refrigerant handling belongs with qualified personnel.

Radiator-Cap and Thermostat Specification Preview

The cooling-system specifications list radiator-cap ratings of 12–15 psi for four-cylinder and V6 engines, compared with 16–18 psi for the inline-six.

The thermostat specification gives an opening temperature of 195°F, alongside the component checks and replacement procedures.