Engine Mechanical:
Detailed procedures for engine disassembly, assembly, component testing, and overhaul for all applicable engine variants.
Engine Fuel System:
In-depth coverage of fuel injection systems (MPI/TBI), carburetors (early models), fuel pumps, lines, filters, and diagnostics.
Engine Cooling System:
Radiator, water pump, thermostat, fan systems, coolant flow, and pressure testing procedures.
Engine Ignition System:
Distributor, ignition coils, spark plugs, timing, and related electronic components.
Engine Lubrication System:
Oil pump, oil pan, oil filter, lubrication passages, and oil pressure testing.
Emission Control Systems:
Catalytic converters, EGR systems, O2 sensors, and emission-related diagnostics.
Transmission Manual:
Service and repair procedures for manual transmissions (e.g., AX-4, NV3550), clutch systems, and gear oil specifications.
Transmission Automatic:
Service and repair procedures for automatic transmissions (e.g., AW4, 30RH), torque converters, and transmission fluid specifications.
Drivetrain Transfer Case:
Service and repair of 2-speed transfer cases (e.g., NP231, NP242), including lubrication and seal replacement.
Drivetrain Axles Differentials:
Front and rear axle assemblies, differential service, gear ratios, axle shafts, and CV joints.
Suspension System:
Front and rear suspension components, coil springs, leaf springs (rear), control arms, bushings, ball joints, and shock absorbers.
Steering System:
Power steering pump, steering box, tie rods, steering linkage, and alignment specifications.
Brake System:
Disc brake systems (front/rear), drum brakes (rear), hydraulic lines, master cylinder, calipers, wheel cylinders, and brake fluid specifications.
Electrical System Charging:
Alternator, battery, voltage regulator, and related charging circuit components.
Electrical System Starting:
Starter motor, starter solenoid, ignition switch, and related starting circuit components.
Electrical System Lighting:
Headlights, taillights, interior lights, and associated wiring and switches.
Electrical System Gauges Instruments:
Dashboard instrumentation, speedometer, tachometer, fuel gauge, temperature gauge, and warning lights.
Electrical System Accessories:
Wipers, horn, power windows, power locks, radio, HVAC controls, and related electrical accessories.
Body Exterior:
Body panel removal and installation, doors, hood, tailgate, bumpers, and trim.
Body Interior:
Seat removal and installation, dashboard disassembly, interior trim, and headliner.
HVAC System:
Air conditioning, heater core, blower motor, climate controls, and refrigerant service.
Body Electrical Wiring Diagrams:
Comprehensive wiring diagrams for all electrical systems, including power distribution, grounds, and component locations.
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, and general inspections.
Diagnostics Troubleshooting:
Systematic troubleshooting guides for identifying and resolving common and uncommon issues across all vehicle systems, including diagnostic trouble codes (DTCs).
Component Removal Installation:
Step-by-step instructions for removing and reinstalling all major and minor components.
Rebuilding Overhauling:
Detailed procedures for rebuilding engines, transmissions, transfer cases, and differentials.
Tune Ups:
Complete tune-up procedures, including spark plug replacement, ignition timing, and fuel system adjustments.
Brake Service Replacement:
Pad and rotor replacement, caliper service, drum brake relining, and bleeding procedures.
Suspension Steering Repair:
Replacement of wear items like ball joints, tie rods, bushings, and shock absorbers.
Electrical Component Testing Replacement:
Testing and replacement of sensors, actuators, switches, motors, and modules.
Body And Frame Repair:
Guidelines for minor bodywork, rust repair, and panel alignment.
Torque Specifications:
Precise torque values for all critical fasteners across all vehicle systems.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics, and electrical system troubleshooting.
Diagnostic Tools:
Likely includes information on diagnostic tools and procedures relevant to the era, possibly mentioning early OBD-I capabilities.
Schematics Diagrams:
Includes detailed schematics and diagrams for mechanical, hydraulic, and electrical systems.
Oil Change Interval:
Typically every 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on oil type and driving conditions (refer to manual for exact specs).
Transmission Fluid Change:
Every 30,000-60,000 miles (50,000-100,000 km) for automatic transmissions; manual transmissions as needed or at higher mileage intervals (refer to manual).
Engine Oil:
API SG or higher, SAE 10W-30 or 10W-40 recommended for most conditions (e.g., Mopar SAE 10W-30).
Coolant:
Ethylene glycol-based antifreeze/coolant. Typically a 50/50 mix with distilled water. Mopar 50/50 Antifreeze/Coolant (blue).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
ATF+4 (Automatic Transmission Fluid Type 9602) or Mopar power steering fluid.
4.0L Head Cracking:
Certain 4.0L engines, particularly early ones, were prone to cylinder head cracking. The manual will detail inspection and replacement procedures.
Rust Susceptibility:
Common areas for rust include rocker panels, floor pans, and rear quarter panels. Manual may offer repair guidance.
Cooling System Overheating:
Can be exacerbated by worn water pumps, thermostats, or radiator issues. The manual provides diagnostic steps.
Automatic Transmission Aw4:
The AW4 transmission is generally robust but can suffer from solenoid issues or cooling problems. Manual covers diagnostics.
Electrical Gremlins:
Aging wiring harnesses and ground points can lead to intermittent electrical faults. Wiring diagrams are crucial.