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Jeep Comanche 1987 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Comanche Year: 1987 Codes Chassis Code: XJ (shared platform with Cherokee) 👋 Introduction Market Position Positioning: A compact pickup truck based on the...
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Jeep Comanche 1987 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Comanche
Year:
1987
Codes
Chassis Code:
XJ (shared platform with Cherokee)
👋 Introduction
Market Position
Positioning:
A compact pickup truck based on the popular Jeep Cherokee (XJ) platform, offering Jeep's renowned off-road capability in a utility vehicle format.
Competitive Analysis
Competitors:
Ford Ranger, Chevrolet S-10, Nissan Hardbody, Toyota Pickup
Key Features
Unique Selling Points:
Unibody construction (shared with XJ Cherokee) for lighter weight and better ride, available 4x4 system, strong off-road heritage, unique utility for its class.
📋 Manual Details
Coverage Areas
Coverage:
Full Service, Repair, Diagnostic, Troubleshooting, Electrical Schematics, Wiring Diagrams, Component Overhaul, Maintenance Schedules
Page Count
Pages:
Extensive (specific number not provided, but implied to be comprehensive)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Likely Digital (PDF) or Printed Booklet
📖 Manual Coverage
Systems Covered
Engine:
2.5L AMC 150 I4, 4.0L AMC 242 I6, 2.1L turbodiesel (Renault) - including diagnostics, overhaul, fuel system, ignition system, cooling system, lubrication system
Transmission:
Aisin Warner AW-4 (automatic), Peugeot BA-10/5 (manual), NV235 (transfer case) - including service, overhaul, and troubleshooting
Drivetrain:
Front and Rear Axles (Dana 30, Dana 35), drivelines, U-joints, differentials - including inspection, repair, and fluid specifications
Suspension:
Front (leaf spring solid axle), Rear (leaf spring solid axle) - including shock absorbers, leaf springs, bushings, alignment specifications
Brakes:
Front Disc, Rear Drum - including hydraulic system, calipers, wheel cylinders, brake pads/shoes, fluid specifications, bleeding procedures
Steering:
Power Steering System - including pump, hoses, steering gear, fluid types, troubleshooting
Electrical:
Complete electrical system, battery, starting system, charging system, lighting, gauges, accessories, fuse block, relays, wiring diagrams, diagnostic procedures
Body:
Body panels, doors, glass, interior trim, bumpers, chassis lubrication, rust prevention, panel alignment
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, battery maintenance, spark plug replacement
Engine Repair:
Engine disassembly, assembly, valve adjustments, piston/ring replacement, bearing replacement, gasket replacement
Transmission Service:
Fluid changes, filter replacement, torque converter service, seal replacement, complete transmission overhaul
Brake Service:
Pad/shoe replacement, rotor/drum resurfacing or replacement, caliper/wheel cylinder overhaul, brake line replacement, bleeding
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, component testing, circuit diagnosis
Suspension And Steering Repair:
Component replacement (shocks, springs, ball joints, tie rods), alignment procedures, steering gear repair
Technical Depth
Depth:
Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts, covering diagnostics, repair, overhaul, and specifications
📊 Manual Specifications
File Format
File Type:
Typically PDF, but can be printed
Print Quality
Quality:
High-resolution diagrams and clear text (assuming original source quality)
Binding Type
Binding:
If printed: Spiral-bound or perfect-bound for ease of use in a workshop
Paper Type
Paper:
If printed: Durable, possibly glossy paper for workshop conditions
⚙️ Engine Specifications
Primary Engine
2.5L I4:
AMC 150, 115 horsepower @ 4600 rpm, 190 lb-ft torque @ 2400 rpm (approximate)
4.0L I6:
AMC 242, 173 horsepower @ 4700 rpm, 220 lb-ft torque @ 3250 rpm (approximate)
2.1L Turbodiesel:
Renault J8S, 85 horsepower @ 3750 rpm, 132 lb-ft torque @ 2750 rpm (approximate)
Performance
Acceleration 0 60:
Varies significantly by engine and configuration, typically 10-14 seconds
Fuel System
Injection Type:
Electronic Fuel Injection (EFI) for all gasoline engines
Fluid Specifications
Engine Oil:
API SF, SAE 10W-30 (check manual for exact spec and viscosity based on temperature)
🔧 Transmission
Standard
Manual:
Peugeot BA-10/5 (5-speed)
Optional
Automatic:
Aisin Warner AW-4 (4-speed automatic)
Features
Transfer Case:
Command-Trac part-time 4WD system with NV235 transfer case
Fluid Specifications
Aw-4:
ATF+3 (Chrysler spec, equivalent to Dexron II/III)
Ba-10/5:
API GL-4, SAE 75W-90 or 80W-90 gear oil
📐 Dimensions
Exterior
Wheelbase:
119.4 inches (standard bed)
Length:
180.7 inches (standard bed)
Width:
71.5 inches
Height:
65.8 inches
Cargo
Bed Length:
6 feet (standard bed)
Weights
Curb Weight:
Approx. 3400-3800 lbs (depending on configuration)
Towing Capacity:
Up to 5,000 lbs (depending on configuration and engine)
🛡️ Safety Features
Ratings
NHTSA Crash Tests:
Limited data available for this era, but generally considered robust for its class due to unibody construction.
Active Features
Braking System:
Front disc brakes, Rear drum brakes; Optional Anti-lock Braking System (ABS) on rear wheels only for some models.
Passive Features
Restraints:
Seat belts (lap and shoulder belts for front occupants), no airbags standard in 1987.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio, optional cassette player. Basic analog controls.
Driver Assistance
Assistance Features:
None (ABS available on rear wheels only on select models)
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 miles or 6 months (whichever comes first), refer to manual for specific conditions
Transmission Fluid Change:
Every 30,000-60,000 miles, or as per severe service schedule. Check manual for specific recommendations.
Tune Up:
Spark plugs every 30,000-60,000 miles, distributor cap and rotor as needed.
Fluid Specifications
Coolant:
50/50 mix of ethylene glycol antifreeze and distilled water
Brake Fluid:
DOT 3
Power Steering Fluid:
Mopar Power Steering Fluid or ATF+3
Known Issues
Common Problems:
Rust on unibody structure, aging electrical components, exhaust manifold cracks (on 4.0L), heater core leaks, clutch wear on manual transmissions, rear main seal leaks.
Diesel Engine Issues:
Glow plug system issues, turbocharger wear, injection pump reliability (Renault diesel).
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Built on Jeep's legacy of rugged, capable off-road vehicles, the Comanche brought this reputation to the compact pickup segment.
Model Evolution
Development:
Introduced in 1986 as a direct response to the growing compact truck market, utilizing the successful XJ Cherokee platform. It aimed to offer a blend of utility, capability, and a more refined driving experience than body-on-frame competitors.
Production
Production Years:
1986-1992
Manufacturing Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Capability:
While not a direct award winner, the Comanche's shared platform and drivetrain with the highly acclaimed XJ Cherokee meant it inherited a strong reputation for off-road prowess.
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