Vehicle Class:
Compact SUV / Off-Road Vehicle
Segment Focus:
Ruggedness, off-road capability, iconic design
Key Competitors:
Ford Bronco (earlier generations), Toyota 4Runner, Suzuki Samurai
Vehicle Appeal:
Renowned for its off-road prowess, robust construction, and distinctive open-air driving experience.
Manual Value Proposition:
Provides essential factory-level repair and maintenance information for owners and independent repair shops to keep the YJ Wrangler in optimal condition.
Vehicle Years Covered:
1989, 1990, 1991, 1992
Engine Coverage:
All gasoline engines offered during the specified years (2.5L, 4.0L)
Transmission Coverage:
Manual transmissions (AX-5, AX-15) and Automatic transmissions (Select-Shift)
Trim Levels Covered:
All trim levels (e.g., Base, Sport, Sahara) equipped with the specified engines and transmissions.
Estimated Page Count:
1000+
Manual Type:
Factory Service Manual / Workshop Manual
Format:
PDF (Downloadable)
Powertrain:
Engine mechanical, fuel system, cooling system, exhaust system, ignition system, driveline (transfer case, axles, driveshafts)
Chassis:
Suspension system (front and rear leaf springs, shocks, steering components), brake system (front disc, rear drum), wheels and tires
Electrical:
12-volt electrical system, battery, charging system, starting system, lighting, instrument cluster, body control modules, wiring diagrams
Body:
Body panels, doors, hood, tailgate, interior trim, seats, convertible top mechanisms, glass, bumpers
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, belt inspections
Repair Procedures:
Engine rebuilds, transmission overhaul, brake caliper replacement, suspension component replacement, electrical diagnostics and repair
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting guides for engine, transmission, electrical, and braking systems
Specifications:
Torque specifications for all fasteners, clearances, fluid capacities, electrical component resistance values
Diagnostics:
Engine control system diagnostics, fuel system pressure testing, ignition timing adjustments, emission control system diagnosis.
Component Replacement:
Alternator replacement, starter motor replacement, fuel pump replacement, power steering pump replacement.
Depth Of Coverage:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
Wiring Diagrams:
Detailed, system-specific wiring diagrams included, essential for electrical troubleshooting.
Engine Code 1:
2.5L "H.O." 4-Cylinder
Displacement 1:
150 cu in (2.5 Liters)
Horsepower 1:
121 hp @ 4800 rpm (approx.)
Torque 1:
170 lb-ft @ 2800 rpm (approx.)
Engine Code 2:
4.0L "High Output" Inline-6
Displacement 2:
242 cu in (4.0 Liters)
Horsepower 2:
177 hp @ 4750 rpm (approx.)
Torque 2:
220 lb-ft @ 3250 rpm (approx.)
Fuel Delivery:
Multi-Point Fuel Injection (MPFI)
Fuel Type:
Unleaded gasoline
Transmission Type 1:
5-Speed Manual (Aisin Warner AX-5)
Transmission Type 2:
3-Speed Automatic (Chrysler TF-904/A904)
Transmission Type 3:
4-Speed Automatic (Chrysler 42RE, introduced later in YJ generation but may be relevant for later model years within the 1989-1992 range)
Transfer Case:
New Process NV242 Selec-Trac (Full-time 4WD capability, optional) or NV242 (Part-time 4WD)
NHTSA Rollover Rating:
3 Stars (indicative for the era)
Braking System:
Front disc brakes, rear drum brakes. Anti-lock Braking System (ABS) available as an option.
Restraints:
Seat belts (front and rear)
Roll Cage:
Integral roll bar/cage structure for enhanced occupant protection in rollovers.
Audio System:
AM/FM radio, optional cassette player, optional CD player (later models).
Climate Control:
Manual heating and ventilation, optional air conditioning.
ABS:
Optional Anti-lock Braking System (ABS) available on rear wheels or all four wheels depending on the model year and configuration.
Connectivity Features:
Limited to basic radio and optional power accessories; no modern connectivity like Bluetooth or USB ports.
Oil Change Interval:
Every 3,000 miles or 6 months (typical recommendation for the era, refer to manual for specific grade/type).
Engine Coolant Flush:
Every 30,000 miles or 24 months (typical).
Transmission Fluid Change Auto:
Every 30,000-50,000 miles (typical, refer to manual for specific type and interval).
Transmission Fluid Change Manual:
Every 50,000-75,000 miles (typical, refer to manual for specific gear oil type).
Engine Oil Type:
API Service SG or SH, SAE 10W-30 or 10W-40 (refer to manual for exact specification based on temperature).
Coolant Type:
Ethylene Glycol based antifreeze (typically green) meeting Chrysler specification MS-7170 or equivalent.
Automatic Transmission Fluid:
Chrysler ATF+3 (or equivalent like Dexron III for earlier models, confirm with manual).
Manual Transmission Fluid:
API GL-5, SAE 75W-90 or 80W-90 gear oil (refer to manual for specific AX-5/AX-15 requirements).
Transfer Case Fluid:
Mopar Transfer Case Lubricant or equivalent (refer to manual for NV242 specifications).
Common Wear Items:
Leaf spring bushings, U-joints, track bar bushings, clutch components (manual transmission), exhaust manifold cracks (4.0L), water pump, radiator.
Electrical Quirks:
Corrosion on electrical connectors, issues with the instrument cluster, faulty turn signal switches.
Jeep Legacy:
Direct descendant of the original Willys-Overland military Jeep, renowned for off-road durability and go-anywhere capability.
Yj Generation Characteristics:
The YJ generation marked a significant shift from the CJ models, introducing coil springs (on some later models and aftermarket) but primarily utilizing leaf springs, distinguishing it from later Wranglers and the earlier CJ series. Notably featured rectangular headlights, a departure from the CJ's round headlights.
Manufacturing Plant:
Toledo, Ohio, USA
Production Period:
1987-1995 (manual covers 1989-1992 subset)
