Systems Covered:
Engine Mechanical, Engine Performance, Fuel System, Cooling System, Lubrication System, Exhaust System, Charging System, Starting System, Ignition System, Emission Control System, Manual Transmission, Automatic Transmission, Transfer Case, Driveline, Driveshaft, Axles, Suspension System, Steering System, Brake System, Frame, Body, Exterior Trim, Interior Trim, HVAC System, Electrical System, Wiring Diagrams, Troubleshooting, Maintenance
Page Count:
Estimated 1000+ pages (typical for comprehensive factory manual)
Manual Type:
Factory Workshop Service Repair Manual
Format:
Print/Digital (likely PDF for modern distribution)
Engine Mechanical:
Detailed procedures for engine disassembly, inspection, repair, and reassembly, including cylinder head, pistons, connecting rods, crankshaft, camshaft, valves, timing components.
Engine Performance:
Diagnosis and repair of performance issues, including fuel delivery, ignition timing, vacuum leaks, and sensor operations.
Fuel System:
Component identification, testing, and repair of fuel pump, fuel injectors, fuel pressure regulator, fuel filter, and fuel lines.
Cooling System:
Radiator, water pump, thermostat, hoses, fan, and coolant flow diagnosis and repair.
Lubrication System:
Oil pump, oil filter, oil pan, and lubrication passages for engine health.
Exhaust System:
Catalytic converter, muffler, exhaust pipes, and oxygen sensors inspection and replacement.
Charging System:
Alternator, voltage regulator, battery, and wiring diagnosis and repair.
Starting System:
Starter motor, solenoid, and battery testing and repair.
Ignition System:
Spark plugs, ignition coils/distributor, spark plug wires, and ignition control module diagnosis and replacement.
Emission Control System:
EGR valve, PCV system, evaporative emission control system components, and diagnostic procedures.
Manual Transmission:
Clutch system, transmission removal, disassembly, repair, and reassembly, including gear sets and bearings.
Automatic Transmission:
Transmission removal, fluid checks, filter replacement, torque converter, and internal component diagnosis and repair.
Transfer Case:
Operation, maintenance, removal, and repair of the 4WD transfer case.
Driveline:
U-joints, driveshafts, and CV joints inspection, service, and replacement.
Axles:
Front and rear axle assemblies, differential service, bearings, and seals.
Suspension System:
Shock absorbers, struts, springs, control arms, ball joints, bushings, and alignment procedures.
Steering System:
Steering column, steering gear/rack and pinion, power steering pump, hoses, and tie rods.
Brake System:
Front and rear brake systems (drum/disc), brake fluid, master cylinder, calipers, wheel cylinders, brake lines, and parking brake.
Frame:
Frame inspection, repair, and alignment considerations.
Body:
Body panel removal and installation, doors, hood, tailgate, and structural components.
Exterior Trim:
Bumpers, grilles, moldings, lighting, and mirrors.
Interior Trim:
Dashboard, seats, door panels, headliner, and interior accessories.
HVAC System:
Heating, ventilation, and air conditioning components, refrigerant system, blower motor, and controls.
Electrical System:
Battery, charging, starting, ignition, lighting, accessories, power windows, locks, and instrumentation.
Wiring Diagrams:
Detailed wiring schematics for all electrical systems, crucial for diagnosis.
Troubleshooting:
Systematic diagnostic procedures and flowcharts for identifying and resolving common and complex issues.
Maintenance:
Regular service checks, fluid changes, filter replacements, and component inspections.
Maintenance Procedures:
Oil changes, fluid level checks and top-offs, filter replacements, lubrication points, tune-up procedures, tire rotation, brake inspections.
Repair Procedures:
Step-by-step instructions for component removal, repair, installation, and adjustment for virtually all vehicle systems.
Troubleshooting Procedures:
Diagnostic flowcharts, symptom-based troubleshooting guides, and specific tests for various components.
Technical Specifications:
Torque specifications for bolts and fasteners, engine data, fluid capacities, electrical specifications, clearances, and tolerances.
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Suitable for professional technicians and experienced DIY enthusiasts.
Oil Change Interval:
Every 3,000 miles (4,800 km) or 3 months, whichever comes first (typical for the era).
Transmission Fluid Change:
Every 30,000 miles (48,000 km) or 2 years for automatic transmissions, manual transmissions as specified in manual.
Coolant Change Interval:
Every 2 years or 30,000 miles (48,000 km).
Engine Oil Type:
API SG or SH rated, SAE 10W-30 or 10W-40 (refer to manual for exact viscosity based on climate).
Automatic Transmission Fluid:
ATF+3 (Chrysler Mopar spec) or equivalent Dexron-III compatible fluid.
Coolant Type:
Ethylene Glycol based, 50/50 mix with distilled water.
Common Wear Items:
Leaf spring bushings, front lower control arm bushings, universal joints, exhaust system rust, radiator leaks, starter motor failures (especially on 4.0L).
Engine Specific Issues:
The 4.0L inline-six is generally robust but can develop cracked cylinder heads over time or issues with oil pressure sender units. The 2.5L can suffer from valve stem seal wear.