Jeep Comanche 1992 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Comanche Year: 1992 Generation Generation Designation: First Generation (XJ/MJ Series) Codes Chassis Code: MJ 👋 Introduction Market Position Segment: Compact Pickup Truck, Sport...

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标签: 1992 Cars Comanche Jeep Misc Truck

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Description

🏷️ Basic Information

Identification

Make:

Model:

Comanche

Year:

Generation

Generation Designation:

First Generation (XJ/MJ Series)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Pickup Truck, Sport Utility Vehicle (SUV) platform derivative

Target Audience:

Off-road enthusiasts, utility buyers, those seeking durable and capable compact trucks.

Competitive Analysis

Primary Competitors:

Ford Ranger, Chevrolet S-10/GMC Sonoma, Nissan Hardbody, Toyota Pickup (RN80/90 series).

Key Features

Platform Sharing:

Built on the robust XJ Cherokee platform, offering shared components and chassis design.

Off Road Capability:

Known for its strong off-road prowess due to Jeep's heritage, available 4WD systems, and solid axles.

Durability:

Renowned for its rugged construction and longevity, appealing to users who demand reliability.

📋 Manual Details

Coverage Areas

Markets Covered:

North America (primarily USA and Canada)

Trim Levels Covered:

All available trim levels for the 1992 model year (e.g., Base, Sport, Pioneer, Laredo, Chief, Eliminator)

Page Count

Estimated Page Count:

900-1200+

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Printed Manual (or Digital PDF reproduction)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, diagnosis, and repair of all gasoline and diesel engine options.

Engine Electrical:

Ignition system, fuel injection, engine control module (ECM/PCM), sensors, actuators, starting and charging system.

Transmission:

Manual and automatic transmission service, overhaul, diagnostics, and fluid specifications.

Drivetrain:

Transfer case operation and repair, Dana 30 front axle, Chrysler 8.25 rear axle (or optional Dana 44), driveshafts, U-joints.

Suspension:

Front leaf spring (standard) and optional coil spring suspension systems, rear leaf spring suspension, shock absorbers, bushings.

Steering:

Power steering system diagnosis and repair, steering linkage, steering column.

Brakes:

Front disc and rear drum brake systems, hydraulic lines, master cylinder, proportioning valve, parking brake system.

Body And Frame:

Body panel removal and installation, interior trim, glass, doors, tailgate, chassis inspection and repair.

Electrical System:

Complete vehicle wiring diagrams, lighting, instrument cluster, power accessories, fuse block, relays.

HVAC:

Heating, ventilation, and air conditioning system diagnosis, repair, and refrigerant handling (R12 specific).

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil change procedures, filter replacements, lubrication points.

Troubleshooting:

Diagnostic charts and flowcharts for common drivability, electrical, and mechanical issues.

Repair:

Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.

Diagnostics:

Diagnostic trouble codes (DTCs) for OBD-I systems, component testing procedures, scan tool usage (where applicable).

Technical Depth

Depth:

Comprehensive (from basic fluid checks to full engine/transmission rebuilds).

Diagnostic Tools:

Specifies required special tools and diagnostic equipment.

Torque Specifications:

Detailed torque specifications for all critical fasteners.

Schematics:

Detailed electrical schematics, vacuum diagrams, and hydraulic circuits.

📊 Manual Specifications

File Format

Digital Format:

PDF (Searchable text, printable pages, often with bookmarks for easy navigation)

Print Quality

Print Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Binding Type

Binding Type:

N/A (for Digital PDF); Typically comb-bound or perfect-bound for physical reproductions.

Paper Type

Paper Type:

N/A (for Digital PDF); Original manuals often used durable, thicker paper stock.

⚙️ Engine Specifications

Primary Engine

Engine Code Gas 1:

2.5L AMC I4 (150 cu in)

Displacement Gas 1:

2469 cc

Horsepower Gas 1:

125 hp @ 4800 rpm (approximate)

Torque Gas 1:

150 lb-ft @ 2400 rpm (approximate)

Optional Engine

Engine Code Gas 2:

4.0L AMC I6 (242 cu in) 'High Output'

Displacement Gas 2:

3960 cc

Horsepower Gas 2:

177 hp @ 4750 rpm (approximate)

Torque Gas 2:

220 lb-ft @ 3300 rpm (approximate)

Optional Engine Diesel

Engine Code Diesel:

2.1L VM Motori TD I4 (Turbodiesel)

Displacement Diesel:

2088 cc

Horsepower Diesel:

85 hp @ 4000 rpm (approximate)

Torque Diesel:

145 lb-ft @ 2000 rpm (approximate)

Fuel System

Fuel Delivery Gas:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended for 4.0L, 87+ for 2.5L), Diesel fuel for TD model

Cooling System

Coolant Type:

Ethylene Glycol based coolant (e.g., Mopar Antifreeze/Coolant, or equivalent meeting Chrysler MS-7170 specification)

Ignition System

Ignition Type:

Distributorless Ignition System (DIS) with Crankshaft Position Sensor and Coil Pack (for 4.0L HO); Distributor ignition for 2.5L and TD

🔧 Transmission

Standard Transmission

Manual Transmission 1:

Aisin AX-4 4-speed manual

Optional Transmission

Manual Transmission 2:

New Process NP231 Command-Trac 2-speed transfer case (standard with 4WD)

Automatic Transmission 1:

Chrysler A904 / A999 3-speed automatic (with 2.5L engine)

Automatic Transmission 2:

Chrysler A500 / A518 4-speed automatic overdrive (with 4.0L HO engine)

Features

Transfer Case Options:

NP231 (2WD/4WD Part-Time) or NP242 Selec-Trac (2WD/4WD Full-Time with 2WD option)

Fluid Specifications

Automatic Transmission Fluid:

ATF+3 (or equivalent meeting Chrysler MS-9602 specification)

Manual Transmission Fluid:

GL-3 or GL-4 80W-90 gear oil (specific to Aisin AX-4)

Transfer Case Fluid:

ATF+3 (or equivalent meeting Chrysler MS-9602 specification) for NP231 and NP242

📐 Dimensions

Exterior

Wheelbase Short Bed:

113.0 inches (2870 mm)

Wheelbase Long Bed:

124.5 inches (3162 mm)

Bed Length Short:

74.0 inches (1880 mm)

Bed Length Long:

93.0 inches (2362 mm)

Weights

Curb Weight Approx:

3,500 - 4,200 lbs (1588 - 1905 kg), depending on configuration.

Towing Capacity Max:

Up to 5,000 lbs (2268 kg), depending on engine and axle ratio.

🛡️ Safety Features

Ratings

NHTSA Rollover Rating 2Wd:

3 out of 5 stars (1992 model year, for 2WD variants)

NHTSA Rollover Rating 4Wd:

4 out of 5 stars (1992 model year, for 4WD variants)

Active Features

Optional rear Anti-lock Braking System (ABS) on some models.

Passive Features

Seat Belts:

Lap and shoulder belts for front occupants, lap belts for rear passengers.

Airbags:

No airbags were standard or optional on the 1992 Jeep Comanche.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player, optional CD player, and 4-6 speaker configurations.

User Interface:

Analog gauges, physical buttons, and knobs for climate control and radio operation.

Driver Assistance

Cruise Control:

Optional cruise control system.

Connectivity

OBD-I (On-Board Diagnostics First Generation) system, requiring specific diagnostic tools or code readers for fault retrieval.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles or 3 months (typical for this era).

Transmission Fluid Change:

Every 30,000-60,000 miles or 24-48 months, depending on usage.

Coolant Flush:

Every 24,000 miles or 24 months.

Fluid Specifications

Engine Oil Spec:

API SG or higher; SAE 10W-30 (warm weather), SAE 5W-30 (cold weather) for 4.0L; SAE 10W-30 for 2.5L and TD.

Engine Oil Capacity:

4.0L I6: 5 US quarts (4.7 liters) with filter; 2.5L I4: 4 US quarts (3.8 liters) with filter; TD: 5.3 US quarts (5.0 liters) with filter.

Brake Fluid Spec:

DOT 3 brake fluid.

Power Steering Fluid Spec:

ATF+3 or Type 7176 (Chrysler spec)

Known Issues

Common Issues Engine:

Cracked cylinder heads on early 4.0L engines (less common by '92, but still a possibility), oil filter housing leaks, valve cover gasket leaks.

Common Issues Transmission:

Aisin AX-4 wear in the synchronizers; A500/A518 torque converter lock-up issues, solenoid failures.

Common Issues Suspension Steering:

Leaf spring sag in the rear, worn ball joints (on coil spring models), power steering pump whine or leaks.

Common Issues Electrical:

Corroded grounds, aging wiring harnesses, intermittent dashboard light failures, starter solenoid issues.

Common Issues Body Rust:

Significant rust potential on floor pans, rocker panels, cab corners, and wheel wells, especially in areas with road salt.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep's long-standing reputation for off-road capability and durable utility vehicles.

Model Evolution

Mj Introduction:

Introduced in 1985 as Jeep's compact pickup truck offering, designed to compete with domestic and import rivals.

Mj Updates 1992:

1992 saw minor updates, including potential revisions to engine options and trim packages. The 4.0L inline-six engine was a significant upgrade for performance.

Mj Discontinuation:

Production ceased after the 1992 model year in North America, making the 1992 model the final year of the Comanche.

Production

Production Plant:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Magazine Awards:

Frequently recognized by off-road publications for its capability and value.

Ratings

Consumer Reports Historicl Ranking:

Often rated average to below average for reliability by consumer reporting agencies of its era, largely due to early 4.0L head issues and general electrical component aging.