1988 JEEP CHEROKEE Service Repair Manual

Fig. 2: 4.0L Fuel Pump, Filter & Accumulator
Courtesy of Chrysler Motors
TESTING & DIAGNOSIS
FUEL PUMP PRESSURE TEST

2.5L TBI
1) Adjustment of fuel pressure is required after replacement
of pressure regulator. Remove air inlet from throttle body. Connect
tachometer to diagnostic connector terminals D1-1 and D1-3. Connect
fuel pressure gauge to fuel body pressure test fitting.
NOTE: Some TBI models do not have a pressure test fitting on
throttle body. Use Fitting (PN 8983 501 572) for this
purpose.
2) Start engine and accelerate to 2000 RPM. Turn adjustment
screw to obtain 14.5 psi (1.02 kg/cm
) fuel pressure. Location of
adjustment screw is on bottom of regulator. Install lead seal ball to
cover regulator adjustment screw after adjusting fuel pressure to
specification. Turn ignition off. Disconnect fuel pressure gauge.
Install cap on test fitting. Install air inlet.
NOTE: To increase fuel pressure, turn adjustment screw inward. To
decrease fuel pressure, turn adjustment screw outward.
4.0L MPFI
1) Remove cap from pressure test port in fuel rail. Connect
Fuel Pressure Gauge (J-37730-1) to pressure fitting. Start vehicle.
Pressure should be approximately 31 psi (2.7 kg/cm
) with vacuum
hose connected to pressure regulator.
2) Pressure should be 39 psi (2.74 kg/cm
) with vacuum
hose removed from regulator. If fuel pressure is not to
specifications, check for kinks or restricting bends in fuel supply
and return lines. Check fuel pump flow rate. Pump should deliver
minimum of 1.06 quarts (one liter) of fuel per minute with fuel
return line pinched off.
3) If flow is inadequate, check system for plugged fuel
filter or filter sock. Fuel pump flow rate can be checked by
connecting a hose to fuel test port on fuel rail and inserting other
end in clean container.
4) To operate fuel pump, install a jumper wire into
diagnostic connector terminals D1-5 and D1-6. Pinch off fuel return
line to ensure that no fuel returns to fuel tank. If fuel pressure is
still not to specifications and fuel flow is normal, replace
regulator.
REMOVAL & INSTALLATION
FUEL PUMP
Removal (2.5L TBI)
1) Disconnect battery cables. Ensure fuel level is less than
1/2 for this procedure. Remove fuel outlet and return hoses. Remove
sending unit wires. Remove sending unit retaining lock ring.
2) Remove sending unit/pump assembly with "O" ring seal.
Disconnect fuel hose from fuel pump. Disconnect wires from fuel pump.
Remove fuel pump from sending unit.
Installation
Clean seal contact are of fuel tank. Install new "O" ring
seal. Install a new filter on end of suction tube. Position sending
unit/pump assembly in tank. To complete installation, reverse removal
procedure. Start engine and check for leaks.
CAUTION: Fuel leaks can develop from over tightening sending
unit/pump during installation.

Removal (4.0L MPFI)
Install clamps (MOT. 453.01) on fuel pump inlet and outlet
hoses. Disconnect hoses from fuel pump. Disconnect electrical
connectors. Remove retaining strap. Remove fuel pump.
Installation
To install, reverse removal procedure. Ensure that clamps
(MOT. 453.01) have been removed from fuel lines. Start engine and
check for leaks.
NOTE: Accumulator is located between fuel pump and fuel filter on
4.0L models.

FU SES & C IR CUIT B REA K ER S

1988 J e ep C hero ke e
Fuses & Circuit Breakers
1984-88 AMC/Jeep
Jeep; Cherokee, Wagoneer
IDENTIFICATION
FUSES & CIRCUIT BREAKERS
Fuse panel is located at the lower left side of dash on most
models.
Fig. 1: Fuse Panel Identification
Courtesy of American Motors Corp.
FUSE & CIRCUIT BREAKER IDENTIFICATION

1 - 25 Amp
Rear Washer/Wiper.
2 - 15 Amp
Radio, Cigarette Lighter.
3 - 25 Amp
Blower Motor.
4 - 20 Amp
Turn Signal, Back-Up Lights, Rear Window Defogger Relay.
5 - 10 Amp
Dome Light, Courtesy Lights, Glove Box Light, Cargo Light,
Radio Memory, Power Mirrors, Teltak Connector.
6 - 15 Amp
Hazard Warning System, Stoplights.
7 - 10 Amp
Parking Lights, Headlight Warning Chime/Buzzer, Instrument
Panel Light Dimmer.
8 - 7.5 Amp
Gauges, Instrument Cluster, Seat Belt Warning, Headlight
Delay, Chime Module, Overhead Console.
9 - 5 Amp
Instrument Panel Illumination.
10 - 25 Amp
Rear Window Defogger.
11 - 30 Amp (Circuit Breaker)
Power Door Locks, Power Seats, Trailer Towing Wiring Harness.
12 - 10 Amp
ETR Radio, Power Antenna.
13 - Not Used (1984-87); 7.5 Amp (1988)
Transmission Control Unit.
14 - 25 Amp
Headlight Delay, Horns, Security Alarm.
15 - 5.5 Amp (Circuit Breaker)
Front Wiper.
16 - 30 Amp (Circuit Breaker)
Power Windows.
17 - 10 Amp
Clock, Security Alarm (Ign).
CAUTIONS & WARNINGS
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous

electrical system overload.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some
vehicles. These vehicles may require a relearn procedure.
See the COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION section.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
HALOGEN BULBS
Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare hands. Eye
protection should be worn when handling or working around halogen
bulbs.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.

GEA R T O OTH C O NTA C T P A TTE R NS

1988 J e ep C hero ke e
GENERAL INFORMATION
Gear Tooth Contact Patterns
* PLEASE READ THIS FIRST *
The following article is for GENERAL INFORMATION purposes
only. Information does not SPECIFICALLY apply to all years, makes and
models, but is to be used as a general reference guide.
INSPECTION
PRELIMINARY INSPECTION
Wipe lubricant from internal parts. Rotate gears and inspect
for wear or damage. Mount dial indicator to housing, and check
backlash at several points around ring gear. Backlash must be within
specifications at all points. If no defects are found, check gear
tooth contact pattern.
GEAR TOOTH CONTACT PATTERN
NOTE: Drive pattern should be well centered on ring gear teeth.
Coast pattern should be centered, but may be slightly toward
toe of ring gear teeth.
1) Paint ring gear teeth with marking compound. Wrap cloth or
rope around drive pinion flange to act as brake. Rotate ring gear
until clear tooth contact pattern is obtained.
2) Contact pattern will indicate whether correct pinion
bearing mounting shim has been installed and if drive gear backlash
has been set properly. Backlash between drive gear and pinion must be
maintained within specified limits, until correct tooth pattern is
obtained.

Fig. 1: Drive Axle Gear Tooth Patterns
ADJUSTMENTS
GEAR BACKLASH & PINION SHIM CHANGES
NOTE: Backlash is adjusted by either moving shims from one side of
differential case to the other or by turning adjusting nuts
on which side bearing races ride. Changing of pinion shims
alters the distance from face of pinion of centerline of
ring gear.
1) With no change in backlash, moving pinion further from
ring gear moves drive pattern toward heel and top of tooth, and moves
coast pattern toward toe and top of tooth.
2) With no change in backlash, moving pinion closer to ring
gear moves drive pattern toward toe and bottom of tooth, and moves
coast pattern toward heel and bottom of tooth.
3) With no change in pinion shim thickness, an increase in
backlash moves ring gear further from pinion. Drive pattern moves
toward heel and top of tooth, and coast pattern moves toward heel and
top of tooth.
4) With no change in pinion shim thickness, decrease in