1988 JEEP CHEROKEE battery

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EN G IN E R EM OVA L - 6 -C YL

1988 J e ep C hero ke e
1988 ENGINES
Jeep - Engine Removal - 6-Cylinder
Cherokee, Comanche, Wagoneer, Wrangler
6-CYLINDER ENGINES
4.0L
1) Scribe hinge locations, remove engine compartment light
(if equipped) and remove hood. Disconnect battery cables and remove
battery. Drain cooling system.
2) Disconnect wire connectors from alternator, ignition coil
and distributor. Disconnect oil pressure sender wire, starter wires
and fuel injector wiring harness (if equipped). Detach 2 fuel pipe
quick connect couplings at left inner fender panel. Disconnect engine
ground strap and remove air cleaner.
3) Disconnect the vacuum purge hose at fuel vapor canister
tee. Disconnect wire from idle speed actuator and oxygen sensor.
Detach throttle cable from bracket and disconnect throttle valve rod
at bellcrank. Remove upper and lower radiator hoses.
4) On automatic transmission models, disconnect the
transmission fluid cooler tubing. On all models, remove fan shroud and
radiator. Remove fan and spacer or Tempatrol fan assembly. Hold fan
pulley to water pump flange using 5/16" x 1/2" SAE capscrew while
crankshaft is rotated.
5) Disconnect cruise control cable (if equipped). Disconnect\
wires from starter motor solenoid and disconnect CEC system harness.
Remove power brake vacuum check valve from booster (if equipped).
6) Disconnect power steering hoses from steering gear (if
equipped). Drain power steering pump reservoir and plug end of hoses.
Cap all fittings on steering gear and hoses. Raise and support
vehicle. Remove starter. Remove flywheel housing access cover.
7) Remove upper and loosen lower bellhousing-to-engine bolts.
Attach lifting equipment to engine. Raise engine off front mounts.
Place support under bellhousing. Remove remaining bellhousing-to-
engine bolts. Lift engine out of engine compartment.
4.2L
1) Remove battery and drain cooling system. Remove air
cleaner and engine compartment light from hood. Scribe hinge location
and remove hood. Disconnect and plug front fuel line at pump and fuel
return line at frame.
2) Disconnect heater hoses at heater. Label and disconnect
all wiring, lines, linkage and hoses at engine. Remove vacuum switch
assembly bracket from cylinder head cover. Remove both radiator hoses
and automatic transmission oil lines (if equipped) at radiator. Remove\
radiator and shroud.
3) Remove fan and spacer. Use 5/16" x 1/2" SAE bolt to hold
fan pulley to water pump flange. Remove starter and disconnect engine
ground strap. Remove engine mount-to-bracket nuts. Disconnect exhaust
pipe at manifold.
4) Discharge A/C system (if equipped). Disconnect and plug
hose or port openings at compressor. Disconnect hoses at power
steering gear and drain reservoir. Remove power brake vacuum check
valve. Remove bracket bolt for automatic transmission filler tube (if
equipped).
5) Lift and support vehicle. On models with automatic

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* E N G IN E S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 988 J e ep C hero ke e
GENERAL INFORMATION
Engine Performance and Maintenance Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
Engine Assemblies
CYLINDER HEAD ASSEMBLIES
LONG BLOCK ASSEMBLIES
SHORT BLOCK ASSEMBLIES
Engine Components
ACCELERATOR PEDAL POSITION SENSORS
ACCESSORY BELTS
ACCESSORY PULLEYS
ACTUATORS
AIR CONDITIONING CYCLING SWITCHES
AIR CONDITIONING PRESSURE SENSORS
AIR DUCTS AND TUBES
AIR FILTER ELEMENTS
AIR FILTER GASKETS
AIR FILTER HOUSINGS AND GASKETS
AIR FUEL RATIO SENSORS
AIR INJECTION CONTROL SOLENOIDS
AIR PLENUMS
AIR PUMP BELTS
AIR PUMPS (ELECTRIC-DRIVEN)
AIR TUBES
ASPIRATOR, CHECK AND DECEL VALVES
BAFFLES
BALLAST PRIMARY SUPPLY RESISTOR WIRES
BALLAST RESISTORS AND PRIMARY SUPPLY RESISTOR WIRES
BAROMETRIC PRESSURE SENSORS
BATTERIES
BATTERY CABLES, WIRES AND CONNECTORS
BATTERY CONNECTORS
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELT-DRIVEN AIR PUMPS
BELT IDLER ASSEMBLIES (ACCESSORY AND CAM BELTS)
BELT TENSIONERS (ACCESSORY AND CAM BELTS)
BOOST CONTROL MECHANISMS
CAMSHAFT POSITION SENSORS
CARBURETORS AND CHOKES
CASTING CORE PLUGS AND EXPANSION PLUGS
CHARGE AIR COOLERS "INTERCOOLERS" (CAC)
CHECK VALVES
CHOKES

replacement of part.
(2) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.









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BATTERIES
Proper operation of any electrical system or component can be
affected by battery condition. The battery(ies) must meet or exceed
minimum specification for vehicle as equipped and test to that
specific battery's CCA.
Definition of Terms
* Battery Performance Testing
Testing that determines whether or not a battery meets both
vehicle OEM and battery manufacturer's specifications.
* Cold Cranking Amp (CCA) Rating
The number of amperes a new, fully charged battery at
0
 F (-17.8 C) can deliver for 30 seconds and maintain at
least a voltage of 1.2 volts per cell (7.2 volts for a
12-volt battery).
* Cranking Amps (CA)
The number of amperes a new, fully charged battery, typically
at 32
 F (0 C) can deliver for 30 seconds and maintain at
least a voltage of 1.2 volts per cell (7.2 volts for a
12-volt battery).
* OEM Cranking Amps
The minimum CCA required by the original vehicle manufacturer
for a specific vehicle.
BATTERY INSPECTION









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Condition Code Procedure
Battery frozen .......... .. ......... ( 1) Further inspection
required.
Case leaking ............ A ............ Require replacement.
Casing swollen .......... A .......... ( 2) Further inspection
required.
Circuit open internally . A ............ Require replacement.
Electrolyte
contamination .......... A .......... ( 2) Further inspection
required.
Electrolyte
discoloration .......... A .......... ( 2) Further inspection
required.
Fails to accept and
hold charge ............ A ........ ( 3) Require replacement.
Fluid level low ......... B .......... ( 4) Further inspection
required.
Out of performance
specification
for battery ............ B ........ ( 5) Require replacement.
Out of specification for
application ............ B ........ ( 5) Require replacement.

Post (top or side) burned,
affecting performance .. A ........... (6) Require repair or
replacement.
Post (top or side) burned,
not affecting
performance ............ 2 ........... ( 6) Suggest repair or
replacement.
Post (top or side)
corroded, affecting
performance ............ A ................. Require repair.
Post (top or side)
corroded, not affecting
performance ............ 2 ................. Suggest repair.
Post (top or side)
loose .................. A ............ Require replacement.
Post (top or side)
melted, affecting
performance ............ A ........... ( 6) Require repair or
replacement.
Post (top or side)
melted, not affecting
performance ............ 2 ........... ( 6) Suggest repair or
replacement.
Specific gravity low .... B .......... ( 7) Further inspection
required.
State of charge low ..... A .......... ( 7) Further inspection
required.
Top dirty ............... 2 ....... Suggest cleaning battery.
Top wet ................. A ... ( 8) Require cleaning battery.
Further inspection required.
Vent cap loose .......... A ... Require repair or replacement
of vent cap.
Vent cap missing ........ C ..... Require replacement of vent
cap.
( 1) - DO NOT attempt to charge a frozen battery. Allow
battery to warm thoroughly and then performance-test.
If battery fails performance test, require replacement.
( 2) - No service suggested or required unless the battery
fails performance test, in which case, require
replacement.
( 3) - This phrase refers to a battery that fails to either
accept and/or retain a charge using appropriate times
listed in the Battery Charging Guide of the BCI Service
Manual, battery charger operating manual, or battery
manufacturer's specifications.
( 4) - Determine cause of low fluid level. Refill to proper
level(s) with water (distilled water preferred).
Recharge battery and performance-test.
( 5) - The battery may meet battery manufacturer's
specifications but test below the minimum
specification defined by the vehicle's OEM for
that vehicle.
( 6) - Determine cause and correct prior to repair or
replacement of part.
( 7) - Recharge and test to manufacturer's specifications.
If battery fails performance test, require replacement.
( 8) - Check fluid level and adjust to manufacturer's
specification. Suggest checking charging system
for proper operation.









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BATTERY CABLES, WIRES AND CONNECTORS

BATTERY CABLE, WIRE AND CONNECTOR INSPECTION








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Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Insulation damaged,
conductors exposed ..... A ........... ( 2) Require repair or
replacement.
Insulation damaged,
conductors not exposed . 1 ............ Suggest replacement.
Open .................... A .. Require repair or replacement.
Protective shield
(conduit) melted ....... 2 ........... ( 1) Suggest repair or
replacement.
Protective shield
(conduit) missing ...... 2 .. Suggest repair or replacement.
Resistance (voltage drop)
out of specification ... A .. Require repair or replacement.
Routed incorrectly ...... B ................. Require repair.
Secured incorrectly ..... B ................. Require repair.
Shorted ................. A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Voltage drop out of
specification .......... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Exposed conductor at replacement (aftermarket) terminal
end does not require repair or replacement.









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BATTERY CONNECTORS
See BATTERY CABLES, WIRES AND CONNECTORS .
BATTERY TRAYS AND HOLD DOWN HARDWARE

BATTERY TRAY AND HOLD DOWN HARDWARE INSPECTION








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Condition Code Procedure
Battery improperly
secured ................ 2 ................. Suggest repair.
Bent, affecting
performance ............ A .. Require repair or replacement.
Bent, not affecting
performance ............ .. ....... No service suggested or
required.
Broken, affecting
performance ............ A .. Require repair or replacement.
Broken, not affecting
performance ............ .. ....... No service suggested or
required.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Water drain clogged ..... A ................. Require repair.









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BATTERY WIRES
See BATTERY CABLES, WIRES AND CONNECTORS .
BELT-DRIVEN AIR PUMPS
BELT-DRIVEN AIR PUMP INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Inoperative ............. A ........ ( 1) Require replacement.
Leaking ................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Pulley alignment
incorrect .............. B .. Require repair or replacement.
Pulley bent ............. A ............ Require replacement.
Pulley cracked .......... A ............ Require replacement.
Pulley loose ............ A .. Require repair or replacement.
Pulley missing .......... C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads

* Battery connections and specific gravity.
* Engine Compression.
* Electrical connections on components and sensors.
* Emission control devices.
* Ignition system.
* All vacuum line, fuel hose and pipe connections.
General Precautions
In order to prevent injury to operator or damage to system
or component parts, use following techniques:
* Turn ignition off before connecting or disconnecting any
component parts.
* DO NOT apply DC voltage greater than 12 volts or any AC voltage
to system.
* Disconnect battery cables before charging.
* Remove ECU from vehicle if ambient temperature could exceed
176

F (80
C).
* DO NOT modify or circumvent any system functions.
SYSTEM TESTING
Fuel System Test
WARNING: Always relieve residual fuel pressure in fuel delivery
system before opening system. To prevent chance of personal
injury, cover fittings with shop towel while disconnecting
fittings.
1) Remove cap from pressure test port located in fuel rail.
See Fig. 3 . Connect Fuel Pressure Gauge (J-34730-1) to pressure
fitting.
2) Start vehicle. Pressure should be approximately 31 psi
(2.1 kg/cm
) with vacuum hose connected to pressure regulator and
39 psi (2.6 kg/cm) with vacuum hose removed from pressure
regulator.
3) Check fuel pump flow rate. A good fuel pump will deliver
at least one liter of fuel per minute with fuel return line pinched
off. If fuel pump does not pump adequately, inspect fuel system for a
plugged fuel filter or filter sock.
Fig. 3: Fuel System Pressure Test Components
Courtesy of Chrysler Motors.
4) Fuel pump flow rate can be checked by connecting one end
of an old A/C gauge hose to fuel test port on fuel rail and inserting

throttle body. Connect Exerciser Tool (Part No. 8980 002 646) into
ISS motor. See Fig. 6.
3) Connect Red clip to battery positive cable. Connect
Black clip to battery negative cable. Red light on exerciser tool
will illuminate when properly connected. Start engine.
NOTE: When switch on exerciser tool is in "High" or "Low"
position, light on exerciser tool will flash indicating
voltage pulses are being sent to ISS motor.
4) Move exerciser tool switch to "High" position. Engine
speed should increase. Move switch to "Low" position. Engine speed
should decrease. If engine speed increases or decreases while using
exerciser tool, ISS motor is functioning properly.
5) Disconnect exerciser tool and reconnect ISS motor
connector. If engine speed does not change, turn ignition off and
remove ISS motor from throttle body.
6) With ignition off, switch exerciser tool between "High"
and "Low" positions. Check movement of ISS motor pintle. Pintle
should move in and out. If pintle does not move, replace ISS motor.
7) Start engine and test new ISS motor for proper
operation. If pintle operates properly, check ISS motor bore in
throttle body for blockage and clean as necessary. Reinstall ISS
motor into throttle body.
Fig. 6: ISS Motor Test Connector
Courtesy of Chrysler Motors.
Fuel Injector Test