Jeep 1987 Wrangler Instruction manual

Jeep.
Wrangler/YJ
Workshop
M.R.280
BODYWORK
MARCH, 1986U.S.A./CanadaEdition
8980 010298
All informationandspecifications in thismanualare based on the latest
data availableatthetimeof publication. AmericanMotorsCorpora-
tion and Jeep Corporation reserve therighttodiscontinue designs or
change specificationswithoutnoticeorincurringobligation.
Copyright © 1986AmericanMotorsCorporationand Jeep Corporation.
All rights reserved. Litho inU.S.A.
Wranglerisa registeredtrademarkintheU.S.A.
YJ isa registeredtrademarkin Canada

CONTENTS
(Thereisa more detailed contentspageatthebeginningofeverychapter.)
— GENERAL BODY
Hood
P-45
Specifications N-1 SeatAssemblies P-47 Specifications N-1 RollBar P-51
Towing— Breakdown N-9
N-11
SeatBelts P-54
Recovery
Lifting Methods
N-9
N-11 Carpet P-55
DrivelineLubrication N-12
R — SEALING
Tools N-13
R — SEALING
Products N-16 SealantApplication R-1
Metric-Decimal
Water LeakDiagnosis
ConversionTables N-18 AndRepair R-9
Water LeakDiagnosis
— DETACHABLE
AndRepair R-10
COMPONENTS
GeneralDescription P-1
S — WELDED
GeneralDescription P-1 COMPONENTS
Windshield COMPONENTS
Replacement P-4 BodyAndFrame
Tailgate P-11 Components S-1
Hard TopEnclosure P-15 FrameSpecifications
S-4
Instrument PanelAnd Body
Holddown
Components P-23 Specifications S-6
Fenders
P-32 BodyRepair
RadiatorGrille P-34
Information S-9
SoftTop P-37
Rear CornerCollision
Bumpers P-42 Repair S-41
FrontSidePanel
CollisionRepairS-53
Rear BodyCollision
Repairs S-57
Side BodyCollision
RepairS-62
Side BodyPanel
CollisionRepairS-67
T— PAINT AND TRIM
PaintAnd Trim Color
Identification T-1
Color Matching T-4
SandpaperT-8
ExteriorRefinishingT-9
RefinishingPlastic
ComponentsT-18
RefinishingPlastic
ComponentsT-23
Refinishing Materials T-24
CorrosionProtectionT-28
ExteriorDecalsT-31
c
E
E
E
E

RECORDING I.S.NOTES
Ruled boxesforrecordingpertinentI.S.Notes
andother service informationareprovided
alongtheouteredgeofeachpageinthemanu-
al. The filing instructionsattheendofeachI.S.
Note specifythepageanI.S. Note istobere-
corded on.Thisprovidesa convenientrefer-
ence to service updatesand/or revisions affect-
ingtheinformationonthepage.
SPECIAL TOOLS
Special toolsneededforthe service operations
described inthismanualarelistedatthebegin-
ningofeachchapter.Thetoolsare also listedin
theappropriatesectionofeachchapter.
WIRINGDIAGRAMS
Wiringdiagramsareprintedseparatelyand
should befiledinthepocketatthebackofthe
plastic binder.Thediagramsprovidethe loca-
tion ofelectricalcomponentsonthevehicleand
howtheyareconnectedand/orwired.
SAFETY NOTES
Cautions andWarningsareusedthroughout
this manual.Theyrelatetocriticaloperations
involvingpersonalsafetyorpotentialcompo-
nentdamage.Cautionsareusedwhenever
componentdamagecould occur if service pro-
cedures arenotfollowed.Warningsareused
whenproceduresmustbefollowedexplicitlyfor
personal safety.Useextremecareandadhere
tostatedprocedureswheninvolvedin such
operations.

/ROOOONj-J
(O illOil1
\0000 000/11
GENERAL
/ROOOOVJ
(O inOil1
\0000000/1_—I
/ROOOONj-J
(O illOil1
\0000 000/11 CONTENTS
/ROOOOVJ
(O inOil1
\0000000/1_—I
SPECIFICATIONS . 1
DIMENSIONS 1
VEHICLE IDENTIFICATIONNUMBER
(VIN). 3
SAFETY CERTIFICATION LABEL 4
VEHICLE IDENTIFICATION PLATE 5
POWERTRAINAVAILABILITY5
FUEL-FLUIDS-LUBRICANTS 6
FLUIDCAPACITIES7
ADHESIVES AND SEALERS..... 8
TOWING-BREAKDOWN RECOVERY.. 9
TOWING SAFETY PRECAUTIONS9
FRONT TOWING 9
REAR TOWING 10
LIFTINGMETHODS11
FLOOR JACK-SAFETY STANDS-HOIST11
DRIVELINELUBRICATION12
LUBRICANTCHANGEAND
INSPECTION12
INTERVALS 12
TOOLS 13
PRODUCTS 16
METRIC-DECIMAL
CONVERSION TABLES 18
I

(O inoni
JDOOODOO7L- .J
GENERAL
SPECIFICATIONS
/R0000\,
(O m O) I
.000000071
DIMENSIONS
A
Overalllength with Polyspare
with ConventionalSpare 386cm(152in.)
388.9 cm(153in.)
B Overall width
167.6cm(66in.)
C
Overallheight (empty)
OpenBody
SoftTop
Hard Top
172.7cm(68in.)
N/A
175.2cm(69in.)
D Wheelbase 237cm(93.4in.)
E Front/Reartrack 147.3cm(58in.)
101166
N-1

/ROOOOVj
(O •••Oil1
\0000 000/11
GENERAL
/ROOOONj J
(O •••Oil1
\0000 000/11
/ROOOOVj
(O •••Oil1
\0000 000/11
SPECIFICATIONS
/ROOOONj J
(O •••Oil1
\0000 000/11
DIMENSIONS (CONTD.)
Head Room (Hard Top):
Driver front seat 102.1 cm (40.2 in.)
Passenger front seat... 101.6 cm (40.0 in.)
Rearseat 102.9 cm (40.5 in.)
Leg Room:
Driver front seat 100.3 cm (39.5 in.)
Passenger front seat... 100.6 cm (39.6 in.)
Rearseat 88.9 cm (35.0 in.)
ShoulderRoom:
Front 134.8 cm (53.1 in.)
Rear 143.0 cm (56.3 in.)
HipRoom:
Front 134.8 cm (53.1 in.)
Rear.. 91.4 cm (36.0 in.)
UsableCargo Volume:
Rearseat folded
1.2cubic meters (43.2cubic feet)
Rearseat removed
1.5cubic meters (53.4cubic feet)
Rearcargoarea
0.35cubic meters (12.5cubic feet)
GroundClearance:
Rear axle to ground * 20.8cm(8.18in.)
(running clearance)
Skid plate to ground * 24.0cm(9.45in.)
(minimum running clearance)
* With P215/75R15 tires.
Wheelbase: 237.2 cm(93.4in.)
Maximum GVWR...1882 kilograms (4150lbs.)
N-;2

/ROOOON' 1
(O ill O) 1 8
\J II® 000/5 —J
GENERAL
/R0000\r-1
(O HIOil1
\oonoooo/i1
/ROOOON' 1
(O ill O) 1 8
\J II® 000/5 —J
SPECIFICATIONS
/R0000\r-1
(O HIOil1
\oonoooo/i1
VEHICLE IDENTIFICATIONNUMBER(VIN)
Thevehicleidentificationnumber(VIN)islocat-
edonthe left sideoftheinstrumentpanelatthe
base ofthewindshield.TheVINchartexplains
thecodecharacters.
TRANSMISSION- TRANSFER CASE
E—3 SPEED AUTO.— PARTTIME
L—5 SPEED MANUAL— PARTTIME
C-MPV
MANUFACTURING
COUNTRY
2—CANADA
B
MANUFACTURER
B—JEEP CORP.
CANADA
ENGINE TYPE
C—258 CUBIC IN.
(4.2L),2V,1-6
AMC- GASOLINE
H—150 CUBIC IN.
(2.46L), FUEL
INJECTION I-4
AMC- GASOLINE
TRIM TYPE ANDGVWR
1—BASE 4001-5000 LBS.
(1815-2268 kg.)
3— SPORT 4001-5000 LBS.
(1815-2268 kg.)
4— LAREDO 4001-5000 LBS.
(1815-2268 kg.)
J—BASE 3001-4000 LBS.
(1361-1814 kg.)
K—SPORT 3001-4000 LBS.
(1361-1814 kg.)
L—LAREDO 3001-4000 LBS.
(1361-1814 kg.)
81
K
H
MANUFACTURING
PLANT
B—BRAMPTON
B
CHECK DIGIT
MODEL YEAR
H—1987
500001
I, I
SERIES
81—2 DR.MPV
(WRANGLER/YJ-S)
82—2 DR.MPV
(WRANGLER/YJ-L)
SEE
I.S
N
O
T
E
S
l
SERIAL NUMBER
SIX DIGITSEQUENTIAL
SERIAL NUMBER
101030
N-3

/ROOOONiJ
(O illOil1
\0000 000/» 1
GENERAL /R0000\« J
(O INOil1
\0000000/11
/ROOOONiJ
(O illOil1
\0000 000/» 1
SPECIFICATIONS
/R0000\« J
(O INOil1
\0000000/11
SAFETY CERTIFICATION LABEL
A safetycertificationlabelisattachedtoall
Wrangler/YJmodels.Thelabelindicates that
thevehicleconformstoFederal motor vehicle
safetycertificationstandards.Thelabelislocat-
edonthedriverdoorpillar.
GVWR.j
GAWR. FRT.I
EE
S.
N
0
T
E
S
ri MFD.
BYJEEP CORPORATION
DATE
J TIRES
I P.S.I. COLD
"I TIRES
THIS VEHICLE CONFORMS TOALL APPLICABLE FEDERAL
MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE
DATE OF MANUFACTURE SHOWN ABOVE
P.S.I. COLD
VEHICLE IDENTIFICATIONNUMBER|
TYPE |
SF5363927
84069
I
N-4

/ROOWjNi 1
(O illOil1
\0000 000/6 1
GENERAL
/ROOOON; 1
(O IIIOil1
\0000 000/1—- i
/ROOWjNi 1
(O illOil1
\0000 000/6 1
SPECIFICATIONS
/ROOOON; 1
(O IIIOil1
\0000 000/1—- i
VEHICLEIDENTIFICATIONPLATE
The metal identification plate is attached tothe
radiatorsupport. The plate displays theVIN,
paint code, trim code,fabricationsequence
number, and vehicleequipmentcode (e.g.49-
State,Canada,California,high altitude).
POWERTRAIN AVAILABILITY
SERIES
ENGINE
TRANSMISSION
TRANSFER
CASE
AXLE RATIO
(STD./OPT.)
80
(Wrangler/YJ)
2.46L
(150cu.in.)
InLine
4-Cyl.
5-SPD. MAN.
207 4.10
80
(Wrangler/YJ) 4.2L
(258cu.in.)
InLine
6-Cyl.
5-SPD. MAN.
3-SPD. AUTO. 207
3.08/3.55
101016
N-5

FUEL-FLUIDS-LUBRICANTS
Engine
I-4-1V
2.46liter
(150cu.in.)
I-6-2V
4.2liter
(258cu.in.)
API "SF" Classification
10W-30,10W-40, 20W-40 Above± 32°F(0°C)
10W-30, 10W-40 Above0°F (-18°C)
5W-30*Below 0°F(-18°C)
*Mustnotbe used above 60°F(15.5°C)
OilFilter I-42.46L
1-64.2L Metricthread
M20x 1.5P/N8933003509
Transmission
999Auto
BA10/5 Man.
AX5 Man.
Use AMC/Jeep/Renaultautomatictransmissionfluidor
equivalent Dexron® IIfluid.
Use AMC/Jeep/Renaultgearlubricant,orequivalent 75W-90
(APIGL-5)lubricant.
Transfer Case
207
Use onlyAMC/Jeep/Renaultautomatictransmissionfluid
orequivalent Dexron® IIfluid.
Axle
Front/Rear
Use AMC/Jeep/RenaultgearlubricantorequivalentSAE
75W-90,APIGL-5qualitygearlubricant.
Brake Fluid All
Use AMC/Jeep/Renaultbrakefluidorequivalentidentifiedas
FMVSS 116DOT-3andSAEJ-17034.
CAUTION: Userecommendedbrakefluidonly.
Engine Coolant All
Use AMC/Jeep/Renaultall season antifreeze(orequivalent
ethylene glycol-based antifreeze)containingAlugard 340-2™
andcleanwaterina 50/50 mixture.
Fuel
All Unleaded
with AKIoctaneratingofatleast87.
Clutch
Hydraulic
Reservoir
Use AMC/Jeep/RenaultbrakefluidP/N8982200215,or
equivalentidentifiedasFMVSS116DOT-3andSAEJ-1703.
CAUTION: Userecommendedbrakefluidsonly.
Power Steering
Pump
Use AMC/Jeep/Renaultpowersteeringfluidorequivalent.
Steering
Linkage, Ball
Joints, Propeller
Shafts, Cardan
Joints, Wheel
Bearings
Use AMC/Jeep/Renaultallpurposelubricantorequivalent
lithium base chassis lubricant.
Parking
Brake Pedal
Mechanism
Use AMC/Jeep/Renaultwhitespraygreaseorequivalent.
ManualSteering
Gear
Use AMC/Jeep/Renaultallpurposelubricantoranequivalent
lithium base chassis lubricant.
101017
N-6

/^OOOONf-;
(O MlOilI
\0000 000/1 —-I
GENERAL
/ROOO^Ni1
(O inOil1
\0Q00 000/1 1
/^OOOONf-;
(O MlOilI
\0000 000/1 —-I
SPECIFICATIONS
/ROOO^Ni1
(O inOil1
\0Q00 000/1 1
FLUID CAPACITIES
Capacities
(ApproximateRefill)
U.S.
Measure Imperial
Measure
Metric
Measure
Engine Oil:
2.46 liter 1-4 (with or without
filter change)
4.2 liter 1-6 (with or without
filter change)
4.0quarts
3.33 quarts
3.78 liters
Engine Oil:
2.46 liter 1-4 (with or without
filter change)
4.2 liter 1-6 (with or without
filter change) 6.0quarts 5.0quarts 5.7liters
Cooling System: (includes
coolantoverflow bottle)
2.46 liter 1-4
4.2 liter 1-6
9.0quarts 75 quarts 8.5liters
Cooling System: (includes
coolantoverflow bottle)
2.46 liter 1-4
4.2 liter 1-6
10.5 quarts 8.7quarts
9.9 liters
Transmission:
BA10/5Man.
AX5Man.
999 Auto.
3.5pints
2.9 pints 1.7liters
Transmission:
BA10/5Man.
AX5Man.
999 Auto.
7.0pints 5.8pints
3.3 liters
Transmission:
BA10/5Man.
AX5Man.
999 Auto. 17.0pints 14.0pints 8.0liters
Transfer Case:
Model 207 4.5pints 3.74pints 2.13liters
Axles:
Front/Rear
2.5pints 2.1pints 1.2liters
Axles:
Front/Rear
Fuel Tank(approx.cap.)
StandardTank
OptionalTank
15.0gallons 12.6gallons 57.0liters
Fuel Tank(approx.cap.)
StandardTank
OptionalTank 20.0gallons 16.8gallons 75.5liters
I
101018
N-7

/ROOOONr-—-i
BO III0111
\0BM0M/i 1
GENERAL
/ROOOOV 1
(O Ml0)11
\0000 OOO/l 1
/ROOOONr-—-i
BO III0111
\0BM0M/i 1
SPECIFICATIONS
/ROOOOV 1
(O Ml0)11
\0000 OOO/l 1
ADHESIVES AND SEALERS
Adhesives/Sealers/Cleaners
Purpose
Loctite242 (Medium strength) Preventslooseningofbolts,
nuts, screws. Doesnotrequire
re-applicationevery time
fasteners areloosenedand
tightened.
Loctite271 (High strength)
Locks bolts,nuts, screws.
Must bereappliediffastener
is loosened.
Loctite290orWickn' Lock
(Medium strength, penetrating)
Preventslooseningof
fasteners, adjustment screws,
etc. Canbeapplied after
fastenerisseated.
LoctiteSuperbonder
For quickbondingofnon-
porousmaterials (glass, metal,
rubber,vinylandplastics).
PermatexGasket
Remover
For removalofgasketsand
cleaninggasket surfaces.
AMC/JeepGasket-ln-A-Tube
orPerfectSealRTVSealant ForusewhereverRTV-Type
sealant isspecified.
84107
N-8

/ROOQOV "i
(O MIOil1
\0000 000/1 1
GENERAL
/msioeNl;
(O MlOil1
\0000 000/1 i
/ROOQOV "i
(O MIOil1
\0000 000/1 1
TOWING-BREAKDOWN RECOVERY
/msioeNl;
(O MlOil1
\0000 000/1 i
TOWINGSAFETYPRECAUTIONS
Secure alllooseorprotrudingpartsofa dam-
agedvehicle.
Lifttheendofa vehiclebeingtoweda minimum
of4-inchesofftheroad surface. Be sure the
oppositeendofthevehicle also hasadequate
groundclearance.
Use safety chains atalltimes.The chains must
beindependantofthetowtruck lifting and tow-
ingattachments.
Donotallowanyportionofthe lifting ortowing
attachmentstobearagainstthefueltankofthe
vehicle beingtowed.
Donotgounderthevehicleafterithasbeen
raised bythe lifting andtowingattachments.
Donotallowanyonetorideina vehiclebeing
towed.
Follow allStateandlocallawsregardingtow
speeds, warninglights,andnighttime
illumination.
Donot attempt a towingoperation that could
jeopardizetheoperator,bystanders,orother
motorists.
Donotexceeda towingspeedof48km/h(30
mph).
Avoidtowing distances ofmorethan24km(15
miles) whenever possible.
Use towingdolliesora carhauler-typetype
wrecker wheneverthevehicleislockedandthe
ignitionkeyisnotavailable.Usedolliesora
hauler-typewreckerwhenever transmission,
transfer case oraxledamageis suspected.
Neverattachtow chains ora towslingtothe
bumper,steeringlinkage,universaljointsor
propellershaft.
FRONT TOWING
CAUTION: Usetow chains with T-hooksforat-
tachmenttotheframe rails. Donotuse J-hooks
underany circumstances.
AttachtheT-hooks(A)tothe slots inthe front
endofeachframerail.
Position eachchainoverthetopofeach front
spring shackle (B).
Doublewrapeach chain.
Position thetowbarunderthe front bumper.
Attachthesafety chains (C)tothelowerhalfof
the front spring shackles.
SEE
I.S.
N
O
T
E
S
l
101267
N-9

/ROOOONI•
(O illOil1
\0000 000/1 1
GENERAL
/ROOOONi™|
[O illOil1
\0000 000/1 -1
/ROOOONI•
(O illOil1
\0000 000/1 1 TOWING-BREAKDOWN
RECOVERY
/ROOOONi™|
[O illOil1
\0000 000/1 -1
REAR TOWING
Shiftthetransmissionandtransfer case into
Neutral.
Raise andtowthevehicleata maximumspeed
of48km/h(30mph).Keep towing distance
under24km(15miles)wheneverpossible.
N-10

/RBOOOV1
(O illOilI
\OO0O 000/1 1
GENERAL
/ROOOONjJ
(O •••Oil1
\0I00 000/1 —i
/RBOOOV1
(O illOilI
\OO0O 000/1 1 LIFTINGMETHODS
/ROOOONjJ
(O •••Oil1
\0I00 000/1 —i
FLOOR JACK-SAFETY STANDS-HOIST
Normal shop lifting equipmentmaybeusedto
raise andsupportWrangler/YJmodelsduring
service operations.
Floor Jack-SafetyStands
Position floor jacksorsafetystandsunderthe
frame rails.Placethejackorsafetystand lifting
padonthe frame railjustaheadoftherear
springshackle,orjustbehindthe front spring
shackle. Besurethejackorstandispositioned
ona levelsectionofthe frame rail.
Hoist
Wrangler/YJmodelscanberaised with thefol-
lowing type ofhoist:
• Swivelingarmhoist.
• Ramp-type(drive-on)hoist.
• Wheel lift, twin posthoist.
NOTE: Ifa swivelingarmhoistisbeing used, be
sure the lifting padsarepositionedatthesame
frame raillocationsrecommendedfor floor
jack-safetystandusage.
CAUTION:Toavoiddamagingthevehicle,do
notraisethevehicle with a floor jackpositioned
undertheaxletubes,bodysheetmetal,steer-
inglinkagecomponents,propellershafts,en-
gine/transmissionoilpans,or fuel tank. Usethe
recommended lift pointsonly.
N-11

/ROOOOV»
(O illOil1
\0000000/1 1
GENERAL
/R0000\iJ
to HIo)ii
\0000 000/1 1
/ROOOOV»
(O illOil1
\0000000/1 1
DRIVELINE LUBRICATION
/R0000\iJ
to HIo)ii
\0000 000/1 1
EE
S.
N
0
T
E
S
i
LUBRICANT CHANGEANDINSPECTION
INTERVALS
Recommendedlubricantchangeandinspection
intervalsfortheengine,transmission,transfer
case andaxlesareasfollows:
Engine Oil
Change engineoilat12000km (7,500 mile)
intervals.
Check engineoillevelatevery fuel fill.Correct
levelisbetweentheAddandFullmarksonthe
enginedipstick.
RefertotheRecommendedFuel-Liquids-Lubri-
cants sectioninthischapterforrecommended
engineoilgrade andviscosity.
Manual Transmission Lubricant
Change manualtransmissionlubricantat
48000km (30,000 mileintervals).
Check lubricantlevelevery12000 km (7,500
miles). Correctlubricantlevelistothe bottom
edgeofthe fill plughole.
Use JeepgearlubricantoranequivalentSAE
75W-90, APIGradeGL-5gearlubricantfortop
offor refill purposes.
AutomaticTransmissionFluidandFilter
Change theautomatictransmission fluid and
filter at48000 km (30,000 mile)intervals.
Check fluid levelevery12000km (7,500 miles).
Correct fluid levelisbetweentheAddandFull
marksonthetransmissiondipstick.
Check the fluid level with theenginerunning
andthetransmissioninParkposition.The fluid
mustbeatnormaloperatingtemperaturetoen-
sure anaccuratereading.
Use Jeepautomatictransmission fluid oran
equivalent Dexron® II fluid only.
Transfer Case Lubricant
Change transfer case lubricantat48000km
(30,000 mile)intervals.
Check lubricantlevelevery12000km (7,500
miles). Correctlubricantlevelistothe bottom
edgeofthe fill plughole.
Use Jeepautomatictransmission fluid oran
equivalent Dexron® II fluid only.
AxleLubricant
Change front andrearaxlelubricantat48000
km (30,000 mile)intervals.
Check lubricantlevelevery12000km (7,500
miles). Correctlubricantlevelistothe bottom
edgeofthe fill plug hole.
Use JeepgearlubricantoranequivalentSAE
75W-90, APIGradeGL-5gearlubricantfortop
offor refill purposes.
N-12