Jeep J-10 Series 1982 Operating manual

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^ Jeep
Jeep,
TECHNICAL
SERVICE
MANUAL

FOREWORD
All information and specificationsin this manual are based on the latest data avail
able at the time of publication. Jeep Corporation reserves the right to discontinue
models and change specifications or design without notice or incurringobligation.
Trade names mentioned in this manual are for convenienceonly and are not intend
ed to be a recommendation to
use aspecific brand ofproduct. They are indicativeof
aclass or
type and may be substituted by an equivalent product.
Proper service and repair are essential to the safe and reliable operation of a motor
vehicle. This manual contains recommended methods for performing proper service
and repair. Use of improper methods could cause personal injury and render the
vehicle unsafe.
Detailed descriptions of standard workshop safety procedures are not included in
this manual. This manual does contain WARNINGS for some service procedures that
could cause personal injury, and CAUTIONS for some procedures that could damage
the vehicle or its components. Please understand that these WARNINGS and CAU
TIONS do not cover all conceivable ways which service might be done or all possible
hazardous consequences of each conceivable way. Anyone using service procedures
or tools (whether or not recommended by Jeep Corporation) must satisfy himself that
neither personal nor vehicle safety will be jeopardized by the procedures or tools
selected.
Jeep, CJ, Scrambler, Cherokee, and Wagoneer are registered trademarks of Jeep Corporation.
PI B, AMC are registered trademarks of American Motors Corporation.
In Canada, American Motors (Canada) Inc. is a licensed user.

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-
1982
JEEP TECHNICAL
SERVICE MANUAL
F1 Jeep Corporation
Service Department
Copyright- 1982 Jeep Corporation
All
Rights Reserved Litho in U.S.A.
1MB
2K2L
General Information |
Maintenance |
CHAPTERS
1A GENERAL SERVICE AND DIAGNOSIS
1B ENGINES
1C COOLING SYSTEMS
1D BATTERIES
1E CHARGING SYSTEM
1F STARTING SYSTEM
1G IGNITION SYSTEM
1H CRUISE COMMAND
1J FUEL SYSTEMS
1K EXHAUST SYSTEMS
1L ENGINE INSTRUMENTATION
CHAPTERS
2A CLUTCH
2B MANUAL TRANSMISSION
2C AUTOMATIC TRANSMISSION
2D TRANSFER CASE
2E PROPELLER SHAFT
2F AXLES
2G BRAKES
2H WHEELS AND TIRES
2J STEERING COLUMNS
2K MANUAL STEERING GEAR
2L POWER STEERING GEAR AND PUMP
2M STEERING LINKAGE
2N SUSPENSION
CHAPTERS
3A WATER LEAK/WIND NOISE
DIAGNOSIS AND REPAIR
3B METAL REPAIR AND PAINTING
3C INSTRUMENT PANELS
AND COMPONENTS
3D HEATER
3E AIR CONDITIONING
3F BODY AND FRAME COMPONENTS
3G HOODS
3H UFTGATES — TAILGATES
3J DOORS
3K REAR QUARTER
3L HARDTOP ENCLOSURE — SUN ROOF
AND LUGGAGE RACKS
3M SEAT ASSEMBLIES
3N WINDSHIELD —REAR WINDOW
3P HEADLINING — EXTERIOR DECALS
AND OVERLAYS
3R LIGHTING SYSTEMS
3S HORN SYSTEMS
3T WINDSHIELD WIPERS
3U TAILGATE WINDOW DEFOGGER
3V RADIO SOUND SYSTEMS
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Alphabetical Index |
Vacuum Line Routing Diagrams |
Wiring Diagrams j

A-1
GENERAL
INFORMATION
INDEX
1982 Model Jeep Vehicles
Conversion of English and
Metric Measures
Decimal Equivalents
General Dimensions
How To Use This Manual
Keys and Locks
Pigs
A-3
ah
A-15
A-n
A-1
A-8
HOW TO USE THIS MANUAL
Organization
This manual is divided into three major parts: Part
1—Power Plant, Part 2—Chassis and Part 3—Body.
These
parts are comprised of chapters pertaining to the
various topics. The Index at the front of this manual has
a locator tab for each part.
The first page of each chapter in this manual contains
a black tab in a position corresponding to the tab on the
Chapter Index page for each part. To locate adesired
chapter, simply fold back the manual slightly so that the
outside edges of the pages are exposed. Find the black
tab that aligns with the tab on the Chapter Index page
and open to the desired chapter.
Each chapter begins with an alphabetical index of
subjects.
Locate the desired subject and turn to the
appropriate page. If the subject is broad, the chapter is
divided
into sections and asubject index of each section
is also included. An
alphabetical index of all subjects is
located at the back of this manual.
Each chapter ends with specifications, torque charts
and special tools pertinent to that chapter.
Warnings and Cautions
Detailed descriptions of standard workshop safety
procedures are not included in this manual. This manual
does contain WARNINGS for some service procedures
that could cause personal injury, and CAUTIONS for
some procedures that could damage the vehicle or its
components. Please understand that these WARNINGS
and CAUTIONS do not cover all conceivable ways which
service might be done or all possible hazardous con
sequences of each conceivable way. Anyone using ser
vice procedures or tools (whether or not recommended
-
Metric System—SI
Powertrain-Driveline Combinations
Standard Torque Specifications and Capscrew Markings
Towing
Vehicle Identification
BO
Pigi
A-14
A-13
A-2
A-8
A-7
by Jeep Corporation) must satisfy himself that neither
personal nor vehicle safety will be jeopardized by the
procedures or tools selected.
Diagnosis and Repair Simplification (DARS) Charts
In several places throughout this manual, Jeep Corpo
ration's new Diagnosis and Repair Simplification
(DARS)
charts provide a graphic method of diagnosis
and troubleshooting through the use of pictures and
symbols.
The DARS charts are different from the ones you
have used before. They
are not "go-no go" decision trees
or tables.
Condition Possible Cause Correction
80371 A
Instead, the new DARS charts use pictures plus afew
words to help you solve a problem.. :
STEP SEQUENCE RESULT
80371B

A-2 GENERAL INFORMATION
and symbols and words help guide you through each
step...
0 <S> © ® 0
CHECK
CONNECT DISCONNECT REPAIR OR
REPLACE
80371C
The charts are divided into three sections: step, se
quence and result. Always start at the first step and go
through
the complete sequence from left to right.
80371o
Asequence could be checking pressure in all tires and
inflating to specified pressures. If the problem is solved,
the symbol @ will send you to @ . If the prob
lem is not solved, the symbol @) will send you
through another sequence of checks which ends with a
result and tells you the next step to go to.
Work through eachstep of the DARS charts until the
system is repaired
Service Diagnosis Charts
You will also find Service Diagnosis Charts through
out this manual. These charts list causes of specific
problems in descending order of probability.
It is more
likely that aproblem would result from the first listed
"possible cause"
than the fourth, for instance.
Visual inspection often leads directly to the correct
solution. All service procedures should begin with a
careful visual inspection of any suspected part or
assembly.
Torque Information
Individual torque charts appear at the end of each
chapter. Torque values are expressed two ways, Set-To
and In-Use Recheck. The Set-To value is used when
assembling components. The In-Use Recheck value is
used to check pretightened items.
Refer to
the Standard Torque Specifications and Cap-
screw Markings
Chart in this chapter for torques not
listed in individual torque charts. Note that torque spec
ifications given in the chart are based on use of clean
and dry threads. Reduce torque by 10 percent when
threads are lubricated with engine oil and by 20 percent
if new plated capscrews are used.
Standard Torque Specifications and Capscrew Markings Chart
CAPSCREW HEAD MARKINGS
CAPSCREW
BODY SIZE
Inches — Thread
SAE GRADE 1 or 2
(Used Infrequently)
SAE GRADE 5
(Used Frequently)
SAE GRADE 6 or 7
(Used at Times)
SAE GRAOE 8
(Used Frequently)
Torque Torque
Torque
Torque
Ft-Lb Nm
Ft-Lb Nm
Ft-Lb
Nm Ft-Lb
Nm
Manufacturer's marks may vary.
The— Una markings on heads
shown below, tor example, indi
cate SAE Grade 5.
SAE lor 2 SAE 5
1/4-20
-28
5
6
6.7791
8.1349
8
10
10.8465
13.5582
10
13.5582
12
14
16.2698
18.9815
5/16-18
-24
11
13
14.9140
17.6256
17
19
23 0489
25.7605
19
25.7605
24
27
32.5396
36 6071
3/8-16
-24
18
20
24.4047
27.1164
31
35
42.0304
47.4536
34
46.0978
44
49
59.6560
66.4351
7/16-14
-20
28
30
37.9629
40.6745
49
55
66.4351
74.5700
55
74.5700
70
78
943073
105.7538
1/2-13
-20
39
41
52.8769
55.5885
75
85
101.6863
115.2445
85
115.2445
105
120
142.3609
162.6960
9/16-12
-18
51
55
69.1467
74.5700
110
120
149.1380
162.6960
120
162.6960 155
170
210.1490
230.4860
5/8-11
-18
83
95
112.5329
128.8027
150
170
203.3700
230.4860
167
226.4186
210
240
284.7180
32S.3920
3/4-10
-16
105
115
142.3609
155.9170
270
295
366.0660
399.9610
280 379.6240
375
420
508.4250
569.4360
7/8- 9
-14
160
175
216.9280
237.2650
395
435
535.5410
589.7730
440
596.5520 605
675
820.2590
915.1650
SAE 8 or 7 8AE8
1- 8
-14
235
250
318.6130
338.9500
590
660
799.9220
894.8280
660
894.8280
910
990
1233.7780
1342.2420
70090

Torx-Head Fasteners
Various sizes of internal and external hex-lobular
(Torx) head fasteners are used as attaching hardware on
numerous components and assemblies in 1981 Jeep ve
hicles.
Due to the ever-changing usage and application
of automotive fasteners, Torx-head fasteners may not be
identified as such throughout this manual. However,
these fasteners may be removed or installed using Tool
Set J-25359-C.
Service Manual Improvements
You are encouraged to report any errors, omissions, or
recommendations for improving this publication. A
form provided for this purpose is included at the end of
this chapter.
1982 MODEL JEEP VEHICLES
CJ/Scrambler Models
Two CJ models are available for 1982: the 83.4-inch
wheelbase CJ-5, model 85, and the 93.4-inch wheelbase
CJ-7, model 87. See figures A-1 and A-2. Beyond the 10-
inch difference in wheelbase, CJ-5 and CJ-7 differ pri
marily in available options. CJ-7 models are available
with an automatic transmission, soft top with metal
doors, moulded hardtop and moon roof. These options
are not available on CJ-5 models.
The Renegade package continues to be offered on CJ
models for 1982. The package features "Tracker PG"
L78xl5 tubeless tires mounted on 7-inch wide, styled-
steel wheels along with unique exterior and interior
trim.
The Laredo package is available on CJ models for
1982. It includes unique exterior paint and decals;
chrome front bumper, rear bumperettes, mirror heads
and arms, and body side steps; 15-inch x7-inch styled-
steel wheels with 9Rxl5 "Wrangler" radial tires, and a
deluxe interior with tachometer and clock.
A new CJ-7 Limited package is available for 1982. The
package features special ride components, chrome front
bumper, rear bumperettes, mirror heads and arms,
bodyside steps; 15-inch x 7-inch white styled-steel
wheels with black "Arriva" radial tires and a deluxe
interior with special carpeting and padding.
GENERAL INFORMATION A-3
Fig. A-1 CJ-5 Model
Fig. A-2 CJ-7 Model

A-4 GENERAL INFORMATION
The Scrambler is a 103.4-inch wheelbase, half-cab,
sport/utility vehicle with atruck-type cargo box at the
rear. Four body versions are available which are: a base
model with open top configuration, a fabric top model
with metal doors (fig. A-3), a fabric top model with
fabric doors, and a hardtop model with metal doors (fig.
A-4).
The standard powertrain for Scrambler models is the
151 CID four-cylinder engine, four-speed manual trans
mission, 3.54 ratio axles and the model 300 transfer case.
Asix-cylinder engine, automatic transmission, different
ratio axles, and a Trac-Lok rear axle differential are all
available as options.
Fig. A-3 Scrambler Hardtop with Metal Doors
Fig. A-4 Scrambler Soft Top with Metal Doors
Cherokee Models
For 1982, three Cherokee models are offered: the base
2-door model 16, the Wide Track model 17, and the
4-door model 18. See figures A-5, A-6 and A-7.
The 2-door model 16 is a dual purpose vehicle in the
sports/utility class featuring an all-steel top, front disc
brakes
and foldup rear seat as standard.
The Wide Track model 17 features steel wheel opening
extensions to accommodate L78xl5 tubeless tires
mounted on 8-inch wide, styled-steel wheels.
The 4-door model 18 features the convenience of rear
doors in a station wagon-type vehicle. The model 18 has
the same grille and taillamps as other Cherokee models.
Two
trim packages are offered for 1982 Cherokee
models. The Chief and Laredo packages are available on
the model 17. Both packages feature deluxe interior trim
and carpeting, chrome bumpers, and unique exterior
trim.
Fig. A-5 Cherokee Model 16
Fig. A-6 Cherokee Model 17
•
~

~
-
Fig. A-7 Cherokee Model 18
Wagoneer Model
For 1982, one Wagoneer model is offered: the model
15. The 4-door Wagoneer station wagon features deluxe
interior trim and carpeting, chrome bumpers and power
steering. A luxury trim package, the Limited, is offered.
It features a leather and corduroy interior, unique exte
rior woodgrain with vinyl surround mouldings, forged
aluminum wheels, and automatic transmission with
Quadra-Trac full-time 4-wheel drive as standard. See
figure A-8.
Truck Models
The truck models are available in two series: the J-10
Series model 24, 25 and 26, and the J-20 Series model 27
(figs. A-9,
A-lOand A-ll).
The J-10 models differ from the J-20 model in gross
vehicle weight (GVW) ratings. For 1982, the J-10 Series
GVW for models 24, 25 and 26 is 6200 while the J-20
model 27 GVW remains at 6800 with optional GVW of
7600 and 8400.
The Truck models are also identified by wheelbase.
Models 24 and 25 have a 118.8-inch wheelbase; models 26
and 27 have a130.8-inch wheelbase. The following chart
outlines Truck differences by wheelbase and GVW
ratings.
GENERAL INFORMATION A-5
Fig. A-8 Wagoneer Model 15
Truck Model Identification
Series
Model
Number
Wheelbase
Gross Vehicle Weight Rating
(Inches)
Standard | Option 1
Option 2
J-10
J-10
J-10
J-20
24
25
26
27
118.8
118.8
130.8
130.8
6200
6200
6200
6800
7600
8400
60532
Custom, Honcho, Laredo, Pioneer, Sportside and Hon-
cho Sportside. The Custom and Pioneer package are
available on all Trucks and features deluxe interior and
exterior trim. The Honcho package is only available on
model 25 and features deluxe interior and unique exte
rior trim, and 15-inch tires mounted on 8-inch wide,
styled-steel wheels.
The Laredo package is available on model 25 trucks.
The package includes unique exterior decals, 10R x 15
"Wrangler" radial tires mounted on 8-inch wide chrome
styled-steel wheels, chrome rear step bumper, and de
luxe interior.
The Sportside Truck package is available on model 25
and features a flare side box with bottom rear fenders
and deluxe interior trim.

A-6 GENERAL INFORMATION
The Honcho Sportside package is available on model
25 and features a flare side box with bottom rear fender
and special interior and exterior trim and decals.
Fig. A-9 J-10 Truck Model 24
Fig. A-10 J-10 Truck Model 25
EEtOta
Fig. A-11 J-20 Truck Model 27
VEHICLE IDENTIFICATION
Vehicle Identification Plate
A
metal vehicle identification plate is affixed to the
left-hand side of the dash panel (fig. A-12). The plate
shows the Sales Order Number; the Vehicle Identi
fication Number (VIN); Special Sales Request & Order
(SSR & 0) Number; Paint Option Number; Trim Option
Number; and the Jeep Model Number.
0
JEEP CORP.
TOLEDO, OH USA 0
Sales Order No.
SSR & 0 No.
71
Paint
Option No.
Trim
Option No.
Vehicle Identification
(VIN) Number
Jeep
Model No.
'Disregard - for
factory
Fig.
use only
A-12 Vehicle Identification Plate
60534
Vehicle Identification Number (VIN)
All Vehicle Identification Numbers contain 17 charac
ters in a combination of letters and numbers that pro
videspecific information about the vehicle. VIN's for all
Jeep vehicles can be decoded using the following chart.
Special Sales Request and Order (SSR & 0] Number
Certain Jeep vehicles are built to special order with
other than standard parts or equipment. To assist the
dealer in ordering correct replacement parts, an SSR &
0
number is assigned and a permanent record of the
deviation is maintained by the factory. The SSR & 0
number is embossed on the Vehicle Identification Plate
as shown in figure A-12.
Parts ordering procedure for SSR & 0 parts is de
tailed in the Jeep Parts Catalog.
Paint Option Number
The Paint Option Number is embossed on the Vehicle
Identification Plate in the location shown in figure A-12.
Paint is not available from the factory. All colors
shown below are available from Ditzler or DuPont paint
jobbers by requesting the paint intermix formula. All
colors are available from Sherwin-Williams in factory
package cans. Option No. 999 indicates special paint. To
obtain information on special paint, contact your Jeep
Parts Distribution Center and provide the Vehicle Iden
tification Number (VIN).
Trim Option Number
The Trim Option Number is embossed on the Vehicle
Identification Plate as shown in figure A-12. Consult
your Jeep Parts Catalog for trim ordering procedure.
Special trim is indicated by trim option number 999. To
obtain
information on special trim, contact your Jeep
Parts Distribution Center and provide the Vehicle Iden
tification Number (VIN).

GENERAL INFORMATION A-7
VIN Decoding Chart
Cherokee, Wagoneer and Truck
tlpOtllKO
IiporlRHO
QVWP.
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owmus.
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*
CuargMaQkatim
(MOB*
irts«9
0 CftaroMalaraoaun
HOOK*
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N
Clown (1*1
WWltw
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(1C0IM
17I0»»
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H00«1
mo>9
Wtanm |W>
•MOW.
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*to Track (14.11XI naou
i»«o»a
P
Tme» mo an
ft
TiwkMOlincOaq
wo at
V T«c»J40iOoa
mow
TUMSmilOH o«nri MS TMNSria CM!
'•MMW
TnaalarCaaa
M4 ScaarJ Maaaal rir
PanT«r«
0
MIm
P(<1 or Pllll 'MM
•
tatawtM floor
PartTrma
c
FaaTana
*
Pan o. Ft* Tint
f
•alvMK Com**"
Pan Tma
A
Pun Tun*
J
Pan or Pan Taut
«V t
SpaM MOMMM »» NO**
P S8oaMMana*l »»
PanTma
P
SINM MKWI »»
Pad Tana
M
iatimnmm f»
Pan o> Fao Tmw
IJTNA27Y8CT000001
r
•
c
N
f
P
ItlCtfMW IV
aal*arivi4
Po*mc How On —
Quorum
MC«KM IV
•41l4arlVi«
Mac - Oaiowci
MOCuMM IV
WMCOMKimVB
(aatai 14s C«DC >«
<tta»-0m»i- 14
OanaHiLitar
[N«m 0Mt«i i «i
COKPMIVMMU
twtwi mcJiaao
Uaa tann
fta*»Tiaa
IS
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If
14
Vrtgo«M» MPV
CftaroM* kpv
OwroM* wpv
ChaiOM* KPV
*Or Wagon
J> Wagon
10* WagonWT
4 0- Wagon
law tartat Omm
Cat Icaka
Tma MM
»
It
V
*10 «M PU !<*-««•
*«0 M P»J <J<~«rl
j-jo sw p>u in-we
7 Or Hidraakc
I Or HiHrnaW
J Or MfOraaW
•NOTE:in order to comply with EECdirectives 767114 and 78/507,the
check digit will be replaced with the letter 'E' In the VIN of all ECE
vehicles.
CJ and Scrambler
TftMttMMOM OHM MB TMMTU CAM
Tm
TraatMr C*aa
M4
IpaM Mam*! • »»
Pan Tma
PuaTtma
Pan o< Pan Imw
tft
jfQMfllf PlnM Pan Tim
Punrarw
Pan at P«a Taw
t
aaiowairt • Cawm
Pan Tana
P«nTwia
J
PanorPaaTaaa
W ttpaaam—1» •*<•
MOM
P1
taaad uarwai • **
PanTaxa
P
ttaaMWaavai • n>
N
ttpaaanawni • »*
Pan v Pa" T«aa
I J C
tSICa0rcta.1V
OS War IV 1-4
Poatlac Motof Oxr -
M0CuowM.lv
CJ-5«S»
cj/on
CJSWJt-tOS
UJOtrVCDS
cj-7 an •« os
SawnMcM)
3
avwnus.
J790IM
J7S0 H»
inotM
4IS0IM
41WM
4t»R»
4190 CM
OraariiaCubcM
patm - Dnwai - M
OraatJ 1.1 Utar
*) CJ-5 MM ZOr.gpanDoar
•7 CJ-7 WPV
aOr.OptfttMy
•S 8e»«mWaf rWV 1 Of.OpanBotfr
H CJ-7
COMM 4 OrOp—Borjy
•NOTE: In order to comply with EEC directives 767114 and 7&V507, the
check digit will be replaced with the letter 'E' in the VIN of ail ECE
vehicles.
STEP
1. Assign to each number
In the vehicle
Identification number Its
actual mathe-
matlcsl value and assign to each letter the
value specified for (t In the following table:
TA8LII
A-1
J-1
T-3
B-2
K-a
tM
C-3
L-3
V-6
tvt
M-4
w-e
E-5 N4
X-7
p-e
P-7 Y-8
0-7
ao
Z-8
H4
s-2
STEP
2. Multiply the assigned value for each
character in the vehicle identification number
by the weight factor specified forit inTable II.
Multiply the check digit by 0.
STEP
3. Add the resulting products and divide the
totalby 11.The remainderIsthe check digit.If
the remainder Is 10. the check digit Is X
Tumple
Vehicle Identification UTNA27Y8CT0
Number Charcter 00001
TAKE II
Character
1st
2nd
3rd
4th
5th
6th
7th
8th
9th (check digit)
10th
11th
12th
13th
14th
13th
19th
17th
WetgM Factor
Assigned Value
Multiply by
Weight Factor
Add Products
Divided by 11
Check Digit
1135127802300
0001
8765432100987
65432
8 + 7+18 + 25+4+6+14 +
60+0 + 18+24+0+0+0+0
+0 + 2 • 206
206711 « 186711
8
60S35