Jeep Comanche 1994 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Comanche Year: 1994 Product Type: Service Repair Workshop Manual Codes Chassis Code: MJ 👋 Introduction Market Position Target Audience: Professional automotive technicians, dealership service departments, and dedicated Jeep Comanche owners seeking to perform their own maintenance and repairs. Competitive Analysis Value Proposition: Offers the definitive resource for maintaining and repairing the 1994 Jeep Comanche, mirroring the information used by factory-trained technicians. Crucial for preserving vehicle integrity and resale value. Key Features Manual Utility: Provides detailed, step-by-step procedures, accurate torque specifications, diagnostic flowcharts, and comprehensive wiring diagrams essential for accurate and efficient servicing. Original Source: Derived from official factory service documentation, ensuring accuracy and completeness. 📋 Manual Details Coverage Areas General Coverage: Complete service and repair instructions for the 1994 Jeep Comanche. Page Count Estimated Pages: Extensive (typically 1500-2500+ pages for factory-level manuals of this era, specific count not provided but implied by 'full service and repair instruction'). Manual Type Type: Workshop Manual / Service Manual Language Language: English Format Format: Digital (likely PDF, as is common for sales, but physical printed copies were the original standard). 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical (assembly, disassembly, inspection), lubrication, cooling, fuel delivery (injection systems), ignition, exhaust, emissions control, engine diagnostics and troubleshooting. Transmission Systems: Manual transmissions (NV3500, AX-15), Automatic transmissions (AW-4, Aisin-Warner), clutch system, transfer case (NP231, NP242). Drivetrain Systems: Front and rear axles (Dana 30, Dana 35), driveshafts, U-joints, differentials, wheel bearings. Suspension Systems: Front suspension (leaf springs, coil springs, shock absorbers, ball joints, steering linkage), rear suspension (leaf springs, shock absorbers). Braking Systems: Front disc brakes, rear drum brakes, parking brake, hydraulic system, ABS (if equipped). Steering Systems: Power steering system, steering gear, steering column, tie rods, steering linkage. Electrical Systems: Battery, charging system (alternator), starting system, lighting, gauges, instrumentation, power windows, power locks, wiper system, horn, fuse block, wiring diagrams, diagnostic connectors. Body And Frame: Body panels, doors, windows, interior trim, seats, tailgate, frame construction, rust prevention, body repair procedures. HVAC Systems: Heating, ventilation, and air conditioning (HVAC) system operation, diagnosis, and repair, refrigerant handling. Fuel System Details: Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, Evaporative Emission Control (EVAP) system. Ignition System Details: Distributor, ignition coil, spark plugs, spark plug wires, ignition control module (ICM). Exhaust Emissions: Catalytic converter, oxygen sensors (O2 sensors), EGR system (if equipped), exhaust manifolds, mufflers. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and changes, lubrication points, belt inspections and replacement, spark plug replacement, brake pad/shoe replacement, tire rotation. Diagnostic Procedures: Troubleshooting guides for various systems, symptom-based diagnosis, electrical circuit testing, fault code interpretation (OBD-I). Repair Procedures: Step-by-step instructions for component removal, installation, and overhaul for all major vehicle systems. Overhaul Procedures: Detailed instructions for rebuilding engines, transmissions, axles, and other major mechanical components. Special Tool Requirements: Identification and usage instructions for specialized tools required for specific repairs. Wheel Alignment: Specifications and procedures for front wheel alignment (caster, camber, toe). Tire Specifications: Recommended tire sizes, inflation pressures, and wheel torque specifications. Torque Specifications: Comprehensive list of all essential torque specifications for engine, transmission, chassis, and body fasteners. Technical Depth Depth Of Coverage: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts. Wiring Diagrams: Detailed, system-specific wiring diagrams for all electrical components, including power distribution, grounds, and sensor circuits. Diagnostic Charts: Troubleshooting flowcharts and diagnostic trees to systematically identify and resolve issues based on symptoms. Manual Completeness Completeness Level: This is a comprehensive workshop manual, covering virtually all aspects of vehicle repair and maintenance. It is not a condensed version. 📊 Manual Specifications File Format Digital Format: Likely PDF with searchable text and high-resolution images/diagrams. Print Quality Print Quality Digital: High quality, suitable for printing individual pages or sections. Binding Type Original Binding: Originally a large, robust bound manual (typical for factory manuals). Paper Type Original Paper: Durable, high-quality paper stock designed for workshop use. ⚙️ Engine Specifications Primary Engine Engine Options: 2.5L (150 cu in) AMC I4, 4.0L (242 cu in) AMC I6. Performance 4.0L Horsepower: Approx. 183 hp @ 4700 rpm (varies slightly by specific configuration). 4.0L Torque: Approx. 220 lb-ft @ 3200 rpm (varies slightly by specific configuration). Fuel System Fuel Injection: Multi-point fuel injection (MPI) for both engines. Engine Type 4.0L Configuration: Overhead Valve (OHV) Inline 6-cylinder 2.5L Configuration: Overhead Valve (OHV) Inline 4-cylinder Cooling System Coolant Type: Chrysler (Mopar) 5/30 Green Antifreeze/Coolant or equivalent (ethylene glycol based). Engine Identification 4.0L Engine Code: AMC 242 2.5L Engine Code: AMC 150 🔧 Transmission Standard Standard Transmission: Manual: AX-15 (4.0L), NV3500 (4.0L - later 1994 models may have this as standard or option) Optional Optional Transmission: Automatic: AW-4 (4-speed automatic, Aisin-Warner) for both engines. Features Transfer Case Options: New Process (NP) 231 (Command-Trac 2-speed part-time 4WD), NP 242...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Comanche

Year:

Product Type:

Service Repair Workshop Manual

Codes

Chassis Code:

👋 Introduction

Market Position

Target Audience:

Professional automotive technicians, dealership service departments, and dedicated Jeep Comanche owners seeking to perform their own maintenance and repairs.

Competitive Analysis

Value Proposition:

Offers the definitive resource for maintaining and repairing the 1994 Jeep Comanche, mirroring the information used by factory-trained technicians. Crucial for preserving vehicle integrity and resale value.

Key Features

Manual Utility:

Provides detailed, step-by-step procedures, accurate torque specifications, diagnostic flowcharts, and comprehensive wiring diagrams essential for accurate and efficient servicing.

Original Source:

Derived from official factory service documentation, ensuring accuracy and completeness.

📋 Manual Details

Coverage Areas

General Coverage:

Complete service and repair instructions for the 1994 Jeep Comanche.

Page Count

Estimated Pages:

Extensive (typically 1500-2500+ pages for factory-level manuals of this era, specific count not provided but implied by 'full service and repair instruction').

Manual Type

Type:

Workshop Manual / Service Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, as is common for sales, but physical printed copies were the original standard).

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical (assembly, disassembly, inspection), lubrication, cooling, fuel delivery (injection systems), ignition, exhaust, emissions control, engine diagnostics and troubleshooting.

Transmission Systems:

Manual transmissions (NV3500, AX-15), Automatic transmissions (AW-4, Aisin-Warner), clutch system, transfer case (NP231, NP242).

Drivetrain Systems:

Front and rear axles (Dana 30, Dana 35), driveshafts, U-joints, differentials, wheel bearings.

Suspension Systems:

Front suspension (leaf springs, coil springs, shock absorbers, ball joints, steering linkage), rear suspension (leaf springs, shock absorbers).

Braking Systems:

Front disc brakes, rear drum brakes, parking brake, hydraulic system, ABS (if equipped).

Steering Systems:

Power steering system, steering gear, steering column, tie rods, steering linkage.

Electrical Systems:

Battery, charging system (alternator), starting system, lighting, gauges, instrumentation, power windows, power locks, wiper system, horn, fuse block, wiring diagrams, diagnostic connectors.

Body And Frame:

Body panels, doors, windows, interior trim, seats, tailgate, frame construction, rust prevention, body repair procedures.

HVAC Systems:

Heating, ventilation, and air conditioning (HVAC) system operation, diagnosis, and repair, refrigerant handling.

Fuel System Details:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, Evaporative Emission Control (EVAP) system.

Ignition System Details:

Distributor, ignition coil, spark plugs, spark plug wires, ignition control module (ICM).

Exhaust Emissions:

Catalytic converter, oxygen sensors (O2 sensors), EGR system (if equipped), exhaust manifolds, mufflers.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and changes, lubrication points, belt inspections and replacement, spark plug replacement, brake pad/shoe replacement, tire rotation.

Diagnostic Procedures:

Troubleshooting guides for various systems, symptom-based diagnosis, electrical circuit testing, fault code interpretation (OBD-I).

Repair Procedures:

Step-by-step instructions for component removal, installation, and overhaul for all major vehicle systems.

Overhaul Procedures:

Detailed instructions for rebuilding engines, transmissions, axles, and other major mechanical components.

Special Tool Requirements:

Identification and usage instructions for specialized tools required for specific repairs.

Wheel Alignment:

Specifications and procedures for front wheel alignment (caster, camber, toe).

Tire Specifications:

Recommended tire sizes, inflation pressures, and wheel torque specifications.

Torque Specifications:

Comprehensive list of all essential torque specifications for engine, transmission, chassis, and body fasteners.

Technical Depth

Depth Of Coverage:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. Suitable for professional mechanics and experienced DIY enthusiasts.

Wiring Diagrams:

Detailed, system-specific wiring diagrams for all electrical components, including power distribution, grounds, and sensor circuits.

Diagnostic Charts:

Troubleshooting flowcharts and diagnostic trees to systematically identify and resolve issues based on symptoms.

Manual Completeness

Completeness Level:

This is a comprehensive workshop manual, covering virtually all aspects of vehicle repair and maintenance. It is not a condensed version.

📊 Manual Specifications

File Format

Digital Format:

Likely PDF with searchable text and high-resolution images/diagrams.

Print Quality

Print Quality Digital:

High quality, suitable for printing individual pages or sections.

Binding Type

Original Binding:

Originally a large, robust bound manual (typical for factory manuals).

Paper Type

Original Paper:

Durable, high-quality paper stock designed for workshop use.

⚙️ Engine Specifications

Primary Engine

Engine Options:

2.5L (150 cu in) AMC I4, 4.0L (242 cu in) AMC I6.

Performance

4.0L Horsepower:

Approx. 183 hp @ 4700 rpm (varies slightly by specific configuration).

4.0L Torque:

Approx. 220 lb-ft @ 3200 rpm (varies slightly by specific configuration).

Fuel System

Fuel Injection:

Multi-point fuel injection (MPI) for both engines.

Engine Type

4.0L Configuration:

Overhead Valve (OHV) Inline 6-cylinder

2.5L Configuration:

Overhead Valve (OHV) Inline 4-cylinder

Cooling System

Coolant Type:

Chrysler (Mopar) 5/30 Green Antifreeze/Coolant or equivalent (ethylene glycol based).

Engine Identification

4.0L Engine Code:

AMC 242

2.5L Engine Code:

AMC 150

🔧 Transmission

Standard

Standard Transmission:

Manual: AX-15 (4.0L), NV3500 (4.0L - later 1994 models may have this as standard or option)

Optional

Optional Transmission:

Automatic: AW-4 (4-speed automatic, Aisin-Warner) for both engines.

Features

Transfer Case Options:

New Process (NP) 231 (Command-Trac 2-speed part-time 4WD), NP 242 (Selec-Trac 2-speed full-time 4WD with optional full-time 2WD mode).

Fluid Specifications

Aw-4 Fluid:

ATF+3 (Chrysler spec) or equivalent Dexron-III/Mercon compatible fluid.

Ax-15 Fluid:

API GL-3 or GL-4, SAE 75W-90 gear oil.

📐 Dimensions

Exterior

Wheelbase:

113.0 inches (Standard Bed), 125.0 inches (Long Bed)

Length:

Approximately 193.7 inches (Standard Bed), 205.7 inches (Long Bed)

Weights

Curb Weight:

Ranging from approx. 3,300 lbs to 4,000+ lbs depending on configuration (engine, 2WD/4WD, cab style).

Towing Capacity:

Varies significantly by configuration, typically between 2,000 lbs and 5,000+ lbs. Consult manual or vehicle VIN for exact rating.

Payload Capacity:

Varies by configuration, typically 1,000 lbs to 1,500+ lbs. Consult manual or vehicle VIN for exact rating.

Cargo

Bed Length Standard:

6 feet

Bed Length Long:

7 feet

🛡️ Safety Features

Ratings

Crash Test Data:

Specific NHTSA/IIHS ratings for the 1994 model year are limited or not readily available in standard databases. However, vehicles of this era generally performed as expected for their time; later revisions of the XJ platform (which the Comanche is based on) saw safety improvements. The manual will detail safety system construction and repair.

Active Features

Active Safety:

Antilock Braking System (ABS) available as an option, typically on rear wheels only for this generation. Power-assisted brakes.

Passive Features

Passive Safety:

Lap and shoulder belts, crumple zones designed into the body structure, reinforced safety cage construction.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM radio with cassette player, optional CD player. Basic speaker configurations (2-4 speakers).

Driver Assistance

Assistance Features:

Minimal by modern standards. ABS available on some models. Cruise control standard on many trims.

Connectivity

Connectivity Features:

None by modern standards (no Bluetooth, USB, or auxiliary inputs from the factory).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000 - 5,000 miles or 3-6 months, depending on driving conditions (severe vs. normal). Refer to manual for specific guidance.

Transmission Fluid Change:

Every 30,000 - 60,000 miles for automatic transmissions, refer to manual for manual transmission intervals.

Coolant Flush Interval:

Typically every 30,000 - 50,000 miles or 2-3 years.

Fluid Specifications

Engine Oil Recommendation:

10W-30 or 10W-40 for 4.0L, 5W-30 or 10W-30 for 2.5L. Always consult the manual for specific viscosity and API service classification (e.g., API SG/SH).

Brake Fluid Type:

DOT 3 Hydraulic Brake Fluid.

Power Steering Fluid:

Mopar power steering fluid or Dexron-III/Mercon compatible ATF.

Transfer Case Fluid:

NP231/NP242: Typically requires a specific transfer case fluid or ATF+4. Consult manual for exact specification.

Differential Fluid Front:

API GL-5, SAE 80W-90 (if equipped with limited-slip, refer to specific friction modifier requirements).

Differential Fluid Rear:

API GL-5, SAE 80W-90 (if equipped with limited-slip, refer to specific friction modifier requirements).

Known Issues

Common Wear Items:

Leaf spring bushings, front and rear suspension components (bushings, ball joints), universal joints, exhaust system, radiator and cooling components, fuel pump.

Engine Issues:

4.0L is generally robust, but can suffer from head gasket issues (less common than later 4.0Ls), oil leaks, and intake manifold gasket leaks. 2.5L can be prone to oil consumption.

Transmission Issues:

AX-15 clutch wear, AW-4 solenoid failures, transfer case chain stretch/wear.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

The Jeep brand has a storied history in off-road vehicles, dating back to World War II. The Comanche (MJ) capitalized on the popularity of the XJ Cherokee platform.

Model Evolution

Comanche Development:

Introduced in 1985 as Jeep's compact pickup truck, the Comanche shared much of its architecture with the highly successful XJ Cherokee. It offered unibody construction for a lighter, more rigid frame than traditional body-on-frame trucks.

Production

Production Years:

1985-1992 (though a 1993 model year was also produced, this manual specifically covers 1994, indicating potential later production runs or a specific market focus for this manual's coverage).

Manufacturing Location:

Toledo, Ohio, USA.

🏆 Awards & Recognition

Recognitions

Vehicle Awards:

While the Comanche itself did not win specific major awards, the XJ Cherokee platform upon which it was based was lauded for its innovative unibody design and off-road capability, often appearing on 'best of' lists for SUVs and trucks of its era.