Just picked up this XJ. It is a 5 speed with 121K on the clock.
First off, can someone steer me to a maintenance manual with wiring diagrams that isn't $100+?
Issues:
Clutch engages just off the floor. Supposed to be a recent clutch. Is there an adjustment?
No gauge lights. All other lights work.
Heater control not opening water valve. Valve does work.

It also needs a tune up, but that is basic SOP.

 

Do you have air conditioning?

4 cylinder or 6?

As far as wiring, a place you'll want to start is clicking on the link in my signature and doing posts 1 through 4 for starters.

 

I do not think it has AC, I'll have to look next time I get out there.
It is the I6.
The gauge lights may just be a fuse, everything else works.
I wire tied the water valve open for now, need to check it and see if it works. I suspect something in the control sliders is not right. I can select the different modes okay, just won't let the hot water in.
Another problem I have that I forgot about is the rear drive shaft seal is leaking. Easy to replace?

 

Okay, I just found this trying different search methods.
http://jeep.zerok.ru/index.php?page=XJ1984-1991

 

Front of shaft or rear of shaft?

 

Oops, at the transfer case. It's bleeding.

 

Replace the seal and make sure the driveshaft doesn't have a groove worn into it.

 

Whale poo!. Guess I may have a plugged heater core, or maybe no thermostat. It has a new radiator and water pump. Dare I assume they also replaced the thermostat.
At least I gots door locks again. Not the amount of progress I wanted to make.
Oh, no AC.
I need to get piglet indoors. Working out side this time of year ain't no fun.

 

Stupid heater valve. Must be broke inside.

 

Don't worry about replacing the heater control valve just by-pass it. It's not needed anyways. The manufacturer deleted the in the later years.

 

Yup. Delete it. Plug the vacuum line. Drive and stay warm.

 

I have Heat! Valve was fine, core was clogged. Found out that vacuum closes valve instead of opening it.
Did a tune up, runs like a champ. Now I need to get 4 matching rims and a decent set of tires on it.
Transfer case seal.
Dash wiring.
Other misc stuff.

 

Someone else posted this link where you can download pre 97 manual.
http://www.ausjeepoffroad.com/forum/vbindex.php

 

Dash lights - pull the gauge cluster and clean ALL the contact pads with an eraser or ultra fine emery cloth. If that doesn't fix it then look further.

On these old XJs, so many problems are fixed just by cleaning decades of crud and corrosion.

 

Yah, I'll be pulling the dash apart maybe Monday. Car and tools are 50 miles from home at work. There I can get it indoors. Too cold to work out doors, especially when the thermometer starts showing numbers with a minus sign in front of them.