🏷️ Basic Information

Make:

Jeep

Model:

Cherokee XJ

Year:

1994

Chassis Code:

XJ

Engine Codes:

2.5L (AMC 150), 4.0L (AMC 242)

👋 Introduction

Market Position:

The 1994 Jeep Cherokee XJ represents the peak of the early to mid-generation XJ platform, a beloved compact SUV known for its ruggedness, capability, and off-road prowess. It competed against vehicles like the Ford Explorer, Toyota 4Runner, and Chevrolet S-10 Blazer.

Competitive Analysis:

The XJ's unibody construction was revolutionary for its time, offering a lighter and more rigid platform than traditional body-on-frame SUVs. This, combined with the legendary 4.0L inline-six engine and Jeep's renowned 4x4 systems, cemented its place as a benchmark in the segment.

Key Features:

Compact SUV, capable off-road, unibody construction, available 4.0L inline-6 engine, robust 4x4 systems, durable and reliable reputation.

📋 Manual Details

Systems Covered:

Engine, Transmission, Drivetrain, Brakes, Suspension, Steering, Electrical, HVAC, Body, Emissions, Troubleshooting, Wiring Diagrams, Lubrication, Maintenance, Specifications

Page Count:

Estimated 1000+ pages (typical for a full factory service manual)

Manual Type:

Factory Service Repair Workshop Manual

Completeness:

Complete Factory Service Manual covering all aspects of repair and maintenance.

Language:

English

Format:

PDF (Downloadable)

📖 Manual Coverage

Engine Systems:

2.5L AMC 150 I4, 4.0L AMC 242 I6: Engine mechanical, cooling system, fuel system (MPI), ignition system, lubrication, exhaust system, emissions control

Transmission Drivetrain:

Manual Transmissions (AX-5, NV3550), Automatic Transmissions (AW4, 30RH): Clutch, transfer case (Command-Trac, Selec-Trac), drive shafts, axles (Dana 30 front, Dana 35 rear, Chrysler 8.25 rear optional)

Suspension Steering:

Front leaf spring suspension, Rear leaf spring suspension, Power steering system, steering gear, steering column

Brake System:

Front disc brakes, Rear drum brakes, Parking brake, Anti-lock Braking System (ABS) for some models

Electrical System:

Battery, starting system, charging system, lighting, instruments and gauges, horn, wipers and washers, power windows, power locks, fuse block, relays, diagnostic trouble codes (OBD-I)

HVAC Body:

Heating, Ventilation, and Air Conditioning (HVAC) system, interior trim, exterior trim, doors, windows, latches, locks, body repair, glass replacement

Chassis Systems:

Frame (unibody) construction, suspension components, steering linkage, exhaust system routing and components

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement, brake pad/shoe replacement, battery maintenance

Repair Procedures:

Engine tune-ups, complete engine overhauls, transmission rebuilds, axle overhauls, suspension component replacement, brake system repairs, electrical diagnostics and repair, HVAC system servicing, body panel repair

Troubleshooting:

Diagnostic flowcharts for common problems, symptom-based troubleshooting guides, electrical troubleshooting using wiring diagrams

Technical Specifications:

Torque specifications, fluid capacities, clearances, component identification, wiring diagrams, diagnostic codes

Diagnostic Procedures:

OBD-I diagnostic code retrieval and interpretation, component testing procedures, circuit testing

Depth:

Comprehensive (from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics)

Wiring Diagrams:

Includes detailed electrical wiring diagrams for all major systems

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable PDF text

Print Quality:

High-resolution, suitable for printing

Printable:

Printable pages

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine:

4.0L (3960cc) AMC 242 Inline-6

Secondary Engine:

2.5L (2460cc) AMC 150 Inline-4

Horsepower 4.0L:

184 hp @ 4700 rpm (approximate)

Torque 4.0L:

220 lb-ft @ 3200 rpm (approximate)

Horsepower 2.5L:

125 hp @ 4600 rpm (approximate)

Torque 2.5L:

150 lb-ft @ 2400 rpm (approximate)

Fuel System:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Ignition System:

Distributorless Ignition System (DIS) with Crankshaft Position Sensor

Engine Block Material 4.0L:

Cast Iron

Engine Block Material 2.5L:

Cast Iron

🔧 Transmission

Standard Transmission:

5-Speed Manual (AX-5)

Optional Transmission:

3-Speed Automatic (AW4)

Optional Transmission 2:

4-Speed Automatic (30RH, later replaced AW4)

Transfer Case Options:

Command-Trac (2WD/4WD Part-Time), Selec-Trac (2WD/4WD Full-Time)

Manual Transmission Fluid:

API GL-3 or GL-4, SAE 75W-90 (AX-5); Mercon ATF or equivalent (NV3550)

Automatic Transmission Fluid:

Dexron III/Mercon ATF

Gear Ratios Ax5:

1st: 3.95, 2nd: 2.18, 3rd: 1.37, 4th: 1.00, 5th: 0.85, Reverse: 3.53 (approximate, consult manual for exact ratios)

Gear Ratios Aw4:

1st: 2.73, 2nd: 1.57, 3rd: 1.00, 4th: 0.69, Reverse: 2.20 (approximate, consult manual for exact ratios)

📐 Dimensions

Wheelbase:

101.4 inches

Length:

164.0 inches

Width:

69.4 inches

Height:

63.1 inches

Ground Clearance:

Approximately 8-10 inches depending on tire and suspension configuration

Curb Weight:

3,200 - 3,500 lbs (approximate, depending on configuration)

Gross Vehicle Weight Rating:

4,700 - 5,000 lbs (approximate)

🛡️ Safety Features

NHTSA Front Impact:

4-star (driver), 4-star (passenger) - 1994 model year safety ratings (may vary slightly by configuration)

IIHS Side Impact:

Acceptable (typically rated for this era)

Active Safety Features:

Four-wheel Anti-lock Braking System (ABS) available on some models

Passive Safety Features:

Seat belts, reinforced unibody structure, driver-side airbag (standard for 1994), passenger-side airbag (optional on some models)

💡 Technology Features

Infotainment System:

Basic AM/FM radio with cassette player, optional CD player. Manual climate controls.

Driver Assistance Features:

Limited to ABS on select models. No advanced electronic driver aids like traction control or stability control.

Connectivity Options:

N/A for the era, basic accessory power outlets.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles, or 6 months, depending on oil type and driving conditions (consult manual for specific recommendations)

Transmission Fluid Change Interval:

Every 30,000-60,000 miles (check manual for specific application)

Coolant Flush Interval:

Every 30,000-50,000 miles or 2-3 years

Engine Oil Specification:

API SG or higher, SAE 10W-30 or 10W-40 for 4.0L; SAE 5W-30 or 10W-30 for 2.5L (consult manual)

Coolant Specification:

Chrysler/Mopar Antifreeze/Coolant (Ethylene Glycol base), typically a 50/50 mix with distilled water

Brake Fluid Specification:

DOT 3

Power Steering Fluid:

ATF+3 or Mopar ATF+3 (refer to manual, may also accept some Dexron/Mercon)

Common Issues:

Head gasket failure on 4.0L (especially earlier models but can occur), cracked exhaust manifolds (4.0L), worn leaf spring bushings, differential gear wear, AC system leaks, death wobble (worn steering/suspension components), CPS sensor failure (4.0L)

Oil Filter Part Number 4.0L:

Mopar: MO-090, Fram: PH8A, Wix: 51515 (verify with specific application)

Air Filter Part Number 4.0L:

Mopar: 53007498, Fram: CA3041 (verify with specific application)

📚 Vehicle History

Brand Heritage:

Jeep has a long-standing heritage in off-road vehicles, dating back to World War II with the Willys MB. This legacy informs the design and engineering of all Jeep vehicles, including the Cherokee XJ.

Model Evolution:

Introduced in 1984, the Cherokee XJ was a groundbreaking compact SUV. The 1994 model year represents a significant update with the introduction of the 4.0L inline-6 engine as standard on many trims, revised interior, and improved safety features like the driver's side airbag.

1994 Updates:

Standard driver-side airbag, revised interior and dashboard design, improved fuel injection system, optional Selec-Trac full-time 4WD system becomes more prevalent.

Production Years:

1984-2001

Manufacturing Locations:

Toledo, Ohio, USA; Beijing, China (Cherokee); Renault-AMC plants (France, Italy, Spain)

🏆 Awards & Recognition

Recognitions:

The Jeep Cherokee XJ, particularly the 4.0L models, is widely recognized by enthusiasts and automotive publications for its durability, off-road capability, and long-term value. Often cited in 'best SUVs of all time' lists.

Consumer Reports Rating:

Varies by year, but generally solid for reliability in its class during its production run, though some years had specific issues noted.