Vehicle Years:
1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996
Manual Classification:
Workshop Service Repair Manual
Language Of Manual:
English
Delivery Format:
Digital (likely PDF, but confirm with vendor)
Engine Systems:
Engine mechanicals (including cylinder head, block, pistons, crankshaft), lubrication system, cooling system, fuel delivery and injection (including specific systems like Renix, MPI), ignition system, exhaust system, engine control unit (ECU) and diagnostics.
Transmission Systems:
Manual transmission (e.g., AX-4, AX-5, NV3550) and automatic transmission (e.g., AW-4, 42RE) overhaul, diagnosis, and repair. Clutch system, drivetrain components (transfer case, driveshafts, differentials).
Chassis And Suspension:
Front and rear suspension (leaf springs, coil springs depending on year/model), steering system (power steering pump, gearbox, linkages), braking system (front discs, rear drums/discs, ABS where applicable), wheel bearings, and alignment specifications.
Electrical Systems:
Wiring diagrams for all major systems, starter, alternator, battery, lighting system, instrument cluster, power windows/locks, HVAC controls, fuse box and relay locations, diagnostic connectors.
Body And Interior:
Body panel removal and installation, door mechanisms, glass replacement, interior trim, seat mechanisms, HVAC system components, body sealing, rust repair considerations.
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad/shoe replacement, tire rotation.
Repair Procedures:
Engine tune-ups, cylinder head gasket replacement, water pump replacement, fuel pump replacement, transmission fluid and filter changes, brake caliper/wheel cylinder replacement, suspension component replacement, exhaust system repairs.
Diagnostic Procedures:
Troubleshooting guides for common drivability issues, electrical faults, cooling system problems, and transmission performance. OBD-I diagnostic codes and interpretation for applicable years.
Diagnostic Level:
Advanced, covering component testing, circuit diagnosis, and symptom-based troubleshooting.
Rebuild Scope:
Comprehensive rebuild procedures for major components like engines, transmissions, and differentials.
Digital File Type:
Likely PDF; searchability and clarity are key indicators of quality.
Image Clarity:
High resolution for diagrams and illustrations is critical for effective repair.
Physical Binding:
N/A (if digital); if printed, ideally spiral-bound for lay-flat use in a workshop.
Physical Paper Quality:
N/A (if digital); if printed, a durable, coated paper to resist grease and shop fluids.
Base Engine 2.5L:
2.5L (150 cu in) AMC 150 I4: Horsepower: ~115-125 hp, Torque: ~190-200 lb-ft. Fuel System: Throttle Body Injection (TBI) early models, Multi-Point Fuel Injection (MPFI) later models.
Optional Engine 4.0L:
4.0L (242 cu in) AMC 242 I6 (High Output): Horsepower: ~177-190 hp, Torque: ~220-250 lb-ft. Fuel System: Throttle Body Injection (TBI) early models, Multi-Point Fuel Injection (MPFI) later models.
Engine Block Material:
Cast Iron
Cylinder Head Material:
Cast Iron
Fuel Delivery Early:
Renix Throttle Body Injection (TBI) for 4.0L I6 (1987-1990), later MPI.
Fuel Delivery Later:
Chrysler Multi-Point Fuel Injection (MPFI) for 4.0L I6 (1991-1996).
Standard Transmission Early:
4-speed manual (e.g., AX-4 or AX-5)
Optional Transmission Auto:
3-speed automatic (e.g., AW-4)
Optional Transmission Manual Later:
5-speed manual (e.g., NV3550) in later years for some models.
Transfer Case Options:
Selec-Trac (part-time 4WD with 2WD option) or Command-Trac (full-time 4WD).
Transmission Fluid Spec:
ATF+3 or ATF+4 for AW-4 (check manual for exact spec per year), gear oil (e.g., GL-5 75W-90) for manual transmissions and differentials.
Wheelbase:
101.4 inches (2576 mm)
Length:
Approximately 167.5 inches (4255 mm)
Width:
Approximately 69.2 inches (1758 mm)
Height:
Approximately 65.5 inches (1664 mm)
Curb Weight Range:
3,300 - 3,700 lbs (1497 - 1678 kg), depending on engine and drivetrain.
Towing Capacity:
Varies by year and configuration, typically around 2,000 - 5,000 lbs (907 - 2268 kg).
Ntsa Crash Test Results:
Limited data for early models; later models received mixed results, generally considered adequate for their era, but not meeting modern standards without significant upgrades.
Active Safety Features:
Standard rear-wheel drive or optional 4WD. Anti-lock Braking System (ABS) became available/standard on later models.
Passive Safety Features:
Seat belts, reinforced unibody structure, energy-absorbing steering column.
Infotainment System Era:
Basic for its time. Typically featured AM/FM radio, cassette player, and optional CD player in later years. Analog gauges.
Driver Assistance Features Era:
Limited. ABS was the primary electronically controlled driver assistance feature available on later models.
Connectivity Features Era:
No modern connectivity features (e.g., Bluetooth, USB ports, smartphone integration).
Oil Change Interval:
Typically 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions. Refer to manual for precise intervals.
Engine Coolant Flush:
Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years. Specific coolant type is crucial.
Transmission Service:
Automatic transmission fluid and filter change every 30,000-60,000 miles (48,000-96,000 km). Manual transmission fluid check/change at similar intervals.
Engine Oil Spec:
10W-30 or 10W-40 for most models (check manual for specific viscosity and API service category, e.g., API SN or earlier).
Coolant Spec:
Ethylene glycol-based antifreeze (e.g., Mopar Antifreeze/Coolant 10 Year/100,000 Mile Formula or equivalent meeting OAT/HOAT specifications).
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid.
Common Engine Issues:
Cracking in the 4.0L cylinder head (later models), fuel injector issues (especially with Renix systems), oil filter housing leaks, distributor O-ring leaks.
Common Suspension Issues:
Worn leaf springs and bushings, front sway bar links, track bar wear, potential death wobble (if steering/suspension components are worn).
Common Electrical Issues:
Wiring harness issues (especially grounds), alternator failures, CPS (Crankshaft Position Sensor) failures on later 4.0L engines.
Common Transmission Issues:
AW-4 automatic transmission issues often related to solenoids or torque converter lock-up; manual clutch wear.
Jeep Legacy:
Part of the Jeep lineage, known for robust off-road vehicles and utility.
Xj Introduction:
Introduced in 1984 as a revolutionary compact SUV, featuring unibody construction which was a significant departure from traditional body-on-frame SUVs of the time.
Xj Updates:
Significant updates occurred throughout its run, including the transition to MPFI for the 4.0L engine, interior and exterior styling revisions, and safety feature additions. The 4.0L I6 became the signature engine, renowned for its torque and durability.
Production Period:
1984-2001 (Globally, North American production for XJ ended in 2001, but this manual covers up to 1996).
Manufacturing Locations:
Primarily Toledo, Ohio, USA.
