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Jeep Cherokee XJ 2.5l & 4.5l Workshop Manual 1988-2001

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Chassis Code: XJ Generation Generation Start Year: 1984 Generation End Year: 2001 Codes Applicable Years: 1988-2001 👋 Introduction Market Position Segment: Compact...
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Type: Car
Vendor:
Jeep
Sku: 261650
Tags: 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 Car Cars Cherokee XJ 2.5l Cherokee XJ 4.5l Jeep Misc
Jeep Cherokee XJ 2.5l & 4.5l Workshop Manual 1988-2001
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee
Chassis Code:
XJ
Generation
Generation Start Year:
1984
Generation End Year:
2001
Codes
Applicable Years:
1988-2001
👋 Introduction
Market Position
Segment:
Compact SUV/Off-Road Vehicle
Key Attributes:
Renowned for off-road capability, durability, and a relatively simple, robust design.
Competitive Analysis
Competitors:
Toyota 4Runner, Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder
Key Features
Vehicle Signature:
Unibody construction (a first for Jeep SUVs), short wheelbase, excellent approach/departure angles, strong aftermarket support.
Manual Value Proposition:
Provides comprehensive coverage for maintaining and repairing one of Jeep's most iconic and long-lived models, empowering owners and independent mechanics.
📋 Manual Details
Coverage Areas
Coverage:
All models, mechanical, electrical, A-Z repairs
Page Count
Estimated Page Count:
Over 1500
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
Printable Digital Format (e.g., PDF)
📖 Manual Coverage
Systems Covered
Engine:
4.5L V8 (AMC 260/304 - Less Common, but potentially covered for specific applications or conversions)
Transmission:
Manual Transmissions (AX-5, NV3550), Automatic Transmissions (AW4, 30RH/32RH)
Drivetrain:
4x4 Systems (Command-Trac, Selec-Trac), Transfer Cases (NP231, NP242), Axles (Dana 30 Front, Dana 35 Rear, Chrysler 8.25 Rear)
Suspension:
Leaf Spring Rear, Coil Spring Front, Steering System, Suspension Component Replacement
Brakes:
Front Disc, Rear Drum/Disc, ABS Systems (if equipped), Hydraulic System Diagnosis and Repair
Electrical:
Wiring Diagrams, Component Location, Diagnosis of Electrical Faults, Lighting, Instruments, Accessories
Body:
Body Panel Repair, Interior Trim, Doors, Glass, Body Electrical Components
HVAC:
Air Conditioning, Heating, Ventilation System Service and Repair
Fuel:
Fuel Tank, Fuel Pump, Fuel Injection System (MPI), Fuel Lines
Cooling:
Radiator, Water Pump, Cooling Fan, Thermostat, Coolant Specifications
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Spark Plug Service, Fluid Level Checks and Top-offs
Engine Repair:
Engine Overhaul, Piston and Connecting Rod Installation, Cylinder Head Service, Timing Component Replacement
Transmission Service:
Clutch Replacement (Manual), Torque Converter Service (Automatic), Transmission Fluid and Filter Changes
Drivetrain Repair:
U-Joint Replacement, CV Axle Service, Differential Fluid Changes, Axle Seal Replacement
Brake System Repair:
Brake Pad/Shoe Replacement, Rotor/Drum Machining or Replacement, Brake Line Flushes, Caliper Overhaul
Electrical Diagnostics:
Troubleshooting using wiring diagrams, Sensor testing, Actuator testing, Module diagnostics
Suspension And Steering Work:
Ball Joint Replacement, Tie Rod End Replacement, Shock/Strut Replacement, Power Steering System Service
Body And Interior Repair:
Dent Removal, Panel Replacement, Door Mechanism Repair, Interior Upholstery Repair
Diagnostics And Troubleshooting:
Diagnostic Trouble Codes (DTCs), Symptom-based troubleshooting guides
Torque Specifications:
Comprehensive list of all fasteners
Technical Tips:
Professional insights and best practices
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine/transmission rebuilds, extensive electrical diagnostics)
Detail Level:
High; Includes detailed step-by-step instructions with accompanying diagrams and pictures
📊 Manual Specifications
File Format
Format Details:
Likely PDF, allowing for searchable text and bookmarking
Print Quality
Quality Description:
Printable, implying high resolution for clear diagrams and text
Binding Type
Binding For Physical Copy:
Typically perfect bound or coil-bound for workshop manuals
Paper Type
Paper Quality For Physical Copy:
Durable, often heavier stock paper to withstand shop use
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
2.5 Liters
Engine 1 Configuration:
Inline 4-Cylinder (AMC 150 OHV)
Engine 1 Horsepower Approx:
125 hp @ 4800 rpm
Engine 1 Torque Approx:
150 lb-ft @ 2800 rpm
Secondary Engine
Engine 2 Displacement:
4.0 Liters
Engine 2 Configuration:
Inline 6-Cylinder (AMC 242 OHV)
Engine 2 Horsepower Approx:
190 hp @ 4750 rpm
Engine 2 Torque Approx:
220 lb-ft @ 3250 rpm
Optional Engine
Engine 3 Displacement:
4.5 Liters (Rare/Conversion)
Engine 3 Configuration:
V8 (AMC 260/304)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
🔧 Transmission
Standard
Standard Transmission Type:
5-Speed Manual (AX-5)
Optional
Optional Transmission Type:
3-Speed Automatic (30RH), 4-Speed Automatic (AW4)
Features
Transfer Case Options:
NP231 (Command-Trac), NP242 (Selec-Trac - Optional on some trims)
Clutch Type:
Hydraulic Clutch System (Manual Transmission)
📐 Dimensions
Exterior
Wheelbase Inches:
101.4
Length Inches:
166.8 - 172.7 (depending on year/trim)
Width Inches:
69.4
Height Inches:
64.0 - 65.5 (depending on suspension/tire size)
Weights
Curb Weight Lbs Approx:
3300 - 3600
Gross Vehicle Weight Rating Lbs Approx:
4600 - 4800
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance Rating:
3/5 Stars (for models tested)
Active Features
ABS:
Optional on some models, particularly later years
Passive Features
Airbags:
Driver-side airbag standard from 1994 onward; Passenger airbag optional on later models
Seat Belts:
3-point front, 2-point rear (later models may have 3-point rear)
💡 Technology Features
Infotainment
Audio System:
AM/FM radio, cassette player, optional CD player (later models). Basic speaker configurations.
Driver Assistance
ABS:
Available as an option on select models, typically on rear wheels first, then 4-wheel ABS.
Connectivity
Cruise Control:
Optional feature on most trims.
Other Tech
Instrument Cluster:
Analog gauges for speedometer, tachometer (optional), fuel, temperature, oil pressure. Warning lights for various systems.
🔧 Maintenance
Service Intervals
Oil Change Interval Miles:
3,000 - 5,000 (depending on oil used and driving conditions)
Transmission Fluid Change Interval Miles:
30,000 - 60,000 (depending on type and driving)
Spark Plug Replacement Interval Miles:
30,000 - 100,000 (depending on plug type, e.g., standard vs. platinum/iridium)
Fluid Specifications
Engine Oil Specification:
API SN or higher, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature)
Coolant Specification:
Chrysler/Dodge/Jeep HOAT (Hybrid Organic Acid Technology) or equivalent (typically green or orange coolant)
Transmission Fluid Specification Aw4:
Dexron III (or equivalent ATF+4 for later models, check manual)
Transmission Fluid Specification Ax-5:
GL-3 or GL-4 Gear Oil, SAE 75W-90
Known Issues
Common Problems Engine:
Head gasket leaks (especially 4.0L), oil filter adapter O-ring leaks, cracked cylinder heads (early 4.0L), tappet noise.
Common Problems Transmission:
AX-5 internal wear, AW4 torque converter shudder, manual clutch wear.
Common Problems Drivetrain:
Dana 35 axle strength limitations for extreme off-roading, U-joint wear, front axle disconnect issues (early models).
Common Problems Electrical:
Crankshaft Position Sensor (CKP) failure (4.0L), erratic gauge readings, headlight switch failure, blower motor resistor failure.
Common Problems Suspension Steering:
Worn control arm bushings, leaf spring sag, steering box looseness.
📚 Vehicle History
Brand Heritage
Heritage Connection:
Continues Jeep's legacy of rugged, go-anywhere utility in a more compact package than the Grand Wagoneer.
Model Evolution
Key Changes 1988-2001:
Introduction of 4.0L I6, unibody construction, fuel injection, improved interiors, updated styling, optional ABS, airbags.
Production
Production Period:
1984-2001
Manufacturing Locations:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Offroad Magazine Recognition:
Frequently cited by off-road publications for its capability and value.
Jeep Heritage Recognition:
Considered by many enthusiasts to be one of the most capable and versatile Jeeps produced in its era.
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