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Jeep CHEROKEE XJ Service Repair Manual 1994

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1994 👋 Introduction Market Position Segment: Compact SUV Competitors: Toyota 4Runner, Ford Bronco II, Nissan Pathfinder, Chevrolet S-10 Blazer Key...
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Jeep CHEROKEE XJ Service Repair Manual 1994
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee XJ
Year:
1994
👋 Introduction
Market Position
Segment:
Compact SUV
Competitors:
Toyota 4Runner, Ford Bronco II, Nissan Pathfinder, Chevrolet S-10 Blazer
Key Features
Unibody Construction:
Cherokee XJ pioneered unibody construction in SUVs, offering a lighter, more refined ride compared to body-on-frame rivals.
Legendary Offroad Capability:
Renowned for its off-road prowess, especially with the 4.0L engine and capable 4x4 systems.
Compact Size:
Maneuverable and practical for urban driving while maintaining utility.
Long Production Run:
A testament to its successful design, produced from 1984 to 2001.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service & Repair Manual
Language:
English
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
2.5L AMC 150 I4, 4.0L AMC 242 I6
Transmission:
AX-5 Manual, AW-4 Automatic
Drivetrain:
Command-Trac (2WD/4WD Part-Time), Selec-Trac (2WD/4WD Full-Time)
Suspension:
Leaf Spring Rear, Leaf Spring Front (non-radius arm)
Brakes:
Front Disc, Rear Drum
Electrical:
Wiring Diagrams, Charging System, Ignition System, Lighting, Gauges, Power Accessories
Body:
Exterior Trim, Doors, Windows, Seats, Interior Trim
HVAC:
Air Conditioning, Heating, Ventilation
Fuel System:
Fuel Injection (MPI), Fuel Tank, Pump, Lines
Procedures Included
Maintenance:
Oil Change, Filter Replacement, Fluid Checks, Belt Tensioning, Spark Plug Replacement
Troubleshooting:
Diagnostic Procedures, Symptom-Based Troubleshooting
Repair:
Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Service, Electrical Component Repair
Diagnostics:
OBD-I Fault Codes, Sensor Testing, Actuator Testing
Technical Depth
Depth:
Comprehensive Engine Mechanical, Fuel, Ignition, Emission Controls, Cooling, Lubrication, Drivetrain, Axles, Brakes, Suspension, Steering, Electrical, Body, HVAC, Diagnostics, and Repair Procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable Text
Printability:
Printable Pages
Print Quality
Quality:
High Resolution, Factory Original Quality
Binding Type
Binding:
Digital Download (Not Applicable to physical binding)
Paper Type
Paper:
Digital Download (Not Applicable to physical paper type)
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
2.5 Liters (150 cubic inches)
Engine 1 Type:
AMC 150 I4
Engine 1 Horsepower:
Approx. 125 hp @ 4600 RPM
Engine 1 Torque:
Approx. 170 lb-ft @ 2800 RPM
Optional Engine
Engine 2 Displacement:
4.0 Liters (242 cubic inches)
Engine 2 Type:
AMC 242 I6 (Straight-6)
Engine 2 Horsepower:
Approx. 190 hp @ 4700 RPM
Engine 2 Torque:
Approx. 220 lb-ft @ 3000 RPM
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Cooling System
Coolant Capacity:
Approx. 10.0 Quarts (9.5 Liters)
Lubrication
Oil Capacity 2.5L:
5 Quarts (4.7 Liters) with filter change
Oil Capacity 4.0L:
6 Quarts (5.7 Liters) with filter change
Recommended Oil Viscosity 2.5L:
API SG, SAE 10W-30
Recommended Oil Viscosity 4.0L:
API SG, SAE 10W-30 (or 5W-30 in very cold climates)
🔧 Transmission
Standard
Transmission Type 2.5L:
AX-5 5-Speed Manual
Optional
Transmission Type 4.0L:
AW-4 4-Speed Automatic
Transmission Type 2.5L Auto:
Optional Automatic Transmission (typically TorqueFlite 727 or A999 variant, though AW-4 also available)
Features
Manual Fluid:
AX-5: Mopar Manual Transmission Lubricant (or equivalent GL-4, SAE 75W-90)
Automatic Fluid:
AW-4: ATF+3 (or equivalent Mopar automatic transmission fluid)
Transfer Case Fluid:
NP231/NP242: Mopar Gear Lubricant & Additive or SAE 75W-90 GL-5
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2576 mm)
Length:
167.5 inches (4255 mm)
Width:
69.4 inches (1763 mm)
Height:
63.0 inches (1600 mm)
Weights
Curb Weight 2.5L:
Approx. 3100 - 3300 lbs (1406 - 1497 kg)
Curb Weight 4.0L:
Approx. 3300 - 3600 lbs (1497 - 1633 kg)
Gross Vehicle Weight Rating:
Approx. 4400 - 4700 lbs (1996 - 2132 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating 1994:
Four Stars (while specific model year ratings can vary, XJ generally performed well for its era)
Active Features
Brakes:
Front disc, rear drum. Power assisted.
Passive Features
Seat Belts:
Front and rear seat belts
Airbags:
Driver-side airbag standard for 1994 model year.
💡 Technology Features
Infotainment
Audio System:
AM/FM Radio with Cassette Player. Optional CD Player on higher trims.
Speaker Configuration:
Typically 4 speakers (2 front, 2 rear).
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was optional on some models/trims.
Connectivity
Auxiliary Input:
Not standard. Aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 6 months, whichever comes first (depending on driving conditions)
Tire Rotation Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km)
Transmission Fluid Change Interval:
AW-4: Every 30,000 - 50,000 miles (48,000 - 80,000 km) or as recommended. AX-5: Check and top off as needed, change if contaminated.
Fluid Specifications
Coolant Type:
Ethylene Glycol based coolant, Mopar Antifreeze/Coolant (or equivalent) - typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3
Power Steering Fluid:
Mopar Power Steering Fluid or ATF+3
Known Issues
Engine 4.0L He 242:
Cracked cylinder heads (especially early versions), oil filter housing leaks, rear main seal leaks, head gasket failures.
Engine 2.5L 150:
Generally reliable but can be underpowered; listen for timing chain noise.
Suspension:
Worn leaf springs (sagging), track bar wear, control arm bushings.
Electrical:
Intermittent issues with the Instrument Cluster (especially the odometer), bad grounds, failing window regulators.
Cooling System:
Radiator leaks, water pump failures, heater core leaks (leading to coolant smell inside).
Fuel System:
Clogged fuel injectors, weak fuel pump.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep, a brand with deep roots in military and off-road vehicles, established a reputation for ruggedness and capability.
Model Evolution
Xj Introduction:
The Cherokee XJ was introduced for the 1984 model year, revolutionizing the SUV market with its compact size and unibody design.
1994 Updates:
The 1994 model year saw significant updates, including the introduction of the driver-side airbag and OBD-I compliant diagnostics. Exterior styling was also refined with revised fascias and potentially new interior materials.
Production
Production Period:
1984-2001
Manufacturing Locations:
Primarily Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Offroad Magazine Accolades:
Frequently cited in off-road publications for its capability and modify-ability.
Ratings
Value Rating:
Consistently praised for its excellent value proposition in the used SUV market.
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