Jeep Cherokee XJ 1994 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Year: 1994 Chassis Code: XJ Codes Vehicle Code: XJ 👋 Introduction Market Position Segment: Compact SUV, off-road capable Competitive Analysis Competitors 1994:...

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Sku: 391734

Tags: 1994 Car Cars Cherokee XJ Jeep Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee

Year:

Chassis Code:

Codes

Vehicle Code:

👋 Introduction

Market Position

Segment:

Compact SUV, off-road capable

Competitive Analysis

Competitors 1994:

Toyota 4Runner, Ford Explorer, Nissan Pathfinder, Chevrolet Blazer

Key Features

Design Philosophy:

Body-on-frame construction, robust 4x4 systems, durable and utilitarian design

Target Audience:

Off-road enthusiasts, utility-focused buyers, adventurers

📋 Manual Details

Coverage Areas

Coverage Type:

Full Service Repair

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Print (Physical Book)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, diagnosis, tune-up, cooling system, lubrication system, fuel injection system, exhaust system

Engine Electrical:

Ignition system, starting system, charging system, emissions control systems, engine control module (ECM) diagnosis and wiring diagrams

Transmission Manual:

AX-4, AX-5, BA-10/5 (Peugeot) - Overhaul, diagnosis, clutch system

Transmission Automatic:

AW-4 (Aisin-Warner) - Overhaul, diagnosis, shift control, cooling

Drivetrain:

Transfer case (Command-Trac, Selec-Trac), Dana 30 front axle, Dana 35c rear axle, U-joints, driveshafts, hub assemblies

Suspension:

Front leaf spring (all models), Rear leaf spring (all models), shock absorbers, bushings, alignment specifications

Steering:

Power steering system, steering gear, linkage, steering column, tilt wheel (if equipped)

Brakes:

Front disc brakes, rear drum brakes, power assist system, parking brake, ABS (if equipped), hydraulic circuits, bleeding procedures

Electrical System:

Battery, charging system, lighting, instrument cluster, gauges, horns, power windows/locks, mirrors, Wiper/washer system

Body And Frame:

Body panel repair, door mechanisms, glass replacement, interior trim, seat mechanisms, rust prevention, frame straightening

HVAC:

Air conditioning system, heater core, blower motor, refrigerant, control panels, ducting

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, lubrication points, belt tensioning, spark plug replacement

Troubleshooting:

Diagnostic flowcharts, symptom-based problem diagnosis, electrical circuit testing, component failure analysis

Repair:

Component removal and installation, sub-assembly repair, seal and gasket replacement, torque specifications for all fasteners

Diagnostics:

On-Board Diagnostics (OBD-I) codes and procedures, sensor testing, actuator testing

Specifications:

All mechanical and electrical specifications, tolerances, capacities, and test procedures

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

📊 Manual Specifications

File Format

Digital Compatibility:

Not applicable (Print)

Print Quality

Print Type:

High-quality, durable paper stock

Binding Type

Binding:

Perfect bound or spiral bound (for lay-flat use)

Paper Type

Paper Quality:

Heavy-duty, grease-resistant paper

⚙️ Engine Specifications

Primary Engine

Engine 1:

4.0L Inline 6-Cylinder (242 ci) "Vortec" (AMC/Chrysler)

Engine 1 Code:

242 ci OHV

Engine 1 Horsepower:

180 hp @ 4500 rpm

Engine 1 Torque:

220 lb-ft @ 3200 rpm

Optional Engine

Engine 2:

2.5L Inline 4-Cylinder (150 ci) "H.O." (Chrysler)

Engine 2 Code:

150 ci OHV

Engine 2 Horsepower:

125 hp @ 4800 rpm

Engine 2 Torque:

150 lb-ft @ 2400 rpm

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Engine Management

Chrysler SBEC (Single Board Engine Controller) or similar

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission (AX-4 or BA-10/5)

Optional

Transmission Type Optional:

4-Speed Automatic Transmission (AW-4)

Features

Aw4 Control:

Electronically controlled with torque converter lock-up

Transfer Case Options:

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

📐 Dimensions

Exterior

Wheelbase:

101.4 inches (2576 mm)

Length:

167.8 inches (4262 mm)

Width:

69.4 inches (1763 mm)

Height:

63.6 inches (1615 mm)

Ground Clearance:

Approx. 8.7 inches (221 mm) depending on tires/suspension

Weights

Curb Weight Min:

Approx. 3,300 lbs (1497 kg) for 4-cyl 2WD

Curb Weight Max:

Approx. 3,700 lbs (1678 kg) for 6-cyl 4WD automatic

Towing Capacity:

Up to 5,000 lbs (2268 kg) with proper equipment

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

Generally considered good for its class and era, though body-on-frame SUVs from this period can have higher rollover risk than modern unibody crossovers.

Active Features

Optional Anti-lock Braking System (ABS) on rear wheels (RWAL) for 1994 models.

Passive Features

Airbags:

Driver-side airbag standard.

Seatbelts:

Front and rear seatbelts, with front pretensioners.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo radio with cassette player; optional CD player available.

Speakers:

Typically 4 or 6 speakers depending on trim level.

Driver Assistance

Cruise Control:

Optional

Keyless Entry:

Optional

Connectivity

OBD Standard:

OBD-I (On-Board Diagnostics, First Generation)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 miles (4,800 km) or 3 months (typical recommendation for this era)

Transmission Fluid Change Auto:

Every 30,000 miles (48,000 km) or 24 months

Transmission Fluid Change Manual:

Every 40,000 miles (64,000 km) or 36 months

Coolant Change Interval:

Every 30,000 miles (48,000 km) or 24 months

Fluid Specifications

Engine Oil:

SAE 10W-30 API SG or higher (preferred)

Engine Coolant:

Chrysler Long Life Antifreeze/Coolant (50/50 mix with distilled water)

Automatic Transmission Fluid:

ATF+3 (Chrysler Specification)

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (for AX-4, BA-10/5)

Transfer Case Fluid:

NP231/242: ATF+3 or Dexron II/III

Differential Fluid Front Rear:

API GL-5, SAE 80W-90 (consider synthetic for better performance)

Known Issues

Common Issues 1:

Headliner sagging, rear main seal leaks (especially on 4.0L), radiator failures, transfer case chain stretch/wear, power steering pump leaks, exhaust manifold cracks (4.0L).

Common Issues 2:

Interior trim squeaks and rattles, door panel detaching, rear axle U-joint wear, brake wear due to weight and use.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Tracing roots to the original Willys MB WWII Jeep, AMC acquisition in 1970.

Model Evolution

Xj Introduction:

Introduced in 1984, revolutionizing the SUV market with its unibody construction and compact size.

Xj 1994 Updates:

Minor styling revisions, improved interior ergonomics, enhanced safety features (driver airbag), OBD-I compliance.

Production

Production Period:

1984-2001

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Automotive Press Acclaim:

Consistently praised by automotive journalists for its off-road prowess and durability, often appearing on "best of" lists for its segment during its production run.