🏷️ Basic Information

Make:

Jeep

Model:

Cherokee XJ

Model Code:

XJ

Generation Designation:

First Generation (XJ)

Production Start Year:

1984

Production End Year:

2001

Chassis Code:

XJ

👋 Introduction

Segment:

Compact SUV

Reputation:

Known for its robust capability, off-road prowess, and long-term durability. A favorite among enthusiasts and off-roaders.

Key Competitors Era:

Toyota 4Runner, Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder, Mitsubishi Montero.

Chassis Design:

Revolutionary unibody construction for its time, offering a lighter and more rigid platform compared to traditional body-on-frame SUVs.

Powertrain Options:

Renowned for the durable and powerful 4.0L inline-six engine.

Off Road Capability:

Excellent approach and departure angles, good ground clearance, and capable 4x4 systems (Command-Trac and Selec-Trac).

📋 Manual Details

Covered Years:

1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001

Engine Variants Covered:

2.5L I4 (AMC 150), 4.0L I6 (AMC 242), 2.1L I4 Turbo Diesel (Renault J8S - early years only, not primary focus for 88-01), 2.5L I4 Turbo Diesel (VM Motori - later years, less common)

Drivetrain Variants Covered:

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

Estimated Page Count:

1500+

Type:

Service and Repair Manual

Publisher Type:

OEM or Equivalent Authorized Publisher

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of all engine components. Includes cylinder head, block, pistons, crankshaft, camshaft, valves, timing system.

Fuel System:

Fuel injection (MPI), fuel pump, injectors, fuel lines, fuel filter, evaporative emission control (EVAP) system.

Cooling System:

Radiator, water pump, thermostat, hoses, fan, coolant specifications.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, emissions control.

Ignition System:

Spark plugs, ignition coils, distributor (early models), crank position sensor, ignition timing.

Transmission Manual:

Removal, overhaul, and installation of AX-5, AX-15 manual transmissions. Clutch system, flywheel, hydraulic clutch actuation.

Transmission Automatic:

Removal, overhaul, and installation of AW4 (4-speed automatic). Torque converter, valve body, transmission fluid.

Drivetrain 4X4:

Service and repair of NP231 (Command-Trac) and NP242 (Selec-Trac) transfer cases. Operation, maintenance, and rebuild procedures.

Drivetrain Axles:

Front and rear axle assemblies, differential service, axle shafts, U-joints, wheel bearings. Dana 30 (front) and Chrysler 8.25 or Dana 35 (rear).

Suspension Front:

Solid front axle, leaf springs, shocks, steering damper (optional), caster/camber adjustment (via shims).

Suspension Rear:

Leaf springs, shocks, bushings, axle locating components.

Brakes:

Front disc brakes, rear drum brakes (standard). ABS (optional on later models). Brake fluid specifications, bleeding procedures, component replacement.

Steering:

Power steering system, steering gear (box), power steering pump, hydraulic lines, steering linkage. Wheel alignment specifications.

Body And Frame:

Unibody construction principles, body panel removal/installation, door mechanisms, glass, interior trim, rust prevention, chassis components.

Electrical System Charging:

Alternator, voltage regulator, battery, wiring diagrams for charging circuit.

Electrical System Starting:

Starter motor, ignition switch, wiring diagrams for starting circuit.

Electrical System Lighting:

Headlights, taillights, interior lights, brake lights, turn signals, wiring diagrams.

Electrical System Accessories:

Power windows, power door locks, mirrors, wipers, horn, audio system, climate control fans, wiring diagrams.

Instrument Panel:

Gauges (speedometer, tachometer, fuel, temperature, oil pressure), warning lights, switches, instrument cluster removal/installation.

HVAC:

Heating, Ventilation, and Air Conditioning system. Blower motor, heater core, evaporator core, refrigerant, control panel, ducting.

Routine Maintenance:

Oil changes, fluid checks and changes (coolant, transmission, differential, brake, power steering), filter replacements, tire rotation, battery maintenance.

Troubleshooting:

Diagnostic procedures for common and uncommon issues across all systems. Includes symptom-based troubleshooting charts.

Engine Repair:

Complete engine overhaul, head gasket replacement, timing chain/belt replacement (if applicable), piston ring replacement, bearing replacement.

Transmission Repair:

Detailed step-by-step instructions for manual and automatic transmission rebuilds, including torque specifications and clearances.

Brake Service:

Brake pad and shoe replacement, rotor and drum resurfacing/replacement, caliper and wheel cylinder overhaul, brake line replacement.

Electrical Diagnostics:

Reading trouble codes, testing sensors, actuators, and wiring harnesses using multimeters and diagnostic tools. Comprehensive wiring diagrams.

Suspension And Steering Repair:

Ball joint replacement, tie rod end replacement, control arm bushing replacement, shock absorber replacement, steering box adjustment/replacement.

Body Repair:

Door hinge adjustment, latch repair, window regulator replacement, trim panel removal/installation, minor dent repair techniques.

Climate Control Service:

AC system charging, leak detection, component replacement (compressor, condenser, expansion valve), heater core replacement.

Depth:

Comprehensive, covering everything from basic maintenance to complete component overhauls and advanced diagnostics.

Diagnostic Tools:

Mentions use of OBD-I (on earlier models) and OBD-II (on later models) diagnostic tools, multimeters, and specific Chrysler diagnostic procedures.

Torque Specs:

Extensive list of torque specifications for all fasteners across all major systems.

Wiring Diagrams:

Detailed, system-specific wiring diagrams with component locations and wire color codes.

📊 Manual Specifications

File Type:

PDF

Searchability:

Fully searchable text for quick information retrieval.

Printability:

Printable pages for on-the-go workshop use.

Image Resolution:

High resolution for clear diagrams and illustrations.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Code 1:

AMC 242 (4.0L I6)

Displacement 1:

3960 cc (242 cubic inches)

Configuration 1:

Inline 6-cylinder, Overhead Valve (OHV)

Horsepower 1 Range:

177-190 hp (varies slightly by year and specific tune)

Torque 1 Range:

220-235 lb-ft (varies slightly by year and specific tune)

Engine Code 2:

AMC 150 (2.5L I4)

Displacement 2:

2468 cc (150 cubic inches)

Configuration 2:

Inline 4-cylinder, Overhead Valve (OHV)

Horsepower 2 Range:

125-130 hp (varies slightly by year)

Torque 2 Range:

145-155 lb-ft (varies slightly by year)

Injection Type:

Multi-Point Fuel Injection (MPI) for all gasoline engines in this range.

🔧 Transmission

Transmission Type Standard:

5-speed manual (AX-5 or AX-15)

Transmission Type Optional:

4-speed automatic (AW4)

Automatic Transmission Control:

Electronically controlled by the Powertrain Control Module (PCM).

Manual Transmission Clutch:

Hydraulic clutch actuation system.

📐 Dimensions

Wheelbase:

101.4 inches (2576 mm)

Length:

167.5 - 170.1 inches (4255 - 4320 mm) depending on year/bumper design

Width:

69.4 inches (1763 mm)

Height:

63.4 - 66.4 inches (1610 - 1687 mm) depending on suspension/options

Ground Clearance:

Approx. 8-10 inches (203-254 mm) depending on tire size and suspension

Curb Weight:

3100 - 3600 lbs (1406 - 1633 kg) depending on configuration

Gross Vehicle Weight Rating Gvw:

Approx. 4600 - 4900 lbs (2087 - 2223 kg)

Towing Capacity:

Up to 2000 lbs (907 kg) typically, may vary based on configuration and year

🛡️ Safety Features

NHTSA Ratings Era:

NHTSA testing procedures and reporting standards were different during this period. Specific crash test data may be limited compared to modern vehicles.

Anti Lock Brakes ABS:

Optional on later models (4-wheel ABS), standard rear-wheel ABS on some configurations.

Airbags:

Driver-side airbag standard from 1994 onwards. Passenger airbag not typically offered.

Seat Belts:

Front lap and shoulder belts, rear lap belts (later models with rear shoulder belts).

Rollover Structure:

Designed with reinforced A and B pillars and roof structure inherent to SUV design.

💡 Technology Features

Audio Systems:

Factory AM/FM radio with cassette player, optional CD player. Speaker configurations varied by trim level.

Cruise Control:

Available on most trim levels.

Instrument Cluster:

Analog gauges, basic warning lights. Higher trims may have tachometer, voltmeter, oil pressure, and coolant temperature gauges.

Bluetooth Availability:

Not factory available. Aftermarket solutions are common.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions and oil type used.

Transmission Fluid Change Automatic:

Every 30,000-60,000 miles (48,000-96,000 km) or as recommended by specific service bulletins.

Transmission Fluid Change Manual:

Every 30,000-50,000 miles (48,000-80,000 km).

Coolant Change:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.

Spark Plug Replacement:

Around 30,000-60,000 miles (48,000-96,000 km) depending on plug type (conventional vs. platinum).

Engine Oil Spec 4.0L:

SAE 10W-30 API SG or higher. Check manual for specific viscosity based on climate.

Engine Oil Spec 2.5L:

SAE 5W-30 or 10W-30 API SG or higher. Check manual for specific viscosity.

Automatic Transmission Fluid Atf:

ATF+3 or ATF+4 (Chrysler specifications, older manuals may specify Dexron III compatible fluids).

Coolant:

Chrysler Antifreeze/Coolant (Green, 50/50 mix with distilled water).

Brake Fluid:

DOT 3 or DOT 4 Brake Fluid.

Power Steering Fluid:

ATF+3 or equivalent power steering fluid.

Common Problems 1:

Cracked cylinder heads (specifically on early 4.0L engines, later ones improved), catalytic converter failure, front clip wear (bushings, ball joints), rear main seal leaks, rust on rockers and rear quarters.

Common Problems 2:

Transmission issues (AW4 can be reliable but prone to cooler line leaks; AX-5 durability concerns), transfer case chain stretch, differential leaks.

Common Problems 3:

Electrical gremlins related to grounds and aging wiring harnesses, HVAC blower resistor failure.

📚 Vehicle History

Jeep Legacy:

Built upon Jeep's long history of producing rugged, go-anywhere vehicles dating back to WWII.

Redesign Points:

Major facelift in 1997 included updated interior, revised front and rear fascia, improved aerodynamics, and significant suspension refinements. Earlier models saw gradual updates to powertrains and features.

Engine Changes:

The 4.0L inline-six became the dominant and most desirable engine option, evolving over the years for increased power and efficiency.

Manufacturing Locations:

Primarily Toledo, Ohio, USA.

Ownership Changes:

Produced under American Motors Corporation (AMC) initially, then Chrysler Corporation after AMC's acquisition in 1987.

🏆 Awards & Recognition

Off Road Magazine Recognition:

Consistently ranked highly by off-road publications for its capability and modification potential.

Consumer Reports Era:

While specific ratings are historical, the XJ generally received mixed-to-positive reviews for its utility and durability, often overshadowed by reliability concerns in some areas.