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Jeep CHEROKEE XJ Workshop Repair Manual 1988-2001

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee (XJ) Years Covered: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 Codes Chassis Code: XJ 👋...
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Sku: 282456
Jeep CHEROKEE XJ Workshop Repair Manual 1988-2001
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee (XJ)
Years Covered:
1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001
Codes
Chassis Code:
XJ
👋 Introduction
Market Position
Segment:
Compact SUV/Off-Road Vehicle
Legacy:
Renowned for its off-road capability, durability, and distinctive styling.
Competitive Analysis
Key Rivals:
Toyota 4Runner, Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder.
Key Features
Off Road Prowess:
Unibody construction with robust four-wheel-drive systems (Command-Trac, Selec-Trac) and solid axles provided exceptional off-road articulation and capability.
Durability:
Built with a reputation for longevity and resilience, making it a favorite for off-road enthusiasts and long-term owners.
Design Language:
Iconic boxy styling, compact dimensions for maneuverability, and a no-nonsense interior.
📋 Manual Details
Coverage Areas
Primary Focus:
Workshop Service and Repair
Page Count
Estimated Page Count:
Thousands (comprehensive coverage across all systems)
Manual Type
Type:
Professional Workshop Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full disassembly, inspection, repair, and reassembly of all engine components for all specified variants.
Fuel System:
Fuel injection (MPI), fuel pump, fuel pressure regulator, injectors, fuel lines, fuel tank servicing.
Ignition System:
Spark plugs, ignition coils, distributor (if applicable), ignition control module, wiring, timing adjustments.
Cooling System:
Radiator, water pump, thermostat, heater core, cooling fan (electric/mechanical), coolant types and capacities.
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, gaskets, emissions control components.
Transmission Manual:
Clutch, gearbox internal components, shift linkages, fluid types, capacities, and service procedures.
Transmission Automatic:
Torque converter, valve body, internal gear sets, seals, solenoids, fluid types, capacities, and service procedures.
Drivetrain 4Wd:
Transfer case (NP231, NP242), front and rear driveshafts, U-joints, axle assemblies, hub locking mechanisms.
Steering System:
Power steering pump, steering gear (steering box), tie rods, drag link, steering column, alignment procedures.
Suspension System:
Front (leaf spring, solid axle), rear (leaf spring, solid axle), shock absorbers, bushings, control arms, sway bars.
Brake System:
Front disc brakes, rear drum brakes (and some rear disc variants), master cylinder, brake booster, ABS (if equipped), bleeding procedures, component replacement.
Electrical System Charging:
Alternator, voltage regulator, battery, starter motor, wiring diagrams, charging system diagnostics.
Electrical System Lighting:
Headlights, taillights, interior lights, turn signals, hazard lights, bulb specifications, wiring.
Electrical System Instruments:
Dashboard gauges, warning lights, instrument cluster removal and repair.
Body And Chassis:
Body panel removal and installation, frame straightening, rust repair, interior trim, door mechanisms, glass replacement.
HVAC System:
Air conditioning compressor, condenser, evaporator, heater core, blower motor, controls, refrigerant types and procedures.
Safety Systems:
Airbags (if equipped), seat belts, child restraint systems, crashworthiness information.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, battery maintenance.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides.
Component Replacement:
Step-by-step instructions for replacing virtually any component on the vehicle.
Engine Rebuilding:
Detailed instructions for complete engine overhaul, including specifications for machining and clearances.
Transmission Overhaul:
Comprehensive guides for the disassembly, repair, and reassembly of both manual and automatic transmissions.
Electrical Diagnostics:
Detailed wiring diagrams, component testing procedures, and troubleshooting for electrical faults.
Suspension And Steering Alignment:
Alignment specifications and procedures for both front and rear suspensions.
Brake System Repair:
Pad/shoe replacement, rotor/drum service, caliper/wheel cylinder rebuild, brake bleeding.
Technical Depth
Depth:
Expert-level, covering everything from basic maintenance to complete factory-level rebuilds and diagnostics.
Diagnostic Tools:
Information pertaining to OBD-I and OBD-II diagnostic procedures and common fault codes for the era.
Torque Specifications:
Precise torque values for all fasteners throughout the vehicle.
Clearances And Tolerances:
Specifications for critical engine and drivetrain component clearances.
📊 Manual Specifications
File Format
Digital Format Details:
Likely high-resolution PDF, optimized for digital viewing and printing of individual pages. Searchable text is a high probability for professional manuals.
Print Quality
Print Recommendation:
Designed for professional printing, with clear diagrams and text.
Binding Type
Binding For Print:
Typically spiral-bound or comb-bound for lay-flat use in a workshop environment (for printed versions).
Paper Type
Paper Quality For Print:
Heavy-duty paper stock suitable for workshop conditions, resistant to grease and dirt.
⚙️ Engine Specifications
Primary Engine
Engine 2.5L Inline 4:
2.5L (150 ci) AMC/Jeep I4 ('Tech Four'). Approx. 125 hp, 140 lb-ft torque. MPI fuel injection.
Engine 4.0L Inline 6:
4.0L (242 ci) AMC/Jeep I6 ('High Output'). Approx. 180-190 hp, 220-235 lb-ft torque. MPI fuel injection. Highly regarded for torque and durability.
Performance
Horsepower Range:
125 hp to 190 hp (depending on engine variant)
Torque Range:
140 lb-ft to 235 lb-ft (depending on engine variant)
Fuel System
Injection Type:
Multi-Point Fuel Injection (MPI) for most models, some earlier models may have Throttle Body Injection (TBI).
Fuel Type:
Unleaded gasoline (87 octane recommended, higher octane for improved performance)
🔧 Transmission
Standard
Manual Transmission:
AX-5 5-speed manual (common with 2.5L I4), NV3550 5-speed manual (later models with 4.0L I6).
Optional
Automatic Transmission:
AW4 4-speed automatic (common with 4.0L I6), 32RH 3-speed automatic (later models, particularly with 2.5L I4).
Features
Transfer Case Options:
NP231 Command-Trac (part-time 4WD), NP242 Selec-Trac (full-time 4WD option).
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2576 mm)
Length:
167.5 - 170.2 inches (4255 - 4323 mm) depending on bumper style.
Width:
69.4 - 70.0 inches (1763 - 1778 mm)
Height:
63.4 - 65.8 inches (1610 - 1671 mm)
Weights
Curb Weight Range:
Approx. 3,300 - 3,800 lbs (1497 - 1724 kg)
Towing Capacity:
Up to 5,000 lbs (2268 kg) with proper equipment and engine.
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating 1997:
4-star driver, 5-star passenger (for specific models/years)
Active Features
ABS:
Anti-lock Braking System (ABS) available on some models and years, typically rear-wheel or 4-wheel.
Passive Features
Airbags:
Driver-side airbag standard from 1994 onwards; passenger airbag optional on some later models.
Seat Belts:
Front and rear seat belts, with driver and front passenger pretensioners on later models.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette tape player, optional CD player on later models. Speaker configurations varied by trim level.
Driver Assistance
Cruise Control:
Available on most trim levels.
Connectivity
Power Windows Locks:
Available on higher trim levels, often part of an options package.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions (refer to manual for precise intervals).
Transmission Fluid Change:
Automatic: Every 30,000-60,000 miles (48,000-96,000 km) or as recommended by severe duty cycles. Manual: Inspect periodically, change if contaminated or worn.
Coolant Flush:
Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.
Fluid Specifications
Engine Oil 4.0L:
API SJ or higher, SAE 10W-30 conventional or synthetic.
Engine Oil 2.5L:
API SJ or higher, SAE 5W-30 or 10W-30 conventional or synthetic.
Transmission Fluid Aw4:
ATF+3 or ATF+4 (Chrysler/Mopar Specification).
Transmission Fluid Ax-5:
GL-3 or GL-4 gear oil, SAE 75W-90 or 80W-90.
Coolant:
Chrysler/Mopar Antifreeze/Coolant (50/50 mix with distilled water), or equivalent HOAT coolant.
Power Steering Fluid:
ATF+3 or ATF+4 (Chrysler/Mopar Specification).
Known Issues
Cooling System Leaks:
Common issues include radiator leaks, water pump failures, and heater core leaks, particularly with age.
Engine Mounts:
Engine mounts can degrade over time, leading to vibrations and clunking noises.
Leaf Spring Sag:
Rear leaf springs can sag due to age and load, impacting ride height and load-carrying capacity.
Rust And Corrosion:
Vulnerable areas include rocker panels, floor pans, and wheel wells, especially in regions with road salt.
Power Steering Pump Leaks:
The power steering pump can develop leaks, typically at the shaft seal or reservoir.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a long-standing heritage in producing rugged, off-road capable vehicles since World War II.
Model Evolution
Xj Introduction:
Introduced in 1984, the XJ was revolutionary for its time as one of the first compact SUVs built with unibody construction, offering a lighter and more car-like ride than traditional body-on-frame SUVs.
Xj Facelift 1997:
Significant styling refresh for 1997, featuring new interior and exterior styling cues, improved aerodynamics, and updated powertrain options. This manual covers the post-1997 refresh.
Production
Production Years Global:
1984-2001 in North America, continued production in other markets for longer.
Manufacturing Locations:
Mainly Toledo, Ohio, USA.
🏆 Awards & Recognition
Recognitions
Four Wheeler Magazine:
Consistently praised by off-road publications for its capability and durability.
Motor Trend SUV Of The Year:
While not a direct 'SUV of the Year' winner in its primary XJ form during its initial release, its longevity and impact cemented its status as an icon.
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