🏷️ Basic Information

Make:

Jeep

Model:

Cherokee XJ

Engine Options:

2.5L I4, 4.0L I6

Production Years Covered:

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

Chassis Code:

XJ

👋 Introduction

Segment:

Compact SUV, renowned for its off-road capability and utilitarian design.

Competitors:

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

Design Philosophy:

Body-on-frame construction, robust four-wheel-drive systems (Command-Trac, Selec-Trac), reliable and torquey inline-six engine, compact footprint.

Cult Following:

Strong enthusiast base due to its durability, customization potential, and classic Jeep character.

📋 Manual Details

General Coverage:

Comprehensive service and repair for Jeep Cherokee XJ models with 2.5L and 4.0L engines.

Specific Systems Covered:

Engine, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Bodywork, Emissions Control.

Estimated Pages:

Extensive (typically over 1500 pages for a complete workshop manual of this scope)

Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul procedures for 2.5L (AMC 150) and 4.0L (AMC 242) inline engines, including disassembly, inspection, repair, and reassembly of cylinder heads, blocks, pistons, crankshafts, camshafts, and valvetrain.

Fuel System:

Covers fuel delivery, injection systems (MPI), fuel pumps, injectors, fuel pressure regulators, and evaporative emissions control (EVAP).

Ignition System:

Diagnosis and repair of electronic ignition systems, spark plugs, coils, distributors (where applicable in early years), and control modules.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan, and fan clutch servicing and repair.

Lubrication System:

Oil pump, oil pan, oil filter, and lubrication passages, including oil change procedures and specifications.

Exhaust System:

Catalytic converter, mufflers, exhaust pipes, and oxygen sensors.

Transmission Manual:

Service and repair for NV1500, NV3550, and AX-15 manual transmissions. Includes clutch system, gearbox disassembly, and component replacement.

Transmission Automatic:

Service and repair for AW4 (Aisin-Warner) and 32RH (Chrysler) automatic transmissions. Covers torque converter, valve body, planetary gears, and electronic controls.

Drivetrain Transfer Case:

Service for Selec-Trac (242) and Command-Trac (231) transfer cases, including chain wear, seal replacement, and fluid capacities.

Drivetrain Axles:

Dana 30 (front) and Dana 35c/AMC 20 (rear) axle servicing, including differential overhaul, gear pattern checks, bearings, and seals.

Suspension Front:

Leaf spring (early models) and coil spring suspension systems. Ball joints, control arms, shock absorbers, and steering stabilizer servicing.

Suspension Rear:

Leaf spring suspension servicing, shock absorbers, and axle housing alignment.

Steering System:

Power steering pump, gearbox, tie rods, drag link, and steering column repair and adjustment.

Brake System:

Front disc and rear drum brakes. Hydraulic system, master cylinder, power booster, caliper and wheel cylinder overhaul, brake pad/shoe replacement, and brake fluid specifications.

Anti Lock Brakes:

Diagnosis and repair for ABS systems (if equipped).

Electrical System Power:

Battery, alternator, starter motor, charging system diagnosis and repair.

Electrical System Lighting:

Headlights, taillights, interior lights, and accessory lighting circuits.

Electrical System Instruments:

Dashboard gauges, warning lights, and instrument cluster servicing.

Electrical System Wiring Diagrams:

Detailed wiring schematics for all major vehicle systems.

HVAC System:

Air conditioning compressor, condenser, evaporator, blower motor, heater core, and climate control system.

Body Exterior:

Door panel removal, body panel alignment, tailgate, liftgate, and bumper servicing.

Body Interior:

Seat removal, dashboard trim, headliner, and carpet replacement.

Body Glass:

Windshield, side glass, and rear window replacement.

Emissions Control:

EGR system, PCV system, and secondary air injection (if equipped) diagnosis and repair.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, and lubrication.

Engine Repair:

Complete engine overhaul, piston ring replacement, bearing replacement, cylinder head gasket replacement, timing chain/belt replacement (chain for XJ).

Transmission Repair:

Clutch replacement, transmission fluid and filter changes, internal transmission component replacement.

Brake Service:

Brake pad and rotor/drum replacement, caliper and wheel cylinder seal replacement, brake bleeding.

Electrical Diagnostics:

Troubleshooting of electrical faults, wiring harness repair, component testing, fuse and relay diagnosis.

Suspension And Steering Alignment:

Wheel alignment procedures, ball joint replacement, tie rod end replacement, power steering system repair.

Diagnostic Trouble Codes:

OBD-I and OBD-II (later models) diagnostic procedures, DTC lookup, and interpretation.

Body And Interior Repair:

Door mechanism repair, window regulator replacement, trim panel installation, dent repair guidance.

Depth:

In-depth, professional-level coverage suitable for experienced DIY mechanics and professional technicians. Includes detailed specifications, torque values, diagnostic flowcharts, and component testing procedures.

📊 Manual Specifications

Format Details:

Digital download, typically PDF. Searchable text, printable pages. High-resolution diagrams and illustrations.

Quality Description:

Clear, legible text and high-quality images of diagrams, illustrations, and photographs.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

2.5L I4:

AMC 150. Displacement: 2467cc (150 cu in). Bore x Stroke: 3.88 x 3.25 in. Compression Ratio: 8.8:1. Horsepower: 125 hp @ 4800 rpm. Torque: 190 lb-ft @ 2400 rpm.

4.0L I6:

AMC 242. Displacement: 3960cc (242 cu in). Bore x Stroke: 3.88 x 3.41 in. Compression Ratio: 8.8:1 (earlier) to 9.7:1 (later). Horsepower: 177-190 hp @ 4800 rpm. Torque: 220-255 lb-ft @ 3200 rpm.

Engine Type:

Inline 6-cylinder (4.0L), Inline 4-cylinder (2.5L)

Induction:

Multi-Point Fuel Injection (MPI) for both engines.

Fuel Type:

Unleaded gasoline (87 octane recommended, higher for performance variants).

🔧 Transmission

Manual Options:

NV1500 (5-speed, 2.5L), AX-15 (5-speed, 4.0L), NV3550 (5-speed, later 4.0L).

Automatic Options:

AW4 (4-speed automatic, Aisin-Warner, 4.0L), 32RH (3-speed automatic, Chrysler, 2.5L and 4.0L).

Drivetrain Options:

2WD (RWD) and 4WD configurations.

📐 Dimensions

Wheelbase:

101.4 inches (2576 mm)

Length:

Approx. 167.9 inches (4265 mm)

Width:

Approx. 70.3 inches (1786 mm)

Height:

Approx. 63.7 inches (1618 mm)

Curb Weight:

Approx. 3200-3600 lbs (1450-1630 kg), depending on engine and configuration.

Towing Capacity:

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

🛡️ Safety Features

NHTSA Ratings:

Variable based on model year and testing protocols. Generally considered safe for its era, with improvements in later years.

Braking:

Front disc, rear drum brakes. Optional Anti-lock Braking System (ABS) available on some models.

Restraints:

Seat belts (3-point front, lap rear). Driver and passenger airbags introduced in later model years (starting around 1994).

Construction:

Unibody construction, known for its rigidity and crashworthiness compared to body-on-frame SUVs of the same era.

💡 Technology Features

Audio System:

Factory AM/FM radio, cassette player, optional CD player. Basic speaker systems.

ABS:

Optional Anti-lock Braking System (ABS) on some models, primarily affecting rear wheels initially, later models with 4-wheel ABS.

Wiring:

Standard automotive wiring for lights, ignition, and accessories. Later models incorporate more complex electronics for engine management and ABS.

🔧 Maintenance

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 specifics.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2-3 years. Consult manual for specific coolant type.

Transmission Fluid Change:

Every 30,000-50,000 miles (48,000-80,000 km). Refer to manual for specific fluid type and capacity.

Engine Oil 2.5L:

API Service SG or higher, SAE 10W-30. Capacity: 5 US quarts (4.7 L) with filter.

Engine Oil 4.0L:

API Service SG/SH or higher, SAE 10W-30 (preferred) or 10W-40. Capacity: 6 US quarts (5.7 L) with filter.

Coolant:

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

Transmission Fluid Aw4:

Dexron III/Mercon ATF. Capacity: 3.2 US quarts (3.0 L) dry fill.

Transmission Fluid Ax-15:

GL-3 or GL-4 gear oil, SAE 75W-90. Capacity: 2.2 US quarts (2.1 L).

Differential Fluid:

API GL-5 gear oil, SAE 75W-90 (front and rear axles). Capacity varies, approx. 1.5-2.0 US quarts per axle.

Common Problems 4.0L:

Head gasket failure (earlier 4.0L engines), cracked cylinder heads (later 4.0L), intake manifold gasket leaks, rear main seal leaks, death wobble (suspension/steering linkage wear).

Common Problems 2.5L:

Less powerful, can be prone to overheating if cooling system is neglected, clutch wear.

General Wear Items:

Leaf springs (sagging), U-joints, brake components, exhaust systems, radiators, water pumps.

📚 Vehicle History

Jeep Legacy:

Jeep has a long history of producing rugged, capable off-road vehicles dating back to WWII.

Design Era:

The XJ generation represented a significant shift with its unibody design, making it lighter and more fuel-efficient than its predecessors, while retaining strong off-road prowess.

Key Changes:

Engine upgrades (4.0L I6 introduction), interior and exterior styling updates, introduction of airbags and ABS in later years, OBD-II compliance in 1996.

Manufacturing Location:

Toledo, Ohio, USA

Production Run:

1984-2001 (North America)

🏆 Awards & Recognition

Offroad Accolades:

Consistently rated highly by off-road publications and enthusiasts for its trail capability and durability.