Jeep XJ 1985 Repair Service Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee (XJ) Year: 1985 Codes Chassis Code: XJ 👋 Introduction Market Position Segment: Compact SUV Design Philosophy: Rugged, off-road capable, unibody construction Competitive...

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Type: Car

Vendor:

Sku: 389087

Tags: 1985 Car Cars Jeep Misc XJ

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee (XJ)

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV

Design Philosophy:

Rugged, off-road capable, unibody construction

Competitive Analysis

Key Competitors 1985:

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

Key Features

Construction:

Unibody construction (pioneering in its class)

Off Road Capability:

Solid front axle (early models), leaf-spring rear, available 4WD

Durability:

Renowned for its robust engineering and long-term reliability

📋 Manual Details

Coverage Areas

Engine Coverage:

4.0L Inline-6 (AMC 242), 2.5L Inline-4 (AMC 150)

Transmission Coverage:

AX4 Automatic, T-4 Manual, BA/10-5 Manual

Drivetrain Coverage:

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

Suspension Coverage:

Front Solid Axle (Leaf Spring), Rear Leaf Spring

Electrical System Coverage:

Wiring diagrams, component testing, diagnostics

Body And Chassis Coverage:

Body panels, interior trim, frame components

Page Count

Estimated Page Count:

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Management:

Fuel injection, ignition system, emissions control

Cooling System:

Radiator, water pump, thermostat, hoses

Lubrication System:

Oil pump, oil filter, oil passages

Exhaust System:

Manifold, catalytic converter, muffler, pipes

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, injectors

Brake System:

Front discs, rear drums, master cylinder, brake lines, parking brake

Steering System:

Steering gear, tie rods, power steering pump

HVAC System:

Heating, ventilation, air conditioning components and operation

Interior Systems:

Seats, dashboard, door panels, headliner

Procedures Included

Diagnostic Procedures:

Troubleshooting charts, symptom-based diagnostics, component testing

Maintenance Procedures:

Oil changes, filter replacements, tune-ups, fluid checks

Repair Procedures:

Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement

Adjustment Procedures:

Valve adjustment (if applicable to engine), parking brake adjustment

Disassembly And Assembly:

Detailed step-by-step instructions for component removal and installation

Wiring Diagrams Interpretation:

Guidance on reading and using electrical schematics

Technical Depth

Depth:

Comprehensive, suitable for professional technicians and advanced DIYers

Torque Specifications:

Detailed torque values for all critical fasteners

Clearances And Tolerances:

Specifications for engine internal clearances, bearing tolerances, etc.

Special Tools:

Identification of specialized tools required for specific repairs

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Print Quality

Resolution:

High-resolution, clear text and diagrams

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

AMC 242

Engine Type 1:

Inline-6, Overhead Valve (OHV)

Displacement 1:

3960 cc (242 cubic inches)

Bore X Stroke 1:

3.875 in x 3.562 in (98.4 mm x 90.5 mm)

Compression Ratio 1:

8.2:1

Horsepower 1:

130 hp @ 4000 rpm

Torque 1:

210 lb-ft @ 2000 rpm

Secondary Engine

Engine Code 2:

AMC 150

Engine Type 2:

Inline-4, Overhead Valve (OHV)

Displacement 2:

2464 cc (150 cubic inches)

Bore X Stroke 2:

4.00 in x 3.00 in (101.6 mm x 76.2 mm)

Compression Ratio 2:

8.8:1

Horsepower 2:

110 hp @ 4800 rpm

Torque 2:

145 lb-ft @ 2800 rpm

Fuel System

Fuel Delivery System:

Multi-Point Fuel Injection (MPI) for both engines

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

🔧 Transmission

Standard

Manual Transmission Standard:

Aisin-Warner AX4 4-speed Automatic

Optional

Manual Transmission Optional 1:

Tremec (Borg-Warner) T-4 4-speed Manual

Manual Transmission Optional 2:

Borg-Warner BA/10-5 5-speed Manual (later availability)

Features

Transfer Case Options:

Command-Trac (NV231), Selec-Trac (NV242)

Fluid Specifications

Automatic Transmission Fluid:

ATF+3 (Chrysler Specification)

Manual Transmission Fluid T4:

GL-4 Gear Oil (75W-90)

Manual Transmission Fluid Ba10:

GL-4 Gear Oil (75W-90)

📐 Dimensions

Exterior

Wheelbase:

101.4 inches (2575 mm)

Length:

167.2 inches (4247 mm)

Width:

69.9 inches (1775 mm)

Height:

63.6 inches (1615 mm)

Weights

Curb Weight Approx:

3200 - 3500 lbs (1450 - 1590 kg)

Gross Vehicle Weight Rating Gvwr Approx:

4500 - 4700 lbs (2041 - 2132 kg)

Towing Capacity Approx:

2000 - 3500 lbs (907 - 1588 kg) depending on configuration

Payload Capacity Approx:

1000 - 1300 lbs (454 - 590 kg)

🛡️ Safety Features

Ratings

NHTSA Ratings 1985:

Not available in modern standardized format for this era

Active Features

Active Safety Features:

Four-wheel disc brakes (optional on some later models, but typically front discs/rear drums for '85)

Passive Features

Passive Safety Features:

Unibody crumple zones, seat belts

💡 Technology Features

Infotainment

Infotainment Features:

Basic AM/FM radio, optional cassette player

Driver Assistance

Driver Assistance Systems:

None (basic ABS became available later in XJ production)

🔧 Maintenance

Service Intervals

Oil Change Interval:

3,000-5,000 miles or 3-6 months (depending on driving conditions)

Transmission Fluid Change Interval Auto:

30,000-60,000 miles

Transmission Fluid Change Interval Manual:

60,000-100,000 miles

Coolant Change Interval:

30,000 miles or 2 years

Spark Plug Replacement Interval:

30,000-60,000 miles (depending on plug type)

Fluid Specifications

Engine Oil Capacity 4.0L:

5 quarts (4.7 L) with filter

Engine Oil Capacity 2.5L:

5 quarts (4.7 L) with filter

Engine Oil Type:

10W-30 or 10W-40 (API SG or higher)

Coolant Type:

Green Ethylene Glycol (50/50 mix with distilled water)

Brake Fluid Type:

DOT 3

Known Issues

Common Wear Items 1985:

Leaf spring bushings, steering box wear, rear main seal leaks, heater core issues

Engine Specific Issues 4.0L:

Cracked cylinder heads (later years, less common on early ones), oil filter adapter seal leaks

Electrical System Quirks:

Flickering gauges, starter motor issues, grounds corrosion

📚 Vehicle History

Brand Heritage

Jeep Legacy:

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

Model Evolution

Xj Introduction:

The XJ Cherokee was introduced in 1984 as a revolutionary unibody SUV, replacing the Cherokee SJ (Grand Wagoneer platform).

Design Innovation:

The XJ was the first compact SUV with a unibody construction, offering a lighter and more rigid chassis than body-on-frame competitors.

1985 Updates:

The 1985 model year saw the introduction of the more powerful 4.0L inline-six engine, which would become iconic for the XJ.

Production

Production Span:

1984-2001

Manufacturing Locations:

USA (various Chrysler/AMC plants)

🏆 Awards & Recognition

Recognitions

Automotive Journal Awards 1984:

Often cited in period reviews for its innovative design and off-road prowess, though formal awards may not be documented comprehensively.

Ratings

Reliability Reputation:

High, especially the 4.0L engine variant, earning it a cult following for durability.