Jeep XJ 1989 Repair Service Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee (XJ) Year: 1989 Codes Chassis Code: XJ 👋 Introduction Market Position Segment: Compact SUV / Off-road Vehicle Target Audience: Enthusiasts and professional...

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Type: Car

Vendor:

Sku: 389091

Tags: 1989 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 / Off-road Vehicle

Target Audience:

Enthusiasts and professional mechanics working on Jeep XJ models.

Competitive Analysis

Competitors:

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

Key Features

Platform Legacy:

Unibody construction, a significant departure from traditional body-on-frame SUVs, contributing to lighter weight and improved handling.

Offroad Capability:

Renowned for its off-road prowess, a hallmark of the Jeep brand, with available 4x4 systems and solid axle options (depending on configuration).

Design Longevity:

The XJ's basic design remained largely unchanged throughout its production run (1984-2001), highlighting its enduring appeal and effectiveness.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

Page Count:

Estimated 1000+ pages (typical for factory service manuals of this era)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine diagnosis, repair, overhaul, and specifications for all gasoline and diesel variants (if applicable for 1989).

Transmission:

Service and repair procedures for manual (e.g., AX-4, AX-5) and automatic (e.g., AW4, 30RH) transmissions.

Drivetrain:

Front and rear axle service, differentials, transfer case (e.g., NP242 Selec-Trac, NP231 Command-Trac), driveshafts, and U-joints.

Suspension:

Front and rear suspension systems, leaf springs, coil springs, shock absorbers, control arms, bushings, and alignment specifications.

Steering:

Power steering system diagnosis and repair, steering gearbox, tie rods, ball joints, and steering column.

Brakes:

Front disc and rear drum brake systems, hydraulic system, parking brake, ABS (if equipped for 1989), component replacement, and bleeding procedures.

Electrical:

Complete wiring diagrams, fuse/relay identification, charging system, starting system, lighting, ignition system, and accessory circuits.

Fuel:

Fuel delivery system, fuel pump, injectors, fuel pressure regulator, evaporative emissions control system (EVAP).

Cooling:

Radiator, water pump, thermostat, cooling fan, heater core, and coolant specifications.

Exhaust:

Exhaust manifold, catalytic converter, mufflers, pipes, and emission control components.

HVAC:

Heating, ventilation, and air conditioning system diagnosis, repair, and refrigerant handling (R-12 for this era).

Body:

Body panel repair, door mechanisms, interior trim, glass replacement, and structural components.

Chassis:

Frame inspection, repair, and related components.

Procedures Included

Maintenance:

Scheduled maintenance intervals, fluid changes, filter replacements, tune-up procedures.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides for common and complex issues.

Repair:

Step-by-step instructions for component removal, installation, and overhaul.

Diagnostics:

Component testing procedures, diagnostic trouble codes (DTCs) interpretation (OBD-I).

Specifications:

Torque specifications, clearances, tolerances, and measurement data for all components.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Designed for professional technicians with detailed diagrams and technical explanations.

📊 Manual Specifications

File Format

File Type:

Digital PDF

Searchability:

Likely searchable text (depending on PDF conversion quality).

Printability:

Printable pages for workshop use.

Quality:

Likely scanned from original factory manuals, with potential for varying image clarity.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

4.0L Inline 6-cylinder (242 ci) 'High Output' (OHV)

Engine Code 2:

2.5L Inline 4-cylinder (150 ci) 'Tech' (OHV)

Performance 1

4.0L Horsepower:

Approximately 173 hp @ 4700 rpm (for 1989)

4.0L Torque:

Approximately 220 lb-ft @ 3200 rpm (for 1989)

Performance 2

2.5L Horsepower:

Approximately 105 hp @ 4800 rpm (for 1989)

2.5L Torque:

Approximately 132 lb-ft @ 3200 rpm (for 1989)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) for 4.0L; Throttle Body Injection (TBI) for 2.5L (typically)

Fuel Type:

Unleaded Gasoline

Engine Management

ECM Type:

OBD-I

🔧 Transmission

Standard Transmission

Standard Transmission Type:

AX-4 (4-speed manual) or AX-5 (5-speed manual)

Optional Transmission

Optional Transmission Type:

AW4 (4-speed automatic) or 30RH (3-speed automatic, less common for XJ in this year)

Features

Aw4 Features:

Electronically controlled, with 'Sport' and 'Comfort' modes.

Fluid Type Auto

Automatic Fluid Spec:

Chrysler ATF+3 or equivalent (check manual for exact spec, may be Dexron II/III compatible)

Fluid Type Manual

Manual Fluid Spec:

API GL-5 gear oil (e.g., 75W-90 or 80W-90)

📐 Dimensions

Exterior

Wheelbase:

101.4 inches (2576 mm)

Length:

167.2 inches (4247 mm)

Width:

69.4 inches (1763 mm)

Height:

63.0 inches (1600 mm)

Weights

Curb Weight Approx:

3100-3500 lbs (depending on configuration)

Gross Vehicle Weight Rating:

Refer to vehicle's compliance plate; typically around 4600-5000 lbs

🛡️ Safety Features

Ratings

NHTSA Crash Test:

Information for 1989 models is limited, but generally rated fair to good for its era. The unibody construction offered some safety advantages over body-on-frame competition.

Active Features

Optional Anti-lock Braking System (ABS) may be present on some models, typically rear-wheel ABS.

Passive Features

Seatbelts:

Front and rear seat belts.

Airbags:

Driver-side airbag was not standard and likely not available on most 1989 models. Passenger airbags were not offered.

💡 Technology Features

Infotainment

Audio System:

Typically a factory AM/FM stereo radio with optional cassette player. Speaker configuration varies by trim level.

Instrument Cluster:

Analog gauges for speedometer, tachometer (on some trims), fuel, oil pressure, temperature, and voltmeter.

Driver Assistance

Cruise Control:

Optional feature on most trims.

Towing Features:

Factory trailer towing packages were available, including wiring harnesses and hitch receivers.

Connectivity

OBD Port:

OBD-I diagnostic port (typically located under the dash or in the engine bay).

🔧 Maintenance

Service Intervals Engine

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months, using a quality conventional or synthetic blend oil (e.g., 10W-30 for 4.0L).

Spark Plug Replacement:

Approximately 30,000 miles (recommend checking manual for specific plug type and gap).

Service Intervals Transmission

Automatic Transmission Fluid Change:

Every 30,000-60,000 miles, or as per severe service schedule.

Service Intervals Drivetrain

Transfer Case Fluid Change:

Every 30,000-60,000 miles.

Fluid Specifications

Engine Oil Spec:

API SG or higher, SAE 10W-30 or 10W-40 (check manual for precise temperature range viscosity).

Coolant Spec:

Ethylene glycol based, 50/50 mix with distilled water. Mopar Antifreeze/Coolant or equivalent.

Brake Fluid Spec:

DOT 3 brake fluid.

Known Issues

Common Issue 1:

Head gasket failures on the 4.0L engine, particularly on earlier models or if overheating occurred.

Common Issue 2:

Leaking oil pans, valve cover gaskets, and rear main seals.

Common Issue 3:

Worn leaf spring bushings and potential frame rust issues in certain climates.

Common Issue 4:

Aging electrical connectors and grounds can lead to intermittent issues.

Common Issue 5:

Cracked exhaust manifolds on the 4.0L engine.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Built upon Jeep's strong reputation for robust, capable off-road vehicles, dating back to WWII.

Model Evolution

Xj Introduction:

Introduced in 1984 as a revolutionary compact SUV, the XJ replaced the Jeep CJ-5 and CJ-7 as Jeep's primary sport utility vehicle offering.

1989 Updates:

Minor styling updates, potential powertrain refinements. For 1989, the 4.0L engine became the dominant and preferred engine option for its torque and refinement.

Production

Production Years:

1984-2001

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Popular Mechanics:

Often cited in contemporary reviews for its innovative unibody design and capability. Earned recognition from various automotive publications.

Ratings

Offroad Ratings:

Consistently rated as one of the most capable off-road vehicles of its era among compact SUVs.