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Jeep Cherokee XJ 2.5L & 4.0L Workshop Service Repair Manual 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Model Code: XJ Product Name: Jeep Cherokee XJ 2.5L & 4.0L Workshop Service Repair Manual 1988-2001 Generation Generation Code: XJ Generation Years:...
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Jeep Cherokee XJ 2.5L & 4.0L Workshop Service Repair Manual 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee
Model Code:
XJ
Product Name:
Jeep Cherokee XJ 2.5L & 4.0L Workshop Service Repair Manual 1988-2001
Generation
Generation Code:
XJ
Generation Years:
1984-2001
Codes
Engine Codes Covered:
2.5L AMC 150 (4-cylinder), 4.0L AMC 242 (inline-6)
👋 Introduction
Market Position
Segment:
Compact SUV / Sport Utility Vehicle
Reputation:
Known for ruggedness, off-road capability, and reliable powertrains (especially the 4.0L I6)
Competitive Analysis
Competitors:
Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder, Toyota 4Runner
Key Features
Design:
Unibody construction (a significant innovation for SUVs at the time), excellent approach and departure angles
Powertrain Longevity:
The 4.0L inline-6 engine is legendary for its durability and longevity
Off Road Prowess:
Renowned off-road capability due to its solid rear axle, leaf springs, and available 4WD systems
📋 Manual Details
Coverage Areas
Covered Years:
1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001
Engine Variants Covered:
2.5L I4, 4.0L I6
Chassis Variants Covered:
2-door, 4-door
Drive Types Covered:
2WD (RWD), 4WD (Part-time Command-Trac, Selec-Trac)
Page Count
Estimated Page Count:
1500-2000+
Manual Type
Type:
Workshop Service Repair Manual
Comparison:
Dealer-level equivalent
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (2.5L I4, 4.0L I6), Fuel & Emissions, Cooling, Lubrication, Ignition, Starting, Charging, Exhaust
Transmission:
Manual Transmissions (AX-5, NV1500), Automatic Transmissions (AW-4, 30RH, 42RE), Transfer Cases (NP231, NP242)
Drivetrain:
Front Axle (Dana 30), Rear Axle (Dana 35, Chrysler 8.25), Driveshafts, CV Joints, U-Joints, Wheel Hubs
Suspension:
Front Leaf Springs, Rear Leaf Springs, Shocks, Bushings, Suspension Geometry
Steering:
Power Steering System, Steering Column, Steering Gearbox/Rack and Pinion (later models), Tie Rods
Brakes:
Front Disc Brakes, Rear Drum Brakes (early models), Rear Disc Brakes (later models), ABS System (where equipped), Parking Brake
Electrical:
12V Battery System, Alternator, Starter Motor, Ignition System, Lighting, Fuses, Relays, Wiring Diagrams, Body Control Modules (BCM)
Body And Interior:
Body Panels, Doors, Windows, Seats, Upholstery, HVAC System, Body Sealing, Frame Repair
Comfort And Convenience:
Power Locks, Power Windows, Mirrors, Cruise Control, Wiper System, Horn
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Fluid Checks & Top-offs, Tire Rotation, Brake Pad Replacement, Spark Plug Replacement
Troubleshooting:
Diagnostic Trouble Codes (DTCs), Symptom-based diagnostics, Electrical system fault finding
Repair:
Component removal and installation, Engine overhaul, Transmission overhaul, Suspension component replacement, Brake system overhaul, Electrical component repair
Diagnostics:
Engine performance diagnostics, ABS diagnostics, HVAC diagnostics
Specifications:
Torque specifications, Component tolerances, Diagnostic parameters
Technical Depth
Depth:
Comprehensive, from routine maintenance to complete engine and transmission rebuilds
Detail Level:
Detailed step-by-step instructions with diagrams and illustrations
Diagnostic Tools:
Covers use of common diagnostic tools and procedures
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text for quick information retrieval
Printability:
Printable pages for workshop use
Print Quality
Quality:
High-resolution scans ensuring clarity of text and diagrams
Binding Type
Type:
N/A (Digital Format)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine 1 Name:
AMC 150 (2.5L)
Engine 1 Type:
Overhead Valve (OHV) Inline-4 Cylinder
Engine 1 Displacement:
2.5 Liters (150 cubic inches)
Engine 1 Power Approx:
123-130 hp @ 4600-4800 rpm
Engine 1 Torque Approx:
190-200 lb-ft @ 2000-2800 rpm
Engine 2 Name:
AMC 242 (4.0L)
Engine 2 Type:
Overhead Valve (OHV) Inline-6 Cylinder
Engine 2 Displacement:
4.0 Liters (242 cubic inches)
Engine 2 Power Approx:
177-190 hp @ 4400-4750 rpm
Engine 2 Torque Approx:
220-255 lb-ft @ 2000-3000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission 1 Type:
Manual Transmission (e.g., AX-5 for 2.5L, NV1500 for 2.5L/4.0L in later years)
Optional
Transmission 2 Type:
Automatic Transmission (e.g., AW-4 4-speed, 30RH 3-speed, 42RE 4-speed)
Features
Transfer Case 1:
New Process NP231 (Command-Trac) - Part-time 4WD
Transfer Case 2:
New Process NP242 (Selec-Trac) - Full-time 4WD (optional)
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2576 mm)
Length Approx:
169.9 - 176.0 inches (4315 - 4470 mm)
Width Approx:
69.9 - 70.5 inches (1775 - 1791 mm)
Height Approx:
64.7 - 65.9 inches (1643 - 1674 mm)
Cargo
Cargo Volume Behind Rear Seat:
Approx. 33.5 cubic feet (0.95 m³)
Cargo Volume With Rear Seat Folded:
Approx. 70.5 cubic feet (2.00 m³)
Weights
Curb Weight Approx:
3,200 - 3,700 lbs (1450 - 1680 kg)
Towing Capacity Max:
Up to 5,000 lbs (2270 kg) depending on configuration
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
3-star (early models), improved in later years
Active Features
ABS:
Available on later models (4-wheel ABS)
Passive Features
Airbags:
Driver airbag standard from 1990s onwards, passenger airbag optional/standard on later models
Seatbelts:
Three-point front seatbelts, three-point rear seatbelts (outboard), lap belt (center rear)
💡 Technology Features
Infotainment
Radio Options:
AM/FM stereo with cassette, optional CD player
Speaker System:
Basic speaker configurations, optional premium systems in later years
Driver Assistance
ABS:
Available, typically 4-wheel ABS on later models
Connectivity
Power Accessories:
Optional power windows, power door locks, power mirrors
🔧 Maintenance
Service Intervals
Oil Change Interval Gasoline:
Every 3,000-5,000 miles or 6 months (refer to specific year/engine recommendations in manual)
Transmission Fluid Change Interval:
Every 30,000-60,000 miles or 2-4 years (depending on transmission type and usage)
Coolant Flush Interval:
Every 30,000-50,000 miles or 2-3 years
Spark Plug Replacement:
Every 30,000-100,000 miles depending on plug type (standard, platinum, iridium)
Fluid Specifications
Engine Oil 2 5L:
API SN or newer, SAE 10W-30 or 5W-30 (check manual for exact viscosity)
Engine Oil 4 0L:
API SN or newer, SAE 10W-30 (check manual for exact viscosity)
Transmission Fluid Aw4 30Rh 42Re:
ATF+4 (Mopar) or equivalent
Transfer Case Fluid:
ATF+4 (Mopar) or equivalent
Coolant:
Mopar HOAT (Hybrid Organic Acid Technology) or equivalent 50/50 mix
Brake Fluid:
DOT 3
Known Issues
Engine Oil Leaks:
Valve cover gasket, oil pan gasket, rear main seal
Cooling System:
Radiator leaks, water pump failures, thermostat housing leaks
Suspension:
Leaf spring sag/breakage, worn bushings, blown shocks
Electrical:
Headlight switch failures, intermittent dash lights, starter solenoid issues
Powertrain Common Failure:
Cracked cylinder heads on early 4.0L models (improved in later revisions), automatic transmission solenoid issues
📚 Vehicle History
Brand Heritage
Brand Focus:
Jeep has a long history of producing capable off-road vehicles, dating back to WWII.
Model Evolution
Introduction:
The XJ Cherokee was introduced in 1984 as a revolutionary compact SUV with unibody construction.
Updates Covered By Manual:
This manual covers significant updates including the introduction of the 4.0L inline-6 in 1987, interior revisions (1997), exterior styling updates (1997), and powertrain refinements.
Production
Production Span For Model:
1984-2001
Manufacturing Locations:
Primarily Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Magazine Ranking:
Frequently cited as one of the best 4x4s of all time by off-road publications
Ratings
Consumer Reports Reliability:
Variable, often mixed reliability ratings, but strong mechanicals in the 4.0L engine
Certifications
Manual Quality:
High-quality, comprehensive documentation trusted by professionals.
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