🏷️ Basic Information

Make:

Jeep

Model:

Cherokee (XJ)

Product Type:

Service Repair Workshop Manual

Internal Product Code:

JEEP_CHEROKEE_XJ_8801_25_40_SRW

👋 Introduction

Segment:

Compact SUV / Sport Utility Vehicle

Positioning:

Renowned for its off-road capability, ruggedness, and relatively compact size compared to larger SUVs of its era. A popular choice for utility and adventure.

Competitors:

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

Differentiators:

Unibody construction (unique for its time in the segment), legendary Selec-Trac and Command-Trac 4WD systems, durable AMC engines.

📋 Manual Details

Year Coverage:

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

Engine Coverage:

2.5L (AMC 150) I4, 4.0L (AMC 242) I6

Estimated Page Count:

1800+

Type:

Comprehensive Service & Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of 2.5L I4 and 4.0L I6 engines, including cylinder head, block, pistons, crankshaft, camshaft, timing system, lubrication system, cooling system.

Engine Fuel System:

Fuel injection systems (MPI), fuel pump, fuel filter, fuel pressure regulator, injectors, throttle body, ECU controls.

Engine Ignition System:

Spark plugs, ignition coils, distributor (early models), distributorless ignition system (DIS) (later models), timing adjustments, ECU controls.

Transmission Manual:

NV1500, NV3500 manual transmissions: Clutch, gearbox, shifter mechanisms, maintenance, repair, overhaul.

Transmission Automatic:

AW4 (AS4.1) automatic transmission: Torque converter, valve body, planetary gearsets, seals, fluid services, electronic controls, troubleshooting.

Drivetrain:

Transfer case (NP231, NP242): Operation, maintenance, seals, bearings, chain tension, repair. Front and rear axles (Dana 30, Dana 35C): Differential service, axle shafts, bearings, seals, U-joints, CV joints (if applicable).

Suspension:

Front and rear suspension: Leaf springs (rear), coil springs (front), shock absorbers, bushings, control arms, sway bars, alignment specifications.

Steering:

Power steering system: Pump, reservoir, lines, steering gear/rack and pinion, tie rods, maintenance, troubleshooting.

Brakes:

Front disc brakes, rear drum brakes (standard), optional rear disc brakes: Master cylinder, brake lines, calipers, rotors, pads, drums, shoes, parking brake system, ABS (where applicable), bleeding procedures.

Electrical System:

Battery, charging system (alternator), starting system (starter), fuse box, relays, wiring diagrams for all major circuits (engine control, lighting, instruments, power accessories, etc.).

HVAC:

Air conditioning system: Compressor, condenser, evaporator, refrigerant, blower motor, controls. Heater core, ducting, operation, maintenance.

Body And Frame:

Body panel removal/installation, doors, hood, tailgate, bumpers, interior trim, chassis lubrication, rust prevention.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups, belt and hose replacement, brake fluid flush, coolant flush.

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based troubleshooting for all major systems, electrical diagnostic procedures.

Repair:

Step-by-step repair instructions for all major mechanical, electrical, and body components. Engine rebuild procedures, transmission overhaul, brake caliper replacement, suspension component replacement, etc.

Disassembly Reassembly:

Detailed instructions for component removal and installation with torque specifications.

Wiring Diagrams:

Comprehensive, system-specific wiring diagrams for all model years and major electrical systems.

Depth:

Factory-level detail for all aspects of vehicle maintenance, repair, and diagnostics. Suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

Digital Format:

High-resolution PDF with searchable text for easy navigation and printing. Optimized for clarity and readability.

Print Quality:

Printable on standard letter/A4 paper. Designed for professional presentation when printed.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine 1 Code:

AMC 150

Engine 1 Type:

Inline 4-Cylinder (I4)

Engine 1 Displacement:

2.5 Liters (150 cubic inches)

Engine 1 Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Engine 1 Horsepower Range:

121-130 hp @ ~4500 rpm

Engine 1 Torque Range:

140-145 lb-ft @ ~3000 rpm

Engine 2 Code:

AMC 242

Engine 2 Type:

Inline 6-Cylinder (I6)

Engine 2 Displacement:

4.0 Liters (242 cubic inches)

Engine 2 Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Engine 2 Horsepower Range:

173-190 hp @ ~4500 rpm

Engine 2 Torque Range:

215-235 lb-ft @ ~3000 rpm

Fuel Type:

Unleaded Gasoline (87 octane recommended)

System Type:

Electronic Multi-Point Fuel Injection (MPI)

🔧 Transmission

Standard Transmission:

5-Speed Manual (NV1500/NV3500) for 2.5L and select 4.0L models.

Optional Transmission:

4-Speed Automatic (AW4 / AS4.1) for 2.5L and 4.0L models.

Transfer Case Options:

Selec-Trac (2WD/4WD High/4WD Low) - NP242; Command-Trac (2WD/4WD High/4WD Low) - NP231.

Automatic Transmission Fluid:

ATF+3 or ATF+4 (check specific year/model for exact recommendation).

Manual Transmission Fluid:

API GL-5, SAE 75W-90 gear oil.

📐 Dimensions

Wheelbase:

101.4 inches

Length:

167.5 - 171.2 inches (depending on year/trim)

Width:

69.9 inches

Height:

63.7 - 65.1 inches (depending on year/trim)

Curb Weight:

3,300 - 3,700 lbs (approximate)

🛡️ Safety Features

NHTSA Ratings:

Varied by year, generally considered adequate for its era. Specific ratings for side impact and frontal impact may be limited for early models.

ABS:

Optional on most models, standard on some later trims. Rear-wheel ABS was common.

Airbags:

Driver airbag became standard during the production run (introduced around 1994).

Seat Belts:

All seating positions equipped with three-point seat belts (front) or lap belts (rear, early models).

💡 Technology Features

Audio System:

Base AM/FM radio, optional cassette or CD player, optional premium sound systems with amplifiers depending on trim level and year.

ABS:

As mentioned under safety, ABS was an optional feature, becoming more prevalent in later model years.

OBD Ii:

OBD-II diagnostics became standard starting with 1996 model year vehicles, replacing the earlier OBD-I systems.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, whichever comes first (conventional oil). Consult manual for synthetic oil recommendations.

Transmission Fluid Change:

Automatic: Every 30,000-60,000 miles. Manual: Inspect regularly, change if fluid appears contaminated or degraded.

Coolant Flush:

Every 30,000-50,000 miles or 2-3 years.

Spark Plug Replacement:

2.5L: Approx. 30,000 miles. 4.0L: Approx. 30,000-60,000 miles (depending on plug type).

Engine Oil:

10W-30 or 10W-40 (check owner's manual for specific ambient temperature ranges). API Service SJ or higher.

Coolant:

Ethylene Glycol based antifreeze, 50/50 mixture with distilled water. Mopar OAT or HOAT coolant recommended for later models.

Brake Fluid:

DOT 3 or DOT 4 (check specific year).

Power Steering Fluid:

ATF+3 or Mopar Power Steering Fluid.

Engine Cooling:

Radiator leaks, heater core failures, thermostat housing leaks are common. Overheating can lead to head gasket issues on the 4.0L.

Electrical:

Aging wiring harnesses, failing sensors (e.g., CPS, TPS), blower motor resistor failures, interior electrical gremlins.

Suspension Steering:

Worn control arm bushings, ball joints, tie rod ends, and sway bar links due to age and off-road use. Steering box wear/play.

Drivetrain:

Transfer case chain stretch, differential pinion seal leaks, rear axle bearing wear on Dana 35.

Body Rust:

Common rust points include rocker panels, rear quarter panels, tailgate, and floor pans, especially in areas with road salt.

📚 Vehicle History

Jeep Legacy:

Building on Jeep's long history of robust 4x4 vehicles, the XJ Cherokee brought SUV capability to a more accessible, unibody platform.

Generation:

XJ (First Generation)

Key Updates 1988-2001:

Introduction of 4.0L HO engine, redesigned interior (1991), introduction of driver airbag, updated exterior styling (1997 facelift including new front fascia, fenders, hood, and interior dashboard).

Production Years:

1984-2001 (North America)

Manufacturing Locations:

Toledo, Ohio, USA.

🏆 Awards & Recognition

Off Road Acclaim:

Consistently praised by automotive journalists and off-road enthusiasts for its capability and durability, earning numerous accolades in its segment.

Segment Leadership:

Considered a benchmark for compact SUV off-road performance and practicality during its production run.