Jeep Cherokee XJ 1994 Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1994 Codes Chassis Code: XJ 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-Road Vehicle Target Audience: Off-road enthusiasts,...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee XJ

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-Road Vehicle

Target Audience:

Off-road enthusiasts, utility vehicle buyers, DIY mechanics.

Competitive Analysis

Key Competitors 1994:

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

Key Features

Chassis Design:

Unibody construction (rare for SUVs at the time), contributing to lighter weight and better on-road manners.

Powertrain Options:

Renowned 4.0L 'High Output' inline-six engine and robust manual transmissions.

Off Road Capability:

Excellent approach/departure angles, available 4WD systems, and durable solid rear axle.

📋 Manual Details

Coverage Areas

Primary Coverage:

1994 Jeep Cherokee XJ

Engine Coverage:

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

Transmission Coverage:

AX-5, AX-15 Manual Transmissions, AW-4 Automatic Transmission

Drivetrain Coverage:

2WD and 4WD Systems (Command-Trac, Selec-Trac)

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, fuel system, ignition system, cooling system, lubrication system, emission control systems.

Transmission:

Manual transmission (AX-5, AX-15) overhaul, automatic transmission (AW-4) operation and diagnosis, transfer case service.

Drivetrain:

Front and rear axle service, driveshafts, universal joints, wheel bearings.

Suspension:

Front and rear suspension components, steering linkage, shock absorbers, leaf springs, coil springs.

Brakes:

Front and rear brake systems (disc/drum), parking brake, hydraulic system.

Electrical:

Charging system, starting system, lighting, instruments, gauges, power accessories, wiring diagrams.

Body And Frame:

Body panels, interior trim, doors, windows, seats, structural components, frame repair.

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair.

Diagnostic Troubleshooting:

Extensive troubleshooting charts and diagnostic procedures for all systems.

Procedures Included

Maintenance:

Routine maintenance, fluid changes, filter replacements, tune-ups.

Repair:

Component removal, installation, and adjustment for all major systems.

Overhaul:

Detailed instructions for engine, transmission, and axle overhauls.

Diagnosis:

System-specific diagnostic trees, symptom-based troubleshooting.

Technical Depth

Depth:

Comprehensive, covering from basic adjustments to complete engine rebuilds and electrical system diagnosis.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Likely text-searchable, allowing quick access to specific information.

Print Quality

Digital Quality:

High resolution, ensuring clarity of diagrams and text.

Binding Type

Physical Binding Analogy:

Professional factory binding (if printed equivalent)

Paper Type

Digital Paper Analogy:

Digital pages, optimized for screen viewing and printing.

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

242 CI (4.0L) OHV Inline-6

Displacement 1:

3956 cc

Bore X Stroke 1:

98.4 mm x 87.0 mm (3.87 in x 3.43 in)

Compression Ratio 1:

8.8:1

Horsepower 1:

177 hp @ 4700 RPM (approx.)

Torque 1:

220 lb-ft @ 3200 RPM (approx.)

Secondary Engine

Engine Code 2:

2.5L (150 ci) OHV Inline-4

Displacement 2:

2493 cc

Horsepower 2:

125 hp @ 4800 RPM (approx.)

Torque 2:

150 lb-ft @ 2400 RPM (approx.)

Performance

0 60 Mph 4.0L:

9.6 - 10.5 seconds (varies with configuration)

Fuel System

Fuel Delivery 1:

Multi-port Fuel Injection (MPFI)

Fuel Type 1:

Unleaded Regular Gasoline (87 octane recommended)

🔧 Transmission

Standard

Manual Transmission:

Aisin AX-5 (4-cylinder), Aisin AX-15 (6-cylinder)

Optional

Automatic Transmission:

Aisin AW-4 4-Speed Automatic

Features

Transfer Case Options:

Command-Trac (NV231) Part-Time 2-Speed, Selec-Trac (NV242) Full-Time 2-Speed

Manual Gear Ratios Ax15:

1st: 3.83, 2nd: 2.37, 3rd: 1.49, 4th: 1.00, 5th: 0.79, Rev: 3.24

Automatic Gear Ratios Aw4:

1st: 2.80, 2nd: 1.53, 3rd: 1.00, 4th: 0.75, Rev: 2.20

📐 Dimensions

Exterior

Length:

167.5 in (4255 mm)

Width:

69.4 in (1763 mm)

Height:

63.7 in (1618 mm) (Base)

Wheelbase:

101.4 in (2576 mm)

Ground Clearance:

8.7 in (221 mm) (approx.)

Weights

Curb Weight Approx:

3300 - 3600 lbs (1497 - 1633 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 4,700 - 5,000 lbs

Cargo

Cargo Volume Behind Front Seats:

Approx. 72 cu ft

Cargo Volume Behind Rear Seats:

Approx. 31 cu ft

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

Likely 3 Stars (typical for SUVs of this era)

Active Features

Brakes:

Front disc, rear drum standard; optional ABS on front discs for some models.

Passive Features

Airbags:

Driver-side airbag standard.

Seat Belts:

Three-point front seat belts, two-point rear seat belts.

Body Structure:

Reinforced unibody structure with integrated roll cage elements.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with cassette player standard; optional CD player.

Speaker Configuration:

Typically 4 or 6 speakers.

Driver Assistance

Anti-lock Braking System available as an option on front disc brakes.

Connectivity

Connectivity Features:

Minimal by modern standards; primarily focused on basic vehicle operation.

🔧 Maintenance

Service Intervals

Oil Change Interval:

3,000 - 7,500 miles (depending on oil type and driving conditions)

Engine Coolant Flush:

Every 30,000 - 60,000 miles or 2-4 years

Transmission Fluid Change Automatic:

Every 30,000 - 60,000 miles

Transmission Fluid Change Manual:

Every 50,000 - 100,000 miles

Fluid Specifications

Engine Oil Spec 4.0L:

API SG or higher, SAE 10W-30 recommended (check manual for specific conditions)

Engine Coolant Spec:

Mopar OAT (Organic Additive Technology) coolant or equivalent (typically a HOAT or OAT green or orange)

Automatic Transmission Fluid Spec:

Chrysler ATF+3 or ATF+4 equivalent

Manual Transmission Fluid Spec Ax15:

GL-3 or GL-4 gear oil, SAE 75W-90 recommended

Transfer Case Fluid Spec:

ATF+3 or ATF+4 (for Selec-Trac NV242), NP-231 (Command-Trac) uses ATF+3 or ATF+4

Differential Fluid Spec:

API GL-5, SAE 80W-90 (check for limited-slip additive if equipped)

Known Issues

Common Problems 1:

Head gasket failure on 4.0L (less common in '94 models compared to earlier ones), cooling system leaks (radiator, water pump), rust on unibody and leaf spring perches.

Common Problems 2:

TPS (Throttle Position Sensor) failure, intermittent electrical gremlins, exhaust manifold cracks (4.0L), sway bar link wear.

Maintenance Part Numbers

Oil Filter Part Number 4.0L Example:

Mopar MO-090 or equivalent Wix 51515 / Fram PH8A

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Founded on military utility vehicles (Willys MB), known for off-road prowess.

Model Evolution

Xj Introduction:

First generation (XJ) introduced for the 1984 model year.

Xj Updates 1994:

Refreshed exterior styling including new front fascia, fenders, hood, and grille. Interior received updated dashboard and ergonomics. Introduction of improved Selec-Trac full-time 4WD system.

Production

Production Years:

1984 - 2001

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Vehicle Reputation:

Highly regarded for its off-road capability, durability, and versatility, often considered a 'cult classic'.