Jeep CHEROKEE XJ 1997-2001 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Product Name: Jeep CHEROKEE XJ 1997-2001 Workshop Service Repair Manual Codes Chassis Code: XJ Generation Generation Identifier: Second Generation (Facelift) Model...

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类型: Car

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标签: 1997 1998 1999 2000 2001 Car Cars CHEROKEE XJ Jeep Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee XJ

Product Name:

Jeep CHEROKEE XJ 1997-2001 Workshop Service Repair Manual

Codes

Chassis Code:

Generation

Generation Identifier:

Second Generation (Facelift)

Model Years Covered:

1997-2001

👋 Introduction

Market Position

Vehicle Class:

Compact SUV

Target Audience:

Off-road enthusiasts, general consumers seeking utility and capability

Competitive Analysis

Key Competitors:

Ford Bronco, Toyota 4Runner, Chevrolet Blazer, Nissan Pathfinder

Key Features

Design Philosophy:

Robust, capable, affordable, off-road focused with unibody construction

Notable Attributes:

Legendary Jeep off-road capability, durable powertrain options, compact and maneuverable size

📋 Manual Details

Coverage Areas

Trim Levels:

SE, Sport/Classic, Limited

Engine Variants:

2.5L Gasoline, 4.0L Gasoline, 2.5L Diesel

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, diagnosis, tuning, timing, cooling, lubrication, fuel delivery, emissions

Transmission Manual:

Service, repair, overhaul, fluid specifications, clutches

Transmission Automatic:

Service, repair, overhaul, fluid specifications, torque converter, valve body

Drivetrain:

Transfer case, differentials (front and rear), axle shafts, CV joints, U-joints, propeller shafts

Suspension:

Front and rear suspension components, springs, shocks, control arms, bushings, alignment specifications

Steering:

Power steering system, steering gear, tie rods, steering column, diagnosis

Brakes:

Front and rear brake systems (disc/drum), hydraulic lines, master cylinder, calipers, wheel cylinders, ABS (if equipped), parking brake

Electrical:

Wiring diagrams, battery, alternator, starter, ignition system, lighting, charging system, fuses, relays, ECUs

Body And Frame:

Body panel repair, interior trim, doors, windows, sunroof, body sealant, frame inspection

HVAC:

Heating, ventilation, and air conditioning systems, components, refrigerant, diagnosis

Fuel System:

Fuel pump, fuel filter, fuel injectors, fuel tank, evaporative emissions system

Exhaust System:

Exhaust manifold, catalytic converter, muffler, pipes, hangers

Procedures Included

Maintenance:

Scheduled maintenance intervals, fluid changes, filter replacements, lubrication, inspections

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting charts, common fault identification

Repair:

Step-by-step repair instructions for all major systems

Overhaul:

Complete engine, transmission, and differential rebuild procedures

Diagnostics:

Electrical system diagnosis, engine performance checks, component testing

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to full engine/transmission rebuilds and advanced diagnostics

📊 Manual Specifications

File Format

Resolution:

High-resolution, clear text and diagrams

Searchability:

Searchable PDF content

Compatibility:

Compatible with all standard PDF readers

Print Quality

Printability:

Printable for hard copy use

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

2.5L Gasoline:

Inline-4 cylinder, 2.5 liters (150 CID), known as the 'AMC 150' or 'Tech II' engine. Approximately 120-130 hp and 170-180 lb-ft torque.

4.0L Gasoline:

Inline-6 cylinder, 4.0 liters (242 CID), known as the 'AMC 242' or 'Power-Tech I6' engine. Approximately 180-190 hp and 220-235 lb-ft torque. Highly regarded for durability and torque.

2.5L Diesel:

Inline-4 cylinder, 2.5 liters, VM Motori Italian-designed turbodiesel engine. Power output typically around 110-120 hp and 180-200 lb-ft torque. Less common in North America.

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI) for gasoline engines. Direct injection or rotary pump for diesel.

Performance

Emission Controls:

Catalytic converters, EGR systems (depending on market and year), O2 sensors

🔧 Transmission

Standard

Manual Transmission:

5-speed manual (e.g., AX-5 or NV3550) common with 2.5L and some 4.0L engines.

Optional

Automatic Transmission:

4-speed automatic (e.g., AW-4 or 42RE) common with 4.0L engines, also available with 2.5L.

Features

Transfer Case:

Command-Trac (NV231) or Selec-Trac (NV242) part-time 4WD systems available.

Fluid Specifications

Automatic Transmission Fluid:

ATF+4 (Chrysler specification) or equivalent DEXRON-III/MERCON.

Manual Transmission Fluid:

API GL-5, SAE 75W-90 gear oil (for AX-5/NV3550).

📐 Dimensions

Exterior

Wheelbase:

101.4 inches (2576 mm)

Length:

163.8 inches (4161 mm)

Width:

70.1 inches (1781 mm)

Height:

63.9 inches (1623 mm)

Weights

Curb Weight:

Approx. 3,300 - 3,800 lbs (1497 - 1724 kg), varies by engine and drivetrain

Towing Capacity:

Up to 5,000 lbs (2268 kg) with proper equipment and engine (4.0L recommended)

Cargo

Cargo Volume Rear Seats Up:

Approx. 33.5 cu ft (948 L)

Cargo Volume Rear Seats Folded:

Approx. 71.0 cu ft (2009 L)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star rating (typically for this era, though specific tests vary by year)

Active Features

Anti-lock Braking System (ABS) available, often standard on higher trims or later models

Four Wheel Drive:

Standard or optional 4WD systems (Command-Trac, Selec-Trac)

Passive Features

Airbags:

Driver and passenger front airbags standard for these model years

Seatbelts:

Three-point front seatbelts, rear seat lap and shoulder belts

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player and optional CD player. Basic speaker systems.

Instrument Cluster:

Analog gauges for speedometer, tachometer (on some models), fuel, coolant temperature, oil pressure, and voltmeter. Warning lights.

Driver Assistance

Cruise Control:

Optional cruise control system.

Rear Defroster:

Standard or optional rear window defroster.

Connectivity

Phone Integration:

No factory integrated smartphone connectivity (e.g., Apple CarPlay, Android Auto). Aftermarket solutions available.

Power Accessories:

Power windows, power door locks, and power mirrors were optional or standard on higher trims.

🔧 Maintenance

Service Intervals

Oil Change Gasoline:

Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 6 months, depending on oil type and driving conditions. Refer to manual for specific recommendation.

Oil Change Diesel:

Typically 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months. Refer to manual.

Transmission Fluid Change:

Every 30,000 - 60,000 miles (48,000 - 96,000 km), or more frequently for severe service. Diesel transmission intervals may differ.

Coolant Flush:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 2-3 years.

Spark Plugs Gasoline:

Every 30,000 - 100,000 miles (48,000 - 160,000 km) depending on spark plug type (copper vs. platinum/iridium).

Fluid Specifications

Engine Oil 4.0L:

API SJ or SL, SAE 10W-30 or 10W-40. Check capacity (approx. 5 quarts with filter).

Engine Oil 2.5L Gasoline:

API SJ or SL, SAE 5W-30 or 10W-30. Check capacity (approx. 4 quarts with filter).

Engine Oil 2.5L Diesel:

API CG-4 or CH-4, SAE 15W-40 heavy-duty diesel engine oil. Check capacity.

Coolant:

Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology) or equivalent, 50/50 mix with distilled water. Capacity approx. 10-12 quarts.

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

4.0L Engine:

Cracked cylinder heads (less common on later models but still a concern), radiator failure causing overheating, oil filter adapter O-ring leaks.

2.5L Gasoline Engine:

Less torque than 4.0L, can feel underpowered, occasional oil leaks.

2.5L Diesel Engine:

Injector pump issues, glow plug problems, turbocharger wear, emissions system concerns.

Transmission:

AW-4 automatic transmission generally robust but can develop solenoid issues; AX-5 manual transmission can have input shaft bearing failures.

Suspension And Steering:

Worn control arm bushings, track bar wear, power steering pump leaks, tie rod end wear.

Electrical:

Faulty alternator, starter issues, window regulator failures, wiring harness corrosion (especially in wet climates).

Body And Frame:

Rust issues, particularly on rocker panels, floor pans, and rear quarter panels in corrosive environments.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Built upon Jeep's long history of rugged, go-anywhere capability dating back to WWII.

Model Evolution

Xj Introduction:

The XJ Cherokee was revolutionary for its time, being one of the first compact SUVs with unibody construction, offering a lighter, more comfortable ride than traditional body-on-frame SUVs.

Xj Facelift:

The 1997-2001 models represent the second generation facelift, featuring updated exterior styling (e.g., revised front fascia, fenders, hood) and interior design.

Production

Production Period:

1984-2001 (XJ generation)

Manufacturing Plant:

Primarily Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Reputation:

Consistently recognized for its off-road prowess and capability within its class.

Ratings

Value Retention:

The XJ Cherokee is known for good value retention, especially well-maintained examples with the 4.0L engine.

Certifications

Diy Friendliness:

Considered one of the more DIY-friendly Jeeps of its era due to relatively straightforward mechanicals, making it a popular choice for enthusiasts.