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1997 1999-2001 Jeep Cherokee XJ Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Chassis Code: XJ Production Years Covered: 1997, 1999, 2000, 2001 Codes Platform: XJ Generation Generation: Second Generation (Facelifted XJ) 👋 Introduction Market...
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1997 1999-2001 Jeep Cherokee XJ Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee
Chassis Code:
XJ
Production Years Covered:
1997, 1999, 2000, 2001
Codes
Platform:
XJ
Generation
Generation:
Second Generation (Facelifted XJ)
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Off-road vehicle
Jeep Heritage:
Continuation of Jeep's legacy in durable, capable off-road vehicles
Competitive Analysis
Key Competitors:
Ford Bronco, Chevrolet S-10 Blazer, Toyota 4Runner, Nissan Pathfinder
Key Features
Offroad Capability:
Renowned for its robust 4x4 systems (Selec-Trac, Command-Trac) and solid axles, making it highly capable off-road.
Durability Reliability:
Known for its robust construction and long-term durability, a hallmark of the XJ generation.
Compact Size:
Its relatively compact dimensions provide maneuverability both on and off-road.
Engine Options:
Primarily offered with the legendary 4.0L inline-six engine.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive workshop service and repair
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for full workshop manuals of this era)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, engine cooling system, lubrication system
Transmission Drivetrain:
Automatic transmission (AW4, 42RE), Manual transmission (AX-15), Transfer case (NP231, NP242), Axles (Dana 30 front, Dana 35 rear or Chrysler 8.25 rear), Driveshafts, CV joints
Suspension Steering:
Front suspension (leaf spring or coil spring depending on specific model year variants and options), Rear suspension (leaf spring), Steering system, Power steering, Wheel alignment
Brakes:
Front disc brakes, Rear drum brakes (standard), ABS system (if equipped), Parking brake system, Brake fluid specifications
Electrical Electronics:
Battery, Charging system, Starting system, Ignition system, Lighting system, Instrumentation, Gauges, Horn, Wiper/Washer system, Power windows, Power locks, Body control modules, ECU diagnostics, Wiring diagrams
Body Chassis:
Body panels, Doors, Hood, Liftgate, Interior trim, Seats, Bumpers, Chassis components, Corrosion protection, Frame inspection
Heating Ventilation Air Conditioning:
HVAC system operation, Refrigerant charging, Blower motor, Evaporator, Condenser, Heater core, A/C system diagnostics
Procedures Included
Routine Maintenance:
Oil changes, Filter replacements, Fluid level checks and top-offs, Tire rotation and pressure checks, Spark plug replacement, Belt inspection and replacement
Engine Repair:
Engine overhaul, Cylinder head removal/installation, Piston and ring replacement, Camshaft and valve train service, Timing chain/belt replacement, Oil pump service
Transmission Drivetrain Repair:
Transmission removal/installation, Clutch service (manual), Torque converter replacement, Transfer case repair, Axle differential service, CV joint replacement
Suspension Steering Repair:
Shock absorber/strut replacement, Ball joint replacement, Tie rod end replacement, Leaf spring replacement, Power steering pump and rack replacement, Wheel bearing service
Brake System Repair:
Brake pad and rotor replacement, Brake caliper service, Wheel cylinder and brake shoe replacement, ABS component testing and replacement, Parking brake adjustment
Electrical Diagnostics:
Troubleshooting electrical faults, Wiring harness repair, Sensor testing and replacement, ECU re-flashing/testing, Component-level diagnostics
Bodywork Cosmetics:
Panel alignment, Door hinge and lock repair, Liftgate mechanism service, Interior trim installation/removal, Bumper repair/replacement
Troubleshooting Guides:
Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting trees
Technical Depth
Depth Of Coverage:
Detailed diagnostic procedures, component testing, specifications, torque values, and overhaul instructions
Diagnostic Tools:
Information on required diagnostic tools, scan tools (OBD-II for later models), and specialized equipment
Wiring Diagrams:
Comprehensive, often color-coded, electrical wiring diagrams for all vehicle systems
Tolerances Specifications:
Precise measurements, clearances, and torque specifications for all mechanical components
Rebuild Procedures:
Detailed instructions for rebuilding major components such as engines, transmissions, and differentials
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Scan Resolution:
High resolution, ensuring readability of text and diagrams
Text Searchability:
Searchable text for quick access to information
Binding Type
Binding Type:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
Completeness
Completeness Guarantee:
100% Complete and Intact, no missing/corrupt pages/sections
⚙️ Engine Specifications
Primary Engine
Engine Code Name:
AMC 242 (4.0L OHV Inline-6)
Engine Type:
Inline 6-cylinder, Overhead Valve (OHV)
Displacement:
3956 cc (242 cubic inches)
Bore X Stroke:
98.5 mm x 86.6 mm (3.88 in x 3.41 in)
Compression Ratio:
8.75:1 (approx.)
Horsepower:
190 hp @ 4600 rpm (approx. for later years)
Torque:
220 lb-ft @ 3000 rpm (approx. for later years)
Performance
Fuel Type:
Unleaded gasoline
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI)
Ignition System:
Distributorless Ignition System (DIS) - coil-on-plug for later models
Engine Variants
Alternative Engine:
2.5L AMC I4 (150 cu in) - Less common in these specific years, but existed earlier in XJ.
🔧 Transmission
Standard
Standard Transmission:
4-Speed Automatic (Chrysler 42RE / Aisin Warner AW4)
Optional
Optional Transmission:
5-Speed Manual (NV3550, replacing AX-15)
Features
Transfer Case:
New Process NP231 (Command-Trac) or NP242 (Selec-Trac)
Fluid Specifications
Automatic Transmission Fluid:
ATF+4 (Chrysler specification, or equivalent Dexron III/Mercon for older specifications)
Manual Transmission Fluid:
GL-3 or GL-4 gear oil (specific viscosity to be confirmed in manual)
📐 Dimensions
Exterior
Wheelbase:
103.4 inches (2626 mm)
Length:
172.5 inches (4382 mm)
Width:
71.2 inches (1808 mm)
Height:
64.4 inches (1636 mm) (approx.)
Ground Clearance:
Variable, typically 8-10 inches depending on tire size and suspension
Weights
Curb Weight:
3,500 - 4,000 lbs (approx.)
Gross Vehicle Weight Rating Gvwr:
Approx. 5,000 - 5,300 lbs
Towing Capacity:
Up to 5,000 lbs (with proper equipment and engine)
Wheel Bolt Pattern:
5 x 4.5 inches (114.3 mm)
Wheel Size:
15 or 16 inches (standard)
Tire Size:
225/75R15, 235/75R15, or 235/70R16 (common)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
Likely 4-star (for driver) and 3-star (for passenger) based on similar vehicles of the era, specific data for this manual's years may vary and should be verified.
IIHS Crash Test Results:
Varies by specific test and year; generally considered adequate for its time but not as advanced as modern vehicles.
Active Features
ABS:
Anti-lock Braking System (Optional or standard on higher trims for some years)
Passive Features
Airbags:
Driver and passenger airbags (standard for 1999 onwards, optional/standard on driver side for 1997)
Seat Belts:
Front 3-point seat belts, rear lap and shoulder belts
Rollover Protection:
Considered to have a relatively high center of gravity, requiring cautious driving. Roll cage structure inherent to its off-road design.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette player, optional CD player. Speaker configuration typically 4-6 speakers.
Navigation:
Not available as factory-installed equipment.
Driver Assistance
Cruise Control:
Standard on most trims
Anti Lock Brakes:
Optional or standard depending on trim and model year.
Connectivity
Auxiliary Inputs:
Not standard, aftermarket solutions common.
Instrumentation
Instrument Cluster:
Includes speedometer, tachometer (on some trims), fuel gauge, engine temperature gauge, oil pressure warning light, voltmeter, and various warning indicators. Updated dashboard for 1997 facelift.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 3,000-5,000 miles (depending on oil type and driving conditions, refer to manual for specific recommendations)
Engine Oil Filter Replacement:
With every oil change
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection
Coolant Flush Interval:
Every 30,000-50,000 miles or 2-5 years
Spark Plug Replacement Interval:
Approx. 100,000 miles for platinum/iridium plugs (if equipped), refer to manual for specific plug type and interval.
Transmission Fluid Change Interval:
Every 30,000-60,000 miles for automatic, consult manual for manual transmission.
Fluid Specifications
Engine Oil Specification:
10W-30 API SJ or higher (typically for 4.0L engine)
Engine Oil Capacity:
6 US quarts (5.7 liters) with filter (4.0L engine)
Coolant Type:
Chrysler/Mopar HOAT (Hybrid Organic Acid Technology) coolant (e.g., Mopar 5 Year/100,000 Mile Formula) or equivalent HOAT coolant
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
ATF+4 or specified power steering fluid
Known Issues
Cracked Cylinder Head:
A known issue with the 4.0L engine, particularly older versions, though less common in later years. Manifests as coolant loss, overheating, or white smoke.
Radiator And Water Pump Failures:
Common wear items that may require replacement over time due to age and mileage.
Interior Rattles And Squeaks:
Typical for vehicles of this age and construction, often addressed with sound deadening or minor trim adjustments.
Rust And Corrosion:
Can be an issue in areas with road salt, particularly on the unibody structure, rocker panels, and wheel wells.
Transfer Case Chain Stretch:
Can lead to a slapping noise or slipping in 4WD. The NP231 chain is robust but can stretch with high mileage.
Idle Air Control Iac Valve Issues:
Can cause rough idling, stalling, or difficulty starting.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Built upon Jeep's decades-long reputation for ruggedness and off-road prowess, originating from military Willys Jeeps.
Model Evolution
Xj Introduction:
The Cherokee (XJ) was revolutionary when introduced in 1984 as the first compact SUV with a unibody construction, offering a smoother ride than body-on-frame competitors.
Xj Facelift 1997:
The 1997 model year represented a significant facelift, including updated exterior styling (new grille, fenders, hood, front bumper), revised interior with a new dashboard and instrument cluster, improved sound insulation, and updated safety features.
Transmission Update:
Introduction of the NV3550 manual transmission for 2000-2001 models, replacing the AX-15.
Production
Production Location:
Toledo, Ohio, USA
Production Run Xj:
1984-2001 (North America)
Production Volume Significance:
The XJ Cherokee was a highly successful model for Jeep, contributing significantly to the growth of the SUV market.
🏆 Awards & Recognition
Recognitions
Four Wheeler Magazine Titles:
The Cherokee XJ, particularly the earlier generations, was a frequent recipient of praise and awards from off-road publications like Four Wheeler Magazine for its capability and value.
Motor Trend SUV Of The Year:
While not explicitly for these model years, the XJ platform's design and capabilities were highly regarded in the evolving SUV market.
Certifications
Certification Standard:
Manufactured to meet all applicable US Federal Motor Vehicle Safety Standards (FMVSS) for its model years.
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