🏷️ Basic Information

Make:

Jeep

Model:

Cherokee XJ / YJ

Product Name:

Jeep Cherokee XJ YJ Complete Workshop Service Repair Manual 1984-1996

Chassis Codes:

👋 Introduction

Positioning:

The Jeep Cherokee XJ and YJ were iconic off-road vehicles, popular for their ruggedness, capability, and relatively simple mechanical design. This manual serves the extensive aftermarket and owner base that continues to maintain and modify these vehicles.

Competitors:

Competed with vehicles like the Toyota 4Runner, Nissan Pathfinder, and Ford Bronco in the compact SUV and off-road segment.

Vehicle Appeal:

Unibody construction (XJ) providing a lighter and more car-like ride, solid front axle (early XJ and all YJ) for robust off-road performance, legendary Jeep 4x4 systems (Selec-Trac, Command-Trac, NP231/NP242 transfer cases).

Off Road Capability:

Renowned for its off-road prowess, thanks to its robust 4x4 systems, solid axle (YJ and early XJ), and compact dimensions.

📋 Manual Details

Years Covered:

1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996

Estimated Pages:

1000+

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital Downloadable (PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical, engine performance, fuel system, cooling system, lubrication system, ignition system, exhaust system, manual transmission, automatic transmission, transfer case, driveline, axles, driveshafts.

Chassis:

Suspension (front and rear), steering system, brake system (front and rear discs/drums), wheel bearings, hubs.

Electrical:

Battery, charging system, starting system, lighting, instruments, gauges, power windows, power locks, wipers, horn, fuse box, wiring diagrams, body control modules, engine control modules (ECU).

Body:

Interior trim, exterior trim, doors, windows, roof, body panels, bumpers, seats, HVAC system, body hardware.

HVAC:

Air conditioning system diagnosis and repair, heater core replacement, blower motor issues, climate control system troubleshooting.

Fuel System:

Fuel pump testing and replacement, fuel injector diagnosis and cleaning, fuel filter replacement, fuel tank inspection and repair.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, belt inspection and replacement.

Repair And Rebuild:

Engine overhaul, transmission overhaul, brake caliper replacement, shock absorber replacement, exhaust system repair, steering component replacement, electrical component diagnosis and replacement.

Diagnostics And Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon faults, fault codes interpretation (OBD-I), wiring diagram analysis for electrical issues.

Specifications And Data:

Torque specifications, fluid capacities, clearances, wiring diagrams, component locations, diagnostic trouble codes (DTCs).

Engine Rebuild:

Detailed steps for engine disassembly, inspection, component replacement (pistons, rings, bearings, valves, camshaft), and reassembly for both 4-cylinder and 6-cylinder engines.

Transmission Repair:

Comprehensive coverage of manual and automatic transmission teardown, component identification, repair, and reassembly, including torque specifications for internal components.

Electrical Diagnostics:

In-depth wiring diagrams, component testing procedures, and troubleshooting trees for electrical systems, including starting, charging, lighting, and sensor circuits.

Bodywork Repair:

Procedures for panel alignment, rust repair techniques, bumper installation/removal, and interior trim panel replacement.

Suspension Overhaul:

Detailed instructions for replacing coil springs, leaf springs, shock absorbers, control arms, bushings, and alignment adjustments.

Depth:

Comprehensive from basic maintenance to in-depth component overhaul and diagnostics. Suitable for DIY enthusiasts and professional mechanics.

Special Tools:

Information on required special tools for specific repairs, such as press tools for bearing replacement, or diagnostic connectors.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely includes searchable text for efficient information retrieval, especially for part numbers and diagnostic procedures.

Quality:

High-resolution, clear text and images, often with searchable text for easy navigation.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine 1:

2.5L AMC 150 Inline-4 (OHV, 8 valves). Often referred to as the '5-Speed' engine.

Engine 2:

4.0L AMC 242 Inline-6 (OHV, 12 valves). Known for its torque and durability.

Engine 3:

2.1L Renault/Jeep J8S Turbo Diesel Inline-4 (OHV, 8 valves). Less common in North American markets.

2.5L Horsepower:

Approx. 125 hp

2.5L Torque:

Approx. 145 lb-ft

4.0L Horsepower:

Approx. 177-190 hp (depending on year and tune)

4.0L Torque:

Approx. 220-255 lb-ft (depending on year and tune)

Injection Type:

Multi-point Fuel Injection (MPI)

🔧 Transmission

Standard Transmission:

4-speed automatic (e.g., AW4) and 5-speed manual (e.g., AX-5 for 2.5L, AX-15 for 4.0L).

Optional Transmission:

4-speed automatic (TorqueFlite A999/32RH for early models), 3-speed automatic (TF-999 on some early models).

Transfer Case:

Command-Trac (2WD, 4WD Part-Time), Selec-Trac (2WD, 4WD Full-Time, 4WD Part-Time), NP242 (Full-Time 4WD).

📐 Dimensions

Wheelbase:

101.4 inches (2576 mm)

Length:

Approx. 167-173 inches (4240-4394 mm) depending on year and front bumper.

Curb Weight:

Approx. 3,000 - 3,500 lbs (1361 - 1588 kg)

🛡️ Safety Features

NHTSA Rollover Resistance:

Early models had a higher rollover risk classification compared to modern SUVs, common for vehicles of this era with solid axles and higher center of gravity.

Braking System:

Front disc brakes, rear drum brakes (standard). Some later models or optional packages may have had rear disc brakes. ABS was introduced later in the production run.

Airbags:

Driver-side airbag became standard in later model years (typically 1994 onwards). Passenger airbags were not common or standard on most XJ/YJ models covered.

💡 Technology Features

Audio System:

Factory-equipped with AM/FM radio, cassette player, and optional CD player. Aftermarket upgrades are very common for Bluetooth and modern audio.

ABS:

Anti-lock Braking System (ABS) became available as an option on later models, particularly from 1993 onwards.

Connectivity Features:

No integrated connectivity features like Bluetooth or USB ports in factory original systems. All connectivity would be via aftermarket installations.

🔧 Maintenance

Oil Change Interval:

Typically 3,000-5,000 miles or 6 months, whichever comes first (refer to manual for specific engine and oil type).

Transmission Fluid Change:

Every 30,000-60,000 miles, depending on driving conditions and transmission type.

Coolant Flush:

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

Spark Plug Replacement:

Typically every 30,000-60,000 miles, depending on spark plug type (conventional, platinum, iridium).

Engine Oil:

SAE 10W-30 or 10W-40 for most engines (check manual for exact viscosity and API service rating, e.g., API SG/SH).

Automatic Transmission Fluid:

ATF+3 or ATF+4 (later models), Dexron II/III compatible fluids (check manual for specific AW4 and TF-999 requirements).

Coolant:

Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Check for Mopar specific coolant if required by manual.

Power Steering Fluid:

ATF+3 or Dexron II/III compatible fluids.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (refer to manual for specific recommendation).

Common Problems:

Head gasket issues (4.0L), cracked cylinder heads (4.0L), distributor drive gear wear (4.0L), NP242 transfer case chain stretch, rust in unibody/frame rails, worn leaf spring bushings, AC system leaks, valve cover gasket leaks.

Steering Components:

Worn steering box, tie rod ends, and track bar bushings are common, especially in off-road driven vehicles.

📚 Vehicle History

Jeep Legacy:

Built upon Jeep's legacy of robust 4x4 capability and off-road prowess, established by models like the CJ and Wagoneer.

Xj Generation 1:

Introduced in 1984 as a revolutionary compact SUV with unibody construction, offering a more refined ride than body-on-frame SUVs of its time. Featured a car-like interior and a lower profile.

Yj Generation 1:

Introduced in 1987 as the successor to the CJ-7. The YJ is visually distinct due to its iconic round headlights (a departure from the CJ's rectangular headlights) and the addition of leaf springs in the front suspension, providing increased articulation and a more traditional off-road setup.

Xj Key Changes Mid Cycle:

Later XJ models received updates including improved interior ergonomics, revised dashboard, introduction of airbags, and the more robust 4.0L HO (High Output) engine.

Yj Key Changes:

The YJ is most noted for the switch to coil springs in the later TJ generation, but the YJ itself introduced the leaf-sprung front axle and the coil-sprung rear suspension (for some models), as well as a standard driver's airbag in later years.

Yj Distinctive Feature:

The YJ generation is most famously recognized by its 'square headlights', a departure from the traditional round headlights of the CJ series, which was a significant styling change.

Manufacturing Location:

Primarily assembled in Toledo, Ohio, USA.

Production End Date:

XJ Cherokee production ended in 2001 (US market), YJ Wrangler production ended in 1995.

🏆 Awards & Recognition

Off Road Magazine Awards:

Both XJ and YJ models frequently received accolades from off-road publications for their capability and value.