Jeep Cherokee XJ 1997-2001 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Product Name: Jeep Cherokee XJ 1997-2001 Service Repair Workshop Manual Download PDF Codes Vehicle Generation Code: XJ (Second Generation Facelift) 👋 Introduction Market Position Category: Compact SUV / Off-Road Vehicle Segment History: The Jeep Cherokee XJ defined the compact SUV segment with its unibody construction and legendary off-road capability. Competitive Analysis Contemporaries: Competed with vehicles like the Ford Explorer, Toyota 4Runner, Nissan Pathfinder, and Chevrolet Blazer. Key Features Platform: Robust unibody construction (UniFrame) providing a balance of strength and lighter weight compared to body-on-frame competitors. Off Road Capability: Renowned for its off-road prowess, often featuring Command-Trac NV231 or Selec-Trac NV242 transfer cases and robust solid axles (especially in earlier models, though this generation uses a Dana 30 front and Chrysler 8.25 rear). Durability: Known for its ruggedness and reliability, making it a popular choice for off-roading and overland travel. 📋 Manual Details Coverage Areas Supported Years: 1997, 1998, 1999, 2000, 2001 Page Count Estimated Page Count: 1500-2000 (typical for a comprehensive factory manual of this era) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Transfer Case, Drivetrain (4x4 systems) Chassis: Suspension (Front & Rear), Steering, Brakes, Wheels & Tires Electrical: 12V Electrical System, Lighting, Instrumentation, Audio Systems, Power Accessories, Engine Control Module (ECM) Diagnostics, Body Control Modules (BCM) Body: Exterior Body Panels, Interior Trim, Seating, Glass, Doors, Hood, Liftgate HVAC: Heating, Ventilation, and Air Conditioning (HVAC) System Components and Operation Procedures Included Maintenance: Scheduled Maintenance Intervals, Fluid Checks and Changes, Filter Replacements, Lubrication Diagnostics: Troubleshooting Guides, Symptom-Based Diagnostics, Diagnostic Trouble Codes (DTCs), Electrical Schematics Repair: Component Removal and Installation, Engine Overhaul, Transmission Repair, Suspension Overhauls, Brake System Repairs, Electrical Component Replacement Adjustments: Wheel Alignment Procedures, Clutch Adjustment, Parking Brake Adjustment Specifications: Torque Specifications, Fluid Capacities, Dimensional Data, Electrical Resistances Technical Depth Depth: Comprehensive Factory Level (covering basic maintenance to complete engine/transmission rebuilds and detailed electrical system diagnostics) 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Searchability: Searchable Text (typically OCR'd for efficient keyword searching) Image Quality: High-Resolution Diagrams and Illustrations Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1 Code: 4.0L Inline-6 (OHV) Engine 1 Displacement: 3957 cc (241.7 cu in) Engine 1 Bore X Stroke: 3.875 in x 3.562 in (98.4 mm x 90.5 mm) Engine 1 Compression Ratio: 8.75:1 Engine 1 Horsepower: 185 hp @ 4600 rpm (approximate for this generation) Engine 1 Torque: 220 lb-ft @ 3000 rpm (approximate for this generation) Engine 2 Engine 2 Code: 2.5L Inline-4 (OHV) Engine 2 Displacement: 2507 cc (153 cu in) Engine 2 Horsepower: 119 hp @ 4500 rpm (approximate for this generation) Engine 2 Torque: 149 lb-ft @ 2500 rpm (approximate for this generation) Performance Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel System Fuel Type: Unleaded Gasoline Fuel Tank Capacity: 20.0 US gallons (75.7 L) Engine Management Ignition System: Distributorless Ignition System (DIS) with Coil-on-Plug (COP) on later 4.0L models 🔧 Transmission Standard Transmission 1 Type: 4-Speed Automatic (42RE) Optional Transmission 2 Type: 5-Speed Manual (AX-15 or NV3550 depending on year) Features Transfer Case Options: Command-Trac NV231 (Part-Time 4WD) or Selec-Trac NV242 (Full-Time 4WD option) Fluid Specifications Automatic Transmission Fluid: ATF+4 (Mopar) Manual Transmission Fluid: GL-3 or GL-4, SAE 75W-90 Synthetic gear oil (check specific manual for exact specs) Transfer Case Fluid: ATF+4 (Mopar) for NV231/NV242 📐 Dimensions Exterior Length: 167.9 in (4265 mm) Width: 69.4 in (1763 mm) Height: 63.5 in (1613 mm) Wheelbase: 101.4 in (2576 mm) Ground Clearance: 7.7 - 8.2 in (196 - 208 mm) depending on configuration Weights Curb Weight: 3300-3600 lbs (1497-1633 kg) approx. Gross Vehicle Weight Rating: 4650-4950 lbs (2109-2245 kg) approx. 🛡️ Safety Features Ratings NHTSA Rollover Rating: 4/5 Stars (for 1997 models, later ratings may vary) Active Features Brakes: Front: Vented Disc; Rear: Drum or Disc (depending on trim/options) ABS: Optional Anti-lock Braking System (ABS) available on rear wheels or all four wheels depending on year/configuration. Passive Features Airbags: Driver and Passenger airbags (standard in later years of this generation) 💡 Technology Features Infotainment Audio System: Factory AM/FM radio with cassette player, optional CD player. Speaker configurations varied by trim level. Instrument Cluster: Analog gauges for speedometer, tachometer, fuel level, engine temperature, oil pressure. Warning lamps for various systems. Driver Assistance Cruise Control: Optional cruise control system. Connectivity Diagnostic Port: OBD-II (On-Board Diagnostics II) connector, typically located under the dashboard, facilitating electronic fault diagnosis. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (using appropriate oil viscosity). Engine Coolant Interval: First service at 30,000 miles (48,000 km), then every 30,000 miles (48,000 km) or 2 years. Transmission Fluid Interval: Every...
Jeep Cherokee XJ 1997-2001 Service Repair Workshop Manual Download PDF
Codes
Vehicle Generation Code:
XJ (Second Generation Facelift)
👋 Introduction
Market Position
Category:
Compact SUV / Off-Road Vehicle
Segment History:
The Jeep Cherokee XJ defined the compact SUV segment with its unibody construction and legendary off-road capability.
Competitive Analysis
Contemporaries:
Competed with vehicles like the Ford Explorer, Toyota 4Runner, Nissan Pathfinder, and Chevrolet Blazer.
Key Features
Platform:
Robust unibody construction (UniFrame) providing a balance of strength and lighter weight compared to body-on-frame competitors.
Off Road Capability:
Renowned for its off-road prowess, often featuring Command-Trac NV231 or Selec-Trac NV242 transfer cases and robust solid axles (especially in earlier models, though this generation uses a Dana 30 front and Chrysler 8.25 rear).
Durability:
Known for its ruggedness and reliability, making it a popular choice for off-roading and overland travel.
📋 Manual Details
Coverage Areas
Supported Years:
1997, 1998, 1999, 2000, 2001
Page Count
Estimated Page Count:
1500-2000 (typical for a comprehensive factory manual of this era)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Transfer Case, Drivetrain (4x4 systems)
12V Electrical System, Lighting, Instrumentation, Audio Systems, Power Accessories, Engine Control Module (ECM) Diagnostics, Body Control Modules (BCM)
Body:
Exterior Body Panels, Interior Trim, Seating, Glass, Doors, Hood, Liftgate
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) System Components and Operation
Procedures Included
Maintenance:
Scheduled Maintenance Intervals, Fluid Checks and Changes, Filter Replacements, Lubrication
Comprehensive Factory Level (covering basic maintenance to complete engine/transmission rebuilds and detailed electrical system diagnostics)
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Searchability:
Searchable Text (typically OCR'd for efficient keyword searching)
Image Quality:
High-Resolution Diagrams and Illustrations
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Code:
4.0L Inline-6 (OHV)
Engine 1 Displacement:
3957 cc (241.7 cu in)
Engine 1 Bore X Stroke:
3.875 in x 3.562 in (98.4 mm x 90.5 mm)
Engine 1 Compression Ratio:
8.75:1
Engine 1 Horsepower:
185 hp @ 4600 rpm (approximate for this generation)
Engine 1 Torque:
220 lb-ft @ 3000 rpm (approximate for this generation)
Engine 2
Engine 2 Code:
2.5L Inline-4 (OHV)
Engine 2 Displacement:
2507 cc (153 cu in)
Engine 2 Horsepower:
119 hp @ 4500 rpm (approximate for this generation)
Engine 2 Torque:
149 lb-ft @ 2500 rpm (approximate for this generation)
Performance
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel System
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
20.0 US gallons (75.7 L)
Engine Management
Ignition System:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP) on later 4.0L models
🔧 Transmission
Standard
Transmission 1 Type:
4-Speed Automatic (42RE)
Optional
Transmission 2 Type:
5-Speed Manual (AX-15 or NV3550 depending on year)
Features
Transfer Case Options:
Command-Trac NV231 (Part-Time 4WD) or Selec-Trac NV242 (Full-Time 4WD option)
Fluid Specifications
Automatic Transmission Fluid:
ATF+4 (Mopar)
Manual Transmission Fluid:
GL-3 or GL-4, SAE 75W-90 Synthetic gear oil (check specific manual for exact specs)
Transfer Case Fluid:
ATF+4 (Mopar) for NV231/NV242
📐 Dimensions
Exterior
Length:
167.9 in (4265 mm)
Width:
69.4 in (1763 mm)
Height:
63.5 in (1613 mm)
Wheelbase:
101.4 in (2576 mm)
Ground Clearance:
7.7 - 8.2 in (196 - 208 mm) depending on configuration
Weights
Curb Weight:
3300-3600 lbs (1497-1633 kg) approx.
Gross Vehicle Weight Rating:
4650-4950 lbs (2109-2245 kg) approx.
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
4/5 Stars (for 1997 models, later ratings may vary)
Active Features
Brakes:
Front: Vented Disc; Rear: Drum or Disc (depending on trim/options)
ABS:
Optional Anti-lock Braking System (ABS) available on rear wheels or all four wheels depending on year/configuration.
Passive Features
Airbags:
Driver and Passenger airbags (standard in later years of this generation)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player, optional CD player. Speaker configurations varied by trim level.
Instrument Cluster:
Analog gauges for speedometer, tachometer, fuel level, engine temperature, oil pressure. Warning lamps for various systems.
Driver Assistance
Cruise Control:
Optional cruise control system.
Connectivity
Diagnostic Port:
OBD-II (On-Board Diagnostics II) connector, typically located under the dashboard, facilitating electronic fault diagnosis.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (using appropriate oil viscosity).
Engine Coolant Interval:
First service at 30,000 miles (48,000 km), then every 30,000 miles (48,000 km) or 2 years.
Transmission Fluid Interval:
Every 60,000-100,000 miles (96,000-160,000 km) depending on driving conditions and fluid type (ATF+4 recommended).
Fluid Specifications
Engine Oil Spec:
SAE 10W-30 API SG or SH for 4.0L; SAE 5W-30 API SG or SH for 2.5L (consult manual for specific oil type and API rating requirements).
Coolant Spec:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant or equivalent, mixed 50/50 with distilled water.
Brake Fluid Spec:
DOT 3 or DOT 4.
Known Issues
Common Problem 1:
Cracked cylinder heads on 4.0L engines (particularly early models, though improved in later revisions).
Common Problem 2:
Water pump leaks and thermostat housing leaks on 4.0L engines.
Common Problem 3:
Oxygen sensor failures contributing to poor fuel economy or check engine lights.
Common Problem 4:
Radiator hose failures and cooling system leaks.
Common Problem 5:
Rust on unibody structure, particularly wheel wells, rocker panels, and floor pans, requiring diligent inspection.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Built upon Jeep's long history of producing capable and rugged 4x4 vehicles, dating back to the World War II era Willys Jeep.
Model Evolution
Generation Context:
The XJ platform was introduced in 1984 and saw significant updates and facelifts throughout its production run. The 1997-2001 models represent the final facelift, featuring updated interior and exterior styling, improved safety features, and powertrain refinements.
Production
Production Period:
1984-2001 (North America)
Manufacturing Location:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Popular Mechanics Award:
Recognized by publications like Popular Mechanics for its innovative design and capability upon its introduction.
Ratings
Off Road Ratings:
Consistently ranked highly by off-road enthusiasts and publications for its trail capability.
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