Jeep CHEROKEE XJ 2.5L 4.0L Full Service & Repair Manual 1988-2001
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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Chassis Code: XJ Production Years: 1988-2001 Codes Engine Codes: 2.5L AMC 150 (4-cylinder), 4.0L AMC 242 (6-cylinder) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Sport Utility Vehicle Jeep Brand Heritage: Renowned for off-road capability and ruggedness Competitive Analysis Key Competitors: Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner, Nissan Pathfinder Key Features Design Philosophy: Unibody construction (a departure from traditional body-on-frame), strong off-road prowess, distinctive Jeep styling Powertrain Options: Longitudinal inline-six (4.0L) known for torque and durability, reliable 2.5L four-cylinder Manual Value Proposition Completeness: Covers entire production run and major mechanical/electrical systems, ideal for DIY mechanics and professional shops Accessibility: Instant download format allows immediate access for diagnosis and repair 📋 Manual Details Coverage Areas Regions Covered: Global (primarily North American market focus) Page Count Estimated Page Count: Extensive (typically 1000+ pages for full factory manuals) Manual Type Manual Type: Factory Service & Repair Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (2.5L I4, 4.0L I6), Transmission (Manual & Automatic), Transfer Case, Drivetrain (4WD systems) Chassis: Suspension (Front & Rear), Steering, Brakes (Front Disc/Rear Drum or Disc), Wheels & Tires Electrical: Wiring Diagrams, Lighting, Instrumentation, Power Distribution, Ignition System, Charging System, Starting System Body And Interior: Body Panels, Doors, Glass, Seats, HVAC System, Trim Components, Exterior/Interior Lighting Diagnostics And Troubleshooting: Component Testing, Diagnostic Trouble Codes (DTCs), Symptom-based Troubleshooting Procedures Included Routine Maintenance: Oil & Filter Changes, Air Filter Replacement, Spark Plug Service, Fluid Level Checks & Top-offs Major Repairs: Engine Overhaul/Rebuild, Transmission Overhaul, Clutch Replacement, Brake System Overhaul, Suspension Component Replacement Diagnostics And Repair: Fuel System Diagnosis, Cooling System Diagnosis, Ignition System Troubleshooting, Electrical System Fault Finding Technical Specifications: Torque Specifications, Clearances, Diagnostic Parameters, Fluid Capacities Technical Depth Depth Of Coverage: Comprehensive (from basic adjustments to complete engine and transmission rebuilds, including detailed wiring diagrams and diagnostic procedures) 📊 Manual Specifications File Format File Quality: High-Resolution PDF, Searchable Text, Printable Pages Print Quality Print Readability: Excellent (designed for clear viewing on digital devices and printing) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Displacement 40L: 4.0 Liters (242 cubic inches) Engine Type 40L: OHV Inline 6-cylinder Engine Displacement 25L: 2.5 Liters (150 cubic inches) Engine Type 25L: OHV Inline 4-cylinder Performance Horsepower 40L Early: 173-177 hp @ 4700 rpm (depending on year) Torque 40L Early: 220-224 lb-ft @ 3200 rpm (depending on year) Horsepower 25L: 125 hp @ 4800 rpm Torque 25L: 150 lb-ft @ 2400 rpm Fuel System Fuel Delivery Type: Multi-point Fuel Injection (MPI) Engine Features Block Material 40L: Cast Iron Head Material 40L: Cast Iron Timing Drive 40L: Timing Chain Timing Drive 25L: Timing Chain 🔧 Transmission Standard Transmission 40L Transmission Type 40L Std: 4-speed Automatic (AW4) Optional Transmission 40L Transmission Type 40L Opt: 5-speed Manual (AX-15) Standard Transmission 25L Transmission Type 25L Std: 5-speed Manual (AX-5) Optional Transmission 25L Transmission Type 25L Opt: 3-speed Automatic (727 TorqueFlite) / 4-speed Automatic (AW4) Features Transfer Case Options: Command-Trac (Part-Time 4WD), Selec-Trac (Full-Time 4WD) Fluid Specifications Automatic Transmission Fluid: ATF+3 (Chrysler Mopar specification) or equivalent Dexron-III Manual Transmission Fluid Ax15: API GL-5, SAE 75W-90 Gear Oil Manual Transmission Fluid Ax5: API GL-5, SAE 75W-90 Gear Oil Transfer Case Fluid: ATF+3 (Chrysler Mopar specification) or equivalent Dexron-III 📐 Dimensions Exterior Wheelbase: 101.4 inches (2576 mm) Length: 168.7 inches (4285 mm) Width: 69.4 inches (1763 mm) Height: 63.6 inches (1615 mm) Weights Curb Weight Approx: 3200-3500 lbs (1450-1590 kg) depending on configuration 🛡️ Safety Features Ratings NHTSA Rollover Rating: 3-star (for early models) Active Features Braking System: Front disc brakes, rear drum brakes (some later models had rear discs) Passive Features Seat Belts: Front and rear seat belts Airbags: Driver and passenger airbags (standard from 1994 onwards) 💡 Technology Features Infotainment Audio Systems: Factory AM/FM/Cassette or CD players, optional premium sound systems (upgrades common) Driver Assistance ABS: Anti-lock Braking System (ABS) became available as an option on later models. Connectivity Cruise Control: Available on most trim levels. 🔧 Maintenance Service Intervals Oil Change Interval Gasoline: Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type (consult manual for specifics) Transmission Fluid Change Interval: Every 30,000-60,000 miles (50,000-100,000 km) for automatic, consult manual for manual transmissions. Spark Plug Replacement Interval: Every 30,000-100,000 miles (50,000-160,000 km) depending on spark plug type (e.g., platinum or iridium) Fluid Specifications Engine Oil Type 40L: API SN/SP, SAE 10W-30 (or 5W-30 in very cold climates) Engine Oil Type 25L: API SN/SP, SAE 10W-30 Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent Ethylene Glycol/Propylene Glycol based antifreeze Brake Fluid Type: DOT 3 Known Issues Common Problems 40L: Cracking cylinder head (especially earlier models), distributorless ignition system (DIS) issues, rear main...
ATF+3 (Chrysler Mopar specification) or equivalent Dexron-III
Manual Transmission Fluid Ax15:
API GL-5, SAE 75W-90 Gear Oil
Manual Transmission Fluid Ax5:
API GL-5, SAE 75W-90 Gear Oil
Transfer Case Fluid:
ATF+3 (Chrysler Mopar specification) or equivalent Dexron-III
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2576 mm)
Length:
168.7 inches (4285 mm)
Width:
69.4 inches (1763 mm)
Height:
63.6 inches (1615 mm)
Weights
Curb Weight Approx:
3200-3500 lbs (1450-1590 kg) depending on configuration
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
3-star (for early models)
Active Features
Braking System:
Front disc brakes, rear drum brakes (some later models had rear discs)
Passive Features
Seat Belts:
Front and rear seat belts
Airbags:
Driver and passenger airbags (standard from 1994 onwards)
💡 Technology Features
Infotainment
Audio Systems:
Factory AM/FM/Cassette or CD players, optional premium sound systems (upgrades common)
Driver Assistance
ABS:
Anti-lock Braking System (ABS) became available as an option on later models.
Connectivity
Cruise Control:
Available on most trim levels.
🔧 Maintenance
Service Intervals
Oil Change Interval Gasoline:
Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type (consult manual for specifics)
Transmission Fluid Change Interval:
Every 30,000-60,000 miles (50,000-100,000 km) for automatic, consult manual for manual transmissions.
Spark Plug Replacement Interval:
Every 30,000-100,000 miles (50,000-160,000 km) depending on spark plug type (e.g., platinum or iridium)
Fluid Specifications
Engine Oil Type 40L:
API SN/SP, SAE 10W-30 (or 5W-30 in very cold climates)
Engine Oil Type 25L:
API SN/SP, SAE 10W-30
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent Ethylene Glycol/Propylene Glycol based antifreeze
Brake Fluid Type:
DOT 3
Known Issues
Common Problems 40L:
Cracking cylinder head (especially earlier models), distributorless ignition system (DIS) issues, rear main seal leaks, catalytic converter failure, rust (body and frame)
Worn control arm bushings, ball joints, and track bar bushings are common due to off-road use and age.
Common Issues Electrical
Wiring Harness Issues:
Corrosion in connectors, brittle insulation, especially in engine bay and at the firewall.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Established in 1941, known for military vehicles and iconic Wrangler
Model Evolution
Generation Introduction:
Introduced in 1984 as a successor to the CJ-8 Scrambler and Wagoneer, the XJ pioneered the compact SUV segment with its unibody construction.
Design Changes:
Facelifted in 1987 with revised interior and exterior styling, updated engines, and improved aerodynamics. Further minor updates occurred throughout its lifespan.
Production
Production Period:
1984-2001 (North America), extended production in other markets until 2001
Manufacturing Locations:
Toledo, Ohio, USA; Brampton, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Popular Mechanics Ooy:
Honored as a "Vehicle of the Year" by Popular Mechanics in 1984.
Ratings
Off Road Capability Reputation:
Consistently praised for its off-road capabilities, often considered one of the most capable compact SUVs of its era.
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