Jeep Cherokee XJ 2.5L 4.0L 1988-2001 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Chassis Code: XJ Codes Engine Code 2.5L: AMC 150 (4-cylinder OHV) Engine Code 4.0L: AMC 242 (inline 6 OHV) Transmission Codes: AW4 (automatic), AX-4 (manual), BA/10-5 (manual) 👋 Introduction Market Position Segment: Compact SUV, Off-road capable Segment Description: Pioneering the modern SUV segment, the Cherokee XJ offered a blend of utility, off-road prowess, and relatively compact dimensions. Competitive Analysis Competitors 1988-2001: Ford Bronco II, Chevrolet S-10 Blazer, GMC Jimmy, Toyota 4Runner, Nissan Pathfinder, Mitsubishi Montero, Isuzu Rodeo Key Features Unibody Construction: Revolutionary for its time, the XJ featured a unibody construction, reducing weight and improving on-road manners compared to body-on-frame SUVs. Powertrain Options: Renowned for the durable and torquey 4.0L inline-six engine, also available with a capable 2.5L four-cylinder. 4X4 Systems: Offered with legendary Jeep 4x4 systems like Command-Trac and Selec-Trac, providing excellent off-road capability. 📋 Manual Details Coverage Areas Coverage Years: 1988-2001 Engine Coverage: 2.5L, 4.0L Model Variants Covered: All XJ body styles (2-door, 4-door) Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (2.5L AMC 150, 4.0L AMC 242), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Clutch, Manual Transmission (AX-4, BA/10-5), Automatic Transmission (AW4) Chassis: Driveline, Four-Wheel Drive System (Command-Trac, Selec-Trac), Axles (Dana 30, Chrysler 8.25), Suspension (Leaf Spring Rear, Coil Spring Front), Steering System, Brake System (Front Disc, Rear Drum/Disc) Electrical: Battery, Charging System, Starting System, Lighting, Instrumentation, Wiper/Washer System, Power Accessories, Fuses and Relays, Engine Control Module (ECM) Diagnostics, Body Control Module (BCM) Diagnostics (later models) Body: Body Panels, Doors, Hood, Tailgate, Interior Trim, Glass, Seals, Bumpers, Structural Components Procedures Included General Maintenance: Oil and filter changes, Air filter replacement, Spark plug replacement, Coolant flush and fill, Brake fluid flush, Belt inspection and replacement, Battery maintenance, Tire rotation and pressure checks Engine Repair: Engine disassembly and reassembly, Cylinder head service, Piston and connecting rod service, Crankshaft service, Camshaft service, Oil pump replacement, Timing chain/gear replacement Transmission Repair: Clutch replacement, Transmission removal and installation, Clutch hydraulic system service, Manual transmission overhaul, Automatic transmission overhaul (AW4 specific procedures) Drivetrain Repair: Driveshaft removal and installation, U-joint replacement, Axle housing inspection and repair, Differential service, Transfer case service (Command-Trac, Selec-Trac) Suspension Steering Brakes: Shock absorber and strut replacement, Leaf spring replacement, Ball joint and tie rod end replacement, Power steering pump and gearbox service, Brake pad and rotor replacement, Brake caliper and wheel cylinder service, Parking brake adjustment Electrical Diagnostics: Wiring diagrams, Troubleshooting guides for electrical faults, Sensor testing and replacement, Actuator testing, ECM/PCM diagnosis and repair Body And Interior: Door and window regulator repair, Lock mechanism service, Seat repair, Headliner replacement, Weatherstrip replacement, Body panel alignment Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and transmission overhauls, in-depth electrical diagnostics, and detailed troubleshooting procedures. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (typically, depending on PDF creation) Print Quality Quality: High-resolution, suitable for printing Binding Type Binding For Print: N/A (Digital download) Paper Type Paper For Print: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Engine Name 1: AMC 150 (2.5L) Configuration 1: Inline 4-cylinder, Overhead Valve (OHV) Displacement 1: 2.5 Liters (150 cubic inches) Bore X Stroke 1: 3.75 in x 3.75 in (95.25 mm x 95.25 mm) Compression Ratio 1: 8.7:1 (typical, varies by year) Horsepower 1: 121-130 hp @ 4000-4600 RPM (varies by year) Torque 1: 170-180 lb-ft @ 2400-3200 RPM (varies by year) Fuel System 1: Multi-Point Fuel Injection (MPI) Ignition System 1: Distributorless Ignition System (DIS) or Distributor type (varies by year) Engine Name 2: AMC 242 (4.0L) Configuration 2: Inline 6-cylinder, Overhead Valve (OHV) Displacement 2: 4.0 Liters (242 cubic inches) Bore X Stroke 2: 3.88 in x 3.41 in (98.5 mm x 86.7 mm) Compression Ratio 2: 8.8:1 to 10.0:1 (varies significantly by year and head design) Horsepower 2: 177-190 hp @ 4400-4700 RPM (varies by year) Torque 2: 220-255 lb-ft @ 2000-3200 RPM (varies by year) Fuel System 2: Multi-Point Fuel Injection (MPI) Ignition System 2: Distributorless Ignition System (DIS) 🔧 Transmission Standard Manual Transmission Options: AX-4 (4-speed), BA/10-5 (5-speed - Peugeot/Renault sourced, less common/desirable) Optional Automatic Transmission: AW4 (4-speed automatic, manufactured by Aisin-Warner) Features Aw4 Features: Electronically controlled, known for durability and smooth shifting. Features multiple drive modes (e.g., 2WD, 4WD High, 4WD Low). Manual Transmission Fluid Spec: API GL-5, SAE 75W-90 or 80W-90 (check specific model year for precise recommendation) Automatic Transmission Fluid Spec: ATF+4 (Chrysler's proprietary fluid, backwards compatible with earlier Mopar ATF+ types) 📐 Dimensions Exterior Wheelbase: 101.4 inches (2576 mm) Length: 167.5 - 177.6 inches (4255 - 4511 mm) (varies by year/bumper style) Width: 69.3 - 70.0 inches (1760 - 1778 mm) Height: 63.7 - 66.0 inches (1618 - 1676 mm) Ground...
Oil and filter changes, Air filter replacement, Spark plug replacement, Coolant flush and fill, Brake fluid flush, Belt inspection and replacement, Battery maintenance, Tire rotation and pressure checks
Engine Repair:
Engine disassembly and reassembly, Cylinder head service, Piston and connecting rod service, Crankshaft service, Camshaft service, Oil pump replacement, Timing chain/gear replacement
Transmission Repair:
Clutch replacement, Transmission removal and installation, Clutch hydraulic system service, Manual transmission overhaul, Automatic transmission overhaul (AW4 specific procedures)
Drivetrain Repair:
Driveshaft removal and installation, U-joint replacement, Axle housing inspection and repair, Differential service, Transfer case service (Command-Trac, Selec-Trac)
Suspension Steering Brakes:
Shock absorber and strut replacement, Leaf spring replacement, Ball joint and tie rod end replacement, Power steering pump and gearbox service, Brake pad and rotor replacement, Brake caliper and wheel cylinder service, Parking brake adjustment
Electrical Diagnostics:
Wiring diagrams, Troubleshooting guides for electrical faults, Sensor testing and replacement, Actuator testing, ECM/PCM diagnosis and repair
Body And Interior:
Door and window regulator repair, Lock mechanism service, Seat repair, Headliner replacement, Weatherstrip replacement, Body panel alignment
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to complete engine and transmission overhauls, in-depth electrical diagnostics, and detailed troubleshooting procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (typically, depending on PDF creation)
Print Quality
Quality:
High-resolution, suitable for printing
Binding Type
Binding For Print:
N/A (Digital download)
Paper Type
Paper For Print:
N/A (Digital download)
⚙️ Engine Specifications
Primary Engine
Engine Name 1:
AMC 150 (2.5L)
Configuration 1:
Inline 4-cylinder, Overhead Valve (OHV)
Displacement 1:
2.5 Liters (150 cubic inches)
Bore X Stroke 1:
3.75 in x 3.75 in (95.25 mm x 95.25 mm)
Compression Ratio 1:
8.7:1 (typical, varies by year)
Horsepower 1:
121-130 hp @ 4000-4600 RPM (varies by year)
Torque 1:
170-180 lb-ft @ 2400-3200 RPM (varies by year)
Fuel System 1:
Multi-Point Fuel Injection (MPI)
Ignition System 1:
Distributorless Ignition System (DIS) or Distributor type (varies by year)
Engine Name 2:
AMC 242 (4.0L)
Configuration 2:
Inline 6-cylinder, Overhead Valve (OHV)
Displacement 2:
4.0 Liters (242 cubic inches)
Bore X Stroke 2:
3.88 in x 3.41 in (98.5 mm x 86.7 mm)
Compression Ratio 2:
8.8:1 to 10.0:1 (varies significantly by year and head design)
Horsepower 2:
177-190 hp @ 4400-4700 RPM (varies by year)
Torque 2:
220-255 lb-ft @ 2000-3200 RPM (varies by year)
Fuel System 2:
Multi-Point Fuel Injection (MPI)
Ignition System 2:
Distributorless Ignition System (DIS)
🔧 Transmission
Standard
Manual Transmission Options:
AX-4 (4-speed), BA/10-5 (5-speed - Peugeot/Renault sourced, less common/desirable)
Optional
Automatic Transmission:
AW4 (4-speed automatic, manufactured by Aisin-Warner)
Features
Aw4 Features:
Electronically controlled, known for durability and smooth shifting. Features multiple drive modes (e.g., 2WD, 4WD High, 4WD Low).
Manual Transmission Fluid Spec:
API GL-5, SAE 75W-90 or 80W-90 (check specific model year for precise recommendation)
Power steering leaks, AC system issues, saggy rear leaf springs, worn out bushings (control arm, sway bar), fuel pump failure, transfer case chain stretch.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Building on a reputation for ruggedness and off-road capability established by earlier Jeep models (CJ series, Wagoneer).
Model Evolution
Introduction Year:
1984 (for the XJ generation)
Major Updates 1988-2001:
1991: Major facelift with revised interior and exterior styling, introduction of the 4.0L HO engine. 1997: Second major facelift (often referred to as 'facelift II' or 'revised XJ') with redesigned front and rear fascias, improved interior, and updated powertrain options.
Product Line Extension:
The XJ platform also underpinned the Jeep Comanche (MJ) pickup truck.
Production
Production Period:
1984-2001 (globally, North American production ended in 2001)
Manufacturing Locations:
Toledo, Ohio, USA; Brampton, Ontario, Canada; and other international facilities.
🏆 Awards & Recognition
Recognitions
Off Road Magazine Awards:
Frequently recognized by off-road publications for its capability and value.
Popular Mechanics Editors Choice:
Often cited as a benchmark in the compact SUV category for its blend of refinement and off-road prowess.
Ratings
Consumer Reports Ratings:
Varies by year; some years received good ratings for performance and reliability, while others noted potential issues with specific components.
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