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1986 Jeep Cherokee XJ Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Generation: XJ (First Generation) Model Code: XJ Year: 1986 👋 Introduction Market Position Market Segment: Compact SUV, highly capable off-road vehicle Target Audience: Enthusiasts, DIY mechanics, professional repair shops, Jeep owners seeking to maintain their vehicle Competitive Analysis Competitors 1986: Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner, Nissan Pathfinder Jeep Cherokee Xj Advantage: Unibody construction, excellent off-road capability, strong aftermarket support, compact size Key Features Jeep Cherokee Xj Features: Compact dimensions, unibody construction, Command-Trac 4WD system, powerful inline-6 engine option Manual Value Proposition Value For Owner: Empowers owners to perform maintenance and repairs, saving money and extending vehicle life Value For Business: Essential tool for repair shops specializing in older Jeep vehicles 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: Printed Manual (implied by description) Page Count: Approximately 800-1200 pages (typical for comprehensive factory manuals of this era) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul and repair procedures for all engine variants Engine Electrical: Ignition system, starting and charging systems, fuel injection systems, engine control module (ECM) diagnostics Transmission Manual: Disassembly, assembly, and repair of manual transmissions (e.g., Aisin Warner AX4, Peugeot BA-10/5) Transmission Automatic: Disassembly, assembly, and repair of automatic transmissions (e.g., Chrysler 727 TorqueFlite, 32RH) Drivetrain: Transfer case (e.g., NP228, NP229), front and rear axles, drive shafts, U-joints Suspension: Front and rear suspension systems, leaf springs, shock absorbers, bushings, steering linkage Brakes: Hydraulic brake systems (disc and drum), parking brake, bleeding procedures, component replacement Steering: Power steering system, steering gear, steering column, alignment specifications Body And Chassis: Body panel removal and installation, structural components, door mechanisms, glass replacement, rust repair guidelines Electrical System: Wiring diagrams, lighting systems, instrument panel, switches, relays, fuses, power windows/locks HVAC: Heating, ventilation, and air conditioning system diagnosis and repair Fuel System: Fuel tank, fuel pump, fuel lines, fuel injectors, evaporative emissions control system Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, emission control components Cooling System: Radiator, water pump, thermostat, cooling fan, coolant specifications Procedures Included Maintenance: Routine scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification Repair: Step-by-step repair instructions for virtually all vehicle components Rebuilds: Detailed procedures for engine, transmission, and axle overhauls Diagnostics: Component testing, electrical system diagnosis, fuel system testing Alignment: Front and rear wheel alignment specifications and procedures Specifications Data: Torque specifications, clearances, and measurement data for all components Technical Depth Depth: Comprehensive, covering from basic fluid checks to full engine and transmission rebuilds Diagnostic Level: Advanced diagnostic procedures and fault code interpretation (where applicable for the era) Diagrams And Illustrations: Extensive use of diagrams, exploded views, and illustrations to clarify procedures 📊 Manual Specifications File Format File Format: Print Print Quality Print Quality: High quality, suitable for workshop environments Binding Type Binding Type: Typically perfect bound or spiral bound for lay-flat usability Paper Type Paper Type: Durable, often glossy or semi-gloss paper to resist shop grime ⚙️ Engine Specifications Primary Engine Engine 1986 1: 2.5L AMC I4 (150 cu in) Engine 1986 1 Horsepower: Approx. 115 hp @ 4000 rpm Engine 1986 1 Torque: Approx. 130 lb-ft @ 2800 rpm Optional Engine Engine 1986 2: 4.0L AMC I6 (242 cu in) 'High Output' Engine 1986 2 Horsepower: Approx. 173 hp @ 4000 rpm Engine 1986 2 Torque: Approx. 220 lb-ft @ 2000 rpm Fuel System Fuel System Type: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Engine Features Block Material I4: Cast Iron Head Material I4: Cast Iron Block Material I6: Cast Iron Head Material I6: Cast Iron Valvetrain I4: Overhead Valve (OHV), 2 valves per cylinder Valvetrain I6: Overhead Valve (OHV), 2 valves per cylinder 🔧 Transmission Standard Transmission Transmission Option 1: 4-Speed Manual (Peugeot BA-10/5 or Aisin Warner AX4) Optional Transmission Transmission Option 2: 3-Speed Automatic (Chrysler 727 TorqueFlite) Transmission Option 3: 4-Speed Automatic (Chrysler 32RH - introduced later, but some early XJs may have had variations) Features Transfer Case Options: Seletrac (2WD/4WD), Command-Trac (Part-time 4WD), Selec-Trac (Full-time 4WD) Transfer Case Models: NP228, NP229 Fluid Specifications Manual Transmission Fluid: API GL-4 gear oil (e.g., SAE 75W-90, check specific manual for exact spec) Automatic Transmission Fluid: ATF+3 or Dexron II/III (check specific manual for exact spec) 📐 Dimensions Exterior Wheelbase: 101.4 inches (2575 mm) Overall Length: 169.4 inches (4303 mm) Overall Width: 70.3 inches (1786 mm) Overall Height: 64.1 inches (1628 mm) Weights Curb Weight I4: Approx. 3,200 lbs (1451 kg) Curb Weight I6: Approx. 3,350 lbs (1519 kg) Gross Vehicle Weight Rating: Varies by configuration, typically around 4,700-5,000 lbs Towing Capacity: Up to 2,000 lbs (check owner's manual for specific ratings) 🛡️ Safety Features Ratings NHTSA Ratings 1986: NHTSA ratings from this era are not directly comparable to modern standards and are often...
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1986 Jeep Cherokee XJ Service Repair Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee
Generation:
XJ (First Generation)
Model Code:
XJ
Year:
1986
👋 Introduction
Market Position
Market Segment:
Compact SUV, highly capable off-road vehicle
Target Audience:
Enthusiasts, DIY mechanics, professional repair shops, Jeep owners seeking to maintain their vehicle
Competitive Analysis
Competitors 1986:
Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner, Nissan Pathfinder
Jeep Cherokee Xj Advantage:
Unibody construction, excellent off-road capability, strong aftermarket support, compact size
Key Features
Jeep Cherokee Xj Features:
Compact dimensions, unibody construction, Command-Trac 4WD system, powerful inline-6 engine option
Manual Value Proposition
Value For Owner:
Empowers owners to perform maintenance and repairs, saving money and extending vehicle life
Value For Business:
Essential tool for repair shops specializing in older Jeep vehicles
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual / Repair Manual
Language:
English
Format:
Printed Manual (implied by description)
Page Count:
Approximately 800-1200 pages (typical for comprehensive factory manuals of this era)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul and repair procedures for all engine variants
Engine Electrical:
Ignition system, starting and charging systems, fuel injection systems, engine control module (ECM) diagnostics
Transmission Manual:
Disassembly, assembly, and repair of manual transmissions (e.g., Aisin Warner AX4, Peugeot BA-10/5)
Transmission Automatic:
Disassembly, assembly, and repair of automatic transmissions (e.g., Chrysler 727 TorqueFlite, 32RH)
Drivetrain:
Transfer case (e.g., NP228, NP229), front and rear axles, drive shafts, U-joints
Suspension:
Front and rear suspension systems, leaf springs, shock absorbers, bushings, steering linkage
Brakes:
Hydraulic brake systems (disc and drum), parking brake, bleeding procedures, component replacement
Steering:
Power steering system, steering gear, steering column, alignment specifications
Body And Chassis:
Body panel removal and installation, structural components, door mechanisms, glass replacement, rust repair guidelines
Electrical System:
Wiring diagrams, lighting systems, instrument panel, switches, relays, fuses, power windows/locks
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel injectors, evaporative emissions control system
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, emission control components
Cooling System:
Radiator, water pump, thermostat, cooling fan, coolant specifications
Procedures Included
Maintenance:
Routine scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification
Repair:
Step-by-step repair instructions for virtually all vehicle components
Rebuilds:
Detailed procedures for engine, transmission, and axle overhauls
Diagnostics:
Component testing, electrical system diagnosis, fuel system testing
Alignment:
Front and rear wheel alignment specifications and procedures
Specifications Data:
Torque specifications, clearances, and measurement data for all components
Technical Depth
Depth:
Comprehensive, covering from basic fluid checks to full engine and transmission rebuilds
Diagnostic Level:
Advanced diagnostic procedures and fault code interpretation (where applicable for the era)
Diagrams And Illustrations:
Extensive use of diagrams, exploded views, and illustrations to clarify procedures
📊 Manual Specifications
File Format
File Format:
Print
Print Quality
Print Quality:
High quality, suitable for workshop environments
Binding Type
Binding Type:
Typically perfect bound or spiral bound for lay-flat usability
Paper Type
Paper Type:
Durable, often glossy or semi-gloss paper to resist shop grime
⚙️ Engine Specifications
Primary Engine
Engine 1986 1:
2.5L AMC I4 (150 cu in)
Engine 1986 1 Horsepower:
Approx. 115 hp @ 4000 rpm
Engine 1986 1 Torque:
Approx. 130 lb-ft @ 2800 rpm
Optional Engine
Engine 1986 2:
4.0L AMC I6 (242 cu in) 'High Output'
Engine 1986 2 Horsepower:
Approx. 173 hp @ 4000 rpm
Engine 1986 2 Torque:
Approx. 220 lb-ft @ 2000 rpm
Fuel System
Fuel System Type:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Engine Features
Block Material I4:
Cast Iron
Head Material I4:
Cast Iron
Block Material I6:
Cast Iron
Head Material I6:
Cast Iron
Valvetrain I4:
Overhead Valve (OHV), 2 valves per cylinder
Valvetrain I6:
Overhead Valve (OHV), 2 valves per cylinder
🔧 Transmission
Standard Transmission
Transmission Option 1:
4-Speed Manual (Peugeot BA-10/5 or Aisin Warner AX4)
Optional Transmission
Transmission Option 2:
3-Speed Automatic (Chrysler 727 TorqueFlite)
Transmission Option 3:
4-Speed Automatic (Chrysler 32RH - introduced later, but some early XJs may have had variations)
Features
Transfer Case Options:
Seletrac (2WD/4WD), Command-Trac (Part-time 4WD), Selec-Trac (Full-time 4WD)
Transfer Case Models:
NP228, NP229
Fluid Specifications
Manual Transmission Fluid:
API GL-4 gear oil (e.g., SAE 75W-90, check specific manual for exact spec)
Automatic Transmission Fluid:
ATF+3 or Dexron II/III (check specific manual for exact spec)
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2575 mm)
Overall Length:
169.4 inches (4303 mm)
Overall Width:
70.3 inches (1786 mm)
Overall Height:
64.1 inches (1628 mm)
Weights
Curb Weight I4:
Approx. 3,200 lbs (1451 kg)
Curb Weight I6:
Approx. 3,350 lbs (1519 kg)
Gross Vehicle Weight Rating:
Varies by configuration, typically around 4,700-5,000 lbs
Towing Capacity:
Up to 2,000 lbs (check owner's manual for specific ratings)
🛡️ Safety Features
Ratings
NHTSA Ratings 1986:
NHTSA ratings from this era are not directly comparable to modern standards and are often unavailable.
Active Features
Active Safety 1986:
Four-wheel drive system (optional), robust chassis construction
Passive Features
Passive Safety 1986:
Seat belts (driver and passenger), strong cabin structure
Airbags:
Not available in 1986 models
💡 Technology Features
Infotainment
Infotainment 1986:
Basic AM/FM radio, optional cassette player, analog gauges
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (depending on driving conditions)
Engine Oil Type:
API SG or SH rated, SAE 10W-30 recommended for most conditions
Engine Oil Capacity:
4.0L I6: 5 quarts (4.7 L) with filter; 2.5L I4: 5 quarts (4.7 L) with filter
Engine Oil Filter Part Number:
Commonly used: Wix 51515, Fram PH8A, Purolator L30001 (verify for specific engine)
Coolant Type:
Ethylene Glycol based antifreeze (green color), 50/50 mix with distilled water
Coolant Capacity:
Approx. 11-12 quarts (10.4-11.3 L)
Spark Plug Replacement Interval:
Every 30,000 miles (check manual for specific plugs and gap)
Transmission Fluid Change Interval:
Every 30,000-60,000 miles (depending on usage and fluid type)
Known Issues
Common Issues Engine:
Valve cover gasket leaks, intake manifold gasket leaks (4.0L), oil pan gasket leaks
Common Issues Transmission:
Manual transmission synchro wear, automatic transmission clutch pack wear
Common Issues Suspension:
Leaf spring sag, worn control arm bushings, worn ball joints
Common Issues Electrical:
Corroded grounds, failing alternators, dashboard gauge issues
Common Issues Body:
Rust in floor pans, rocker panels, and rear quarter panels
📚 Vehicle History
Brand Heritage
Jeep Heritage:
Jeep's legacy of ruggedness and off-road capability dating back to WWII
Model Evolution
Xj Introduction:
Introduced for the 1984 model year, revolutionizing the SUV market with its compact size and unibody construction.
Xj Generation 1 Years:
1984-1996
1986 Updates:
Minor refinements, introduction of the more powerful 4.0L inline-6 engine as an option
Production
Manufacturing Location:
Toledo, Ohio, USA
Jeep Ownership 1986:
American Motors Corporation (AMC)
🏆 Awards & Recognition
Recognitions
Automotive Press Awards Xj:
Widely praised for its off-road capability and utility by automotive journalists of the era.
Motor Trend Truck Of The Year Xj:
Jeep Comanche (pickup based on XJ platform) was Motor Trend Truck of the Year for 1986.
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