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Manual Coverage
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Systems Covered
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Powertrain Systems:
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Engine mechanical (including disassembly, assembly, inspection), Fuel system, Ignition system, Cooling system, Lubrication system, Exhaust system
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Drivetrain Systems:
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Manual transmission (AX-5, AX-15), Automatic transmission (AW4, Select-Shift), Transfer case (NP231 Command-Trac, NP242 Selec-Trac), Drive axles (Dana 30 front, Dana 35 rear, Chrysler 8.25 rear), Driveshafts, Wheel bearings
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Suspension Steering Systems:
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Front suspension (leaf spring, solid axle), Rear suspension (leaf spring), Steering system (power steering pump, steering gear), Shocks and struts, Ball joints, Tie rod ends
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Brake Systems:
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Front disc brakes, Rear drum brakes, Parking brake system, ABS (Anti-lock Braking System) if equipped
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Electrical Systems:
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12-volt battery system, Charging system (alternator), Starting system (starter motor), Lighting system (headlights, taillights, interior), Fuses and relays, Wiring diagrams, Instrument cluster, Power windows and locks, Audio system
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Body And Chassis:
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Body panels, Doors, Hood, Tailgate, Bumpers, Frame, Interior trim, Seats, HVAC system (heating, ventilation, air conditioning)
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Procedures Included
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Maintenance Procedures:
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Oil changes, Filter replacements, Fluid checks and top-offs, Tire rotations, Brake inspections, Spark plug replacement, Belt inspections and replacement
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Repair Procedures:
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Engine overhaul, Transmission rebuild, Clutch replacement, Differential service, Brake caliper and rotor replacement, Suspension component replacement, Electrical component diagnosis and repair, HVAC system repair
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Troubleshooting Guidance:
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Diagnostic flowcharts for common problems, Symptom-based troubleshooting, Component testing procedures
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Specifications And Tolerances:
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Torque specifications for all fasteners, Wear limits for critical components, Clearances and adjustments
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Technical Depth
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Diagnostic Capability:
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Comprehensive diagnostic trouble codes (DTCs) and their interpretations, On-board diagnostics (OBD-II) procedures
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Rebuild Instructions:
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Detailed step-by-step instructions for complete engine and transmission rebuilds, including torque sequences and clearances.
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Wiring Diagrams:
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Complete and detailed electrical system wiring diagrams for all major systems.
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Engine Specifications
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Primary Engine
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Engine Type 1:
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4.0L Inline-6 OHV 'High Output' (6-242)
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Engine Displacement 1:
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3956 cc (242 cubic inches)
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Engine Bore Stroke 1:
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3.875 in x 3.563 in (98.4 mm x 90.5 mm)
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Engine Compression Ratio 1:
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8.8:1
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Performance
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Horsepower 1:
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190 hp @ 4750 rpm (approx.)
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Torque 1:
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235 lb-ft @ 3250 rpm (approx.)
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Fuel System
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Fuel Induction 1:
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Multi-port Fuel Injection (MPI)
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Fuel Type 1:
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Unleaded Regular Gasoline
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Secondary Engine
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Engine Type 2:
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2.5L Inline-4 OHV (4-150)
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Engine Displacement 2:
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2469 cc (150 cubic inches)
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Horsepower 2:
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121 hp @ 4800 rpm (approx.)
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Torque 2:
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147 lb-ft @ 2500 rpm (approx.)
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Transmission
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Standard
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Standard Transmission:
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5-Speed Manual (AX-15 on 4.0L, AX-5 on 2.5L)
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Optional
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Optional Transmission:
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4-Speed Automatic (AW4)
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Features
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Transfer Case Options:
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NP231 Command-Trac (2WD High, 4WD High, Neutral, 4WD Low), NP242 Selec-Trac (2WD High, 4WD High Part-Time, 4WD High Full-Time, Neutral, 4WD Low)
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Fluid Specifications
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Automatic Transmission Fluid:
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ATF+3 (MS-7176D) or equivalent
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Manual Transmission Fluid:
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API GL-4, SAE 75W-90 or 80W-90 (verify specific type for AX-5/AX-15)
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Transfer Case Fluid:
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NP231/NP242: ATF+3 (MS-7176D) or equivalent
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 3,000 miles (4,800 km) or 3 months, whichever comes first (for conventional oil); consider longer intervals with synthetic oil as per manual recommendation.
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Engine Air Filter Replacement:
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Every 15,000 miles (24,000 km) or 12 months.
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Spark Plug Replacement 4.0L:
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Every 30,000 miles (48,000 km) (OEM copper plugs); longer with platinum or iridium plugs.
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Transmission Fluid Change:
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Every 30,000 miles (48,000 km) or 24 months for automatic transmissions, or sooner under severe driving conditions.
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Transfer Case Fluid Change:
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Every 30,000 miles (48,000 km) or 24 months.
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Fluid Specifications
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Engine Oil Spec:
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API SG or SH, SAE 10W-30 (check owner's manual for specific recommendations and viscosity index). Synthetic 10W-30 or 5W-30 often recommended for improved performance and longevity.
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Engine Coolant Type:
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Ethylene Glycol based coolant, typically Mopar OAT (Orange) or HOAT (Hybrid Orange) or equivalent compatible coolant. Consult manual for exact specification.
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Power Steering Fluid:
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ATF+3 (MS-7176D) or equivalent.
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Known Issues
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Common Wear Items:
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Leaf spring bushings, track bar bushings, U-joints, water pump, alternator, radiator, headliner sag (interior fabric).
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4.0L Engine Concerns:
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Crankshaft position sensor failures, rear main seal leaks, cracked cylinder heads (less common on later models).
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Electrical Issues:
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Headlight switch failures, intermittent wiper issues, fuse box corrosion.
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Maintenance Schedule Overview
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Comprehensive Intervals:
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The manual provides detailed intervals for all major maintenance items, including checks, replacements, and fluid changes, tailored for different driving conditions.
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Vehicle History
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Brand Heritage
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Jeep Legacy:
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Jeep's heritage is rooted in rugged, go-anywhere capability, a reputation built through military vehicles and iconic models like the CJ and Wrangler.
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Model Evolution
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Cherokee Xj Introduction:
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The XJ Cherokee, introduced for the 1984 model year, revolutionized the SUV market with its unibody construction, offering a lighter, more car-like ride than traditional body-on-frame SUVs.
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1997 Facelift:
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The 1997 model year marked a significant mid-cycle refresh for the XJ, including revised exterior styling (new grille, headlights, front fenders, hood, and rear liftgate), updated interior with a new dashboard and improved ergonomics, and enhanced safety features.
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Production
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Production Period:
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1984-2001 (North America)
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Manufacturing Locations:
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Toledo, Ohio, USA
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