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Jeep CHEROKEE XJ Complete Workshop Repair Manual 1994

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1994 Codes Chassis Code: XJ Platform: Jeep Cherokee (XJ) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-road vehicle Key Selling Points: Proven off-road capability, rugged construction, accessible maintenance Competitive Analysis Competitors 1994: Toyota 4Runner, Ford Bronco II, Nissan Pathfinder, Chevrolet S-10 Blazer Key Features Manual Benefit: Enables DIY repairs, saving significant costs compared to dealership service Manual Value: Provides professional-level technical information for accurate diagnosis and repair 📋 Manual Details Coverage Areas Primary Coverage: North America Engine Coverage: 4.0L Inline-6 (242 ci) 'High Output', 2.5L Inline-4 (150 ci) Transmission Coverage: AX-5 Manual, AX-15 Manual, AW-4 Automatic Drivetrain Coverage: 2WD (RWD), 4WD (Command-Trac, Selec-Trac) Trim Level Coverage: All trim levels including SE, Sport, Country, Classic Page Count Estimated Page Count: 1500-2500 (estimated for comprehensive professional manual) Manual Type Type: Workshop Service and Repair Manual Scope: Professional Technician Level Language Language: English Format Digital Format: Downloadable Digital Format (PC, Mac, Tablet, Smartphone Compatible) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling Engine Performance: Fuel delivery, ignition system, emissions control, engine management (ECU) Transmission Manual: AX-5, AX-15 clutch, gearbox, shifting mechanisms, driveshafts Transmission Automatic: AW-4 torque converter, valve body, internal components, cooling, controls Drivetrain: Transfer case (NV231, NP242), differentials (front and rear), axles, U-joints, CV joints Brakes: Front and rear brake systems (disc/drum), hydraulic lines, master cylinder, calipers, wheel cylinders, parking brake Suspension: Front solid axle (Dana 30), rear leaf spring suspension, shock absorbers, steering stabilizer Steering: Power steering system, steering gear, tie rods, steering column, steering wheel Electrical System: Battery, charging system (alternator), starting system (starter), lighting, instrumentation, power distribution, fuses, relays Body And Chassis: Body construction, chassis frame, doors, hood, tailgate, bumpers, interior trim, seats, glass, weatherstripping HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components, operation, and service Diagnostics: Diagnostic trouble codes (DTCs) where applicable, diagnostic procedures for various systems Procedures Included Preventative Maintenance: Oil changes, fluid checks and changes, filter replacements, tire rotations, belt inspections, spark plug replacement Routine Repairs: Brake pad/shoe replacement, muffler replacement, belt replacement, fluid hose replacement Major Repairs: Engine overhaul, transmission rebuild, differential repair, suspension component replacement Troubleshooting: Step-by-step diagnostic guides for common and complex issues Electrical Diagnostics: Wiring diagrams, component testing, circuit diagnosis Chassis And Body: Body panel alignment, glass replacement, interior trim removal/installation Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) Diagrams: Detailed exploded views, wiring diagrams, schematic diagrams Specifications: Torque values, clearances, tolerances, fluid capacities, electrical specifications Special Tools: Identification and usage of specialized tools required for specific procedures 📊 Manual Specifications File Format Digital Format Type: PDF (likely, optimized for digital viewing) Searchability: Likely text-searchable for efficient information retrieval Print Quality Printability: Designed for easy printing of specific sections or the entire manual Binding Type Digital Access: Downloadable File Paper Type Print Medium: Digital (N/A for printed product, but implies suitability for printing) ⚙️ Engine Specifications Primary Engine Engine Code 1: 242 ci (4.0L) OHV V6 (High Output) Engine Code 2: 150 ci (2.5L) OHV Inline-4 Performance 4.0L Horsepower: 177 hp @ 4500 RPM (approx.) 4.0L Torque: 220 lb-ft @ 2400 RPM (approx.) 2.5L Horsepower: 125 hp @ 4800 RPM (approx.) 2.5L Torque: 150 lb-ft @ 2400 RPM (approx.) Fuel System Fuel Delivery 1: Multi-port Fuel Injection (MPI) for 4.0L Fuel Delivery 2: Throttle Body Injection (TBI) for 2.5L Fuel Type: Unleaded Gasoline Fuel Tank Capacity: 20 gallons (75.7 L) 🔧 Transmission Standard Standard Transmission Type: AX-5 5-speed Manual (common with 2.5L) Optional Optional Transmission Type 1: AX-15 5-speed Manual (common with 4.0L) Optional Transmission Type 2: AW-4 4-speed Automatic Features Transfer Case 1: New Process (NP) 231 Command-Trac (2WD High, 4WD High, 4WD Low, Neutral) Transfer Case 2: New Process (NP) 242 Selec-Trac (2WD High, Full-Time 4WD High, Part-Time 4WD High, 4WD Low, Neutral) Axle Ratios: 3.55, 3.73, 4.10 (common depending on engine/package) Fluid Specifications Manual Transmission Fluid: API GL-5, SAE 75W-90 (AX-5, AX-15) Automatic Transmission Fluid: Chrysler ATF+3 (or equivalent Dexron III compatible) 📐 Dimensions Exterior Wheelbase: 101.4 inches (2576 mm) Length: 166.7 inches (4234 mm) Width: 66.9 inches (1700 mm) Height: 63.5 inches (1613 mm) Ground Clearance: 8.1 inches (206 mm) (approx. stock) Weights Curb Weight Min: 3220 lbs (1460 kg) (approx.) Curb Weight Max: 3650 lbs (1655 kg) (approx.) Gross Vehicle Weight Rating Gvwr: 4850-5000 lbs (2200-2268 kg) (depending on configuration) 🛡️ Safety Features Ratings NHTSA Rollover Rating: 3-star (typical for vehicles of this era) Active Features Braking System: Front disc brakes, Rear drum brakes Four Wheel Drive: Optional Command-Trac or Selec-Trac systems Passive Features Seat Belts: Front and rear seat belts, shoulder belts Airbags: Driver-side airbag (standard on most models for 1994) 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player; optional CD player Speakers: 4...
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Jeep CHEROKEE XJ Complete Workshop Repair Manual 1994
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee XJ
Year:
1994
Codes
Chassis Code:
XJ
Platform:
Jeep Cherokee (XJ)
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV / Off-road vehicle
Key Selling Points:
Proven off-road capability, rugged construction, accessible maintenance
Competitive Analysis
Competitors 1994:
Toyota 4Runner, Ford Bronco II, Nissan Pathfinder, Chevrolet S-10 Blazer
Key Features
Manual Benefit:
Enables DIY repairs, saving significant costs compared to dealership service
Manual Value:
Provides professional-level technical information for accurate diagnosis and repair
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Engine Coverage:
4.0L Inline-6 (242 ci) 'High Output', 2.5L Inline-4 (150 ci)
Transmission Coverage:
AX-5 Manual, AX-15 Manual, AW-4 Automatic
Drivetrain Coverage:
2WD (RWD), 4WD (Command-Trac, Selec-Trac)
Trim Level Coverage:
All trim levels including SE, Sport, Country, Classic
Page Count
Estimated Page Count:
1500-2500 (estimated for comprehensive professional manual)
Manual Type
Type:
Workshop Service and Repair Manual
Scope:
Professional Technician Level
Language
Language:
English
Format
Digital Format:
Downloadable Digital Format (PC, Mac, Tablet, Smartphone Compatible)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling
Engine Performance:
Fuel delivery, ignition system, emissions control, engine management (ECU)
Transmission Manual:
AX-5, AX-15 clutch, gearbox, shifting mechanisms, driveshafts
Transmission Automatic:
AW-4 torque converter, valve body, internal components, cooling, controls
Drivetrain:
Transfer case (NV231, NP242), differentials (front and rear), axles, U-joints, CV joints
Brakes:
Front and rear brake systems (disc/drum), hydraulic lines, master cylinder, calipers, wheel cylinders, parking brake
Suspension:
Front solid axle (Dana 30), rear leaf spring suspension, shock absorbers, steering stabilizer
Steering:
Power steering system, steering gear, tie rods, steering column, steering wheel
Electrical System:
Battery, charging system (alternator), starting system (starter), lighting, instrumentation, power distribution, fuses, relays
Body And Chassis:
Body construction, chassis frame, doors, hood, tailgate, bumpers, interior trim, seats, glass, weatherstripping
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system components, operation, and service
Diagnostics:
Diagnostic trouble codes (DTCs) where applicable, diagnostic procedures for various systems
Procedures Included
Preventative Maintenance:
Oil changes, fluid checks and changes, filter replacements, tire rotations, belt inspections, spark plug replacement
Routine Repairs:
Brake pad/shoe replacement, muffler replacement, belt replacement, fluid hose replacement
Major Repairs:
Engine overhaul, transmission rebuild, differential repair, suspension component replacement
Troubleshooting:
Step-by-step diagnostic guides for common and complex issues
Electrical Diagnostics:
Wiring diagrams, component testing, circuit diagnosis
Chassis And Body:
Body panel alignment, glass replacement, interior trim removal/installation
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
Diagrams:
Detailed exploded views, wiring diagrams, schematic diagrams
Specifications:
Torque values, clearances, tolerances, fluid capacities, electrical specifications
Special Tools:
Identification and usage of specialized tools required for specific procedures
📊 Manual Specifications
File Format
Digital Format Type:
PDF (likely, optimized for digital viewing)
Searchability:
Likely text-searchable for efficient information retrieval
Print Quality
Printability:
Designed for easy printing of specific sections or the entire manual
Binding Type
Digital Access:
Downloadable File
Paper Type
Print Medium:
Digital (N/A for printed product, but implies suitability for printing)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
242 ci (4.0L) OHV V6 (High Output)
Engine Code 2:
150 ci (2.5L) OHV Inline-4
Performance
4.0L Horsepower:
177 hp @ 4500 RPM (approx.)
4.0L Torque:
220 lb-ft @ 2400 RPM (approx.)
2.5L Horsepower:
125 hp @ 4800 RPM (approx.)
2.5L Torque:
150 lb-ft @ 2400 RPM (approx.)
Fuel System
Fuel Delivery 1:
Multi-port Fuel Injection (MPI) for 4.0L
Fuel Delivery 2:
Throttle Body Injection (TBI) for 2.5L
Fuel Type:
Unleaded Gasoline
Fuel Tank Capacity:
20 gallons (75.7 L)
🔧 Transmission
Standard
Standard Transmission Type:
AX-5 5-speed Manual (common with 2.5L)
Optional
Optional Transmission Type 1:
AX-15 5-speed Manual (common with 4.0L)
Optional Transmission Type 2:
AW-4 4-speed Automatic
Features
Transfer Case 1:
New Process (NP) 231 Command-Trac (2WD High, 4WD High, 4WD Low, Neutral)
Transfer Case 2:
New Process (NP) 242 Selec-Trac (2WD High, Full-Time 4WD High, Part-Time 4WD High, 4WD Low, Neutral)
Axle Ratios:
3.55, 3.73, 4.10 (common depending on engine/package)
Fluid Specifications
Manual Transmission Fluid:
API GL-5, SAE 75W-90 (AX-5, AX-15)
Automatic Transmission Fluid:
Chrysler ATF+3 (or equivalent Dexron III compatible)
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2576 mm)
Length:
166.7 inches (4234 mm)
Width:
66.9 inches (1700 mm)
Height:
63.5 inches (1613 mm)
Ground Clearance:
8.1 inches (206 mm) (approx. stock)
Weights
Curb Weight Min:
3220 lbs (1460 kg) (approx.)
Curb Weight Max:
3650 lbs (1655 kg) (approx.)
Gross Vehicle Weight Rating Gvwr:
4850-5000 lbs (2200-2268 kg) (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
3-star (typical for vehicles of this era)
Active Features
Braking System:
Front disc brakes, Rear drum brakes
Four Wheel Drive:
Optional Command-Trac or Selec-Trac systems
Passive Features
Seat Belts:
Front and rear seat belts, shoulder belts
Airbags:
Driver-side airbag (standard on most models for 1994)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player; optional CD player
Speakers:
4 or 6 speaker configurations
Driver Assistance
Cruise Control:
Optional
Connectivity
Vhf Radio:
Not applicable to this model year
🔧 Maintenance
Service Intervals
Oil Change Interval:
3000 miles (4800 km) or 3 months (severe duty) / 5000 miles (8000 km) or 6 months (normal duty)
Engine Coolant Flush:
Every 30,000 miles (48,000 km) or 24 months
Transmission Fluid Change:
Every 30,000 miles (48,000 km) for automatic, 50,000 miles (80,000 km) for manual
Transfer Case Fluid Change:
Every 30,000 miles (48,000 km)
Fluid Specifications
Engine Oil Spec:
API SG or SH, SAE 10W-30 (check manual for specific climate recommendations)
Coolant Type:
Chrysler/Mopar Antifreeze/Coolant (Green Ethylene Glycol based)
Brake Fluid Type:
DOT 3
Known Issues
Common Issue 1:
Head gasket leaks (especially on early 4.0L models, though improved by 1994)
Common Issue 2:
Cracked cylinder heads (less common on 1994 but possible)
Common Issue 3:
Water pump failures
Common Issue 4:
Leaf spring sag/breakage (due to age and load)
Common Issue 5:
Transmission cooler line leaks (AW-4)
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep's reputation for off-road prowess dating back to WWII
Model Evolution
Xj Introduction:
Introduced for the 1984 model year, a unibody SUV that redefined the segment
Xj Updates 1994:
1994 saw minor updates, including improved interior ergonomics and revised optional equipment packages. The 4.0L engine was further refined for better performance and emissions.
Production
Production Period:
1984-2001
Assembly Locations:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Accolades:
Consistently recognized as one of the most capable off-road vehicles of its era
Ratings
Consumer Reports Historical:
Often rated average to above average for reliability and owner satisfaction, particularly the 4.0L models.
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