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Jeep Cherokee XJ 1994 Workshop Service Manual for Repair

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$141.00
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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1994 Codes Chassis Code: XJ 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Competitive Analysis Key Competitors 1994: Toyota 4Runner, Ford Explorer, Nissan Pathfinder, Chevrolet S-10 Blazer Key Features Chassis Design: Unibody construction providing a balance of rigidity and weight savings, a departure from body-on-frame SUVs of its era. Off Road Capability: Renowned for its off-road prowess, featuring available Command-Trac (2WD/4WD part-time) and Selec-Trac (2WD/4WD full-time) transfer cases. 📋 Manual Details Coverage Areas General: Comprehensive repair and service for the 1994 Jeep Cherokee XJ Page Count Total Pages: 1756 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed diagnostics, repair, overhaul, and specifications for all engine types Engine Management: Fuel injection systems (MPI), ignition systems, emission controls, ECU diagnostics Transmission Manual: Repair, overhaul, and specifications for manual transmissions Transmission Automatic: Repair, overhaul, and specifications for automatic transmissions Drivetrain: Front axle, rear axle, differentials, drive shafts, CV joints Suspension: Front and rear suspension components, alignment, shock absorbers, springs Steering: Power steering system, steering gear, tie rods, linkages Brakes: Front and rear brake systems (disc/drum), hydraulic systems, ABS (if equipped), parking brake Electrical System: Battery, charging system, starting system, lighting, accessories, wiring diagrams Body And Frame: Exterior body panels, interior trim, glass, doors, tailgate, chassis repairs HVAC: Heating, ventilation, and air conditioning system diagnosis and repair Emissions Control: Catalytic converter, EGR system, evaporative emission control Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Troubleshooting: Systematic diagnostic procedures, fault code interpretation, common problem solutions Repair: Step-by-step repair procedures for all major components and systems Overhaul: Complete engine and transmission overhaul procedures Disassembly Assembly: Detailed instructions for component disassembly and reassembly Specifications Data: Torque specifications, clearances, test procedures, diagnostic values Technical Depth Level: Professional-level diagnostic and repair, suitable for DIY mechanics and professional technicians 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchable: Yes (text-searchable PDF) Print Quality Quality: High-resolution, clear text and diagrams Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code 1: 4.0L OHV V6 (242 ci) Engine Description 1: AMC 242 Straight-6 OHV Performance 1 Horsepower 1: 177 hp @ 4700 rpm Torque 1: 220 lb-ft @ 3200 rpm Engine Code 2 Engine Code 2: 2.5L OHV I4 (150 ci) Engine Description 2 Engine Description 2: AMC 150 Straight-4 OHV Performance 2 Horsepower 2: 125 hp @ 4500 rpm Torque 2: 147 lb-ft @ 2500 rpm Fuel System Fuel Delivery: Multi-Port Fuel Injection (MPI) Fuel Type Fuel Type: Unleaded Gasoline Engine Codes Engine Codes 1994: 4.0L: 8th VIN digit 'X'; 2.5L: 8th VIN digit 'E' 🔧 Transmission Standard Transmission Standard Transmission Type: 4-Speed Automatic (AW4) Optional Transmission Optional Transmission Type: 5-Speed Manual (AX-5) Features Transfer Case Options: Command-Trac (NV231) part-time 4WD, Selec-Trac (NV242) full-time 4WD Fluid Specifications Automatic Transmission Fluid: ATF+3 (Chrysler specification Mopar) Manual Transmission Fluid: Mopar Manual Transmission Lubricant (or equivalent GL-3/GL-4 gear oil) Fluid Capacity Automatic Capacity Aw4: Approx. 8 US quarts (7.6 liters) for service fill Fluid Capacity Manual Capacity Ax5: Approx. 2.4 US quarts (2.3 liters) 📐 Dimensions Exterior Wheelbase: 101.4 inches (2576 mm) Length: 167.9 inches (4265 mm) Width: 69.9 inches (1775 mm) Height: 63.4 inches (1610 mm) (without roof rack) Weights Curb Weight Approx: 3,300 - 3,600 lbs (1497 - 1633 kg) Gross Vehicle Weight Rating Gvwr: Approx. 4,750 - 5,200 lbs (2154 - 2359 kg) Cargo Cargo Volume Behind Rear Seat: Approx. 30.0 cubic feet (850 liters) Cargo Volume With Rear Seat Folded: Approx. 69.0 cubic feet (1954 liters) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: Three-star rating (earlier versions of testing methodology) Passive Features Seat Belts: Front and rear seat belts Airbags: Driver-side airbag standard for 1994 model year Active Features ABS: Optional Anti-lock Braking System (ABS) on rear wheels 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player available. Speaker Configuration: Typically 4 or 6 speakers depending on trim level. Driver Assistance Cruise Control: Available electronic cruise control. Instrument Cluster: Analog gauges (speedometer, tachometer, fuel, temperature, oil pressure), warning lights. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 miles (4,800 km) or 3 months (under normal driving conditions); 1,500 miles (2,400 km) or 3 months (under severe driving conditions). Air Filter Replacement: Inspect every 15,000 miles (24,000 km), replace as needed. Spark Plug Replacement 4.0L: Approx. 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type. Refer to manual for specific recommendations. Transmission Fluid Change Automatic: Every 30,000 - 60,000 miles (48,000 - 96,000 km) or as per severe service schedule. Fluid Specifications Engine Oil 4.0L And 2.5L: API Service Classification SG, SH, or SJ; SAE 10W-30 viscosity recommended...
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Jeep Cherokee XJ 1994 Workshop Service Manual for RepairJeep Cherokee XJ 1994 Workshop Service Manual for RepairJeep Cherokee XJ 1994 Workshop Service Manual for RepairJeep Cherokee XJ 1994 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee XJ
Year:
1994
Codes
Chassis Code:
XJ
👋 Introduction
Market Position
Segment:
Compact SUV / Off-Road Vehicle
Competitive Analysis
Key Competitors 1994:
Toyota 4Runner, Ford Explorer, Nissan Pathfinder, Chevrolet S-10 Blazer
Key Features
Chassis Design:
Unibody construction providing a balance of rigidity and weight savings, a departure from body-on-frame SUVs of its era.
Off Road Capability:
Renowned for its off-road prowess, featuring available Command-Trac (2WD/4WD part-time) and Selec-Trac (2WD/4WD full-time) transfer cases.
📋 Manual Details
Coverage Areas
General:
Comprehensive repair and service for the 1994 Jeep Cherokee XJ
Page Count
Total Pages:
1756
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed diagnostics, repair, overhaul, and specifications for all engine types
Engine Management:
Fuel injection systems (MPI), ignition systems, emission controls, ECU diagnostics
Transmission Manual:
Repair, overhaul, and specifications for manual transmissions
Transmission Automatic:
Repair, overhaul, and specifications for automatic transmissions
Drivetrain:
Front axle, rear axle, differentials, drive shafts, CV joints
Suspension:
Front and rear suspension components, alignment, shock absorbers, springs
Steering:
Power steering system, steering gear, tie rods, linkages
Brakes:
Front and rear brake systems (disc/drum), hydraulic systems, ABS (if equipped), parking brake
Electrical System:
Battery, charging system, starting system, lighting, accessories, wiring diagrams
Body And Frame:
Exterior body panels, interior trim, glass, doors, tailgate, chassis repairs
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair
Emissions Control:
Catalytic converter, EGR system, evaporative emission control
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Troubleshooting:
Systematic diagnostic procedures, fault code interpretation, common problem solutions
Repair:
Step-by-step repair procedures for all major components and systems
Overhaul:
Complete engine and transmission overhaul procedures
Disassembly Assembly:
Detailed instructions for component disassembly and reassembly
Specifications Data:
Torque specifications, clearances, test procedures, diagnostic values
Technical Depth
Level:
Professional-level diagnostic and repair, suitable for DIY mechanics and professional technicians
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchable:
Yes (text-searchable PDF)
Print Quality
Quality:
High-resolution, clear text and diagrams
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
4.0L OHV V6 (242 ci)
Engine Description 1:
AMC 242 Straight-6 OHV
Performance 1
Horsepower 1:
177 hp @ 4700 rpm
Torque 1:
220 lb-ft @ 3200 rpm
Engine Code 2
Engine Code 2:
2.5L OHV I4 (150 ci)
Engine Description 2
Engine Description 2:
AMC 150 Straight-4 OHV
Performance 2
Horsepower 2:
125 hp @ 4500 rpm
Torque 2:
147 lb-ft @ 2500 rpm
Fuel System
Fuel Delivery:
Multi-Port Fuel Injection (MPI)
Fuel Type
Fuel Type:
Unleaded Gasoline
Engine Codes
Engine Codes 1994:
4.0L: 8th VIN digit 'X'; 2.5L: 8th VIN digit 'E'
🔧 Transmission
Standard Transmission
Standard Transmission Type:
4-Speed Automatic (AW4)
Optional Transmission
Optional Transmission Type:
5-Speed Manual (AX-5)
Features
Transfer Case Options:
Command-Trac (NV231) part-time 4WD, Selec-Trac (NV242) full-time 4WD
Fluid Specifications
Automatic Transmission Fluid:
ATF+3 (Chrysler specification Mopar)
Manual Transmission Fluid:
Mopar Manual Transmission Lubricant (or equivalent GL-3/GL-4 gear oil)
Fluid Capacity Automatic
Capacity Aw4:
Approx. 8 US quarts (7.6 liters) for service fill
Fluid Capacity Manual
Capacity Ax5:
Approx. 2.4 US quarts (2.3 liters)
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2576 mm)
Length:
167.9 inches (4265 mm)
Width:
69.9 inches (1775 mm)
Height:
63.4 inches (1610 mm) (without roof rack)
Weights
Curb Weight Approx:
3,300 - 3,600 lbs (1497 - 1633 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 4,750 - 5,200 lbs (2154 - 2359 kg)
Cargo
Cargo Volume Behind Rear Seat:
Approx. 30.0 cubic feet (850 liters)
Cargo Volume With Rear Seat Folded:
Approx. 69.0 cubic feet (1954 liters)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
Three-star rating (earlier versions of testing methodology)
Passive Features
Seat Belts:
Front and rear seat belts
Airbags:
Driver-side airbag standard for 1994 model year
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on rear wheels
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player available.
Speaker Configuration:
Typically 4 or 6 speakers depending on trim level.
Driver Assistance
Cruise Control:
Available electronic cruise control.
Instrument Cluster:
Analog gauges (speedometer, tachometer, fuel, temperature, oil pressure), warning lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles (4,800 km) or 3 months (under normal driving conditions); 1,500 miles (2,400 km) or 3 months (under severe driving conditions).
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed.
Spark Plug Replacement 4.0L:
Approx. 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type. Refer to manual for specific recommendations.
Transmission Fluid Change Automatic:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) or as per severe service schedule.
Fluid Specifications
Engine Oil 4.0L And 2.5L:
API Service Classification SG, SH, or SJ; SAE 10W-30 viscosity recommended for most ambient temperatures (check owner's manual for specific temperature ranges).
Coolant:
Chrysler/Mopar Antifreeze/Coolant (50/50 mix with distilled water) or equivalent ethylene glycol-based coolant.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Issues 1:
Cracking of the cylinder head on the 4.0L inline-six engine (especially earlier models, though 1994 is less prone but still possible).
Common Issues 2:
desgaste de los componentes de la suspensión (ball joints, tie rod ends, bushings) debido al uso off-road y la edad del vehículo.
Common Issues 3:
Leaks from the rear main crankshaft seal and oil filter housing.
Common Issues 4:
Interior electronic component failures (e.g., blower motor resistor, window regulators) due to age and heat exposure.
Common Issues 5:
Rust and corrosion, particularly in the rocker panels, floor pans, and rear quarter panels, especially in areas with road salt.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a long history of producing rugged, capable off-road vehicles dating back to World War II with the Willys MB.
Model Evolution
Cherokee Xj Introduction:
The Jeep Cherokee XJ was first introduced for the 1984 model year, pioneering the compact SUV segment with its unibody construction.
Cherokee Xj 1994 Updates:
The 1994 model year saw significant updates including revised interior and exterior styling, dual airbags, and the introduction of the OBD-II compliant engine management system.
Production
Production Years:
1984-2001 (North America)
Manufacturing Locations:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Automotive Press Awards:
The Jeep Cherokee XJ was frequently lauded by automotive publications for its capability and value proposition in the SUV market throughout its production run.
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