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Jeep Cherokee XJ 1984-1996 Workshop Service Manual Repair

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$133.00
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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Model Code: XJ Generation Generation Name: First Generation Generation Years: 1984-2001 Codes Chassis Code: XJ 👋 Introduction Market Position Segment: Compact SUV / Sport Utility Vehicle Target Audience: Off-road enthusiasts, outdoor adventurers, everyday drivers seeking utility and capability Competitive Analysis Key Competitors: Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner, Nissan Pathfinder Key Features Body On Frame: Yes (robust construction for off-road durability) Unibody Construction: Yes (revolutionary for its time, contributing to lighter weight and better on-road manners compared to body-on-frame competitors) 4X4 Capability: Yes (iconic Selec-Trac and Command-Trac transfer cases) Compact Size: Yes (agile and maneuverable for urban and trail use) 📋 Manual Details Coverage Areas Applicable Years: 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 Page Count Estimated Pages: 1500+ Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (including disassembly, assembly, diagnosis, and overhaul) Engine Electrical: Yes (including ignition, fuel injection, sensors, actuators, wiring diagrams) Transmission Manual: Yes (for manual transmissions like AX-5, AX-15) Transmission Automatic: Yes (for automatic transmissions like AW4, 30RH) Drivetrain 4X4: Yes (including NP231 transfer case, Dana 30 front axle, Dana 35/44 rear axle) Suspension: Yes (front leaf spring/coil spring systems, rear leaf spring suspension, shocks, bushings) Steering: Yes (power steering system, steering column, linkages) Brakes: Yes (front disc, rear drum/disc systems, ABS where applicable, hydraulics, parking brake) Cooling System: Yes (radiator, fan, water pump, thermostat, coolant types) Fuel System: Yes (fuel tank, pump, injectors, lines, pressure) Exhaust System: Yes (manifold, catalytic converter, muffler, pipes) Electrical System Body: Yes (lighting, wipers, horn, power windows/locks, interior components) HVAC: Yes (heating, ventilation, air conditioning system) Body Interior: Yes (trim panels, seats, dashboard components) Body Exterior: Yes (doors, fenders, hood, tailgate, glass, bumpers) Procedures Included Routine Maintenance: Yes (oil changes, filter replacements, fluid checks, lubrication) Troubleshooting: Yes (diagnostic flowcharts, symptom-based troubleshooting) Repair Procedures: Yes (step-by-step instructions for component removal and installation) Overhaul Rebuild: Yes (detailed instructions for engine, transmission, and axle rebuilds) Diagnostics: Yes (including OBD-I system information for applicable years) Wiring Diagrams: Yes (comprehensive electrical schematics) Specifications Data: Yes (torque values, clearances, tolerances) Technical Depth Depth: Comprehensive (from basic maintenance to full engine and drivetrain rebuilds) 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF Printable: Yes Print Quality Quality: N/A (Digital Format) Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 2.5L: 2.5L AMC "Tech" I4 (Standard for most years) Engine Code 4.0L: 4.0L AMC I6 (Optional for most years, standard on higher trims later in generation) Performance 2.5L Horsepower: Approx. 125 hp @ 4800 rpm Torque: Approx. 150 lb-ft @ 2800 rpm Performance 4.0L Horsepower: Approx. 177-190 hp @ 4750 rpm (varies by year) Torque: Approx. 220-235 lb-ft @ 3000-3500 rpm (varies by year) Fuel System Fuel Delivery 2.5L: Throttle Body Injection (TBI) early, Multi-Point Fuel Injection (MPFI) later Fuel Delivery 4.0L: Multi-Point Fuel Injection (MPFI) Fuel Type Required Fuel: Unleaded gasoline 🔧 Transmission Standard Standard Transmission: 4-speed automatic (AW4) became common, 5-speed manual (AX-15) also prevalent Optional Optional Transmission: 4-speed automatic (30RH, later years), 3-speed automatic (904, early years), 5-speed manual (AX-5, early years) Features Transfer Case: New Process NP231 (part-time 4WD with 2WD, 4WD High, 4WD Low, Neutral options) common; Selec-Trac (full-time 4WD) available on some models Fluid Specifications Aw4 Fluid Type: Dexron III/Mercon Automatic Transmission Fluid Fluid Specifications Ax15 Fluid Type: ATF+4 or equivalent manual transmission fluid (check specific manual for exact spec) 📐 Dimensions Exterior Wheelbase Wheelbase: 101.4 inches (2576 mm) Exterior Length Length: Approx. 167.4 inches (4252 mm) Exterior Width Width: Approx. 69.9 inches (1775 mm) Exterior Height Height: Approx. 63.8 inches (1621 mm) Cargo Cargo Volume Behind Rear Seat: Approx. 30.5 cu ft (864 L) Cargo Volume With Rear Seat Folded: Approx. 70.2 cu ft (1988 L) Weights Curb Weight: Approx. 3,200 - 3,600 lbs (1451 - 1633 kg), varies by configuration Gross Vehicle Weight Rating Gvwr: Approx. 4,500 - 4,900 lbs (2041 - 2223 kg), varies by configuration 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: Good (for later models with improved structural integrity and restraint systems, early models may vary) NHTSA Frontal Impact Passenger: Good (for later models with improved structural integrity and restraint systems, early models may vary) Active Features ABS: Optional on some models, standard on later 4.0L High Output models Passive Features Airbags: Driver-side airbag introduced mid-generation (around 1994-1995), passenger airbag not typically available for this generation Seatbelts: 3-point front seat belts, 2-point rear seat belts (later models may have 3-point rear) 💡 Technology Features Infotainment Audio System: Factory AM/FM radio with cassette player was standard. Optional CD player or premium sound systems available on higher trims. Basic speaker configurations. Driver Assistance Cruise...
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Jeep Cherokee XJ 1984-1996 Workshop Service Manual Repair
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee XJ
Model Code:
XJ
Generation
Generation Name:
First Generation
Generation Years:
1984-2001
Codes
Chassis Code:
XJ
👋 Introduction
Market Position
Segment:
Compact SUV / Sport Utility Vehicle
Target Audience:
Off-road enthusiasts, outdoor adventurers, everyday drivers seeking utility and capability
Competitive Analysis
Key Competitors:
Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner, Nissan Pathfinder
Key Features
Body On Frame:
Yes (robust construction for off-road durability)
Unibody Construction:
Yes (revolutionary for its time, contributing to lighter weight and better on-road manners compared to body-on-frame competitors)
4X4 Capability:
Yes (iconic Selec-Trac and Command-Trac transfer cases)
Compact Size:
Yes (agile and maneuverable for urban and trail use)
📋 Manual Details
Coverage Areas
Applicable Years:
1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Yes (including disassembly, assembly, diagnosis, and overhaul)
Engine Electrical:
Yes (including ignition, fuel injection, sensors, actuators, wiring diagrams)
Transmission Manual:
Yes (for manual transmissions like AX-5, AX-15)
Transmission Automatic:
Yes (for automatic transmissions like AW4, 30RH)
Drivetrain 4X4:
Yes (including NP231 transfer case, Dana 30 front axle, Dana 35/44 rear axle)
Suspension:
Yes (front leaf spring/coil spring systems, rear leaf spring suspension, shocks, bushings)
Steering:
Yes (power steering system, steering column, linkages)
Brakes:
Yes (front disc, rear drum/disc systems, ABS where applicable, hydraulics, parking brake)
Cooling System:
Yes (radiator, fan, water pump, thermostat, coolant types)
Fuel System:
Yes (fuel tank, pump, injectors, lines, pressure)
Exhaust System:
Yes (manifold, catalytic converter, muffler, pipes)
Electrical System Body:
Yes (lighting, wipers, horn, power windows/locks, interior components)
HVAC:
Yes (heating, ventilation, air conditioning system)
Body Interior:
Yes (trim panels, seats, dashboard components)
Body Exterior:
Yes (doors, fenders, hood, tailgate, glass, bumpers)
Procedures Included
Routine Maintenance:
Yes (oil changes, filter replacements, fluid checks, lubrication)
Troubleshooting:
Yes (diagnostic flowcharts, symptom-based troubleshooting)
Repair Procedures:
Yes (step-by-step instructions for component removal and installation)
Overhaul Rebuild:
Yes (detailed instructions for engine, transmission, and axle rebuilds)
Diagnostics:
Yes (including OBD-I system information for applicable years)
Wiring Diagrams:
Yes (comprehensive electrical schematics)
Specifications Data:
Yes (torque values, clearances, tolerances)
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine and drivetrain rebuilds)
📊 Manual Specifications
File Format
Quality:
High-resolution, searchable PDF
Printable:
Yes
Print Quality
Quality:
N/A (Digital Format)
Binding Type
Type:
N/A (Digital Format)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 2.5L:
2.5L AMC "Tech" I4 (Standard for most years)
Engine Code 4.0L:
4.0L AMC I6 (Optional for most years, standard on higher trims later in generation)
Performance 2.5L
Horsepower:
Approx. 125 hp @ 4800 rpm
Torque:
Approx. 150 lb-ft @ 2800 rpm
Performance 4.0L
Horsepower:
Approx. 177-190 hp @ 4750 rpm (varies by year)
Torque:
Approx. 220-235 lb-ft @ 3000-3500 rpm (varies by year)
Fuel System
Fuel Delivery 2.5L:
Throttle Body Injection (TBI) early, Multi-Point Fuel Injection (MPFI) later
Fuel Delivery 4.0L:
Multi-Point Fuel Injection (MPFI)
Fuel Type
Required Fuel:
Unleaded gasoline
🔧 Transmission
Standard
Standard Transmission:
4-speed automatic (AW4) became common, 5-speed manual (AX-15) also prevalent
Optional
Optional Transmission:
4-speed automatic (30RH, later years), 3-speed automatic (904, early years), 5-speed manual (AX-5, early years)
Features
Transfer Case:
New Process NP231 (part-time 4WD with 2WD, 4WD High, 4WD Low, Neutral options) common; Selec-Trac (full-time 4WD) available on some models
Fluid Specifications Aw4
Fluid Type:
Dexron III/Mercon Automatic Transmission Fluid
Fluid Specifications Ax15
Fluid Type:
ATF+4 or equivalent manual transmission fluid (check specific manual for exact spec)
📐 Dimensions
Exterior Wheelbase
Wheelbase:
101.4 inches (2576 mm)
Exterior Length
Length:
Approx. 167.4 inches (4252 mm)
Exterior Width
Width:
Approx. 69.9 inches (1775 mm)
Exterior Height
Height:
Approx. 63.8 inches (1621 mm)
Cargo
Cargo Volume Behind Rear Seat:
Approx. 30.5 cu ft (864 L)
Cargo Volume With Rear Seat Folded:
Approx. 70.2 cu ft (1988 L)
Weights
Curb Weight:
Approx. 3,200 - 3,600 lbs (1451 - 1633 kg), varies by configuration
Gross Vehicle Weight Rating Gvwr:
Approx. 4,500 - 4,900 lbs (2041 - 2223 kg), varies by configuration
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Good (for later models with improved structural integrity and restraint systems, early models may vary)
NHTSA Frontal Impact Passenger:
Good (for later models with improved structural integrity and restraint systems, early models may vary)
Active Features
ABS:
Optional on some models, standard on later 4.0L High Output models
Passive Features
Airbags:
Driver-side airbag introduced mid-generation (around 1994-1995), passenger airbag not typically available for this generation
Seatbelts:
3-point front seat belts, 2-point rear seat belts (later models may have 3-point rear)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player was standard. Optional CD player or premium sound systems available on higher trims. Basic speaker configurations.
Driver Assistance
Cruise Control:
Available on most trims.
Connectivity
Connectivity Options:
Minimal by modern standards; typically limited to optional power accessories and basic radio connectivity.
🔧 Maintenance
Service Intervals Oil Change
Interval:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used.
Service Intervals Oil Filter
Interval:
Replace with every oil change.
Service Intervals Air Filter
Interval:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Service Intervals Coolant Flush
Interval:
Every 30,000-50,000 miles or 2-3 years, using appropriate coolant type.
Service Intervals Transmission Fluid
Interval:
Automatic: Every 30,000-50,000 miles. Manual: Check for leaks, fluid replacement per manual recommendation.
Fluid Specifications
Engine Oil 2.5L:
10W-30 or 5W-30 (refer to manual for climate specific recommendations)
Engine Oil 4.0L:
10W-30 or 5W-30 (refer to manual for climate specific recommendations)
Coolant:
Ethylene Glycol based, typically a 50/50 mix with distilled water. Mopar Antifreeze/Coolant (MS-7170) or equivalent.
Brake Fluid:
DOT 3 or DOT 4 (check manual for exact specification)
Known Issues
Head Gaskets 4.0L:
Historically, some 4.0L engines experienced head gasket failures due to coolant leaks and overheating. Regular maintenance and preventing overheating are crucial.
Crankshaft Position Sensor Cps:
Common failure point on 4.0L engines, leading to stalling or no-start conditions. Often located in a difficult-to-access spot.
Power Steering Pump:
Can develop leaks or whine over time.
Rust And Corrosion:
Can affect floor pans, rocker panels, and frame rails, especially in rust-belt regions.
Leaf Spring Sag:
Rear leaf springs can sag over time, affecting ride height and load capacity.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Founded on military vehicle development, Jeep has a long history of producing capable off-road vehicles.
Model Evolution
First Generation Xj:
Launched in 1984, the XJ was a radical departure for Jeep, featuring unibody construction and a more modern, car-like interior and driving experience while retaining significant off-road prowess.
Major Updates 1984-1996:
Significant updates included the introduction of the 4.0L inline-six engine (1987), updated interior and exterior styling cues (facelifts in 1991 and 1997), and improvements to safety and emissions systems.
Production
Production Start Year:
1984
Production End Year:
2001 (XJ production for North America ended in 2001, with some export markets continuing longer)
Manufacturing Locations:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
4X4 Magazine Title:
Often cited in off-road publications for its capability and durability.
Ratings
Consumer Reports Rating:
Variable by year; some years received better reliability ratings than others, with the 4.0L engine generally praised for longevity.
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