Jeep Cherokee XJ 1994 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1994 Codes Chassis Code: XJ Engine Code Primary: 4.0L Inline-6 (AMC 242) Engine Code Optional: 2.5L Inline-4 (AMC 150) 👋 Introduction Market Position Segment: Compact SUV Usp: Renowned for its off-road capability, ruggedness, and reliable powertrain in a compact and manageable package. Competitive Analysis Key Competitors 1994: Toyota 4Runner, Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder Key Features Off Road Capability: Command-Trac and Selec-Trac 4WD systems, solid front axle (early models) transitioning to Dana 30 or Dana 35 axles, good ground clearance. Powertrain Reliability: The legendary 4.0L AMC 242 inline-six engine is highly regarded for its durability and torque. Practicality: Compact size offers maneuverability, while the interior provides ample cargo space for its class. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Secondary Coverage: Diagnostics, Troubleshooting, Maintenance, Overhaul Page Count Estimated Pages: Approximately 1000+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine (4.0L & 2.5L), Transmission (Automatic & Manual), Transfer Case, Driveline Chassis: Suspension (Front & Rear), Steering, Brakes (Front Disc/Rear Drum, Optional Rear Disc), Wheels & Tires Electrical: 12V System, Battery, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Powertrain Control Module (PCM), Body Control Modules, Fuses & Relays, Wiring Diagrams Body And Trim: Exterior Body Panels, Interior Trim, Seats, Doors, Windows, Roof (Fixed, Optional Sunroof), HVAC System, Emissions Control System Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks & Top-offs, Spark Plug Replacement, Belt Inspections & Replacement, Brake Pad/Shoe Replacement, Tire Rotation Repair And Overhaul: Engine Rebuilding, Transmission Overhaul, Differential Repair, Suspension Component Replacement, Brake System Repair, Electrical Component Diagnosis & Replacement, HVAC System Service Diagnostics And Troubleshooting: Component Testing, Diagnostic Trouble Codes (DTCs), Symptom-based Troubleshooting Guides, Electrical Schematics Interpretation Technical Depth Depth: Comprehensive, covering everything from basic preventative maintenance to full engine and transmission rebuilds, including detailed torque specifications and diagnostic procedures. 📊 Manual Specifications File Format Quality: High-resolution scans, often with searchable text for ease of navigation. Searchability: Optimized for keyword searching of specific components, symptoms, or procedures. Print Quality Printability: Designed for clear printing of individual pages or sections as needed. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Name: 4.0L High Output Inline-6 (242 cu. in.) Bore X Stroke 40L: 3.875 in. x 3.560 in. (98.4 mm x 90.4 mm) Compression Ratio 40L: 8.8:1 Horsepower 40L 1994: 177 hp @ 4500 rpm Torque 40L 1994: 220 lb-ft @ 2500 rpm Optional Engine Engine Name: 2.5L (150 cu. in.) Inline-4 Bore X Stroke 25L: 3.875 in. x 3.250 in. (98.4 mm x 82.5 mm) Compression Ratio 25L: 8.7:1 Horsepower 25L 1994: 125 hp @ 4800 rpm Torque 25L 1994: 145 lb-ft @ 2800 rpm Fuel System Induction: Multi-Point Fuel Injection (MPFI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Engine Management ECU Type: Chrysler/Jeep NGC (Next Generation Controller) or equivalent for the era. 🔧 Transmission Standard Transmission Type 40L: 4-Speed Automatic (AW4) Transmission Type 25L: 5-Speed Manual (AX-5) Optional Transmission Type Optional: 4-Speed Automatic (700R4/AW4) for 2.5L, 5-Speed Manual (NV3550 or AX-15) for 4.0L. Features Transfer Case Options: Selec-Trac (Part-Time 4WD, 2WD High, 4WD High Auto), Command-Trac (Part-Time 4WD only). Fluid Specifications Automatic Transmission Fluid: ATF+3 (Chrysler Mopar) Manual Transmission Fluid: GL-3 or GL-4 Hypoid Gear Oil, 75W-90 📐 Dimensions Exterior Wheelbase: 101.4 inches (2576 mm) Length: 167.5 inches (4255 mm) Width: 71.5 inches (1816 mm) Height: 63.4 inches (1610 mm) Weights Curb Weight Min Max: Approx. 3300 - 3700 lbs (1497 - 1678 kg) Gross Vehicle Weight Rating: Approx. 4600 - 4900 lbs (2087 - 2223 kg) Cargo Cargo Volume Behind Rear Seat: Approx. 30.5 cu. ft. (0.86 m³) Cargo Volume With Rear Seat Folded: Approx. 73.3 cu. ft. (2.08 m³) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 3-Star (Vehicle Specific Rating) Active Features Brakes: Front Disc Brakes, Rear Drum Brakes (Optional Rear Disc available on some trims). ABS available on some models. Steering: Power Assisted Steering Passive Features Airbags: Driver-side airbag standard. Seat Belts: 3-point front seat belts with pretensioners, 2-point rear seat belts (lap belts in center). Structure: Unibody construction with integrated roll cage elements for improved rigidity and crashworthiness. 💡 Technology Features Infotainment Audio System: AM/FM Stereo with Cassette Player. Optional CD player available on higher trims. Speakers: Typically 4 or 6 speaker configuration. Driver Assistance Cruise Control: Optional Connectivity Connectivity Features: Basic; primarily focused on analog vehicle systems. No factory Bluetooth or USB integration. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 miles or 3 months (recommended for optimal longevity). Air Filter Replacement: Every 12,000 - 15,000 miles or 12 months. Spark Plug Replacement 40L: Every 30,000 - 60,000 miles depending on plug type (e.g., copper vs. platinum). Transmission...
Comprehensive, covering everything from basic preventative maintenance to full engine and transmission rebuilds, including detailed torque specifications and diagnostic procedures.
📊 Manual Specifications
File Format
Quality:
High-resolution scans, often with searchable text for ease of navigation.
Searchability:
Optimized for keyword searching of specific components, symptoms, or procedures.
Print Quality
Printability:
Designed for clear printing of individual pages or sections as needed.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Name:
4.0L High Output Inline-6 (242 cu. in.)
Bore X Stroke 40L:
3.875 in. x 3.560 in. (98.4 mm x 90.4 mm)
Compression Ratio 40L:
8.8:1
Horsepower 40L 1994:
177 hp @ 4500 rpm
Torque 40L 1994:
220 lb-ft @ 2500 rpm
Optional Engine
Engine Name:
2.5L (150 cu. in.) Inline-4
Bore X Stroke 25L:
3.875 in. x 3.250 in. (98.4 mm x 82.5 mm)
Compression Ratio 25L:
8.7:1
Horsepower 25L 1994:
125 hp @ 4800 rpm
Torque 25L 1994:
145 lb-ft @ 2800 rpm
Fuel System
Induction:
Multi-Point Fuel Injection (MPFI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Engine Management
ECU Type:
Chrysler/Jeep NGC (Next Generation Controller) or equivalent for the era.
🔧 Transmission
Standard
Transmission Type 40L:
4-Speed Automatic (AW4)
Transmission Type 25L:
5-Speed Manual (AX-5)
Optional
Transmission Type Optional:
4-Speed Automatic (700R4/AW4) for 2.5L, 5-Speed Manual (NV3550 or AX-15) for 4.0L.
Rust in rocker panels, rear quarter panels, tailgate, and floor pans. Cracked dashboard and door panels due to age.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a long-standing heritage of producing rugged, capable off-road vehicles dating back to its military origins in WWII.
Model Evolution
Xj Introduction:
The Cherokee XJ was introduced in 1984 as a revolutionary unibody SUV, marking a departure from traditional body-on-frame construction for SUVs. The 1994 model represents the mid-cycle refresh with updated interior and exterior styling.
1994 Updates:
Significant interior redesign including new dashboard, seats, and door panels. Exterior updates included revised front and rear fascia, and optional new wheel designs. Introduction of improved NVH (Noise, Vibration, Harshness) dampening.
Production
Production Period:
1984-2001
Manufacturing Plant:
Toledo, Ohio, USA
🏆 Awards & Recognition
Recognitions
Off Road Title:
Frequently cited as one of the 'Greatest SUVs of All Time' by automotive publications for its off-road prowess and utility.
Versatility Accolade:
Praised for its balance of daily drivability and serious off-road capability, making it a highly versatile vehicle for its era.
Certifications
Emission Compliance:
Complies with 1994 US Federal and California Emission Standards.