Jeep CHEROKEE XJ Workshop Repair Manual 1988-2001

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee (XJ) Years Covered: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 Codes Chassis Code: XJ 👋 Introduction Market Position Segment: Compact SUV/Off-Road Vehicle Legacy: Renowned for its off-road capability, durability, and distinctive styling. Competitive Analysis Key Rivals: Toyota 4Runner, Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder. Key Features Off Road Prowess: Unibody construction with robust four-wheel-drive systems (Command-Trac, Selec-Trac) and solid axles provided exceptional off-road articulation and capability. Durability: Built with a reputation for longevity and resilience, making it a favorite for off-road enthusiasts and long-term owners. Design Language: Iconic boxy styling, compact dimensions for maneuverability, and a no-nonsense interior. 📋 Manual Details Coverage Areas Primary Focus: Workshop Service and Repair Page Count Estimated Page Count: Thousands (comprehensive coverage across all systems) Manual Type Type: Professional Workshop Manual Language Language: English Format Format: Downloadable Digital Format (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Full disassembly, inspection, repair, and reassembly of all engine components for all specified variants. Fuel System: Fuel injection (MPI), fuel pump, fuel pressure regulator, injectors, fuel lines, fuel tank servicing. Ignition System: Spark plugs, ignition coils, distributor (if applicable), ignition control module, wiring, timing adjustments. Cooling System: Radiator, water pump, thermostat, heater core, cooling fan (electric/mechanical), coolant types and capacities. Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, gaskets, emissions control components. Transmission Manual: Clutch, gearbox internal components, shift linkages, fluid types, capacities, and service procedures. Transmission Automatic: Torque converter, valve body, internal gear sets, seals, solenoids, fluid types, capacities, and service procedures. Drivetrain 4Wd: Transfer case (NP231, NP242), front and rear driveshafts, U-joints, axle assemblies, hub locking mechanisms. Steering System: Power steering pump, steering gear (steering box), tie rods, drag link, steering column, alignment procedures. Suspension System: Front (leaf spring, solid axle), rear (leaf spring, solid axle), shock absorbers, bushings, control arms, sway bars. Brake System: Front disc brakes, rear drum brakes (and some rear disc variants), master cylinder, brake booster, ABS (if equipped), bleeding procedures, component replacement. Electrical System Charging: Alternator, voltage regulator, battery, starter motor, wiring diagrams, charging system diagnostics. Electrical System Lighting: Headlights, taillights, interior lights, turn signals, hazard lights, bulb specifications, wiring. Electrical System Instruments: Dashboard gauges, warning lights, instrument cluster removal and repair. Body And Chassis: Body panel removal and installation, frame straightening, rust repair, interior trim, door mechanisms, glass replacement. HVAC System: Air conditioning compressor, condenser, evaporator, heater core, blower motor, controls, refrigerant types and procedures. Safety Systems: Airbags (if equipped), seat belts, child restraint systems, crashworthiness information. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, battery maintenance. Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides. Component Replacement: Step-by-step instructions for replacing virtually any component on the vehicle. Engine Rebuilding: Detailed instructions for complete engine overhaul, including specifications for machining and clearances. Transmission Overhaul: Comprehensive guides for the disassembly, repair, and reassembly of both manual and automatic transmissions. Electrical Diagnostics: Detailed wiring diagrams, component testing procedures, and troubleshooting for electrical faults. Suspension And Steering Alignment: Alignment specifications and procedures for both front and rear suspensions. Brake System Repair: Pad/shoe replacement, rotor/drum service, caliper/wheel cylinder rebuild, brake bleeding. Technical Depth Depth: Expert-level, covering everything from basic maintenance to complete factory-level rebuilds and diagnostics. Diagnostic Tools: Information pertaining to OBD-I and OBD-II diagnostic procedures and common fault codes for the era. Torque Specifications: Precise torque values for all fasteners throughout the vehicle. Clearances And Tolerances: Specifications for critical engine and drivetrain component clearances. 📊 Manual Specifications File Format Digital Format Details: Likely high-resolution PDF, optimized for digital viewing and printing of individual pages. Searchable text is a high probability for professional manuals. Print Quality Print Recommendation: Designed for professional printing, with clear diagrams and text. Binding Type Binding For Print: Typically spiral-bound or comb-bound for lay-flat use in a workshop environment (for printed versions). Paper Type Paper Quality For Print: Heavy-duty paper stock suitable for workshop conditions, resistant to grease and dirt. ⚙️ Engine Specifications Primary Engine Engine 2.5L Inline 4: 2.5L (150 ci) AMC/Jeep I4 ('Tech Four'). Approx. 125 hp, 140 lb-ft torque. MPI fuel injection. Engine 4.0L Inline 6: 4.0L (242 ci) AMC/Jeep I6 ('High Output'). Approx. 180-190 hp, 220-235 lb-ft torque. MPI fuel injection. Highly regarded for torque and durability. Performance Horsepower Range: 125 hp to 190 hp (depending on engine variant) Torque Range: 140 lb-ft to 235 lb-ft (depending on engine variant) Fuel System Injection Type: Multi-Point Fuel Injection (MPI) for most models, some earlier models may have Throttle Body Injection (TBI). Fuel Type: Unleaded gasoline (87 octane recommended, higher octane for improved performance) 🔧 Transmission Standard Manual Transmission: AX-5 5-speed manual (common with 2.5L I4), NV3550 5-speed manual (later models with 4.0L I6). Optional Automatic Transmission:...

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Type: Car

Verkoper:

Sku: 282456

Collecties: ALL Jeep

Beschikbaarheid: Op voorraad

Labels: 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 Car Cars CHEROKEE XJ Jeep Misc

Productvarianten

Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee (XJ)

Years Covered:

1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact SUV/Off-Road Vehicle

Legacy:

Renowned for its off-road capability, durability, and distinctive styling.

Competitive Analysis

Key Rivals:

Toyota 4Runner, Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder.

Key Features

Off Road Prowess:

Unibody construction with robust four-wheel-drive systems (Command-Trac, Selec-Trac) and solid axles provided exceptional off-road articulation and capability.

Durability:

Built with a reputation for longevity and resilience, making it a favorite for off-road enthusiasts and long-term owners.

Design Language:

Iconic boxy styling, compact dimensions for maneuverability, and a no-nonsense interior.

📋 Manual Details

Coverage Areas

Primary Focus:

Workshop Service and Repair

Page Count

Estimated Page Count:

Thousands (comprehensive coverage across all systems)

Manual Type

Type:

Professional Workshop Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full disassembly, inspection, repair, and reassembly of all engine components for all specified variants.

Fuel System:

Fuel injection (MPI), fuel pump, fuel pressure regulator, injectors, fuel lines, fuel tank servicing.

Ignition System:

Spark plugs, ignition coils, distributor (if applicable), ignition control module, wiring, timing adjustments.

Cooling System:

Radiator, water pump, thermostat, heater core, cooling fan (electric/mechanical), coolant types and capacities.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, gaskets, emissions control components.

Transmission Manual:

Clutch, gearbox internal components, shift linkages, fluid types, capacities, and service procedures.

Transmission Automatic:

Torque converter, valve body, internal gear sets, seals, solenoids, fluid types, capacities, and service procedures.

Drivetrain 4Wd:

Transfer case (NP231, NP242), front and rear driveshafts, U-joints, axle assemblies, hub locking mechanisms.

Steering System:

Power steering pump, steering gear (steering box), tie rods, drag link, steering column, alignment procedures.

Suspension System:

Front (leaf spring, solid axle), rear (leaf spring, solid axle), shock absorbers, bushings, control arms, sway bars.

Brake System:

Front disc brakes, rear drum brakes (and some rear disc variants), master cylinder, brake booster, ABS (if equipped), bleeding procedures, component replacement.

Electrical System Charging:

Alternator, voltage regulator, battery, starter motor, wiring diagrams, charging system diagnostics.

Electrical System Lighting:

Headlights, taillights, interior lights, turn signals, hazard lights, bulb specifications, wiring.

Electrical System Instruments:

Dashboard gauges, warning lights, instrument cluster removal and repair.

Body And Chassis:

Body panel removal and installation, frame straightening, rust repair, interior trim, door mechanisms, glass replacement.

HVAC System:

Air conditioning compressor, condenser, evaporator, heater core, blower motor, controls, refrigerant types and procedures.

Safety Systems:

Airbags (if equipped), seat belts, child restraint systems, crashworthiness information.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, battery maintenance.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides.

Component Replacement:

Step-by-step instructions for replacing virtually any component on the vehicle.

Engine Rebuilding:

Detailed instructions for complete engine overhaul, including specifications for machining and clearances.

Transmission Overhaul:

Comprehensive guides for the disassembly, repair, and reassembly of both manual and automatic transmissions.

Electrical Diagnostics:

Detailed wiring diagrams, component testing procedures, and troubleshooting for electrical faults.

Suspension And Steering Alignment:

Alignment specifications and procedures for both front and rear suspensions.

Brake System Repair:

Pad/shoe replacement, rotor/drum service, caliper/wheel cylinder rebuild, brake bleeding.

Technical Depth

Depth:

Expert-level, covering everything from basic maintenance to complete factory-level rebuilds and diagnostics.

Diagnostic Tools:

Information pertaining to OBD-I and OBD-II diagnostic procedures and common fault codes for the era.

Torque Specifications:

Precise torque values for all fasteners throughout the vehicle.

Clearances And Tolerances:

Specifications for critical engine and drivetrain component clearances.

📊 Manual Specifications

File Format

Digital Format Details:

Likely high-resolution PDF, optimized for digital viewing and printing of individual pages. Searchable text is a high probability for professional manuals.

Print Quality

Print Recommendation:

Designed for professional printing, with clear diagrams and text.

Binding Type

Binding For Print:

Typically spiral-bound or comb-bound for lay-flat use in a workshop environment (for printed versions).

Paper Type

Paper Quality For Print:

Heavy-duty paper stock suitable for workshop conditions, resistant to grease and dirt.

⚙️ Engine Specifications

Primary Engine

Engine 2.5L Inline 4:

2.5L (150 ci) AMC/Jeep I4 ('Tech Four'). Approx. 125 hp, 140 lb-ft torque. MPI fuel injection.

Engine 4.0L Inline 6:

4.0L (242 ci) AMC/Jeep I6 ('High Output'). Approx. 180-190 hp, 220-235 lb-ft torque. MPI fuel injection. Highly regarded for torque and durability.

Performance

Horsepower Range:

125 hp to 190 hp (depending on engine variant)

Torque Range:

140 lb-ft to 235 lb-ft (depending on engine variant)

Fuel System

Injection Type:

Multi-Point Fuel Injection (MPI) for most models, some earlier models may have Throttle Body Injection (TBI).

Fuel Type:

Unleaded gasoline (87 octane recommended, higher octane for improved performance)

🔧 Transmission

Standard

Manual Transmission:

AX-5 5-speed manual (common with 2.5L I4), NV3550 5-speed manual (later models with 4.0L I6).

Optional

Automatic Transmission:

AW4 4-speed automatic (common with 4.0L I6), 32RH 3-speed automatic (later models, particularly with 2.5L I4).

Features

Transfer Case Options:

NP231 Command-Trac (part-time 4WD), NP242 Selec-Trac (full-time 4WD option).

📐 Dimensions

Exterior

Wheelbase:

101.4 inches (2576 mm)

Length:

167.5 - 170.2 inches (4255 - 4323 mm) depending on bumper style.

Width:

69.4 - 70.0 inches (1763 - 1778 mm)

Height:

63.4 - 65.8 inches (1610 - 1671 mm)

Weights

Curb Weight Range:

Approx. 3,300 - 3,800 lbs (1497 - 1724 kg)

Towing Capacity:

Up to 5,000 lbs (2268 kg) with proper equipment and engine.

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating 1997:

4-star driver, 5-star passenger (for specific models/years)

Active Features

Anti-lock Braking System (ABS) available on some models and years, typically rear-wheel or 4-wheel.

Passive Features

Airbags:

Driver-side airbag standard from 1994 onwards; passenger airbag optional on some later models.

Seat Belts:

Front and rear seat belts, with driver and front passenger pretensioners on later models.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette tape player, optional CD player on later models. Speaker configurations varied by trim level.

Driver Assistance

Cruise Control:

Available on most trim levels.

Connectivity

Power Windows Locks:

Available on higher trim levels, often part of an options package.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, depending on driving conditions (refer to manual for precise intervals).

Transmission Fluid Change:

Automatic: Every 30,000-60,000 miles (48,000-96,000 km) or as recommended by severe duty cycles. Manual: Inspect periodically, change if contaminated or worn.

Coolant Flush:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.

Fluid Specifications

Engine Oil 4.0L:

API SJ or higher, SAE 10W-30 conventional or synthetic.

Engine Oil 2.5L:

API SJ or higher, SAE 5W-30 or 10W-30 conventional or synthetic.

Transmission Fluid Aw4:

ATF+3 or ATF+4 (Chrysler/Mopar Specification).

Transmission Fluid Ax-5:

GL-3 or GL-4 gear oil, SAE 75W-90 or 80W-90.

Coolant:

Chrysler/Mopar Antifreeze/Coolant (50/50 mix with distilled water), or equivalent HOAT coolant.

Power Steering Fluid:

ATF+3 or ATF+4 (Chrysler/Mopar Specification).

Known Issues

Cooling System Leaks:

Common issues include radiator leaks, water pump failures, and heater core leaks, particularly with age.

Engine Mounts:

Engine mounts can degrade over time, leading to vibrations and clunking noises.

Leaf Spring Sag:

Rear leaf springs can sag due to age and load, impacting ride height and load-carrying capacity.

Rust And Corrosion:

Vulnerable areas include rocker panels, floor pans, and wheel wells, especially in regions with road salt.

Power Steering Pump Leaks:

The power steering pump can develop leaks, typically at the shaft seal or reservoir.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep has a long-standing heritage in producing rugged, off-road capable vehicles since World War II.

Model Evolution

Xj Introduction:

Introduced in 1984, the XJ was revolutionary for its time as one of the first compact SUVs built with unibody construction, offering a lighter and more car-like ride than traditional body-on-frame SUVs.

Xj Facelift 1997:

Significant styling refresh for 1997, featuring new interior and exterior styling cues, improved aerodynamics, and updated powertrain options. This manual covers the post-1997 refresh.

Production

Production Years Global:

1984-2001 in North America, continued production in other markets for longer.

Manufacturing Locations:

Mainly Toledo, Ohio, USA.

🏆 Awards & Recognition

Recognitions

Four Wheeler Magazine:

Consistently praised by off-road publications for its capability and durability.

Motor Trend SUV Of The Year:

While not a direct 'SUV of the Year' winner in its primary XJ form during its initial release, its longevity and impact cemented its status as an icon.