1984-1993 Jeep Cherokee XJ Service Repair Workshop Manual (1984 1985 1986 1987 1988 1989 1990 1991 1992 1993)

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Chassis Code: XJ Applicable Model Years: 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993 Codes Product Name: 1984-1993 Jeep Cherokee XJ Service Repair Workshop Manual 👋 Introduction Market Position Vehicle Segment: Compact SUV Jeep Cherokee Xj Significance: Pioneered the unibody construction for SUVs, offering a blend of off-road capability and on-road comfort. Highly influential in establishing the modern SUV market. Competitive Analysis Key Competitors Era: Ford Bronco II, Chevrolet S-10 Blazer, GMC S-15 Jimmy, Toyota 4Runner, Nissan Pathfinder. Key Features Unibody Construction: Revolutionary for its time, providing a lighter and more car-like ride compared to traditional body-on-frame SUVs. Off Road Capability: Renowned for its legendary Jeep off-road prowess, often enhanced by the available 4WD systems and robust suspension. Engine Options: Offered a range of reliable and capable engines, with the 4.0L inline-six becoming particularly iconic for its torque and durability. Interior Versatility: Practical interior layout with folding rear seats offering significant cargo space for its class. 📋 Manual Details Coverage Areas Engine Variants Covered: 2.5L AMC I4 (150 cu in), 4.0L AMC I6 (242 cu in), 2.1L turbodiesel (Renault J8S), 2.8L V6 (GM LR2/LC8) Transmission Variants Covered: AX4, AX5, AX15 (manual), AW4 (automatic), TF-904, TF-999, TF-727 (automatic) Drivetrain Variants Covered: 2WD (RWD), 4WD (Command-Trac, Selec-Trac) Page Count Estimated Page Count: Over 1000 pages (typical for comprehensive factory service manuals of this era) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Digital (PDF) - typically searchable and printable 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures, component diagnostics, lubrication systems, cooling systems, fuel delivery and injection systems, exhaust systems, emission controls. Transmission And Drivetrain: Manual and automatic transmission overhaul, clutch service, transfer case operation and repair, propeller shaft service, axle overhaul (Dana 30 front, Chrysler 8.25/Dana 44 rear). Suspension And Steering: Front and rear suspension (leaf spring and coil spring configurations), steering gear, power steering systems, wheel alignment specifications. Brakes: Front disc and rear drum brake systems, power brake systems, parking brake, hydraulic system diagnostics and repair, ABS (where applicable). Electrical System: Battery, starting system, charging system, ignition system, lighting, instrumentation, power windows, power locks, wipers, horn, fuse box diagrams, wiring schematics for all major systems. Body And Chassis: Body panel removal and installation, interior trim, doors, windows, bumpers, chassis lubrication, rustproofing. HVAC: Heating, ventilation, and air conditioning system diagnostics and repair. Procedures Included Maintenance: Routine maintenance schedules, oil changes, filter replacements, fluid checks and changes, tune-up procedures, spark plug replacement, belt inspection and replacement. Troubleshooting: Systematic diagnostic charts for common problems related to engine performance, starting issues, transmission slippage, electrical faults, and braking problems. Repair And Overhaul: Detailed, step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and reinstallation across all major vehicle systems. Diagnostics: Procedures for using diagnostic tools, interpreting error codes, and performing specific tests to identify malfunctions. Technical Specifications: Torque specifications for all fasteners, clearance specifications, resistance values, pressure readings, and other critical data. Technical Depth Depth Of Coverage: Comprehensive - covers everything from basic scheduled maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics. 📊 Manual Specifications File Format Digital File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Diagram Quality: High-quality diagrams, illustrations, and schematics. Text Legibility: Easy-to-read text sections with clear formatting. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 2.5 Liters (150 cubic inches) Engine 1 Configuration: Inline 4-Cylinder (I4) Engine 1 Valvetrain: Overhead Valve (OHV) Engine 1 Power Approx: 125 hp @ 4800 rpm Engine 1 Torque Approx: 150 lb-ft @ 2800 rpm Engine 2 Displacement: 4.0 Liters (242 cubic inches) Engine 2 Configuration: Inline 6-Cylinder (I6) Engine 2 Valvetrain: Overhead Valve (OHV) Engine 2 Power Approx: 177 hp @ 4700 rpm (later models) Engine 2 Torque Approx: 220 lb-ft @ 3200 rpm (later models) Optional Engine Optional Engine 1 Displacement: 2.8 Liters (171 cubic inches) Optional Engine 1 Configuration: V6 (GM LR2/LC8) Optional Engine 1 Power Approx: 114 hp @ 4800 rpm Optional Engine 1 Torque Approx: 150 lb-ft @ 2000 rpm Optional Engine 2 Displacement: 2.1 Liters (127 cubic inches) Optional Engine 2 Configuration: Inline 4-Cylinder (I4) Turbo Diesel (Renault J8S) Optional Engine 2 Power Approx: 85 hp @ 3750 rpm Optional Engine 2 Torque Approx: 132 lb-ft @ 2000 rpm Fuel System Fuel Injection Type: Multi-point Fuel Injection (MPI) for 4.0L I6, Throttle Body Injection (TBI) for 2.5L I4 (early years), Electronic Fuel Injection (EFI) for later 2.5L I4. Fuel Type Recommendation: Unleaded gasoline (Octane rating as per manual, typically 87) 🔧 Transmission Standard Standard Transmission Type: AX4 (4-speed manual - early years), AX5 (5-speed manual - common) Optional Optional Transmission Type 1: AX15 (5-speed manual - later models, preferred) Optional Transmission...

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Tags: 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 Car Cars Cherokee XJ Jeep Misc

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee

Chassis Code:

Applicable Model Years:

1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993

Codes

Product Name:

1984-1993 Jeep Cherokee XJ Service Repair Workshop Manual

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV

Jeep Cherokee Xj Significance:

Pioneered the unibody construction for SUVs, offering a blend of off-road capability and on-road comfort. Highly influential in establishing the modern SUV market.

Competitive Analysis

Key Competitors Era:

Ford Bronco II, Chevrolet S-10 Blazer, GMC S-15 Jimmy, Toyota 4Runner, Nissan Pathfinder.

Key Features

Unibody Construction:

Revolutionary for its time, providing a lighter and more car-like ride compared to traditional body-on-frame SUVs.

Off Road Capability:

Renowned for its legendary Jeep off-road prowess, often enhanced by the available 4WD systems and robust suspension.

Engine Options:

Offered a range of reliable and capable engines, with the 4.0L inline-six becoming particularly iconic for its torque and durability.

Interior Versatility:

Practical interior layout with folding rear seats offering significant cargo space for its class.

📋 Manual Details

Coverage Areas

Engine Variants Covered:

2.5L AMC I4 (150 cu in), 4.0L AMC I6 (242 cu in), 2.1L turbodiesel (Renault J8S), 2.8L V6 (GM LR2/LC8)

Transmission Variants Covered:

AX4, AX5, AX15 (manual), AW4 (automatic), TF-904, TF-999, TF-727 (automatic)

Drivetrain Variants Covered:

2WD (RWD), 4WD (Command-Trac, Selec-Trac)

Page Count

Estimated Page Count:

Over 1000 pages (typical for comprehensive factory service manuals of this era)

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF) - typically searchable and printable

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul procedures, component diagnostics, lubrication systems, cooling systems, fuel delivery and injection systems, exhaust systems, emission controls.

Transmission And Drivetrain:

Manual and automatic transmission overhaul, clutch service, transfer case operation and repair, propeller shaft service, axle overhaul (Dana 30 front, Chrysler 8.25/Dana 44 rear).

Suspension And Steering:

Front and rear suspension (leaf spring and coil spring configurations), steering gear, power steering systems, wheel alignment specifications.

Brakes:

Front disc and rear drum brake systems, power brake systems, parking brake, hydraulic system diagnostics and repair, ABS (where applicable).

Electrical System:

Battery, starting system, charging system, ignition system, lighting, instrumentation, power windows, power locks, wipers, horn, fuse box diagrams, wiring schematics for all major systems.

Body And Chassis:

Body panel removal and installation, interior trim, doors, windows, bumpers, chassis lubrication, rustproofing.

HVAC:

Heating, ventilation, and air conditioning system diagnostics and repair.

Procedures Included

Maintenance:

Routine maintenance schedules, oil changes, filter replacements, fluid checks and changes, tune-up procedures, spark plug replacement, belt inspection and replacement.

Troubleshooting:

Systematic diagnostic charts for common problems related to engine performance, starting issues, transmission slippage, electrical faults, and braking problems.

Repair And Overhaul:

Detailed, step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and reinstallation across all major vehicle systems.

Diagnostics:

Procedures for using diagnostic tools, interpreting error codes, and performing specific tests to identify malfunctions.

Technical Specifications:

Torque specifications for all fasteners, clearance specifications, resistance values, pressure readings, and other critical data.

Technical Depth

Depth Of Coverage:

Comprehensive - covers everything from basic scheduled maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.

📊 Manual Specifications

File Format

Digital File Type:

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Diagram Quality:

High-quality diagrams, illustrations, and schematics.

Text Legibility:

Easy-to-read text sections with clear formatting.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

2.5 Liters (150 cubic inches)

Engine 1 Configuration:

Inline 4-Cylinder (I4)

Engine 1 Valvetrain:

Overhead Valve (OHV)

Engine 1 Power Approx:

125 hp @ 4800 rpm

Engine 1 Torque Approx:

150 lb-ft @ 2800 rpm

Engine 2 Displacement:

4.0 Liters (242 cubic inches)

Engine 2 Configuration:

Inline 6-Cylinder (I6)

Engine 2 Valvetrain:

Overhead Valve (OHV)

Engine 2 Power Approx:

177 hp @ 4700 rpm (later models)

Engine 2 Torque Approx:

220 lb-ft @ 3200 rpm (later models)

Optional Engine

Optional Engine 1 Displacement:

2.8 Liters (171 cubic inches)

Optional Engine 1 Configuration:

V6 (GM LR2/LC8)

Optional Engine 1 Power Approx:

114 hp @ 4800 rpm

Optional Engine 1 Torque Approx:

150 lb-ft @ 2000 rpm

Optional Engine 2 Displacement:

2.1 Liters (127 cubic inches)

Optional Engine 2 Configuration:

Inline 4-Cylinder (I4) Turbo Diesel (Renault J8S)

Optional Engine 2 Power Approx:

85 hp @ 3750 rpm

Optional Engine 2 Torque Approx:

132 lb-ft @ 2000 rpm

Fuel System

Fuel Injection Type:

Multi-point Fuel Injection (MPI) for 4.0L I6, Throttle Body Injection (TBI) for 2.5L I4 (early years), Electronic Fuel Injection (EFI) for later 2.5L I4.

Fuel Type Recommendation:

Unleaded gasoline (Octane rating as per manual, typically 87)

🔧 Transmission

Standard

Standard Transmission Type:

AX4 (4-speed manual - early years), AX5 (5-speed manual - common)

Optional

Optional Transmission Type 1:

AX15 (5-speed manual - later models, preferred)

Optional Transmission Type 2:

AW4 (4-speed automatic - common, very robust)

Optional Transmission Type 3:

TF-904, TF-999, TF-727 (3-speed automatic - older applications or heavier duty)

Features

Transfer Case Options:

Command-Trac (Part-time 4WD), Selec-Trac (Full-time 4WD)

Manual Transmission Fluid Spec:

GL-3 or GL-4 gear oil (refer to manual for specific fill)

Automatic Transmission Fluid Spec:

ATF+3 or ATF+4 ( Chrysler spec, check manual for early specific recommendations)

📐 Dimensions

Exterior

Wheelbase:

101.4 inches

Length:

166.7 inches (approx.)

Width:

69.4 inches (approx.)

Height:

63.7 inches (approx.)

Ground Clearance:

Varies by model and tire size, typically 8-10 inches

Cargo

Cargo Volume Behind Rear Seat:

Approximately 30-40 cu ft (varies slightly by year/configuration)

Cargo Volume With Rear Seat Folded:

Approximately 70-80 cu ft

Weights

Curb Weight:

Approximately 3,200 - 3,600 lbs (varies by engine, drivetrain, and options)

Gross Vehicle Weight Rating Gvwr:

Approximately 4,600 - 5,000 lbs

Towing Capacity:

Up to 2,000-3,500 lbs (depending on configuration and equipment)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

Not rated by NHTSA in modern standardized format during this era; however, SUVs of this type were generally prone to higher rollover risk.

Active Features

Braking System Type:

Front disc, rear drum (standard). Some later models may have offered rear disc options or early ABS systems.

Optional on some later models, typically rear-wheel only ABS during this production run.

Passive Features

Seatbelts:

Standard lap and shoulder belts (front), lap belts (rear, often with optional shoulder belts).

Airbags:

No airbags were standard or optional on this generation XJ. Airbags were not common in SUVs of this era.

💡 Technology Features

Infotainment

Radio System:

AM/FM radio, optional cassette player, and later optional CD player; basic analog controls.

Speaker Configuration:

Typically 2 or 4 speakers.

Driver Assistance

Cruise Control:

Optional on most models.

Anti Lock Braking System ABS:

Available on some later models, typically RWD only.

Connectivity

Connectivity Options:

No advanced connectivity features like Bluetooth or USB; basic power accessories if equipped.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 6 months, whichever comes first (depending on oil type and driving conditions - check manual for specifics).

Transmission Fluid Change Interval:

Every 30,000-60,000 miles for automatic transmissions, refer to manual for manual transmissions. Consider more frequent changes for severe use.

Coolant Flush Interval:

Every 30,000-50,000 miles or 2-3 years.

Spark Plug Replacement Interval:

Typically 30,000-60,000 miles depending on plug type (copper vs. platinum/iridium).

Fluid Specifications

Engine Oil Type Viscosity:

10W-30 or 10W-40 (check manual for specific recommendations based on temperature).

Engine Oil Capacity:

4.0L I6: 5 US quarts (with filter); 2.5L I4: 5 US quarts (with filter).

Coolant Type:

Ethylene glycol based antifreeze (green color), 50/50 mixture with distilled water.

Power Steering Fluid Type:

ATF or specific power steering fluid (check manual).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Engine Cooling System:

Water pump leaks, thermostat issues, radiator leaks are common; overheating can lead to head gasket failure on the 4.0L.

Transmission Issues:

AX5 manual transmission synchro wear; AW4 automatic transmission kickdown issues or solenoids failing.

Suspension Wear:

Leaf spring sag, worn shackle bushings, ball joint wear, and worn control arm bushings due to off-road use and age.

Electrical Gremlins:

Aging wiring harnesses, failing grounds, and worn switches can lead to intermittent electrical problems.

Rust And Corrosion:

Frame rails, rocker panels, and fender wells are susceptible to rust, especially in areas with salt used on roads.

Exhaust Manifold:

The 4.0L I6 is known for cracking exhaust manifolds, leading to exhaust leaks and ticking noises.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep has a storied history in off-road vehicles, originating with military vehicles in WWII. The brand is synonymous with capability and adventure.

Model Evolution

Xj Introduction:

Introduced in 1984 as a revolutionary compact SUV, designed to compete with smaller car-based SUVs and offer a more refined experience than traditional Jeeps.

Xj Generation Timeline:

First Generation (XJ): 1984-1996. This manual covers the first half of the XJ's lifespan, including significant updates like the introduction of the 4.0L I6 engine in 1987.

Key Updates Within Generation:

1987: Introduction of the 4.0L HO I6, revised interior, new dashboard, improved aerodynamics. 1991: Front fascia refresh, new interior trim. 1993: Introduction of the Chrysler 8.25 rear axle as an option.

Production

Manufacturing Location:

Primarily Toledo, Ohio, USA.

Production Duration:

1984-2001 (though this manual covers only up to 1993 models).

🏆 Awards & Recognition

Recognitions

Automotive Journalism Accolades:

Consistently praised for its blend of capability, comfort, and utility, earning it a loyal following and numerous positive reviews during its production run. Often cited as a benchmark in the compact SUV segment.

Jeep Cherokee Xj Popularity:

Remains a highly sought-after vehicle in the used market due to its off-road prowess, customization potential, and robust mechanicals.

Ratings

Off Road Ratings:

Universally recognized as a highly capable off-road vehicle, often rated higher than competitors in its class due to its design and available 4x4 systems.

Certifications

Manufacturer Certification:

Factory Service Manual - produced by or for the manufacturer (Chrysler/AMC/Jeep) to provide authorized service and repair information.