Jeep Cherokee XJ 1988-2001 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Chassis Code: XJ Generation Generation Years: 1984-2001 Codes Covered Years: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 👋 Introduction Market Position Segment: Compact SUV, Sport Utility Vehicle Target Audience: Off-road enthusiasts, adventure seekers, practical everyday users Competitive Analysis Competitors Era: Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder, Toyota 4Runner Key Features Design Philosophy: Unibody construction for lighter weight and better ride comfort compared to body-on-frame rivals Off Road Capability: Command-Trac and Selec-Trac 4x4 systems, good ground clearance, solid axle rear (initially) Durability: Renowned for its robust powertrain and chassis, especially the 4.0L engine Iconic Status: Long production run, strong aftermarket support, beloved by enthusiasts for its classic styling and capability 📋 Manual Details Coverage Areas Areas Covered: All systems and components for Jeep Cherokee XJ models from 1988-2001 Page Count Estimated Page Count: 1500+ Manual Type Type: Comprehensive Workshop Service Repair Manual Language Language: English Format Format: Digital (PDF, often searchable) 📖 Manual Coverage Systems Covered Engine: 4.0L Inline-6 (AMC 242), 2.5L Inline-4 (AMC 150), 2.1L Turbo Diesel (VM Motori), 2.5L Turbo Diesel (VM Motori) Transmission: AX-4, AX-5, AX-15, AW-4 (automatic), NV242, NV231 (transfer cases) Drivetrain: Front and rear axles (Dana 30, Dana 35, Chrysler 8.25), 4WD systems, differentials Brakes: Front disc, rear drum/disc (depending on year/trim), ABS systems Suspension: Front leaf spring (early), coil spring (late), rear leaf spring, shock absorbers, steering components Electrical: Starting and charging system, ignition system, lighting, accessories, instrument cluster, body control modules HVAC: Air conditioning, heating, ventilation system components and diagnostics Body: Body panels, doors, glass, interior trim, bumpers, exterior trim Chassis: Frame, subframes, exhaust system, fuel system, cooling system Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and flushes, tune-ups, brake inspections Repair: Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component diagnostics and replacement Troubleshooting: Diagnostic charts, symptom-based troubleshooting guides for various systems Diagnostics: OBD-I and OBD-II diagnostic codes, sensor testing, circuit testing Specifications: Torque specifications, clearances, fluid capacities, wiring diagrams, vacuum diagrams Technical Depth Depth: Full workshop level, suitable for professional mechanics and experienced DIYers Detail Level: Step-by-step instructions, exploded diagrams, detailed component removal and installation procedures 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Quality: High-resolution scans, clear text and images, often printable Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: AMC 242 Engine Displacement 1: 4.0 Liters (3957 cc) Engine Configuration 1: Inline-6, Overhead Valve (OHV) Bore Stroke 1: 3.875 in x 3.5625 in (98.4 mm x 90.5 mm) Compression Ratio 1: 8.8:1 (typical) Horsepower 1 Early: 177 hp @ 4700 rpm (approx. 1988-1990) Horsepower 1 Late: 190 hp @ 4600 rpm (approx. 1991-2001) Torque 1 Early: 220 lb-ft @ 2500 rpm (approx. 1988-1990) Torque 1 Late: 225 lb-ft @ 3000 rpm (approx. 1991-2001) Engine Code 2 Engine Code 2: AMC 150 Engine Displacement 2: 2.5 Liters (2497 cc) Engine Configuration 2: Inline-4, Overhead Valve (OHV), High Output (HO) version introduced in 1991 Horsepower 2: 121 hp @ 4800 rpm (early), 130 hp @ 4800 rpm (HO) Torque 2: 145 lb-ft @ 2400 rpm (early), 157 lb-ft @ 2400 rpm (HO) Fuel System Fuel Delivery Early: Throttle Body Injection (TBI) - some early models Fuel Delivery Late: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended) Ignition System: Distributorless Ignition System (DIS) from ~1991 onwards 🔧 Transmission Standard Transmission Early Manual Transmission Early: AX-4 (4-speed manual) Standard Transmission Late Manual Transmission Late: AX-5 (5-speed manual), AX-15 (5-speed manual - common with 4.0L) Optional Transmission Automatic Transmission: AW-4 (4-speed automatic, electronically controlled) Transfer Cases Transfer Case Options: NV231 (Command-Trac part-time 4WD), NV242 (Selec-Trac full-time 4WD) Features Transmission Fluid Spec Aw4: Dexron III (or equivalent) Transmission Fluid Capacity Aw4: Approx. 7-9 quarts (depending on torque converter drain) Manual Transmission Fluid Spec: GL-3 or GL-4 (check specific manual for details, typically 75W-90) 📐 Dimensions Exterior Length: Approx. 173.5 - 174.5 inches (440.7 - 443.2 mm) Width: Approx. 70.1 - 71.0 inches (1781 - 1803 mm) Height: Approx. 63.5 - 64.5 inches (1613 - 1638 mm) Wheelbase: 104.4 inches (2652 mm) Weights Curb Weight: Approx. 3100 - 3600 lbs (1406 - 1633 kg) Gross Vehicle Weight Rating Gvw: Approx. 4700 - 5000 lbs (2132 - 2268 kg) Cargo Cargo Volume Behind Rear Seat: Approx. 30.5 cu ft (0.86 m³) Cargo Volume With Rear Seat Folded: Approx. 69.0 cu ft (1.95 m³) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 3-star (Varies slightly by year and configuration, due to SUV nature) Passive Features Airbags: Driver and passenger airbags (introduced later in the XJ run, standard from mid-90s) Seatbelts: Three-point seatbelts (front and rear, lap belts for center rear often) โครงสร้าง: Unibody construction with integrated roll cage...

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Type: Car

Vendor:

Sku: 413692

Collections: ALL Jeep

Availability: In stock

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

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee

Chassis Code:

Generation

Generation Years:

1984-2001

Codes

Covered Years:

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

👋 Introduction

Market Position

Segment:

Compact SUV, Sport Utility Vehicle

Target Audience:

Off-road enthusiasts, adventure seekers, practical everyday users

Competitive Analysis

Competitors Era:

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

Key Features

Design Philosophy:

Unibody construction for lighter weight and better ride comfort compared to body-on-frame rivals

Off Road Capability:

Command-Trac and Selec-Trac 4x4 systems, good ground clearance, solid axle rear (initially)

Durability:

Renowned for its robust powertrain and chassis, especially the 4.0L engine

Iconic Status:

Long production run, strong aftermarket support, beloved by enthusiasts for its classic styling and capability

📋 Manual Details

Coverage Areas

Areas Covered:

All systems and components for Jeep Cherokee XJ models from 1988-2001

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Comprehensive Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF, often searchable)

📖 Manual Coverage

Systems Covered

Engine:

4.0L Inline-6 (AMC 242), 2.5L Inline-4 (AMC 150), 2.1L Turbo Diesel (VM Motori), 2.5L Turbo Diesel (VM Motori)

Transmission:

AX-4, AX-5, AX-15, AW-4 (automatic), NV242, NV231 (transfer cases)

Drivetrain:

Front and rear axles (Dana 30, Dana 35, Chrysler 8.25), 4WD systems, differentials

Brakes:

Front disc, rear drum/disc (depending on year/trim), ABS systems

Suspension:

Front leaf spring (early), coil spring (late), rear leaf spring, shock absorbers, steering components

Electrical:

Starting and charging system, ignition system, lighting, accessories, instrument cluster, body control modules

HVAC:

Air conditioning, heating, ventilation system components and diagnostics

Body:

Body panels, doors, glass, interior trim, bumpers, exterior trim

Chassis:

Frame, subframes, exhaust system, fuel system, cooling system

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and flushes, tune-ups, brake inspections

Repair:

Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component diagnostics and replacement

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting guides for various systems

Diagnostics:

OBD-I and OBD-II diagnostic codes, sensor testing, circuit testing

Specifications:

Torque specifications, clearances, fluid capacities, wiring diagrams, vacuum diagrams

Technical Depth

Depth:

Full workshop level, suitable for professional mechanics and experienced DIYers

Detail Level:

Step-by-step instructions, exploded diagrams, detailed component removal and installation procedures

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Print Quality

Quality:

High-resolution scans, clear text and images, often printable

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

AMC 242

Engine Displacement 1:

4.0 Liters (3957 cc)

Engine Configuration 1:

Inline-6, Overhead Valve (OHV)

Bore Stroke 1:

3.875 in x 3.5625 in (98.4 mm x 90.5 mm)

Compression Ratio 1:

8.8:1 (typical)

Horsepower 1 Early:

177 hp @ 4700 rpm (approx. 1988-1990)

Horsepower 1 Late:

190 hp @ 4600 rpm (approx. 1991-2001)

Torque 1 Early:

220 lb-ft @ 2500 rpm (approx. 1988-1990)

Torque 1 Late:

225 lb-ft @ 3000 rpm (approx. 1991-2001)

Engine Code 2

Engine Code 2:

AMC 150

Engine Displacement 2:

2.5 Liters (2497 cc)

Engine Configuration 2:

Inline-4, Overhead Valve (OHV), High Output (HO) version introduced in 1991

Horsepower 2:

121 hp @ 4800 rpm (early), 130 hp @ 4800 rpm (HO)

Torque 2:

145 lb-ft @ 2400 rpm (early), 157 lb-ft @ 2400 rpm (HO)

Fuel System

Fuel Delivery Early:

Throttle Body Injection (TBI) - some early models

Fuel Delivery Late:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Ignition System:

Distributorless Ignition System (DIS) from ~1991 onwards

🔧 Transmission

Standard Transmission Early

Manual Transmission Early:

AX-4 (4-speed manual)

Standard Transmission Late

Manual Transmission Late:

AX-5 (5-speed manual), AX-15 (5-speed manual - common with 4.0L)

Optional Transmission

Automatic Transmission:

AW-4 (4-speed automatic, electronically controlled)

Transfer Cases

Transfer Case Options:

NV231 (Command-Trac part-time 4WD), NV242 (Selec-Trac full-time 4WD)

Features

Transmission Fluid Spec Aw4:

Dexron III (or equivalent)

Transmission Fluid Capacity Aw4:

Approx. 7-9 quarts (depending on torque converter drain)

Manual Transmission Fluid Spec:

GL-3 or GL-4 (check specific manual for details, typically 75W-90)

📐 Dimensions

Exterior

Length:

Approx. 173.5 - 174.5 inches (440.7 - 443.2 mm)

Width:

Approx. 70.1 - 71.0 inches (1781 - 1803 mm)

Height:

Approx. 63.5 - 64.5 inches (1613 - 1638 mm)

Wheelbase:

104.4 inches (2652 mm)

Weights

Curb Weight:

Approx. 3100 - 3600 lbs (1406 - 1633 kg)

Gross Vehicle Weight Rating Gvw:

Approx. 4700 - 5000 lbs (2132 - 2268 kg)

Cargo

Cargo Volume Behind Rear Seat:

Approx. 30.5 cu ft (0.86 m³)

Cargo Volume With Rear Seat Folded:

Approx. 69.0 cu ft (1.95 m³)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star (Varies slightly by year and configuration, due to SUV nature)

Passive Features

Airbags:

Driver and passenger airbags (introduced later in the XJ run, standard from mid-90s)

Seatbelts:

Three-point seatbelts (front and rear, lap belts for center rear often)

โครงสร้าง:

Unibody construction with integrated roll cage structure

Active Features

Anti-lock Braking System (ABS) available as an option or standard on some later models, typically rear-wheel only until later iterations.

💡 Technology Features

Infotainment

Infotainment Early:

Basic AM/FM radio, cassette player, optional CD player.

Infotainment Late:

More integrated audio systems, optional premium sound, some models may have had early attempts at navigation systems but were rare.

Driver Assistance

Driver Assistance Early:

Minimal; focused on core driving functions.

Driver Assistance Late:

ABS (as noted in safety), cruise control.

Connectivity

Connectivity Late:

Optional power windows, power locks, keyless entry on some higher trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions and oil type used. Refer to manual for specifics.

Coolant Flush Interval:

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

Transmission Fluid Change Interval:

Every 30,000-60,000 miles (48,000-96,000 km), more frequently for heavy use.

Spark Plug Replacement 4.0L:

Approx. 100,000 miles (160,000 km) with modern iridium or platinum plugs.

Fluid Specifications

Engine Oil Spec 4.0L:

API SG/SH, SAE 10W-30 recommended by Jeep. 10W-30 or 10W-40 depending on climate. Check manual for precise recommendations.

Engine Oil Capacity 4.0L:

6 Quarts (5.7 Liters) with filter.

Coolant Spec:

Chrysler HOAT (Hybrid Organic Acid Technology) antifreeze/coolant or equivalent, typically a green type. Mix 50/50 with distilled water.

Brake Fluid Spec:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Known Issues

Common Issue 1:

Cracked cylinder heads on the 4.0L engine (especially earlier versions, though less common on later models due to design changes). Mopar or aftermarket performance heads are often replacements.

Common Issue 2:

Oil filter housing leaks (common on the 4.0L).

Common Issue 3:

Leaf spring wear and sag, especially on older, higher-mileage vehicles.

Common Issue 4:

Heater core leaks (often leads to a musty smell inside the cabin).

Common Issue 5:

Power steering pump whine or leaks.

Common Issue 6:

Rust, particularly on rocker panels, rear quarter panels, and floor pans. Rust prevention and treatment are crucial.

Common Issue 7:

TPS (Throttle Position Sensor) failure leading to erratic acceleration or stalling.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep's long history in 4x4 vehicles, built on the Willys MB foundation, emphasizing ruggedness and capability.

Model Evolution

Xj Introduction:

Introduced in 1984 as a replacement for the CJ-7 based Scrambler, pioneering the compact SUV segment with its unibody design.

Key Updates 1988-2001:

Major facelifts include the 1991 redesign (new interior, revised exterior styling, introduction of 4.0L HO and improved aerodynamics), and further refinements through the late 90s. Introduction of OBD-II in 1996.

Production

Production Period:

1984-2001 (US Market)

Manufacturing Plants:

Toledo, Ohio, USA

Ownership Changes:

Produced under AMC, then Chrysler Corporation, later DaimlerChrysler, and finally Fiat Chrysler Automobiles (FCA).

🏆 Awards & Recognition

Recognitions

Motor Trend SUV Of The Year:

Motor Trend's 4x4 of the Year in 1993.

Popular Mechanics Car Of The Year:

Recognized by Popular Mechanics for its engineering and versatility.

Ratings

Off Road Magazines:

Consistently highly rated in off-road enthusiast publications for its capability.