Jeep Cherokee 1994 Factory Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee Year: 1994 Chassis Code: XJ Generation: Second Generation (XJ Facelift) Trim Levels Covered: SE, Sport, Country, Limited (coverage may vary based on specific engine/drivetrain options) 👋 Introduction Market Position Market Position: The Jeep Cherokee (XJ) was a revolutionary compact SUV that defined the segment. It was known for its rugged capability, unibody construction (a first in its class), and legendary off-road prowess. The 1994 model represents a mature iteration of the XJ platform, benefiting from earlier refinements and facing competition from vehicles like the Toyota RAV4 and Ford Explorer. Competitive Analysis Competitive Analysis: The 1994 Cherokee continued to hold its ground against emerging car-based SUVs by emphasizing its traditional Jeep strengths: robust chassis, capable 4x4 systems, and a more utilitarian design. Its direct competitors were often more car-like, offering less off-road capability but potentially better on-road comfort and fuel economy. The XJ's unibody design offered a compromise, being lighter and more comfortable than body-on-frame SUVs of the era. Key Features Key Features: Unibody construction, Command-Trac (2WD/4WD) and Selec-Trac (full-time 4WD) systems, legendary 4.0L Inline-6 engine, durable build quality, excellent off-road articulation and capability for its size. 📋 Manual Details Coverage Areas Coverage Areas: North America Page Count Page Count: Estimated 1000+ pages (typical for factory workshop manuals of this era) Manual Type Manual Type: Factory Workshop Service Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Systems Covered: Engine Mechanical (4.0L I6, 2.5L I4), Fuel System, Ignition System, Emission Control Systems, Exhaust System, Cooling System, Lubrication System, Starting System, Charging System, Air Conditioning System, Heater & Air Conditioner, Steering System, Brake System, Suspension Systems (Front & Rear), Drivetrain (2WD/4WD), Transfer Case, Axles, Electrical System, Body Repair, Interior Components, Exterior Components, Wiper and Washer System, Lighting System, Audio & Visual System, Supplemental Restraint System (Airbags), Security System, Instrument Panel, Power Accessories. Procedures Included Procedures Included: Routine Maintenance, Scheduled Maintenance, Diagnostics and Troubleshooting, Component Removal and Installation, Repair Procedures, Overhaul and Reassembly, Electrical System Diagnosis, Wiring Diagrams, Body Panel Repair, Fluid Capacities and Specifications, Torque Specifications, Wheel Alignment Procedures, Drivetrain Adjustments, Airbag System Servicing (with safety precautions), Refrigerant Handling (with safety precautions). Technical Depth Technical Depth: Comprehensive: Covers everything from basic fluid checks and filter changes to complete engine and transmission rebuilds, complex electrical diagnostics, and body panel repair. Includes detailed exploded views, diagrams, and troubleshooting flowcharts. Specific Procedures Engine Specific Procedures Engine: Engine overhaul (cylinder head removal/installation, piston/ring replacement, crankshaft/bearing service), camshaft timing, valve adjustment (if applicable), fuel injector testing/replacement, ignition coil/distributor servicing. Specific Procedures Transmission Specific Procedures Transmission: Automatic transmission fluid and filter change, manual transmission clutch inspection and replacement, transfer case gear oil change, driveshaft U-joint inspection and replacement. Specific Procedures Brakes Specific Procedures Brakes: Brake pad and rotor replacement (front), brake shoe and drum service (rear), brake caliper overhaul, brake line replacement, ABS system troubleshooting (if equipped). Specific Procedures Suspension Specific Procedures Suspension: Front and rear shock absorber replacement, coil spring inspection/replacement, control arm bushing replacement, ball joint and tie rod end replacement, steering linkage service, wheel bearing service. Specific Procedures Electrical Specific Procedures Electrical: Detailed wiring diagrams for all major systems (engine control, lighting, charging, starting, accessories), component testing (starter, alternator, sensors), fuse and relay identification and testing, troubleshooting electrical faults using multimeter. Specific Procedures Body Specific Procedures Body: Door panel removal, glass replacement (windshield, side, rear), bumper removal/installation, fender panel repair, tailgate/back door mechanisms, weatherstrip replacement. Specific Procedures Diagnostics Specific Procedures Diagnostics: Troubleshooting guides for common drivability issues, no-start conditions, charging system faults, HVAC problems, and suspension/steering noises. Includes diagnostic trouble codes (DTCs) where applicable for the engine control module (ECM). Specific Procedures Air Conditioning Specific Procedures Air Conditioning: Refrigerant recovery and recharge procedures (emphasizing safety and environmental compliance), component replacement (compressor, condenser, evaporator, receiver/dryer), leak detection, system evacuation and charging. Specific Procedures Wheels Tires Specific Procedures Wheels Tires: Tire pressure specifications, wheel torque specifications, wheel stud replacement, tire rotation and balancing procedures. Specific Procedures Exterior Lighting Specific Procedures Exterior Lighting: Headlamp bulb replacement, taillight assembly replacement, side marker lamp replacement, fog lamp service. Specific Procedures Interior Components Specific Procedures Interior Components: Seat removal and installation, headliner removal, dashboard trim panel removal, center console disassembly, interior light replacement. Specific Procedures Parking Brake Specific Procedures Parking Brake: Parking brake cable adjustment and replacement, parking brake shoe inspection and replacement. Specific Procedures Wiper Washer Specific Procedures Wiper Washer: Wiper blade replacement, wiper arm replacement, wiper motor testing and replacement, washer pump replacement, washer nozzle adjustment. Specific Procedures Fuel System Specific Procedures Fuel System: Fuel pump testing and replacement, fuel filter replacement, fuel injector cleaning, fuel pressure testing. Specific Procedures Exhaust System Specific Procedures Exhaust System: Exhaust pipe and muffler replacement, catalytic converter inspection, exhaust hanger replacement. Specific Procedures Emission Control Specific Procedures Emission Control:...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee

Year:

Chassis Code:

Generation:

Second Generation (XJ Facelift)

Trim Levels Covered:

SE, Sport, Country, Limited (coverage may vary based on specific engine/drivetrain options)

👋 Introduction

Market Position

Market Position:

The Jeep Cherokee (XJ) was a revolutionary compact SUV that defined the segment. It was known for its rugged capability, unibody construction (a first in its class), and legendary off-road prowess. The 1994 model represents a mature iteration of the XJ platform, benefiting from earlier refinements and facing competition from vehicles like the Toyota RAV4 and Ford Explorer.

Competitive Analysis

Competitive Analysis:

The 1994 Cherokee continued to hold its ground against emerging car-based SUVs by emphasizing its traditional Jeep strengths: robust chassis, capable 4x4 systems, and a more utilitarian design. Its direct competitors were often more car-like, offering less off-road capability but potentially better on-road comfort and fuel economy. The XJ's unibody design offered a compromise, being lighter and more comfortable than body-on-frame SUVs of the era.

Key Features

Key Features:

Unibody construction, Command-Trac (2WD/4WD) and Selec-Trac (full-time 4WD) systems, legendary 4.0L Inline-6 engine, durable build quality, excellent off-road articulation and capability for its size.

📋 Manual Details

Coverage Areas

Coverage Areas:

North America

Page Count

Page Count:

Estimated 1000+ pages (typical for factory workshop manuals of this era)

Manual Type

Manual Type:

Factory Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Systems Covered:

Engine Mechanical (4.0L I6, 2.5L I4), Fuel System, Ignition System, Emission Control Systems, Exhaust System, Cooling System, Lubrication System, Starting System, Charging System, Air Conditioning System, Heater & Air Conditioner, Steering System, Brake System, Suspension Systems (Front & Rear), Drivetrain (2WD/4WD), Transfer Case, Axles, Electrical System, Body Repair, Interior Components, Exterior Components, Wiper and Washer System, Lighting System, Audio & Visual System, Supplemental Restraint System (Airbags), Security System, Instrument Panel, Power Accessories.

Procedures Included

Procedures Included:

Routine Maintenance, Scheduled Maintenance, Diagnostics and Troubleshooting, Component Removal and Installation, Repair Procedures, Overhaul and Reassembly, Electrical System Diagnosis, Wiring Diagrams, Body Panel Repair, Fluid Capacities and Specifications, Torque Specifications, Wheel Alignment Procedures, Drivetrain Adjustments, Airbag System Servicing (with safety precautions), Refrigerant Handling (with safety precautions).

Technical Depth

Technical Depth:

Comprehensive: Covers everything from basic fluid checks and filter changes to complete engine and transmission rebuilds, complex electrical diagnostics, and body panel repair. Includes detailed exploded views, diagrams, and troubleshooting flowcharts.

Specific Procedures Engine

Specific Procedures Engine:

Engine overhaul (cylinder head removal/installation, piston/ring replacement, crankshaft/bearing service), camshaft timing, valve adjustment (if applicable), fuel injector testing/replacement, ignition coil/distributor servicing.

Specific Procedures Transmission

Specific Procedures Transmission:

Automatic transmission fluid and filter change, manual transmission clutch inspection and replacement, transfer case gear oil change, driveshaft U-joint inspection and replacement.

Specific Procedures Brakes

Specific Procedures Brakes:

Brake pad and rotor replacement (front), brake shoe and drum service (rear), brake caliper overhaul, brake line replacement, ABS system troubleshooting (if equipped).

Specific Procedures Suspension

Specific Procedures Suspension:

Front and rear shock absorber replacement, coil spring inspection/replacement, control arm bushing replacement, ball joint and tie rod end replacement, steering linkage service, wheel bearing service.

Specific Procedures Electrical

Specific Procedures Electrical:

Detailed wiring diagrams for all major systems (engine control, lighting, charging, starting, accessories), component testing (starter, alternator, sensors), fuse and relay identification and testing, troubleshooting electrical faults using multimeter.

Specific Procedures Body

Specific Procedures Body:

Door panel removal, glass replacement (windshield, side, rear), bumper removal/installation, fender panel repair, tailgate/back door mechanisms, weatherstrip replacement.

Specific Procedures Diagnostics

Specific Procedures Diagnostics:

Troubleshooting guides for common drivability issues, no-start conditions, charging system faults, HVAC problems, and suspension/steering noises. Includes diagnostic trouble codes (DTCs) where applicable for the engine control module (ECM).

Specific Procedures Air Conditioning

Specific Procedures Air Conditioning:

Refrigerant recovery and recharge procedures (emphasizing safety and environmental compliance), component replacement (compressor, condenser, evaporator, receiver/dryer), leak detection, system evacuation and charging.

Specific Procedures Wheels Tires

Specific Procedures Wheels Tires:

Tire pressure specifications, wheel torque specifications, wheel stud replacement, tire rotation and balancing procedures.

Specific Procedures Exterior Lighting

Specific Procedures Exterior Lighting:

Headlamp bulb replacement, taillight assembly replacement, side marker lamp replacement, fog lamp service.

Specific Procedures Interior Components

Specific Procedures Interior Components:

Seat removal and installation, headliner removal, dashboard trim panel removal, center console disassembly, interior light replacement.

Specific Procedures Parking Brake

Specific Procedures Parking Brake:

Parking brake cable adjustment and replacement, parking brake shoe inspection and replacement.

Specific Procedures Wiper Washer

Specific Procedures Wiper Washer:

Wiper blade replacement, wiper arm replacement, wiper motor testing and replacement, washer pump replacement, washer nozzle adjustment.

Specific Procedures Fuel System

Specific Procedures Fuel System:

Fuel pump testing and replacement, fuel filter replacement, fuel injector cleaning, fuel pressure testing.

Specific Procedures Exhaust System

Specific Procedures Exhaust System:

Exhaust pipe and muffler replacement, catalytic converter inspection, exhaust hanger replacement.

Specific Procedures Emission Control

Specific Procedures Emission Control:

Catalytic converter inspection, EGR (Exhaust Gas Recirculation) valve inspection and cleaning, charcoal canister system checks.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution scans of original factory documentation, suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Primary Engine:

4.0L (242 cu in) AMC I6

Engine Options

Engine Options:

4.0L I6 (most common), 2.5L (150 cu in) AMC I4

Performance 4 0L

Performance 4 0L:

Approx. 190 hp @ 4,750 rpm, 220 lb-ft @ 3,000 rpm (figures can vary slightly)

Performance 2 5L

Performance 2 5L:

Approx. 125 hp @ 4,800 rpm, 150 lb-ft @ 2,500 rpm (figures can vary slightly)

Fuel System

Fuel System:

Multi-point Fuel Injection (MPI)

Engine Codes

Engine Codes:

For 4.0L: Typically 'E' or 'S' in VIN. For 2.5L: Typically 'H' in VIN.

Cooling System Capacity

Cooling System Capacity:

Approx. 11.5 quarts (10.9 liters) for 4.0L, 10.5 quarts (9.9 liters) for 2.5L (with heater)

🔧 Transmission

Standard Transmission

Standard Transmission:

5-Speed Manual (AX-5 for 2.5L I4, AX-15 for 4.0L I6)

Optional Transmission

Optional Transmission:

4-Speed Automatic (AW4 - French-built Aisin-Warner)

Transmission Fluid Type

Transmission Fluid Type:

ATF+3 (for automatic), Manual Transmission Fluid (GL-3 or GL-4, viscosity varies by temperature)

Transfer Case Options

Transfer Case Options:

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

Transfer Case Fluid

Transfer Case Fluid:

NP231: ATF+3 or Dexron II/III. NP242: ATF+3 or Dexron II/III.

📐 Dimensions

Exterior Length

Exterior Length:

Approx. 167.2 inches (4247 mm)

Exterior Width

Exterior Width:

Approx. 70.5 inches (1791 mm)

Exterior Height

Exterior Height:

Approx. 64.9 inches (1648 mm)

Wheelbase

Wheelbase:

Approx. 101.4 inches (2576 mm)

Curb Weight

Curb Weight:

Approx. 3,100 - 3,400 lbs (1406 - 1542 kg), depending on configuration.

Cargo Volume Behind Rear Seat

Cargo Volume Behind Rear Seat:

Approx. 30.5 cu ft (0.86 m³)

Cargo Volume With Rear Seat Folded

Cargo Volume With Rear Seat Folded:

Approx. 67.0 cu ft (1.89 m³)

🛡️ Safety Features

Passive Features

Passive Features:

Seat belts, reinforced safety cage, available airbags (driver and passenger). Note: Airbag systems are complex and require careful handling as detailed in the manual.

Active Features

Active Features:

Four-wheel disc or front disc/rear drum brakes, optional Anti-lock Braking System (ABS) on rear wheels for some models.

Ratings General

Ratings General:

As with many vehicles of this era, official NHTSA crash test ratings for this specific year may be limited or unavailable in modern formats. The XJ was generally considered a robust vehicle for its time.

💡 Technology Features

Infotainment

Infotainment:

Basic AM/FM radio with cassette player was standard. Optional CD player available. Features are limited by era, focusing on audio playback rather than advanced connectivity.

Driver Assistance

Driver Assistance:

Limited by modern standards. Available ABS on rear wheels for some models. No advanced electronic driver aids like traction control or stability control.

Connectivity

Connectivity:

No factory integrated Bluetooth or USB ports. Connectivity would be aftermarket additions.

Instrument Panel

Instrument Panel:

Revised for 1994 with a more integrated design, including tachometer on some trims, speedometer, fuel gauge, temperature gauge, and warning lights. The manual provides detailed schematics for instrument cluster diagnostics.

🔧 Maintenance

Service Intervals Oil Change

Service Intervals Oil Change:

Every 3,000 miles (4,800 km) or 3 months for severe service, 5,000-7,500 miles (8,000-12,000 km) or 6 months for normal service (refer to manual for exact recommendations based on oil type and driving conditions).

Service Intervals Coolant Flush

Service Intervals Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years (typically using a 50/50 mix of Mopar Antifreeze/Coolant (HOAT) or equivalent).

Service Intervals Transmission Fluid

Service Intervals Transmission Fluid:

Automatic: Every 30,000-60,000 miles (48,000-96,000 km). Manual: Check for leaks, replace as needed (often around 50,000-100,000 miles depending on use).

Fluid Specifications Engine Oil

Fluid Specifications Engine Oil:

10W-30 or 10W-40 for 4.0L I6. 5W-30 or 10W-30 for 2.5L I4. Check manual for API service classification (e.g., API SG or higher).

Fluid Specifications Brake Fluid

Fluid Specifications Brake Fluid:

DOT 3

Fluid Specifications Power Steering Fluid

Fluid Specifications Power Steering Fluid:

ATF+3 or Dexron II/III

Known Issues

Known Issues:

Common issues can include: radiator leaks, heater core failure, minor oil leaks (valve cover, oil pan), front suspension wear (ball joints, tie rods, control arm bushings), exhaust manifold cracks (especially on 4.0L), rear main seal leaks, TPS (Throttle Position Sensor) failure, intermittent electrical issues, and rust in critical areas (frame rails, rocker panels). The manual is essential for diagnosing and repairing these.

Spark Plug Part Number 4 0L

Spark Plug Part Number 4 0L:

Champion Copper Plus (e.g., RC12LYC) or equivalent is common. Exact part number depends on application and replacement standard. Refer to manual for definitive specs.

Oil Filter Part Number

Oil Filter Part Number:

Commonly Wix 51515, Fram PH8A, or equivalent. Refer to manual or filter manufacturer for exact fitment.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Jeep, a brand with a rich military and off-road heritage dating back to WWII, consistently produced rugged and capable vehicles. The Cherokee line, starting with the SJ in the 1970s, established Jeep as a leader in the SUV market.

Model Evolution

Model Evolution:

The XJ Cherokee, introduced in 1984, was a groundbreaking vehicle. It was the first compact SUV with unibody construction. The 1994 model year marked a significant facelift, including updated exterior styling (new bumpers, grille, headlights, and side moldings), a revised interior with a more modern dashboard and improved ergonomics, and updated powertrain options. The 4.0L engine was a key evolution, becoming the benchmark for Jeep's inline-six power and durability.

Production

Production:

The XJ Cherokee was produced from 1984 to 2001, with the 1994 facelift being a crucial update in its long production run. It was primarily manufactured in North America.

🏆 Awards & Recognition

Recognitions

Recognitions:

The Cherokee XJ as a platform consistently received accolades for its off-road capability and utility. While specific awards for the 1994 model year might not be prominently documented in easily accessible public records, it was widely recognized as a benchmark in the compact SUV segment throughout the 1990s.

Ratings

Ratings:

Consumer satisfaction and capability ratings from automotive publications of the era generally favored the XJ for its robustness and off-road prowess, often outperforming more car-like competitors in those specific areas.