Jeep CHEROKEE XJ Full Service & Repair Manual 1994
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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1994 👋 Introduction Market Position Vehicle Class: Compact SUV / Off-Road Vehicle Target Audience: Off-road enthusiasts, Jeep owners seeking DIY maintenance and repair, restorers. Competitive Analysis Key Competitors 1994: Toyota RAV4, Honda CR-V, Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder Key Features Vehicle Strengths: Legendary off-road capability, robust powertrain, durable construction, relatively simple mechanicals. Manual Value Proposition: Empowers owners with factory-level knowledge for all maintenance and repair tasks, reducing reliance on expensive dealership services. 📋 Manual Details Coverage Areas Primary Coverage: Full Service & Repair Secondary Coverage: Workshop, Maintenance, Diagnostics, Troubleshooting, Reassembly Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: 4.0L Inline 6-Cylinder (AMC 242), 2.5L 4-Cylinder (AMC 150) Transmission: AX-15 (5-Speed Manual), AW4 (4-Speed Automatic), NP231 (Command-Trac Transfer Case) Drivetrain: Front Axle (Dana 30), Rear Axle (Chrysler 8.25, Dana 35), 4WD System Suspension: Front Leaf Spring (Early models), Front Coil Springs (4.0L), Rear Leaf Springs Brakes: Front Disc, Rear Drum (Standard); Anti-lock Braking System (ABS) on some models Steering: Power Steering System Electrical: Ignition System, Charging System, Starting System, Lighting, Gauges, HVAC Controls, Power Accessories, Wiring Diagrams Body: Body Panels, Doors, Windows, Seats, Interior Trim, Bumpers HVAC: Heating, Ventilation, and Air Conditioning System Fuel: Fuel Tank, Fuel Pump, Fuel Injection System (MPI) Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks & Changes, Spark Plug Replacement, Belt Adjustments Diagnostics: Engine Performance Diagnosis, DTC (Diagnostic Trouble Code) Interpretation, Electrical System Troubleshooting Repair: Engine Overhaul, Transmission Rebuild, Brake System Overhaul, Suspension Component Replacement, Electrical Component Repair Troubleshooting: Step-by-step diagnostic guides for common and uncommon issues Installation: Component replacement procedures Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (OCR) Print Quality Print Recommendation: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: AMC 242 (4.0L) Engine Description 1: Overhead Valve (OHV) Inline 6-Cylinder Displacement 1: 3960 cc (242 cubic inches) Bore X Stroke 1: 3.875 in x 3.570 in (98.4 mm x 90.7 mm) Compression Ratio 1: 8.8:1 Horsepower 1: 180 hp @ 4500 rpm (approx.) Torque 1: 220 lb-ft @ 3200 rpm (approx.) Secondary Engine Engine Code 2: AMC 150 (2.5L) Engine Description 2: Overhead Valve (OHV) Inline 4-Cylinder Displacement 2: 2500 cc (150 cubic inches) Horsepower 2: 121 hp @ 5200 rpm (approx.) Torque 2: 145 lb-ft @ 2400 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Multi-Port Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) 🔧 Transmission Standard Transmission Type 1: AX-15 Transmission Description 1: 5-Speed Manual Transmission Optional Transmission Type 2: AW4 Transmission Description 2: 4-Speed Automatic Transmission with Overdrive Features Transfer Case: NP231 Command-Trac (Part-Time 2WD/4WD) Clutch Type: Dry, Single Plate (Manual Transmission) 📐 Dimensions Exterior Wheelbase: 101.4 inches (2576 mm) Length: 167.5 inches (4255 mm) Width: 69.2 inches (1758 mm) Height: 63.7 inches (1618 mm) Ground Clearance: 8.7 inches (221 mm) (approx. stock) Weights Curb Weight Start: 3,250 lbs (1474 kg) (approx.) Gross Vehicle Weight Rating Start: 4,600 lbs (2087 kg) (approx.) 🛡️ Safety Features Ratings NHTSA Overall Rating 1994: Not rated or data not readily available for this model year. Active Features ABS: Optional on select models/trims. Passive Features Airbags: Driver-side airbag standard for 1994 model year. Seat Belts: Front: 3-point retractable; Rear: Lap belts. 💡 Technology Features Infotainment Audio System Options: AM/FM stereo with cassette player, optional CD player. Speakers: Standard 4-speaker system, optional premium systems. Driver Assistance ABS Availability: Available on some higher trims or as an option. Connectivity Connectivity Features: Limited to basic vehicle functions; no integrated Bluetooth or navigation systems. 🔧 Maintenance Service Intervals Oil Change Interval: 3,000 - 5,000 miles (4,800 - 8,000 km) or 6 months, depending on driving conditions. Refer to manual for specific recommendations. Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on inspection. Spark Plug Replacement: 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (copper vs. platinum). Fluid Specifications Engine Oil Type 4.0L: API SG or SH, SAE 10W-30 or 10W-40. (Refer to manual for precise specification). Engine Oil Capacity 4.0L: 5 Quarts (4.7 Liters) with filter. Transmission Fluid Type Aw4: ATF+3 or equivalent (Chrysler specification). Transmission Fluid Capacity Aw4: Approx. 10.5 Quarts (9.9 Liters) (Pan drop and filter change). Transfer Case Fluid Type: ATF+3 or equivalent (Chrysler specification). Transfer Case Fluid Capacity: Approx. 1.6 Quarts (1.5 Liters) (NP231). Coolant Type: Ethylene Glycol based coolant (Green) - 50/50 mix with distilled water. Known Issues Common Issue...
Not rated or data not readily available for this model year.
Active Features
ABS:
Optional on select models/trims.
Passive Features
Airbags:
Driver-side airbag standard for 1994 model year.
Seat Belts:
Front: 3-point retractable; Rear: Lap belts.
💡 Technology Features
Infotainment
Audio System Options:
AM/FM stereo with cassette player, optional CD player.
Speakers:
Standard 4-speaker system, optional premium systems.
Driver Assistance
ABS Availability:
Available on some higher trims or as an option.
Connectivity
Connectivity Features:
Limited to basic vehicle functions; no integrated Bluetooth or navigation systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
3,000 - 5,000 miles (4,800 - 8,000 km) or 6 months, depending on driving conditions. Refer to manual for specific recommendations.
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on inspection.
Spark Plug Replacement:
30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (copper vs. platinum).
Fluid Specifications
Engine Oil Type 4.0L:
API SG or SH, SAE 10W-30 or 10W-40. (Refer to manual for precise specification).
Engine Oil Capacity 4.0L:
5 Quarts (4.7 Liters) with filter.
Transmission Fluid Type Aw4:
ATF+3 or equivalent (Chrysler specification).
Transmission Fluid Capacity Aw4:
Approx. 10.5 Quarts (9.9 Liters) (Pan drop and filter change).
Transfer Case Fluid Type:
ATF+3 or equivalent (Chrysler specification).
Transfer Case Fluid Capacity:
Approx. 1.6 Quarts (1.5 Liters) (NP231).
Coolant Type:
Ethylene Glycol based coolant (Green) - 50/50 mix with distilled water.
Known Issues
Common Issue 1:
Head Gasket Failure (particularly on 4.0L with early designs, though less prevalent by 1994).
Common Issue 2:
Leaf Spring Sag/Breakage (rear suspension).
Common Issue 3:
Radiator Leaks/Overheating (due to age/material).
Common Issue 4:
Minor Electrical Gremlins (door locks, power windows, instrument cluster issues are common with age).
Common Issue 5:
Transmission Cooler Lines Leaking.
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a storied history rooted in military vehicles, known for ruggedness and off-road prowess since WWII.
Model Evolution
Cherokee Xj Introduction:
Introduced in 1984, the XJ was the first compact SUV and pioneered the unibody construction for this class, distinguishing it from truck-based competitors.
Cherokee Xj 1994 Updates:
The 1994 model year saw minor updates, including the standard driver-side airbag and some interior refinements. It represents a mature iteration of the XJ design.
Production
Cherokee Xj Production Years:
1984-2001 (North America)
Manufacturing Locations:
Toledo, Ohio, USA; Brampton, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Vehicle Awards Historical:
The XJ platform has been consistently praised for its off-road capabilities and durability by automotive publications and off-road communities throughout its production run.
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