Jeep Cherokee XJ 1988-2000 Factory Service Repair Manual
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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 👋 Introduction Market Position Segment: Compact SUV / Sport Utility Vehicle Target Audience: Off-road enthusiasts, adventure seekers, families requiring utility and ruggedness. Competitive Analysis Key Competitors: Toyota 4Runner, Ford Bronco, Chevrolet S-10 Blazer, Nissan Pathfinder. Key Features Chassis Design: Unibody construction, offering a lighter weight and better on-road manners compared to body-on-frame SUVs of the era. Offroad Capability: Renowned off-road prowess due to solid axles (early models), robust suspension, and available four-wheel-drive systems. 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes Page Count Estimated Pages: 2000+ Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: All engine variants, including inline-4 and inline-6 configurations, internal components, cooling system, lubrication system, fuel delivery, exhaust system. Engine Performance: Engine tuning, diagnostics, emission controls, turbocharging (if applicable). Transmission Manual: NV3500, AX-15, BA-10/5 (Peugeot) transmissions: disassembly, assembly, repair, troubleshooting, fluid specifications. Transmission Automatic: AW4 (Aisin-Warner) automatic transmission: overhaul, adjustments, diagnostic procedures, fluid specifications. Drivetrain: Transfer case (Command-Trac, Selec-Trac, NP231, NP242), front and rear axle assemblies (Dana 30, Dana 35, Chrysler 8.25), driveshafts, universal joints, CV joints. Suspension: Front and rear suspension systems, including leaf springs (rear), coil springs (front), shock absorbers, control arms, sway bars, bushings, alignment specifications. Steering: Power steering system, steering gear, steering column, tie rods, drag links, alignment specifications. Brakes: Front disc and rear drum/disc brake systems, anti-lock braking system (ABS) where applicable, brake component replacement, bleeding procedures, hydraulic system diagnostics. Electrical System: Battery, charging system (alternator), starting system (starter motor), ignition system, lighting systems, horn, power windows, power locks, interior and exterior lighting troubleshooting, wiring diagrams. Body And Frame: Unibody construction, body panel repair, rust prevention, door mechanisms, glass replacement, interior trim, exterior trim, sealants, undercoating. HVAC: Air conditioning, heating, ventilation system components, refrigerant handling, blower motor, evaporator, condenser, heater core, controls. Safety Systems: Seat belts, airbag system (if equipped), passive restraint systems. Procedures Included Preventive Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, brake fluid flush, coolant flush, tire rotation and pressure checks. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, electrical diagnostic charts, fault code interpretation. Repair And Rebuild: Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation. Diagnostic Procedures: On-board diagnostics (OBD-I and early OBD-II), sensor testing, actuator testing, pressure testing, resistance testing, continuity testing. Wiring Diagrams: Complete and detailed wiring diagrams for all electrical systems, including power distribution, grounds, and component connections. Technical Depth Depth: Complete factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format Quality: High-resolution scans, searchable text (OCR enabled), bookmark functionality for easy navigation. Print Quality Quality: Professionally digitized for clear text and legible diagrams. Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Variant 1: 2.5L (150 cu in) AMC I4 Variant 1 Power: Approx. 125 hp @ 4600 rpm Variant 1 Torque: Approx. 160 lb-ft @ 3200 rpm Variant 2: 4.0L (242 cu in) AMC I6 'High Output' Variant 2 Power: Approx. 177-190 hp @ 4750 rpm (depending on year) Variant 2 Torque: Approx. 220-255 lb-ft @ 3000-3200 rpm (depending on year) Performance Engine Management: Renix, Mopar, Chrysler EFI systems. Fuel System Type: Multi-point fuel injection (MPI) 🔧 Transmission Standard Transmission Type: 5-speed manual (e.g., AX-15, NV3500) or 3-speed/4-speed automatic (e.g., AW4) Optional Transmission Type: 4-speed automatic (AW4) became increasingly common and refined through the years. Features Transfer Cases: Command-Trac (NP231), Selec-Trac (NP242), part-time and full-time 4WD options. 📐 Dimensions Exterior Wheelbase: 101.4 inches (2575 mm) Length: 167.1 - 173.3 inches (4244 - 4399 mm) Width: 69.3 - 70.0 inches (1760 - 1778 mm) Height: 63.7 - 64.3 inches (1618 - 1633 mm) Weights Curb Weight: Approx. 3,300 - 3,700 lbs (1497 - 1678 kg) 🛡️ Safety Features Ratings Crash Test Results: Varies by year and specific test; generally adequate for its era, but lacking modern safety advancements like side curtain airbags. Active Features ABS: Available on some later models and higher trims. Passive Features Airbags: Driver airbag standard from early 90s, passenger airbag optional or standard on later models. No side airbags or advanced airbag systems. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio, cassette player, optional CD player in later models. Speaker configuration varies by trim. Driver Assistance Features: Limited to basic features like power steering and optional cruise control. No advanced driver-assistance systems (ADAS) such as adaptive cruise control or lane keeping assist. Connectivity Features: No integrated Bluetooth, USB ports, or smartphone integration. Aftermarket solutions are common. 🔧 Maintenance Service Intervals Oil Change: Every 3,000-5,000 miles or 6 months (depending on...
Transfer case (Command-Trac, Selec-Trac, NP231, NP242), front and rear axle assemblies (Dana 30, Dana 35, Chrysler 8.25), driveshafts, universal joints, CV joints.
Suspension:
Front and rear suspension systems, including leaf springs (rear), coil springs (front), shock absorbers, control arms, sway bars, bushings, alignment specifications.
Steering:
Power steering system, steering gear, steering column, tie rods, drag links, alignment specifications.
Brakes:
Front disc and rear drum/disc brake systems, anti-lock braking system (ABS) where applicable, brake component replacement, bleeding procedures, hydraulic system diagnostics.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), ignition system, lighting systems, horn, power windows, power locks, interior and exterior lighting troubleshooting, wiring diagrams.
Body And Frame:
Unibody construction, body panel repair, rust prevention, door mechanisms, glass replacement, interior trim, exterior trim, sealants, undercoating.
HVAC:
Air conditioning, heating, ventilation system components, refrigerant handling, blower motor, evaporator, condenser, heater core, controls.
Safety Systems:
Seat belts, airbag system (if equipped), passive restraint systems.
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, brake fluid flush, coolant flush, tire rotation and pressure checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, electrical diagnostic charts, fault code interpretation.
Repair And Rebuild:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.
Diagnostic Procedures:
On-board diagnostics (OBD-I and early OBD-II), sensor testing, actuator testing, pressure testing, resistance testing, continuity testing.
Wiring Diagrams:
Complete and detailed wiring diagrams for all electrical systems, including power distribution, grounds, and component connections.
Technical Depth
Depth:
Complete factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY mechanics.
📊 Manual Specifications
File Format
Quality:
High-resolution scans, searchable text (OCR enabled), bookmark functionality for easy navigation.
Print Quality
Quality:
Professionally digitized for clear text and legible diagrams.
Binding Type
Type:
N/A (Digital Format)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Variant 1:
2.5L (150 cu in) AMC I4
Variant 1 Power:
Approx. 125 hp @ 4600 rpm
Variant 1 Torque:
Approx. 160 lb-ft @ 3200 rpm
Variant 2:
4.0L (242 cu in) AMC I6 'High Output'
Variant 2 Power:
Approx. 177-190 hp @ 4750 rpm (depending on year)
Variant 2 Torque:
Approx. 220-255 lb-ft @ 3000-3200 rpm (depending on year)
Performance
Engine Management:
Renix, Mopar, Chrysler EFI systems.
Fuel System
Type:
Multi-point fuel injection (MPI)
🔧 Transmission
Standard
Transmission Type:
5-speed manual (e.g., AX-15, NV3500) or 3-speed/4-speed automatic (e.g., AW4)
Optional
Transmission Type:
4-speed automatic (AW4) became increasingly common and refined through the years.
Features
Transfer Cases:
Command-Trac (NP231), Selec-Trac (NP242), part-time and full-time 4WD options.
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2575 mm)
Length:
167.1 - 173.3 inches (4244 - 4399 mm)
Width:
69.3 - 70.0 inches (1760 - 1778 mm)
Height:
63.7 - 64.3 inches (1618 - 1633 mm)
Weights
Curb Weight:
Approx. 3,300 - 3,700 lbs (1497 - 1678 kg)
🛡️ Safety Features
Ratings
Crash Test Results:
Varies by year and specific test; generally adequate for its era, but lacking modern safety advancements like side curtain airbags.
Active Features
ABS:
Available on some later models and higher trims.
Passive Features
Airbags:
Driver airbag standard from early 90s, passenger airbag optional or standard on later models. No side airbags or advanced airbag systems.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, cassette player, optional CD player in later models. Speaker configuration varies by trim.
Driver Assistance
Features:
Limited to basic features like power steering and optional cruise control. No advanced driver-assistance systems (ADAS) such as adaptive cruise control or lane keeping assist.
Connectivity
Features:
No integrated Bluetooth, USB ports, or smartphone integration. Aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-5,000 miles or 6 months (depending on oil type and driving conditions).
Transmission Fluid Change:
Automatic: Every 30,000-60,000 miles. Manual: Check fluid condition; typically longer intervals.
Coolant Flush:
Every 30,000-50,000 miles or 2-3 years.
Fluid Specifications
Engine Oil:
API Service SG, SH, SJ or higher. Viscosity: 10W-30 recommended for most climates (refer to manual for specific recommendations).
Automatic Transmission Fluid:
ATF+3 or ATF+4 ( Chrysler spec)
Manual Transmission Fluid:
GL-3 or GL-4 gear oil (refer to manual for specific SAE weight).
Power Steering Fluid:
Mopar Power Steering Fluid or equivalent (Dexron II/III for some years).
Known Issues
Common Problems Engine:
Head gasket issues on the 4.0L I6 (especially earlier models), cracked cylinder heads on early 4.0L, intake manifold gasket leaks on I4.