Jeep Grand Cherokee ZJ 1993-1998 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Jeep Model: Grand Cherokee Generation: ZJ Model Years: 1993-1998 Codes Chassis Code: ZJ 👋 Introduction Market Position Segment: Mid-size Luxury SUV Jeep Heritage: Built upon Jeep's legendary off-road capability and ruggedness, transitioning into a more refined and comfortable package for daily driving and family use. Competitive Analysis Competitors: Ford Explorer, Chevrolet Blazer/Tahoe, Toyota 4Runner, Land Rover Discovery, Mitsubishi Montero. Key Features Platform: Unibody construction (ZJ) which offered a more car-like ride and better handling compared to older body-on-frame SUVs, while retaining significant off-road prowess. Powertrain Options: Renowned inline-6 and V8 engines known for their durability and torque. Capability: Available with sophisticated 4WD systems like Quadra-Trac and Selec-Trac, coupled with robust axles and suspension for off-road adventures. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Workshop Manual Language: English Format: Downloadable PDF Page Count Estimated Pages: Over 2000 pages (typical for comprehensive service manuals of this era) 📖 Manual Coverage Systems Covered Engine: 4.0L I6 (Power-Tech inline-6), 5.2L V8 (Magnum), 5.9L V8 (Magnum) Transmission: 42RE (4-speed automatic), 44RE (4-speed automatic), NV242 (Selec-Trac 2-speed transfer case), NV249 (Quadra-Trac 2-speed full-time transfer case) Drivetrain: Front Axle (Dana 30), Rear Axle (Dana 35C, Dana 44A), Axle Ratios, Driveshafts, U-joints, CV Joints Suspension: Front (Solid Axle with Leaf Springs or Coil Springs depending on year/trim), Rear (Leaf Springs), Shocks, Bushings, Control Arms Brakes: Front Disc Brakes (Vented Rotors), Rear Disc Brakes (Solid Rotors), ABS System (Bosch 2S/3 or Teves), Parking Brake Steering: Power Steering System, Steering Column, Tie Rods, Ball Joints, Steering Gear Electrical System: 12V Battery System, Alternator, Starter Motor, Ignition System (Distributorless Ignition System - DIS for later models), Lighting, Fuses, Relays, Wiring Diagrams Body And Frame: Unibody Construction, Body Panels, Doors, Hood, Tailgate, Glass, Interior Trim, Bumpers HVAC: Air Conditioning System, Heater Core, Blower Motor, Controls, Refrigerant Charging Fuel System: Fuel Tank, Fuel Pump, Fuel Filter, Fuel Injectors, Fuel Pressure Regulator Cooling System: Radiator, Water Pump, Thermostat, Hoses, Coolant Specifications Exhaust System: Exhaust Manifold, Catalytic Converter, Muffler, Pipes Procedures Included Maintenance: Routine Service, Oil Changes, Filter Replacements, Fluid Checks and Changes, Spark Plug Replacement, Belt Inspection and Replacement Troubleshooting: Diagnostic Procedures, Symptom-Based Troubleshooting Guides, DTC (Diagnostic Trouble Code) Interpretation Repair: Component Removal and Installation, Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Overhaul, Electrical Component Repair Diagnostics: On-Board Diagnostics (OBD-I and early OBD-II), Sensor Testing, Actuator Testing, Wiring Harness Diagnosis Specifications: Torque Specifications, Clearances, Timing Specifications, Component Dimensions Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission overhauls and complex electrical diagnostics. Diagnostic Tools: Information on using factory diagnostic tools and procedures for the era (e.g., OBD-I scanners, multimeter usage). 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes, typically fully text-searchable for quick information retrieval. Print Quality Image Resolution: High-resolution scans of original factory documentation, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper Quality: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine 1: 4.0L I6 (Power-Tech) Engine 1 Displacement: 3956 cc (242 cubic inches) Engine 1 Bore X Stroke: 3.88 x 3.41 inches (98.5 x 86.7 mm) Engine 1 Compression Ratio: 8.7:1 Engine 1 Horsepower: Approx. 185-190 hp @ 4500-4700 RPM (varies slightly by year) Engine 1 Torque: Approx. 220-225 lb-ft @ 2500-3000 RPM (varies slightly by year) Secondary Engine Engine 2: 5.2L V8 (Magnum) Engine 2 Displacement: 5210 cc (318 cubic inches) Engine 2 Horsepower: Approx. 205-210 hp @ 4400-4500 RPM Engine 2 Torque: Approx. 285-295 lb-ft @ 2400-2800 RPM Tertiary Engine Engine 3: 5.9L V8 (Magnum) Engine 3 Displacement: 5900 cc (360 cubic inches) Engine 3 Horsepower: Approx. 215-225 hp @ 4400-4600 RPM Engine 3 Torque: Approx. 320-330 lb-ft @ 2800-3200 RPM Fuel System Fuel Injection: Multi-Port Fuel Injection (MPFI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) 🔧 Transmission Standard Transmission Standard: 4-Speed Automatic (42RE for 4.0L and 5.2L, 44RE for 5.2L/5.9L later years) Optional Transmission Optional: Manual transmission was not commonly offered or available for the ZJ Grand Cherokee in most markets during this period. Primarily automatic. Features Transfer Case Standard: NV242 Selec-Trac (Part-time 4WD with 2WD option, 4-All Time, 4-Part Time, Neutral, Low Range) Transfer Case Optional: NV249 Quadra-Trac (Full-time 4WD with a viscous coupling center differential, 4-All Time, Neutral, Low Range) Transmission Fluid Spec: Chrysler ATF+4 (MS-9602) or equivalent (earlier models may spec ATF+3). 📐 Dimensions Exterior Length: Approx. 179.1 - 180.4 inches (4550 - 4582 mm) Width: Approx. 70.5 - 71.2 inches (1791 - 1808 mm) Height: Approx. 63.7 - 64.7 inches (1618 - 1643 mm) Wheelbase: Approx. 104.7 inches (2659 mm) Ground Clearance: Approx. 8.4 - 8.7 inches (213 - 221 mm), depending on tire size and suspension. Cargo Cargo Volume Behind Rear Seat: Approx. 33.2 cu ft (940 L) Cargo Volume With Rear...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Grand Cherokee

Generation:

Model Years:

1993-1998

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Mid-size Luxury SUV

Jeep Heritage:

Built upon Jeep's legendary off-road capability and ruggedness, transitioning into a more refined and comfortable package for daily driving and family use.

Competitive Analysis

Competitors:

Ford Explorer, Chevrolet Blazer/Tahoe, Toyota 4Runner, Land Rover Discovery, Mitsubishi Montero.

Key Features

Platform:

Unibody construction (ZJ) which offered a more car-like ride and better handling compared to older body-on-frame SUVs, while retaining significant off-road prowess.

Powertrain Options:

Renowned inline-6 and V8 engines known for their durability and torque.

Capability:

Available with sophisticated 4WD systems like Quadra-Trac and Selec-Trac, coupled with robust axles and suspension for off-road adventures.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Workshop Manual

Language:

English

Format:

Downloadable PDF

Page Count

Estimated Pages:

Over 2000 pages (typical for comprehensive service manuals of this era)

📖 Manual Coverage

Systems Covered

Engine:

4.0L I6 (Power-Tech inline-6), 5.2L V8 (Magnum), 5.9L V8 (Magnum)

Transmission:

42RE (4-speed automatic), 44RE (4-speed automatic), NV242 (Selec-Trac 2-speed transfer case), NV249 (Quadra-Trac 2-speed full-time transfer case)

Drivetrain:

Front Axle (Dana 30), Rear Axle (Dana 35C, Dana 44A), Axle Ratios, Driveshafts, U-joints, CV Joints

Suspension:

Front (Solid Axle with Leaf Springs or Coil Springs depending on year/trim), Rear (Leaf Springs), Shocks, Bushings, Control Arms

Brakes:

Front Disc Brakes (Vented Rotors), Rear Disc Brakes (Solid Rotors), ABS System (Bosch 2S/3 or Teves), Parking Brake

Steering:

Power Steering System, Steering Column, Tie Rods, Ball Joints, Steering Gear

Electrical System:

12V Battery System, Alternator, Starter Motor, Ignition System (Distributorless Ignition System - DIS for later models), Lighting, Fuses, Relays, Wiring Diagrams

Body And Frame:

Unibody Construction, Body Panels, Doors, Hood, Tailgate, Glass, Interior Trim, Bumpers

HVAC:

Air Conditioning System, Heater Core, Blower Motor, Controls, Refrigerant Charging

Fuel System:

Fuel Tank, Fuel Pump, Fuel Filter, Fuel Injectors, Fuel Pressure Regulator

Cooling System:

Radiator, Water Pump, Thermostat, Hoses, Coolant Specifications

Exhaust System:

Exhaust Manifold, Catalytic Converter, Muffler, Pipes

Procedures Included

Maintenance:

Routine Service, Oil Changes, Filter Replacements, Fluid Checks and Changes, Spark Plug Replacement, Belt Inspection and Replacement

Troubleshooting:

Diagnostic Procedures, Symptom-Based Troubleshooting Guides, DTC (Diagnostic Trouble Code) Interpretation

Repair:

Component Removal and Installation, Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Overhaul, Electrical Component Repair

Diagnostics:

On-Board Diagnostics (OBD-I and early OBD-II), Sensor Testing, Actuator Testing, Wiring Harness Diagnosis

Specifications:

Torque Specifications, Clearances, Timing Specifications, Component Dimensions

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission overhauls and complex electrical diagnostics.

Diagnostic Tools:

Information on using factory diagnostic tools and procedures for the era (e.g., OBD-I scanners, multimeter usage).

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Yes, typically fully text-searchable for quick information retrieval.

Print Quality

Image Resolution:

High-resolution scans of original factory documentation, ensuring clarity of diagrams and text.

Binding Type

Binding:

N/A (Digital Download - PDF)

Paper Type

Paper Quality:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Primary Engine

Engine 1:

4.0L I6 (Power-Tech)

Engine 1 Displacement:

3956 cc (242 cubic inches)

Engine 1 Bore X Stroke:

3.88 x 3.41 inches (98.5 x 86.7 mm)

Engine 1 Compression Ratio:

8.7:1

Engine 1 Horsepower:

Approx. 185-190 hp @ 4500-4700 RPM (varies slightly by year)

Engine 1 Torque:

Approx. 220-225 lb-ft @ 2500-3000 RPM (varies slightly by year)

Secondary Engine

Engine 2:

5.2L V8 (Magnum)

Engine 2 Displacement:

5210 cc (318 cubic inches)

Engine 2 Horsepower:

Approx. 205-210 hp @ 4400-4500 RPM

Engine 2 Torque:

Approx. 285-295 lb-ft @ 2400-2800 RPM

Tertiary Engine

Engine 3:

5.9L V8 (Magnum)

Engine 3 Displacement:

5900 cc (360 cubic inches)

Engine 3 Horsepower:

Approx. 215-225 hp @ 4400-4600 RPM

Engine 3 Torque:

Approx. 320-330 lb-ft @ 2800-3200 RPM

Fuel System

Fuel Injection:

Multi-Port Fuel Injection (MPFI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

🔧 Transmission

Standard

Transmission Standard:

4-Speed Automatic (42RE for 4.0L and 5.2L, 44RE for 5.2L/5.9L later years)

Optional

Transmission Optional:

Manual transmission was not commonly offered or available for the ZJ Grand Cherokee in most markets during this period. Primarily automatic.

Features

Transfer Case Standard:

NV242 Selec-Trac (Part-time 4WD with 2WD option, 4-All Time, 4-Part Time, Neutral, Low Range)

Transfer Case Optional:

NV249 Quadra-Trac (Full-time 4WD with a viscous coupling center differential, 4-All Time, Neutral, Low Range)

Transmission Fluid Spec:

Chrysler ATF+4 (MS-9602) or equivalent (earlier models may spec ATF+3).

📐 Dimensions

Exterior

Length:

Approx. 179.1 - 180.4 inches (4550 - 4582 mm)

Width:

Approx. 70.5 - 71.2 inches (1791 - 1808 mm)

Height:

Approx. 63.7 - 64.7 inches (1618 - 1643 mm)

Wheelbase:

Approx. 104.7 inches (2659 mm)

Ground Clearance:

Approx. 8.4 - 8.7 inches (213 - 221 mm), depending on tire size and suspension.

Cargo

Cargo Volume Behind Rear Seat:

Approx. 33.2 cu ft (940 L)

Cargo Volume With Rear Seat Folded:

Approx. 65.7 cu ft (1859 L)

Weights

Curb Weight:

Approx. 3800 - 4200 lbs (1724 - 1905 kg), depending on engine and trim.

Towing Capacity:

Up to 6,500 lbs (2,948 kg) with optional towing package.

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3/5 Stars (considered acceptable for its class and era, but higher center of gravity inherent to SUVs).

Active Features

Standard Anti-lock Braking System (ABS) on all wheels for most models/years.

Traction Control:

Optional or standard on higher trims depending on the year; often integrated with ABS or a separate system.

Passive Features

Airbags:

Driver and Passenger Front Airbags standard from 1994/1995 onwards. Early models may have only had a driver airbag.

Seat Belts:

Front and rear seat belts with pretensioners for front occupants.

Child Seat Anchors:

LATCH system not standard; requires aftermarket installation or older methods.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM Cassette/CD Player, optional Infinity Gold premium sound system with amplifier.

Climate Control:

Manual or optional Automatic Temperature Control (ATC) on higher trims.

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

OBD Standard:

OBD-I for early models (up to 1995/96), transitioning to OBD-II for later 1996+ models. This manual will cover both.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions. Check manual for specific recommendations.

Tire Rotation:

Every 5,000-7,500 miles.

Transmission Fluid Change:

Every 30,000-60,000 miles, depending on usage and fluid type. Consult manual for specific intervals.

Coolant Flush:

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

Fluid Specifications

Engine Oil Spec:

SAE 5W-30 or 10W-30 (depending on temperature). API certified. Refer to manual for exact viscosity range.

Engine Oil Capacity:

4.0L: 5 quarts (4.7 L); 5.2L/5.9L: 5 quarts (4.7 L) with filter. Verify with manual.

Coolant Spec:

Chrysler Long Life Antifreeze/Coolant (HOAT) or equivalent. Typically a 50/50 mix with distilled water.

Known Issues

Common Problems:

Head gasket leaks (especially on 4.0L), intake manifold gasket leaks, rear main seal leaks, transmission valve body issues (42RE/44RE), cracked exhaust manifolds (4.0L), sagging headliner, minor electrical gremlins.

Transfer Case Issues:

NV249 viscous coupler failure, NV242 chain stretch.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep, a brand synonymous with ruggedness and off-road capability, established by Willys-Overland during WWII. The Grand Cherokee represented Jeep's expansion into the premium SUV market.

Model Evolution

Introduction Of Zj:

The ZJ generation, introduced for the 1993 model year, was a significant departure from Jeep's previous Cherokee (XJ) and Grand Cherokee (ZJ predecessor) models. It was designed to compete with luxury SUVs and featured a unibody construction for improved refinement.

Facelift:

Received a facelift for the 1996 model year, including revised front and rear styling, updated interior, and significant powertrain upgrades (e.g., improved engines, introduction of OBD-II on some models).

Production

Production Years:

1993 - 1998

Assembly Locations:

Detroit, Michigan (Jefferson North Assembly Plant)

🏆 Awards & Recognition

Recognitions

Automotive Journal Awards:

Often praised by automotive publications of the era for its blend of luxury, capability, and off-road prowess. Competed strongly in the burgeoning SUV market.

Consumer Reviews:

Generally well-received by consumers for its comfort, V8 power (when equipped), and Jeep's reputation. However, reliability was considered average for the era, with some common issues.