Description
Factory Jeep Cherokee XJ Workshop Manual (1984-2001)
This factory-level repair manual covers every Cherokee XJ built during its entire 18-year production run, giving American DIYers and professional shops the complete technical reference needed to service these legendary off-road-capable SUVs from radiator to rear axle.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | 2.5L AMC 150 I4, 2.8L V6, 4.0L AMC 242 I6 |
| Diesel | 2.5L turbo diesel |
| Transmissions | AX5 5-speed manual, AX15 5-speed manual, BA10/5 5-speed manual, 3-speed automatic, AW4 4-speed automatic |
| Drive | RWD, Command-Trac & Selec-Trac 4WD |
| Model Years | 1984-2001 |
| Badge Twins | N/A |
Common Cherokee Repairs Covered
| System | Procedures |
|---|---|
| 4.0L Cylinder Head / Cooling | Head gasket replacement, coolant leak diagnosis, thermostat and radiator service – a well-known weak point on high-mileage XJs |
| Front Axle & Steering | Dana 30 axle shaft, ball joint, and track bar replacement; steering box adjustment and sector shaft seal service |
| Transfer Case | NP231 and NP242 rebuild, chain and sprocket inspection, shift linkage adjustment, and fluid change procedures |
| Electrical / Ignition | Crankshaft position sensor replacement (common no-start fault), wiring harness inspection, and fuel injector testing |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Why do so many XJ 4.0L engines overheat, and does this manual cover the fix?
The 4.0L AMC 242 inline-six is prone to head gasket failure and cracked cylinder heads, especially when the cooling system is neglected. This manual includes complete cylinder head removal and installation procedures, torque sequences, coolant system bleeding steps, and thermostat housing replacement – everything needed to properly address overheating on any 1987-2001 XJ equipped with the 4.0L.
Does this manual cover both 2-door and 4-door Cherokee XJ body styles?
Yes. The Cherokee XJ was offered as both a two-door and four-door wagon throughout the 1984-2001 production run, and this manual addresses both configurations. Body, interior, electrical, and trim procedures note differences between the two body styles where applicable.
Are the NP231 and NP242 transfer cases fully covered?
Both transfer cases are included. The manual provides disassembly, inspection, and rebuild procedures for the NP231 Command-Trac and NP242 Selec-Trac units, covering chain wear, mode fork adjustment, output shaft seals, and fluid specifications across all applicable model years.
What format is the manual?
The manual is delivered as a PDF file. After purchase you receive an instant download link, and the file is available for re-download at any time. The PDF is fully searchable and compatible with any device – Windows, Mac, iOS, or Android – using a standard PDF reader.
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