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Jeep

Jeep Cherokee XJ Service & Repair Manual 1995

Jeep Cherokee XJ Service & Repair Manual 1995

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Vehicle data plateRef 287408
Brand
Jeep
Vehicle
Cars
Models covered
Cherokee XJ, Highlander, Toyota
Years
1995
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee XJ
Year:
1995
Codes
Chassis Code:
XJ
👋 Introduction
Market Position
Positioning:
A critical resource for owners and mechanics looking to maintain and repair their 1995 Jeep Cherokee XJ, providing dealer-level information for DIYers and professionals alike.
Competitive Analysis
Advantage:
Offers a complete, intact, and high-detail solution unlike fragmented or incomplete online resources. It's the same type of manual used by authorized Jeep service centers.
Key Features
Features:
Detailed illustrations, step-by-step instructions, troubleshooting guides, wiring diagrams, comprehensive system coverage, and printable format.
📋 Manual Details
Coverage Areas
Coverage Scope:
All styles and configurations of the 1995 Jeep Cherokee XJ.
Page Count
Total Pages:
Over 1,300
Manual Type
Type:
Factory Service & Repair Manual (Workshop Manual)
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete coverage of engine disassembly, assembly, inspection, and repair for all applicable engines.
Engine Control System Mechanical:
Detailed information on engine management, including fuel delivery, ignition timing, and emissions control components.
Engine Coolant:
Cooling system components, coolant types, capacities, and maintenance procedures.
Emission Control Systems:
Diagnosis and repair of emission control systems, including catalytic converters and evaporative emission systems.
Drive Shaft:
Service and repair of front and rear driveshafts, including U-joints and differentials.
Drive Belt:
Inspection, replacement, and tensioning of drive belts for all accessories.
Differential Case Assy:
Repair and maintenance of front and rear differential assemblies, including fluid types and capacities.
Cylinder Head Assy:
Detailed procedures for cylinder head removal, installation, valve seating, and gasket replacement.
Cylinder Head:
Information on cylinder head inspection, machining, and repair.
Cylinder Block Assy:
Procedures for cylinder block inspection, honing, piston and ring installation, and crankshaft bearing services.
Curtain Shield Air Bag Assy:
Information related to airbag systems, including diagnosis and safety precautions.
Cooling System:
Comprehensive coverage of radiators, water pumps, thermostats, hoses, and fans.
Cooling Fan System:
Diagnosis and repair of electric and mechanical cooling fans.
Combination Meter:
Troubleshooting and repair of the instrument cluster and gauges.
Clutch Unit:
Service and repair for manual transmission clutch systems.
Clutch System:
Hydraulic clutch system components, bleeding, and adjustment.
Clutch Start Switch Assy:
Information on the clutch start interlock switch.
Clutch Release Cylinder Assy:
Service and replacement of the clutch slave cylinder.
Clutch Pedal Sub-Assy:
Adjustment and repair of the clutch pedal assembly.
Clutch Master Cylinder Assy:
Service and replacement of the clutch master cylinder.
Cigarette Lighter Assy:
Electrical diagnosis of the cigarette lighter and 12V accessory outlets.
Charging System:
Diagnosis and repair of the alternator, voltage regulator, and battery system.
Charcoal Canister:
Function and service of the evaporative emission control charcoal canister.
Chain Sub-Assy:
Timing chain inspection and replacement procedures.
Center Stop Lamp Assy:
Troubleshooting and repair of the third brake light.
Center Cluster Module Switch:
Service for central control switches.
Center Air Bag Sensor Assy:
Information on airbag sensor locations and diagnosis.
Camshaft Position Sensor:
Diagnosis and replacement of the camshaft position sensor.
Camshaft:
Inspection, measurement, and replacement of camshafts.
Brake System:
Complete coverage of brake system components, including pads, rotors, calipers, lines, and master cylinder.
Brake Pedal:
Brake pedal assembly adjustment and repair.
Brake Master Cylinder:
Service and replacement of the brake master cylinder.
Brake Fluid:
Brake fluid type specifications and bleeding procedures.
Brake Booster:
Diagnosis and replacement of the vacuum brake booster.
Brake Actuator:
Information on ABS (Anti-lock Braking System) components if equipped.
Body Repair:
Body panel repair, collision damage assessment, and panel replacement procedures.
Yaw Rate Sensor:
Diagnosis of electronic stability control sensors if applicable.
Wiring Diagrams:
Comprehensive wiring schematics for all vehicle electrical systems.
Wire Harness Repair:
Procedures for diagnosing and repairing wiring harnesses, including connector service.
Wiper Rubber:
Replacement of wiper blades.
Wiper And Washer System:
Diagnosis and repair of the windshield wiper and washer systems.
Windshield Wiper Switch Assy:
Service for the wiper control switch.
Windshield Wiper Motor Assy:
Diagnosis and replacement of the windshield wiper motor.
Windshield Glass:
Information on windshield removal and installation, including sealant specifications.
Window Defogger System:
Troubleshooting and repair of the rear window defogger.
Wheel And Tire System:
Tire pressure recommendations, wheel torque specifications, and wheel bearing service.
Water Pump Assy:
Replacement procedures for the engine water pump.
Valve Clearance:
Procedures for checking and adjusting valve clearances (if applicable to specific engine).
Transmission Wire:
Wiring for automatic transmission control modules.
Transmission Valve Body:
Service and diagnosis of automatic transmission valve bodies.
Transmission Revolution Sensor:
Diagnosis and replacement of transmission speed sensors.
Transmission Control Cable:
Adjustment and replacement of gear shift cables.
Torque Converter Clutch:
Information on torque converter operation and service.
Throttle Body Assy:
Cleaning and diagnosis of the throttle body.
Thermostat:
Testing and replacement of the engine thermostat.
Supplemental Restraint System:
Detailed SRS (Airbag) system diagnosis, component replacement, and recalibration procedures.
Sun Roof System:
Service for power and manual sunroofs, including motor and track repair.
Steering System:
Complete coverage of steering gear, power steering pump, hoses, and steering column.
Steering Sensor:
Diagnosis of steering angle sensors if equipped.
Steering Column:
Service and replacement of the steering column assembly.
Starting System:
Diagnosis and repair of the starter motor, starter solenoid, and ignition switch.
Starter Switch:
Service for the ignition starter switch.
Starter Assy:
Removal, installation, and testing of the starter motor assembly.
Spiral Cable Sub-Assy:
Service for the clock spring within the steering column, crucial for airbag and horn.
Speed Sensor Front:
Diagnosis and replacement of wheel speed sensors for ABS.
Skid Control Sensor:
Information on ABS and traction control sensors.
Side Turn Signal Lamp Assy:
Troubleshooting and replacement of fender-mounted turn signals.
Side Mudguard:
Information on body side moldings and splash guards.
Side Air Bag Sensor Assy:
Diagnosis and replacement of side impact airbag sensors.
Shift Lock System:
Troubleshooting the shift lock mechanism on automatic transmissions.
Shift Select Lever Shaft:
Service for the gear selector shaft and linkage.
SFI System:
Sequential Fuel Injection system diagnosis and repair.
Seat Position Air Bag Sensor:
Information on occupant detection systems for airbags.
Seat Belt Warning System:
Troubleshooting the seat belt reminder light and sensor.
Seat Belt:
Service and replacement of seat belt assemblies.
Roof Headlining:
Procedures for removing and installing the interior roof lining.
Roof Drip Side Finish Moulding:
Information on exterior roof trim and weatherstripping.
Roof Antenna Pole Sub-Assy:
Service for the radio antenna.
Receiver Condenser Assy:
Air conditioning system component service.
Rear Wiper Rubber:
Replacement of rear wiper blades.
Rear Wiper Motor Assy:
Diagnosis and replacement of the rear windshield wiper motor.
Rear Wheel Alignment:
Specifications and procedures for rear wheel alignment.
Rear Suspension System:
Detailed coverage of rear axle, leaf springs, shock absorbers, and bushings.
Rear Suspension:
Components and service procedures for the rear suspension.
Rear Speaker Assy:
Audio system component service.
Rear Shock ABSorber Assy:
Replacement of rear shock absorbers.
Rear Seat Belt:
Service and replacement of rear seat belt assemblies.
Rear Door Window Frame Moulding:
Information on rear door trim and weatherstripping.
Rear Door Glass Weatherstrip:
Replacement of rear door glass seals.
Rear Door:
Body panel repair and trim service for rear doors.
Rear Combination Lamp Assy:
Troubleshooting and replacement of taillights and rear turn signals.
Rear Coil Spring:
Service for rear coil springs (if applicable, though XJ primarily uses leaf springs in rear).
Rear Bumper:
Repair and replacement of the rear bumper assembly.
Rear Brake:
Service and repair of rear drum or disc brakes.
Rear Axle Hub:
Service for rear axle shafts and hubs.
Rear Axle Beam:
Information on the rear axle housing and its components.
Radio Receiver Assy:
Audio system component service and diagnosis.
Radiator Assy:
Removal, installation, and repair of the radiator.
Quarter Window Assy:
Service for fixed rear side windows.
Pulley Compressor Assy:
Service for A/C compressor clutch and pulley.
Power Window Control System:
Diagnosis and repair of power window motors, switches, and regulators.
Power Steering Link Assy:
Service for power steering linkage components.
Power Steering:
Complete coverage of the power steering system, including pump, reservoir, hoses, and gearbox/rack.
Power Source:
General electrical system information and power distribution.
Power Mirror Control System:
Diagnosis and repair of power side view mirror systems.
Power Door Lock Control System:
Troubleshooting and repair of power door lock actuators and switches.
Passenger Air Bag Assy:
Information and procedures for the passenger airbag system.
Partial Engine:
Specific component overhauls or replacements.
Park Neutral Position Switch:
Diagnosis and adjustment of the neutral safety switch.
Parking Brake Lever:
Service and adjustment of the parking brake lever.
Parking Brake Cable:
Replacement and adjustment of parking brake cables.
Parking Brake:
Complete coverage of the parking brake system.
Output Shaft Assy:
Service for transmission output shafts.
Outer Rear View Mirror Assy:
Service for exterior side view mirrors.
Oil Pump:
Engine oil pump inspection, removal, and installation.
Oil Filter:
Oil filter replacement intervals and specifications.
Name Plate:
Information on VIN and vehicle identification plates.
Manual Transaxle System:
Coverage for 5-speed manual transmissions, including clutch and drivetrain components.
Manual Transaxle Oil:
Manual transmission fluid type and capacity.
Manual Transaxle Assy:
Repair and rebuild procedures for manual transmissions.
Maintenance:
Routine maintenance procedures, fluid changes, filter replacements, and lubrication.
Lubrication System:
Engine lubrication system, oil pressure, and oil cooler service.
Lighting System:
Headlights, taillights, interior lights, and accessory lighting troubleshooting.
License Plate Lamp Assy:
Service for the license plate illumination.
Knock Sensor:
Diagnosis and replacement of the engine knock sensor.
Introduction:
Overview of the manual, vehicle identification, and general information.
Instrument Panel:
Removal, installation, and repair of the dashboard and instrument panel components.
Input Shaft Assy:
Service for transmission input shafts.
Inner Rear View Mirror Assy:
Service for the interior rearview mirror.
Ignition System:
Spark plugs, ignition coils/distributor, and related components.
Hood:
Service for the hood latch, hinges, and exterior panel.
Heater Radiator Assy:
Heater core removal, installation, and related plumbing.
Heater Or Boost Ventilator Control:
Diagnosis and repair of HVAC controls and blower systems.
Heater & Air Conditioner:
Comprehensive coverage of the HVAC system, including components, refrigerants, and troubleshooting.
Headlamp Protector Retainer:
Information on headlight bezels and protective covers.
Headlamp Dimmer Switch Assy:
Service for the headlight high/low beam switch.
Headlamp Assy:
Headlight bulb replacement and housing service.
Generator Assy:
Synonymous with Alternator; coverage of the charging system.
Fuel Tank:
Fuel tank removal, installation, and inspection.
Fuel System:
Fuel pumps, lines, injectors, and filters for both gasoline and diesel (if applicable).
Fuel Pump:
Diagnosis and replacement of the fuel pump assembly.
Fuel Injector:
Cleaning, testing, and replacement of fuel injectors.
Front Wheel Alignment:
Specifications and procedures for front wheel alignment.
Front Suspension System:
Detailed coverage of steering knuckles, control arms, ball joints, tie rods, and bushings.
Front Suspension Arm:
Service for control arms and their associated components.
Front Suspension:
Components and service procedures for the front suspension.
Front Stabilizer Bar:
Service and replacement of the front sway bar and links.
Front Speaker Assy:
Audio system component service.
Front Shock ABSorber:
Replacement of front shock absorbers and struts.
Front Seat Belt:
Service and replacement of front seat belt assemblies.
Front Seat Airbag Assy:
Information and procedures for front seat mounted airbags.
Front Marker Lamp Assy:
Troubleshooting and replacement of front side marker lights.
Front Drive Shaft:
Service and repair of the front driveshaft, including U-joints and CV joints.
Front Door Glass Weatherstrip:
Replacement of front door glass seals.
Front Door:
Body panel repair and trim service for front doors.
Front Differential Oil Seal:
Procedures for replacing the front differential oil seals.
Front Bumper:
Repair and replacement of the front bumper assembly.
Front Brake:
Service and repair of front disc brakes, including pads, rotors, and calipers.
Front Axle Hub:
Service for front axle shafts and hubs, including wheel bearing replacement.
Floor Shift Parking Lock Cable:
Service for the parking brake cable integrated with the floor shifter.
Floor Shift Assy:
Service for the floor-mounted gear shifter assembly.
Fender Panel Mudguard:
Information on fender components and splash guards.
Exhaust Pipe:
Repair and replacement of exhaust system components.
Exhaust:
Exhaust system components, including manifold, catalytic converter, muffler, and pipes.
Back Door Glass:
Service for the rear liftgate glass.
Back Door Garnish:
Information on rear liftgate interior and exterior trim panels.
Back Door:
Body panel repair and trim service for the rear liftgate.
Automatic Transaxle Fluid:
Automatic transmission fluid type, capacity, and change intervals.
Automatic Transaxle Assy:
Detailed overhaul, diagnosis, and repair procedures for automatic transmissions.
Audio & Visual System:
Service and troubleshooting for the radio, speakers, and any other integrated audio/visual components.
Antenna Cord Sub-Assy:
Service for antenna cabling.
Amplifier Antenna Assy:
Service for powered antenna amplifiers.
Air Conditioning System:
Comprehensive coverage of the A/C system, including refrigerant handling, component diagnosis, and repair.
Air Conditioning Blower Assy:
Diagnosis and replacement of the cabin air blower motor.
Air Conditioning Amplifier Assy:
Service for climate control amplifiers.
Air Conditioner Refrigerant:
Refrigerant type (R-134a for this era) and charging procedures.
Air Bag Sensor Rear:
Diagnosis and replacement of rear impact airbag sensors.
Air Bag Sensor Front:
Diagnosis and replacement of front impact airbag sensors.
Procedures Included
Maintenance:
Regular maintenance schedules, fluid checks and changes, filter replacements, lubrication points.
Troubleshooting:
System-specific troubleshooting guides, diagnostic flowcharts, and common problem resolutions.
Repair Procedures:
Step-by-step instructions for disassembling, repairing, and reassembling all major vehicle components.
Diagnostics:
Detailed diagnostic procedures for electrical and mechanical systems, including use of scan tools.
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical values, and performance data.
Wiring Diagrams:
Comprehensive and detailed wiring schematics for all electrical systems.
Bodywork And Collision Repair:
Procedures for body panel alignment, repair, and replacement.
Engine Rebuild:
Complete engine overhaul procedures, including machining and assembly.
Transmission Overhaul:
Detailed rebuild instructions for both manual and automatic transmissions.
Suspension And Steering Repair:
Component replacement and alignment procedures for front and rear suspension and steering.
Brake System Service:
Brake pad/rotor replacement, caliper service, brake bleeding, and ABS diagnostics.
HVAC Service:
Air conditioning system diagnosis, refrigerant servicing, and component replacement.
Safety Systems Service:
SRS airbag system diagnostics, component replacement, and recalibration.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, with detailed diagnostic procedures and wiring diagrams.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
Windows, Mac, and Linux operating systems.
Print Quality
Printability:
All pages are printable without restriction.
Image Quality:
High-quality, clear illustrations, drawings, and photos.
Binding Type
Binding:
Digital Download (PDF) - No physical binding.
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Likely includes the 4.0L (242 cu in) Inline-6 and potentially the 2.5L (150 cu in) Inline-4.
Performance
4.0L Horsepower:
Approximately 190 hp @ 4750 rpm (varies slightly by year/tune).
4.0L Torque:
Approximately 220 lb-ft @ 3250 rpm (varies slightly by year/tune).
Fuel System
Fuel Injection:
Multi-point fuel injection (MPFI) or Sequential Fuel Injection (SFI) depending on the specific engine.
Fuel Type:
Unleaded Gasoline
Cooling System
Coolant Type:
Ethylene glycol based coolant (e.g., Mopar Antifreeze/Coolant, HOAT or OAT depending on original fill, but typically HOAT for this era).
Lubrication System
Oil Type:
Typically 10W-30 or 10W-40 API SG or higher for the 4.0L engine. Refer to manual for precise specification.
Oil Capacity:
Approximately 6 US quarts (5.7 liters) with filter for the 4.0L engine. Refer to manual for precise specification.
🔧 Transmission
Standard
Transmission Type:
Manual: NV2500 5-speed, Automatic: AW4 4-speed automatic.
Optional
Transmission Type:
Depending on trim and engine, the 4-speed automatic (AW4) was very common.
Features
Transfer Case:
Command-Trac NP231 part-time 2-speed transfer case.
Manual Transmission Fluid
Fluid Type:
GL-3 or GL-4 gear oil, typically SAE 75W-90 or 80W-90.
Automatic Transmission Fluid
Fluid Type:
Dexron III/Mercon Automatic Transmission Fluid.
Fluid Capacity:
Approximately 8 US quarts (7.6 liters) for the AW4. Refer to manual for precise specification.
📐 Dimensions
Exterior
Wheelbase:
108.7 inches (2761 mm)
Length:
169.9 inches (4315 mm)
Width:
66.9 inches (1700 mm)
Height:
63.7 inches (1618 mm)
Weights
Curb Weight:
Approximately 3,300 - 3,700 lbs (1497 - 1678 kg) depending on configuration.
Gross Vehicle Weight Rating:
Varies by configuration, typically around 4,500 - 4,800 lbs.
Suspension Geometry
Front Suspension Type:
Solid axle with leaf springs and track bar (leaf spring conversion likely by '95 for many models, but some earlier configurations may persist).
Rear Suspension Type:
Solid axle with leaf springs and track bar.
Wheels And Tires
Bolt Pattern:
5 x 4.5 inches (5 x 114.3 mm)
Standard Tire Size:
Typically P225/75R15, P235/75R15, or P215/85R16 depending on trim and options.
Wheel Size:
Typically 15x7 or 15x8 inches.
🛡️ Safety Features
Ratings
NHTSA Front Crash Rating:
N/A for this era, as comprehensive ratings were not standardized as they are today.
IIHS Crash Test Data:
N/A for this era.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on some models, typically rear-wheel ABS.
Passive Features
Airbags:
Driver and passenger airbags.
Seat Belts:
Front and rear seat belts; driver and front passenger feature pre-tensioners.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM radio with cassette player was standard; optional CD player available on some trims. Basic speaker systems.
Driver Assistance
ABS Availability:
Optional rear-wheel Anti-lock Braking System (ABS).
Connectivity
Connectivity Features:
Limited by era; primarily focused on basic audio and power features. No advanced smartphone integration or telematics.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-5,000 miles (4,800-8,000 km) or 6 months, whichever comes first, using the correct oil viscosity and API service rating. Refer to manual for precise recommendation.
Tire Rotation:
Every 5,000-7,500 miles (8,000-12,000 km).
Coolant Flush:
Typically every 30,000 miles (48,000 km) or 2 years. Refer to manual for specific interval.
Transmission Fluid Change:
Automatic: ~30,000 miles (48,000 km). Manual: ~50,000-60,000 miles (80,000-96,000 km). Refer to manual.
Spark Plugs:
Typically every 30,000-60,000 miles depending on type (copper vs. platinum). Refer to manual.
Fluid Specifications
Engine Oil Spec:
Refer to manual, likely SAE 10W-30 or 10W-40, API SG or higher.
Coolant Spec:
Ethylene glycol-based coolant.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid Spec:
Dexron III/Mercon ATF.
Known Issues
Common Problems:
Common issues include: head gasket leaks on the 4.0L engine, starter relay failures, worn leaf spring bushings, transfer case chain stretch, and aging electrical connectors/grounds. The AW4 transmission is generally very robust.
Critical Checks:
Regularly check for coolant leaks around the engine block and cylinder head. Inspect U-joints for wear. Monitor brake system performance.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Jeep has a storied history in off-road vehicles, dating back to its military origins in World War II. The brand is synonymous with ruggedness and capability.
Model Evolution
Cherokee Xj Genesis:
The Cherokee XJ was revolutionary for its time, debuting in 1984 as the first compact SUV to offer unibody construction, providing a lighter and more refined ride compared to traditional body-on-frame SUVs.
Cherokee Xj 1995 Updates:
The 1995 model year saw continued refinement. Key updates for this generation often included interior revisions, improved safety features, and engine/transmission enhancements over its production run (1984-2001).
Production
Production Years:
1984-2001 (Globally, North American production ended earlier for some variants).
Assembly Locations:
Toledo, Ohio, USA (main assembly plant for North America).
🏆 Awards & Recognition
Recognitions
Off Road Awards:
The Jeep Cherokee XJ, particularly the 4.0L variant, is widely recognized and revered by off-road enthusiasts and publications for its off-road prowess and reliability.
Industry Impact:
Considered a foundational vehicle in the SUV segment, influencing the design and development of many subsequent sport utility vehicles.

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Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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