Jeep Cherokee XJ (2000) Repair Manual — Sport, SE & Limited (P/N 81-370-0046)

The 2000 Jeep Cherokee XJ service manual (P/N 81-370-0046) covers the Sport, SE, and Limited series in 4x2 and 4x4 form. It includes two- and four-door body styles, left- and right-hand-drive configurations, and separate service sections for the 2.5L and 4.0L gasoline engines and the 2.5L turbo-diesel.

PDF Search, Bookmarks, and Page Count

Searchable workshop text and chapter bookmarks help you find procedures and wiring references. The group locator is a linked image. Zooming in makes small pin numbers and wire color codes easier to read on dense schematics.

The download is a single 2,099-page printable PDF. The total includes the cover, the group locator, and 41 otherwise blank pages that carry only a footer.

Engine, Drivetrain, and Electrical Repair Highlights

These are selected workshop topics. Other sections cover Sentry Key immobilizer diagnosis and rear window defogger testing.

• Gasoline engine repair covers compression and leakage diagnosis, oil-pressure testing, valve timing, cylinder-head and valvetrain work, and engine removal and installation.
• Turbo-diesel service includes engine removal, cylinder-head and liner work, turbocharger and exhaust service, fuel-system bleeding, injection-pump timing, and glow-system testing.
• Transmission and transfer case repair includes AX5 and NV3550 manual gearboxes, 30RH and AW-4 automatics, and NV231 and NV242 transfer cases. Clutch service, propeller-shaft angle and vibration diagnosis, and U-joint repair are also covered.
• Axles, suspension, and steering include 181-FBI and 186-FBI front axles, 194-RBI and 8-1/4 rear axles, standard and Trac-Lok differentials, wheel alignment, coil and leaf springs, and steering gear and linkage.
• Base brakes and ABS cover hydraulic diagnosis, master-cylinder and system bleeding, rotor and drum inspection, caliper and wheel-cylinder repair, parking-brake adjustment, wheel-speed sensors, and hydraulic-control-unit service.
• Group 8W wiring diagrams cover power and ground distribution, connector pinouts and locations, and splices. Circuits include PCM, fuel and ignition, transmission control, ABS, airbags, HVAC, lighting, trailer towing, and power accessories.

The manual suits technicians and experienced DIY mechanics familiar with electrical testing, precision measurements, and special service tools.

Vehicle Identification and Maintenance

VIN tables distinguish drivetrain, body style, engine, and other build details. The identification section also explains the Vehicle Safety Certification label, E-Mark label, and manufacturer plate. These references help match the vehicle to the applicable procedure before parts or tools are selected.

Maintenance includes normal Schedule A, severe-duty Schedule B, diesel-specific service, lubricant requirements, fluid-capacity tables, towing guidance, and lifting points. Component illustrations and special-tool numbers support service work. Replacement part-number lookup requires a parts catalog.

Engine and Fuel System Repair

Gasoline engine procedures include timing-chain, camshaft, and oil-pump service, plus bearing, piston, and connecting-rod fitting. Diagnostic sections address oil leaks, head-gasket leaks, and hydrostatic lock.

Diesel repair covers valves, hydraulic tappets, camshaft bearings, oil and internal vacuum pumps, and left- and right-hand-drive installations. The fuel and emissions sections cover the fuel filter and water separator, high-pressure lines, injectors, boost and engine-speed sensors, glow plugs, and EGR. The leak-detection-pump section refers testing to the separate Powertrain Diagnostic Procedures manual.

Transmission Testing and Axle Setup

The 30RH chapter covers hydraulic-pressure and clutch and band air tests, valve-body and clutch-pack repair, cooler flushing, and band and cable adjustments. The AW-4 chapter adds transmission control module, solenoid, speed-sensor, time-lag, pressure, and cooler-flow tests. The manual gearbox and transfer case chapters include internal disassembly, inspection, and reassembly.

Axle procedures cover differential removal, pinion seals and bearings, matched ring-and-pinion replacement, and checks for pinion depth, preload, backlash, and runout. Tools referenced include spreader W-129-B, dial indicator C-3339, pinion depth set 6774, ball stud kit 6289, and pinion seal installer C-3972-A. Torque tables, wear limits, and clearances support setup and inspection.

The manual distinguishes the 181-FBI pinion preload shims from the 186-FBI collapsible spacer. Over-crushing the spacer can require a new one, and tightening suspension bushings with the axle hanging can shorten bushing life.

Wiring, HVAC, and Body Service

Group 8W pairs wiring and terminal repair with connector views and junction-block, ground, and splice locations. The starting-system chapter covers voltage-drop testing, which helps isolate resistance in the starter feed circuit before replacing components.

Heating and A/C coverage includes performance and leak testing, vacuum controls, refrigerant recovery, evacuation and charging, compressor and clutch service, heater-core and evaporator access, and diesel-specific layouts. Body sections cover stationary glass, doors and regulators, seats and trim, liftgate service, water leaks and wind noise, weld and sealing locations, structural adhesives, body-opening dimensions, and gap and flush measurements.

Illustrations include Wheel Alignment Measurements, Universal Joint Angle Example, Gear Tooth Contact Patterns, Pinion Gear Depth Gauge Tools, and the 2.5L diesel coolant-flow diagram.

For axle, brake, suspension, or driveline repair, follow the manual’s lifting points and support the vehicle on properly rated stands. Removing major chassis or drivetrain components can shift the vehicle’s center of gravity.

Sample Compression and Cylinder Liner Specs

For the cranking compression test, the manual calls for a fully charged battery and a starter in good working order. Both gasoline engines have a listed range of 120–150 psi, with a maximum variation of 30 psi between cylinders.

For the 2.5L diesel, installed cylinder liner protrusion is specified at 0.01–0.06 mm above the block deck, measured on the camshaft side with the liner clamped in place.