Jeep Cherokee XJ Factory Service Manual (1997)

This Chrysler Corporation factory service manual covers the 1997 Jeep Cherokee XJ in SE, Sport, and Country trims, with two- and four-door, 2WD and 4WD, and left- and right-hand-drive configurations. The main engine repair sections cover the 2.5L and 4.0L MPI gasoline engines. Integrated supplement sections cover service and diagnosis for the 2.5L VM turbo-diesel.

Searchable PDF with Chapter Bookmarks

Text search and diagram detail: Search the service text and use embedded bookmarks to jump to chapters and subsections, including the diesel material. Small pin numbers and wire codes are easiest to read when zoomed in.

The download is one printable English-language PDF with 1,724 pages, including 74 pages of diesel supplement material and 38 blank pages.

Engine, Drivetrain, and Electrical Service

These selected highlights cover common shop jobs. The manual also includes tire wear diagnosis and EVAP canister replacement.

• Gasoline engines and cooling: Step-by-step engine removal and internal repair, with cylinder compression and leakage tests, cooling-system pressure checks, and radiator and water-pump replacement.

• Clutch, transmission, and transfer case: Clutch and hydraulic linkage service, manual gearbox teardown, automatic transmission testing and overhaul, and NV231 and NV242 transfer case repair.

• Axles, steering, and suspension: Propeller-shaft and Cardan-joint service, differential setup, wheel alignment, and repair procedures for steering, front link-and-coil suspension, and rear leaf springs.

• Fuel and engine controls: Fuel pump pressure, delivery, leak-down, and current-draw tests, plus tank, pump module, quick-connect fitting, and injector rail service.

• Brakes, HVAC, and body: Base brake and all-wheel ABS bleeding, R-134a recovery and charging, heater-A/C housing repair, and frame, bumper, and body-panel service.

• Vehicle electrical systems: Battery, starter, charging, and ignition diagnosis, with separate service sections for the instrument panel, lighting, wipers and washers, airbag, heated glass, speed control, and power accessories.

• Wiring and circuit tracing: Power distribution, junction block, fuel and ignition, transmission control, ABS, and heater-A/C schematics, with connector pinouts and ground and splice locations.

The manual suits technicians and experienced owners who are comfortable with vehicle service measurements, electrical testing, and the special tools called out for individual jobs.

Maintenance and Mechanical Repair

Schedule A and Schedule B distinguish normal and severe-duty service. The schedules cover oil and filters, plugs and ignition cables, belts, coolant, driveline fluids, brake inspections, and steering-linkage lubrication. The lifting section identifies frame-rail contact points and explains how removing major assemblies changes the vehicle’s balance.

The gasoline engine chapters include head-gasket and intake-leak checks, oil-pressure testing, cylinder-head and valvetrain repair, camshaft and timing work, piston and ring fitting, and crankshaft and connecting-rod bearing inspection. Clutch coverage includes disc runout, contamination, flywheel inspection, and pilot and release bearing service.

The AX5 and AX15 chapters cover manual gearbox teardown and inspection. The 30RH and AW4 sections add road, stall, hydraulic pressure, time-lag, cooler-flow, and solenoid tests where applicable, along with pump, valve body, clutch pack, and geartrain repair. The 181 FBI front axle and 194 RBI and 8¼ rear axle chapters cover pinion depth, bearing preload, backlash, gear contact patterns, and Trac-Lok service where fitted.

Fuel, Electrical, and Chassis Diagnostics

The fuel tests help separate low pump output from regulator, check-valve, and injector leakage faults before parts are replaced. Coverage includes ASD and fuel pump relay checks, PCM inputs and outputs, throttle-body minimum airflow, and MAP, throttle-position, oxygen, coolant-temperature, and intake-air-temperature sensor tests.

The tool references identify Fuel Pressure Gauge Set 5069, adapters 6539 and 6631, pump-module locknut tool 6856, and fixed-orifice tool 6714. Driveline and engine sections identify inclinometer 7663, timing-cover alignment and seal tool 6139, and rear main seal installer 6271A.

An incorrectly indexed fuel pump module can let the sender float rod contact the tank. Tightening rubber-bushed suspension joints with the suspension hanging can affect ride quality and cause premature bushing wear.

The ABS section covers the hydraulic control unit, controller, and wheel-speed sensors. The body and HVAC sections add frame dimensions, tow hooks, skid plates, trailer hitch, doors, liftgate, glass, seats, welded panels, refrigerant performance testing, and heater-A/C housing repair. For full powertrain DTC fault trees and detailed ABS scan-tool diagnosis, the manual directs readers to the separate Powertrain Diagnostics Procedures and Chassis Diagnostic Manual.

Diesel Supplement Coverage

The diesel material adds its own maintenance schedules, left- and right-hand-drive turbocharger and exhaust procedures, injection pump timing, injector and high-pressure line service, fuel-system bleeding, and filter, water separator, and fuel heater service. It also covers glow plug and engine-control tests, power steering, and selected AX15 and NV231 procedures. Full internal engine overhaul coverage is for the gasoline engines.

Fuel Pressure and Glow Plug Test Preview

For the gasoline fuel system, the pressure test specifies 49.2 ± 5 psi at warm idle. In the warm-engine leak-down test, residual pressure should stay at or above 30 psi for five minutes after shutdown.

For the 2.5L diesel, the glow plug specifications give an approximate draw of 22–25 A per plug initially and 9–12 A per plug after 20 seconds of operation.