Jeep Cherokee XJ / Wrangler YJ 1994 Service Manual Set (P/N 81-370-4146)

Use the R-134a supplement with the base manual for the applicable late-build vehicles. The ATSG booklet provides a separate AW-4 bench reference.

Coverage limit: Group 3, Rear Suspension and Axles, is missing from the main PDF, although its entries remain in the index. Owner's operating instructions and separate service-training material are outside this set.

Text Search, Bookmarks and File Layout

Search and diagram detail: The main PDF has searchable service text and chapter bookmarks; some tables and illustration labels are not searchable. The AW-4 PDF has no usable text search or embedded bookmarks. Small wiring and component labels require zooming.

ZIP download containing 2 printable PDFs and 1,818 pages total. The main file combines the base manual and R-134a supplement; the AW-4 booklet is separate. The totals include 2 introductory cover/navigation pages and 31 blank separator pages.

Powertrain, Chassis and Electrical Service

The following is a selected content overview, rather than a complete contents list. Further topics include propeller-shaft vibration diagnosis, U-joint replacement and tire/wheel vibration checks.

• Engine repair: 2.5L/4.0L removal and installation, compression/leakage diagnosis, and step-by-step cylinder-head, valvetrain, timing, lubrication, piston/rod, crankshaft and block repair.

• Fuel, ignition and cooling: MFI fuel-pressure and injector tests, PCM input/output checks, ignition, exhaust and emissions service, plus cooling-system diagnosis and radiator, thermostat and water-pump service.

• Transmissions and transfer cases: Clutch service; AX 4/5, AX 15, 30RH/32RH and AW-4 diagnosis, removal and overhaul; automatic valve-body service and adjustment; NP231/NP242 teardown, reassembly and linkage work.

• Front chassis and steering: XJ link/coil and YJ leaf-spring suspension, 2WD tube axle and Model 30 service, alignment, hub/bearing, ball-stud, track-bar and manual/power steering-gear repair, plus tilt/non-tilt column service.

• Brakes and electrical tests: Disc/drum service, standard and ABS bleeding, ECU/HCU and wheel-sensor work, plus battery, starter, charging, ignition-off-draw, lighting and accessory diagnosis.

• Body and climate control: Doors, glass, seats, liftgate/tailgate, tops, trim, bumpers, frame/unibody inspection and refinishing, plus heating, A/C and late-production R-134a service.

• Wiring references: Separate YJ, XJ and XJ RHD circuits covering factory options, connectors, pin identification, splices, fuse charts and relay banks; add-on equipment is outside the wiring coverage.

The Chrysler service information was prepared for professional automotive technicians involved in daily repair operations and assumes workshop knowledge, measuring tools and normal shop equipment.

Configuration and Fuel-System Diagnosis

Vehicle coverage includes XJ two- and four-door 2WD/4WD configurations and YJ two-door 4WD models. VIN, vehicle code-plate, sales-code and safety-certification information supports configuration checks before parts are ordered; engine, transmission, transfer-case and axle identification locations are also documented.

The MFI sections distinguish monitored circuits from faults the PCM cannot detect directly, including fuel-pressure and compression problems. This connects electronic fault codes with mechanical tests rather than treating a DTC as proof of a failed part.

The 1994 fuel-pump information documents deletion of the ballast resistor and bypass relay. DRB scan-tool operation refers to separate Powertrain Diagnostic Procedures manuals, which are not included.

AW-4 Testing and Transfer-Case Variants

The ATSG booklet adds hydraulic-pressure, stall, time-lag and solenoid diagnostics. Its Component Application Chart relates solenoid states and clutch/brake application to gear selection.

The NP231 chapter distinguishes versions with and without synchronizer components.

Late-Build R-134a Service

The supplement provides refrigerant-system diagnosis, performance testing, leak testing, evacuation and charging information. Its SD-709 compressor is serviced as an assembly; clutch and coil service are covered.

Diagrams, Tools and Workshop Specifications

Reference illustrations include Model 30 Gear Tooth Contact Patterns, secondary-ignition wiring and vacuum-routing schematics for both gasoline engines, XJ/YJ/XJ-RHD splice-location views, and XJ/YJ A/C performance charts.

Factory tool references include DRB II, Model 30 Spreader W-129-B and Bearing Installer C-3716-A, plus AW-4 Tool Kit 6294 and Pressure Test Port Adapter 7554. The adapter is not included in that tool kit.

Component-specific torque data, fluid capacities, pressure-test values, electrical specifications, wear limits, clearances and adjustment tables accompany the procedures.

Model 30 and Suspension Repair Cautions

The Model 30 procedure warns that over-spreading can distort the housing and increasing total shim-pack thickness can cause excessive bearing preload and damage. The suspension sections also flag premature rubber-bushing wear from tightening outside normal ride height.

Follow the specified hoisting points and safety precautions when working with fuel pressure, brakes, heavy assemblies and refrigerant.

Sample Fuel-System and AW-4 Test Specifications

For both gasoline engines, the fuel-pressure test lists approximately 214 kPa (31 psi) at idle with regulator vacuum connected and 269 kPa (39 psi) with it disconnected.

Injector resistance is approximately 14.5 ± 1.2 ohms at 20°C (68°F). The AW-4 valve-body solenoid test specifies 11–15 ohms.