Jeep Cherokee XJ 2001 Service & Repair Manual Set (P/N 81-370-0046)

Use the 2001 supplement with the included 2000 service manual: the supplement contains new or updated information, while unchanged procedures remain in the base manual. The diagnostic books provide separate fault-finding procedures for their identified systems and engine applications.

The dedicated gasoline powertrain diagnostic book covers the 4.0L engine. AX15 information appears in the base manual’s lubrication specifications; the detailed manual-transmission repair chapters cover AX5 and NV3550.

PDF Text Search, Bookmarks and Wiring Detail

Search and navigation: The base manual and five diagnostic books have searchable text and embedded bookmarks. Text search in the supplement excludes many wiring sheets. Internal chapter bookmarks are available, but the two service PDFs’ “FOREWORD” bookmarks target a filename absent from the ZIP. Small wiring labels require enlargement; sampled labels remain readable when zoomed.

The ZIP contains nine printable PDFs totaling 3,664 pages, including the two separate supplementary sheets. The publication totals above also include their internal contents pages, notes, blank pages and comment forms.

Engine Overhaul, Drivetrain Setup and Electronic Fault Finding

The following selected coverage highlights outline the main workshop content rather than reproduce the complete contents lists. Other topics include power-window troubleshooting and heating and air-conditioning service.

• Engine repair: Step-by-step procedures for cylinder-head work, valve-train service, timing components, pistons, connecting rods, crankshaft bearings, oil pumps and engine removal.

• Transmission and transfer cases: AX5, NV3550, 30RH and AW4 disassembly, inspection and assembly procedures, plus NV231 and NV242 transfer-case service.

• Axles and driveline: Differential setup, pinion-depth measurement, bearing-preload adjustment, gear-contact checks, universal-joint service and propeller-shaft inspection.

• Brakes, suspension and steering: Hydraulic brake service, Teves Mark 20 ABS diagnosis, wheel-alignment checks, hub/bearing replacement and steering-component repair.

• Powertrain diagnostics: DRBIII-based fault isolation for the 4.0L gasoline and 2.5L VM diesel systems, with separate AW4 electronic-transmission tests.

• Body electronics and wiring: Airbag, instrument-cluster, security and CCD-bus diagnosis supported by system schematics, connector pinouts and component-location views.

Suited to technicians and experienced owners familiar with workshop measurements; the electronic diagnostic procedures require DRBIII equipment, and internal drivetrain work calls for the specified specialty tools.

Engine, Cooling and Exhaust Work

Gasoline-engine coverage addresses the cylinder head, valve train, timing chain, camshaft, pistons, connecting rods, crankshaft, rear main seal, oil pump and cylinder block. Diesel mechanical sections add cylinder-head service, hydraulic tappets, cylinder-liner inspection and internal vacuum-pump work.

Cooling-system material identifies the reverse-rotating water pumps used on the gasoline engines and the belt routing relevant to correct operation. The manual warns that fitting the wrong pump can cause overheating.

The base manual distinguishes early- and late-build gasoline exhaust layouts, including exhaust pipes, catalytic converters, mufflers and tailpipes.

Chassis Measurements and Differential Rebuilding

Suspension and shafts: Alignment material covers caster, camber and toe. Component procedures address shocks, coil springs, control arms, stabilizer bars, track bars, steering knuckles and the one-piece front hub/bearing assembly. Propeller-shaft sections include joint-angle measurement, runout checks and shaft removal and installation.

Differential setup: The FBI, RBI and 8¼ axle sections explain pinion depth, pinion-bearing preload, differential-bearing preload, backlash and tooth-contact patterns. Capacity tables distinguish axle applications, AW4 service versus overhaul fills, NV3550 lubrication, NV231/NV242 transfer cases and Trac-Lok friction-modifier requirements.

Factory-tool references help identify equipment needed before planning an axle rebuild. Examples include wheel-stud remover C-4150A, pinion-yoke holder 6958, seal installer C-3972-A with handle C-4171, and pinion-depth tooling from sets 6774/6987.

The front-axle procedures warn that excessive pinion preload can damage the collapsible spacer or bearings; loosening the nut is not a corrective substitute. ABS-equipped axle-shaft procedures also identify the pressed-on tone ring and nearby wheel-speed sensor as vulnerable to damage.

Before axle, suspension, driveline, brake or underbody repair, follow the manual’s hoisting and support guidance, including its warning about changed vehicle balance when drivetrain components are removed.

DRBIII Diagnostics and Circuit Identification

Body and ABS: Body diagnostics address the Airbag Control Module, Instrument Cluster, Compass/Mini-Trip Computer, Remote Keyless Entry and Sentry Key Immobilizer System. CCD-bus communication tests and separate Teves Mark 20 ABS/CAB procedures support module and circuit fault isolation.

Gasoline and diesel controls: The 4.0L book covers JTEC powertrain diagnosis. The diesel volume addresses ECM/PCM and SKIM faults, no-start conditions, sensor circuits, glow-system faults, EGR, injection-pump concerns and turbocharger diagnosis.

AW4 controls: Dedicated tests address the Transmission Range Sensor, input/output speed sensors, solenoid circuits and TCM/PCM communication over the CCD bus. Connector pinouts and component locations connect these tests to the vehicle wiring.

Diagram examples include “2001 JEEP XJ 4.0L JTEC SYSTEM,” “Vehicle Communication,” “Instrument Cluster,” “Transmission Connectors 4.0L Engine,” “Headliner Splices” and “2000 XJ Teves Mark 20 Antilock Brake System.” LHD/RHD location views and connector/splice identification support tracing circuits beyond a schematic alone.

A Preview of Axle Setup and Hub Fastener Specifications

For the 181-FBI/186-FBI front axles, the supplement lists ring-gear backlash of 0.12–0.20 mm (0.005–0.008 in) and pinion-bearing preload with new bearings of 1.7–3.4 N·m (15–30 in-lb). Its 8¼ rear-axle adjustment procedure specifies final backlash of 0.15–0.203 mm (0.006–0.008 in).

Front-axle fastener tables distinguish the axle-shaft nut at 237 N·m (175 ft-lb) from the hub/bearing mounting bolts at 102 N·m (75 ft-lb).