2000 Jeep Cherokee XJ Factory Service Manual OEM (PN 07353900)

• Covers 2000 Cherokee XJ SE, Sport, Classic, and Limited models with the 2.5L and 4.0L gasoline engines, plus the 2.5L diesel variant. Identification charts distinguish two- and four-door bodies, 4x2 and 4x4 configurations, and left- and right-hand-drive vehicle lines.
• Gasoline engine repair covers removal, cylinder-head service, valve timing, piston-ring fitting, crankshaft bearing fitting, and rear main seal replacement, supported by compression, cylinder-leakage, and oil-pressure tests.
• Factory teardown and reassembly procedures cover AX5 and NV3550 manual transmissions, 30RH and AW-4 automatics, and NV231 and NV242 transfer cases. Automatic-transmission coverage extends to hydraulic pressure testing, valve bodies, clutch assemblies, and adjustment procedures.
• Differential repair addresses 181/186 FBI front axles, the 194 RBI rear axle, and the 8¼-inch rear axle, including Trac-Lok units. Procedures cover pinion depth, bearing preload, gear backlash, and contact-pattern analysis.
• Fuel-delivery troubleshooting includes gasoline fuel-pump pressure, delivery-capacity, leak-down, and amperage tests, plus injector and throttle-body checks. Diesel procedures address air in the fuel supply, system bleeding, and injection-pump timing.
• Brake service includes caliper and drum-brake work, scan-tool-assisted ABS bleeding, and hydraulic control unit replacement. Chassis sections cover wheel alignment, suspension component replacement, power-steering pressure testing, and steering-gear service.
• The 516-page wiring section includes Fuel/Ignition System and Transmission Control System diagrams, Powertrain Control Module (PCM) circuit references, Connector Pin-Outs, and harness connector and splice locations.

Inside the Manual

DaimlerChrysler’s 2000 Jeep Cherokee Electronic Service Manual is a 2,100-page PDF set across 60 files: 1,890 pages in the main sections, 208 pages of supplemental material, including diesel and export coverage, and two navigation pages. It is suited to experienced mechanics comfortable with electrical testing and precision assembly, with DRB III scan-tool access required for specified procedures.

Routine maintenance coverage separates gasoline maintenance schedules A and B from the diesel schedule. The reference data includes fluid-capacity charts, lubricant requirements, component-specific torque tables, bearing clearances, inspection limits, and electrical test specifications.

Gasoline ignition coverage distinguishes the 2.5L distributor from the 4.0L coil rail. The 4.0L procedures include camshaft-sensor and oil-pump-drive alignment, with DRB verification of fuel synchronization rather than ignition-timing adjustment.

Diesel-Specific Repair Coverage

The diesel engine section identifies the VM engine as DD85C and covers cylinder-head work, cylinder-liner replacement and protrusion checks, internal vacuum-pump service, and crankshaft bearing replacement. Related sections address turbocharger replacement, glow-plug and relay testing, and the Bosch VP36 injection pump’s electronic controls.

Tool references include the VM.1003 injection-pump gear-removal set and VM.1011 dial-indicator adapter. The pump procedures flag an engine-damage risk if the engine is rotated while the gear-removal tool remains installed.

Cooling, Body, and Repair References

Cooling-system chapters cover leak testing, coolant-flow checks, and water-pump and fan-drive replacement. Heating and air-conditioning service includes refrigerant recovery, evacuation and charging, heater-core and evaporator replacement, and heater-A/C housing disassembly.

Body procedures address water-leak detection, stationary glass, door hinges, window regulators, and liftgate components. Exhaust routing and bumper mounting-bracket service are covered as well.

The AW-4 Component Application Chart, Gear Tooth Contact Patterns, and Frame Dimensions drawings provide references for transmission operation, differential setup, and structural measurements. NV3550 assembly cautions explain how incorrect synchronizer positioning can damage the housings, shift forks, and gears.

Diagnostic Scope and Service Precautions

Diagnostic trouble-code tables, onboard monitor descriptions, evaporative-emission controls, and diesel EGR coverage are included. However, separate Powertrain and Chassis Diagnostic manuals are not part of this set. Those publications are referenced for certain code-specific, diesel EGR-flow, and ABS diagnostic routines. Diesel injection-pump coverage includes replacement and timing, not internal pump overhaul.

Working on high-pressure fuel systems or hoisting a unibody platform carries inherent risks. Follow the designated lifting points and pressure-release precautions in the manual before the relevant service work. The air-conditioning section specifies that refrigerant-system repairs should be performed only by qualified service personnel.