1994 JEEP CHEROKEE Service Repair Manual

CHRYSLER
CORPORATION
SERVICE MANUAL and SUPPLEMENT
1994 JEEP
T
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME-
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to
make additions to or improvements in its products without imposing any ob-
ligations upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright 1993 Chrysler Corporation 20M0693
NEXT PAGE©

FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner 's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components. To as-
sist in locating a group title page, use the Group Tab Locator on the following page. The solid bar after the
group title is aligned to a solid tab on the first page of each group. The first page of the group has a contents
section that lists major topics within the group. If you are not sure which Group contains the information you
need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide Chrysler
Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re-
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930.
NEXT PAGE©

NOTE: Groups with the suffix ª-Sº are supplements to
the original service manual publication.
GROUP TAB LOCATOR PAGE
INIntroduction
0Lubrication and Maintenance
2Front Suspension and Axle
3Rear Suspension and Axles
5Brakes
6Clutch
7Cooling System
8Electrical
9Engines
11Exhaust System and Intake Manifold
13Frame and Bumpers
14Fuel System
16Propeller Shafts
19Steering
21Transmissions and Transfer Cases
22Wheels and Tires
23Body Components
24Heating and Air Conditioning
24-SAir Conditioning
25Emission Control Systems
Index
Index Supplement
Service Manual Comment Forms (Rear of Manual)

CHRYSLER
CORPORATION
SERVICE MANUAL
1994 JEEP
T
To order the special service tools used and
illustrated, please refer to the instructions on
inside back cover.
NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME-
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.
Chrysler Corporation reserves the right to make changes in design or to
make additions to or improvements in its products without imposing any ob-
ligations upon itself to install them on its products previously manufactured.
Litho in U.S.A. Copyright 1993 Chrysler Corporation 20M1193

FOREWORD
The information contained in this service manual
has been prepared for the professional automotive
technician involved in daily repair operations. This
manual does not cover theory of operation, which is
addressed in service training material. Information
describing the operation and use of standard and op-
tional equipment is included in the Owner 's Manual
provided with the vehicle.
This manual is designed as a supplement to be
used along with the 1994 Jeep Cherokee/Wrangler
Service Manual, 81-370-4146. It includes information
related to 1994 vehicles built after December, 1993.
It should be used in conjunction with the initial man-
ual for complete vehicle coverage.
This contains general information, diagnosis, and
testing procedures for the new R134a refrigerant sys-
tem.
The Component and System Index of th is man-
ual identifies the correct page for the component or
system to be serviced. In addition, a Service Manual
Comment form is included at the rear of this manual.
Use the form to provide Chrysler Corporation with
your comments and suggestions.
Chrysler Corporation reserves the right to
change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without
prior notice or incurring obligation.
HEATING AND AIR CONDITIONING 1
INDEX 1
Service Manual Comment Forms (Rear of Manual)
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930.

INTRODUCTION
CONTENTS
page page
DESIGNATIONS, LABELS/PLATES, CODES
AND DIMENSIONS..................... 1SPECIFICATIONS........................ 8
DESIGNATIONS, LABELS/PLATES, CODES AND DIMENSIONS
INDEX
page page
Engine and Transmission/Transfer Case Identification.3
International Vehicle Control and Display Symbols . 3
Major Component Identification............... 3
Tire Inflation Pressure Label................. 3
Vehicle Code Plate........................ 2Vehicle Designations....................... 1
Vehicle Dimension Data.................... 3
Vehicle Identification Number (VIN) Plate....... 1
Vehicle Load Data........................ 3
Vehicle Safety Certification Label............. 1
VEHICLE DESIGNATIONS
The Vehicle Designation Codes chart lists the vehi-
cle description(s) and the corresponding vehicle des-
ignation code for each type of Jeeptvehicle (Figs. 1,
2, and 3 ). The vehicle designation codes are different
from the Vehicle Identification Number (VIN) or
body-type/style codes.
VEHICLE SAFETY CERTIFICATION LABEL
A vehicle safety certification label (Fig. 4) is at-
tached to each Jeeptvehiclee. The label also lists
the:
²gross vehicle weight rating (GVWR) and the gross
front and rear axle weight ratings (GAWR's) based
on a minimum tire rim size and a maximum cold tire
inflation pressure;²month and year of vehicle manufacture;
²vehicle identification number (VIN);
²type of vehicle and
²month, day and hour (MDH) of final assembly.
The label is located on the driver's side door edge.
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE
The vehicle identification number (VIN) plate is at-
tached to the top left side of the instrument panel at
the base of the windshield. Each VIN contains 17 al-
pha-numerical characters. Refer to the decoding
chart to determine the actual identification of a
Jeeptvehicle.
VEHICLE DESIGNATION CODES
Fig. 1 YJÐWrangler Multi-Purpose Vehicle (With
Hard Top)
JINTRODUCTION1

VEHICLE CODE PLATE
A metal vehicle code plate is attached to the left
(driver) side of the dash panel in the engine compart-
ment (Fig. 5). There can be a maximum of seven rows
of vehicle information imprinted on the plate. The in-
formation should be read from left to right, starting
with line 1 at the bottom of the plate up through line
7 (as applicable) at the top of the code plate.
Refer to the decoding chart to decode lines 1 up
through 3.
Lines 4 through 7 (if used) on the vehicle code
plate are imprinted on the plate (in sequence) accord-
ing to the following:
²3-character sales code,
²3-digit numerical code, and
²6-digit SEC code.
Fig. 2 XJÐCherokee 2-Door Multi-Purpose Vehicle
Fig. 3 XJÐCherokee 4-Door Multi-Purpose Vehicle
Fig. 4 Vehicle Safety Certification Label
VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
2 INTRODUCTIONJ