1994 JEEP CHEROKEE Service Repair Manual

VARIATION, DISC BRAKE ROTOR
THICKNESS..........................5-31
VEHICLE CODE DECODING............INTRO.-3
VEHICLE CODE PLATE................INTRO.-2
VEHICLE CONTROL AND DISPLAY
SYMBOLS........................INTRO.-7
VEHICLE CONTROL AND DISPLAY
SYMBOLS, INTERNATIONAL.........INTRO.-3
VEHICLE DESIGNATION CODES........INTRO.-1
VEHICLE DESIGNATIONS.............INTRO.-1
VEHICLE DIMENSION DATA....INTRO.-3,INTRO.-4
VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL............25-1
VEHICLE, ENGINE STARTER MOTOR
TEST PROCEDURES ON................8A-9
VEHICLE, GEAR ADJUSTMENTS IN........19-37
VEHICLE, GENERATOR TEST
PROCEDURES ON....................8A-14
VEHICLE IDENTIFICATION NUMBER (VIN)
DECODING.......................INTRO.-2
VEHICLE IDENTIFICATION NUMBER (VIN)
PLATE...........................INTRO.-1
VEHICLE LOAD DATA................INTRO.-3
VEHICLE LOAD DATA, XJ.............INTRO.-5
VEHICLE RESPONSE IN ANTILOCK MODE.....5-3
VEHICLE SAFETY CERTIFICATION LABEL . INTRO.-1
VEHICLE SPEED CONTROL SYSTEM
ELECTRICAL TESTS...................8H-5
VEHICLE SPEED SENSOR................14-60
VEHICLE SPEED SENSOR TEST; FUEL
SYSTEM............................14-45
VEHICLE SPEED SENSOR TEST;
VEHICLE SPEEDCONTROL SYSTEM.......8H-5
VEHICLE SPEED SENSORÐPCM INPUT....14-23
VEHICLE VIBRATION....................22-9
VENT DOOR CONTROL CABLES...........24-39
VENT, HARD TOP ROOF................23-165
VENT WINDOW, FRONT DOOR............23-50
VENT WINDOW GLASS, FULL-METAL
DOOR............................23-177
VENT WINDOW GLASSÐXJ VEHICLES,
REAR QUARTER.....................23-80
VENTILATION, FRESH AIR...............24-39
VENTILATION SYSTEM, CRANKCASE;
EMISSIONCONTROL SYSTEMS...........25-5
VENTILATION SYSTEM, CRANKCASE;
LUBRICATIONAND MAINTENANCE........0-17
VIBRATION; FRONT SUSPENSION AND AXLE . 2-17
VIBRATION; PROPELLER SHAFTS..........16-3
VIBRATION; REAR SUSPENSION AND AXLES . . 3-8
VIBRATION DAMPER; ENGINES........9-26,9-67
VIBRATION DIAGNOSIS; WHEELS AND
TIRES.........................22-9,22-10
VIBRATION, DRIVELINE..................16-3
VIBRATION, TIRE NOISE OR..............22-4
VIBRATION TYPES......................22-9
VIBRATION, VEHICLE....................22-9
VISUAL INSPECTION...................14-32
VOLTAGE, BATTERY OPEN CIRCUIT.........8A-4
VOLTAGE DROP METHOD, STARTER
FEED CIRCUITTESTS -.................8A-9
VOLTAGE SPECIFICATIONS, OUTPUT.......8B-12
VOLTAGE TEST, BATTERY OPEN CIRCUIT....8A-3
VOLTAGEÐPCM INPUT, BATTERY.........14-19
VOLTMETER...........................8E-1
VOLTMETER INOPERATIVE................8E-3
VOLTMETER, OPERATIONAL CHECK.......8A-15
WARNING INOPERATIVE, LOW FUEL........8E-4
WARNING LAMP, LOW FUEL..............8E-2
WARNING LIGHT DISPLAY, ABS............5-3
WARNING LIGHT DISPLAY, BRAKE..........5-4
WARNING LIGHTS, BRAKE.................5-1
WARNING SWITCH REPLACEMENT,
IGNITION KEY........................8U-4
WASHER, DIAGNOSING INTERMITTENT
WINDSHIELD........................8K-12
WASHER, DIAGNOSING NON-
INTERMITTENTWINDSHIELD............8K-12
WASHER, DIAGNOSING REAR WIPER.......8K-6
WASHER INDICATOR INOPERATIVE, LOW....8E-4
WASHER (INTERMITTENT), DIAGNOSING
WINDSHIELD
.........................8K-4
WASHER, INTERMITTENT WIPER
.........8K-20
WASHER (NON-INTERMITTENT),
DIAGNOSINGWINDSHIELD
..............8K-4
WASHER NOZZLE REPLACEMENT
.........8K-13WASHER PUMP REPLACEMENT . . 8K-2 8K-6,8K-11
WASHER PUMP REPLACEMENT, REAR.....8K-13
WASHER PUMP REPLACEMENTÐRIGHT
HAND DRIVE.........................8K-3
WASHER, STANDARD WIPER............8K-19
WASHERS, WINDSHIELD WIPERS..........8A-1
WASHER/THRUST PLATE SPECIFICATIONS,
30RH/32RH SNAP RING/THRUST.......21-322
WATER LEAK DETECTION AND REPAIR,
FIXEDGLASS..................23-83,23-189
WATER PUMPS.....................7-9,7-10
WATER PUMP TESTS.....................7-9
WATERDAM, FULL-METAL DOOR.........23-176
WEAR COMPENSATION, CALIPER
OPERATION..........................5-24
WEAR INDICATORS, TREAD...............22-3
WEAR PATTERNS, TIRE..................22-4
WEATHERSTRIP SEAL, COWL...........23-139
WEATHERSTRIP SEAL, LIFTGATE
OPENING...........................23-70
WEATHERSTRIP SEAL REPLACEMENT,
LIFTGATEGLASS....................23-163
WEATHERSTRIP SEAL, TAILGATE........23-161
WEATHERSTRIP SEAL, WINDSHIELD
FRAME............................23-185
WEATHERSTRIP SEAL/CROSSMEMBER
AIRDEFLECTOR, COWL................23-10
WEATHERSTRIP SEALS, DOOR WINDOW
GLASSAND DOOR OPENING............23-62
WEATHERSTRIP SEALS, FULL-METAL
DOOR............................23-180
WHEEL ALIGNMENT, FRONT...............2-5
WHEEL BALANCE, TIRE..................22-6
WHEEL BEARING LUBRICANTS, CHASSIS
COMPONENT.........................0-30
WHEEL BEARINGS, FRONT...............0-31
WHEEL BRAKE COMPONENTS..............5-1
WHEEL CYLINDER INSTALLATION..........5-37
WHEEL CYLINDER OVERHAUL.............5-36
WHEEL CYLINDER REMOVAL.............5-36
WHEEL INSTALLATION...................22-6
WHEEL LUG NUT......................22-11
WHEEL NUT TIGHTENING............5-32,5-37
WHEEL ORNAMENTATION................22-6
WHEEL REPLACEMENT..................22-6
WHEEL RUNOUT, TIRE...................22-8
WHEEL SENSOR AIR GAP ADJUSTMENT....5-49
WHEEL SENSOR INSTALLATION, FRONT.....5-49
WHEEL SENSOR INSTALLATION, REAR......5-50
WHEEL SENSOR REMOVAL, FRONT........5-49
WHEEL SENSOR REMOVAL, REAR.........5-49
WHEEL SPEED SENSOR OPERATION........5-45
WHEEL SPEED SENSORS.................5-41
WHEEL, STEERING.....................19-45
WHEEL/TIRE SIZE AND INPUT SIGNALS......5-3
WHEELHOUSE FLARES AND LINERS, REAR . 23-18
WHEELHOUSE SPLASH LINERS..........23-146
WHEELHOUSE TRIM PANELSÐXJ
VEHICLES,QUARTER.................23-115
WHEELS..............................22-6
WINDOW APPLIQUEÐXJ VEHICLES,
QUARTER..........................23-29
WINDOW DEFOGGER GRID REPAIR, REAR . . . 8N-2
WINDOW DEFOGGER GRID TEST, REAR.....8N-1
WINDOW DEFOGGER, REAR..............8A-1
WINDOW DEFOGGER SWITCH
REPLACEMENT, REAR..................8N-4
WINDOW EXTERIOR MOULDINGS, DOOR . . . 23-61
WINDOW, FRONT DOOR VENT
............23-50
WINDOW GLASS AND DOOR OPENING
WEATHERSTRIP SEALS, DOOR
..........23-62
WINDOW GLASS, FIXED
..........23-73,23-183
WINDOW GLASS, FRONT DOOR
..........23-49
WINDOW GLASS, FULL-METAL DOOR
.....23-178
WINDOW GLASS, FULL-METAL DOOR
VENT
.............................23-177
WINDOW GLASS, HARD TOP QUARTER
. . . 23-188
WINDOW GLASS, REAR DOOR
...........23-52
WINDOW GLASS, REAR DOOR FIXED
......23-53
WINDOW GLASS REGULATOR, FRONT
DOOR
.............................23-48
WINDOW GLASS REGULATOR, FULL-
METAL DOOR
......................23-177
WINDOW GLASS REGULATOR HANDLE,
FULL-METALDOOR
..................23-175WINDOW GLASS REGULATOR, REAR
DOOR
.............................23-51
WINDOW GLASSÐXJ VEHICLES,
LIFTGATE
...........................23-81
WINDOW GLASSÐXJ VEHICLES,
REAR QUARTERVENT
.................23-80
WINDOW GLASS/REAR QUARTER
PLASTIC INSERTÐXJ VEHICLES,
QUARTER
..........................23-80
WINDOW REGULATOR REPLACEMENT
.......8S-9
WINDOW SWITCH, PASSENGER DOOR
......8S-8
WINDOW SWITCH
..............8S-5,8S-6,8S-7
WINDSHIELD FRAME
..................23-184
WINDSHIELD FRAME WEATHERSTRIP
SEAL
.............................23-185
WINDSHIELD GLASS
..................23-185
WINDSHIELD GLASS REPLACEMENT
......23-75
WINDSHIELD REVEAL MOULDING
. . . 23-73,23-183
WINDSHIELD SERVICE INFORMATION
......23-75
WINDSHIELD SIDE MOULDINGÐXJ
VEHICLES
.........................23-114
WINDSHIELD WASHER, DIAGNOSING
INTERMITTENT
......................8K-12
WINDSHIELD WASHER,
DIAGNOSINGNON-INTERMITTENT
.......8K-12
WINDSHIELD WASHER (INTERMITTENT),
DIAGNOSING
.........................8K-4
WINDSHIELD WASHER (NON-
INTERMITTENT),DIAGNOSING
............8K-4
WINDSHIELD WIPER MOTOR
.............8K-2
WINDSHIELD WIPERS, DIAGNOSING
. . 8K-3,8K-11
WIPER ARM AND PIVOT ASSEMBLY
REPLACEMENT,FRONT
.................8K-9
WIPER ARM REPLACEMENT, FRONT
........8K-8
WIPER ARM REPLACEMENT, REAR
........8K-12
WIPER BLADE REPLACEMENT, FRONT
......8K-8
WIPER CONTROL SWITCH REPLACEMENT
. . . 8K-15
WIPER, DIAGNOSING REAR
...............8K-6
WIPER, LIFTGATE
.......................8K-5
WIPER MODULE, INTERMITTENT
..........8K-5
WIPER MOTOR, FRONT
.................8K-10
WIPER MOTOR REPLACEMENT, REAR
.....8K-13
WIPER MOTOR, WINDSHIELD
.............8K-2
WIPER SWITCH REPLACEMENT,
LIFTGATE
............................8K-6
WIPER SWITCH REPLACEMENT,
REAR
..............................8K-13
WIPER SWITCH TESTING
...............8K-19
WIPER SWITCHES, REAR DEFOGGER/
FOGLAMP/REAR
.....................8E-21
WIPER WASHER, DIAGNOSING REAR
.......8K-6
WIPER WASHER, INTERMITTENT
.........8K-20
WIPER WASHER, STANDARD
............8K-19
WIPERS, DIAGNOSING WINDSHIELD
. . 8K-3,8K-11
WIPERS/WASHERS, FRONT
...............8K-1
WIPERS/WASHERS GENERAL INFORMATION,
FRONT
..............................8K-8
WIPER/WASHER, DIAGNOSING REAR
......8K-14
WIPER/WASHER SWITCH TESTING,
REAR
..........................8K-7,8K-14
WIRE CODE IDENTIFICATION
.............8W-2
WIRING AND COMPONENT IDENTIFICATION
. 8W-13
WIRING AND ELECTRICAL CIRCUITS,
ABS SYSTEM
..........................5-4
WIRING DIAGRAM SHEETS AND INDEXES
. . . 8W-1
WIRING DIAGRAMS YJ
.................8W-73
WIRING PROBLEMS, TROUBLESHOOTING
. . . 8W-3
WIRING REPAIR
.......................8W-4
WIRING, SECONDARY IGNITION
...........8W-1
WOODGRAIN MOULDING
................23-19
WOODGRAIN OVERLAY
.................23-22
WORM SHAFT REPLACEMENT, RACK
PISTON
............................19-30
WORN THREADS, REPAIR DAMAGED OR
.....9-4
JINDEX25
Description Group-Page Description Group-Page Description Group-Page

A/C COMPONENTS........................1
AIR CONDITIONING EQUIPMENT..............4
AIR CONDITIONING PERFORMANCE
TESTS.................................5
CAUTIONS FOR R134A SYSTEM,
WARNINGS.............................3
CHARGING, REFRIGERANT LEAK
TESTING, DISCHARGING, EVACUATING.......8
CHARGING REFRIGERANT SYSTEM...........8
CHART, XJ PERFORMANCE
TEMPERATURE AND PRESSURE............6
CHART, YJ PERFORMANCE
TEMPERATURE AND PRESSURE............5
CONDITIONING EQUIPMENT, AIR.............4
CONDITIONING PERFORMANCE TESTS,
AIR ...................................5
CONNECTIONS, MANIFOLD GAUGE SET........4
DISCHARGING, EVACUATING AND
CHARGING, REFRIGERANT LEAK
TESTING...............................8
DISCHARGING REFRIGERANT SYSTEM..........8
EQUIPMENT, AIR CONDITIONING.............4
EVACUATING AND CHARGING,
REFRIGERANT LEAK TESTING,
DISCHARGING..........................8
EVACUATING REFRIGERANT SYSTEM..........8GAUGE SET CONNECTIONS, MANIFOLD........4
GENERAL INFORMATION....................1
LEAK TESTING, DISCHARGING,
EVACUATING AND CHARGING,
REFRIGERANT..........................8
LEAK TESTING REFRIGERANT................8
LEVEL, OIL..............................9
MANIFOLD GAUGE SET CONNECTIONS.........4
OIL LEVEL...............................9
OIL, REFRIGERANT.......................2,9
PERFORMANCE TEMPERATURE AND
PRESSURE CHART, XJ....................6
PERFORMANCE TEMPERATURE AND
PRESSURE CHART, YJ....................5
PERFORMANCE TEST......................5
PERFORMANCE TESTS, AIR
CONDITIONING..........................5
PRECAUTIONS, SERVICE....................3
PRESSURE CHART, XJ PERFORMANCE
TEMPERATURE..........................6
PRESSURE CHART, YJ PERFORMANCE
TEMPERATURE..........................5
R134A SYSTEM, WARNINGS
AND CAUTIONS.........................3
REFRIGERANT............................1
REFRIGERANT, LEAK TESTING...............8REFRIGERANT LEAK TESTING,
DISCHARGING, EVACUATING AND
CHARGING.............................8
REFRIGERANT OIL.......................2,9
REFRIGERANT SYSTEM, CHARGING...........8
REFRIGERANT SYSTEM, DISCHARGING........8
REFRIGERANT SYSTEM, EVACUATING.........8
SET CONNECTIONS, MANIFOLD GAUGE........4
SYSTEM, CHARGING REFRIGERANT...........8
SYSTEM, DISCHARGING REFRIGERANT........8
SYSTEM, EVACUATING REFRIGERANT.........8
SYSTEM, WARNINGS AND CAUTIONS
FOR R134A
.............................3
TEMPERATURE AND PRESSURE CHART,
XJ PERFORMANCE
.......................6
TEMPERATURE AND PRESSURE CHART,
YJ PERFORMANCE
.......................5
TEST, PERFORMANCE
......................5
TESTING, DISCHARGING, EVACUATING
AND CHARGING, REFRIGERANT LEAK.........8
TESTING REFRIGERANT LEAK
................8
TESTS, AIR CONDITIONING
PERFORMANCE
.........................5
WARNINGS AND CAUTIONS FOR R134A
SYSTEM
...............................3
JINDEX1
Description Page Description Page Description Page

UNITED STATES
The special service tools referred to herein are required for certain service operations. These special service tools
or their equivalent, if not obtainable through a local source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
OTC Division, SPX Corporation
Telephone 1-800-801-5420 FAX 1-800-578-7375
CANADA
The special service tools referred to herein are required for certain service operations. These special service tools
or their equivalent, if not obtainable through a local source, are available through the following outlet.
C & D Riley Enterprises Ltd., P.O. Box 243, Amherstburg, Ontario N9V 2Z4
Telephone (519) 736-4600 FAX (519) 736-8433
INTERNATIONAL
The special service tools referred to herein are required for certain service operations. These special service tools
or their equivalent, if not obtainable through a local source, are available through the following outlet.
28635 Mound Road, Warren, Michigan 48092, U.S.A.
MILLER SPECIAL TOOLS
OTC Division, SPX Corporation
Telephone 1-800-801-5420 FAX 1-800-578-7375
NEXT PAGE©

CAUTION
ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN
ARE APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE
TRADE ONLY. All test and repair procedures on components or assemblies in
non-automotive applications should be repaired in accordance with instructions
supplied by the manufacturer of the total product.
Proper service and repair is important to the safe, reliable, operation of all motor
vehicles. The service procedures recommended and described in this publication were
developed for professional service personnel and are effective methods for performing
vehicle repair. Following these procedures will help assure efficient economical vehicle
performance and service reliability. Some of these service procedures require the use
of special tools designed for specific procedures. These special tools should be used
when recommended throughout this publication.
Special attention should be exercised when working with spring or tension loaded
fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal
may cause personal injury. Always wear safety goggles whenever working on vehicles
or vehicle components.
It is important to note that this publication contains variousCautionsandWarnings.
These should be carefully read in order to minimize the risk of personal injury, or the
possibility that improper service methods may damage the vehicle or render it unsafe.
It is important to note that theseCautionsandWarningscover only the situations
and procedures DaimlerChrysler Corporation has encountered and recommended.
DaimlerChrysler Corporation could not possibly know, evaluate, and advise the
service trade of all conceivable ways that service may be performed, or of the possible
hazards of each. Consequently, DaimlerChrysler Corporation has not undertaken any
such broad service review. Accordingly, anyone who uses a service procedure, or tool,
that is not recommended in this publication must assure oneself thoroughly that
neither personal safety, nor vehicle safety, be jeopardized by the service methods they
select.
SERVICE AND OWNER MANUALS
Available for Chrysler, Plymouth, Dodge,
Dodge Truck, and Jeep
Tvehicles.
Telephone orders may be placed at the number below.
Credit cards are accepted (no CODs). Please have your
order information available at time of call.
CALL: (800) 890-4038 OR FAX: (440) 572-0815
FOR A FREE CATALOG OR TO PLACE AN ORDER.
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Page 1
03/30/99
Rev. 0
7DEOH2I&RQWHQWV
Section Page
1.0 Viewing A Manual In Windows98/95/NT
…………………………………. 2
2.0 Viewing A Manual In Windows 3.1 ……………………………………………. 3
3.0 Using The CD-ROM
3.1 Welcome Page Of A Manual ……………………………………………………… 4
3.2 Tab Page Of A Manual ……………………………………………………………. 5
3.3 Returning To The Tab Page Of A Manual ……………………………………… 6
3.4 Viewing The Contents Of A Group W ithin A Manual ………………………….. 7
3.5 Using Electronic Bookmarks To Navigate A Manual ………………………….. 8
4.0 Using The Acrobat Reader Toolbar
4.1 Acrobat Reader On-Line Help …………………………………………………… 9
4.2 Summary Of Acrobat Reader Toolbar Features ………………………………. 10

2
1.0 Viewing A Manual In Windows98/95/NT
To view the contents of A CD-ROM, you will need to keep the CD-ROM in
the CD-ROM drive. The Acrobat Reader runs off the hard drive and
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Figure 1.0-1
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