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2001 Jeep XJ Cherokee Service Manual – PDF DOWNLOAD
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2001 Jeep XJ Cherokee Service Manual – PDF DOWNLOAD
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Description
2001 Jeep XJ Cherokee Service Manual – PDF DOWNLOAD
DESCRIPTION:
2001 Jeep XJ Cherokee Service Manual – PDF DOWNLOAD
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) plate is located on the lower windshield fence near the left A-pillar. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decoding chart to determine the identification of a vehicle.
The Vehicle Identification Number is also imprinted on the:
† Body Code Plate.
† Vehicle Safety Certification Label.
† Frame rail.
To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Identification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.
DESCRIPTION – FUEL REQUIREMENTS :
- Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality unleaded “regular” gasoline having an octane rating of 87. The routine use of premium gasoline is not recommended. Under normal conditions the use of premium fuel will not provide a benefit over high quality regular gasolines and in some circumstances may result in poorer performance.
- Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations.
- If you experience these symptoms, try another brand of gasoline before considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle. We recommend the use of gasolines that meet the WWFC specifications if they are available.
TABLE OF CONTENTS:
2001 Jeep XJ Cherokee Service Manual – PDF DOWNLOAD
XJ GAS POWERTRAIN................................................................................... 0 XJ DIESEL POWERTRAIN................................................................................ 0 XJ BODY............................................................................................. 0 XJ CHASSIS.......................................................................................... 0 XJ TRANSMISSION..................................................................................... 0 2000 XJ SERVICE MANUAL.............................................................................. 0 2001 XJ SERVICE MANUAL.............................................................................. 1 GROUP TAB LOCATOR............................................................................... 1 FOREWORD........................................................................................ 0 ins-INTRODUCTION................................................................................ 2 VEHICLE IDENTIFICATION NUMBER............................................................... 2 DESCRIPTION............................................................................. 2 DESCRIPTION......................................................................... 2 E-MARK LABEL................................................................................ 3 DESCRIPTION............................................................................. 3 DESCRIPTION......................................................................... 3 0s-LUBRICATION & MAINTENANCE.................................................................... 4 LUBRICATION & MAINTENANCE................................................................... 4 DESCRIPTION............................................................................. 4 DESCRIPTION - FUEL REQUIREMENTS..................................................... 4 REFORMULATED GASOLINE........................................................... 4 GASOLINE/OXYGENATE BLENDS....................................................... 4 MMT IN GASOLINE................................................................. 4 SULFUR IN GASOLINE.............................................................. 4 MATERIALS ADDED TO FUEL......................................................... 5 FUEL SYSTEM CAUTIONS............................................................ 5 SPECIFICATIONS.......................................................................... 5 FLUID CAPACITIES.................................................................... 5 FLUID TYPES................................................................................. 5 DESCRIPTION............................................................................. 5 DESCRIPTION - TRANSFER CASE - NV231................................................. 5 DESCRIPTION - TRANSFER CASE - NV242................................................. 5 DESCRIPTION - GEAR LUBRICATION RECOMMENDATIONS...................................... 5 DESCRIPTION - AUTOMATIC TRANSMISSION FLUID.......................................... 6 FLUID ADDITIVES................................................................. 6 DESCRIPTION - ENGINE OIL............................................................ 6 API SERVICE GRADE CERTIFIED..................................................... 6 SAE VISCOSITY................................................................... 6 ENERGY CONSERVING OIL........................................................... 6 CONTAINER IDENTIFICATION........................................................ 7 FLUID FILL/CHECK LOCATIONS.................................................................. 7 DESCRIPTION............................................................................. 7 DESCRIPTION......................................................................... 7 DESCRIPTION - TRANSFER CASE......................................................... 7 FLUID FILL LOCATIONS AND LUBRICATION POINTS......................................... 8 MAINTENANCE SCHEDULES....................................................................... 8 DESCRIPTION............................................................................. 8 DESCRIPTION......................................................................... 8 UNSCHEDULED INSPECTION.............................................................. 8 EMISSION CONTROL SYSTEM MAINTENANCE............................................. 8 FLUID FILL LOCATIONS AND LUBRICATION POINTS..................................... 8 SCHEDULE—A...................................................................... 8 SCHEDULE “B”.................................................................... 9 UNSCHEDULED INSPECTION.............................................................. 10 EMISSION CONTROL SYSTEM MAINTENANCE............................................. 11 FLUID FILL LOCATIONS AND LUBRICATION POINTS..................................... 11 SCHEDULE “A”.................................................................... 11 SCHEDULE “B”.................................................................... 12 3s-DIFFERENTIAL & DRIVELINE..................................................................... 18 FRONT AXLE - 181FBI - 186FBI................................................................ 18 FRONT AXLE - 181FBI - 186FBI................................................................ 18 SPECIFICATIONS.......................................................................... 18 FRONT AXLE.......................................................................... 18 SPECIAL TOOLS........................................................................... 19 181FBI AXLE......................................................................... 19 PINION SEAL................................................................................. 22 REMOVAL................................................................................. 22 REMOVAL............................................................................. 22 INSTALLATION............................................................................ 22 INSTALLATION........................................................................ 22 COLLAPSIBLE SPACER.......................................................................... 23 REMOVAL................................................................................. 23 REMOVAL............................................................................. 23 INSTALLATION............................................................................ 24 INSTALLATION........................................................................ 24 PINION GEAR/RING GEAR....................................................................... 25 REMOVAL................................................................................. 25 REMOVAL............................................................................. 25 INSTALLATION............................................................................ 27 INSTALLATION........................................................................ 27 REAR AXLE - 194RBI.......................................................................... 31 REAR AXLE - 194RBI.......................................................................... 31 ADJUSTMENTS............................................................................. 31 ADJUSTMENT.......................................................................... 31 PINION DEPTH MEASUREMENT........................................................ 32 DIFFERENTIAL BEARING PRELOAD.................................................... 33 PRELOAD SHIM SELECTION.......................................................... 34 GEAR CONTACT PATTERN............................................................ 37 DIFFERENTIAL BEARING PRELOAD CHECK.............................................. 37 SPECIFICATIONS.......................................................................... 39 REAR AXLE........................................................................... 39 REAR AXLE - 8 1/4........................................................................... 40 REAR AXLE - 8 1/4........................................................................... 40 ADJUSTMENTS............................................................................. 40 ADJUSTMENTS......................................................................... 40 PINION DEPTH MEASUREMENT........................................................ 41 BEARING PRELOAD AND GEAR BACKLASH............................................... 42 GEAR CONTACT PATTERN............................................................ 43 SIDE GEAR CLEARANCE............................................................. 45 SPECIFICATIONS.......................................................................... 46 REAR AXLE - 8 1/4................................................................... 46 8wa-WIRING...................................................................................... 48 8Wa-01 WIRING DIAGRAM INFORMATION........................................................... 50 WIRING DIAGRAM INFORMATION.................................................................. 50 DESCRIPTION............................................................................. 50 DESCRIPTION - HOW TO USE WIRING DIAGRAMS............................................ 50 SYMBOLS......................................................................... 50 TERMINOLOGY..................................................................... 54 WARNING................................................................................. 54 WARNINGS - GENERAL.................................................................. 54 DIAGNOSIS AND TESTING................................................................... 54 DIAGNOSIS AND TESTING - WIRING HARNESS.............................................. 54 TROUBLESHOOTING TOOLS........................................................... 54 INTERMITTENT AND POOR CONNECTIONS............................................... 55 TROUBLESHOOTING WIRING PROBLEMS................................................. 55 STANDARD PROCEDURE...................................................................... 55 STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL.................................. 55 STANDARD PROCEDURE - TESTING FOR CONTINUITY......................................... 56 STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND.................................. 56 STANDARD PROCEDURE - TESTING FOR SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS.... 56 STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP..................................... 56 SPECIAL TOOLS........................................................................... 56 SPECIAL TOOLS - WIRING/TERMINAL..................................................... 56 CONNECTOR - AUGAT........................................................................... 57 REMOVAL................................................................................. 57 REMOVAL............................................................................. 57 INSTALLATION............................................................................ 57 INSTALLATION........................................................................ 58 CONNECTOR - MOLEX........................................................................... 58 REMOVAL................................................................................. 58 REMOVAL............................................................................. 58 INSTALLATION............................................................................ 58 INSTALLATION........................................................................ 58 CONNECTOR - THOMAS AND BETTS................................................................ 58 REMOVAL................................................................................. 58 REMOVAL............................................................................. 58 INSTALLATION............................................................................ 59 INSTALLATION........................................................................ 59 DIODE....................................................................................... 59 REMOVAL................................................................................. 59 REMOVAL............................................................................. 59 INSTALLATION............................................................................ 59 INSTALLATION........................................................................ 59 TERMINAL.................................................................................... 60 REMOVAL................................................................................. 60 REMOVAL............................................................................. 60 INSTALLATION............................................................................ 60 INSTALLATION........................................................................ 60 WIRE........................................................................................ 61 STANDARD PROCEDURE...................................................................... 61 STANDARD PROCEDURE - WIRE SPLICING.................................................. 61 8Wa-02 COMPONENT INDEX...................................................................... 62 COMPONENT INDEX......................................................................... 62 8Wa-10 POWER DISTRIBUTION................................................................... 64 POWER DISTRIBUTION...................................................................... 64 8Wa-12 JUNCTION BLOCK.......................................................................100 JUNCTION BLOCK..........................................................................100 8Wa-15 GROUND DISTRIBUTION..................................................................138 GROUND DISTRIBUTION.....................................................................138 8Wa-18 BUS COMMUNICATIONS...................................................................158 BUS COMMUNICATIONS......................................................................158 8Wa-20 CHARGING SYSTEM......................................................................164 CHARGING SYSTEM.........................................................................164 8Wa-21 STARTING SYSTEM......................................................................170 STARTING SYSTEM.........................................................................170 8Wa-30 FUEL/IGNITION SYSTEM.................................................................174 FUEL/IGNITION SYSTEM....................................................................174 8Wa-31 TRANSMISSION CONTROL SYSTEM..........................................................206 TRANSMISSION CONTROL SYSTEM.............................................................206 8Wa-33 VEHICLE SPEED CONTROL................................................................212 VEHICLE SPEED CONTROL...................................................................212 8Wa-35 ANTILOCK BRAKES......................................................................218 ANTILOCK BRAKES.........................................................................218 8Wa-39 VEHICLE THEFT SECURITY SYSTEM........................................................224 VEHICLE THEFT SECURITY SYSTEM...........................................................224 8Wa-40 INSTRUMENT CLUSTER...................................................................234 INSTRUMENT CLUSTER......................................................................234 8Wa-41 HORN/CIGAR LIGHTER/POWER OUTLET......................................................252 HORN/CIGAR LIGHTER/POWER OUTLET.........................................................252 8Wa-42 AIR CONDITIONING-HEATER..............................................................256 AIR CONDITIONING-HEATER.................................................................256 8Wa-43 AIRBAG SYSTEM........................................................................266 AIRBAG SYSTEM...........................................................................266 8Wa-44 INTERIOR LIGHTING....................................................................270 INTERIOR LIGHTING.......................................................................270 8Wa-47 AUDIO SYSTEM.........................................................................280 AUDIO SYSTEM............................................................................280 8Wa-48 REAR WINDOW DEFOGGER.................................................................292 REAR WINDOW DEFOGGER....................................................................292 8Wa-49 OVERHEAD CONSOLE.....................................................................296 OVERHEAD CONSOLE........................................................................296 8Wa-50 FRONT LIGHTING.......................................................................302 FRONT LIGHTING..........................................................................302 8Wa-51 REAR LIGHTING........................................................................320 REAR LIGHTING...........................................................................320 8Wa-52 TURN SIGNALS.........................................................................332 TURN SIGNALS............................................................................332 8Wa-53 WIPERS...............................................................................340 WIPERS..................................................................................340 8Wa-54 TRAILER TOW..........................................................................348 TRAILER TOW.............................................................................348 8Wa-60 POWER WINDOWS........................................................................352 POWER WINDOWS...........................................................................352 8Wa-61 POWER DOOR LOCKS.....................................................................358 POWER DOOR LOCKS........................................................................358 8Wa-62 POWER MIRRORS........................................................................364 POWER MIRRORS...........................................................................364 8Wa-63 POWER SEAT...........................................................................372 POWER SEAT..............................................................................372 8Wa-70 SPLICE INFORMATION...................................................................378 SPLICE INFORMATION......................................................................378 8Wa-80 CONNECTOR PIN-OUTS...................................................................382 CONNECTOR PIN-OUTS......................................................................382 8Wa-90 CONNECTOR/GROUND LOCATIONS...........................................................490 CONNECTOR/GROUND LOCATIONS..................................................................490 DESCRIPTION.............................................................................490 DESCRIPTION.........................................................................490 8Wa-95 SPLICE LOCATIONS.....................................................................536 SPLICE LOCATIONS............................................................................536 DESCRIPTION.............................................................................536 DESCRIPTION.........................................................................536 21s-TRANSMISSION/TRANSAXLE......................................................................562 TRANSMISSION/TRANSAXLE......................................................................562 DESCRIPTION.............................................................................562 DESCRIPTION.........................................................................562 MANUAL NV 3550..............................................................................562 MANUAL NV 3550..............................................................................562 DISASSEMBLY.............................................................................562 DISASSEMBLY.........................................................................562 FRONT HOUSING...................................................................562 SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT.....................................566 REAR HOUSING - 2WD..............................................................569 REAR ADAPTER HOUSING - 4WD......................................................569 GEARTRAIN FROM FIXTURE..........................................................571 OUTPUT SHAFT....................................................................571 REVERSE IDLER...................................................................574 ASSEMBLY................................................................................575 ASSEMBLY............................................................................575 SYNCHRONIZER....................................................................575 OUTPUT SHAFT....................................................................576 REVERSE IDLER ASSEMBLY..........................................................582 SHIFT SHAFT AND BUSHINGS/BEARINGS...............................................584 DETENT PLUNGER BUSHING..........................................................584 GEARTRAIN ASSEMBLY..............................................................585 REAR HOUSING - 2WD..............................................................587 ADAPTER HOUSING - 4WD...........................................................589 SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET...........................590 FRONT HOUSING AND INPUT SHAFT BEARING RETAINER..................................593 SHIFT TOWER AND LEVER...........................................................595 EXTENSION HOUSING BUSHING...................................................................596 REMOVAL.................................................................................596 REMOVAL - YOKE BUSHING..............................................................596 INSTALLATION............................................................................596 INSTALLATION - YOKE BUSHING.........................................................596 EXTENSION HOUSING SEAL 2WD..................................................................597 REMOVAL.................................................................................597 REMOVAL - YOKE SEAL 2WD.............................................................597 INSTALLATION............................................................................597 INSTALLATION - YOKE SEAL 2WD........................................................597 VEHICLE SPEED SENSOR........................................................................597 DESCRIPTION.............................................................................597 DESCRIPTION.........................................................................597 OPERATION...............................................................................597 OPERATION...........................................................................597 REMOVAL.................................................................................597 REMOVAL.............................................................................598 INSTALLATION............................................................................598 INSTALLATION........................................................................598 AUTOMATIC - AW4.............................................................................599 AUTOMATIC - AW4.............................................................................599 DIAGNOSIS AND TESTING...................................................................599 DIAGNOSIS AND TESTING - AUTOMATIC TRANSMISSION......................................599 INPUT SHAFT SPEED SENSOR....................................................................601 DESCRIPTION.............................................................................601 DESCRIPTION.........................................................................601 OPERATION...............................................................................601 OPERATION...........................................................................601 VALVE BODY SOLENOIDS........................................................................602 DESCRIPTION.............................................................................602 DESCRIPTION.........................................................................602 OPERATION...............................................................................602 OPERATION...........................................................................602 TRANSFER CASE NV-231........................................................................603 TRANSFER CASE NV-231........................................................................603 DISASSEMBLY.............................................................................603 DISASSEMBLY.........................................................................603 REAR RETAINER AND OIL PUMP......................................................603 YOKE AND RANGE LEVER............................................................604 FRONT OUTPUT SHAFT AND DRIVE CHAIN..............................................605 SHIFT FORKS AND MAINSHAFT.......................................................606 MAINSHAFT.......................................................................607 INPUT GEAR AND LOW RANGE GEAR...................................................608 INPUT AND LOW RANGE GEAR........................................................609 ASSEMBLY................................................................................610 ASSEMBLY............................................................................610 BEARINGS AND SEALS..............................................................610 INPUT AND LOW RANGE GEAR........................................................615 INPUT GEAR AND LOW RANGE GEAR...................................................615 MAINSHAFT.......................................................................615 SHIFT FORKS AND MAINSHAFT.......................................................616 FRONT OUTPUT SHAFT AND DRIVE CHAIN..............................................618 OIL PUMP AND REAR CASE..........................................................618 YOKE AND RANGE LEVER............................................................619 REAR RETAINER...................................................................620 VEHICLE SPEED SENSOR........................................................................622 REMOVAL.................................................................................622 REMOVAL.............................................................................622 INSTALLATION............................................................................622 INSTALLATION........................................................................622 SERVICE MANUAL COMMENTS.........................................................................624
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