After 13 years of production, (December 1996 production) February 1997 saw the Cherokee receive updated exterior and interior styling. Both the two- and four-door bodies remained in production, receiving a steel liftgate (replacing the fiberglass one used previously), restyled taillights, additional plastic molding along the doors, as well as a new front header panel that featured more aerodynamic styling. The spare tire remained mounted to the interior rear quarter panel on the driver's side in the trunk. A new, unique spare tire carrier was invented by Peter Gruich while working for Jeep Special Programs that utilized the trailer hitch bar and a unique pivot bracket and although it was the only external spare tire carrier to pass the full Jeep durability test, it was not offered for sale. The interior was similarly updated with an all-new design and instrument panel featuring the first blow-molded symmetrical instrument panel retainer structure. This instrument panel featured a unique cluster/airbag bracket invented by Peter Gruich that allowed the interchange of the two components in order for the vehicle to be sold in the right hand and left-hand drive markets with both driver and passenger airbags. A stiffer unibody frame brought improvements to noise, vibration, and harshness (NVH) measurements. Also contributing to NVH improvements were new door seals that reduced wind noise at higher speeds.

In the middle of the 1999 model year, vehicles with the 4.0 L engine received a revised intake manifold. This was done to help counteract smaller exhaust porting on the latest casting of cylinder heads, which was done to meet more stringent emissions control laws. Both the four- and six-cylinder engines were offered through the 2000 model year, though only the straight-six was available in 2001. For the 2000 and 2001 model years, all six-cylinder XJs received a distributorless ignition system using coil-on-plug ignition replacing the "traditional" system previously used; coupled with better exhaust porting and the newer intake manifolds, this gave a minor increase in power over the previous models. Transmission, axle, and transfer case choices were carried over from the previous models. However, major changes were underway with a new executive, Wolfgang Bernhard, who was known as a "cost-slasher" nicknamed "whirlwind", who came from Mercedes-Benz to turn around Chrysler. "One of the first moves Bernhard made when he came to Chrysler in 2000 was to help kill the Jeep Cherokee, an aging, somewhat bland SUV." Thus, the (XJ) Cherokee line was replaced in 2001 by the Jeep Liberty (KJ), although it retained the "Cherokee" nameplate in most foreign markets.

The Cherokee (XJ) remains a popular vehicle among off-roading enthusiasts. Its design has been noted as one of the greatest of all time. Popular Mechanics listed the XJ as one of "the 25 greatest boxy cars of all time".When (XJ) Cherokee production ended in May 2001, the portion of the Toledo South Assembly Plant devoted to its production was torn down.

Designs of the compact-size XJ Cherokee date back to 1978 when a team of American Motors (AMC) and Renault engineers drew several sketches. Clay models were based on the then-current full-size SJ Cherokee. Early sketches of the XJ Cherokee had a European influence, and most of the styling cues were done by AMC engineers under the direction of Dick Teague, vice president of design.

Noticing that General Motors was developing a new two-door S-10-based Blazer, AMC decided to develop an entirely new four-door model in addition to a two-door version. American Motors' vice president of engineering, Roy Lunn, designed what is known as the "Quadra-Link" suspension, that limited rollovers.Renault's François Castaing developed the drivetrain using a much smaller engine than normally found in 4WD vehicles and reduced the weight of the new model. It "is noteworthy as the first nonmilitary 4x4 with unibody construction."The unconventional design enhanced XJ's durability and off-road capability that eventually won over most critics, even those models with the early underpowered GM engines.The XJ is described "as the first small crossover SUV in the U.S.," with "plenty of the Jeep toughness (and a straight-six engine) built-in." The design and market positioning of the XJ, along with the AMC Eagle essentially "foreshadowed the car-based crossover utility-vehicle fad."

"The new XJ Jeep ... was 1,200 pounds lighter, 31 inches shorter, six inches narrower and four inches lower than the Cherokee SJ it replaced, and yet — thanks to unibody construction — the XJ kept 90 percent of its predecessor’s interior volume." And, not only was fuel economy much improved, but "articulation is also better, as is ground clearance, as well as approach, departure and breakover angles. These, along with its smaller profile, make the XJ better both off-road and on." Teague, who was responsible for the Jeep Cherokee (XJ) that was launched in the United States in 1983. He described the practical and utilitarian appearance of the new SUV: "We didn't want to lose the flavor of the older Jeeps ... We wanted it to look like something you'd want to take into the rough country

Although the XJ models had just been introduced, AMC quickly began development of its successor. To compete against its much larger rivals, the smallest U.S. automaker created a business process that is now known as "product lifecycle management" (PLM) to speed up its product development process. By 1985, development and engineering was based on computer-aided design (CAD) software systems while new systems stored all drawings and documents in a central database. The pioneering PLM was so effective that after Chrysler purchased AMC in 1987, it expanded the system throughout its own enterprise.

British TV presenter and motoring expert Quentin Willson described the XJ Jeep as "a real 4x4 icon" and one of the "few truly great cars... which, despite being left behind by newer models, still offer fresh and urgent possibilities. Cars which become more relevant the older they get."

Jeep is a brand of American automobiles that is a division of Stellantis North America. The history of the Jeep brand dates back to World War II, when the U.S. government commissioned the development of a small, lightweight, and versatile vehicle that could be used by the military in a variety of roles.

The prototype for the Jeep was developed in 1940 by American Bantam Car Company. This prototype, known as the "Blitz Buggy," was designed to meet the U.S. Army's requirements for a lightweight reconnaissance vehicle. However, American Bantam was unable to meet the Army's production needs, so the project was handed over to Willys-Overland and Ford Motor Company.

In 1941, Willys-Overland began production of the first Jeeps, which were officially known as the Willys MB. The Jeep quickly proved to be a versatile and reliable vehicle, and it was used in a variety of roles by the military, including reconnaissance, transportation, and as a weapons platform.

After World War II, Willys-Overland began producing Jeeps for civilian use. The first post-war Jeep model was the CJ-2A, which was similar in design to the Willys MB, but with a few modifications for civilian use.

Over the next few decades, the Jeep brand continued to evolve and expand. In 1953, Willys-Overland was purchased by Kaiser Motors, and the company was renamed Kaiser-Jeep. Under Kaiser-Jeep, the company introduced new models such as the Jeep Wagoneer and the Jeep Cherokee.

In 1970, American Motors Corporation (AMC) purchased Kaiser-Jeep, and the company was renamed AMC Jeep. Under AMC, the Jeep brand continued to grow, with the introduction of new models such as the Jeep CJ-7 and the Jeep Grand Wagoneer.

In the 1980s, the Jeep brand was acquired by Chrysler Corporation. Under Chrysler, the Jeep brand continued to evolve and expand, with the introduction of new models such as the Jeep Wrangler and the Jeep Grand Cherokee.

In the late 1990s and early 2000s, Daimler-Benz AG and later DaimlerChrysler AG owned the brand, but in 2007, Chrysler LLC separated from Daimler AG and the brand became part of the newly formed company.

Today, the Jeep brand continues to be an important part of the automotive industry, with a range of popular models such as the Jeep Wrangler, the Jeep Grand Cherokee, and the Jeep Gladiator. The brand is known for its rugged, off-road capable vehicles and its reputation for durability and reliability.

Overall, the Jeep brand has a rich history that is closely tied to the history of the United States. From its origins as a military vehicle in World War II, to its evolution into a popular civilian vehicle, the Jeep has played an important role in the automotive industry and continues to be a symbol of American ingenuity and versatility.

The thermal switch in a Jeep Cherokee XJ is responsible for managing the operation of the cooling fan based on engine temperature. Here’s a breakdown of the theory and process involved in replacing a faulty thermal switch:

### Theory of Operation

1. **Function of the Thermal Switch**: The thermal switch monitors the temperature of the engine coolant. When the coolant reaches a predetermined temperature, the switch closes (or opens), signaling the cooling fan to turn on (or off) to help regulate engine temperature.

2. **Failure Symptoms**: A faulty thermal switch may cause the cooling fan to operate incorrectly—either running continuously, not running at all, or not responding to changes in coolant temperature. This can lead to engine overheating or inefficient cooling.

### Repair Process

1. **Diagnosis**: First, confirm that the thermal switch is the issue. Check for symptoms like overheating or non-functioning cooling fan. Use a multimeter to test the switch for continuity at specified temperatures.

2. **Disconnect Battery**: Safety first—disconnect the negative terminal of the battery to avoid electrical shorts.

3. **Locate the Thermal Switch**: The thermal switch is typically located near the engine's coolant outlet or in the radiator. Familiarize yourself with its location in relation to the cooling system.

4. **Drain Coolant (if necessary)**: Depending on the location of the switch, you may need to drain some coolant to prevent spillage when removing the switch.

5. **Remove the Old Thermal Switch**: Unscrew the old thermal switch using the appropriate tools. Be careful to avoid damaging the threads in the engine block or radiator.

6. **Install the New Thermal Switch**: Apply thread sealant (if required) and screw in the new thermal switch, ensuring it is secure but not over-tightened.

7. **Reconnect Components**: Reconnect any disconnected electrical connectors and hoses that were disturbed during the removal process.

8. **Refill Coolant**: If you drained coolant, refill the system with the appropriate mixture of coolant and water, ensuring there are no air pockets.

9. **Reconnect Battery**: Reattach the negative battery terminal.

10. **Test the System**: Start the engine and let it reach operating temperature. Observe the cooling fan operation to ensure it activates at the correct temperature.

### How the Repair Fixes the Fault

Replacing the faulty thermal switch restores the proper function of the cooling fan, allowing it to activate at the right temperatures. This ensures effective cooling of the engine, preventing overheating and maintaining optimal operating conditions. By addressing the root cause (the faulty switch), the repair resolves the symptoms (overheating or fan malfunction) and improves the overall reliability of the cooling system.
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### Exhaust Pipe Replacement on a Jeep Cherokee XJ

**Overview of the Exhaust System:**
The exhaust system in your Jeep Cherokee XJ is crucial for directing harmful gases away from the engine and cabin, reducing emissions, and controlling noise. It consists of several components:

1. **Exhaust Manifold:** Collects exhaust gases from the engine cylinders.
2. **Catalytic Converter:** Reduces harmful emissions by converting them into less harmful substances.
3. **Muffler:** Reduces noise produced by the exhaust gases.
4. **Exhaust Pipe:** Connects these components and directs gases to the rear of the vehicle.

**Why Repair the Exhaust Pipe?**
Over time, exhaust pipes can rust, develop holes, or become damaged due to road debris or corrosion. A damaged exhaust pipe can lead to:

- Increased noise from the engine.
- Poor fuel efficiency.
- Harmful exhaust gases entering the cabin.
- Failing emissions tests.

### Tools and Materials Needed:

- **Tools:**
- Jack and jack stands or ramps
- Wrench set (including socket wrench)
- Screwdrivers
- Exhaust pipe cutter or saw (if necessary)
- Pliers
- Wire brush
- Torque wrench

- **Materials:**
- New exhaust pipe (make sure it fits your XJ model)
- Exhaust clamps (if needed)
- Gasket or sealant (if required)
- Rust inhibitor spray (optional)

### Step-by-Step Process:

1. **Safety First:**
- Park the Jeep on a flat surface and engage the parking brake.
- Allow the engine to cool down completely.

2. **Lift the Vehicle:**
- Use a jack to lift the vehicle and secure it with jack stands or drive onto ramps. Make sure it’s stable.

3. **Locate the Exhaust Pipe:**
- The exhaust pipe runs from the catalytic converter to the rear of the vehicle.

4. **Inspect the Pipe:**
- Look for rust, holes, or damage. If you find significant corrosion or perforation, it’s time for a replacement.

5. **Remove the Old Exhaust Pipe:**
- **Disconnect Clamps:** Use a wrench to loosen and remove any clamps holding the exhaust pipe to the catalytic converter and muffler.
- **Cut the Pipe (if necessary):** If the pipe is severely rusted or stuck, use an exhaust pipe cutter or saw to remove it. Cut it at a point where it’s still solid.
- **Remove Mounting Brackets:** If there are brackets holding the pipe, use a wrench to remove them.

6. **Clean the Area:**
- Use a wire brush to clean the mounting surfaces where the new exhaust pipe will attach. This ensures a good seal.

7. **Install the New Exhaust Pipe:**
- Position the new exhaust pipe in place. If it has flanges or a gasket, make sure they are aligned properly.
- **Attach Clamps:** Use new clamps (if required) to secure the pipe to the catalytic converter and muffler. Ensure they are tightened but do not overtighten, as this can crush the pipe.

8. **Secure the Pipe:**
- Reinstall any mounting brackets you removed. Ensure the pipe is secure and does not hang lower than necessary.

9. **Check for Leaks:**
- Start the engine and listen for any exhaust leaks (a hissing or popping sound). You can also use a soapy water solution; bubbles will form at any leaks.

10. **Lower the Vehicle:**
- Once everything is secure, carefully lower the vehicle back to the ground.

11. **Final Check:**
- After a short drive, check the exhaust pipe for any signs of leaks or looseness.

### Common Issues with Exhaust Pipes:

- **Rust and Corrosion:** Common in areas with road salt or moisture.
- **Holes:** Can be caused by road debris or excessive rust.
- **Loose Connections:** Can lead to exhaust leaks, increasing noise and emissions.
- **Broken Mounts:** May cause the exhaust to hang lower than normal, risking damage.

### Analogy:
Think of your exhaust system like a straw in a drink. If the straw has holes or is crimped, it becomes difficult to drink (or in this case, for exhaust gases to flow). Just as a good straw ensures smooth sipping, a well-maintained exhaust system ensures the safe and efficient expulsion of harmful gases.

### Conclusion:
Changing the exhaust pipe on your Jeep Cherokee XJ is a straightforward task with the right tools and understanding. Regularly inspecting this component can prevent larger issues down the road. Always prioritize safety, and don’t hesitate to consult a professional if you're unsure about any step.
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