🏷️ Basic Information

Make:

Jeep

Model:

Cherokee XJ

Year:

1991-1996

Platform Code:

XJ

Generation Designation:

Second Generation (facelifted XJ)

👋 Introduction

Target Audience:

DIY enthusiasts with basic to intermediate mechanical skills, independent auto repair shops, and knowledgeable vehicle owners seeking to better understand their vehicle.

Value Proposition:

Provides factory-level technical information, empowering users to perform accurate diagnostics and repairs, saving time and money compared to relying solely on professional mechanics. Offers superior detail to generic online guides.

Instant Access:

Immediate download post-purchase eliminates shipping costs and delays, enabling prompt commencement of maintenance or repair tasks.

Digital Versatility:

Viewable on PCs, Macs, and various mobile devices and e-readers, offering flexibility in access and use.

📋 Manual Details

Primary Coverage:

North American Market Models

Secondary Coverage:

Export Models (where applicable, engine differences noted)

Estimated Page Count:

Approx. 2000+ pages (typical for comprehensive service manuals of this era)

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Systems:

2.5L I4 (AMC 150), 4.0L I6 (High Output AMC 242), induction, fuel injection, emission controls, cooling, lubrication, ignition, engine overhaul, diagnostics

Transmission Systems:

AX-4 Auto (4-speed), AW-4 Auto (4-speed, electronically controlled), BA-10/5 (5-speed manual), NV2500 (5-speed manual), NV3550 (5-speed manual), clutch systems, torque converters, seals, internal components, service and overhaul

Drivetrain And Differentials:

Transfer cases (NP231, NP242 Command-Trac/Selec-Trac), Dana 30 front axle, Dana 35 rear axle (various ratios), Chrysler 8.25 rear axle, U-joints, CV joints, axle seals, lubrication, differential overhaul

Chassis And Suspension:

Frame construction, leaf spring rear suspension, coil spring front suspension, control arms, bushings, ball joints, sway bars, shock absorbers, steering linkage, steering gear (power steering pump, box), wheel bearings, alignment specifications

Brake Systems:

Front disc brakes (Vented), Rear drum brakes, ABS (Anti-lock Braking System) for equipped models, brake lines, calipers, wheel cylinders, master cylinder, parking brake system, fluid specifications, bleeding procedures

Electrical And Wiring:

Complete wiring diagrams, fuse box locations, relay assignments, battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), instrument cluster, body control modules, engine control modules (ECU/PCM), sensor inputs/outputs, diagnostics of electrical faults

Body And Interior:

Body panel removal/installation, door mechanisms, glass replacement, interior trim, seats, HVAC system (heating, ventilation, air conditioning), body sealing, rust prevention, corrosion repair guidance

Fuel And Emission Control:

Fuel tank, fuel pump, fuel lines, injectors, fuel pressure testing, evaporative emission control (EVAP), catalytic converter, oxygen sensors, EGR system, PCV system, emission control component testing

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication points, tune-up procedures, spark plug replacement, belt tensioning and replacement

Diagnostics And Troubleshooting:

Systematic diagnostic flowcharts, common fault symptom identification, DTC (Diagnostic Trouble Code) interpretation, use of diagnostic tools, electrical circuit testing, performance issue diagnosis

Repair And Overhaul:

Component removal and installation, engine rebuilding procedures, transmission overhaul, axle rebuilds, suspension component replacement, brake caliper and drum service, radiator replacement, starter/alternator testing and replacement

Technical Specifications And Settings:

Torque specifications for all fasteners, engine timing, valve lash adjustments (if applicable), wheel alignment angles, tire pressure recommendations, fluid capacities, component tolerances

Depth Of Coverage:

Comprehensive: Covers basic to advanced repair and diagnostic procedures, including engine and transmission rebuilds. Equivalent to dealership-level service information.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable due to digital format, allowing quick access to specific topics.

Printability:

Designed for printing individual pages, ensuring clarity and durability for workshop use.

Binding Type:

Not applicable (Digital file)

Paper Type:

Not applicable (Digital file)

⚙️ Engine Specifications

Engine 1:

2.5L (150 cu in) AMC 150 Inline-4

Engine 2:

4.0L (242 cu in) AMC 242 "High Output" Inline-6

Engine 1 Hp Range:

Approx. 125 hp @ 4500 rpm (Varies slightly by year)

Engine 1 Torque Range:

Approx. 170 lb-ft @ 2400 rpm (Varies slightly by year)

Engine 2 Hp Range:

Approx. 180-190 hp @ 4750 rpm (Varies slightly by year, typically 'HO' spec)

Engine 2 Torque Range:

Approx. 220-230 lb-ft @ 3000-3250 rpm (Varies slightly by year, typically 'HO' spec)

Fuel Delivery:

Electronic Fuel Injection (EFI), Multi-point Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Fuel Pump Type:

In-tank electric fuel pump

🔧 Transmission

Transmission Options:

4-speed Automatic (Chrysler A904/AX-4, Chrysler AW-4), 5-speed Manual (BA-10/5, NV2500, NV3550)

Transmission Selection Notes:

AW-4 transmission became increasingly common and featured electronic control for improved performance and economy.

Manual Transmission Details:

Details on clutch operation, internal gearsets, synchronizers, and shift linkage adjustments for various manual transmissions.

Automatic Transmission Details:

Torque converter operation, valve body function, electronic control module (if applicable) inputs/outputs, fluid types, and service procedures.

📐 Dimensions

Wheelbase Inches:

101.4 inches (approx.)

Length Inches:

167.5 - 173.0 inches (approx., depending on model/year)

Width Inches:

69.4 - 70.5 inches (approx.)

Height Inches:

62.8 - 64.0 inches (approx.)

Curb Weight Lbs:

3200 - 3600 lbs (approx., depending on configuration)

Towing Capacity Lbs:

Up to 5,000 lbs (properly equipped, varies by configuration and year)

🛡️ Safety Features

NHTSA Rollover Resistance:

Not explicitly rated by NHTSA for this era in modern terms, but known for its stable platform.

ABS Availability:

Optional on select models, typically front wheel ABS.

Airbags:

Driver-side airbag became standard during this generation (from 1994 onwards).

Seatbelts:

Three-point front seat belts, lap belts for rear occupants.

💡 Technology Features

Audio System:

Standard AM/FM radio, optional cassette or CD player. Basic speaker systems.

ABS System:

Optional Anti-lock Braking System (ABS) was available on some models during this period.

OBD Standard:

Transition from OBDI to OBDII systems occurred during this production run, with OBDII becoming standard by 1996 for most vehicles.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (consult manual for specific recommendations).

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic transmissions, depending on usage (heavy use may require more frequent changes).

Coolant Flush Interval:

Every 2 years or 30,000 miles (typically uses a conventional green or HOAT coolant).

Engine Oil Spec:

API SN or newer, SAE 10W-30 recommended for most conditions. Refer to manual for precise viscosity based on climate.

Automatic Transmission Fluid:

Chrysler ATF+4 (or equivalent, check manual for early models which might specify Dexron III).

Power Steering Fluid:

Chrysler power steering fluid or Dexron III compatible.

Brake Fluid Type:

DOT 3 Hydraulic Brake Fluid.

Common Problems Engine:

Head gasket leaks (especially on early 4.0L), oil filter adapter housing leaks, exhaust manifold cracks (4.0L), CPS (Crankshaft Position Sensor) failure.

Common Problems Transmission:

AW-4 valve body issues, clutch wear in manual transmissions, leaky seals.

Common Problems Suspension Steering:

Worn leaf spring bushings, sagging springs, worn tie rod ends, steering box wear.

Common Problems Electrical:

Corroded grounds, failing headlight switches, intermittent power to accessories, ABS sensor failures.

Common Problems Body:

Rust, especially in wheel wells, rocker panels, and tailgate.

📚 Vehicle History

Jeep Legacy:

Built upon Jeep's renowned off-road heritage and ruggedness, the Cherokee XJ continued to offer capability in a more compact and refined package.

Xj Generation:

The 1991-1996 models represent the second generation of the XJ Cherokee, featuring significant updates including interior revisions, updated powertrains, and improved aerodynamics. Key changes include the introduction of the High Output 4.0L engine and the move to OBD-II diagnostics later in this range.

Production Period:

1984-2001 (global production, US production ended in 2001 for this generation of Cherokee)

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Automotive Journalism:

The XJ Cherokee was frequently praised by automotive journalists for its blend of off-road capability, compact size, and affordability. Often cited as a benchmark in the compact SUV segment.