🏷️ Basic Information

Make:

Jeep

Model:

Cherokee

Chassis Code:

XJ

Model Years:

1991-1996

Generation Designation:

Second Generation (facelifted XJ)

Facelift Details:

Introduced in 1987, the XJ received a significant facelift in 1991, including updated exterior styling (new grille, bumpers, headlights), revised interior (dashboard, seats), and improved aerodynamics. This manual covers the post-facelift models.

👋 Introduction

Vehicle Segment:

Compact SUV (Sport Utility Vehicle)

Jeep Cherokee Xj Positioning:

The XJ Cherokee was a groundbreaking vehicle, pioneering the unibody construction for SUVs. It was positioned as a rugged, capable, and relatively affordable option for off-roading and everyday use.

Key Competitors:

Ford Bronco II, Chevrolet S-10 Blazer, Nissan Pathfinder, Toyota 4Runner.

Competitive Advantage:

The XJ's unibody design offered a more comfortable ride and lighter weight than body-on-frame competitors, while retaining significant off-road capability thanks to its legendary 4.0L inline-six engine and robust drivetrain options.

Unibody Construction:

Revolutionary for its time, contributing to a lighter curb weight and improved handling.

4X4 Capability:

Available Command-Trac (part-time) and Selec-Trac (full-time) four-wheel-drive systems offered exceptional off-road prowess.

Durable Powertrains:

The robust 4.0L inline-six is renowned for its longevity and torque.

📋 Manual Details

Coverage Scope:

Comprehensive workshop repair and maintenance

Specific Systems Covered:

Engine, Transmission, Drivetrain, Suspension (Front & Rear), Axles, Brakes, Cooling System, Fuel System, Exhaust System, Steering, Electrical System, Climate Control, Body & Chassis, Interior Trim

Estimated Page Count:

Likely 1000+ pages (typical for full workshop manuals of this era and scope)

Manual Type:

Full Workshop Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed diagnostics, overhaul, component testing, timing, and specifications for both the 2.5L I-4 and 4.0L I-6 engines.

Engine Performance:

Includes fuel delivery, ignition system, emissions control, and cooling system diagnostics and repair.

Transmission Manual:

Repair and maintenance of the AX-4 manual transmission (if applicable to certain models).

Transmission Automatic:

Repair and maintenance of the AW4 automatic transmission (common on 4.0L models).

Drivetrain:

Front and rear axle overhaul, differential service, U-joints, driveshafts, and transfer case (NP231 Command-Trac) repair.

Suspension Front:

Leaf spring system, shock absorbers, steering linkage, sway bar, and wheel bearing service.

Suspension Rear:

Leaf spring system, shock absorbers, and axle housing service.

Brakes:

Front and rear brake systems (disc/drum), hydraulic system, parking brake, and ABS (if equipped) diagnostics and repair.

Electrical System:

Wiring diagrams, component testing, fuse and relay identification, lighting, ignition, starting, charging, and dashboard diagnostics.

Body Chassis:

Body panel alignment, door and window mechanisms, seat adjustments, and chassis component inspection.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, and belt inspections.

Diagnostic Procedures:

Step-by-step troubleshooting guides for common and uncommon issues, including engine performance problems, electrical faults, and braking concerns.

Repair Procedures:

Detailed instructions for component replacement, system overhauls, and adjustments for all covered systems.

Special Tools:

Lists and descriptions of special tools required for specific procedures.

Torque Specifications:

Essential torque values for critical fasteners across all vehicle systems.

Depth Of Coverage:

Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts.

Diagnostic Capability:

Covers electrical diagnostics, engine management system checks, and mechanical system troubleshooting.

Rebuild Instructions:

Likely includes detailed rebuild procedures for major components like engines and transmissions.

📊 Manual Specifications

File Format:

PDF

File Size Mb:

73MB

Searchability:

Assumed to be searchable if OCR-processed.

Print Quality:

Likely scanned from original factory manuals, quality can vary but is generally sufficient for detailed viewing and printing.

Binding Type:

Digital (PDF)

Paper Type:

Not applicable for digital format.

⚙️ Engine Specifications

Engine 1 Displacement Liters:

2.5

Engine 1 Configuration:

Inline-4 (I-4)

Engine 1 Fuel Type:

Gasoline

Engine 1 Fuel Induction:

Multi-point Fuel Injection (MPI)

Engine 2 Displacement Liters:

4.0

Engine 2 Configuration:

Inline-6 (I-6)

Engine 2 Fuel Type:

Gasoline

Engine 2 Fuel Induction:

Multi-point Fuel Injection (MPI)

Engine 1 Horsepower Est:

125 hp @ 4600 rpm (approx.)

Engine 1 Torque Ft Lbs Est:

150 lb-ft @ 2800 rpm (approx.)

Engine 2 Horsepower Est:

180-190 hp @ 4750 rpm (approx.)

Engine 2 Torque Ft Lbs Est:

220-235 lb-ft @ 3000 rpm (approx.)

Fuel Pump Type:

In-tank electric

Recommended Fuel Octane:

87 octane (minimum) for both engines.

🔧 Transmission

Transmission Option 1 Type:

Manual Transmission

Transmission Option 1 Model:

AX-4 (4-speed manual, common on 2.5L models)

Transmission Option 2 Type:

Automatic Transmission

Transmission Option 2 Model:

AW4 (4-speed automatic, common on 4.0L models)

Transfer Case Options:

NP231 Command-Trac (part-time 2WD/4WD) is standard on most models. Selec-Trac (full-time 4WD) may be optional on some trims.

📐 Dimensions

Wheelbase Inches:

101.4

Length Inches:

167.5

Width Inches:

70.5

Height Inches:

63.9

Curb Weight Lbs Est:

3100 - 3600 lbs (depending on configuration)

Towing Capacity Lbs Est:

2000 - 5000 lbs (depending on engine, axle ratio, and configuration)

🛡️ Safety Features

NHTSA Rollover Rating Est:

Likely 3-star (typical for SUVs of this era)

Anti Lock Brakes ABS:

Optional or standard on higher trims, typically rear-wheel only or rear axle only for this period.

Airbags:

Driver's side airbag became standard around 1994/1995. Passenger airbag was not common in this generation.

Seatbelts:

Front and rear seatbelts.

💡 Technology Features

Audio System:

Factory AM/FM radio with cassette player. Optional CD player in later models. Speaker configurations varied by trim level.

User Interface:

Basic analog gauges, physical buttons for climate control and radio. Reflective of early 90s automotive technology.

Cruise Control:

Available on most models.

ABS:

As mentioned in safety, typically optional and rear-wheel only.

Phone Integration:

None (analog era).

🔧 Maintenance

Oil Change Interval Miles:

Every 3,000 - 6,000 miles or 6 months, depending on oil type and driving conditions (refer to manual for exact recommendations).

Transmission Fluid Change Interval Miles:

Every 30,000 - 60,000 miles for automatic transmissions (AW4), manual transmissions vary. Consult manual.

Coolant Flush Interval Miles:

Every 30,000 - 60,000 miles or 2-3 years.

Spark Plug Replacement Interval Miles:

Around 30,000 - 60,000 miles, depending on plug type (copper vs. platinum).

Engine Oil Type 1:

API SG or higher, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature).

Engine Oil Capacity Quarts 4 0L:

6 quarts (with filter)

Engine Oil Capacity Quarts 2 5L:

5 quarts (with filter)

Transmission Fluid Type Aw4:

Dexron III (or equivalent)

Transfer Case Fluid Type Np231:

ATF+4 (or Dexron III/Mercon equivalent)

Coolant Type:

Ethylene Glycol based, typically a green or orange coolant (check manual for specific Mopar recommendations).

Common Issue 1:

Cracked cylinder heads on early 4.0L engines (though less common by 1991-1996 models, it's a known point for earlier XJs).

Common Issue 2:

Water pump leaks/failure.

Common Issue 3:

Leaf spring sag/breakage due to age and load.

Common Issue 4:

Radiator leaks/failure.

Common Issue 5:

Interior trim component wear (headliner sag, door panel issues).

Common Issue 6:

Power steering pump leaks.

Common Issue 7:

Brake wear, especially rear drums on some models.

📚 Vehicle History

Jeep Legacy:

Jeep has a rich history of producing robust, go-anywhere vehicles, dating back to World War II with the Willys MB.

Cherokee Xj Introduction:

Introduced in 1984, the XJ was a revolutionary vehicle that redefined the SUV segment with its compact size, unibody construction, and excellent off-road capability.

Cherokee Xj Generation Timeline:

First Generation: 1984-1990. Second Generation (facelifted): 1991-1996. Third Generation (later models, but XJ continued): 1997-2001 (facelifted XJ).

Production Period For This Manual:

1991, 1992, 1993, 1994, 1995, 1996

Manufacturing Locations:

Primarily Toledo, Ohio, USA.

🏆 Awards & Recognition

Jeep Cherokee Xj Recognition:

Consistently lauded for its off-road prowess and durability. Often cited as a benchmark for compact SUVs and a favorite among off-road enthusiasts.

Off Road Magazine Awards:

While specific awards for the 1991-1996 period might be difficult to pinpoint without deep historical archives, the XJ platform was a frequent feature and subject of praise in off-road publications like Four Wheeler and Off-Road Magazine throughout its lifespan.

Emission Standards:

Designed to meet US federal emission standards for the respective model years (e.g., EPA regulations). The manual would detail emissions control systems.