🏷️ Basic Information

Make:

Jeep

Model:

Cherokee

Model Code:

XJ

Year:

1991

Chassis Code:

XJ

👋 Introduction

Positioning:

Iconic compact SUV, known for its off-road capability, ruggedness, and affordability in its segment.

Competitors 1991:

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

Offroad Prowess:

Renowned for its leaf-spring solid rear axle and optional Command-Trac/Selec-Trac 4WD systems, providing excellent off-road articulation and capability.

Durability:

Built with a robust unibody construction and reliable powertrains, earning a reputation for longevity.

Versatility:

Practical for daily driving, capable for trailering, and adept at off-road excursions.

📋 Manual Details

Coverage:

Complete vehicle repair, maintenance, and diagnostics

Estimated Pages:

1500+

Type:

Factory Service Manual (FSM) / Digital Repair Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine:

All engine types, including 4.0L I6 and 2.5L I4, engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control

Transmission:

Manual (AX-4, AX-5) and Automatic (AW4, 30RH) transmissions, removal, installation, overhaul, diagnostics

Drivetrain:

Four-wheel drive system (Command-Trac, Selec-Trac), transfer case, front and rear axles, driveshafts, CV joints, U-joints

Suspension:

Front (leaf spring/solid axle, later models coil spring) and Rear (leaf spring) suspension systems, shocks, struts, bushings, alignment

Steering:

Power steering system, steering gear, linkage, power steering pump

Brakes:

Front disc brakes, rear drum brakes, anti-lock braking system (ABS) if equipped, brake hydraulics, parking brake

Electrical:

Battery, charging system, starting system, ignition system, lighting, instrument panel, power accessories, wiring diagrams, fuses, relays

Body:

Body construction, exterior trim, interior trim, doors, windows, seats, bumpers, chassis lubrication

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, components, refrigerant, diagnosis

Emissions:

Emissions control systems, catalytic converter, EGR, PCV, evaporative emission control

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, lubrication, tire rotation

Troubleshooting:

Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts

Repair:

Step-by-step repair instructions for all major vehicle components and systems, including engine overhauls, transmission rebuilds, brake repairs, electrical diagnostics

Replacement:

Component replacement procedures for wear items and major assemblies

Specifications:

Torque specifications, clearances, fluid capacities, alignment angles, diagnostic values

Wiring Diagrams:

Comprehensive electrical wiring schematics for all circuits

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, advanced diagnostics, and body repair

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchable:

Yes (typically)

Printable:

Yes

Quality Description:

High-resolution digital scans for clarity and readability

Binding:

N/A (Digital format)

Paper:

N/A (Digital format)

⚙️ Engine Specifications

Engine Type:

Inline 6-Cylinder (I6)

Displacement:

4.0 Liters (242 cubic inches)

Horsepower:

Approximately 170-177 hp @ 4500-4700 rpm (specific to 1991 variations)

Torque:

Approximately 220-225 lb-ft @ 2400-3000 rpm (specific to 1991 variations)

Bore X Stroke:

3.875 in x 3.560 in (98.4 mm x 90.4 mm)

Compression Ratio:

8.8:1

Fuel Induction:

Multi-port Electronic Fuel Injection (MPI)

Block Material:

Cast Iron

Cylinder Head Material:

Cast Iron

Timing Drive:

Roller timing chain

Engine Type:

Inline 4-Cylinder (I4)

Displacement:

2.5 Liters (150 cubic inches)

Horsepower:

Approximately 125 hp @ 4800 rpm

Torque:

Approximately 145 lb-ft @ 2400 rpm

Fuel Induction:

Throttle Body Injection (TBI) or Multi-port Fuel Injection (MPI) depending on specific configuration

Fuel Type:

Unleaded gasoline

🔧 Transmission

Type:

5-Speed Manual (AX-4 or AX-5)

Type:

3-Speed Automatic (30RH)

Type:

4-Speed Automatic (AW4)

Transfer Case:

Command-Trac (NV231) or Selec-Trac (NV242) part-time/full-time 4WD system

Manual Transmission Fluid:

API GL-5, SAE 75W-90 gear oil (check manual for exact spec)

Automatic Transmission Fluid:

ATF+3 or equivalent (check manual for exact spec)

📐 Dimensions

Length:

Approximately 170.5 inches (4331 mm)

Width:

Approximately 69.3 inches (1760 mm)

Height:

Approximately 63.8 inches (1620 mm)

Wheelbase:

101.4 inches (2576 mm)

Ground Clearance:

Varies by trim and options, typically around 8-10 inches

Curb Weight:

Approximately 3200-3600 lbs (1451-1633 kg), depending on configuration

Gross Vehicle Weight Rating:

Approximately 4700-5000 lbs (2132-2268 kg)

Cargo Volume:

Approx. 69.9 cubic feet with rear seats folded

🛡️ Safety Features

NHTSA Rating Driver Front Impact:

Not extensively tested under modern protocols for this era; expected moderate performance.

IIHS Rating Small Overlap Front:

N/A (Test not performed on vehicles of this vintage)

ABS:

Optional Anti-lock Braking System (ABS) available on some models.

Traction Control:

Not typically available

Airbags:

Driver's side airbag standard, passenger airbag not typically available.

Seat Belts:

Front and rear seat belts, shoulder belts for front occupants.

Rollover Protection:

Reinforced unibody structure and roll bar integrated into the roof structure.

💡 Technology Features

Audio System:

Factory AM/FM stereo radio with cassette player, optional CD player available on some trims.

Speakers:

Typically 4-6 speakers depending on trim level.

Cruise Control:

Available on most models.

Connectivity Features:

Limited by era; no Bluetooth, USB, or advanced smartphone integration.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (consult manual for specifics).

Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on conditions.

Fuel Filter Replacement:

Every 30,000-60,000 miles (depending on filter type and location).

Coolant Flush Interval:

Every 30,000 miles or 2-3 years.

Brake Fluid Flush Interval:

Every 2-3 years or 30,000 miles.

Engine Oil Specification:

API SJ/SL/SM or higher, SAE 10W-30 or 10W-40 (consult manual for precise viscosity based on temperature).

Engine Oil Capacity 4.0L:

6 US quarts (5.7 liters) with filter

Engine Oil Capacity 2.5L:

5 US quarts (4.7 liters) with filter

Coolant Type:

Ethylene Glycol based, typically a 50/50 mix of coolant and distilled water (green coolant for this era).

Power Steering Fluid:

ATF+3 or equivalent (check manual).

Engine Cooling System:

Water pump leaks, radiator issues, thermostat failures are common wear items.

Interior Electronics:

Door lock actuators, window regulators, and instrument cluster issues can occur with age.

Suspension Components:

Worn ball joints, leaf spring bushings, and shock absorbers are typical on high-mileage XJs.

Rust Perforation:

Common in areas exposed to road salt, particularly on the unibody structure, rocker panels, and floor pans.

Tune Up Components:

Spark plugs, distributor cap and rotor, spark plug wires recommended every 30,000-60,000 miles.

📚 Vehicle History

Jeep Legacy:

Jeep has a long history of producing rugged, off-road capable vehicles dating back to World War II.

Xj Introduction:

The XJ Cherokee was introduced for the 1984 model year, revolutionizing the SUV market as the first mass-produced compact SUV with a unibody construction.

Xj Generation Updates:

The 1991 model year represents a significant mid-cycle refresh for the XJ, including updated styling (new front fascia, revised taillights), improved interior ergonomics, and the introduction of the 4.0L HO (High Output) engine.

Xj Production End:

The XJ Cherokee was produced until the 2001 model year.

Manufacturing Location:

Toledo, Ohio, USA

🏆 Awards & Recognition

Four Wheeler Magazine Award:

The XJ Cherokee has consistently been lauded by off-road publications for its capabilities and has been a frequent recipient of '4x4 of the Year' type awards in its segment and era.

Kl Safety Rating Legacy:

While specific crash test data for 1991 models is not readily comparable to modern standards, the XJ was recognized for its innovative unibody structure at its introduction.