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Jeep Cherokee XJ 1992 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1992 Codes Chassis Code: XJ Model Generation: Second Generation (XJ Facelift) 👋 Introduction Market Position Segment: Compact SUV / Off-road...
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Jeep Cherokee XJ 1992 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Jeep
Model:
Cherokee XJ
Year:
1992
Codes
Chassis Code:
XJ
Model Generation:
Second Generation (XJ Facelift)
👋 Introduction
Market Position
Segment:
Compact SUV / Off-road capable utility vehicle
Target Audience:
Enthusiasts, DIY mechanics, professional repair shops maintaining the Jeep Cherokee XJ.
Competitive Analysis
Competitors 1992:
Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner, Nissan Pathfinder
Key Features
Vehicle Philosophy:
Compact, capable, and versatile SUV known for its unibody construction and off-road prowess.
Manual Value Proposition:
Provides authoritative, factory-level repair information essential for accurate and efficient maintenance and repair of the 1992 Cherokee XJ.
📋 Manual Details
Coverage Areas
Documentation Type:
Factory Service Repair Manual
Dealer Equivalent:
Yes, official dealer workshop equivalent
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Comprehensive Repair and Service Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System
Drivetrain:
Transmission (Automatic & Manual), Transfer Case, Drive Shafts, Differentials (Front & Rear), Axles, CV Joints
Chassis:
Suspension (Front & Rear), Steering System, Brake System (Front & Rear), Wheels & Tires
Electrical:
Wiring Diagrams, Lighting, Instruments, Gauges, Power Distribution, Ignition Switch, Starter, Alternator, Battery, Fuses, Relays
Body And Trim:
Body Panels, Doors, Hood, Liftgate, Interior Trim, Seats, Glass, Sealing Systems, Exterior Trim
HVAC:
Heating, Ventilation, and Air Conditioning System Components and Operation
Procedures Included
Maintenance:
Oil Change, Filter Replacement, Spark Plug Replacement, Coolant Flush, Brake Fluid Flush, Belt Inspection/Replacement, Fluid Level Checks
Diagnostics:
Troubleshooting Guides, Symptom Analysis, Diagnostic Trouble Codes (DTCs) if applicable, Component Testing
Repair:
Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Electrical Component Repair/Replacement, Body Panel Repair
Installation:
Component Installation (e.g., new engine, transmission, suspension parts)
Technical Depth
Depth:
From basic tune-ups to complete engine and transmission overhauls, including detailed electrical troubleshooting and component-level repair.
Diagrams:
Step-by-step diagrams, exploded views, wiring schematics, and torque specifications.
📊 Manual Specifications
File Format
Searchability:
Fully searchable PDF text for quick information retrieval.
Print Quality
Resolution:
High-resolution digital scans for clarity on diagrams and text.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
4.0L Inline 6-Cylinder (OHV)
Engine Code 2:
2.5L Inline 4-Cylinder (OHV)
Performance 4.0L
Horsepower 4.0L:
177 hp @ 4750 rpm (approx.)
Torque 4.0L:
220 lb-ft @ 3250 rpm (approx.)
Performance 2.5L
Horsepower 2.5L:
125 hp @ 4800 rpm (approx.)
Torque 2.5L:
150 lb-ft @ 2400 rpm (approx.)
Fuel System
Fuel Delivery 4.0L:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Delivery 2.5L:
Electronic Fuel Injection (EFI)
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with distributor for some models
Cooling System
Coolant Type:
Mopar Antifreeze/Coolant (Ethylene Glycol Based)
Lubrication System
Oil Type 4.0L:
SAE 10W-30 API SG or SH (check manual for exact spec)
Oil Capacity 4.0L:
5 US quarts (4.7 Liters) with filter
Oil Type 2.5L:
SAE 10W-30 API SG or SH (check manual for exact spec)
Oil Capacity 2.5L:
4 US quarts (3.8 Liters) with filter
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Automatic (AW4)
Optional
Transmission Type Optional:
5-speed Manual (AX-5)
Features
Transmission Fluid Automatic:
ATF+3 (or equivalent Dexron-III/Mercon)
Transmission Fluid Manual:
API GL-4 75W-90 Gear Oil (check manual for exact spec)
Transfer Case Models:
Selec-Trac (2WD/4WD Full-Time) or Command-Trac (Part-Time 4WD)
📐 Dimensions
Exterior
Wheelbase:
101.4 inches (2576 mm)
Length:
163.8 inches (4161 mm)
Width:
69.9 inches (1775 mm)
Height:
64.0 inches (1626 mm)
Weights
Curb Weight Approx:
3100-3400 lbs (1406-1542 kg)
Gross Vehicle Weight Rating Gvwr:
Varies by model/configuration, typically around 4400-4700 lbs
🛡️ Safety Features
Ratings
NHTSA Ratings 1992:
N/A (Standards were different in 1992, refer to specific crash test data if available)
Active Features
ABS:
Available on some models, typically rear-wheel anti-lock (RWAL)
Passive Features
Airbags:
Driver side airbag standard for 1992 models
Seat Belts:
Front and rear seat belts, shoulder belts for front occupants
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo radio with cassette player. Optional CD player on some higher trims.
Speakers:
Typically 4 or 6 speakers depending on trim level.
Driver Assistance
Cruise Control:
Optional, speed-sensitive cruise control.
Connectivity
Connectivity Features:
None by modern standards (e.g., no Bluetooth, USB, or Wi-Fi).
🔧 Maintenance
Service Intervals
Oil Change Interval:
3,000 - 5,000 miles (or 6 months, whichever comes first) - consult manual for specific oil type and conditions.
Transmission Fluid Change Interval:
30,000 - 60,000 miles (or 24-36 months, depending on usage)
Coolant Flush Interval:
30,000 - 50,000 miles (or 24-36 months)
Spark Plug Replacement 4.0L:
60,000 - 100,000 miles (depending on spark plug type)
Brake Pad Replacement:
Variable based on driving conditions and material, typically 30,000-70,000 miles.
Fluid Specifications
Brake Fluid Type:
DOT 3 (check manual for exact spec)
Power Steering Fluid Type:
ATF+3 or equivalent (check manual)
Transfer Case Fluid Type:
ATF+3 or equivalent (check manual)
Known Issues
Common Wear Item 1:
Leaf spring bushings and shackles (wear and tear from suspension articulation)
Common Wear Item 2:
Crankshaft Position Sensor (CPS) failure on 4.0L engines (causes stalling)
Common Wear Item 3:
Radiator hoses and water pump leaks
Common Wear Item 4:
Jeep Lean (sagging driver's side suspension, common with age)
Common Wear Item 5:
Interior dome light issues (corroded contacts)
📚 Vehicle History
Brand Heritage
Jeep Legacy:
Jeep has a long history of rugged, go-anywhere vehicles dating back to World War II.
Model Evolution
Cherokee Xj Introduction:
Introduced in 1984, the XJ revolutionized the SUV market as the first compact SUV with unibody construction.
Cherokee Xj Facelift 1992:
The 1992 model year was part of the second generation facelift, featuring updated interior and exterior styling, and the introduction of the driver's side airbag.
Production
Manufacturing Plant:
Toledo, Ohio, USA
Production Years Xj:
1984-2001
🏆 Awards & Recognition
Recognitions
Automotive Journal Awards:
Consistently ranked highly by automotive publications for its capability and value.
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