Jeep XJ 1991 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee (XJ) Year: 1991 Codes Chassis Code: XJ 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-road Vehicle Brand Perception: Renowned for...

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Sku: 447825

Tags: 1991 Car Cars Jeep Misc XJ

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee (XJ)

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-road Vehicle

Brand Perception:

Renowned for ruggedness, off-road capability, and durability.

Competitive Analysis

Competitors 1991:

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

Key Features

Vehicle Platform:

Unibody construction (revolutionary for its time in the SUV segment), providing a more car-like ride than body-on-frame competitors.

Off Road Capability:

Solid front axle (leaf spring or optional coil spring), robust transfer cases, good approach/departure angles.

Utility:

Versatile cargo space, towing capacity, and passenger comfort suitable for daily driving and adventure.

📋 Manual Details

Coverage Areas

Manual Type:

Full Service and Repair Manual

Language:

English

Format:

Likely Digital (PDF) or Printed Book

Intended Audience:

Professional Technicians and DIY Enthusiasts

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, tuning, lubrication system, cooling system, fuel system, emission control system, engine electrical system.

Transmission Manual:

Clutch, manual transmission (e.g., AX-5, AX-15) repair, service, and overhaul.

Transmission Automatic:

Automatic transmission (e.g., AW4) diagnosis, service, overhaul, and fluid specifications.

Drivetrain:

Front and rear axles (Dana 30, Dana 35/44), transfer case (e.g., NP231), driveshafts, U-joints, differentials.

Suspension:

Front coil spring, solid axle suspension; rear leaf spring suspension. Components: control arms, sway bars, shock absorbers, springs.

Steering:

Power steering system, steering gear, steering column, linkages, alignment specifications.

Brakes:

Front disc brakes, rear drum brakes (typical for 1991 XJ). ABS diagnosis (if equipped), brake fluid specifications, bleeding procedures.

Electrical System:

Battery, charging system (alternator), starting system, ignition system, lighting, horns, wipers, power windows, power locks, dashboard indicators.

Body:

Exterior body panels, doors, hood, tailgate, interior trim, body sealants, rust prevention.

Climate Control:

HVAC system diagnosis and repair, A/C system servicing, heater core replacement, blower motor.

Fuel System:

Fuel pump, fuel injectors, fuel filter, fuel tank, evaporative emission control system.

Emission Control:

Catalytic converter, oxygen sensors, EGR system, PCV system, evaporative emission control.

Procedures Included

Routine Maintenance:

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

Diagnostic Troubleshooting:

Step-by-step diagnostic procedures for all major systems, common fault identification, wiring diagrams and component testing.

Repair And Rebuild:

Detailed instructions for component removal, installation, and overhaul (e.g., engine rebuild, transmission rebuild, brake caliper replacement).

Component Replacement:

Specific guides for replacing common wear items and larger components like radiators, alternators, starter motors, water pumps.

Torque Specifications:

Essential torque values for critical fasteners throughout the vehicle (engine, drivetrain, suspension, brakes).

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems, including engine controls, lighting, and accessories.

Diagnostic Trouble Codes:

Interpretation of OBD-I codes (if applicable for 1991 models) and manufacturer-specific diagnostic procedures.

Special Tools:

Identification and usage instructions for specialized tools required for certain repairs.

Technical Depth

Depth Level:

Comprehensive, covering everything from basic maintenance to full mechanical and electrical system overhauls.

Diagnostic Capabilities:

Advanced diagnostic flowcharts and component testing methods for efficient problem-solving.

Rebuild Instructions:

Detailed instructions for rebuilding major components like engines, transmissions, and differentials.

📊 Manual Specifications

File Format

Format Type:

PDF (Searchable, Printable)

Resolution Quality:

High-resolution scans for clear diagrams and text.

Print Quality

Print Option:

Printable pages suitable for home or professional printing.

Binding Type

Binding Style:

N/A (if digital); Spiral-bound or perfect-bound (if printed).

Paper Type

Paper Quality:

N/A (if digital); Heavy-duty paper to withstand shop environment (if printed).

Page Count

Estimated Page Count:

1000+ pages (typical for a full service manual of this era)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

2.5L (150 ci) AMC I4 (4.0L I6 was standard on many trims)

Engine Code 2:

4.0L (242 ci) AMC I6 (High Output)

Performance

4.0L Horsepower:

177 hp @ 4,500 rpm (estimated)

4.0L Torque:

220 lb-ft @ 2,000 rpm (estimated)

2.5L Horsepower:

121 hp @ 4,800 rpm (estimated)

2.5L Torque:

190 lb-ft @ 2,000 rpm (estimated)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPFI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Engine Construction

Block Material 4.0L:

Cast Iron

Head Material 4.0L:

Cast Iron

Bore Stroke 4.0L:

3.875 in x 3.414 in

Compression Ratio 4.0L:

8.7:1

🔧 Transmission

Standard

Standard Transmission Type:

AX-5 5-Speed Manual (on some models)

Optional

Optional Transmission Type:

AW4 4-Speed Automatic

Features

Automatic Transmission Features:

Electronically controlled, overdrive.

Manual Transmission Features:

Robust design for off-road use.

📐 Dimensions

Exterior

Wheelbase:

101.4 inches

Length:

167.5 inches

Width:

69.4 inches

Height:

63.4 inches

Weights

Curb Weight Est:

3,400 - 3,700 lbs (depending on configuration)

Towing Capacity Est:

2,000 - 5,000 lbs (depending on engine and axle ratio)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

4/5 stars (typical for SUVs of the era)

Active Features

Braking System:

Front disc, Rear drum (Optional ABS available on some trims).

Passive Features

Seat Belts:

Front and rear seat belts.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM radio with cassette player (optional CD player).

Driver Assistance

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

Connectivity

Connectivity Features:

Limited by era; primarily focused on basic vehicle operation.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions.

Transmission Fluid Change:

Every 30,000-60,000 miles (automatic), check manual for manual transmission.

Coolant Flush Interval:

Every 30,000-60,000 miles.

Spark Plug Replacement:

Every 30,000-60,000 miles (depending on plug type).

Fluid Specifications

Engine Oil Spec 4.0L:

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

Transmission Fluid Automatic:

Chrysler ATF+3 or equivalent (e.g., Dexron III compatible).

Brake Fluid Spec:

DOT 3.

Coolant Spec:

Ethylene glycol-based coolant (e.g., Mopar Antifreeze/Coolant).

Known Issues

Common Problem 1:

Head gasket failures (especially on early 4.0L engines).

Common Problem 2:

Radiator leaks and thermostat housing leaks.

Common Problem 3:

Front track bar wear and mounting issues.

Common Problem 4:

Rust on rocker panels, floor pans, and rear quarter panels.

Common Problem 5:

Cracked exhaust manifolds (especially on 4.0L).

Common Problem 6:

Transmission cooler line leaks.

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep has a long-standing reputation for robust, go-anywhere vehicles, originating from military roots.

Model Evolution

Xj Introduction:

The XJ Cherokee was introduced in 1984, marking a significant shift in SUV design with its unibody construction.

1991 Updates:

1991 saw minor refinements, possibly including updated interior features or option packages. The 4.0L inline-six became increasingly popular and standard on many trims.

Production

Production Period:

1984-2001 (North America), 1984-2000 (International)

Production Location

Assembly Plant:

Toledo, Ohio, USA.

🏆 Awards & Recognition

Recognitions

Off Road Magazine Award:

Often recognized by off-road publications for its capability and aftermarket support.

Ratings

Consumer Reports Rating:

Variable, but generally praised for reliability and capability.